Understanding the True Costs and Benefits of Adopting New Materials
K. O. Legg1, J. P. Sauer2, (1)Rowan Technology Group, Libertyville, LA, (2)SauerEngineering, Cincinnati, OH
We describe a new approach, called Implementation Assessment, for evaluating the readiness, cost and risk of new materials for DoD use. The methodology measures technical readiness, and the full costs, benefits and risks to determine how the material can be cost-effectively implemented with the least technical and financial risk.
Considerations in the Implementation of Composite Materials on Military Assets
R. B. Mason1, L. A. Gintert1, M. F. Singleton1, D. Skelton2, (1)Concurrent Technologies Corporation, Largo, FL, (2)US Army, Picatinny Arsenal, NJ
Composite materials can provide reduced weight for military vehicles while providing enhanced properties. However, the absence of specific data has impeded use in many military systems. Information on life-cycle cost, manufacturability, and reliability must be gathered for specific applications. This paper discusses considerations for replacing monolithic components with composites in Army vehicles.
Microstructure Evolution of Titanium Alloy Ti-5111 for US Naval Applications
A. C. Stauffer1, E. J. Czyryca1, D. Koss2, (1)Naval Surface Warfare Center, Carderock Division, West Bethesda, MD, (2)Pennsylvania State University, University Park, PA
Titanium and its alloys are finding increasing application on U.S. Navy surface ships and submarines. This presentation describes the microstructure developed in Ti-5111 wrought and cast plates as a function of various heat treatments. The effects of microstructure on tensile strength and ductility will be presented.
Non-Magnetic Steel For Naval Ship Hulls
G. W. Steele, Northrup Grumman Newport News, Newport News, VA
N/A
Thermal Sprayed Polymeric Coatings for Landing Gear
G. D. Davis1, R. A. Zatorski2, (1)DACCO SCI, INC., Columbia, MD, (2)Zatorski Coating Company, East Hampton, CT
Landing gears are subject to corrosion and other damage due to aggressive environments and to foreign object debris on runways. A coating is needed that is both impact resistant and corrosion resistant. Thermally sprayed EAA (ethylene acrylic acid) coatings exhibit impact and corrosion protection superior to that of current coatings.
Environmentally Benign Replacement Coatings for Chromium
D. Kosikowaski1, P. S. Mohanty1, A. Hart2, (1)University of Michigan, Dearborn, MI, (2)U. S. Army, Warren, MI
A High Velocity Oxy-Fuel process is used to deposit Ta, Re and Mo coatings as alternatives to chrome plating. The effect of process variables such as fuel type and combustion parameters on coating quality will be presented. The cost effectiveness of the replacement coating in comparison to the current method of chrome plating will also be discussed.
An Overview of Critical Materials Employed in Spinning Mass Inertial Measuring Units
T. Hunyady, BAE Systems North America, Heath, OH
“Spinning Mass” Inertial Measuring Units (SMIMU’s) such as gyroscopes operate with remarkable levels of precision. This requires a number of critical materials which have been used in the same manner since the late 1950’s. The basics of SMIMU operation are given, as well as examples of critical materials and applications.
Development of Polymeric Microfibrous Materials and Their Applications
E. A. Luna, B. J. Tatarchuk, Auburn University, Auburn, AL
Polymeric microfibrous materials are made from a sinter-locked matrix of micron diameter polymer fibers formed in a wet-lay process. Breakthrough testing has demonstrated that a single layer of polymeric microfibrous material can sustain 5-Log filtration until 95% of the saturation capacity is attained.
Enhancement of Personal Protection Devices by Using High Effectiveness Sorbent Particulates Entrapped in Microfibrous Polymer Fibers as Polishing Adsorbents
D. R. Cahela1, B. J. Tatarchuk1, P. Jones2, C. Karwacki2, (1)Auburn University, Auburn, AL, (2)SBCCOM-Research, Development and Engineering Command, Aberdeen Proving Ground, MD
Polymeric materials made by entrapping particulates using wet lay process are a new class of materials. DMMP gas life test results for COTS RCA-CBA canisters and the same canisters with polymeric polishing sorbents added will be presented. The pressure drop increased minimialy and gas life was improved by 50 %.
Kohrt - TBD
C. Kohrt, Battelle, Columbus, OH
TBD
Chernoby - TBD
M. Chernoby, DaimlerChrysler, Auburn Hills, MI
TBD
Globalization, Lean Manufacturing & Out-Sourced Engineering
T. Epply, Continental Design & Engineering, Anderson, IN
Perspective on Outsourcing Engineering in the Aerospace Industry
R. Schafrik, GE Aircraft Engines, Cincinnati, OH
High Temperature Material Challenges in Aero Gas Turbine Engines
M. C. Thomas, Rolls-Royce plc, Derby, United Kingdom
Summary not available.
High Temperature Materials Challenges for Advanced IGT Applications
S. J. Balsone1, R. Schwant2, (1)GE Gas Turbines, LLC, Greenville, SC, (2)GE Energy, Schenectady, NY
Summary not available.
A Comprehensive Approach to Commerical Aircraft Engine Critical Parts Life
T. Mouzakis1, N. Provenzano2, (1)Federal Aviation Administration, Burlington, MA, (2)Protec Consulting, Inc., Indianapolis, IN
This paper describes an improved methodology used to determine the service life of commerical engine rotating disks. The improved techniques are based on the recognition that anomalies may not be detectable by existing nondestructive inspection techniques and can reduce the life of components by acting as crack initiation sites.
Advanced Remelting Technology - The Role of the Specialty Metals Processing Consortium in Improving Aircraft Disk Reliability
J. J. DeBarbadillo1, R. A. Williamson2, F. J. Zanner3, (1)Special Metals Corporation, Huntington, WV, (2)Sandia National Laboratory, Albuquerque, NM, (3)Zan Tek Enterprises, Sandia Park, NM
This paper describes the active programs of work cosponsored by the Specialty Metals Processing Consortium and the Federal Aviation Administration and aimed at developing nickel and titanium alloy remelting technology to reduce the incidence of defects in aircraft gas turbine disks.
Powder Metal Superalloys for Advanced Turbo Machinery
A. Banik, Special Metals, Princeton, KY
Improvements in powder metal processing are facilitating the introduction of new technologies for the production of turbine engine components. The improved chemistry controls of powder metal alloys reduce the variability in property response encountered in ingot metallurgy products. The recent advances in powder metal disk production will be reviewed in light of new alloy considerations for advanced high temperature applications.
Current and Future Trends in the Manufacture of Turbine Engine Disks
D. U. Furrer1, G. Groppi2, G. Bunge2, (1)Roll-Royce Corporation, Indianapolis, IN, (2)Ladish Co., Inc., Cudahy, WI
The state of the art in material and process technology for disk manufacturing will be compared to recent developments and trends.
Improved Life Remaining Predictions for Turbine Engine Components Based on Nondestructive, Real-Time Damage Measurements
C. A. Rideout, D. W. Akers, Positron Systems, Inc., Boise, ID
Advanced, high temperature turbine engine components require accurate diagnostic methods to measure existing damage and remaining life. Photon Induced Positron Annihilation has demonstrated the capability to quantify damage accumulation in single crystal, nickel-based superalloys, correlate the measurement data with known operational histories, and provide remaining life predictions with a high degree of accuracy.
Counter-gravity Casting of Haynes 230 Using Inert Atmosphere
S. Shendye1, B. King1, P. McQuay2, M. C. Flemings3, (1)Metal Casting Technology, Inc., Milford, NH, (2)Hitchiner Manufacturing Company, Inc., Milford, NH, (3)Massachusetts Institute of Technology, Cambridge, MA
Haynes 230 alloy was melted and test bars were cast in an inert atmosphere using the Counter-gravity Low-pressure Inert-atmosphere (CLI) investment casting process. Chemical composition, grain size, tensile and stress rupture properties met the customer requirements. No notable defects were identified by non-destructive X-ray and fluorescent penetrant inspection (FPI), or by fractographic and microstructure evaluations.
Material Issues in Next Generation Coal-Fired Power Plants
R. Viswanathan, EPRI, Palo Alto, CA
EPRI has recently completed a state-of-the-art review of materials technology for ultra supercritical power plants. This review will serve as a basis for defining material issues for both the boiler and the turbine in the next generation ultra supercritical power plants.
Weld Overlay Coatings for Corrosion Protection in Boilers with Low NOx Burners
J. DuPont, A. R. Marder, R. Deacon, J. Regina, Lehigh University, Bethlehem, PA
A wide range of commercially available weld overlay coatings, and newly developed FeCrAl weld overlay alloys, were evaluated under a wide range of corrosion conditions in order to determine their potential use for corrosion protection in fossil fired power plants.
Alloy Development for Advanced Waste-to-Energy Boilers
Y. Kawahara, Mitsubishi Heavy Industries, Yokohama, Japan
Recently, many kinds of waste-to-energy combustion systems have been operated to minimize harmful emissions. Corrosion environments in these plants have become severe and complex. This presentation shows recent progress in corrosion resistant alloys and coatings for advanced waste-to-energy boilers.
Materials and Performance Issues for Alloys in the Supercritical Water Cooled Reactor
G. Was, S. Teysseyre, University of Michigan, Ann Arbor, MI
The Supercritical Water Cooled Reactor (SCWR) is one of the most promising Generation IV nuclear reactor designs. Operating above the thermodynamic critical point of water this design takes advantage of the unique properties of this single-phase coolant, but also presents numerous challenges for materials.
High Temperature Strength Considerations for Ultrasupercritical Steam Boiler Materials
J. P. Shingledecker1, R. W. Swindeman1, V. K. Vasudevan2, Q. Wu2, (1)Oak Ridge National Laboratory, Oak Ridge, TN, (2)University of Cincinnati, Cincinnati, OH
The high temperature strength (creep strength) of commercially available (Haynes® 230), modified/controlled chemistry (CCA617/Marco 617), and new (INCONEL® 740) alloys and weldments is being investigated for determining the maximum operating conditions in Ultrasupercritical Steam Power boilers. Microstructural analysis is being used to further understand the structure-properties relationship in these materials.
Development of Gd Enriched Austenitic Alloys for Spent Nuclear Fuel Applications
J. DuPont1, D. B. Williams1, C. Robino2, J. Michael2, R. Mizia3, (1)Lehigh University, Bethlehem, PA, (2)Sandia National Laboratory, Albuquerque, NM, (3)Idaho National Engineering and Environmental Laboratory, Idaho Falls, ID
Ni base alloys containing Gd additions with good weldability and hot workability were developed for spent nuclear fuel applications. This presentation will summarize the basic solidification behavior, microstructure, hot ductility, and weldability of these alloys.
Materials Performance in Black Liquor Gasification Systems
J. R. Keiser, R. A. Peascoe-Meisner, J. G. Hemrick, C. R. Hubbard, Oak Ridge National Laboratory, Oak Ridge, TN
Gasification of black liquor offers the potential for better utilization of a readily available "green power" source. However, material problems present formidable obstacles to the successful implementation of this technology.
The Representation of Creep Rupture in Alloy 617 by Continuum Damage Models
M. J. Swindeman1, R. W. Swindeman2, (1)Stress Engineering Services, Mason, OH, (2)Oak Ridge National Laboratory, Oak Ridge, TN
Alloy 617, an attractive material for ultra-supercritical boilers and Generation IV nuclear power and hydrogen production systems, is being re-examined in terms of continuum damage models. The damage mechanisms that operate at high temperatures are considered and incorporated in rate formulations. The work represents progress toward a useful model of this material’s behavior.
Paper Withdrawn
M. K. Budinski, General Motors Corporation, Honeoye Falls, NY
This presentation will review key challenges and discuss potential materials solutions for proton exchange membrane (PEM) fuel cell stacks and on-board fuel reformers for hydrogen-powered electric automobiles.
Fe-15Cr-5.5Al Alloy Foil for Diesel Engine Catalytic Converter Substrate
L. Chen, B. Jha, Engineered Materials Solutions, Inc., Attleboro, MA
This paper describes a new FeCrAl alloy for diesel engine catalytic converters. It does not contains reactive elements. The alloy was made by roll-bonding and diffusion alloying. Diffusion alloying transferred Al/FeCr/Al composite to Fe-15Cr-5.5Al alloy in either foil processes or converter fabrication. Brazed characteristics, pre-oxidation, and oxidation and creep resistances were examined
High Temperature Behavior of New FeCrAl Alloys
L. Chen1, B. Jha1, J. Hemrick2, E. Lara-Curzio2, (1)Engineered Materials Solutions, Inc., Attleboro, MA, (2)Oak Ridge National Laboratory, Oak Ridge, TN
High temperature behavior is major design characteristics to be considered for catalytic converter substrate applications. Oxidation resistance and creep resistance were examined on new FeCrAl alloys at 0.050mm thickness, produced by roll-bonding and diffusion alloying processes. The influence of alloy chemistry and other effects were investigated.
Hot Corrosion of Austenitic Stainless Steels and Nickel-Base Superalloys in Diesel Exhaust Valve Applications
S. Sinharoy, C. Bennett, S. Narasimhan, J. Larsen, Eaton Corporation, Marshall, MI
In this study, the development of an accelerated corrosion test to simulate hot corrosion attack in diesel exhaust valves is presented and the relative hot corrosion resistance of typical exhaust valve materials are evaluated at 760 oC and 870 oC, exposed for 80 hours is discussed.
Characterization of New, Cast, High Temperature Aluminum Alloys for Diesel Engine Applications
P. Prasad1, V. Vasudevan2, Y. C. Chen3, (1)Gatan, Inc., Pleasanton, CA, (2)University of Cincinnati, Cincinnati, OH, (3)Cummins Inc., Columbus, IN
New environmental regulations can only be met if engines can perform more efficiently, which requires components fabricated from materials that have the required set of mechanical, physical and environmental-resistance properties at elevated temperatures to ~200¡ãC, in combination with low-density and high stiffness. In this context, cast aluminum silicon (354 and 388) alloys are being evaluated.
Tribological Evaluation of Valvetrain Materials for Internal Combustion Engine Applications
C. Y. Qiao, L.E. Jones Company, Menominee, MI
Wear mechanisms of engine valvetrain materials are reviewed. Demands for developing a universally accepted testing method for engine valvetrain applications are addressed. Wear testing conditions for the related applications are discussed.
Lightweight Tailgates with Stainless Steel
G. Tandon1, J. G. Tack2, (1)Altair Engineering Inc., Allen Park, MI, (2)AK Steel Corporation, Middletown, OH
AK Steel commissioned Troy, MI based Altair Engineering Inc. to design a lightweight tailgate using stainless steel. This design resulted in weight reduction over the carbon steel tailgate and a more cost effective solution to other alternative materials. This design does not compromise strength, improves durability and an economical solution for lightweight initiatives.
Development of High Strength Light Weight Alloys by Equal Channel Angular Extrusion (ECAE) Processing
S. Sastry1, R. Mahapatra2, (1)Washington University, St. Louis, MO, (2)NAVAIR-Naval Air Systems Command, Patuxent River, MD
Abstract not available.
Construction of the Data Warehouse for Materials Selection in Mechanical Design
Y. Li, University of Birmingham, Birmingham, United Kingdom
The fundamental aspects of constructing a materials data warehouse to support materials selection in mechanical design were discussed. The significance of having such a data warehouse is that all different types of materials information can be potentiall
Processing and Publishing Materials Property Data on an Enterprise Level
D. E. Mies, MSC.Mvision Databanks, Santa Ana, CA
As companies and OEM'S strive to streamline their processes, they must efficiently collate and disseminate materials property data to support manufacturing operations, both in-house and between suppliers. MSC.Software Corporation explores the possibilities, eventualities, and realities of fully integrating the flow of materials data from test house through manufacturing.
Navy Material Property Database
M. J. Hayden, The Naval Surface Warfare Center, Carderock Division, West Bethesda, MD
The Navy Material Property Database stores mechanical property data on Navy metals for both ship designers and materials engineers. Materials engineers will analyze and store test data while designers will access summaries of test data. Materials will be searched and selected via the web.
Using Databases to Improve Crystal Structure Prediction
D. Morgan1, G. Ceder1, S. Curtarolo2, (1)MIT, Cambridge, MA, (2)Duke University, Durham, NC
This paper describes a novel data mining method for crystal structure prediction. The method combines traditional knowledge based approaches with modern quantum mechanical techniques. We believe this method can provide a general structure prediction tool that makes optimal use of existing databases and computational techniques.
A Seamlessly Integrated Toolset for Reversible and Irreversible Material Modeling: From Laboratory to Structural Analysis
S. M. Arnold, NASA Glenn Research Center, Cleveland, OH
The U.S. aerospace community has a great desire to develop and integrate appropriate software tools and database schemas which enable the capture, discovery, utilization and distribution of engineering relevant material and structural information within a specific organization. Herein an overview will be given of recent activities in developing an integrated toolset which enables a “cradle” to “arm-chair” information management system.
Idea for a New Integrated Materials and Chemicals Database
N. E. Ooi, J. B. Adams, Arizona State University, Tempe, AZ
We present a blueprint for a materials database that incorporates both simulation and experimental data. We describe several methods that major funding institutions can use to encourage contributions to this database. We also describe how it can incorporate data that currently exists in other online databases.
How Can Engineers Get the Materials Information they Need?
W. Marsden, Granta Design Limited, Cambridge, United Kingdom
Software used by some influential organizations (e.g. ASM-online) integrate data from the lab to the designers desktop, so all aspects lie within a single quality controlled, fully traceable, comprehensive system. These systems sustain all data types used to describe materials performance including: · Point data - e.g. a number · functional data - e.g. graphical series · graphics - e.g. micrographs · text - descriptions
An Update on the Development of MatML, the Extensible Materials Markup Language
G. Kaufman1, L. Bartolo2, (1)Kaufman Associates, Columbus, OH, (2)Kent State University, Kent, OH
The development of MatML, the extensible materials markup language, will be discussed, with the principal focus being upon (a) the development of Version 3.1 of the MatML schema, and (b) the initiation of effort to produce an OASIS specification for MatML. An update on other activities of the MatML Coordination Committee will also be covered.
Augmenting MatML with Heat Treating Semantics
A. Varde, E. Rundensteiner, M. Mani, M. Maniruzzaman, R. D. Sisson Jr., Worcester Polytechnic Institute, Worcester, MA
This paper describes a "Quenching Element" proposed as an extension to "MatML", the XML for "Materials Property Data". The Quenching Element aims to augment MatML with the semantics of the "Heat Treating of Materials", thus aiming to be a widespread standard for web-based data storage and exchange in Heat Treating.
Materials Digital Library: Investigating Delivery of Materials Property Data with MatML
L. M. Bartolo1, C. S. Lowe1, K. Stemen1, A. C. Powell2, D. R. Sadoway2, J. Vieyra2, (1)Kent State University, Kent, OH, (2)Massachusetts Institute of Technology, Cambridge, MA
The Materials Digital Library of NSF’s National Science Digital Library program investigates delivery of materials science information. A pilot project using MatML to supply property data to a web-based application is presented. Data access strategies include using: 1) a relational database, 2) MatML directly, and 3) a native XML database.
Enhancing the Flow of Materials Information in Engineering Organizations
W. Marsden, Granta Design Limited, Cambridge, United Kingdom
The Materials Data Management Consortium made significant progress towards the goal of an integrated software system to manage the consortium's materials information. Members defined software requirements to maintain the standards of data quality, efficiency and traceability. This paper describes a key features, including data import/export/compatibility and access control.
An Overview of the Materials and Processes Technical Information System (MAPTIS-II)
M. Mitchell, NASA Marshal Space Center, Huntsville, AL
MAPTIS-II is an information technology tool to acquire, process, and disseminate materials data to dependent audiences. The system is designed to serve engineers, scientists and technologists with up-to-date information of materials for their tasks. XML allows the system to capitalize on the latest Internet technology to exchange information.
Using MATML to Achieve Seamless Data Connectivity Between Diverse Applications
H. Lobo, Matereality and DatapointLabs, Ithaca, NY
Matereality 2.0 now routinely generates MATML as an interchange format for data export. In this paper, we discuss the some of the benefits and limitations of MATML when it is used to transfer data to other applications.
MatWeb's Implementation of MatML
D. Fleming, Automation Creations, Inc., Blacksburg, VA
One barrier for exchanging materials property data on the World Wide Web is the interoperability and interpretation problems that arise from the myriad of existing computer platforms and databases. MatML provides an opportunity to eliminate these barriers and MatWeb has made MatML an integral part of its data-sharing capabilities.
World Trade Center -- Structural Steel Evaluation
F. W. Gayle, NIST, Gaithersburg, MD
In September 2002 the National Institute of Standards and Technology became the lead agency in an investigation of the World Trade Center (WTC)disaster. The investigation addresses many aspects of the catastrophe, from occupant egress to factors affecting how long the Twin Towers stood after being hit by the airplanes, with the goal of gaining valuable information for the future. A major part of the investigation is the metallurgical analysis of structural steel from the Twin Towers. The analysis includes characterization of mechanical properties, failure modes, and temperature excursions seen by the steel. This talk on the metallurgical investigation will describe the structure of the towers, steel recovered from the site, and special issues faced in the analysis of the steel.
Paper Withdrawn II
C. C. Murnane, Frantz Ward LLP, Cleveland, OH
When an accident involving a product occurs, the injured party often files a lawsuit claiming that there was a defect in the manufacture or design of the product. How are these product liability claims proven? While the elements of a design or manufacturing defect claim vary from state to state, the role of the expert is often pivotal. In fact, in certain circumstances, the plaintiff cannot present his case to the jury unless he has obtained and can offer the requisite expert testimony. Contesting the manufacturer’s design often raises issues concerning the state of the art of the applicable technology when the product was manufactured, and technical and feasible alternative designs that could have been used for that product – topics on which only the expert is qualified to opine. In presenting or defending a manufacturing defect claim, the expert will analyze the manufacturer’s design specifications, formula or performance standards and opine on how the product did (or did not) materially deviate from those standards. Industry standards, like ASTM and ANSI, can play an important role in determining the existence of such defects. This presentation will discuss the elements of design and manufacturing defect claims under Ohio law, the role of the expert in establishing or defending such claims, and the relevancy and use of industry standards in the adjudication of these claims.
Optimized Welds in HPS 70W and 100W Steels
A. W. Pense, N. Repetto, Lehigh University, Bethlehem, PA
Optimzed welds,using undermatched weld metals to make weldments with properties equal to matching ones, can be made in HPS 70W and 100W plates 38mm thick or greater if the width to thickness ratio of the weldment is >7 and the undermatch is <20% for HPS 70W and <10% for HPS 100W.
The Effects of Material Variables and Key Processing Parameters on the Oxygen-Assisted CO2 Laser Cutting of Mild-Carbon Steel Plates
S. Thompson, J. Sieber, Colorado School of Mines, Golden, CO
Summary not available.
Effect of Steel Composition on the Laser Cutting Behavior of 25 mm Thick Plates
M. Manohar1, R. Bodnar1, R. I. Asfahani2, M. D. Tumuluru2, G. A. Dries2, N. Chen3, C. Huang3, (1)ISG Research, Bethlehem, PA, (2)US Steel, Monroeville, PA, (3)Caterpillar, Peoria, IL
Hybrid Laser+GMAW Process for High Fatigue Strength Welds
D. F. Farson1, M. H. Cho2, H. W. Choi2, (1)Ohio State University, Columbus, OH, (2)The Ohio State University, Columbus, OH
The shape of the solidified weld metal deposit is important in most structural Gas Metal Arc Welding (GMAW) applications. The work clearly shows the benefits of a hybrid Laser + GMAW process for producing welds with large toe angles and fatigue life.
Fire-Resistant Steels with Enhanced Elevated Temperature Mechanical Properties by Microalloying
M. Walp1, J. Speer2, D. Matlock2, (1)DaimlerChrysler, Auburn Hills, MI, (2)Colorado School of Mines, Golden, CO
The elevated temperature mechanical properties of four microalloyed steels (C-Mn, 0.02Nb, 0.5Mo-0.02Nb, and 0.05V-0.02Nb) and one copper containing steel (1.0Cu) were examined at temperatures up to 700°C. The addition of Mo (0.5wt%) and Nb (0.02wt%) to C-Mn steel demonstrated the most favorable preservation of room temperature strength at higher temperatures. Precipitating species in solution (versus aged) prior to mechanical testing showed to have the highest elevated temperature properties relative to room temperature.
X80 Steel Plates for Gas Line Pipe
A. O. Nosochenko1, I. V. Ganoshenko1, Y. I. Matrossov2, (1)Azovstal Iron & Steel Works, Mariupol, Ukraine, (2)I.P. Bardin, Moscow, Russia
Vanadium Technology Program
J. D. Tirpak1, J. Beatty2, (1)Advanced Technology Institute, North Charleston, SC, (2)United States Army Research Laboratory, Aberdeen Proving Grounds, MD
The Vanadium Technology Program is a multi-year cooperative agreement which is investigating, developing and deploying vanadium micro-alloyed steels in a variety of US Army applications. The current project portfolio addresses mobility and civil engineering applications within the US Army.
Steel Plates for Shipbuilding Without Conventional Heat-Treatment
A. M. Kulkarni, M. S. Patil, Essar Steel Limited, Surat, India
Essar Steel has a long term objective to manufacture increased volumes of steel for shipbuilding application and hence, the current development activities have been initiated.
Effect of In-Line Cooling on the Properties of Hot-Rolled and Quenched-and-Tempered Microalloyed Steel
R. I. Asfahani, US Steel, Monroeville, PA
Customers for steel tubular products require ever increasing strength and toughness for their applications. To meet these demands, steel producers generally must resort to increasing the amount of alloying elements and/or applying thermomechanical-processing techniques. The present study addresses the use of a TMCP processing practice for enhancing the toughness of the steel during the production of microalloyed steel tubulars.
Sour Service Line-Pipe Steel - Comparison of "Low Manganese Steel" with Conventional Alloy Design
A. M. Kulkarni1, M. S. Patil1, J. M. Gray2, (1)Essar Steel Limited, Surat, India, (2)Microalloying International Inc., Houston, TX
There is growing requirement of line-pipe steel with improved resistance to hydrogen induced cracking. Elements like carbon and manganese have a strong tendency to segregate at the center-line of as-cast slabs. Alloy design with reduced manganese levels have given encouraging results when compared to conventional alloy design practice.
Evidence Preservation Issues in Corrosion Failure Analysis
B. A. Miller, IMR Metallurgical Services, Louisville, KY
Identification of substances responsible for corrosion failures is necessary for determining actions to prevent recurrence. Obtaining unaltered corrosion product for instrumental analysis is often problematic, as foreign substances are often intentionally or inadvertently introduced. The purpose of this presentation is to address corrosion evidence preservation from the failure analyst’s perspective.
Intergranular Corrosion of an Aluminum Alloy Light Aircraft Propeller
A. A. Johnson1, R. J. Storey2, (1)Metals Research Inc., Louisville, KY, (2)University of Louisville, Louisville, KY
A light aircraft crashed killing the pilot and passenger. Several inches were found to be missing from one tip of its propeller which was found to have failed by severe intergranular corrosion. Fluorine was found in the vicinity of the fracture and on the fracture surface.
How the Misapplication of a Material Specification can Cause a Major Problem in the Boat Building Industry
R. G. Baggerly1, R. K. Kent2, (1)Associate of MDE, Anacortes, WA, (2)MDE Engineers Inc., Seattle, WA
Aluminum has been used successfully for many years in the boat building industry with the Al-Mg alloy system being of major importance. These alloys are readily weldable and provide good corrosion resistance as well as adequate strength. However, with increasing magnesium content the alloy may develop sensitization in the grain boundaries and become susceptible to stress corrosion cracking. The sheet and plate of these alloys can be processed thermally to immunize them from this condition. In very recent history, a problem developed in the Pacific Northwest where 5083 aluminum alloy was being used for welded boat construction and stress corrosion cracks developed within months of being placed in marine service. This presentation will discuss failures in new boats, a particular temper designation for this alloy that should not have been used in the marine industry, the tests conducted and some metallurgical history for this alloy.
Corrosion Induced Deformation Failure of a Dry Chemical Reactor – A Case Study In Forensic Investigation Approaches, Methods and Frustrations
B. H. Clarke, Williams & Beck, Inc., Rockford, MI
Case study of corrosion induced, deformation failure of two steel reaction vessels. A forensic engineering investigation led to involving an independent metallurgist and the owner’s metallurgist. Presentation will discuss methods and approaches for conducting investigation and engineering and non-technical issues influencing the investigation.
Water Chemistry and Processing Effects on the Corrosion Degradation of Copper Tubing in Cooling Water Systems
J. L. McDougall, M. E. Stevenson, Metals & Materials Engineers, Suwanee, GA
Copper tubing from an industrial chiller was subjected to a complete corrosion failure analysis. Inspection of the tubing indicated substantial corrosion. A metallurgical failure investigation coupled with additional chemical analysis allowed for the most probable cause of failure to be identified. Recommendations were made regarding water treatment.
Corrosion Related Failures of Stainless Steels-Case Histories
R. M. Kain, Corrosion Consultant to the Nickel Institute, Wilmington, NC
The causes of stainless steel corrosion failures in chloride containing aqueous and atmospheric environments are presented. Contributing factors such as material susceptibility, environmental conditions and design elements are reviewed. In some case specially designed tests replicated the service failures.
Corrosion Failure Case Studies
D. Aliya, Aliya Analytical, Inc., Grand Rapids, MI
Case studies of corroded plumbing components will be presented. The importance of understanding the environment in which the component functions, and how that might influence evidence preservation protocols will be emphasized.
Delayed Failure Mechanism in Powder Metallurgy Gears
J. F. Lane, Applied Technical Services, Inc., Marietta, GA
P/M gears used in small motors were experiencing delayed failures. The failures were observed during in-comming inspection, assembly, installation and in the field. The failures were attributed to high residual stresses associated with a steel pin inserted in the end of the gear and environmental factors associated with the microstructure.
Environmental Degradation of Polymers
L. D. Hanke, Materials Engineering and Evaluation, Inc., Plymouth, MN
Environmental stress cracking (ESC) is one of the most insidious failure mechanisms for structural polymer components. ESC failures can occur with very little warning and with catastrophic consequences. A combination of tensile stress and a damaging chemical environment is necessary for ESC, and the mechanism is a time-dependent phenomenon that usually manifests as a delayed failure. The tensile stress required for failure can be a fraction of the materials tensile strength and failure of some polymers can occur in seemingly innocuous environments. ESC is a major problem for long-term service reliability, so better understanding and diagnosis of failures has important economic implications. This presentation will discuss techniques for analysis of polymer failures with emphasis on methods for characterization of ESC failures. Several case studies will be included.
An Overview of the Space Shuttle Columbia Accident from Recovery Through Reconstruction
S. McDanels, National Aeronautics and Space Administration, Kennedy Space Center, FL
TBA
A Review of the Findings and Recommendations of the Columbia Accident Investigation Board
D. P. Dennies, Boeing, Huntington Beach, CA
The Findings and Recommendations of the Columbia Accident Investigation Board will be reviewed and compared to another accident.
Failure Analysis of A286 Carrier Panel Fasteners
T. E. Collins1, B. Tucker2, R. Russell3, (1)The Boeing Company, Huntington Beach, CA, (2)United Space Alliance, KSC, FL, (3)NASA, KSC, FL
During the initial phases of the Shuttle Columbia investigation, one scenario analyzed was loss of a carrier panel behind the wing leading edge. Observations of carrier panel debris noted a brittle fracture appearance on several attach fasteners. Although later determined not to be causal, investigation into these fastener failures was interesting nonetheless.
Columbia Accident Investigation Board (CAIB) Pathfinder Analysis Of Item 33767
P. DeVries, The Boeing Company, Huntington Beach, CA
The Pathfinder Analysis sought to answer Academic questions regarding the maximum heat attained, heating direction/duration, and identify debris imposed on this fuselage section during Columbia break-up and re-entry. The results of debris characterization and heat effects incurred will be presented in the context of traditional failure analysis techniques.
Columbia Tragedy: High Temperature Materials Chemistry and Thermodynamic Considerations of the Breached Wing Leading Edge
E. Opila1, N. Jacobson1, G. Jerman2, (1)NASA Glenn Research Center, Cleveland, OH, (2)NASA Marshall Space Flight Center, Huntsville, AL
The Columbia tragedy has been attributed to ingress of hot plasma into a breach in the wing leading edge upon re-entry. High temperature materials chemistry and thermodynamics of interactions of the re-entry plasma with components of the wing leading edge were used to evaluate possible failure mechanisms.
The Future of Failure Investigation in the Aerospace Industry
D. P. Dennies, Boeing, Huntington Beach, CA
What is the future of failure investigation in the Aerospace Industry? This presentation shall look at the future of various aspects of failure investiation.
Passing the Court’s Test for Allowing Expert Testimony
A. M. Andrews, Ulmer & Berne LLP, Columbus, OH
Product Liability Claims for Design and Manufacturing Defects and the Role of the Expert
C. C. Murnane, Frantz Ward LLP, Cleveland, OH
A Fiberglass Reinforced Plastic Case Study - A Focus on the Importance of Joint Testing Protocols in Current Forensic Practice
C. R. Morin, D. Alexander, Engineering Systems Inc., Aurora, IL
Case study addressing the importance of joint testing protocols in forensic practice particularly related to litigation-related investigations.
Standard Practices for an Expert Witness
D. McGarry, SEA Limited, Columbus, OH
Product Liability and Failure Analysis
R. J. Parrington, IMR Test Labs, Lansing, NY
Failure analysis is a valuable tool in determining product liability. Product failure is reviewed from legal and technical perspectives. Legal definitions, liability and possible defenses are covered as well as the process of failure analysis. Litigation-related failure analyses of metallic and nonmetallic materials are illustrated with numerous images.
Consequence Modeling of Fire: A Study Comparing Large Eddy Simulation and Finite Element Analysis Predicted Failure Criteria to ASTM Standards
N. L. Ryder, C. F. Schemel, J. Sonntag, Packer Engineering, Inc, Columbia, MD
Welding Residual Stress-Induced Buckling of Aluminum Thin Plate
H. Fang1, X. Wang2, C. Fan2, (1)State Key Laboratory of Advanced Welding Production Technology, Harbin Institute of Technology, Harbin, China, (2)Harbin Institute of Technology, Harbin, China
This paper is focused on the welding-induced buckling behavior of Aluminum plate.
Optical Technique for Measuring Distortion of Heat Treated Parts in Situ
F. M. Sciammarella1, P. Nash2, C. T. Tszeng2, (1)Northern Illinois Unvoersity, DeKalb, IL, (2)Illinois Institute of Technology, Chicago, IL
Understanding the effects of heat treatments that cause distortion to a part is critical. Typically, work carried out in this field is post mortem (after heat treatment). This paper provides in-situ measurements of the distortions that a heat-treated part
Characteristics of Fracture Behavior and Fatigue Life for Automotive Crankshaft
J. W. Park, Y. S. Ko, H. O. Ban, H. Park, J. D. Lim, Hyundai Motor Company, Whasung-Si, Gyunggi-Do, South Korea
In the automotive industry, fatigue strength of materials for engine moving parts such as crankshaft is very important. We investigated the fatigue strength and fracture behavior at different fatigue cycles. From the evaluation results, we enable to optimize the design and materials for maximizing the engine performance.
Learning Fractography with Food Fractures
D. Aliya1, M. Pepi2, (1)Aliya Analytical, Inc., Grand Rapids, MI, (2)Naval Air Warfare Center, China Lake, CA
Using inexpensive "test coupons" created from common food items can be a good way to learn macrofractography. Photos of chocolates, carrots, etc., broken in bending, torsion and tension will be presented. Aspects of the effect of the structural object structure and how it affects the fracture appearance will also be described.
Simulation of Hull Rupture During Ship Allision with Dock
R. A. Sire, V. K. Saraf, P. D. Moncarz, Exponent Failure Analysis Associates, Menlo Park, CA
A nonlinear finite element analysis was used to simulate an allision between a bulk cargo vessel and a concrete dock structure that ruptured the vessel's hull. Comparative simulations were run with and without a rubber fender on the dock structure. The analysis included three-dimensional contact, elastic-plastic and nonlinear elastic material constitutive relations, and a hull failure criterion based on local strain energy density.
Failure Analysis in a Vehicle Accident Reconstruction
M. Stevenson, J. McDougall, E. Vernon, L. McCalll, R. Bowman, Metals & Materials Engineers, Suwanee, GA
A metallurgical and mechanical failure analysis was applied as part of a vehicle accident reconstruction of a multi-vehicle collision. One of these vehicles was a coal hauling tractor-trailer. The failure scenario developed in this investigation is compared with other conclusions made by other investigators.
Catching a Thief Who Left No Fingerprints: Failure Analysis of a Hammer Drill Shaft
P. A. Manohar, Modern Industries, Inc., Pittsburgh, PA
Failure investigation of a hammer drill shaft is described. The basic failure mode was identified notwithstanding completely damaged fracture surface as a combination of rotating bending and torsional fatigue failure. The recommendations to prevent such f
Cracking Failure of Piston Crown Ring Land for Marine Engines and Practical Manufacturing Review for its Prevention
J. H. Hwang, J. G. Youn, Hyundai Heavy Industries, Co, LTD., Ulsan, South Korea
Cracked region of Cr-plated piston ring land showed intergranular fracture mode due to hydrogen embrittlement. High matrix hardness by Induction hardening prior to Cr-plating was attributed to the cracking failure. For preventing further cracking, groove quenching method instead of induction hardening was successfully adopted to provide a reasonable matrix hardness.
Evaluation of Aluminum Alloy Heat Treatment Using Fractography
J. L. Evans1, S. A. Batzer2, J. W. Newkirk3, D. S. MacKenzie4, (1)University of Arkansas, Fayetteville, AR, (2)Renfroe Engineering, Inc., Farmington, AR, (3)University of Missouri, Rolla, MO, (4)Houghton International, Inc., Valley Forge, PA
This study evaluated the effect of varying the cooling rate and aging time on the fracture surface of 7050 and 7075 aluminum alloys. Samples were heat treated and tested to failure in uniaxial tension. SEM fractography was conducted, and the ductile dimple size was correlated with the measured tensile strength.
Case Histories: Heat Treatment-Related Failures
E. Vernon, Metals & Materials Engineers, Suwanee, GA
Current Issues and Trends in Failure Analysis: A Roundtable Discussion
A. Tanzer, Siemens Westinghouse, Orlando, FL
INVITED: From Bulk and Thick-Film Sensors to Ceramic Nano-Structures
S. A. Akbar, The Ohio State University, Columbus, OH
This talk will present an overview of a multidisciplinary research effort in ceramic-based chemical sensors by highlighting opportunities as well as challenges. While there are exciting possibilities in nano-ceramics and thin films, there are problems associated with the selectivity and long-term durability of these sensors in real-life applications. Particular emphasis will be given on the development of combustion gas sensors for pollution monitoring and control. Field-test results of these sensors in automobile engines will be presented. The talk will also highlight two future directions: (i) a novel approach for understanding the behavior of electrodes used for sensors and fuel cells and (ii) a very inexpensive process for creating nano-structures in ceramic oxides that has potential for applications in chemical sensing and catalysis.
INVITED: II-VI Opto-electronic Crystals and Their Novel Applications
S. Trivedi1, C. C. Wang1, S. W. Kutcher1, U. Hommerich2, T. O. Poehler3, (1)Brimrose Corporation, Baltimore, MD, (2)Hampton University, Hampton, VA, (3)Johns Hopkins University, Baltimore, MD
We will review our work of 15 years, on binary and ternary II-VI compound semiconductors. We will present our recent work on tunable, room temperature, mid-IR solid state lasing in Cadmium based II-VI tellurides and results on the applications based on electro-optic and magneto-optic characteristics of these materials.
Performance of Crystals for AOTF Imaging: Parameters for Production and Quality Control
N. B. Singh1, N. Gupta2, M. Gottlieb3, D. Suhre3, T. Waite3, A. Berghmans3, D. Kahler3, A. Kirschenbaum3, (1)Northrop Grumman Corporation ES, Baltimore, MD, (2)U.S. Army Research Laboratory, Adelphi, MD, (3)Northrop Grumman, Linthicum, MD
INVITED: Transmission Electron Microscopy for Process Development, Manufacturing, and Failure Analysis of Semiconductor Devices
R. Rai, Freescale Semiconductor, Austin, TX
Self-Assembly – Review and Applications
N. M. Ravindra1, A. T. Fiory1, V. R. Mehta1, S. Shet1, M. P. Lepselter2, (1)New Jersey Institute of Technology, Newark, NJ, (2)BTL Fellows, Inc., Summit, NJ
INVITED: Selective Laser Sintering as a Bridge between University Research and Manufacturing
D. L. Bourell, J. J. Beaman Jr., M. A. Ervin, The University of Texas, Austin, TX
INVITED: Advances in Laser Powder Deposition for Additive Manufacturing
J. W. Sears, South Dakota School of Mines & Technology, Rapid City, SD
Developments in Laser Cladding and Rapid Prototyping have led to a Solid Freeform Fabrication (SFF) technology that produce near net shape metal components by local laser fusion of metal powder alloys. These processes are known by various names such as: Directed Light Fabrication (DLF™), Laser Engineered Net Shaping (LENS™), and Direct Metal Deposition (DMD™) to name a few. For simplicity, we generically refer to this technology as laser powder deposition (LPD. LPD technology has the capability to produce fully dense components with little need for subsequent processing. The LPD technology is also proving to be very useful for repair, including gas turbine engine (GTE) components, due to the high solidification rates and low heat input inherent in laser processing. This presentation gives an overview of the process, process control, material response and applications.
Relations Between Process Variables and Steady-State and Transient Melt Pool Size in Laser Additive Manufacturing Processes
J. L. Beuth, A. J. Birnbaum, P. Aggarangsi, Carnegie Mellon University, Pittsburgh, PA
This research relates melt pool size in laser additive manufacturing to process variables. Steady-state process maps for small- and large-scale processes are used to relate process size to process robustness. The process map approach is also used to study transient changes in melt pool size, with applications to real-time process control.
Effects of Process Variables and Size-Scale on Microstructure in Laser Additive Manufacturing of Ti-6Al-4V
N. W. Klingbeil, S. Bontha, D. Gaddam, Wright State University, Dayton, OH
This work applies simulation-based methods to investigate the effects of process variables (laser power and velocity) and size-scale (LENS vs. industrial) on microstructure in laser additive manufacturing processes. Results suggest that changes in process variables and size-scale can have a significant effect on grain size and morphology in Ti-6Al-4V.
Phase Transformation and Microstructure of Dental Porcelain Powder in Laser-Assisted Rapid Prototyping Processes
L. Shaw1, X. Li2, (1)University of Connecticut, Storrs, CT, (2)University of Tennessee Space Institute, Tullahoma, TN
INVITED: Nanostructured Materials and Nanoscale Manufacturing
J. Narayan, North Carolina State University, Raleigh, NC
INVITED: Process Development and Micro/Nano Fabrication of Piezoelectric Based MEMS and NEMS Devices
R. G. Polcawich, US Army Research Laboratory, Adelphi, MD
INVITED: Designing Semiconducting Materials
S. Mahajan, Arizona State University, Tempe, AZ
INVITED: Material Challenges in Advanced Interconnects for Future Microelectronics
C. U. Kim, N. L. Michael, D. Meng, The University of Texas, Arlington, TX
INVITED: Challenges for Engineering Ultra-Fine Electronic Interconnects
S. Kang, Agere Systems, Allentown, PA
INVITED: Scaleable Cost-Effective Synthesis and Self-Assembly of Single Wall Carbon Nanotubes
Z. Iqbal, A. Goyal, New Jersey Institute of Technology, Newark, NJ
INVITED: Solid Freeform Fabrication in Computer-Aided Tissue Engineering
W. Sun, University of Connecticut, Storrs, CT
Tissue Engineering, integrating a variety of science and engineering disciplines to create artificial tissues and organs for transplantation, which restore, maintain or improve the function of human tissues, is emerging as one of the most promising therapies in regenerative medicine. Advance in computer-aided technologies and solid freeform fabrication, along with their integrations with Biology, Engineering, Biomaterials, and Information Technology to tissue engineering applications has evolved a new field of computer-aided tissue engineering. This interdisciplinary field spans medical imaging process, CAD/CAM and advanced manufacturing for modeling, design, and fabrication of biological tissue and organ substitutes. Among many critical technologies adopted in the field of computer-aided tissue engineering, solid freeform fabrication has been one of the most important for manufacturing tissue extra-cellular matrices or scaffolds onto which cells can attach, grow, and are guided to form new tissues. Latest advances of the freeform fabrication technology have further extended its application to bio-plotting, cell and organ printing, and construction of bioactive tissue and organ constructs. This presentation will introduce some salient advances in the research and development of solid freeform fabrication in computer-aided tissue engineering, particularly to focus on the integration of solid freeform fabrication with computer-aided tissue modeling, computer-aided implantology, and manufacturing of complex tissue scaffolds. An overview of computer-aided tissue engineering, its scope and challenges, applications of using rapid prototyping biomodeling for surgical rehearsal and planning, example of computer-aided tissue engineering based biomimetic design approach and freeform fabrication of load-bearing tissue replacements and scaffolds, and our development of biopolymer deposition for freeform fabrication of cell-imbedded tissue constructs will also be presented.
Characterization of Mechanical Properties of Porous Bio-Ceramics Bone Replacement Structures Fabricated by TheriForm™Three-Dimensional Printing
W. K. Lau1, J. Sharobiem1, J. Delfino1, T. Bradbury1, C. Gaylo1, S. Khalil2, W. Sun3, A. Lau2, (1)Therics Inc., Princeton, NY, (2)Drexel University, Philadelphia, PA, (3)University of Connecticut, Storrs, CT
This paper presents the approach being developed for characterization of elastic-plastic properties of bio-ceramics materials with different porosity fabricated by 3-dimensional Printing (3DP) process. It involves conducting Continuous Depth-Sensing Indentation tests, analytical modeling with Finite Element Analysis and Inverse Analysis using Kalman Filter.
INVITED: Bridging Prototyping and Manufacturing via Robocasting Fine Particle Pastes
J. Cesarano III, Sandia National Laboratories, Albuquerque, NM
Robocasting is a freeform fabrication technique that uses computer controlled layer-wise extrusion of colloidal pastes to fabricate components from fine powders. Complicated and unique components may be manufactured without the use of molds or containers. The process is relatively rapid and does not require waxes, thermosetting polymers, or polymerization reactions to build parts. Instead, robocasted parts ”cure” when highly concentrated pastes transition from a yield-pseudoplastic rheology to a dilatant, solid-like state upon minimal drying. Processing particulate pastes in this semi-plastic state requires careful control of rheology and is accomplished with polyvalent cation complexation of the polyelectrolyte dispersants. This presentation will focus on: 1) the fundamentals of manipulating inter-particle forces in concentrated colloidal suspensions for the explicit use in robocasting; 2) the versatility of robocasting for catalytic, filtration, bio-medical, electronic, and composite applications; 3) properties of unique structures fabricated via robocasting; 4) potential for automated manufacturing and 5) limitations of the technology. Sandia is a multiprogram laboratory operated by Sandia Corporation, a Lockheed Martin Company, for the United States Department of Energy under Contract DE-AC04-94AL85000.
Rapid Prototyping of Dental Restoration via Multi-Material Slurry Extrusion
J. Wang1, L. Shaw2, (1)Institute of Materials Science, University of Connecticut, Storrs, CT, (2)University of Connecticut, Storrs, CT
This study investigates dental restoration via a rapid prototyping process, multi-material slurry extrusion. Fabrication of tooth crowns without supporting materials has been demonstrated. The shape of the tooth crown is reserved after sintering. This study shows the possibility of reducing the time and cost on dental restoration via rapid prototyping processes.
Rapid Prototyping of Single-Walled Carbon Nanotube Reinforced Ceramic Composites
E. L. Corral1, N. Perry1, E. V. Barrera1, J. N. Stuecker2, J. Cesarano III2, N. S. Bell2, M. Pasquali1, (1)Rice University, Houston, TX, (2)Sandia National Laboratories, Albuquerque, NM
Single-walled carbon nanotube reinforced ceramic composites parts were successfully fabricated using a free form fabrication process called robocasting. The colloidal processing methods used to manipulate charging behavior between carbon nanotube and ceramic particle surfaces while maintaining high solids loading suspensions suitable for robocasting solid parts will be discussed.
INVITED: Recent Advances in Design and Rapid Prototyping Methods for Heterogeneous Multifunctional Devices
S. Das, University of Michigan, Ann Arbor, MI
This talk discusses ongoing research in my laboratory on advanced design and rapid prototyping (RP) techniques addressing the construction of multifunctional devices. The first part of this presentation focuses on one such class of devices, namely bone tissue engineering scaffolds. The emerging field of tissue engineering poses many challenges, particularly in the repair and reconstruction of complex joints such as the temporo-mandibular joint (TMJ). To reconstruct such joints, novel design and fabrication methods are needed to build scaffolds with anatomic shapes incorporating multiple, spatially varying, biomaterial compositions and porous architectures that will enable the simultaneous regeneration of multiple tissues while temporarily providing structure and functionality. One aim of our ongoing research is to develop techniques for fabricating such scaffolds by combining RP and computational design methods. Using such methods, scaffolds with periodic and biomimetic architectures were fabricated by selective laser sintering of polycaprolactone, a biocompatible, biosorbable polymer with applications in implantable long-term drug delivery devices, as well as bone and cartilage repair. Results of scaffold design, fabrication, in vitro bio-compatibility, mechanical testing and implantation studies will be presented. The second part of this talk will describe the development of a new direct write RP technique for the layered fabrication of meso- and macroscale, compositionally heterogeneous devices. This technique is based on patterned deposition of micro- to nanoscale granular materials through miniature nozzles with a target minimum in-plane feature resolution of 100ìm. While substantial theoretical and experimental work has been conducted on large scale hoppers, little or no work exists on the flow of granular materials in miniature hoppers. I will present existing background, the design of our system and the results of experiments on gravity and vibration assisted deposition of spherical sub-125ìm particles. Proof-of-concept demonstrations on patterned deposition for a variety of applications will be presented. This talk will conclude with a discussion of scientific and technical challenges, potential applications of and devices envisaged by this technique.
INVITED: New Directions for the Global Materials Enterprise
T. Marechaux, National Materials Advisory Board, Washington, DC
A number of national and international trends are affecting the research, development, and production of materials. Although financial drivers (the costs of energy and labor, for example) are most often cited, some higher-level trends may ultimately be more important. Some of the drivers for this trend include new information technology, which allows more timely and complete communication of not only business information, but also of real-time technical data among designers, developers, and producers. Another critical factor is the cost of compliance with regulations and policies which have been found to have both intended and unintended consequences in their implementation. An additional driver, which may turn out to be the most important, is the levelling of education, training, knowledge, and skills around the world. This presentation will outline the progress of these and other trends as applied to the materials industry.
INVITED: Retooling Manufacturing: Bridging Design, Materials, and Processing
R. B. Pipes, The University of Akron, Akron, OH
The Department of Defense (DoD), having identified gaps in the communication and feedback processes between design and manufacturing, requested that the National Research Council conduct a study to develop and define a coherent framework for “bridging” these gaps through data management, modeling, and simulation. This framework is intended to guide investment decisions in basic research to create better modes and methods of communication and collaboration between the various groups involved in bringing complex products through the design and testing process and into production. While the charge to the committee was to concentrate on the research aspects of design and manufacturing, the committee recognized that bridging the various domains involved will require substantial cultural and organizational changes. This study described a framework for virtual design and manufacturing and the tools that are part of this framework. The study addressed the economic dimension of this framework and the barriers to its implementation in DoD acquisition. Finally, the study provides recommendations and research needed to implement the virtual design and manufacturing framework. These study results will be presented.
INVITED: Accelerating Technology Transition: Bridging the Valley of Death for Materials & Processes in Defense Systems
D. Apelian, WPI, Worcester, MA
Summary not available.
INVITED: Better Solder Joints by Design
E. A. Holm, M. K. Neilsen, A. F. Fossum, P. T. Vianco, S. N. Burchett, Sandia National Laboratories, Albuquerque, NM
Because solders operate at high homologous temperatures, their microstructures continually change. In environments that include thermal cycling, microstructural evolution combines with cyclic strain to initiate thermomechanical fatigue (TMF), a principal failure mechanism in Pb-Sn solders. However, most interconnect design tools do not account for these microstructural changes. Since predicting solder joint lifetime is critical to designing for product reliability, we have developed a viscoplastic continuum damage (VCD) model for TMF of Pb-Sn solders that includes the coupling between microstructural evolution and thermomechanical response. This model captures experimentally observed phenomena, and corroborates empirical observations of existing circuit boards. Utilizing a microstructural failure criterion, we predict widely varying interconnect lifetimes for different joint geometries. A simplified version of the VCD model, the Solder Interconnect Predictor (SIP), is available as a desktop design tool. This science-based approach to solder joint design can improve manufactured products that undergo frequent or severe thermal cycling (automobiles) as well as high reliability products (satellites, aircraft). This work was performed in part at Sandia National Laboratories, a multiprogram laboratory operated by Sandia Corporation, a Lockheed Martin Company, for the United States Department of Energy under Contract DE-AC04-94AL85000.
Round Table Panel Discussions
R. Abbaschian1, T. Marechaux2, R. B. Pipes3, D. Apelian4, E. A. Holm5, (1)University of Florida, Gainesville, FL, (2)National Materials Advisory Board, Washington, DC, (3)The University of Akron, Akron, OH, (4)WPI, Worcester, MA, (5)Sandia National Laboratories, Albuquerque, NM
This session will be open to the attendeess to share their views with the authors.
INVITED: Prediction of Microstructure/Property Relationships in Ti Alloys
H. L. Fraser1, T. Searles2, S. Kar2, E. Lee2, R. Banerjee2, G. Viswanathan2, J. Tiley3, (1)Center for Accelerated Maturation of Materials, Columbus, OH, (2)The Ohio State University, Columbus, OH, (3)Air Force Research Laboratory, Wright-Patterson, AFB, OH
INVITED: Challenges of Bridging the Science and Manufacturing of Utility Gas Turbine Components
B. B. Seth, Siemens-Westinghouse Power Corporation, Orlando, FL
INVITED: Structural Materials for Terrestrial and Space Nuclear Applications
S. J. Zinkle, Oak Ridge National Laboratory, Oak Ridge, TN
This paper compares and contrasts performance requirements and summarizes candidate structural materials in existing fission reactors, proposed fusion and Generation IV fission reactors, and proposed space fission reactors. Higher temperature capability (driven by creep strength and chemical compatibility phenomena) and neutron irradiation resistance are crosscutting themes.
INVITED: Second Phase of Ultra Steel Project at NIMS
K. Tsuzaki, K. Nagai, National Institute for Materials Science, Tsukuba, Japan
INVITED: Nanoindentation as a Tool for Developing New Structural Materials
G. M. Pharr1, E. P. George1, A. Rar1, H. Bei1, M. L. Santella2, D. Lee3, (1)University of Tennessee/Oak Ridge National Laboratory, Knoxville, TN, (2)Oak Ridge National Laboratory, Oak Ridge, TN, (3)University of Tennessee, Knoxville, TN
INVITED: Plasticity in Structural Amorphous Alloys
T. G. Nieh, Lawrence Livermore National Laboratory, Livermore, CA
Summary not available.
INVITED: Friction Stir Processing: A Technique to Locally Tailor Properties
M. W. Mahoney, C. B. Fuller, W. H. Bingel, Rockwell Scientific, Thousand Oaks, CA
Friction-stir processing (FSP) is an emerging surface-engineering technology used to locally eliminate casting defects and refine microstructures, thereby improving strength and hardness, increase resistance to corrosion and fatigue, enhance formability, and improve other properties. FSP has been applied to Al, Cu, Fe, and Ni-based alloys with resulting property improvements. Details of the benefits and limitations of FSP, along with examples of current and potential applications, will be presented.
INVITED: Friction Stir Welding of Aircraft and Aerospace Structures
W. Arbegast, C. D. Allen, South Dakota School of Mines and Technology, Rapid City, SD
INVITED: FSW of Steels and Other High Temperature Materials
T. Nelson, Brigham Young University, Provo, UT
Technology improvements and new process innovations in friction stir welding (FSW) of high temperature materials (HTM) opens the potential to broader application. Improvements in the wear resistance and fracture toughness of PCBN tooling continue to enhance the feasibility of FSW of HTM in a variety of materials. More significantly, new developments in process application, such as underwater FSW of steels and stainless steels, and FSW equipment for joining linepipe steels in oil and gas transportation, have expanded the potential of this innovative manufacturing technology. Innovated developments in FSW welding equipment has made feasible interior and exterior FSW of steel piping. FSW of linepipe for oil and gas transmission offers improved weld quality, reliability, reproducibility and the ability to joining higher strength linepipe steels. Weld demonstrations and resulting weld microstructures and mechanical properties of underwater FSW and linepipe FSW in steels will be presented.
Expanding Superplastic Forming Applications via Friction Stir Processing
R. S. Mishra, Missouri University of Science and Technology, Rolla, MO
Superplastic forming is often used for manufacturing of unitized structures. The conventional superplastic forming is limited to sheet metals of <3 mm thicknesses. Severe plastic deformation processes are being evaluated to, (a) increase the forming rates, and (b) expand the superplastic forming applications. Friction stir processing has the potential to enable several new concepts for expanding the superplastic forming domain. The potential of friction stir processing for the development of some of these concepts, including thick sheet superplasticity, selective superplasticity, and superplastic forging will be presented.
Nanostructured Ceramics for Orthopaedic Prostheses
R. J. Narayan, Georgia Institute of Technology, Atlanta, GA
We have developed a diamondlike carbon/HA bilayer, in which the bilayer surface (HA) is bioactive and the interlayer (diamondlike carbon) is biocompatible, wear resistant, and corrosion resistant. We have successfully deposited nanocrystalline hydroxyapatite and DLC films by ablating a hydroxyapatite target and a graphite target using a KrF laser. The DLC/nanocrystalline HA bilayer material is potentially useful for several orthopedic implant designs.
Synthesis of Uniformly Dispersed Pre-Compacted Composite Powders via the Glycine Nitrate Process
K. S. Weil1, J. S. Hardy2, (1)Pacific Northwest National Laboratory, Richland, WA, (2)Pacific Northwest National Laborotory, Richland, WA
We have used a chemical synthesis approach known as the glycine-nitrate combustion synthesis process to prepare a series of ceramic-metal composite powders. By adjusting the ratio of the reactants in the process, it is possible to synthesize both CMC and MMC type powders with a unifrom dispersion nanoscale reinforcement particles.
Processing of Al-TiC Nano-Composites by Thermal Plasma
R. G. Reddy, L. Tong, The University of Alabama, Tuscaloosa, AL
Quenching: Understanding, Controlling and Optomizing the Process
R. D. Sisson, M. Maniruzzaman, S. Ma, Worcester Polytechnic Institute, Worcester, MA
While quenching is a critical commercial heat treating process the current systems to control and optimize this process are not fully developed. In this paper the need for a reliable, robust quench probe will be presented followed by the possible use of a quench probe for process control.
A Study of Gas Phase Dynamics in Combustion Assisted Thermal Spray Process
C. Xia, T. Shamim, P. Mohanty, The University of Michigan, Dearborn, MI
A numerical investigation is conducted to gain fundamental understanding of gas phase dynamics through the nozzle of a combustion assisted thermal spray gun. The results elucidate the influence of various design parameters, including the reacting gas properties and nozzle barrel geometry, on the coating quality of thermal spray process.
Microstructure and Properties of Boronized Metallic Alloys
R. S. Petrova, New Jersey Institute of Technology, Newark, NJ
Paper Withdrawn
S. H. Wang1, L. Xue2, (1)National Research Council of Canada, London, ON, Canada, (2)National Research Council Canada, London, ON, Canada
Exploration is made to deposit thick, dense and uniform W/Cu composite overlays using laser-cladding technique. W and Cu separate after reaching certain coating thickness, making the fabrication difficult. This technical challenge is overcome by adjusting processing parameters, by modifying the composition of powder blends and by depositing functionally gradient coatings.
Development of Low Young's Modulus Amorphous Carbon Finer Reinforced Aluminum Composites
T. Imai1, I. Shigematsu1, N. Saito1, K. Suzuki1, S. Dong2, K. Osamura3, (1)National Institute of Advanced Industrial Science & Technology, Nagoya, Japan, (2)Harbin Institute of Technology, Harbin, China, (3)Kyoto University, Kyoto, Japan
Aluminum matrix composites, which exhibit high tensile strength of 400~600 Mpa and low YoungOs modulus of 40~60GPa, could be developed. The low YoungOs modulus aluminum composites have a potential to apply to medical application, an industrial robot, a spring for automobiles, a glasses flame and a vibration absorption.
Microstructure and Mechanical Properties of AZ31 Alloys Processed by Extrusion and Different-Speeds-Rolling
T. Imai1, N. Saito1, I. Shigematsu1, K. Suzuki1, S. Dong2, (1)National Institute of Advanced Industrial Science & Technology, Nagoya, Japan, (2)Harbin Institute of Technology, Harbin, China
The microstructure and the mechanical properties of AZ31 alloys processed by extrusion and different-speeds-rolling(DSR) were investigated. The AZ31 deformed by DSR has relatively uniformly fine grain size of 10~15micron and indicates strong anisotropy for yield stress and tensile strength in the case the roller was kept at room temperature and the billets heated up to 573K. But, the anisotropy of strength for AZ31 removed in the case the roller temperature becomes to 573K and the billet was heated to more than 573K and formability of the AZ31 was investigated. AZ31 deformed by extrusion and DSR produces superplasticity which indicates 250% total elongation at the strain rate of 10-3 s-1 and 723~748K.
Large Stranded Renewables: The International Renewable Hydrogen Transmission Demonstration Facility
W. C. Leighty, The Leighty Foundation, Juneau, AK
Summary not available.
The Effect of Ca Addition on Castability and Electrochemical Properties of Mg-alloys Produced by Casting
H. S. Kim1, C. Suryanarayana2, (1)Dept. of Materials Engineering, Miryang National University, Kyongnam, South Korea, (2)University of Central Florida, Orlando, FL
The effect of Ca additions in Mg on cast ability; ignition temperature and electrochemical properties have been investigated in the as-cast magnesium alloys. Not only the remarked improvement of electrochemical properties but also the ignition prevention
Paper Withdrawn
P. Naud1, A. Chalifour1, Y. Dubé1, M. Brochu2, (1)Université du Québec, Trois-Rivières, QC, Canada, (2)XperX, Inc., Montréal, QC, Canada
In this paper we present a computer vision approach developed for defects detection and wall thickness measurements of corroded pipes inspected by tangential radiography. First the methodology and algorithms are presented. Then, the system performance is tested by analysing radiographs gathered from industrial applications which covers a wide variety of corrosion and pipe profile.
Mechanical Behavior of Poly(Trimethylene Terephthalate)(PTT)-Polyolefin Blends for Thermoplastic Engineering Application
S. N. Paul1, S. Deo1, K. Dangayach2, J. D. Ekhe1, (1)Visvesvaraya National Institute of Technology, Nagpur, India, (2)Shell Chemical LP., Houston, TX
Inclusion Rating by SEM/EDS
J. J. Friel, Princeton Gamma-Tech, Rocky Hill, NJ
As inclusions in steel get fewer and smaller, a new ASTM standard is available to characterize them by size, shape, and chemistry using the scanning electron microscope (SEM) with energy-dispersive spectrometry (EDS). Chemical classes can be set up for specific materials, but the number and size of detected inclusions varies with magnification.
Microwave Melting of Metals - An Efficient Furnace/Holder
M. S. Morrow1, H. E. Huey2, (1)Microwave Synergy, Inc., Chattanooga, TN, (2)Micramics, Inc., San Jose, CA
The reduction of impurities in the new microwave furnace reduces metal loss and provides a better product with fewer inclusions or chemical reactions. Samples of aluminum alloy molten and cast in a microwave furnace illustrates the new paradigm for microwave heating of crucibles for metal melting freeing the user from the use of painted refractory coatings. This reduces inclusions and the formation of carbides. Controlling the atmosphere/vacuum also reduces chemical interaction and/or gas absorbtion.
Microwave Melting and Casting of Metals-Impurity Reduction
H. E. Huey1, M. S. Morrow2, (1)Micramics, Inc., San Jose, CA, (2)Microwave Synergy, Inc., Chattanooga, TN
In addition to the energy efficiency of microwave furnaces, the reduction of impurities in the new processes reduces metal loss and provides a better product with fewer inclusions or chemical reactions. A discussion of the new paradigm for microwave heating of crucibles for metal melting frees the user from the need for coatings. This reduces inclusions and the formation of carbides.
Paper Withdrawn
I. S. Jawahir, I. A. Arriola, P. C. Wanigarathne, University of Kentucky, Lexington, KY
This paper will present the results of an experimental study showing the effects of tool coatings on machining performance (chip-forms/chip breakability, cutting forces, tool-wear patterns, etc.) in orthogonal machining of 1045 steel with grooved tool inserts.
Materials for Ultra-Supercritical Steam Power Plants
J. P. Shingledecker, R. W. Swindeman, I. G. Wright, R. R. Judkins, P. J. Maziasz, R. L. Klueh, R. Battiste, Oak Ridge National Laboratory, Oak Ridge, TN
Increased cycle efficiency is the key to the cleaner use of coal for generating electricity. As efficiency increases, less coal is burned, and less CO2 is produced per megawatt of electricity. Increasing the maximum steam temperature will increase cycle efficiency and thus will require improved materials and components.
High Speed Machining Modeling
N. Saini, Third Wave Systems, Minneapolis, MN
Machining modeling is becoming an increasingly important tool in gaining understanding and improving machining processes. This is particularly true in hard to machine materials. Latest developments in Titanium machining with material removal rates two times the industry standard and the use of modeling technology will be the focal point of discussion.
Microstructural and Mechanical Properties of AA6061 SPD Processed by Multi-Axial Compressions (MAC)
B. Cherukuri, R. Srinivasan, Wright State University, Dayton, OH
The variation of microhardness with accumulated strain, the flow behavior of the MAC processed material determined through tension and compression tests at different strain rates and temperatures will be presented.
Low Total Ownership Cost Continuously Regenerable ChemBio Mitigation System
D. R. Cahela1, A. P. Queen1, B. J. Tatarchuk1, M. W. Meffert2, W. A. Jacoby3, (1)Auburn University, Auburn, AL, (2)Intramicron, Inc, Birmingham, AL, (3)University of Missouri, Columbia, MO
A 3000 cfm continuous regenerable ChemBio Mitigation system has been tested at the Anniston Immune Room facility. The regenerable system permits lower sorbent inventory and lower pressure drop. Regeneration is key to reducing weight, volume and power requirements resulting in advantages in total cost of ownership over throw away units.
High Efficiency CPE Filters by Regenerable Composite Bed
A. P. Queen, B. J. Tatarchuk, Auburn University, Auburn, AL
5-log protection for 85 minutes at Collective Protection Equipment (CPE) rates was achieved by a composite bed composed of large sorbent particles followed by a polishing filter. The system exhibits 1.3” H2O pressure drop at 1.3 cm total bed thickness and is regenerable by hot air purge.
Aim to Offer User-Friendly Materials Databases
M. Yamazaki1, K. Yagi2, D. Cebon3, M. Ashby4, (1)Tokai University, Kanagawa-ken, Japan, (2)National Institue for Materials Science, Tsukuba-shi, Japan, (3)Granta Design Ltd., Cambridge, United Kingdom, (4)Granta Design Limited, Cambridge, United Kingdom
NIMS Materials Database was connected to a Materials Database@Network developed by Granta Design, enabling integrated retrieval of major databasesDThe user will be able to get the needed information more exactly using this integrated retrieval system of materials databasesD
Composition on the Basis of Phenol –Formaldehyde Resin and Basalt Fabric
G. S. Abashidze1, N. M. Chikhradze2, (1)Institute of Mining Mechanics, Tbilisi, Georgia, (2)Mining Institute, Tbilisi, Georgia
The obtained material in comparison with the analogous composition based on phenol- formaldehyde resin has both less contraction and less corrosion activity relating to the products contacting with it.
Ab Initio Studies of Bulk and Surface Properties of Cubic Boron Nitride
N. E. Ooi, J. B. Adams, Arizona State University, Tempe, AZ
We calculated the surface energy, structure, and work function of the cubic boron nitride (110) surface using density functional theory. Calculations were done using plane waves, pseudopotentials, and both the LDA and GGA. Our surface energy and work function data is the first available for the cubic boron nitride (110)
Microstructure Characterization Using 3-D Orientation Data Collected by an Automated FIB-EBSD System
M. A. Groeber1, B. K. Haley2, S. Ghosh2, M. D. Uchic3, (1)The Materials and Manufacturing Directorate, Wright-Patterson AFB, OH, (2)The Ohio State University, Columbus, OH, (3)Air Force Research Laboratory, Wright-Patterson AFB, OH
The scope of this work is to develop new techniques to characterize microstructures in both 2-D and 3-D. The development of the FIB-EBSD system yields fast, useful information that presents new opportunities to characterize materials. Correlations between 2-D and 3-D information are also being explored.
Materials and Performance Issues for Alloys in the Supercritical Water Cooled Reactor
S. Teysseyre, G. Was, University of Michigan, Ann Arbor, MI
The Supercritical Water Cooled Reactor (SCWR) is one of the most promising Generation IV nuclear reactor designs. A presentation of the reactor operating conditions will led to the specific challenges facing the materials in SCWR.
Alloy Development for Advanced Waste-to-Energy Boilers
Y. Kawahara, Mitsubishi Heavy Industries, Yokohama, Japan
Recently, many kinds of waste-to-energy combustion systems have been operated to minimize harmful emissions. Corrosion environments in these plants have become severe and complex. This presentation shows recent progress in corrosion resistant alloys and coatings for advanced waste-to-energy boilers.
Biaxially Textured Copper and Copper Alloy Substrates for use in HTS Coated Conductors
N. A. Yust1, D. P. N. Barnes1, R. Srinivasan2, C. V. Varanasi3, (1)Air Force Research Laboratory, Wright-Patterson AFB, OH, (2)Wright State University, Dayton, OH, (3)University of Dayton Research Institute, Dayton, OH
A study on preferred texture development in copper and copper alloy substrate tapes produced by heavy cold rolling and subsequent recrystallization heat treatments. Preliminary results on deposited intermediate buffer layers and superconducting YBCO.
Alfa Foams- Production Process, Characterization and Applications
Y. Bhambri1, J. Snider1, V. Sikka1, L. Boyd2, R. Purgert2, (1)Oak Ridge National Laboratory, Oak Ridge, TN, (2)Energy Industries of Ohio, Independence, OH
A new processing technique for producing Aluminum based foam (Alfa foam) containing fly ash has been developed. The processing method for producing Alfa foam with different particulate aggregate sizes has been discussed. The foam is characterized for mechanical properties as well as microstructure. Detailed image analysis reveals that difference in mechanical properties among foams of different particulate sizes is due to variation in relative amount of constituent phases. Work is continuing in altering the processing parameters in the production of Alfa foams to meet the application demands of foam in acoustic damping and structural panels.
Evolution of Microstructures Upon Aging Around 1000oC in Nb-Si-Ti-Al-Cr-X Alloys for High Temperature Aeroengine Applications
H. Song1, R. Tewari1, V. K. Vasudevan1, A. Chatterjee2, (1)University of Cincinnati, Cincinnati, OH, (2)Rolls-Royce Corporation, Indianapolis, IN
Aging of Nb-Si-Ti-Al-Cr-X complex alloys have produced various morphologies of the Laves phase. Formation of these phases has been rationalized in terms of solute partitioning of different elements in various phases. Role of these phase in high deformation and on mechanical properties of these alloys has been determined.
Recent Advances in Weldability Testing for Advanced Materials
J. C. Lippold, The Ohio State University, Columbus, OH
Over the years, a number of new weldability tests or modifications of previous tests have been developed at the Ohio State University and Edison Welding Institute. This presentation reviews the current status of weldability testing as it applies to advanced and specialty materials.
Reactive Air Brazing for High-Temperature Electrochemical Applications
J. Y. Kim1, K. S. Weil1, J. S. Hardy2, (1)Pacific Northwest National Laboratory, Richland, WA, (2)Pacific Northwest National Laborotory, Richland, WA
A novel technique, referred to as reactive air brazing (RAB), has shown a promise in joining components used for high-temperature electrochemical applications. The important advantage of RAB over conventional brazing techniques is that RAB joining is conducted directly in air. Properties and microstructure of this braze will be discussed.
Analysis of Interface in Diamond Brazed Joint
F. Sun, Harbin University of Science and Technology, Harbin, China
CVD diamond thick film was brazed to cemmented carbide by using a active filler metal. The interfacial reactions and characterization of joints under different processing condition were studied. Some micrographs of new phase were found for the first time and the microstructure model near interface were advanced
Long-Term Effects in Ag-CuO Brazes Under Dual Reducing/Oxidizing Gas Conditions
J. Y. Kim1, J. S. Hardy2, K. S. Weil1, (1)Pacific Northwest National Laboratory, Richland, WA, (2)Pacific Northwest National Laborotory, Richland, WA
Exposure to reducing gas on one side of a Ag-CuO brazed seal and oxidizing gas on the other initiates degradation after several hundred hours. We will discuss the apparent mechanisms by which degradation takes place and what methods are being investigated to combat this problem.
Development of Hyper-Interfacial Bonding Process of Ultra-Fine Grained High Strength Steels
K. Nishimoto, K. Saida, B. Jeong, Osaka University, Osaka, Japan
A new conceptual bonding technique, "hyper-interfacial bonding" has been proposed as the most effective bonding technique for ultra-fine grained steels. The hyper-interfacial bonding process was characterized by the instantaneously surface-melted pressu
Important Lessons Learned in the Design of Consumables
S. Liu, Colorado School of Mines, Golden, CO
Colorado School of Mines has built a tradition in consumables research for high strength steels during the past three decades. In the 1970's, Mines researchers investigated submerged arc welding for pipeline applications and systematically characterized the fundamental behavior of welding fluxes. They determined the effects of the individual flux ingredients on weld pool chemistry and weld metal chemical composition. They also established the relationships between flux ingredients, weld metal microstructure and weld joint mechanical properties. The knowledge gained in these studies was later applied to the development of coated electrodes for welding steels of 130-ksi yield strength. These studies established the importance of molten flux-weld pool interaction on alloying elements recovery and the non-uniform nature of weld chemical composition. The bimodal nature of weld metal inclusions were observed and related to weld pool deoxidation and weld solidification. High strength steel welding requires more stringent consumables that can deliver low diffusible hydrogen and high weld metal toughness. Consumables that result in low diffusible hydrogen, increased productivity and enhanced weld properties are in great demand. As strength and toughness levels of the steels continue to increase, new generations of consumables must be developed. Two novel consumables design concepts are being investigated at the Colorado School of Mines for steels with strengths greater than 100-ksi yield strength. The first one is based on a duplex microstructure consisted of lath martensite and ferrite. The second one is based on low carbon, high alloy martensite.
Filler Alloy Design for Titanium Weldments
C. E. Cross, University of Montana, Butte, MT
Amongst my more memorable research collaborations with Prof. Glen Edwards at the Colorado School of Mines was a study into the weldability of Ti-6211. It became apparent early in this study that there is a serious problem with formation of large columnar grains in the weld metal, a problem commonly experienced whenever titanium is welded. Titanium appears to be particularly insensitive to the competitive grain growth mechanism, which normally results in some grain refinement in other metals. The reason for this insensitivity is likely due to the limited amount of constitutional undercooling accruing from the limited partitioning of alloying elements. It may also be attributed to the flat shape of the weld pool. In this study, the phase equilibria of different alloying elements in titanium will be examined with regard to their effect on constitutional undercooling, and an approach for new filler alloy development will be proposed.
The Development of a Compressive Residual Stress Around a Structural Steel Weld by Means of Phase Transformations
F. Martinez, S. Liu, G. Edwards, Colorado School of Mines, Golden, CO
By means of weld metal design, a composition that produced martensitic microstructure that induced compressive residual stresses at weld toes was developed. The target weld exhibited good morphology, competitive cost, and offers a good alternative to post-weld treatments in the improvement of fatigue life.
People at the Forks in the Road
G. Edwards, Colorado School of Mines, Golden, CO
Summary not available.
Micro Electron Beam Welding in an SEM
G. A. Knorovsky, B. Nowak-Neely, D. MacCallum, Sandia National Laboratories, Albuquerque, NM
A method of generating micro-scale (or smaller) welds using a suitably-modified scanning electron microscope (SEM) is presented. We discuss: advantages of the approach, energetics of the beam, thermal models of typical specimen geometries, beam characterization tools, techniques applied, and future directions. We present examples of welds in both metallic and non-metallic specimens from micro-electromechanical systems (MEMS) and LIGA-sourced components. As a process that provides a clean, consistent method for joining micro-to-nano scale materials, micro-EBW appears to be a promising new tool.
Nd-YAG Laser Micro Welding of Ti-Ni Type Shape Memory Alloy Wire and its Corrosion Resistance
Y. Ogata, M. Takatugu, T. Kunimasa, K. Uenishi, K. F. Kobayashi, Osaka University, Osaka, Japan
In order to investigate the applicability of laser micro welding to the fabrication of medical devices, Ti-Ni shape memory alloy wires with pseudo-elasticity were micro spot melted by using YAG laser. By changing the melting parameters, the evolution in microstructure, tensile strength and pseudo-elasticity was investigated. In addition, these corrosion resistances were investigated.
Micro-Laser Processing: Surface Modification and Welding of Features Less than 50 Microns
T. Frech, K. Fenner, EWI, Columbus, OH
Hole drilling with lasers is a well-understood technology for hole size greater than 50 microns. However, laser drilling of smaller holes is more difficult because of inconsistent hole sizes and shapes. A greater understanding of this effect has been obtained. Surface modification (dimpling) can be controlled for small features and has potential for applications in tribology and medical devices. Micro-welding applications for MEMS were also explored.
Analysis of Stress Relaxation Characteristic of Chilled Eutectic Sn-Pb Solder
W. H. Bang1, M. W. Moon1, K. H. Oh1, J. P. Jung2, J. W. Morris3, (1)Seoul National University, Seoul, South Korea, (2) University of Seoul, Seoul, South Korea, (3)Univeristy of California, Berkeley, CA
On the chilled eutectic Sn-Pb, correlations of stress relaxation, uniaxial creep, displacement-controlled tensile and shear characteristics will be discussed in this presentation.
The Effect of Surface Tension on Microjoining
G. A. Knorovsky1, D. O. MacCallum1, R. A. Roach1, V. V. Semak2, (1)Sandia National Laboratories, Albuquerque, NM, (2)Applied Research Lab, College Park, PA
The recoil force created by a highly focused beam produces a keyholing effect at intensities of several kW/mm2. Recent calculations indicate that at small beam diameters needed for true microwelding, this force may effectively causing drilling upon the onset of melting. These calculations neglect surface tension, which at radii of curvature <10 microns produces restraining forces of >bar. In this work we will present efforts at combining dynamic modelling which treats surface tension, validation experiments and determination of practical thresholds for very small welds.
A Review of Microjoing Technology in Harbin Institute of Technology, China
C. Wang, M. Li, Y. Tian, Harbin Institute of Technology, Harbin, China
A introduction of Microjoining research activities in Microjoining Lab of Harbin Institute of Technology, CHINA
Metallography of Welds
G. F. VanderVoort, Buehler Ltd., Lake Bluff, IL
The microstructure of welds are fascinating to study metallographically as they usually consist of regions that are cast and wrought with variations in grain size and shape, and the potential for a wide variety of microstructures (depending upon the alloy composition) and hardnesses. The talk will illustrate weld microstructures in a wide variety of metals and alloys and by a wide variety of processes. Emphasis will be on the use of selective etchants and color techniques.
Reflections on Weldment Failure
R. W. Warke, LeTourneau University, Longview, TX
Not currently available
Filler Metals for Welding of Steels
M. A. Qunitana, The Lincoln Electric Company, Cleveland, OH
Not available
Reaction Layers at Friction-Bonded Interfaces of Aluminum Alloys to Steel
K. Ikeuchi, Osaka University, Osaka, Japan
Summary not available.
Interfacial Reaction Between Sn8Zn3Bi and NiAu Plating
Y. Sogo1, T. Hojo1, H. Iwanishi1, A. Hirose1, K. F. Kobayashi1, A. Yamaguchi2, A. Furusawa2, K. Nishida2, (1)Osaka University, Osaka, Japan, (2)Matsushita Electric Industrial Co., Ltd, Kadoma, Japan
We investigated the joint strength and the interfacial reaction between Sn-8Zn-3Bi solder and Ni/Au plating with varying thickness of Au layer and reflow peak temperature. It was found that a combination of 0.05µm thick Au plating and a reflow peak temperature of 498K is the optimum condition for the joint reliability.
Room Temperature Lead-Free Soldering of Microelectronic Components using a Local Heat Source
T. P. Weihs1, T. R. Rude1, J. P. Levin1, O. M. Knio1, D. Van Heerden1, M. T. Powers2, C. D. Enns2, J. Subramanian1, (1)Reactive NanoTechnologies, Inc, Hunt Valley, MD, (2)Agilent Technologies, Santa Rosa, CA
A new joining process is presented that enables fluxless, lead-free soldering at room temperature through the use of multilayer foils as local heat sources. By inserting a foil between two solder layers and components, heat generated by a reaction within the foil melts the solder and consequently bonds the components.
Nanoindentation of Intermetallics Formed in Pb-free Solder Joints: Experiments and Simulation
X. Deng1, N. Chawla1, M. Koopman2, K. Chawla2, (1)Arizona State University, Tempe, AZ, (2)University of Alabama, Birmingham, AL
This talk will discuss new measurements of Young's modulus and hardness, by nanoindentation, of intermetallics formed by reaction of Sn-rich solder and Cu substrate.
Pb Free, Active Solder Joining for Electronic Packing and Thermal Management Applications
R. W. Smith1, T. Nelson2, R. Redd2, (1)Materials Resources International, Lansdale, PA, (2)S-Bond Technologies, LLC, Lansdale, PA
This presentation will introduce active solder advances for use in joining for electonic packages and thermal management. Such active solders join metals, ceramics and composites without plating and flux and are Pb-free. The presentation will show examples of applicaitons and present recent advances in joining low temperature co-fire ceramics.
Study for Increasing in the Melting Temperature of Micro Joint using Sn-Ag Solder and Au/Ni-Co Plating
T. Yamamoto1, S. Sakatani1, K. Uenishi1, K. F. Kobayashi1, M. Ishio2, K. Shiomi2, A. Hashimoto2, M. Yamamoto3, (1)Osaka University, Osaka, Japan, (2)NEOMAX Materials Co., Ltd, Osaka, Japan, (3)NEOMAX Kagoshima Co., Ltd, Kagoshima, Japan
We studied the reactivity of Sn-Ag solder with Au/Ni-20Co plating to form the joint which does not melt during secondary reflow soldering. The addition of Co is effective for rapid formation of the intermetellic compounds, which heightened the melting temperature of the solder layer.
Microstructural Characterization of Eutectic Tin-Gold Solder as a Lead-Free Solution
D. Hunting, University of California, Davis, CA
This research aims to characterize a lead-free solder joint which uses eutectic tin-gold solder on a gold plated microcircuit package. Solder characterization was performed by standard optical microscopy procedures as well as scanning electron microscopy (SEM). Care was taken to investigate possible Sn-Au intermetallic formation which could have detrimental results on the reliability of the solder joint.
Repair of Unrepairable Components by Laser Deposition
R. J. Grylls, Optomec, Inc., Albuquerque, NM
Not available
Effect of Melt Pool Geometry on Crystal Growth and Microstructure Development in Laser Surface-Melted Superalloy Single Crystals
J. DuPont, W. Liu, Lehigh University, Bethlehem, PA
The effects of melt pool geometry on crystal growth and microstructure development during laser surface melting of single-crystal alloys were studied by means of mathematical modeling and experiments.
Weldability of Ni-Base Single Crystal Superalloys
S. Katayama, M. Sakamoto, Osaka University, Osaka, Japan
The laser and TIG weldability of Ni-base single crystal superalloys were investigated to evaluate the effects of welding process, conditions and melt flows as well as HAZ inclusions and surface crystallographic orientations on the formation of cracks and different crystals.
Repair of Turbine Components Using Laser and Filler Wire
A. Dodd1, J. Bialach2, (1)GSI Lumonics, Northville, MI, (2)Liburdi Automation Inc, Dundas, ON, Canada
Modern gas turbine components, such as blades and vanes, are subjected to some of the most severe operating conditions imaginable. They are continually exposed to thermal, corrosive, abrasive, and other damaging influences. As a result, these parts need to be periodically replaced or repaired to avoid loss of engine power, efficiency and eventual breakdown. Due to high manufacturing costs of these highly engineered components, repair is usually the preferred solution. The repair process typically requires that the damaged portion of the blade surface be removed using a machining or grinding process. The missing material is then replaced with a suitable filler metal. Typically this is a nickel or titanium alloy selected to match the substrate or to achieve specific properties. The material replacement is conventionally performed in one of two ways. The first method involves an arc process such as GTAW or PAW and a filler wire. The second method involves a LASER and powder metal. Although these processes are suitable for material deposition, they each have certain limitations. These include excessive heat input, distortion, high porosity levels and material deposition inefficiency. The LASER AND WIRE process combines the best features of the conventional methods resulting in welds characterized by low defect levels and "near-net" geometry. When incorporated into a fully automated system, with complete control and synchronization of all process parameters, it enables repair of complex components, such as impellers, with unmatched speed, precision and weld quality.
Modeling Microstructure Evolution in Single Crystal Nickel Base Superalloy Welds
S. Babu1, J. M. Vitek2, S. A. David2, (1)Edison Welding Institute, Columbus, OH, (2)Oak Ridge National Laboratory, Oak Ridge, TN
The paper reviews scientific and technological issues related to modeling of repair weldability of nickel base single crystal superalloys. Models relating the role of weld pool geometry and crystallographic orientation of the single crystals on the solidification grain structure will be presented. The role of high-resolution characterization tools including electron microscopy and atom probe field ion microscopy in modeling nonequilibrium microstructure evolution will be discussed.
Microstructure of Laser Deposited Superalloy Rene-80 on GTD-111
L. Li, M. J. Harrison, T. Tang, Utah State University, Logan, UT
Superalloy Rene-80 was deposited on GTD-111 base metal by the LENS process. Process parameters were systematically varied to study their effect on the resulting microstructure of the cladding. Directional solidification was shown to be achievable in the cladding with optimal combinations of process parameters.
Characterization of the Micro Textures in a Friction Stir Weld
J. Schneider1, A. C. Nunes2, (1)Mississippi State University, Mississippi State, MS, (2)NASA-MSFC, Marshall Space Flight Center, AL
The texture observed in OIM mapping correlate with the flow path expected for a retained current in the secondary induced rotational flow around the pin tool. It is this residue current that is carried for multiple rotations of the tool and swept down by vertical currents induced by the threads on the tool.
Detonation Plasma Torch for Processing a Surface of Materials
M. Gelenidze1, F. D. S. Marquis2, (1)Georgian Technical University, Tbilisi, Georgia, (2)Naval Postgraduate School, Monterey, CA
It is submitted plasma torch to a detonation jet of plasma allowing to receive very strong shock waves with generation pulse jets of dense plasma. Thus can beat parameters are achieved up to: temperatures - 3.105 K, speeds - 20000 m/c, thermal stream - 106 w/cm2, frequency of following of shock waves up to 5 Hz. It enables to change structure and a chemical compound of a surface of a material on which this plasma jet is directed.
Designing Sealing Glasses for Solid Oxide Fuel Cells
R. K. Brow, D. S. Reis, University of Missouri-Rolla, Rolla, MO
The material requirements for hermetic seals for solid oxide fuel cells (SOFC) are severe. For most SOFC designs, the sealing material must have thermal expansion characteristics that do not contribute to the formation of thermal stresses between a variety of ceramic and metallic materials used in the SOFC stack; must be thermochemically compatible with those other materials; must remain stable at elevated temperatures (700-800°C) over the lifetime of the SOFC (thousands of hours), in the oxidizing and reducing environments of an SOFC cell. In addition, the sealing conditions are limited by the thermal stability of other materials in the stack, leaving the materials designers with a relatively narrow processing window for making the seals. We will review the desirable properties for glasses designed for hermetic seals between Y-stabilized zirconia (YSZ) electrolytes and oxidation-resistant Cr-Fe interconnect alloys and will discuss the relationships between glass composition and structure that help determined the desirable properties. Highly depolymerized alkaline earth/zinc silicate structures have the viscosity characteristics necessary to form a seal at 800-850°C and then be crystallized to form thermo-chemically stable glass-ceramics with the requisite thermal expansion characteristics for these seals. Studies of the long-term interfacial reactions between the glass-ceramics and the interconnect alloys will be reviewed.
Glass-Ceramics for Sealing Solid Oxide Fuel Cells
K. Meinhardt, Pacific Northwest National Laboratory, Richland, WA
In the last few years significant progress has been made in the development of glass-ceramic seals for solid oxide fuel cells. However there are still a number of areas that are in need of development. Details of glass-ceramic seal limitations and the current status of their development will be presented.
Compressive Mica Seal for Solid Oxide Fuel Cells
Y. S. Chou, J. W. Stevenson, Pacific Northwest National Laboratory, Richland, WA
In this paper, a comprehensive study of mica seals will be presented. Muscovite and Phlogopite micas are investigated in either a monolithic or a paper form. The development of hybrid micas and infiltrated micas will be discussed along with the leak rates during thermal cycling. The micas were also subjected to thermal stability test, the effect of compressive stresses on leak rates, and the long-term open circuit voltage versus thermal cycling.
Composite Seals for Intermediate Temperature SOFCs
M. M. Seabaugh, D. M. J. Day, K. Hasinska, B. Emley, D. S. Swartz, NexTech Materials, Ltd, Lewis Center, OH
NexTech Materials is developing sealing systems for intermediate temperature solid oxide fuel cells. In an ongoing Phase II SBIR, NexTech has developed and synthesized several different textured sealing composites that demonstrate significant performance advantages over conventional compressive seals. This presentation documents progress in seal design and evaluation in NexTech’s current program.
Sealing Methods and Seal Testing for SOFCs
I. Reimanis1, C. Lewinsohn2, (1)Colorado School of Mines, Golden, CO, (2)Ceramatec ,Inc., Salt Lake City, UT
A review of sealing methods and seal testing methods for mechanical reliability of planar solid oxide fuel cells will be given.
High Temperature Seals for Solid Oxide Fuel Cells (SOFC)
R. N. Singh, University of Cincinnati, Cincinnati, OH
A variety of seals such metal-metal, ceramic-metal and ceramic-ceramic are needed for solid oxide fuel cells to enhance reliability and life of the cell stacks. These seals are expected to function in the most severe environments of a SOFC operating between 600-900°C and under thermal gradients. An overview of the requirements, type of possible seals, approaches for reliable seals, and recent results on ceramic-metal seals will be presented.
Development of a Compliant Seal for Use in Planar Solid Oxide Fuel Cells
K. S. Weil, J. S. Hardy, Pacific Northwest National Laboratory, Richland, WA
We are currently developing an alternative approach that appears to combine some of the advantages of the other two techiques, including hermeticity, mechanical integrity, and minimization of interfacial stresses in either of the joint substrate materials, particulary the ceramic.
Effects of Surface Microstructure of Copper on Surface Energy after Pulse Nd:YAG Laser Irradiation
Z. Zhao, C. Wang, M. Li, Harbin Institute of Technology, Harbin, China
The effect of pulsed Nd:YAG laser irradiation on copperplate surface was investigated . It is found that the surface microstructure was influenced by laser power.
Welding Nitinol to Stainless Steel
P. C. Hall, Edison Welding Institute, Columbus, OH
Fusion welding Nitinol to stainless steel has historically been very difficult because of a persistent brittle intermetallic phase readily formed by Ti and Fe. This brittle intermetallic phase makes the resulting weld very brittle as well. A method has been developed for making strong, ductile fusion welds through selective weld metal additions that suppress or alter the brittle intermetallic phase. This approach has been demonstrated using an Nd-YAG laser to make wire-to-wire butt weld joints between Nitinol and 316 stainless steel. One target application is the welding of medical guide wires used in vascular intervention procedures for treatment of coronary disease.
Damage Control of Soldering Iron Tip for Lead-Free Solder
H. Nishikawa1, T. Uetani2, T. Takemoto1, (1)Osaka University, Osaka, Japan, (2)Hakko Corporation, Osaka, Japan
The reaction tests between lead-free solder and plated iron were performed. It was found that the dissolution of plated iron into solder was largely attributable to the grain size of the plated surface. And the small addition of iron in solder was effective for the reduction of dissolution of iron.
Resistance Microwelding of Fine Nickel Wires
S. Fukumoto1, H. Tsubakino1, Y. Zhou2, (1)University of Hyogo, Himeji, Japan, (2)University of Waterloo, Waterloo, ON, Canada
A study has been performed to clarify the basic joining mechanisms of resistance microwelding of cross nickel wire. The effects of main process parameters (welding current and force, and weld time) were investigated by detailed mechanical testing and metallurgical examinations. A bonding mechanism with several main process stages was proposed.
Novel Bonding Process Using Ag Nanoparticles-Influence of Bonding Conditions
E. Ide, S. Angata, A. Hirose, K. F. Kobayashi, Osaka University, Osaka, Japan
We have proposed a novel bonding process using Ag nanoparticles, which can be alternative to lead-rich high melting point solders. The influence of bonding parameters on the bondability of Cu-to-Cu joints was examined based on the measurement of the shear strength of the joints, the observation of the fracture surfaces and cross-sectional microstructures.
Hybrid Laser+GMAW Process for High Speed Welding
D. F. Farson1, M. H. Cho1, H. W. Choi1, I. Harris2, (1)The Ohio State University, Columbus, OH, (2)Edison Welding Institute, Columbus, OH
An upper limit on the travel speed, and hence productivity, of Gas Metal Arc Welding (GMAW) is often provided by the formation of a so-called “humped bead”. This work clearly shows the benefits of a hybrid Laser+GMAW process for producing welds at high travel speed.
FEM Simulation on Temperature Field and Distortion of 6061Al Alloy during Electron Beam Welding
Y. Tian1, C. Wang1, J. Gong1, Y. Zhou2, (1)Harbin Institute of Technology, Harbin, China, (2)University of Waterloo, Waterloo, ON, Canada
This paper develops a numerical model to simulate the temperature field and residual stress on an electron beam welding structure of 6061 aluminum, with the final aim of controlling welding distortion.
YAG Laser and TIG Arc Hybrid Welding Phenomena
S. Katayama, Y. Naito, M. Mizutani, Osaka University, Osaka, Japan
YAG laser-TIG arc hybrid welding was carried out on Type 304 steel plate under various conditions. The melt flows induced by the surface tension depending upon the oxygen content and electromagnetic force exerted a great effect on the penetration and geometry of the weld bead.
Effect of Joint Design on Mechanical Properties of AL7075 Weldment
L. Li, K. Orme, W. Yu, Utah State University, Logan, UT
The effect of filler metal dilution on the microstructure and mechanical properties of AL7075 welded joint was studied. Using the ER5356 filler, full penetration welds were made by GTAW on workpieces with various included joint angles. Testing was done in the as-welded, naturally aged, and post weld heat-treated conditions.
Properties of Weld Joints of Bake-Hardening Steel for Automobile
T. Katayama1, F. Matsui1, N. Yoshida1, A. Hirose1, K. F. Kobayashi1, K. Shibata2, H. Sakamoto2, H. Sakurai2, K. Kanamori2, (1)Osaka University, Osaka, Japan, (2)Nissan Motor Company, Ltd., Kanagawa, Japan
The BH steel was welded using laser welding and TIG welding. Laser welding was found to be more effective bonding process for the BH steel than TIG welding base on the evaluation of the joint properties. The tensile strength of the welds can be quantitatively prediction from the hardness of the welds.
Evaluation of the Solderability and Joint Properties of a New Sn-Cu-Bi-In Solder
J. P. Jung1, J. M. Kim1, J. S. Lee1, J. H. Park1, J. S. Cheon2, J. W. Park3, J. O. Lee3, (1) University of Seoul, Seoul, South Korea, (2)Danyang Soltech Co, Gyung Gi-do, South Korea, (3)Aju Metals Co, Inchon, South Korea
New Sn-Cu-Bi-In alloy was developed for the Pb-free solder. Solderability, microstructure, and bond strength after aging and thermal cycles were evaluated. The characteristics of the solder were comparable to Sn-Pb and Sn-Ag-Cu solders.
Lead-Free Soldering of a Hybrid Microcircuit Package Assembly – A University/Industry Design Project Collaboration
M. Powers1, J. F. Shackelford2, J. R. Groza2, R. Bramlett2, F. De Martino2, S. Fukumoto2, D. Hunting2, S. Khalsa2, A. Liu2, C. Merrill2, J. Tao2, J. Yamanaga2, (1)Agilent Technologies, Inc., Santa Rosa, CA, (2)University of California, Davis, CA
This paper presents a collaborative investigation by students in a project design course at UC Davis. The team developed a cost effective process for lead-free solder assembly of a hybrid microelectronic package. It was found that eutectic Sn90-Au10 solder could be used as a suitable lead-free solder alloy replacement.
Effect of Ni Addition on Interfacial Reaction Between Sn-Cu Solder and Cu Base Metal
H. Nishikawa, J. Piao, T. Takemoto, Osaka University, Osaka, Japan
The interfacial reaction between Sn-0.7Cu-xNi solders (x = 0, 0.05, 0.1, 0.2 mass%) and Cu substrate was investigated to reveal the effect of Ni minor addition on the formation of intermetallic compounds (IMC). It was found that the growth of IMC during aging depended on the Ni content in solder.
Microstructural Characterization of Tin-Silver Eutectic Solder Alloyed with Small Concentration of Lead
L. Vettraino, D. Hunting, University of California, Davis, CA
Larry Vettraino has done research on the characterization of Tin-Silver solder as it applies to the repair of military electronic applications. This is part of his master's thesis performed at the University of California Davis. The researcher investigated the changes of the solder microstructure with small amounts of lead.
Effect of Au Coating Thickness on Interfacial Reaction and Joint Strength of Sn-Ag Based Solders Reflowed on Electroless Ni-P/Au Plated Cu Land
A. Hirose1, K. F. Kobayashi1, T. Hiramori1, M. Ito2, Y. Tanii2, (1)Osaka University, Osaka, Japan, (2)Toray Research Center Inc., Otsu, Shiga, Japan
We evaluated the interfacial microstructure and joint strength of Sn-Ag solder and Sn-Ag-Cu solder bumps reflowed on electroless Ni-P/Au plated Cu land with varying thickness of Au layer (0 to 500nm) to clarify the effect of Au coating thickness on the reliability of the solder joints.
Selecting Cluster Model in Sn-based Solder Alloy Design with DV- Xa Calculation Method
C. Wang, W. Wu, Harbin Institute of Technology, Harbin, China
It is proved that cluster model should be dominant in Sn-based Solder Alloy Design calculation.
Novel Nanostructured Materials and Systems
J. Narayan, North Carolina State University, Raleigh, NC
Novel Nanostructured Materials and Systems J. Narayan, Distinguished University Professor, Department of Materials Science and Engineering, North Carolina State University, Raleigh, NC 27695-7916. Abstract This talk will focus on self-assembly based methods for processing of novel nanostructured materials for structural, optoelectronic and magnetic systems. Modeling of these unique structures has been carried out to evaluate system level performance. A specific example of naotechnology to manufacture high-efficiency quantum-confined LEDs with "nanopockets" invented in collaboration with Kopin Corporation will be discussed(1). (1) J. Narayan et al. Applied Physics Letters 81, 841(2002); Applied Physics Letters 81, 3978(2002): US Patent Pending.
Tailoring Nanocrystalline and Ultrafine-Grained Cu for Optimized Strength and Ductility
E. Ma, Johns Hopkins University, Baltimore, MD
Optimization of strength and ductility in ultrafine-grained Cu is discussed.
Nano-Structured Component Fabrication by Electron Beam Physical Vapor Deposition (EB-PVD)
J. Singh, D. E. Wolfe, Penn State University, University Park, PA
summary to follow shortly...
Fabrication of High Purity Sn Nano Powder by Low Temperature Phase Transformation
J. S. Lee1, S. H. Yun1, E. S. Yoon2, Y. J. Joo2, (1)Hanyanag University, Ansan, South Korea, (2)NAMATECH Co., Ltd., Ansan, South Korea
Synthesis of nanocrystalline high-purity Sn powders by a low temperature phase transformation is described.
Synthesis and Prospects for Novel Nanostructured Thin Film Materials in the C-B-N System
R. N. Singh, University of Cincinnati, Cincinnati, OH
A large number of the technologically useful, unusual, and exciting superhard, superstrong, and electronic/photonic materials such as diamond, carbon and BN nanotubes, C3N4 and SiC are derived from carbon by covalent bonding of C to itself, and with other elements such as N, B, and Si. Consequently, our research activities are focussed on the synthesis of new materials with unusual properties in the C-B-N system. The rationale for these activities, nanoscale materials synthesis, and their properties will be presented.
Carbon Nanotube Formation in Bulk Carbonaceous Solid
T. M. Keller, S. B. Qadri, Naval Research Laboratory, Washington, DC
A method is described for the in situ synthesis of carbon nanotubes (CNTs) in high yield and in a bulk solid composition from pyrolysis of an organometallic compound and an excess amount of a multi(ethynyl)aromatic compound. Shaped CNT-containing compositions can be readily fabricated by the method. The composition can be tailored to have mainly CNTs or varying amounts of CNTs and metal nanoparticles.
Nanostructured Diamondlike Carbon Thin Films
R. J. Narayan1, D. Scholvin2, (1)Georgia Institute of Technology, Atlanta, GA, (2)Wright Medical Technology, Memphis, TN
Properties and applications of diamondlike carbon thin films are discussed.
A Study of Undercooling in the Formation of Amorphous Aluminum Coatings Produced by Plasma Spray
Y. Kato1, D. C. Van Aken2, (1)University of Missouri-Rolla, Rolla, MO, (2)University of Missouri, Rolla, MO
As given in an abstract
Electrical Field Effects in Nanopowder Sintering
J. R. Groza, University of California at Davis, Davis, CA
This presentation will look at nanopowder sintering demands to achieve high densities and final fine grain size. Electrical field/current assisted sintering has emerged as a scientifically challenging and technologically important processing avenue for nanopowders. The scientific interest is due to new phenomena, which occur upon field exposure such as microdischarges with resultant surface effects and electrodiffusion. Technologically, electrical field application has distinct benefits: enhanced sintering rates, control and production of novel microstructures, and flexible manufacturing capabilities (near net shape, modulated structures). Results of field assisted consolidation of conductive and non-conductive nanopowders, and a discussion of electrically induced sintering mechanisms will be presented.
Preparation and Analytical Electron Microscopy of SiC Continuous Fiber Ceramic Composite (CFCC)
G. Drazic, S. Novak, N. Daneu, K. Mejak, Jozef Stefan Institute, Ljubljana, Slovenia
Composite materials based on SiC continuous-fibers, embedded in SiC based matrix with nanometer-sized particles were prepared using various methods (CVI, EPD, infiltration with suspensions) and the microstructure of materials was studied with an analytical electron microscopy using dedicated FEG-STEM system. Emphasis was on the investigation of the SiC-fiber/matrix interfaces.
Microwave Sintering of Ultrafine Grained Tungsten-based Materials
M. Jain1, G. Skandan1, D. Kapoor2, D. Agrawal3, J. Cheng3, R. Dowding4, K. Cho4, B. Klotz4, (1)NEI Corporation, Pisctaway, NJ, (2)AMSTA-AR-WEA, Picatinny Arsenal, NJ, (3)The Pennsylvania State University, University Park, PA, (4)Army Research Laboratory, Aberdeen Proving Ground, MD
Sintering behavior of tungsten-based materials is described.
Formation and Consolidation of Mullite with Nanocrystalite from Halloysite
T. Imai, T. A. Yamamoto, H. Nakano, M. Ohyanagi, Ryukoku University, Otsu, Japan
Halloysite transformed to gamma-alumina or gamma-alumina-silica solid solution at 1200oC and to mullite with nanocrystallite by subsequently heating at 1390oC for 10 hrs using electric furnace. The consolidation at 900o C by spark plasma sintering gave the dense form of amorphous silica and mullite with 45nm of the crystallite size.
A TEM Study of a Plastically Deformed Nanocrystalline Al-Fe-Cr-Ti Alloy
H. Luo1, L. Shaw1, D. Miracle2, (1)University of Connecticut, Storrs, CT, (2)Air Force Research Laboratory, Wright-Patterson AFB, OH
Deformation behavior of a nanocrystalline Al93Fe3Ti2Cr2 alloy and its microstructure before and after deformation have been characterized. The TEM analysis reveals the evidence of dislocation activities. Decreasing strain rate or increasing test temperature decreases the dislocation density. Deformation mechanisms are discussed based on the TEM analysis and the stress-strain curves obtained.
Shock Compaction of Bulk Nanocomposite Magnetic Materials
N. N. Thadhani1, Z. Q. Jin1, J. P. Liu2, (1)Georgia Institute of Technology, Atlanta, GA, (2)University of Texas, Arlington, TX
Shock consolidation of bulk nanocomposite magentic materials is described.
Plastic Flow Mechanisms in Nanocrystalline Materials
I. A. Ovid'ko, Institute of Problems of Mechanical Engineering, Russian Academy of Sciences, St.Petersburg, Russia
Theoretical models are overeviewed which describe plastic flow mechanisms – lattice dislocation slip, grain boundary sliding, twin deformation, diffusional creep modes and rotational deformation – operating in nanocrystalline bulk materials and coatings. Also, suppression of the nanocrack generation, the strengthening and softening effects in nanocrystalline materials under high-strain-rate superplastic deformation are discussed.
Deformation Mechanisms of Nanocrystalline Materials
Y. T. Zhu1, X. Liao1, S. G. Srinivasan1, Y. Zhao1, M. I. Baskes1, E. J. Lavernia2, (1)Los Alamos National Laboratory, Los Alamos, NM, (2)University of California, Davis, CA
Deformation twins and wide stacking faults have been experimentally found in nanocrystalline (NC) Al and copper. They were found formed by partial dislocations emitted from nano grain boundaries/domains. This work explores the formation and growth mechanisms of these twins and wide stacking faults. Theoretical modelling will be compared with experimental results to give an in-depth understanding on how the partial dislocations from grain boundaries form twins and wide stacking faults in fcc NC metals. It presents new critical pieces to the puzzle of deformation mechanisms in NC materials and provide insights into the mechanical properties of NC materials.
Tensile Behavior of Bulk Nanostructured Al-Y-Ni Alloys Containing Fe or Co
R. S. Mishra1, X. L. Shi2, T. J. Watson3, (1)Missouri University of Science and Technology, Rolla, MO, (2)University of Missouri, Rolla, MO, (3)Pratt & Whitney, East Hartford, CT
The Al-based alloys extruded after crystallization from amorphous state in Al-Y-Ni-X (where X = Fe or Co) systems are nanostructured and high volume fraction of intermetallic compounds. The tensile behavior was evaluated in the temperature range of 298-623 K. Very good combination of strength and ductility can be obtained in these nanostructured aluminum alloys. The influence of temperature on the transition of dislocation based deformation mechanism will be presented.
Mechanical Properties of β-SiC Fabricated by Spark Plasma Sintering
T. A. Yamamoto1, Y. Kodera1, T. Ishii1, M. Ohyanagi1, Z. A. Munir2, (1)Ryukoku University, Otsu, Japan, (2)University of California, Davis, CA
The effect of grain size of âSiC without sintering agent on the mechanical properties was mainly studied. Despite consisting of nano sized grains, the mechanical properties were roughly constant without corresponding to Hall-Petch effect. This phenomenon was considered as the reflected result of weak bonding between grains.
Mechanical Behavior of Nanolayered Laminated Composites
N. Chawla1, D. X. Deng1, M. Koopman2, K. Chawla2, (1)Arizona State University, Tempe, AZ, (2)University of Alabama, Birmingham, AL
This talk will discuss the processing and mechanical properties of novel, high strength Al/SiC multilayered structures at the nanoscale.
Simulation of Deformation and Failure of Bimodal Nanostructured Al Alloys
R. Q. Ye, B. Q. Han, E. J. Lavernia, University of California, Davis, CA
Simulation of deformation and failure in bimodal nanostructured Al alloys are discussed.
Wear Resistant Spray Coatings based on Nanocrystalline Cermet Precursor Powders
T. Klassen1, N. Eigen2, X. Qi2, E. Aust2, R. Bormann2, F. Gartner3, H. Kreye4, (1)Helmut Schmidt University, Hamburg, Germany, (2)GKSS Research Center, Geesthacht, Germany, (3)University of the Federal Armed Forces, Hamburg, Germany, (4)Helmut Schmidt University Hamburg, Hamburg, Germany
Use of nanocrystalline materials for wear-resistant coating applications are discussed.
Engineering of Sub-Wavelength Photonic Meta Materials: A Route Towards Nano-Scale Plasmonics and Super Imaging
X. Zhang, University of California, Los Angeles, CA
Applications o fnanocrystalline materials in super-imaging techniques are described.
Nanostructured Electrodes for Next Generation Rechargeable Electrochemical Devices
A. Singhal1, G. Skandan1, G. Amatucci2, F. Badway2, H. Ye2, J. J. Xu2, N. Ye3, A. Manthiram3, (1)NEI Corporation, Piscataway, NJ, (2)Rutgers University, Piscataway, NJ, (3)University of Texas, Austin, TX
Use of nanostructured materials for rechargeable electrochemical devices are discussed.
Martensitic Alloy Steels having Intermetallic Compounds in a Nano-Structural Condition as a Substitute for Cobalt
D. Huffman1, A. Bahmiller2, , (1)The Timken Company (retired), Canton, OH, (2)Medina, OH
Abstract not available.
Deformation Behavior of Bimodal Nanostructured 5083 Al Alloys
B. Q. Han1, D. Witkin1, E. J. Lavernia1, Z. Lee2, S. Nutt2, (1)University of California, Davis, CA, (2)University of Southern California, Los Angeles, CA
Deformation behavior of bimodal nanostructured 5083 Al alloys processed by cryomilling is discussed.
Invited: Materials Science-Based Approaches for High-Temperature Corrosion Resistance in Aggressive Environments
P. F. Tortorelli, M. P. Brady, B. A. Pint, I. G. Wright, Oak Ridge National Laboratory, Oak Ridge, TN
Approaches to corrosion protection and material selection based on our scientific understanding of environmental degradation and related life-limiting processes at high temperatures will be discussed.
Short and Long-term Hot Corrosion Behavior of Gas Turbine Superalloys
V. H. Desai, University of Central Florida, Orlando, FL
Hot corrosion can become a significant factor obstructing rapid progress in developing next generation turbines designed for fuel flexibility, high efficiency and least NOx levels. In this study, the short and long term hot corrosion behavior of some gas turbine superalloys was comparatively evaluated. Superalloys with low Cr suffered severe hot corrosion by acidic fluxing due to the presence of high refractory elements. Scale spalling occurred due to the coalescence of pores underneath the oxide scale.
Alloy Selection for High-Temperature Heat Exchangers
B. A. Pint, J. R. Keiser, Oak Ridge National Laboratory, Oak Ridge, TN
The long-term oxidation resistance of various commercial alloys is being evaluated for industrial heat exchangers intended to operate at 900°-1100°C. At higher temperatures, many chromia-forming alloys have limited lifetime due to high rates of metal consumption and alumina-forming alloys are being considered.
Corrosion Resistant Materials for High Temperature Halogen Containing Environments
M. McNallan, University of Illinois, Chicago, IL
Because volatile species are formed during corrosion of metals and ceramics by halogens, many of the mechanisms for high temperature corrosion resistance are not effective in halogen containing atmospheres. Some of the problems and solutions associated with this corrosion will be discussed.
The Effect of Niobium Addition upon the High Temperature Corrosion Behavior of Nickel-Base Alloys
B. A. Baker, G. D. Smith, Special Metals Corporation, Huntington, WV
The effect of niobium addition upon the high temperature corrosion behavior of nickel-base alloys systems has been explored. Examined high temperature environments include oxidation, sulfidation-oxidation, and simulated waste incineration conditions. Corrosion rate results and proposed mechanisms governing observed behavior will be discussed.
The Effect of Water Vapor on the Oxidation of Nickel-Base Superalloy Thin Foils
J. M. Rakowski, C. P. Stinner, ATI Allegheny Ludlum, Brackenridge, PA
Water vapor has been shown to be detrimental to the oxidation resistance of stainless steels. The performance of nickel-base superalloys has been evaluated in humidified atmospheres. Significant changes in oxidation behavior were observed, depending on factors native to both the test environment and the substrate.
High Temperature Corrosion Rate Probes
B. S. Covino1, S. J. Bullard1, S. D. Cramer1, G. R. Holcomb1, M. Ziomek-Moroz1, D. A. Eden2, M. S. Cayard2, (1)US Department of Energy, Albany, OR, (2)InterCorr International, Houston, TX
Corrosion rate probes can facilitate the use of corrosion as a process variable in high temperature fossil energy operations. Studies to date show that these probes can qualitatively predict changes in corrosion rate but that sensor composition may be a variable affecting the quantitative nature of the probes.
Invited: Durability and Protective Coating Research at NASA Glenn Research Center
L. A. Greenbauer-Seng, NASA Glenn Research Center, Cleveland, OH
The focus of materials research at NASA Glenn Research Center is the identification, development and demonstration of advanced high temperature structural and functional materials for use in aerospace propulsion and power systems. Evaluation of the durability limits for a number of research materials of interest to NASA (and industry) and the coating development research underway at NASA Glenn will be discussed.
Low Pressure Plasma Sprayed Overlay Coatings for GRCop-84 Combustion Chamber Liners for Reusable Launch Vehicles
S. V. Raj1, B. A. Lerch1, C. A. Barrett1, L. J. Ghosn2, R. C. Robinson3, G. Thom4, (1)NASA Glenn Research Center, Cleveland, OH, (2)Ohio Aerospace Institute, Cleveland, OH, (3)QSS, Inc., Cleveland, OH, (4)Plasma Processes, Inc., Huntsville, AL
The development of coatings technology for a state-of-the art copper alloy (GRCop-84) has involved a combination of modeling, alloy development, characterization and process optimization. Microstructural, mechanical property data and thermophysical results on the low pressure plasma sprayed coated substrates are presented and discussed.
Microstructure and Oxidation Behavior of Hf-Modified Aluminide Coatings on Ni-Based Superalloys by Pack Cementation
Y. Wang1, Y. Zhang1, B. A. Pint2, J. A. Haynes2, (1)Tennessee Technological University, Cookeville, TN, (2)Oak Ridge National Laboratory, Oak Ridge, TN
Summary not available.
The Effect of Filler Particle Size and Particle Size Distribution on the Kinetics of Halide-Activated Pack Cementation
V. A. Ravi, D. T. K. Nguyen, Cal Poly Pomona, Pomona, CA
In this talk, we will review the relevant kinetic models, and present our current thoughts on the importance of the filler in controlling the arrival of the halide vapor species at the substrate surface. The focus will be on the effects of particle size, size distribution, etc., on the vapor transport rate.
High Temperature Corrosion of Iron Aluminide Coatings
B. S. Covino1, S. J. Bullard1, S. D. Cramer1, G. R. Holcomb1, M. Ziomek-Moroz1, D. Harvey2, S. Shrestha3, (1)US Department of Energy, Albany, OR, (2)TWI Ltd, Cambridge, United Kingdom, (3)Keronite Plc, Cambridge, United Kingdom
Iron aluminide (Fe-14Al) coatings were applied to F22 steel using the HVOF process. The coated steels were exposed to a mixed oxidizing/sulfidizing environment for approximately seven days at 500, 600, and 700C. Weight gains were inversely proportional to temperature.
Hot Corrosion Behavior of Cobalt-Based Coatings
T. S. Sidhu1, R. D. Agarwal1, S. Prakash2, (1)Indian Institute of Technology, Roorkee, India, (2)Indian Institute of Technology, Roorkee, India, Roorkee, India
Degradation by high-temperature oxidation is one of the main failure modes of hot-section components in the gas turbines. No alloy is immune to hot corrosion attack indefinitely, although there are some alloy compositions that require long initiation time at which hot corrosion process moves from initiation stage to propagation stage. This paper briefly reviews the hot corrosion behaviour of cobalt-based coatings, including its properties and microstructure, as well as to review the performance of coatings on various substrates.
Keynote: The CES Eco-Selector - Background Reading
P. Coulter, M. F. Ashby, A. Miller, F. Rutter, C. Seymour, U. G. K. Wegst, Granta Design, Ltd., Cambridge, United Kingdom
Summary not available.
Aqueous Cleaner Selection Guidelines
M. McLaughlin, Alconox, Inc., White Plains, NY
Deciding to clean with aqueous cleaners to replace hazardous solvents is easy. Selecting the right aqueous cleaner can be hard. The goal of this presentation is to help make that selection process easier. The relationship between cleaning method, the type of soil, the type of substrate, the type of rinsing, the type of drying, handling and waste treatment considerations will be reviewed with guidelines given for selecting the right kind of aqueous cleaner.
Environmentally Benign Pb-free Solder Alloys
N. Chawla, Arizona State University, Tempe, AZ
This talk will cover some of the issues and opportunities associated with development of new, environmentally benign Pb-free solders for electronic packaging.
Keynote: Case Studies Illustrating the Twelve Principles of Green Engineering
J. B. Zimmerman, US Environmental Protection Agency, Washington, DC
Summary not available.
Teaching and Learning Green Engineering
R. D. Sisson, J. O'Shaughnessy, W. Weir, Worcester Polytechnic Institute, Worcester, MA
A graduate course in Green Engineering has been offered at WPI for several years. The students in this course are seniors and graduate students from many majors including; materials, manufacturing, mechanical, civil and environmental engineering as well as biology. The course is taught using a series of projects as well guest lecturers. In this paper our positive and negative experiences will be presented.
Self-Cleaning, Economic and Energy Efficiency Arc Plasma Torch for Materials Processing
G. Gelenidze1, F. D. S. Marquis2, (1)Mining Institute, Tbilisi, Georgia, (2)Naval Postgraduate School, Monterey, CA
In work it is submitted arc plasma torches, cooled by evaporations heat of water filled in arc plasma torch. Allocated thus of pairs water it is used for formation of a jet of plasma. Advantages of this kind arc plasma torches are: 1. Is absent external water supply and gas supply, 2. Ecological cleanliness is excluded formation of harmful gases (NO, CO) and 3. The energy - efficiency of arc plasma torch is increased on 10-15 %.
A Method of Powder Injection Molding that Employs Recyclable Binder Materials
K. S. Weil, E. A. Nyberg, K. L. Simmons, Pacific Northwest National Laboratory, Richland, WA
We have developed a powder injection molding technique that is requires only a small amount of binder for processing. Additionally, because of its volatility, the binder can be collected after removal for re-use in fabricating additional parts.
Environmental Barrier Coatings for Metals and Alloys Using Particle-Filled Preceramic Polymers
C. Henager1, Y. Shin1, Y. Blum2, S. M. Schwarz3, L. A. Giannuzzi4, R. Bordia5, J. Torrey5, (1)PNNL, Richland, WA, (2)SRI International, Inc., Menlo Park, CA, (3)University of Central Florida and NanoSpective, Inc., Orlando, FL, (4)University of Central Florida, Orlando, FL, (5)University of Washington, Seattle, WA
Corrosion resistant coatings that can be applied using paint spraying methods in air are being developed at PNNL using preceramic polymers filled with reactive metal powders and inert powders. Starting with a poly(hydromethylsiloxane) precursor, a method to produce a poly(methylsilsesquioxane) preceramic polymer together with the desired filler powder(s) is described.
Development of New Nickel Alloys with Low Coefficient of Thermal Expansion
P. D. Jablonski1, D. E. Alman2, (1)Albany Research Center, Albany, OR, (2)Albany Reserch Center, Albany, OR
The present research is aimed at formulating low CTE nickel-base superalloys for use in the SOFC temperature range of 700 to 800C. Ni-Cr alloys were modified with W and Mo to lower CTE to about 12x10^-6/C. CTE was determined in accordance with ASTM E-228-85. Oxidation tests (in dry and wet air) were conducted at 750 and 800C to evaluate the corrosion resistance of the alloys. The results were compared to the behavior of Crofer 22APU and Haynes 230. Several of the custom alloys had CTEs in the useful range for interconnect application. Further, several compositions proved to be significantly more oxidation resistance than Crofer 22APU.
Evaluation of Ni-Based Alloys for Potential SOFC Interconnect Applications
Z. G. Yang, G. Xia, P. Singh, J. Stevenson, Pacific Northwest National Laboratory, Richland, WA
In this work, Haynes242, Hastelloy S, and Haynes230, three Ni-Cr-Mo based alloys with different levels of chromium, have been evaluated via a series of experimental studies, which include: (i) thermal expansion, (ii) scale composition, crystal structure and microstructure during exposure in air and wet hydrogen, (iii) oxidation behavior under dual atmosphere exposure, (iv) scale electrical conductivity, and (v) scale thermo-chemical stability. In this paper, results of these studies and the suitability of these three alloys will be presented in comparison with ferritic stainless steels.
Evaluation of Haynes 242 Alloy as SOFC Interconnect Material
S. Geng, J. Zhu, Z. Lu, Tennessee Technological University, Cookeville, TN
This paper characterized oxidation behavior of the Haynes 242 alloy in air at 700°C, 800°C and 900°C using thermal balance. Oxidation kinetics of this alloy was studied. Surface morphologies, cross-section and phase structure of oxidized specimens were examined using scanning electron microscopy with an energy-dispersive X-ray analysis attachment (SEM/EDX) and X-Ray diffraction (XRD). Oxidation mechanism was discussed.
The Effect of Manganese Additions on the Reactive Evaporation of Chromium in Ni-Cr Alloys
G. R. Holcomb, D. E. Alman, Albany Reserch Center, Albany, OR
Chromium oxide undergoes evaporation at high temperatures. Manganese additions to the alloy are predicted to reduce chromium evaporation by as much as a factor of 34 at 800°C and 53 at 700°C. Results of evaporation loss measurements on nickel-chromium-manganese alloys are compared with the predicted reduction.
Materials Issues for Balance of Plant Components
J. Hawk, U.S. Department of Energy, Albany, OR
Solid oxide fuel cells operating at temperatures in excess of 600ºC in air/fuel environments present unusual problems for engineers designing balance of plant components. This presentation will summarize the current materials challenges for designing and selecting balance of plant alloys in terms of alloy microstructural stability, strength, and corrosion/oxidation resistance. Available alloys suitable for use in the balance of plant will be surveyed with respect to cost and performance.
An Improved Creep and Oxidation Resistant Stainless Steel for Heat Exchanger and Recuperators
C. P. Stinner1, J. Rakowski1, P. J. Maziasz2, P. Montague3, (1)ATI Allegheny Ludlum, Brackenridge, PA, (2)Oak Ridge National Laboratory, Oak Ridge, TN, (3)Solar Turbines, Inc, San Diego, CA
The properties of AL20-25+Nb alloy will be discussed with regard to high temperature applications. The alloy possesses excellent resistance to creep and oxidation in water vapor, which makes it ideal for recuperator air cells. A joint Allegheny Ludlum - ORNL project to optimize creep resistance will also be discussed.
Homeland Security Roles and Opportunities for Universities
M. Bernstein, Department of Homeland Security, Washington, DC
The university community is playing an increasingly important role in homeland security related science, technology and education. Examples to be discussed include, support for students and faculty, academic-based Centers of Excellence and applied research projects, primarily through the Homeland Security Advanced Research Project Agency.
Novel Biosensors Derived from Atomic Force Microscopy
R. J. Colton, C. Cole, M. P. Malito, S. P. Mulvaney, J. C. Rife, A. N. Scribner, C. R. Tamanaha, K. A. Wahowski, L. J. Whitman, U. S. Naval Research Laboratory, Washington, DC
Paper describes the development of novel biosensors derived from atomic force microscope measurements. The biosensors show high sensitivity approaching the single molecule level. They have been used to detect potential biological warfare agents.
A Plant Virus as a Scaffold for Enhanced Detection Sensitivity
B. R. Ratna1, A. S. Blum1, C. M. Soto1, G. Vora1, J. E. Johnson2, T. Lin2, A. Chatterji2, (1)Naval Research Laboratory, Washington, DC, (2)Scripps Research Institute, La Jolla, CA
A novel but simple detection methodology using cow pea mosaic virus as a scaffold to enhance the sensitivity of detection, of six Vibrio cholerae toxin encoding genes from a single genomic copy, by at least 2 orders of magnitude and faster detection capability is presented.
Cavitands and Liquid Crystals for Chemical Sensing
D. K. Shenoy, Naval Research Laboratory, Washington, DC
New materials (cavitands and liquid crystals) for chemical vapor detection with higher selectivity and sensitivity are described. These materials show far higher sensitivity than polymer sensing layers. A highly sensitive optical technique, surface plasmon resonance, is used to transduce the signal due to interaction of chemical vapors with the sensing layer. It is shown that such materials can be used for sub ppb level detection of chemical agent simulants with fast response times.
Thermodynamic and Kinetic Evaluation of Alloys
S. Babu1, V. A. Sikka2, R. P. Martukanitz3, (1)Edison Welding Institute, Columbus, OH, (2)Oak Ridge National Laboratory, Oak Ridge, TN, (3)The Pennsylvania State University, State College, PA
Materials used in the industrial process are exposed to wide range of thermomechanical conditions during processing, fabrication and service. Depending upon these thermal cycles, both equilibrium and nonequilibrium microstructure evolution may occur in these materials. This talk will highlight thermodynamic and kinetic evaluation of these microstructure evolutions.
Development of Combinatorial Methods for Alloy Design and Optimization
G. M. Pharr1, E. P. George1, A. Rar1, M. L. Santella2, E. D. Specht2, J. Frafjord3, P. Rack3, J. Fowlkes3, (1)University of Tennessee/Oak Ridge National Laboratory, Knoxville, TN, (2)Oak Ridge National Laboratory, Oak Ridge, TN, (3)University of Tennessee, Knoxville, TN
Combinatorial libraries for binary and ternary alloy systems were synthesized by physical vapor deposition and post-deposition processing. The chemical compositions and crystal structures of the libraries were measured by synchrotron-based x-ray fluorescence and diffraction techniques. The utility of the techniques is demonstrated by construction of isothermal sections of the Fe-Ni-Cr ternary phase diagram.
Development of a New Class of Fe-3Cr-W(V) Ferritic Steels for Industrial Applications
V. K. Sikka1, R. L. Klueh1, M. L. Santella1, S. Babu2, M. H. Jawad3, (1)Oak Ridge National Laboratory, Oak Ridge, TN, (2)Edison Welding Institute, Columbus, OH, (3)M. H. Jawad Consulting, St. Louis, MO
This paper deals with the development of a new class of Fe-3Cr-W(V) ferritic steels with excellent combination of toughness and strength properties. The creep properties of this steel exceed the highest strength alloy that currently exists in this class. The commercialization status of the alloy will be discussed.
Development of Stronger and More Reliable Cast Austenitic Stainless Steels (H- Series) Based on Scientific Design Methodology
G. Muralidharan1, P. J. Maziasz1, N. D. Evans1, M. L. Santella1, K. C. Liu1, J. G. Hemrick1, V. K. Sikka1, R. I. Pankiw2, (1)Oak Ridge National Laboratory, Oak Ridge, TN, (2)Duraloy Technologies, Scottdale, PA
In this talk, we present some of our recent work in developing cast HP-series stainless steels. Using a combination of thermodynamic modeling, microstructural characterization, and mechanical property measurements, composition-structure-property relationships have been derived for this class of alloys. New alloys with improved high-temperature creep properties have been successfully designed using these relationships.
Advanced Alloys and Intermetallics for Ethylene Crackers
V. K. Sikka1, J. R. Keiser1, M. L. Santella1, S. Babu2, G. B. Sarma1, (1)Oak Ridge National Laboratory, Oak Ridge, TN, (2)Edison Welding Institute, Columbus, OH
This paper will describe the identification of new alloys and intermetallics that have significantly better coking and carburization resistance than the currently used alloys for ethylene production tubes. The paper will also describe the current status of pilot-scale fabrication of tubes of the new alloys for plant testing.
Hydrogenation and Working Temperature Control of Large Magnetocaloric Effects in La(FexSi1-x)13 Refrigerants
A. Fujita1, K. Fukamichi2, (1)Tohoku University, Sendai, Japan, (2)Tohoko University, Sendai, Japan
La(FexSi1-x)13 compounds exhibit large magnetocaloric effects due to the first-order magnetic phase transition induced by relatively low applied magnetic fields just above the Curie temperature TC. To apply these compounds to magnetic refrigerants working around room-temperature, TC is controlled from about 185 to 340 K by hydrogen absorption.
An Industrial Perspective on New Materials for a Hydrogen Economy
T. Copeman, Air Products and Chemicals, Inc., Allentown, PA
Much needs to be done to advance material technologies for a fully developed hydrogen economy, which are key to realizing successful implementation. This presentation will provide an overview of the transportation, stationary, and portable energy market segments, and discuss the associated challenges in hydrogen production, distribution, storage, sensing, and fueling.
Hydrogen Futures: Science & Technology Opportunities
S. E. Walker, Argonne National Laboratory, Argonne, IL
Hydrogen technologies, including nuclear co-generation, fuel cells, storage media, and distribution networks, will be needed for cost efficient production, storage and distribution. Membranes for hydrogen production/separation, thermochemical and electrochemical water splitting, leak detection, safety surrounding nuclear/hydrogen cogeneration and heat exchanges, and balance of plant systems engineering will help ensure success.
H2-Economy: Incentives, Barriers, And R&D Needs
N. Kassem, Royal Institute of Technology, Stockholm, Sweden
Major barriers to a hydrogen economy are capital investment requirements, lack of hydrogen fuelling infrastructure, and establishment of codes and standards for hydrogen systems. Novel materials especially designed for hydrogen production, storage and utilization are needed.
Hydrogen Economy: Needs and Challenges
S. T. Revankar, Purdue University, West Lafayette, IN
The role of various sources of energy in the equation of hydrogen economy is examined. Technical and social challenges associated with the hydrogen economy and their impacts on global market s are discussed. The talk will review current road maps towards reaching hydrogen economy in US and around the globe.
Hydrogen from Coal - A RD & D Plan for the Next Ten Years
R. Walters1, E. Schmetz2, J. Winslow3, (1)Albany Research Center, Albany, OR, (2)U. S. Department of Energy, Washington, DC, (3)National Energy Technology Laboratory, Washington, DC
This paper specifically addresses the strategy and goals of the Department of Energy to use the Nation’s large domestic coal resource to cleanly produce hydrogen, while capturing carbon for ultimate sequestration. The paper identifies research areas of interest with the Hydrogen from Coal Program to reduce the cost of producing hydrogen.
DOE’s Solid Oxide R&D Efforts
M. Williams, National Energy Technology Laboratory, Morgantown, WV
Summary not available.
Canadian Fuel Cell Program: Leading the Way to the Hydrogen Highway
D. Semczyszyn, D. Ghosh, National Research Council, Vancouver, BC, Canada
This paper describes the topics related to science and technology to be discussed in the fuel cells materials processing of ASM.
Hydrogen Infrastructure - Proposed
J. Milliken, US Department of Energy, Washington, DC
Summary not available.
Application of NanoActive Materials for Protection and Treatment of Chemical Hazards
O. Koper, NanoScale Materials Inc., Manhattan, KS
Nanoporous Organosilica Adsorbent Materials For Forensic Detection Of Explosives
M. A. Markowitz, M. Zeinali, S. Jayasundera, M. S. Spector, Naval Research Laboratory, Washington, DC
Our current objective is the development of materials for the selective adsorption of TNT and RDX from air and water supplies. A nanoporous organosilica has been developed that selectively adsorbs TNT from a mixture of aromatic hydrocarbons with a detection limit of 0.5 micrograms/L (0.002 micromoles/L) and can be readily regenerated.
Explosive Detection and Blast Mitigation
L. Malotky, Transportation Security Administration, Arlington, VA
The protection of our national transportation infrastructure depends on the detection of threats and the mitigation of those threats that escape detection. Threat detection depends on identifying the potential threat, understanding its unique materials properties and developing detection technologies that exploit these properties.
Materials and Structures for Anti-Terrorism Blast Protection
G. B. Olson, Northwestern University, Evanston, IL
A multidiciplinary design project integrating materials science, applied mechanics and quantum physics explores the concurrent design of materials and structures for anti-terrorism blast protection applications. Naval hull applications and civilian anti-terrorism applications, with emphasis on ground transportation systems, are addressed.
Paper Withdrawn
A. Singh, Y. Lee, W. J. Dressick, Naval Research Laboratory, Washington, DC
Light-weight, hazmat free, biocatalytic protective coatings are prepared. Ultrathin, catalytic coatings deposited on fabric and filter materials can destroy chemical and biological agents upon contact.
Development of Fire Escape Gas Mask using Advanced Microfibrous Entrapped Catalysis
M. R. Karanjikar, B. J. Tatarchuk, Auburn University, Auburn, AL
The motivation of the work is to develop escape mask that meets the CBRN standards proposed by NIOSH. The present work deals with developing a suitable microfibrous entrapped catalyst for CO removal. Microfibrous entrapped Catalyst development, catalyst optimization and relevant test data would be presented.
Thoracic Model Analysis Using Finite Element Modeling and Vibration Table Testing
P. Matic, A. Leung, K. Simmonds, Naval Research Laboratory, Washington, DC
GelMan2 is an instrumented thoracic surrogate with simulated skeletal structure, tissue and lungs developed to measure the response of the human body to various injuries. Experimental and computational methods were applied to study the biomechanics and injury mechanisms resulting from blunt trauma, personal body protection, sports injuries and automobile accidents.
Ohio's Fuel Cell Initiative
M. McKay, Ohio Department of Development, Columbus, OH
This paper describes the topics related to science and technology to be discussed in the fuel cells materials processing of ASM.
Solid Oxide Fuel Cell/Gas Turbine Hybrid Power Systems
N. Q. Minh, GE Energy, Torance, CA
This paper describes the topics related to science and technology to be discussed in the fuel cells materials processing of ASM.
Navy Ship Board Programs: Demonstrating Power Plants for Ships of the Future
A. Nickens, US Navy, No Name, OH
Summary not available.
Overview of FuelCell Energy Direct FuelCell® Products
M. Farooque, D. Brdar, A. Leo, FuelCell Energy, Inc., Danbury, CT
The DoD ERDC/CERL Fuel Cell Demonstration Program
S. M. Lux, M. Binder, F. Holcomb, N. Josefik, M. White, U.S. Army Engineer Research and Development Center, Champaign, IL
ERDC-CERL has demonstrated numerous applications of stationary fuel cells, and it has established a national resource facility for the independent, unbiased testing and validation of fuel cell systems for both military and commercial applications. Performance data and the lessons learned from these projects will be presented.
An Overview of Creep Strength and Oxidation of Heat-Resistant Alloy Sheets and Foils for Compact Heat-Exchangers
P. J. Maziasz, J. P. Shingledecker, B. A. Pint, N. D. Evans, Oak Ridge National Laboratory, Oak Ridge, TN
Fine-grained foils and sheets of heat resistant steels and alloys are processed and behave differently than typical plate or piping made from the same alloys. ORNL has conducted extensive research over the last 4-5 years on such materials for microturbine recuperator applications, including understanding the effects moisture-enhanced oxidation resistance. Knowledge of processing, properties and microstructure effects in such commercial or development alloys is also directly relevant to their use in fuel-cell components.
Subcritical Crack Growth Susceptibility of Low-Alloy Steels in High-Pressure Hydrogen Gas
D. K. Balch, B. P. Somerday, C. W. San Marchi, Sandia National Laboratories, Livermore, CA
Since hydrogen can promote subcritical crack growth in low-alloy steels, it is uncertain whether current pressure vessels steels are suitable for hydrogen gas containment at high pressures. The objective of this study is to measure subcritical crack growth thresholds for low-alloy steels in high-pressure hydrogen gas using fracture mechanics methods.
International Renewable Hydrogen Transmission Demonstration Facility (IRHTDF)
W. C. Leighty1, M. Hirata2, K. O'Hashi3, J. Benoit4, (1)The Leighty Foundation, Juneau, AK, (2)University of Tokyo, Tokyo, Japan, (3)Nippon Steel Corporation, Tokyo, Japan, (4)AMEC, Tokyo, Japan
Developing Magnesium Diboride Superconductors for Future Hydrogen Economy
K. Cooper, H. N. Jones, C. S. Pande, Naval Research Laboratory, Washington, DC
It is believed that MgB2 superconductors will make feasible the SuperGrid concept, delivering lossless electricity and hydrogen fuel simultaneously to neighborhoods and industries using a “superconducting energy pipeline.” Unlike NbTi and Nb3Sn, which require expensive liquid helium for their operation, MgB2 can function in relatively inexpensive liquid hydrogen.
Development of Energy Efficient Process using Microwave Heating
R. Roy1, D. Agrawal1, M. Sato2, (1)The Pennsylvania State University, University Park, PA, (2)National Institute for Fusion Science, Toki-City,, Japan
High Temperature Mechanical Properties of Spray Formed 7034 Aluminum Alloy
K. Xu, R. F. Alessi, D. S. Kmiotek, R. Zawierucha, Praxair, Tonawanda, NY
Spray forming is a relatively new technology in material fabrication. In this investigation, tensile and creep properties of spray formed 7034 aluminum alloy were studied between 90 to 150 „aC. It was found that the new alloy had an improved tensile strength and creep resistance compared with 7075-T6. The enhanced properties were attributed to the high Zn content and the addition of Zr. The spray forming process made it possible to produce the high Zn aluminum alloy without defects.
Processing Advantages and Energy Savings in the Manufacture of Tool Steel Molds and Dies by Spray Deposition
K. M. McHugh1, Y. Zhou2, E. J. Lavernia3, (1)Idaho National Engineering and Environmental Laboratory, Idaho Falls, ID, (2)University of California, Davis, Davis, CA, (3)University of California, Davis, CA
Spray deposition provides a proven alternative approach to machining of forged tool steel in the manufacture of molds, dies, and related tooling. This paper summarizes processing steps, energy expenditures, and material properties of tool steels processed conventionally and by spray deposition.
Ultrahigh Magnetic Field (UHMF) Processing: Altering Phase Transformation Kinetics and Microstructural Evolution in Several Ferromagnetic Materials
G. M. Ludtka1, R. A. Jaramillo1, R. A. Kisner1, G. L. Mackiewicz-Ludtka1, D. M. Nicholson1, J. B. Wilgen1, T. R. Watkins1, P. N. Kalu2, R. D. England3, (1)Oak Ridge National Laboratory, Oak Ridge, TN, (2)FAMU-FSU College of Engineering, Tallahassee, FL, (3)Cummins Inc., Columbus, IN
This presentation will discuss results and ramifications from some experiments performed using a 33T maximum field strength magnet. For these experiments, a Fe-15Ni binary plus SAE 1045, 52100 and a high strength bainitic steel were exposed to various thermal histories both with and without a magnetic field. Temperature measurements, metallography and hardness measurements indicate a significant shift in phase transformation kinetics and resulting microstructure.
A Simple Thermal Model of Microwave Heating
H. E. Huey1, M. S. Morrow2, (1)Micramics, Inc., San Jose, CA, (2)Microwave Synergy, Inc., Chattanooga, TN
Why is microwave heating so efficient? A simple thermal model illustrates the thermal advantage of the microwave heating process. Developments in the processing of ceramics has led to the use of ceramics in the melting and casting of metals. A brief review of the heating mechanism of microwaves and its particular application with metal melting will reveal how efficient a microwave furnace can be.
Impurity Reduction in Metal Melts with Microwaves
H. E. Huey1, M. S. Morrow2, (1)Micramics, Inc., San Jose, CA, (2)Microwave Synergy, Inc., Chattanooga, TN
How can microwaves be used to melt and cast metals in industry if aluminum foil causes arcing in the home microwave oven? Developments in the processing of ceramics has led to the use of ceramics in the melting and casting of metals. A brief review of the heating mechanism of microwaves and its particular application with metal melting will reveal how efficient a microwave furnace can be.
Fabrication of Micro-Reactors by Foil Lamination
D. E. Alman1, R. D. Wilson2, (1)Albany Reserch Center, Albany, OR, (2)U.S. Department of Energy, Albany, OR
Micro reactors are devices that possess small internal features (<500μm high), which allow for increased heat and mass transfer rates between fluids. These reactors can be manufactured through diffusion bonding of metallic sheets that have been precision machined to produce the internal architecture. This study investigated the influence of diffusion bonding parameters pressure on an embedded channel.
Materials For Industrial Heat Recovery Systems
J. R. Keiser1, G. M. Sarma1, C. R. Hubbard1, J. P. Gorog2, (1)Oak Ridge National Laboratory, Oak Ridge, TN, (2)Weyerhaeuser, Tacoma, WA
Heat recovery systems are essential components of most industrial processes. This report will describe the studies of corrosion and cracking encountered in heat recovery systems in the secondary aluminum industry and the pulp and paper industry.
Carbide Derived Carbon Surface Treatments for Seal Faces and Tribological Applications
M. McNallan1, A. Lee1, A. Erdemir2, A. Kovalchenko2, Y. Gogotsi3, (1)University of Illinois, Chicago, IL, (2)Argonne National Laboratory, Argonne, IL, (3)Drexel University, Philadelphia, PA
Carbide derived carbon (CDC) is a nanostructured form of carbon produced by halogenation of carbide ceramics. CDC lowers friction and improves tribological performance of SiC and other carbide seal faces.
Development of Ultrananocrystalline Diamond (UNCD) Coatings for Multipurpose Mechanical Pump Seals
J. A. Libera, J. W. Elam, J. N. Hryn, J. A. Carlisle, O. Auciello, A. Erdemir, A. M. Kovalchenko, Argonne National Laboratory, Argonne, IL
Ultrananocrystalline diamond (UNCD) films were applied to improve the performance of SiC shaft seals for multipurpose mechanical pumps. Remarkably smooth UNCD films were prepared using microwave plasma chemical vapor deposition in an argon/methane atmosphere. The UNCD-coated SiC seals exhibited reduced friction and negligible wear compared to uncoated SiC seals.
Ultrafine Coatings on Inner Walls of Small ID Tubes by Electroexplosion Technique
M. Batalov1, P. S. Mohanty1, A. Hart2, (1)University of Michigan, Dearborn, MI, (2)U. S. Army, Warren, MI
When a high density current is rapidly passed through a metallic wire, the wire explodes destructively. The explosion products can be in liquid, vapor vapor-plasma, or fully plasma states. The condensation of the plasma resulted in an ultra-fine coating on the inside wall, (ID~1-10mm) which was characterized by an AFM scan.
Manufacturing Process Design for Optimization of High Temperature Performance of Chromium Copper Alloy for Welding Tip
J. H. Hwang, T. Y. Hur, O. J. Kweon, J. R. Park, Hyundai Heavy Industries, Co, LTD., Ulsan, South Korea
Aged hardness of Chromium-Copper alloy was affected by prior solution temperature as well as ageing time and an optimum condition to maximize the aged hardness was presented. Introduction of cold drawing between solution annealing and ageing contributed to increase of hardness. Finally, an optimum manufacturing process was designed for application.
Direct Fuel Power Module
. S. Swartz1, M. Day1, S. Barnett2, M. Pillai2, N. McDonald2, (1)NexTech Materials, Ltd, Lewis Center, OH, (2)Functional Coating Technology, LLC, Evanston, IL
NexTech Materials, Ltd. and Functional Coating Technology, LLC are collaborating on a NIST-funded ATP project to develop the Direct Fuel Power Module (DFPM). The DFPM concept is based on integration of a low temperature solid oxide fuel cell with novel catalytic materials in a compact, modular design that allows for direct utilization of hydrocarbon fuels. Progress towards program goals will be presented.
SOFC Field Demonstration Experience – The FCT ALPHA Story
M. Adams, T. K. Konvalina, L. Sweet, A. Tuck, Fuel Cell Technologies Ltd., Kingston, ON, Canada
The paper will summarize field demonstration results from Fuel Cell Technologies Ltd's (FCT) 5kW Solid Oxide Fuel Cell combined heat and power system deployments to Japan, Germany, Alaska and Michigan.
A Novel High Out-put Voltage Fuel Cell
A. K. Shukla, R. K. Raman, N. A. Choudhury, Indian Institute of Science, Bangalore, India
A direct borohydride fuel cell (DBFC) employing hydrogen peroxide as oxidant with a power density of about 350 mWcm-2 at the cell voltage of almost 1.2V at 70oC is reported. The use of liquid reactants in DBFCs simplifies the engineering problems of fuel cells and facilitates their under water applications.
A Radiation-Based Approach to the Design of Modules for Planar, Anode-Supported Solid Oxide Fuel Cells
K. Krist, Gas Technology Institute, Des Plains, IL
Under the sponsorship of the California Energy Commission and in coordination with a DOE Solid State Energy Conversion Program with Fuel Cell Energy, the Gas Technology Institute and its partners are developing a hot module for 10-kW, planar, SOFC systems. System heat management is based on radiation of stack-generated heat.
Stack Manufacturing Barriers to SOFC Power Generation
J. J. Lannutti1, W. Li1, M. Walter1, D. England2, E. Lara-Curzio3, P. C. Hall4, G. Jong4, F. Jakobs4, W. Lin4, C. Haynes5, M. M. Seabaugh6, S. Swartz6, (1)The Ohio State University, Columbus, OH, (2)Delphi, Inc., Henrietta, NY, (3)Oak Ridge National Laboratory, Oak Ridge, TN, (4)Edison Welding Institute, Columbus, OH, (5)Georgia Technological Institute, Atlanta, GA, (6)NexTech Materials, Ltd, Lewis Center, OH
Solid oxide fuel cell stacks are complex structures containing challenging materials problems typically not encountered during the operation of a single cell. We have recently begun to utilize novel tools – optical profilometry, laser dilatometry and X-ray microdiffraction – to move toward accurate, robust stack modeling and affordable SOFC-based power generation.
Assembling Single Cells to Create a Stack: the Case of a 100 W Micro Tubular Anode Supported SOFC Stack
N. M. Sammes, Y. Du, R. England, University of Connecticut, Storrs, CT
This paper describes the fabrication of a 100 W SOFC micro-tubular stack using extruded anode tubes. The paper describes the output characteristics (thermal, power, voltage, and longevity) of the stack running off both hydrogen and methane fuels.
Carbonate Fuel Cell Materials
C. Y. Yuh, J. Colpetzer, K. Dickson, M. Farooque, G. Xu, FuelCell Energy, Inc., Danbury, CT
The Carbonate Fuel Cell is a clean and efficient power generator. This paper will review FuelCell Energy, Inc., long-term material stability experience of various cell components, stack hardware and balance-of-plant equipment. We will discuss new materials results that would help extend carbonate fuel cell life well beyond the initial goal.
Materials Challenges for Production of Hydrogen from Nuclear Energy
B. Wong, K. Schultz, General Atomics, San Diego, CA
Advanced techniques are under development to use high temperature electrolysis and thermochemical water-splitting processes to produce hydrogen from high temperature nuclear reactors. These processes have unique materials challenges due to the high temperatures needed and the process fluids used. This paper will summarize the state of development of nuclear production of hydrogen and discuss the materials development needs of the candidate processes.
Materials Challenges in Sulfur-Iodine Thermochemical Water-Splitting Process for Hydrogen Production
B. Wong, B. Buckingham, L. Brown, G. Besenbruch, General Atomics, San Diego, CA
Sulfur-Iodine (SI) thermochemical water splitting cycle offers the potential for clean and cost-effective large scale production of hydrogen. However, the cycle presents an extremely corrosive environment and imposes severe demand on the materials of construction. This talk will outline the reaction conditions and present up to date materials testing results.
Development of Dense Ceramic Membranes For Hydrogen Production and Separation
U. Balachandran1, B. Ma1, T. Lee1, L. Chen2, S. J. Song1, S. E. Dorris1, (1)Argonne National Laboratory, Argonne, IL, (2)Engineering Materials Solutions, Inc., Attleboro, MA
Summary not available.
Paper Withdrawn
C. Pickett, John Innes Centre, Norwich, United Kingdom
Iron sulfur materials might offer the prospect of developing new electrocatalysts to replace platinum group metals in fuel cell applications. The active site of the all-iron hydrogenase which catalyses hydrogen evolution / uptake is comprised of a di-iron sub-site linked to an {4Fe4S} – cubane cluster.
Photoelectrochemical and Photobiological Approaches to Generation of Hydrogen from Water
S. Deb, National Renewable Energy Laboratory, Golden, CO
The photolytic production of hydrogen from water by photoelectrochemical and photobiological approaches has the potential for efficient and low-cost generation of hydrogen. In recent years major advances have been made in materials and device technologies that make these options viable alternatives to many pathways to the generation of hydrogen.
Metal Membranes for Hydrogen Separation
S. N. Paglieri1, R. C. Dye1, C. R. Tewell1, S. A. Birdsell1, R. C. Snow1, F. M. Smith1, D. R. Pesiri2, (1)Los Alamos National Laboratory, Los Alamos, NM, (2)Essex Technology Group, LLC, Irvine, CA
Hydrogen-separating membranes may facilitate the generation of pure hydrogen for use in fuel cells. Due to the high cost of the palladium presently used to purify hydrogen, thin metal films supported on hydrogen-permeable substrates are required to reduce membrane cost. Composite metal membranes were fabricated and characterized.
Fuel Cell and Hydrogen Economy
R. G. Reddy, The University of Alabama, Tuscaloosa, AL
This presentation reviews some of the recent developments in the materials, design, and concepts for bipolar/end plates in the polymer electrolyte membrane fuel cell stack. Experimental results for use of Fe-based alloys for bipolar plate as an alternative to the expensive conventionally used graphite material are presented.
Bread-Board Fuel Processor Development for Logistic Fuel to Hydrogen using Novel Microfibrous Entrapped Catalysts and Sorbents for PEM Fuel Cell
M. R. Karanjikar, Y. Lu, B. K. Chang, B. J. Tatarchuk, Auburn University, Auburn, AL
The present work deals with hydrogen generation from JP8 (Aviation Fuel) and clean-up of the steam reformate stream to produce PEM quality hydrogen using microfibrous entrapped catalysts and sorbents. Efficiency, weight, volume, operating conditions, robustness and balance-of-plant details of the fuel processor will be discussed.
Critical Issues in Catalytic Diesel Reforming for Solid Oxide Fuel Cells
D. J. Liu, M. Krumpelt, H. T. Chien, S. H. Sheen, Argonne National Laboratory, Argonne, IL
We report the recent progresses in developing low-cost, perovskite type catalysts for diesel autothermal reforming (ATR) to produce H2-rich reformate with high hydrogen yield and reforming efficiency and the investigation on the fuel/air mixing for ATR reaction using a newly constructed test apparatus outfitted with a commercial diesel injector.
Facile Regeneration Vitreous Microfibrous Entrapped Supported ZnO Sorbent with High Contacting Efficiency for Bulk H2S Removal from Reformate Streams in Fuel Cell Applications
B. K. Chang, Y. Lu, H. Yang, B. J. Tatarchuk, Auburn University, Auburn, AL
Microfibrous carriers consisting of 3-5vol% of 8mm (dia.) glass fibers are utilized to entrap 25-45vol% of 150-250mm (dia.) SiO2 particulates. ZnO is then nano-dispersed onto SiO2 at loadings of 17-20wt%. Preparation, characterization and evaluation are discussed as well as the impact of performance on reactor weight/volume, and bed utilization efficiency.
Sulfur Sensors for Solid Oxide Fuel Cell Systems
C. T. Holt1, S. L. Swartz1, A. M. Azad2, (1)NexTech Materials, Ltd., Lewis Center, OH, (2)University of Toledo, Toledo, OH
NexTech Materials is currently developing multiple chemical sensors for fuel cell applications. A number of ceramic-based sensing strategies have been identified for the detection of low levels of sulfur (up to 10 ppm H2S), and this presentation will describe the status of this development effort.
Oxidation of Ferritic Alloys for Interconnects in Solid Oxide Fuel Cells
G. H. Meier1, J. Hammer1, L. Scot1, F. S. Petti1, N. Dhanaraj2, J. L. Beuth2, (1)University of Pittsburgh, Pittsburgh, PA, (2)Carnegie Mellon University, Pittsburgh, PA
This presentation will discuss the results of exposures of ferritic alloys to simulated SOFC operating conditions. Oxidation kinetics, oxide evaporation, oxide conductivity, and metallurgical stability of the alloys will be discussed.
Compatibility of MnCr2O4-Based Spinel with SOFC Cathode Materials at Elevated Temperatures
Z. Lu1, J. Zhu1, R. Careim1, A. Payzant2, (1)Tennessee Technological University, Cookeville, TN, (2)Oak Ridge National Laboratory, Oak Ridge, TN
The compatibility of potential SOFC interconnect material MnCr2O4 spinel with perovskite cathode materials were studied using XRD, SEM, EDS and other techniques. No other phases were formed except the interdiffusion of cations. A model was set up to explain and also predict the diffusion between these two phases.
Clad Metal by Roll Bonding for SOFC Interconnects
L. Chen1, B. Jha1, Z. G. Yang2, G. G. Xia2, J. W. Stevenson2, (1)Engineered Materials Solutions, Inc., Attleboro, MA, (2)Pacific Northwest National Laboratory, Richland, WA
Metallic interconnects have been studied in recent development in SOFC. Clad metal, a layered composite material made by roll-bonding technologies, has been considered as a candidate for such applications by combining merits and overcoming shortfalls of different existing alloys. This paper presents this developing effort.
Corrosion of Ferritic Stainless Steels during High Tempearture Simultaneous Exposures to Moist Air and Reforming Gases
Z. G. Yang, G. Xia, P. Singh, J. Stevenson, Pacific Northwest National Laboratory, Richland, WA
In this work, several ferriitc stainless steels with different level of chromium content have been evaluated under a simultaneous, dual exposure, with one side exposed to air and the other to a reforming gas. The composition, structure, and microstructure of the scale and bulk alloy in dual atmospheres will be presented in comparison with the results from the evaluation in either air or the reforming gas only.
Environmental Degradation of Ferritic Stainless Steels Intended for Solid Oxide Fuel Cell Interconnects
J. Rakowski, D. S. Bergstrom, C. P. Stinner, ATI Allegheny Ludlum, Brackenridge, PA
The development of a low-cost metallic interconnect is integral to the commercialization of solid oxide fuel cells. Surface oxidation during cell operation is detrimental to the performance of the interconnect. Long-term test results for commercially available alloys will be presented, along with analysis and suggestions for performance enhancements.
Metal Dusting Corrosion of High Temperature Alloys Under Fuel Cell Exposure Conditions
Z. Zeng, K. Natesan, Argonne National Laboratory, Argonne, IL
High-temperature Fe- and Ni-base alloys were tested in carbonaceous gases that are relevant to the fuel cell operating condition. The effects of gas and alloy composition on corrosion rates were studied. The phases present in the oxide scales were found to play an important role in the ability to protect the alloys from metal dusting corrosion.
Microstructured Fuel Processors For Fuel Cell Applications
G. Kolb, V. Hessel, H. Löwe, Institut für Mikrotechnik, Mainz, Germany
Within the scope of hydrogen generation for fuel-cells system volume is a critical issue for small and medium sized applications ranging from few watts to some ten kilowatts. Thus, the process intensification benefits of micro-technology are currently within focus of the world-wide research related to reforming.
Reformation of Gaseous and Liquid Hydrocarbon Fuels into Syngas at Short Contact Times: Design of Monolithic Catalysts and Process Parameters
V. A. Sadykov1, V. N. Parmon1, I. A. Zolotarskii1, V. A. Sobyanin1, A. P. Khristolyubov2, S. Neophytides3, (1)Boreskov Institute of Catalysis, Novosibirsk, Russia, (2)Russian Federal Nuclear Center -All-Russian Scientific Research Institute of Experimental Physics, Sarov, Russia, (3)Institute of Chemical Engineering &High Temperature Processes, Patras, Greece
Monolithic catalysts based upon nanostructured metal-oxide active components on heat and electric current –conducting monolithic substrates were designed. High and stable performance in selective oxidation and autothermal reforming of gaseous and liquid hydrocarbon fuels is demonstrated. Support of ISTC 2529, INTAS 01-2162 and IP SB RAS 39 Projects is acknowledged.
Internal Reforming SOFC Technology Development and Materials Considerations
P. Patel1, B. Borglum1, P. Huang1, A. V. Virkar2, P. Singh3, (1)Fuel Cell Energy, Inc., Danbury, CT, (2)University of Utah, Salt Lake City, UT, (3)Pacific Northwest National Laboratory, Richland, WA
This paper describes the topics related to science and technology to be discussed in the fuel cells materials processing of ASM.
Microfibrous Entrapment of Small Catalyst Particulates for High Contacting Efficiency Removal of Trace CO from Practical Reformates for PEM H2-O2 Fuel Cells
B. K. Chang1, Y. Lu2, B. J. Tatarchuk2, (1)Auburn univesity, Auburn, AL, (2)Auburn University, Auburn, AL
Preferential oxidation (PROX) of CO in H2 is the most efficient way to remove CO from practical reformate stream for PEM H2-O2 fuel cells. In this study, promotion of conventional Pt/Al2O3 with a transition metal results in significantly enhanced catalytic performance in the temperature range of 25 to 150oC.
A Regenerable Sorbent for Natural Gas Desulfurization
G. Alptekin, TDA Research, Inc., Wheat Ridge, CO
Natural gas and LPG contain small amounts of sulfur compounds, which are added to the fuels to facilitate leak detection. However, sulfur poisons catalysts used in the fuel cell stacks and fuel processors. TDA Research is developing a low cost, regenerable sorbents to remove organic sulfur compounds from these fuels.
A Micromachined Ultrasonic Atomizer for Liquid Fuels
J. M. Meacham, M. J. Varady, D. Esposito, F. L. Degertekin, A. G. Fedorov, The Georgia Institute of Technology, Atlanta, GA
A micromachined ultrasonic droplet generator is demonstrated for atomization of liquids for fuel processing applications. The device is inherently capable of energy efficient drop-on-demand atomization of liquid fuels due to resonant operation and is suitable for mist generation at low flow rates relevant to micro fuel cells.
Oxidation Behavior of Nickel and its Alloys under "Bi-Polar" Dual Atmosphere Condition
Z. G. Yang, C. Xia, J. Stevenson, P. Singh, Pacific Northwest National Laboratory, Richland, WA
In the SOFC stack “bi-polar” arrangement, fuel cell current collector/ gas separators not only provide cell to cell electrical connection, but also separate and distribute fuel and oxidant gases. We have investigated the oxidation behavior of nickel and nickel base alloys under the “bi-polar” condition by simultaneously exposing tubular and planar samples to reducing (H2-3%H2O) and oxidizing (air) environments. Metal loss and scale morphologies have been examined and compared with the samples oxidized in air only. Oxidation mechanisms will be presented.
Dual Environment Effects on the Oxidation of Metallic Interconnects
G. R. Holcomb, M. Ziomek-Moroz, S. D. Cramer, B. S. Covino, S. J. Bullard, Albany Reserch Center, Albany, OR
Scale on a metallic interconnect exposed to air is disrupted by H2 on the other side of the interconnect. A model is presented where hydrogen diffusing through the interconnect reacts with oxygen diffusing through the scale to form water vapor, which has sufficient vapor pressure to mechanically disrupt the scale.
Selection and Surface Treatment of Alloys in Solid Oxide Fuel Cell Systems
S. Elangovan, S. Balagopal, J. Hartvigsen, I. Bay, M. Timper, J. Pendleton, Ceramatec, Inc., Salt Lake City, UT
Cost and performance considerations determine the selection of various component materials in SOFC power systems. While the use of commercial alloys provides an opportunity for cost reduction, the requirements of different components vary widely. Coating processes were developed for alloy materials for potential use as interconnects and fuel feed.
Early Stages of Oxidation for CrAlON Superlattice Coatings Used to Improve Oxidation Resistance of Steel Plates for Applications as SOFC Interconnects
R. J. Smith1, A. Kayani1, C. V. Ramana1, P. E. Gannon1, M. C. Deibert1, V. I. Gorokhovsky2, V. Shutthanandan3, D. Gelles3, (1)Montana State University, Bozeman, MT, (2)Arcomac Surface Engineering, LLC., Bozeman, MT, (3)Pacific Northwest National Laboratory, Richland, WA
The oxidation and electrical resistance of coated 440A disks were investigated for use as SOFC interconnects. CrAlON coatings, deposited using filtered arc deposition, were annealed in air at 800 oC, and characterized using RBS, NRA, XPS, AFM, TEM, and ASR. Significant reductions were observed for oxidation rates.
Interfacial Fracture Testing to Investigate the Mechanics of SOFC Interconnect Alloy Durability
J. L. Beuth1, N. Dhanaraj1, J. Hammer2, S. Laney2, F. S. Pettit2, G. H. Meier2, (1)Carnegie Mellon University, Pittsburgh, PA, (2)University of Pittsburgh, Pittsburgh, PA
This presentation will focus on the thermo-mechanical aspects of SOFC interconnect alloy durability. Indentation test measurements of interfacial fracture toughness of coating systems will be described. Results will be presented for the toughness of interfaces between ferritic interconnect alloys and chromia scales grown under simulative environmental exposures.
Investigation of Interfacial Interactions and Electrical Resistance between Conductive Oxide Cathodes and Alloy Interconnects in SOFCs
G. Xia, Z. G. Yang, S. Simner, J. Stevenson, Pacific Northwest National Laboratory, Richland, WA
In this work, a series of perovskite conductive oxides that are potential cathode candidates were selected and their chemical compatibility and interfacial electrical resistance with the ferritic stainless steel Crofer22 APU, a candidate interconnect alloy, were investigated. This paper will present details of this study.
Simulated Solid Oxide Fuel Cell (SOFC) Interconnect Performance of Crofer 22 APU with and without Filtered Arc Coatings from the Cr-Al-O-N Elemental System
P. E. Gannnon1, M. C. Deibert1, C. V. Ramana1, A. Kayani1, R. J. Smith1, V. I. Gorokhovsky2, V. Shutthanandan3, D. Gelles3, (1)Montana State University, Bozeman, MT, (2)Arcomac Surface Engineering, LLC., Bozeman, MT, (3)Pacific Northwest National Laboratory, Richland, WA
Intermediate tempearture (600 - 800C) Solid Oxide Fuel Cells may enable the use of inexpensive metallic alloys as interconnect components. Recently, attention has been drawn to the use of protective, conductive coatings on metallic alloys to reduce SOFC stack performance degradation. Filtered arc coatings from the Cr-Al-O-N elemental system have been invesigated on specifically designed SOFC metallic interconnects. Simulated SOFC performance of these coatings as well as morphologies, chemical and phase compositions of these materials are discussed.
Designing Sealing Glasses for Solid Oxide Fuel Cells
R. K. Brow, D. S. Reis, University of Missouri-Rolla, Rolla, MO
The material requirements for hermetic seals for solid oxide fuel cells (SOFC) are severe. For most SOFC designs, the sealing material must have thermal expansion characteristics that do not contribute to the formation of thermal stresses between a variety of ceramic and metallic materials used in the SOFC stack; must be thermochemically compatible with those other materials; must remain stable at elevated temperatures (700-800°C) over the lifetime of the SOFC (thousands of hours), in the oxidizing and reducing environments of an SOFC cell. In addition, the sealing conditions are limited by the thermal stability of other materials in the stack, leaving the materials designers with a relatively narrow processing window for making the seals. We will review the desirable properties for glasses designed for hermetic seals between Y-stabilized zirconia (YSZ) electrolytes and oxidation-resistant Cr-Fe interconnect alloys and will discuss the relationships between glass composition and structure that help determined the desirable properties. Highly depolymerized alkaline earth/zinc silicate structures have the viscosity characteristics necessary to form a seal at 800-850°C and then be crystallized to form thermo-chemically stable glass-ceramics with the requisite thermal expansion characteristics for these seals. Studies of the long-term interfacial reactions between the glass-ceramics and the interconnect alloys will be reviewed.
Glass-Ceramics for Sealing Solid Oxide Fuel Cells
K. Meinhardt, Pacific Northwest National Laboratory, Richland, WA
In the last few years significant progress has been made in the development of glass-ceramic seals for solid oxide fuel cells. However there are still a number of areas that are in need of development. Details of glass-ceramic seal limitations and the current status of their development will be presented.
Compressive Mica Seal for Solid Oxide Fuel Cells
Y. S. Chou1, J. W. Stevenson2, (1)Pacific Northwest National Laboratory, Richland, WA, (2)Pacific Northwest Natinal Laboratory, Richland, WA
Compressive mica seals are being evaluated as an alternative seal for solid oxide fuel cells. This paper covers the comprehensive study of mica seals at the Pacific Northwest National Laboratory. Two types of micas are tested : Muscovite mica and Phlogopite mica. The major goal of mica seal development is to lower the leak rate and to increase the thermal cycle stability. In this paper we'll present two modifications of commercially available micas : hybrid micas, and infiltrated micas. High temperature leak rates will be reported as function of thermal cycles, mica thickness, compressive stresses, and sample size. In addition to the thermal cycling, mica seals were also subjected to mid-term (300-500 hours) stability tests in air and a wet reducing environments, and leak rate tested. Allowable leak rates based on thermaldynamic calculations will be presented and correlated with experimental results.
Composite Seals for Intermediate Temperature SOFCs
M. M. Seabaugh1, M. Day1, K. Hasinska1, B. Emley1, S. L. Swartz2, (1)NexTech Materials, Ltd, Lewis Center, OH, (2)NexTech Materials, Ltd., Lewis Center, OH
NexTech Materials is developing sealing systems for intermediate temperature solid oxide fuel cells. In an ongoing Phase II SBIR, NexTech has developed and synthesized several different sealing composites that demonstrate significant performance advantages over conventional compressive seals. Composite seals offer a number of advantages over single-phase glass seals. The chemical compatibility, thermal expansion, and mechanical properties can be tailored through the selection of appropriate glassy and crystalline phases. Compared to glass-ceramic seals, where the crystalline phase nucleates and grows from the starting glass, the crystalline component of composites can be selected for its properties, morphology or chemical behavior. In addition, the content and orientation of the crystalline phase can be controlled during formulation and fabrication. In Phase I the feasibility of composite seals was demonstrated; in Phase II the focus of the effort has moved toward optimization and electrochemical validation of seal performance. The composite seals are designed to exhibit thermo-mechanical and chemical compatibility with electrode, electrolyte and interconnect materials for intermediate temperature SOFCs. The goal the program is to develop seals that will have general applicability to the SECA vertical team designs of SOFC systems and are tailored for operating temperatures at 800C. The added benefits of reduced cost and improved reliability to current standards are some of the key features of the textured sealing composites. This presentation documents progress in seal design and evaluation in NexTech's current program.
Sealing Methods and Seal Testing for SOFCs
I. Reimanis1, C. Lewinsohn2, (1)Colorado School of Mines, Golden, CO, (2)Ceramatec Incorporated, Salt Lake City, UT
Methods to join the metallic interconnect and ceramic electrolyte in planar, solid oxide fuel cells (SOFCs) will be described and briefly assessed. A particular focus will be on strategies to overcome thermally induced residual stresses that limit the stack structural reliability. Two principal strategies are increased seal compliance through seal geometry or material property changes, and matching of thermal expansion coefficients through the use of metal and ceramic fillers. The associated challenges of each are reviewed. The second half of the presentation will concentrate on seal strength testing techniques and their utility in providing scientific information on the seal microstructure and chemistry that ultimately relates to lifetime prediction and performance. Some specific examples with silicate and silicon carbide seal materials will be provided.
High Temperature Seals for Solid Oxide Fuel Cells (SOFC)
R. N. Singh, University of Cincinnati, Cincinnati, OH
A variety of seals such metal-metal, ceramic-metal and ceramic-ceramic are needed for solid oxide fuel cells to enhance reliability and life of the cell stacks. These seals are expected to function in the most severe environments of a SOFC operating between 600-900°C and under thermal gradients. An overview of the requirements, type of possible seals, approaches for reliable seals, and recent results on ceramic-metal seals will be presented.
Development of a Compliant Seal for Use in Planar Solid Oxide Fuel Cells
K. S. Weil1, J. S. Hardy2, (1)Pacific Northwest National Laboratory, Richland, WA, (2)Pacific Northwest National Laborotory, Richland, WA
One of the critical issues in designing and fabricating a high performance planar solid oxide fuel cell (pSOFC) stack is the development of the appropriate materials and techniques for hermetically sealing the metal and ceramic components. There are essentially two standard methods of sealing: (1) by forming a rigid joint or (2) by constructing a compressive “sliding” seal. Each method has its own set of advantages and design constraints. We are currently developing an alternative approach that appears to combine some of the advantages of the other two techiques, including hermeticity, mechanical integrity, and minimization of interfacial stresses in either of the joint substrate materials, particulary the ceramic. The new sealing concept relies on a plastically deformable metal seal; one that offers a quasi-dynamic mechanical response in that it is adherent to both sealing surfaces, i.e. non-sliding, but readily yields or deforms under thermally generated stresses, thereby mitigating the development of stresses in the adjacent ceramic and metal components even when a significant difference in thermal expansion exists between the two materials.
Thermal Expansion Behavior of Perovskite Compositions
K. T. Jacob, India Institute of Science, Bangalore, India
Perovskite compositions ABO3-x with rare-earth and alkaline-earth cations in the A-site and a mixture of Fe, Co, Ni or Mn on the B-site have been considered as cathode materials for solid oxide fuel cells (SOFC). Others with similar A-site occupancy and a mixture of Cr and Ti in the B-site can be used as interconnect materials. LaGaO3 with lower valence Sr, Ca or Ba cations substituting for La and bivalent Mg and Co for Ga can be used as an electrolyte at lower temperatures than yttria-stabilized zirconia (YSZ). Appropriate substitutions in the A and B sites can tune thermal expansion and other properties of these perovskites to obtain thermomechanical compatibility of cell components. Thermal expansion measurements were conducted on the systems Nd1-xSrxFeO3-ƒÔ (0„Tx„T0.4), Nd0.7Sr0.3Fe1-xCoxO3 (0„Tx„T0.8), Y0.8Ca0.2Fe1-xMnxO3+ƒÔ (0„Tx„T1.0), RE0.7Sr0.3FeO3-ƒÔ (RE = rare-earth element), La0.7Ca0.2Sr0.1Cr0.5Ti0.5O3+x and La1-xSrxGa1-yMgyO3-0.5(x+y) (0.1„Tx„T0.2; 0.1„Ty„T0.2) in the temperature range from 298 to 1273 K using a horizontal, quartz dilatometer. The average linear thermal expansion coefficient (ƒÑav) increased with Sr content in the system Nd1-xSrxFeO3-ƒÔ, and with Co content in the system Nd0.7Sr0.3Fe1-xCoxO3. ƒÑav exhibited inverse correlation with the unit cell volume in both systems. In the Y0.8Ca0.2Fe1-xMnxO3+ƒÔ system, ƒÑav showed negligible decrease with x up to x = 0.4; thereafter, ƒÑav decreased rapidly with increasing x. Substitution of La by other rare-earth ions resulted in decreased thermal expansion. Increase of Mg concentration on the B-site of substituted lanthanum gallates was found to increase ƒÑav ; increase of Sr on the A-site had a smaller effect. The interconnect material La0.7Ca0.2Sr0.1Cr0.5Ti0.5O3+x exhibited ƒÑav= 10.4 between 298 and 1273 K, with little length change between oxidizing and reducing cycles. The results are discussed in relation to ionic radii and oxidation state of the cations, oxygen nonstoichiometry and crystal structure.
Cathode Materials for Solid Oxide Fuel Cells
M. M. Seabaugh, E. M. Sabolsky, K. Hasinska, M. Day, S. Ibanez, R. Cooley, S. Swartz, NexTech Materials, Ltd, Lewis Center, OH
Improved cathode materials are critical to improving the performance of solid oxide fuel cells (SOFCs). Compositional modifications and additions of electrolyte material to two state-of-the-art cathodes have been shown to improve electrochemical performance. The relationship between these variables and cell performance is discussed
Doped Lanthanum Manganite -Based Materials for SOFC Cathodes
V. A. Sadykov1, N. Orlovskaya2, S. Neophytides3, V. V. Zyryanov4, (1)Boreskov Institute of Catalysis, Novosibirsk, Russia, (2)Drexel University, Philadelphia, PA, (3)Institute of Chemical Engineering &High Temperature Processes, Patras, Greece, (4)Institute of Solid State Chemistry and Mechanochemistry, Novosibirsk, Russia
Factors determining the oxygen mobility in cation and anion substituted lanthanum manganite samples as well as in their nanocomposites with doped ceria systems synthesized by Pechini and/or mechanical activation route and sintered at temperatures up to 1300 C are considered. Support of INTAS o1-2162 and NATO PST.CLG.979411 Grants is acknowledged.
Neutron-Based Metrology for Fuel-Cell Research
T. J. Udovic, National Institute of Standards and Technology, Gaithersburg, MD
An overview of the capabilities of modern neutron instrumentation for the study of fuel-cell systems will be presented, from micron-scale imaging of water in working fuel-cell stacks to atomic-scale characterization of the amount, location, bonding states, and dynamics of hydrogen and water within fuel-cell membranes.
Radiation Heat Transfer in SOFC Materials and Components
D. L. Damm, A. G. Fedorov, Georgia Institute of Technology, Atlanta, GA
The current state-of-the-art and challenges that remain in accounting for the effects of radiation in SOFC materials and systems is presented. This includes radiative transport within participating media, thermal radiation within flow channels and from the stack to environment, and determination of radiative properties of the relevant materials.
Micro Solid Oxide Fuel Cell for Portable Applications
P. Sarkar, H. Rho, L. Yamarte, G. Kovacik, Alberta Research Council Inc., Edmonton, AB, Canada
This paper describes the topics related to science and technology to be discussed in the fuel cells materials processing of ASM.
Rechargeable Metal Hydrides - An Introductory Overview
G. Sandrock, SunaTech, Inc., Ringwood, NJ
This paper will provide an introductory overview of rechargeable metal hydrides, their evolution and applications, thus setting the stage for the balance of the symposium.
USDOE National Hydrogen Storage Project: Addressing Critical System Performance Issues
C. Read1, A. Bouza1, S. Satyapal1, J. Milliken1, J. Petrovic2, (1)US Department of Energy, Washington, DC, (2)Los Alamos National Laboratory, Los Alamos, NM
This talk will be an update on the USDOE portfolio of projects in hydrogen storage, stressing the materials-based longer-term options. We will also provide data on the status of technologies currently funded by DOE and the necessary performance targets that are required for transportation applications for a broad range of vehicle platforms.
Materials for Hydrogen Storage: Issues and Challenges
P. Jena1, M. A. Imam2, B. B. Rath2, D. R. Hardy2, (1)Virginia Commonwealth University, Richmond, VA, (2)Naval Research Laboratory, Washington, DC
I will discuss hydrogen storage properties of a class of materials called alanates which have the chemical composition [Mn+ (AlH4)n-, M= Li, Na, K, Mg]. Using first principles calculations, we will provide a molecular level understanding of the role of Ti in lowering hydrogen desorption temperature in NaAlH4 and LiBH4.
Keynote: Hydrogen Storage in Clathrate Hydrates under Mild Conditions using THF Promoter Molecules
K. T. Miller1, E. D. Sloan1, C. Koh1, S. Dec1, L. J. Florusse2, C. J. Peters2, J. Schoonman2, K. Marsh3, (1)Colorado School of Mines, Golden, CO, (2)Delft University of Technology, Delft, Netherlands, (3)University of Canterbury, Christchurch, New Zealand
Abstract not available.
Hydrogen Storage Materials Research at Sandia National Laboratories
J. C. Wang, Sandia National Laboratories, Livermore, CA
Research and development efforts searching for light weight solid state hydrogen storage materials at Sandia National Laboratories will be presented with up-to-date accomplishments.
Search for Hydrogen Storage Materials at GE Global Research
J. C. Zhao1, J. T. Rijssenbeek1, J. P. Lemmon1, V. S. Smentkowski1, W. C. Bushko1, T. R. Raber1, M. LaTorre1, S. Sanyal2, M. Chandran2, Q. Fu3, (1)General Electric Company, Schenectady, NY, (2)General Electric Company, Bangalore, India, (3)General Electric Company, Shanghai, China
A review of GE's research activity on hydrogen storage materials.
Characterization and Mechanistic Studies of the Active Titanium Species in the Reversible Dehydrogenation of Ti-Doped Sodium Aluminum Hydride
C. M. Jensen1, M. Sulic1, M. Kuba1, S. Srinivasan1, S. Eaton2, J. T. Rijssenbeek3, Y. Gao4, H. Brinks5, B. Hauback5, K. Yvon6, H. Hans6, D. S. Gomes6, (1)University of Hawaii, Honolulu, HI, (2)University of Denver, Denver, CO, (3)General Electric Company, Schenectady, NY, (4)South China University of Technology, Guangzhou, China, (5)Institute for energy Technology, Kjeller, Norway, (6)University of Geneva, Geneva, Switzerland
Ti-doped sodium aluminum hydride has attracted considerable attention as the prototype of a promising new class of hydrogen storage materials based on complex hydrides. However, in the seven years since Bogdanovic’s original report of the remarkable hydrogen cycling properties of this material, the nature and mechanism of action the Ti-dopant has remained an enigma. This talk will report on fundamental insights about Ti-doped NaAlH4 that we have recently gained through infra red and electron paramagnetic resonance spectroscopy; synchrontron X-ray and neutron diffraction, X-ray absorption fine structure (XAFS), and kinetic investigations.
The Role of Catalysts and Nanocrystalline Microstructure for Hydrogen Reaction Kinetics of Light Metal Hydrides
T. Klassen1, G. Barkhordarian2, P. A. Huhn2, M. Dornheim2, R. Bormann2, (1)Helmut Schmidt University, Hamburg, Germany, (2)GKSS Research Center, Geesthacht, Germany
Light metal hydrides, e.g. Mg or Alanates, are promising for hydrogen storage in zero-emission vehicles. We aim to elucidate the mechanisms of hydrogen reaction. In particular, advantages of nanocrystalline microstructures and tentative rules for good catalysts will be discussed, which may also apply for other hydrogen reactions.
Atomistic View of the H Uptake/Release Mechanisms in the Ti-Doped Na-Al-H System
R. Stumpf, K. Thürmer, R. Bastasz, Sandia National Laboratories, Livermore, CA
The application of the Ti-doped Na-Al-H system for hydrogen storage is hampered by very low reaction speeds. In search for kinetic bottlenecks we explore basic atomistic processes, such as H2-dissociation/recombination at the surface or the long-range mass transport, with a combination of first-principles calculations and surface-analytical experiments.
Mechanochemical Transformations of Lithium-Based Aluminohydrides
V. K. Pecharsky, Iowa State University, Ames, IA
Lithium tetrahydroaluminate – LiAlH4 – contains 10.5 per cent hydrogen by weight, half of which is available at room temperature and a quarter below ~150ºC, making it a nearly 8 wt.% H2 material. Chemical transformations induced by mechanical energy are effective in dehydrogenation of LiAlH4 and in solid state synthesis of hydroaluminates.
Development and Characterization of Complex Hydrides
R. Zidan, Savannah River Technology Center, Aiken, SC
Novel methods were developed to alter and form complex hydrides alanate materials to improve their suitability for hydrogen storage. Thermodynamic study, kinetic measurements, X-ray analysis and spectroscopic investigation are reported. The experimental effort was guided by theoretical modeling.
Structural Studies of the Additives in Alanates
H. W. Brinks1, B. C. Hauback1, D. Blanchard1, C. M. Jensen2, (1)Institute for Energy Technology, Kjeller, Norway, (2)University of Hawaii, Honolulu, HI
Alanates, metal hydrides based on the AlH4– unit, are promising for reversible hydrogen storage at moderate temperatures. Additives increased the desorption kinetics of NaAlH4 and made re-hydrogenation possible. Structural studies of the NaAlD4 and LiAlD4 systems with different additives will be presented along with in-situ studies of the desorption.
Solid Hydrogen Storage Materials & Systems: An Overview
R. C. Young, B. Chao, Texaco Ovonic Hydrogen Systems, LLC, Rochester Hills, MI
None of the current storage technologies for hydrogen as a transportation fuel are satisfactory. Solid hydrogen storage may be the solution for both onboard vehicle and refueling applications. Near term bridging technologies such as a hydrogen ICE vehicle powered by the advanced metal hydride technology will be presented and discussed.
Electronic and Magnetic Assessment of Reversible Hydrogen Storage in Intermetallic Materials
B. Mishra, Y. D. Park, D. L. Olson, Colorado School of Mines, Golden, CO
Electronic and magnetic properties have been measured and interpreted to assess hydrogen storage capacity for intermetallic alloys. The use of physics, chemistry, and materials science analytical techniques can offer more thorough scientific insight of the role of electronic behaviors essential to promote significant hydrogen storage capability. The measurements on hydrogen storage materials by Thermoelectric Power coefficient, magnetic susceptibility, and the traditional pressure-temperature-composition (PTC) profile assessment techniques have been found to correlate well. These correlations will be described and interpreted their significance on alloy development for hydrogen storage materials will be presented. Thermodynamic bases of these correlations have been established and will be discussed.
Thermal, Mechanical, and Electrical Properties of Sodium Alanate
D. E. Dedrick, B. C. Replogle, Sandia National Laboratories, Livermore, CA
The thermal, mechanical, and electrical properties of sodium alanate have been characterized to understand the behavior of complex hydrides in storage systems. This effort provides the framework and expertise to measure the engineering properties of new materials as they become viable for hydrogen storage applications.
A Metal Hydride System for Hydrogen Recovery and Storage
S. N. Paglieri1, J. R. Wermer1, J. I. Abes1, H. Oona1, J. D. Baker2, (1)Los Alamos National Laboratory, Los Alamos, NM, (2)Idaho National Engineering & Environmental Laboratory, Idaho Falls, ID
While metal hydrides are presently uneconomical for hydrogen energy applications, they present opportunities to study material properties that affect performance. Ongoing research has focused on the development of metal hydrides that are reusable, resist degradation, and can be used in the presence of common gases such as nitrogen.
Quantitative Predictions of H Solubility and Diffusion Kinetics in Ordered and Disordered Metal Alloys Using Density Functional Theory
D. S. Sholl, P. Kamakoti, B. Bhatia, Carnegie Mellon University, Pittsburgh, PA
We will discuss the ability of plane wave Density Functional Theory (DFT) to quantitatively assess the solubility and diffusion of hydrogen in metal alloys by careful comparisons of calculated results with numerous experimental examples. We will argue that DFT provides a powerful tool for aiding the screening of metal alloys for hydrogen storage.
Combinatorial Growth and High-Throughput Calorimetric Characterization of Metallic Hydrides
M. Sridharan1, J. Rodriguez-Viejo1, A. F. Lopeandía1, F. Pi1, M. Chacon1, M. T. Clavaguera-Mora1, J. Casado2, F. J. Muñoz3, (1)Universidad Autonoma de Barcelona, Bellaterra, Spain, (2)MATGAS R&D Center, Bellaterra, Spain, (3)Institut de Microelectronica de Barcelona, CNM-CSIC, Bellaterra, Spain
Combinatorial synthesis is used to prepare multicompositional thin-film Mg-based samples. The libraries are deposited on Si wafers previously microfabricated to host 64 microreactors. A high throughput calorimetric technique is employed to determine the influence of composition and grain size on the heats of reaction and the hydriding/dehydriding kinetics of the samples.
Hydrogen Storage in Amorphous GdFe2 Laves Phases
D. Chandra1, R. B. Schwarz2, (1)University of Nevada, Reno, NV, (2)Los Alamos National Laboratory, Los Alamos, NM
Summary not available.
Increasing Hydrogen Storage Capacities in Metal Hydrides: More of the Same isn’t Enough!
A. J. Maeland, Institute for Energy Technology, Kjeller, Norway
Investigation and development of reversible metal hydrides as storage materials began in the late 1960’s. However, conventional metal hydrides are limited to hydrogen capacities less than 3 wt.% and fall short of today’s requirement for vehicular use. Other solutions are needed; possible candidates include complex hydrides, irreversible metal hydrides, dihydrogen complexes, and others.
Hydrogen Storage-A Critical Challenge to the Hydrogen Economy
R. H. Jones, Pacific Northwest National Laboratory, Richland, WA
Vehicle range on a single tank of hydrogen is critical. Storage concepts being considered and evaluated include: 1) compressed H2, 2) liquid H2, 3) bulk storage in hydrides, 4) surface adsorption on carbon and boron nitride nanotubes and 5) generation by chemical reaction of a hydride with water.
Paper Withdrawn
P. Chen, Z. Xiong, J. Hu, G. Wu, National University of Singapore, Singapore, Singapore
Seven novel Metal-N-H systems were developed for hydrogen storage. It is revealed that interaction between amides and hydrides leads to hydrogen desorption and new structure formation. Mg(NH2)2+LiAlH4, LiNH2+LiAlH4 and Mg(NH2)2+MgH2 systems can release hydrogen near ambient temperature with storage capacity higher than 4.5wt%, showing great promising for the practical application.
Towards a Viable Hydrogen Storage System for Transportation Application
W. Luo, Sandia National Laboratories, Livermore, CA
A new type of hydrogen storage material has been developed by partial substitution of Li by Mg in lithium imide/hydride. This new material can absorb 4.5% hydrogen by weight reversibly at pressure of 32 bars at 200oC. This material is very promising for "on board" hydrogen storage for vehicle transport.
Advanced Hydrogen Storage Properties of Li-Based Complex Hydrides
S. I. Orimo, N. Yuko, Tohoku University, Sendai, Japan
Based on the experimental results, we propose that an effective method for destabilizing Li-based complex hydrides is to partially substitute Li by other elements with larger electronegativity, such as Mg. Actually, at the start of the reaction, the dehydriding temperature of LiNH2 drastically decreased with increasing Mg concentrations.
Production of NaBH4 by Using Al in NaOH-NaBO2 Liquid Solution under Dynamic Conditions
S. Suda1, Y. Iwase2, N. Morigasaki2, Z. Li2, (1)Kogakuin Univeristy, Hachioji-shi, Japan, (2)Materials & Energy Research Institute Tokyo, Ltd., Chino-shi, Japan
A new process for producing sodium borohydride (NaBH4) as an H-storage material has been developed where the "spent fuel" as sodium metaborate (NaBO2•4H2O) and borax (Na2BO7•10H2O) as abundant natural resource were used to prepare anhydrous metaborate (NaBO2).
Doped and Catalyzed Alkali Metal Borohydrides for Hydrogen Storage
M. Au, Savannah River Technology Center, Aiken, SC
This paper reports the updated results on the development of the doped and catalyzed metal borohydrides for hydrogen storage. The methodology of new materials synthsis, thermal dehydrogenation capacity and condition, and the rehydrogenation feasibility will be discussed.
Hydrogen Storage in Molecular Compounds
V. Struzkhin, H. K. Mao, W. L. Mao, Carnegie Institution of Washington, Washington, DC
At low temperature (T) and high pressure (P), gas molecules can be held in ice cages to form crystalline molecular compounds that may have application for energy storage. We synthesized a hydrogen clathrate hydrate, H2(H2O)2, that can be preserved to ambient P at 77 K.
Optimizing Hydrogen Storage using Singlewalled Carbon Nanotubes
A. C. Cooper1, H. Cheng1, G. P. Pez1, M. K. Kostov2, P. Piotrowski3, S. J. Stuart3, (1)Air Products and Chemicals, Inc., Allentown, PA, (2)Pennsylvania State University, University Park, PA, (3)Clemson University, Greenville, SC
Experimental and computational studies were performed to understand the effects of nanotube diameter and chirality on the heat of adsorption and hydrogen capacity. A novel methodology has been developed for molecular dynamics simulations of carbon-hydrogen interactions. The prospects for achieving effective hydrogen storage using adsorption on nanotubes will be discussed.
Electrochemically-Induced Hydrogen Adsorption in Metal-Functionalized Carbon Nanotubes
Z. Iqbal, Y. Wang, New Jersey Institute of Technology, Newark, NJ
Electrochemically induced hydrogen adsorption on single wall carbon nanotube electrodes functionalized by nanoscale cobalt and magnesium metal particles has been investigated in detail and will be reported.
Design of Materials for Hydrogen Storage
A. Lueking, Pennsylvania State University, University Park, PA
DOE has set stringent targets for hydrogen storage based on scientific (e.g. energy density, delivery temperature, desorption rates) and practical considerations (e.g. system cost, safety considerations, release). We will discuss the reliability of hydrogen uptake methodology, limitations and promise of existing materials, and development of composite materials for hydrogen storage.
Test Designs for Portable Hydrogen Storage Canisters
B. Chao, P. D. Ferro, Texaco Ovonic Hydrogen Systems, LLC, Rochester Hills, MI
Possible uses for portable hydrogen storage canisters include uninterrupted power supply (UPS) devices, modular fuel containers for lift trucks and other applications. Some of the work at Texaco Ovonic Hydrogen Systems during the past three years has led to the development of tests for quickly and thoroughly evaluating canister designs.
Utilization Of Zr-Fe Alloys in Nuclear Gettering Operations: Issues of Disproportionation and Phase Stability
D. Chandra1, M. A. Coleman1, J. R. Wermer2, S. N. Paglieri2, T. J. Udovic3, (1)University of Nevada, Reno, NV, (2)Los Alamos National Laboratory, Los Alamos, NM, (3)National Institute of Standards and Technology, Gaithersburg, MD
Summary not available.
A Study on the Shear Strength of the Mastic Joint for Cryogenic Vessels
Y. S. So, J. G. Youn, M. S. Han, D. Y. Kim, C. K. Park, Hyundai Heavy Industries, Co. Ltd., Ulsan, South Korea
Effect of bonding procedure parameters on adhesive strength in the coated metal to polymer joint has been studied. As a result of this study, it was found that inherent fracture strength of the coating is a principal factor to determine the shear strength of the joint.
The U.S. Department of Energy Program on Hydrogen Production
M. Paster, U.S. Department of Energy, Washington, DC
The potential benefits of a hydrogen economy include increased energy security through the use of domestic and renewable energy feedstocks and a dramatic reduction in green house gas and other criteria air pollutants. Technologies for hydrogen production, delivery, storage, conversion, and applications must be developed and demonstrated.
The Hydrogen-Fueled Transportation System – Why, How, and When
J. Spearot, General Motors Research and Development Center, Warren, MI
Recent debate in both government and technical forums has focused on the value, the possibility, and the timing of meeting future transportation fuel demands by use of hydrogen generated from renewable sources of primary energy. The justifications for and the criticisms against development of renewable energy supplies and hydrogen-fueled propulsion systems are reviewed, and the hurdles to be overcome in creating such a future vision are identified. If the vision of a hydrogen-fueled transportation system is to become reality, significant material inventions and developments will be required. The opportunities for critical materials research programs in the areas of hydrogen generation, fuel cell development, and hydrogen storage are described. The status of General Motors’ progress in development of hydrogen-fueled, fuel cell-powered vehicles is used to demonstrate the potential that a clean, renewable-hydrogen fuel-based transportation system can provide in meeting societal goals.
Synthesis and Behavior of Nanostructured Alloys
E. J. Lavernia, University of California, Davis, Davis, CA
Summary not available.
Improving Innovation: Using Selected Six Sigma Tools and Methods within the Stage Gate Innovation Process
J. B. Stamatoff, L. Boatwright, W. S. Hildebrand, B. D. Kirk, Corning, Inc., Corning, NY
Corning has used the Innovation Process over the last 20 years. One innovation, the Corning® CellBIND(tm) surface for drug discovery and protein production highlights both the voice of customer and manufacturing. Such examples and Six Sigma methodology have led to key tools and a new role: the Innovation Process Expert.
Failure Analysis and Characterization of Epoxy Underfill with Designed Experiments
D. Sanchez, S. King, L. Halbleib, M. Walsh, Sandia National Laboratories, Albuquerque, NM
Hysol is an underfill encapsulant used in the manufacturing of weapon components. In July 2003, components began to display incompletely cured encapsulant regions. A team was formed to investigate the problem using statistical experimental design techniques, such as Design of Experiments (DOE). This paper describes the success of experimental design in a manufacturing environment.
Paper Withdrawn
J. Mascolino, Lockheed Martin, Akron, OH
This presentation includes a description of a program Pre-development Kaizen event and how the Fabric team's mission was developed using a subsequent Kaizen event. Also discussed is the use of tools such as brainstorming, cause and effect diagrams, pick charts, action item newspapers, Design of Experiments and advanced statistical analysis.
The Application of Process Modeling Tools to the Determination of Work Flow through a High Traffic Research Lab
K. Mitchiner, Sandia National Laboratories, Albuquerque, NM
The purpose of this study was to apply Lean / Six Sigma techniques to the determination of an optimal process and schedule for a photolithography laboratory within a compound semiconductor research laboratory. Since this was a research laboratory, each person had their own process and utilized the equipment differently. Various techniques, including process modeling, were used to understand the variation in processing times at various stations, the number of people as a function of time, etc.
Experimental Determination and Thermodynamic Calculation of the Phase Equilibria in the Fe-Mn-Al System
R. Umino, X. J. Liu, Y. Sutou, C. P. Wang, I. Ohnuma, R. Kainuma, K. Ishida, Tohoku University, Sendai, Japan
The phase diagrams of the Fe-Mn-Al ternary system were experimentally determined by the DSC and EPMA techniques. Based on those results, thermodynamic assessment was carried out, and a good agreement between the experimental and calculated data was obtained.
Thermodynamic Study of Phase Equilibria in the Sn-Zn-Ti Ternary System
K. Doi, S. Ono, H. Ohtani, M. Hasebe, Kyushu Institute of Technology, Kitakyushu, Japan
The phase equilibria in the Sn-Zn-Ti ternary system were studied experimentally and using thermodynamic calculations. The microstructure observation showed that the compound with the composition of Sn3Zn12Ti5 exists in the ternary system. Based on these results, phase diagram calculations and a non-equilibrium solidification simulation using the Scheil model were performed.
Interaction Between Chemical and Magnetic Ordering in the bcc Phase of Fe-X (X=Co, Al, Si) Systems
N. Kamiya, I. Ohnuma, R. Kainuma, K. Ishida, Tohoku University, Sendai, Japan
Phase equilibria including magnetic and chemical ordering temperatures of the bcc phase in the Fe-Co-Al and Fe-Co-Si ternary systems were experimentally investigated. Based on the obtained data, the interaction between the chemical and magnetic orderings were quantitatively evaluated.
Study of the Ternary Pd-Ag-CuO System
K. S. Weil1, J. S. Hardy2, J. T. Darsell3, (1)Pacific Northwest National Laboratory, Richland, WA, (2)Pacific Northwest National Laborotory, Richland, WA, (3)Washington State University, Pullman, WA
We have investigated the ternary system, Pd-Ag-CuO, using differential thermal analysis and X-ray diffraction. Although no ternary compound was found, preliminary results suggest a eutectic reaction occurs in air at 1056°C: Ag/Pd(s) + CuO(s) = L.
Paper Withdrawn
J. Norwisz, M. Swierczek, AGH Technical University, Krakow, Poland
Lest square method is often used in experimental estimations, but usually in the most simple variants, to evaluate the parameters of linear equations based on two-dimnsional experimental data. But in the form of non-linear least square problem can be used to solve more complicated problem like consistency of thermodynamic data. It also possible to estimate precision of evaluated data. In the paper, the theoretical elaboration was used to create consisntent phase diagram of Au-Ag binary system
CT-Calphad Thermodynamics
L. Kaufman, MIT, Brookline, MA
Calphad Thermodynamics has recently been applied to many problems including the synthesis of new Nb-alloys,giant magneto resistance,lithium battery electrodes, zirconia ceramics,multicomponent rhenium alloys and corrosion.The (CT) framework applied in all of these anlyses is based on application of a wide variety of coupled phase diagrams and thermochemical databases which have been developed and tested by use in the analysis and synthesis of multicomponent materials systems over a broad range of conditions. Integration of ab-initio calculations of phase stability into the (CT) framework will be addressed.
From ab initio Phase Diagram Calculation to Materials Databese Construction
Y. Kawazoe1, M. Sluiter1, R. Sahara1, J. Z. Yu1, K. Ohno2, (1)Tohoku University, Sendai, Japan, (2)Yohohama National University, Yohohama, Japan
Recent activity at the Institute for Materials Research, Tohoku University on the ab initio phase diagram calculation and materials database contruction will be presented.
Phase Diagram Calculation as a Critical Tool in Advancing Materials and Processing Development/Improvement
Y. A. Chang1, F. Zhang2, S. Chen2, F. Xie2, (1)University of Wisconsin, Madison, WI, (2)CompuTherm, LLC, Madison, WI
Phase diagrams are the foundation in performing basic materials research and serve as a road map for materials design and process optimization. In this presentation, we will present several concrete examples to show how the Calphad approach can be used to calculate multicomponent phase diagrams for industrial applications.
Efficient Phase Diagram Information From Computational Thermodynamics
U. R. Kattner, NIST, Gaithersburg, MD
Industries that process and use metals, from microelectronics to aerospace, need data on the phase formation in complex alloys. Thermodynamic and diffusion databases and computer software enable efficient data delivery in concise and useful form. Examples from NIST projects on casting of superalloys and lead-free solders will be presented.
Phase Diagram Research and Application at GE Global Research
J. C. Zhao, M. R. Jackson, B. P. Bewlay, P. R. Subramanian, M. F. Henry, General Electric Company, Schenectady, NY
A review of phase diagram research and application activities at GE Global Research
A GeometricalApproach to Reaction Schemes of Multi-component Phase Diagrams
S. Miura, Hokkaido University, Sapporo, Japan
A geometrical representation of the connections between invariant reactions is considered for the basis to introduce matrix formula of a graph which models a reaction scheme of the multi-component phase diagrams. By utilizing matrix operation the most probable (full or partial) reaction scheme(s) can be selected within available experimental data.
Application of Phase Diagram on the Formation Mechanism of Internal Cracks in Continuously Cast Slabs
Q. Tian, J. Chen, Bao Shan Iron and Steel Co. Ltd., Shanghai, China
The internal transverse cracks of continuously cast slabs of a Nb-bearing peritectic grade of steel are investigated. An eutectic mixture rich in Nb was found existing on the crack surface. Based on the phase diagram, as well as the conditions of continuous casting, formation mechanism of the eutectics and its relationship to the internal cracks is proposed.
Application of CALPHAD in R&D of Advanced Titanium Alloys
J. Shen, General Research Institute for Non-ferrous Metals of Beijing, Beijing, China
Some examples are presented about the application of CALPHAD in the development of new titanium alloys with special requirement, such as anti-combustion, high elastic module, good mechanical properties at high temperature, good combination of of high temperature strength, room-temperature ductility and fracture toughness etc.
Thermodynamic Evaluation of Phase Equilibria and Glass Forming Ability in the Ti-Be System
T. Tokunaga1, H. Ohtani2, M. Hasebe2, (1)Fukuoka Industrial Technology Center, Kitakyushu, Japan, (2)Kyushu Institute of Technology, Kitakyushu, Japan
A thermodynamic analysis has been carried out using the experimental phase diagram data and the thermochemical properties by ab initio calculations. Evaluation of glass forming ability was also attempted utilizing the thermodynamic quantities from the phase diagram assessment.
Diffusion Behavior of Ni-Al-Ir Alloys
M. Ikeda1, H. Murakami2, M. Ode2, H. Onodera3, (1)University of Tokyo, Tokyo, Japan, (2)National Institute for Materials Science, Ibaraki, Japan, (3)National Institute for Materials Science, Tsukuba, Japan
Database Development and Microstructure Modeling in Ni-base Superalloys
T. Wang1, S. H. Zhou1, J. Z. Zhu1, Y. Wang2, L. Q. Chen1, Z. K. Liu1, R. A. MacKay3, (1)The Pennsylvania State University, University Park, PA, (2)Ohio State University, Columbus, OH, (3)NASA Glenn Research Center, Cleveland, OH
This presentation will describe our recent efforts for developing thermodynamic, diffusional mobility, and lattice parameter databases for the Ni-Al-Mo-Ta subsystem within the CMSX series of superalloys.
An Assessed Thermodynamic Database for Al Alloy 519
X. M. Pan1, C. Lin2, J. E. Morral1, H. D. Brody1, (1)The Ohio State University, Columbus, OH, (2)University of Connecticut, Storrs, CT
In order to predict the solidification microstructure and heat treatment response of aluminum alloy 519, a thermodynamic assessment of the Al-Si-Cu ternary system was developed by fitting thermodynamic and phase diagram information available from the litera. The databases were used to predict the solidification behavior of both an Al-7wt.%Si-3.5wt.%Cu alloy and an Al-7wt.%Si-3.5wt.%Cu-0.5wt.%Mg. These predictions were validated by comparisons with experimental measurements made on cast alloys ture.
Solidification Paths in Al Alloys with Immiscible Liquids
J. L. Murray, R. T. Shuey, Alcoa, Inc., Alcoa Center, PA
Summary not available.
Thermodynamic Assessment of Cu-Pt System
T. Abe1, H. Onodera1, B. Sundman2, (1)National Institute for Materials Science, Tsukuba, Japan, (2)Royal Institute of Technology, Stockholm, Sweden
The Cu-Pt system was assessed by means of the CALPHAD technique. The four sublattice model was used for describing Gibbs free energy of L12, L10 and FCC phases. The effect of short range ordering was taken into account through the reciprocal parameters in the model.
A CALPHAD Database for the Prediction of Liquidus Temperatures for Fe-Based Bulk Metallic Glasses
C. J. Kuehmann, J. A. Wright, W. Huang, QuesTek Innovations LLC, Evanston, IL
In the development of bulk metallic glasses the liquidus temperature is an important parameter in assessing glass formability. A CALPHAD approach to prediction of Fe-based bulk metallic glasses has been accomplished. The inclusion of associate models to describe the liquid thermodynamics in regions near strong eutectics is of particular importance.
First-Principles Calculations of Phase Equilbria and Transformation Dynamics of Fe-Based Alloys
T. Mohri1, M. OHNO2, Y. Chen3, (1)Hokkaido Univeristy, Sapporo, Japan, (2)Techinische Universitaet Calusthal, Clausthal Zellerfeld, Germany, (3)Institute of metal research, Chinese academy of sciences, Shenyang, China
First-Principles calculations of phase stability, phase equilibria and transformation dynamics were attempted for Fe-based alloy systems. Calculated phase diagrams for Fe-Ni, -Pd and -Pt are presented. The microstructure consisting of Anti Phase Boundaries are also predicted for Fe-Pd alloy system.
Development of Advanced High Strength Steels using Thermodynamic Calculations
C. S. Oh1, H. N. Han2, S. J. Kim1, C. G. Lee3, T. H. Lee1, (1)Korea Institute of Materials Science, Changwon, Kyungnam, South Korea, (2)Korea Institute of Machinery and Materials, Changwon, Kyungnam, South Korea, (3)Korea Institute of Machinery and Materials, Changwon, South Korea
In the development of the advanced high strength steels, despite that manufacturing routes are in a highly non-equilibrium situation, thermodynamic calculations combined with high quality database give valuable information in each processing stage. Taken the case of the TRIP and HNS steels as examples, some calculated results are presented.
Design Criteria for High-Temperature Steels Strengthened with Vanadium Nitride
V. A. Yardley, Y. de Carlan, Commissariat à l'Energie Atomique, Gif sur Yvette, France
Fe-8-12Cr ferritomartensitic steels used for high-temperature applications can be strengthened with vanadium nitride (VN) precipitates. However, this requires a high nitrogen content, which could cause porosity during fabrication. Using phase stability calculations and experimental results, a porosity criterion has been determined. This should facilitate future alloy design.
Application of Thermodynamic Calculation to the Developments of High Performance Steels
T. Yamashita, JFE Steel Corporation, Chiba, Japan
This paper describes studies on phase transformation kinetics of austenite to pearlite phase in 0.4mass%C-X(X=Cr,Ni). The isothermal transformation were dependent on the energy differences of ferrite from supercooled austenite regardless of alloy compositions and transformation temperatures. The pearlite transformation rate of 0.4%C steels was found to be controlled by eutectoid ferrite growth.
Molecular Dynamics Study on Lindemann Criterion for Melting
M. Shimono, H. Onodera, National Institute for Materials Science, Tsukuba, Japan
For both V-T ensemble and P-T ensemble, we calculate the solid/liquid phase boundary in a Lennard-Jones system by using the molecular dynamics simulation. The results coincide with those derived analytically from thermodynamics by supposing the Lindemann criterion and the Mie-Grüneisen equation of state.
Computational and Experimental Investigations of CVD Coating of Cemented Carbides
Z. K. Liu1, Z. J. Liu2, P. Mehrotra3, A. Gates3, Y. X. Liu3, (1)Pennsylvania State University, University Park, PA, (2)Penn State University, University Park, PA, (3)Kennametal, Inc., Latrobe, PA
Bonding layers between tungsten carbide substrate and Al2O3 coating were investigated experimentally and computationally. In contrast to the common belief in the literature that the bonding layer is a cubic Ti(C,N,O) phase, titanium oxides were found.
Thermodynamic Assessment of the Interaction between the Chemical and Magnetic Ordering in the Fe-X (X=Al, Co, Ga, Ni, Si) Binary Systems
I. Ohnuma, N. Kamiya, R. Kainuma, K. Ishida, Tohoku University, Sendai, Japan
Thermodynamic assessment of the Fe-X (X=Al, Co, Ga, Ni and Si) binary systems, taking into account the interaction between the chemical and magnetic ordering. The quantitative effect of the interaction on the stability of the B2, D03 and L12 configurations and on the phase equilibria were evaluated.
Phase-field Modeling of Microstructure Changes in Fe-Cr-Co Magnetic Alloy Under External Magnetic Field
T. Koyama, H. Onodera, National Institute for Materials Science, Tsukuba, Japan
The phase decomposition in the bcc phase of Fe-Cr-Co ternary alloy under an external magnetic field is simulated based on the phase-field method. The calculated microstructure shows a lamella shape elongated along the external magnetic field, which is in good agreement with the experimental results.
Revolutionary Microstructure Control with Phase Diagram Evaluation for the Design of E21 Co3AlC Based Heat Resistant Alloys
Y. Kimura, K. Sakai, Y. Mishima, Tokyo Institute of Technology, Yokohama, Japan
The Co-Al-C phase diagram was evaluated particularly for phase equilibria involving Co3AlC,(Co) and liquid phase, to conduct our alloy design on Co3AlC based heat resistant alloys. Microstructure control, including fabrication of single crystals and eutectic lamellar microstructures, was performed to improve mechanical properties using optical floating zone melting.
Phase Equilibria and Martensitic Transformation of the Co-Ni-Ga Ferromagnetic Shape Memory Alloy System
O. Katsunari1, O. Takuya2, T. Omori2, Y. Sutou2, R. Kainuma2, K. Ishida2, (1)National Institute of Advanced Industrial Science and Technology, Sendai, Japan, (2)Tohoku University, Sendai, Japan
Phase equilibria between β (B2) and γ (A1) phases at temperatures ranging from 600 to 1100�‹C and aging effect on martensitic transformation in the Co-Ni-Ga system have been investigated. It is shown that the composition region showing a ferromagnetic shape memory effect almost coincides with the β+γ two-phase region and that the martensitc transformation disappears with precipitation of ω phase induced by ageing at 300�‹C.
Die Wear Prediction using the Upper Bound Element Technique and Heat Transfer Analysis
J. Moller, Miami University, Oxford, OH
Forging die life is largely determined by wear. The Upper Bound Element Technique is augmented with a pressure element approach to predict contact pressure along with workpiece energy dissipation, strain, strain rate, and velocity. These results enable use of an Archard wear model to predict worn die profiles.
Prototype Forging Dies - A New Marketing Weapon
J. R. Knirsch, RSP Tooling, LLC, Solon, OH
RSP Tooling is a new process that can produce production quality forging dies in prototype timing. The commercializing company has been shipping production tooling since January 2004 and there are now several case studies which demonstrate the cost and lead time benefits of this new technology.
PRO-FORGE: A Teamed Design and Acquisition Process for Forgings
J. D. Tirpak1, W. Harris2, (1)Advanced Technology Institute, North Charleston, SC, (2)Sikorsky Aircraft, Stratford, CT
PRO FORGE is an acquisition driven process for designing and acquiring forgings for new rotorcraft such as Sikorsky Aircraft’s UH-60M helicopter and for legacy systems supported by the Defense Logistics Agency.
Implications of NORSOK M-650 Standard in the Offshore Industry
R. A. G. Bolton, Area 42 Consulting, Leeds, United Kingdom
NORSOK M-650 is the Norwegian standard for the qualification by the customer of component suppliers in Duplex and Super Austenitic Stainless Steels, Nickel Base and Titanium and its Alloys. The paper describes the qualification process for open die forgings in a variety of product forms.
State of the Art and Future Directions for Material Processing Simulation
D. Lambert, J. Walters, Scientific Forming Technologies Corporation, Columbus, OH
This work details the capabilities of FEM code DEFORM as applied to material supply processes, including rolling, extrusion and drawing operations. Discussed are the various types of rolling simulations, an extrusion template and the ALE steady state approach to modeling.
Artificial Neural Network Models to Predict Materials Behaviour
R. Ravi, Y. V. R. K. Prasad, V. V. S. Sarma, Indian Institute of Science, Bangalore, India
Artificial Neural Network(ANN) models have been developed to capture the patterns of Dynamic recrystallisation and instability domains from the test data. These models can be used as an alternate to Dynamic Materials Model and as well as the expert's interpretation skills to extract process parameters.
Application of 3D Hot Forging Process Simulation for Near Net Shaped Automotive Connecting Rod
Y. S. Ko, J. W. Park, H. O. Ban, H. Park, J. D. Lim, Hyundai Motor Company, Whasung-Si, Gyunggi-Do, South Korea
The parameters of forging process are strongly dependent on the shape of forging product as well as process conditions. Therefore, it is essential that materials characteristics at high temperature should be assessed to the FEM analysis. We proposed the optimum preform design and forging parameters to obtain the desirable near net shaped connecting rod.
Heat Treatment of Aluminum Alloy 6061 Processed by Severe Plastic Deformation
P. K. Chaudhury, G. Regalado, General Dynamics, Garland, TX
Heat treatment of Aluminum Alloy 6061 after severe plastic deformation was investigated. The results show a marked difference between the starting material and the severely deformed and ultrafine grain material. The results of this investigation will be presented in the light of enhanced properties and processing cost savings for industrial application of SPD material.
Forging Studies with Severe Plastic Deformation (SPD) Processed AA 6061
R. Srinivasan1, P. Chaudhury2, (1)Wright State University, Dayton, OH, (2)General Dynamics-Ordnance and Tactical Systems, Garland, TX
This paper discusses the first use of severe plastic deformation (SPD) processed AA-6061 as forging stock to make several parts in an industrial setting. Results show this material can be processed at lower billet temperatures, and have higher material yield. Both these factors can contribute to energy and cost savings.
On Frictional Boundary Conditions in Metal Forming
S. Alexandrov, Russian Academy of Sciences, Moscow, Russia
Summary not available.