JULY/AUGUST 2021 | VOL 179 | NO 5 24 37 45 Processing of Ancient Metals ASM Materials Education Foundation Annual Report iTSSe Newsletter Included in This Issue FAIR PRINCIPLES FOR AMDATAMANAGEMENT ADDITIVE MANUFACTURING P. 12
JULY/AUGUST 2021 | VOL 179 | NO 5 24 37 45 Processing of Ancient Metals ASM Materials Education Foundation Annual Report iTSSe Newsletter Included in This Issue FAIR PRINCIPLES FOR AMDATAMANAGEMENT ADDITIVE MANUFACTURING P. 12
37 2020 ASM FOUNDATION ANNUAL REPORT ASM’s Materials Education Foundation aims to inspire young people to pursue careers in materials, science, and engineering. UNLEASHING THE POTENTIAL OF ADDITIVE MANUFACTURING: FAIR AM DATA MANAGEMENT PRINCIPLES William E. Frazier, Yan Lu, Paul Witherell, Ray Fryan, and Alex Kitt Additive manufacturing workshop advocates the use of guidelines for data management to realize Materials 4.0 and achieve process qualification. 12 A D V A N C E D M A T E R I A L S & P R O C E S S E S | J U L Y / A U G U S T 2 0 2 1 2 A 3D printer produces a steel part. Courtesy of Aleksey Popov/Dreamstime. On the Cover: 57 ASM NEWS The latest news about ASM members, chapters, events, awards, conferences, affiliates, and other Society activities. 34 HEAT TREAT 2021 SHOW PREVIEW The ASM Heat Treating Society will hold its 31st conference in St. Louis this September to share information on heat treating technology.
4 Editorial 5 Research Tracks 6 Machine Learning 7 Metals/Polymers/Ceramics 9 Testing/Characterization 11 Emerging Technology 71 Editorial Preview 71 Special Advertising Section 71 Advertisers Index 72 3D PrintShop TRENDS INDUSTRY NEWS DEPARTMENTS Check out the Digital Edition online at asminternational.org/news/magazines/am-p ASM International serves materials professionals, nontechnical personnel, and managers wordwide by providing high-quality materials information, education and training, networking opportunities, and professional development resources in cost-effective and user-friendly formats. ASM is where materials users, producers, and manufacturers converge to do business. Advanced Materials & Processes (ISSN 0882-7958, USPS 762080) publishes eight issues per year: January, February/ March, April, May/June, July/August, September, October, and November/December, by ASM International, 9639 Kinsman Road, Materials Park, OH 44073-0002; tel: 440.338.5151; fax: 440.338.4634. Periodicals postage paid at Novelty, Ohio, and additional mailing offices. Vol. 179, No. 5, JULY/AUGUST 2021. Copyright © 2021 by ASM International®. All rights reserved. Distributed at no charge to ASMmembers in the United States, Canada, and Mexico. International members can pay a $30 per year surcharge to receive printed issues. Subscriptions: $499. Single copies: $54. POSTMASTER: Send 3579 forms to ASM International, Materials Park, OH 44073-0002. Change of address: Request for change should include old address of the subscriber. Missing numbers due to “change of address” cannot be replaced. Claims for nondelivery must be made within 60 days of issue. Canada Post Publications Mail Agreement No. 40732105. Return undeliverable Canadian addresses to: 700 Dowd Ave., Elizabeth, NJ 07201. Printed by Publishers Press Inc., Shepherdsville, Ky. 20 SCAN STRATEGIES IN ELECTRON BEAM AM Ti-6Al-4V Maria J. Quintana, Katie O’Donnell, Matthew J. Kenney, and Peter C. Collins The fraction and size of pores present in EBM Ti-6Al-4V specimens varies depending on the melting strategy used, whether linear raster melting or point melting. 24 ARCHAEOMETALLURGY OF COPPER AND SILVER ALLOYS IN THE OLD WORLD Omid Oudbashi and Russell Wanhill The production and processing of advanced materials began in the Old World about 8000 years ago. 28 MEASURING VIRUS INFECTIVITY ON MATERIAL SURFACES Hideyuki Kanematsu, Risa Kawai, Dana M. Barry, Eri Nakajima, and Yasuo Imoto Various methods are used to evaluate the behavior of viruses on material surfaces, an important area of research. 31 IMAT 2021 SHOW PREVIEW IMAT—the International Materials, Applications, & Technologies Conference and Exhibition will be held in St. Louis September 13-16. FEATURES JULY/AUGUST 2021 | VOL 179 | NO 5 A D V A N C E D M A T E R I A L S & P R O C E S S E S | J U L Y / A U G U S T 2 0 2 1 3 20 45 28 24 45 iTSSe The official newsletter of the ASM Thermal Spray Society (TSS). This timely supplement focuses on thermal spray and related surface engineering technologies along with TSS news and initiatives.
4 A D V A N C E D M A T E R I A L S & P R O C E S S E S | J U L Y / A U G U S T 2 0 2 1 ASM International 9639 Kinsman Road, Materials Park, OH 44073 Tel: 440.338.5151 • Fax: 440.338.4634 Joanne Miller, Editor joanne.miller@asminternational.org Victoria Burt, Managing Editor vicki.burt@asminternational.org Frances Richards and Corinne Richards Contributing Editors Jan Nejedlik, Layout and Design Toby Hansen, Production Manager toby.hansen@asminternational.org Press Release Editor magazines@asminternational.org EDITORIAL COMMITTEE Adam Farrow, Chair, Los Alamos National Lab John Shingledecker, Vice Chair, EPRI Somuri Prasad, Past Chair, Sandia National Lab Beth Armstrong, Oak Ridge National Lab Margaret Flury, Medtronic Surojit Gupta, University of North Dakota Nia Harrison, Ford Motor Company Michael Hoerner, KnightHawk Engineering Hideyuki Kanematsu, Suzuka National College of Technology Ibrahim Karaman, Texas A&M University Scott Olig, U.S. Naval Research Lab Amit Pandey, Lockheed Martin Space Satyam Sahay, John Deere Technology Center India Kumar Sridharan, University of Wisconsin Jean-Paul Vega, Siemens Energy Vasisht Venkatesh, Pratt & Whitney ASMBOARDOF TRUSTEES Diana Essock, President and Chair of the Board Judith A. Todd, Vice President Zi-Kui Liu, Immediate Past President John C. Kuli, Treasurer Burak Akyuz Elizabeth Ho man Diana Lados Navin Manjooran Toni Marechaux Jason Sebastian Larry Somrack Priti Wanjara Ji-Cheng Zhao Ron Aderhold, Secretary and Acting Managing Director STUDENT BOARDMEMBERS Ho Lun Chan, PayamEmadi, Casey Gilliams Individual readers of AdvancedMaterials & Processes may, without charge, make single copies of pages therefrom for personal or archival use, or may freelymake such copies in such numbers as are deemed useful for educational or research purposes and are not for sale or resale. Permission is granted to cite or quote fromarticles herein, provided customary acknowledgment of the authors and source is made. The acceptance and publication of manuscripts in Advanced Materials & Processes does not imply that the reviewers, editors, or publisher accept, approve, or endorse the data, opinions, and conclusions of the authors. THE NEW AM BUILD: COLLABORATIONS This past spring, I was fortunate to view several talks fromthe AeroMat and ITSC 2021 Virtual Events, including a panel discussion on “Emerging Additive Manufacturing of Materials” moderated by James Cotton, FASM. Speakers from McGill University, QuesTek Innovations LLC, Airbus, and more shared insights on the biggest challenges and latest trends in the thriving additive manufacturing (AM) sector. Some of the key challenges and opportunities include qualification of vendors and parts, proper welding and joining of AM parts, and creation of high entropy alloys. Much research will be required to solve these issues. But several groups are already making headway and “building a better model”—like AM itself—one layer at a time. In the AeroMat “Emerging Materials and Processes” session, I learned from Nicolas Nutal of CRM Group that Belgium has its own consortium for AM. Nutal’s work, aided by the consortium, focuses on the use of advanced aluminum in additively manufactured, high-end spacecraft parts. Consulting with others in the group, they determined that the 2000/7000 aluminum series cannot be used in fusion welding due to poor weldability. So they are now developing new aluminum alloys more compatible with AM. As another example, Ron Aman, principal engineer at EWI, mentioned in his AeroMat keynote that EWI leads an AM consortium. The group serves as a platform for collaboration between industry, government, and academia; works together on precompetitive research opportunities; and partners on government-funded projects. For this issue of AM&P, EWI provided a co-author to help describe another AM collaboration: a workshop developed by NIST, ASM International, and Pilgrim Consulting LLC to address the need for AM data management standards and the acceleration of part certification. With ASM past president William E. Frazier, FASM, as the lead author, the article describes the path forward to a collaborative AM data management system. The plan includes building community acceptance through influential early adopters. Indeed, our views can be influenced by people and organizations we look up to. We can benefit from their experience and wisdom. As Mitchell Dorfman, FASM, TSS-HoF, prepares for retirement from Oerlikon Metco, an attendee at his joint AeroMat/ITSC keynote Q&A session asked what he foundmost rewarding in his career. Part of his answer was “working together and solving problems to get a new material into an application.” More praise for the benefits of collaboration. For additional industry insights, see a summary of his keynote talk in this issue’s iTSSe supplement. Also in iTSSe, we are proud to share the names of members of our TSS community who are on a Stanford University list of the world’s top 2%most-cited researchers. In addition to the TSS-related names on pages 51-52, we were pleased to find other ASM members on the Stanford list including these Fellows: Rodney Boyer, Zi-Kui Liu, Tresa Pollock, Christopher Schuh, and David B. Williams. This is clear evidence that ASM members are recognized as trusted sources of reliable materials information. Our expert members are building up the materials community by authoring highly cited papers, presenting at global events, leading international collaborations, and solving newmaterials challenges in AM and many other sectors. joanne.miller@asminternational.org
A D V A N C E D M A T E R I A L S & P R O C E S S E S | J U L Y / A U G U S T 2 0 2 1 5 3D MAGNETIC NANOSTRUCTURES COULD TRANSFORM COMPUTING A team led by scientists at Cardiff University, U.K., and including researchers at Los Alamos National Laboratory, N.M., created the first 3D replica of a spin-ice material using a sophisticated type of 3D printing and processing. They say the 3D printing technology allowed them to tailor the geometry of the artificial spin-ice, meaning they can control the way the magnetic monopoles are formed and moved around in the systems. Being able to manipulate the mini monopole magnets in 3D could RESEARCH TRACKS open up numerous applications, from enhanced computer storage to 3D computing networks that mimic the neural structure of the human brain. The artificial spin-ice was created using 3D nanofabrication techniques in which tiny nano- wires are stacked into four layers in a lattice structure. Magnetic force microscopy was then used to visualize the magnetic charges present on the device, allowing the team to track the movement of the single-pole magnets across the 3D structure. “Ultimately, this work could provide ameans to produce novel magnetic metamaterials, where material properties are tuned by controlling the 3D geometry of an artificial lattice,” says researcher Sam Ladak of Cardiff University. “Magnetic storage devices are another area that could be massively impacted by this breakthrough. As current devices use only two of the three dimensions available, this limits the amount of information that can be stored. Since the monopoles can be moved around the 3D lattice using a magnetic field, it may be possible to create a true 3D storage device based upon magnetic charge.” www.cardiff.ac.uk. IONOPHOBIC ELECTRODE IMPROVES ENERGY STORAGE A group of scientists led by Zhang Suojiang, a professor at the Institute of Process Engineering (IPE) of the Chinese A team fromCardiff University and Los Alamos National Lab created the first 3D replica of spin-ice. Academy of Sciences, discovered that ionophobic electrodes can boost energy storage performance. Electric double-layer capacitors (EDLCs) with ionic liquids (ILs), a new type of energy storage device, can fill the gap between the power density of batteries and the energy density of conventional capacitors, say researchers. However, ILs in nanopores often exhibit sluggish diffusion dynamics, which hinder high power density. In this study, the team proposed a newstrategy to improve the energy density and power density of EDLCs with ILs based on massive molecular dynamics simulations. When comparing EDLCs with an ionophilic electrode to those with an extremely ionophobic electrode, the researchers found that the charging time for the latter decreased by roughly 80% while the capacitance increased by nearly 100%. The idea of introducing ionophobicity holds promise for improving the design of IL-based high-performance supercapacitors and other new energy storage devices and applications. www.cas.ac.cn. Researchers at the University of Marburg, Germany, and Aalto University, Finland, discovered a new carbon network that is atomically thin like graphene, but is made up of squares, hexagons, and octagons forming an ordered lattice. In contrast to graphene and other forms of carbon, the new biphenylene network has metallic properties. www.aalto.fi. BRIEF Ionophilic and ionophobic pore mechanisms and their influence on charging dynamics. Courtesy of IPE.
A D V A N C E D M A T E R I A L S & P R O C E S S E S | J U L Y / A U G U S T 2 0 2 1 6 MACHINE LEARNING | AI AI DRIVES CERAMIC COATINGS INNOVATION Tanvir Hussain, a materials scientist at the University of Nottingham, U.K., received nearly $3 million to develop new coatings for use in aerospace that could reduce CO2 emissions and help spacecraft travel further into the solar system. The five-year fellowship, funded by the Engineering and Physical Sciences Research Council, aims to find newmodeling and processing techniques to overhaul the design and manufacture of advanced ceramic materials for next-generation air and space travel. Using artificial intelligence and advanced chemistry, Hussain will manipulate the molecular architecture of ceramic materials to make themmore durable and sustainable. The project aims to produce ceramic coatings designed and manufactured with thermal, electrical, and environmental barrier properties that can be fine-tuned to specific aerospace applications. Ex- amples include thermal barrier coatings to protect superalloys from high temperatures, environmental barrier coatings to protect ceramic composites from steam, insulating coatings for electric motors for the electrification of aircrafts, and corrosion and wear- resistant coatings for critical engine components. “The research will lead to the creation of products for the aerospace industry with improved properties, performance, and reduced materials processing times that can be manufactured in large volumes at a fraction of the cost of today’s methods,” says Hussain. www. nottingham.ac.uk. FINDING SINGLE-ATOM-ALLOY CATALYSTS WITH AI Researchers from Skolkovo Institute of Science and Technology (Skoltech), Russia, and their colleagues from China and Germany developed a new search algorithm for single- atom-alloy catalysts (SAACs) that found more than 200 new candidates. SAACs, where single atoms of rare and expensive metals such as platinum are dispersed on an inert metal host, are highly efficient in numerous catalytic reactions, including selective hydrogenations, dehydrogenations, C-C and C-O coupling reactions, NO reduction, and CO oxidation. Assistant professor Sergey Lev- chenko and his colleagues were able to identify accurate and reliable machine learning models based on first-principles calculations for the description of the hydrogen binding energy, dissociation energy, and guest-atom segregation energy for SAACs. This led them to make a much faster (by a factor of 1000) yet reliable prediction of the catalytic performance of thousands of SAACs. They used artificial intelligence to extract important parameters (descriptors) from computational data that correlate with the catalytic performance of SAACs and at the same time are very fast to calculate. “The developed methodology can be easily adapted to designing new functional materials for various applications, including electrocatalysis, fuel cells, reforming of methane, and water- gas shift reactions,” says Levchenko. www.skoltech.ru. Flower-like ceramic coating structure inspired by nature, for use in aero engines. Materials scientist Ming Tang of Rice University, Houston, in collaboration with physicist Fei Zhou at Lawrence Livermore National Laboratory, Calif., developed a technique to predict the evolution of microstructures in materials. The research explores how neural networks can train themselves to predict how a structure will grow in a certain environment. Tang believes the computation efficiency of neural networks could speed development of new materials, such as for his lab’s design of more efficient batteries. rice.edu. BRIEF New research is using machine learning to find promising single-atom-alloy catalysts (SAACs), providing a recipe to determine the best SAACs for a range of applications. Courtesy of pixabay.com.
A D V A N C E D M A T E R I A L S & P R O C E S S E S | J U L Y / A U G U S T 2 0 2 1 7 METALS | POLYMERS | CERAMICS BRIEFS Aleris, Cleveland, offers a new 7017 aluminum alloy in North America for commercial plate and defense uses. After extensive review and testing, the U.S. Army Research Lab issued MIL-DTL-32505 for use in armor applications. 7017 offers high strength, good weldability, and corrosion resistance. It is currently used in Europe and Asia on combat vehicles to achieve superior ballistic protection. aleris.com. In a joint venture, SSAB, LKAB, and Vattenfall report production of the world’s first hydrogen-reduced sponge iron at pilot scale. The new hybrid technology captures roughly 90% of emissions produced by steelmaking. The pilot plant in Sweden has completed test production of sponge iron and proves it is possible to use fossil-free hydrogen gas to reduce iron ore instead of using coal and coke to remove the oxygen. The goal is to eliminate CO2 emissions from the steelmaking process by using only fossil-free feedstock and energy. www.hybritdevelopment.se. Honeywell, Houston, and Cobalt Blue Holdings Ltd., Australia, announced Honeywell will provide control, utomati n, and nergy optimiz tion solutions to help Cobalt Blue streamlin its Brok n Hill Cobalt Proj ct (BHCP). Located in western New South Wales, BHCP will develop a new global supply of ethicall sour ed cobalt for green energy applications such as lithium-ion batteries and wind turbin blades. honeywellprocess.com. BRIEFS they are placed onto a graphite surface covered with an alkane. The next step is the photopolymerization itself, when the pattern is solidified with light. The molecules are illuminated by a violet laser that excites the electrons in the outermost electron shell, causing strong and durable covalent bonds to form between the molecules. The result is a porous 2D polymer, half a nanometer thick, consisting of several hundred thousand molecules identically linked, culminating in a material with nearly perfect order—right down to the atomic level. www.liu.se/en. TOUGHENING CERAMICS With existing techniques, it has been a challenge to observe transformation toughening in zirconia ceramics during dynamic fracture at the atomic level. Now, researchers from the University of Tsukuba, Japan, are using timeresolved x-ray diffraction to get realtime in situ pictures of materials’ responses to dynamic loading. Transformation toughening of ceramicmaterials is related to changes in their arrangement on the atomic level, which is why the new imaging technique is critical to gaining a complete picture of the process. The researchers use the timeresolved diffraction method to follow the behavior of yttria-stabilized tetragonal zirconia polycrystals subjected to shock loading. Studying these polycrystals, they demonstrated the toughening is related to a process known as spall fracture, providing insight into the origin of the high spall strength of zirconia ceramics. The researchers believe that Jonas Björk, assistant professor at Linköping university, led the polymer innovation. Courtesy of Thor Balkhed. MAKING ULTRATHIN POLYMERS Researchers from Sweden’s Linköping University, Sweden, and Germany’s Technical University of Munich and the Deutsches Museum, along with other international collaborators, created a new method to manufacture 2D polymers. The discovery makes it possible to develop new ultrathin functional materials with highly defined and regular crystalline structures. The polymerization of the material takes place in two steps. The researchers use a contraction of fluorinated anthracene triptycene, known as fantrip, to cause the molecules to spontaneously arrange themselves into a pattern suitable for photopolymerization when Illustration of hydrogen storage. Courtesy of SSAB.
A D V A N C E D M A T E R I A L S & P R O C E S S E S | J U L Y / A U G U S T 2 0 2 1 8 their findings will contribute to the continued development of tough ceramics for a wide range of applications from electric insulator parts to kitchen utensils. www.tsukuba.ac.jp/en. SUSTAINABLE MINERAL EXTRACTION A team of international researchers, including collaborators from the University of Exeter, U.K., developed a new method to extract metals, such as copper, from their parent ore body. The researchers provided a proof of concept for the application of an electric field to control the movement of an acid within a low permeability copper-bearing ore deposit to selectively dissolve and recover the metal in situ. Their new method contrasts the conventional approach for the mining of such deposits where the material must be physically excavated, which requires removal of Copper ore sample before the start of the experiment. Source- facing side (left) and target-facing side (right). Courtesy of University of Exeter. both overburden and any impurities within the ore, known as gangue material. The researchers believe the new technique has the potential to transform the mining industry, because it has the capability to dissolve metals from a wide range of ore deposits that were previously considered inaccessible. Also, due to the noninvasive nature of the extraction, the work will help usher in a more sustainable future for the industry. Making mineral extraction more sustainable is especially imperative now in order to provide the breadth of metals required to deliver green technology, such as re- newable energy infra- structure and electri- fied vehicles, while limiting any potential environmental damage associated with the mining process. The team demonstrated that a targeted electric field can be used to dissolve and then recover copper in situ from the ore— avoiding any requirement to physically excavate the material. www.exeter. ac.uk.
A D V A N C E D M A T E R I A L S & P R O C E S S E S | J U L Y / A U G U S T 2 0 2 1 9 existing technology. “This breakthrough will spark all sorts of new technologies—from better navigation systems to better MRI machines,” continues Bowen. Entanglement is thought to lie at the heart of a quantum revolution, and the researchers say their work demonstrates that sensors that use it can supersede existing, nonquantum technology—and, furthermore, that it’s the first proof of the paradigm-changing potential of entanglement for sensing. Australia’s Quantum Technologies Roadmap sees quantum sensors spurring a new wave of technological innovation in healthcare, engineering, transport, and resources. TESTING | CHARACTERIZATION MORE SUSTAINABLE PLASTICS A new path toward sustainable plastics is being forged by researchers at the DOE’s Lawrence Berkeley National Lab, Calif., in collaboration with Dow and Eindhoven University of Technology in the Netherlands. Their new technique provides atomic-resolution details about magnesium chloride, a material involved in the production of the most common plastic, polyethylene. The researchers used pulsed electron beams in an electron microscope to produce first-of-their-kind images of magnesium chloride. A continuous electron beam rapidly damages this delicate, beam-sensitive material, but the new technique allowed the researchers to study it without harm. According to the scientists, the newmethod is useful for imaging a wide range of materials that are normally damaged inside an electron microscope. Pulsed electron beams also could be used to study soft membranes and plastics in general, advancing the quest for sustainable plastics. lbl.gov. SEEING THE INVISIBLE Researchers at the University of Queensland, Australia, created a quantum microscope that can reveal biological structures that would otherwise be impossible to see. This opens opportunities for applications in biotechnology and could extend far beyond into areas ranging from navigation to medical imaging. The microscope is powered by the science of quantum entanglement, an effect Einstein described as “spooky interactions at a distance.” Warwick Bowen from UQ’s Quantum Optics Lab says it is the first entanglement-based sensor with performance beyond the best possible Graphical depiction of the new quantum microscope in action. Courtesy of University of Queensland. Triangular holes make this material more likely to crack from left to right. Courtesy of N.R. Brodnik et al./Phys. Rev. Lett. Rolls-Royce recently opened Testbed 80 in Derby, U.K., reportedly the world’s “largest and smartest indoor aerospace testbed,” according to company sources. The $125 million project required three years of construction. The new facility will support the next stage of the company’s high-efficiency UltraFan engine program, with the first demonstrator to be tested in 2022. It will also test a range of current engines such as the Trent XWB and Trent 1000 as well as future hybrid or all-electric flight systems. rolls-royce.com. BRIEF Atomic-resolution details about magnesium chloride are now obtainable via a new technique. Courtesy of Irina Vodneva. Testbed 80. Courtesy of Rolls-Royce. A major success of the team’s quantum microscope was its ability to catapult over a hard barrier in traditional light-based microscopy. “The quantum entanglement in our microscope provides 35% improved clarity
1 0 A D V A N C E D M A T E R I A L S & P R O C E S S E S | J U L Y / A U G U S T 2 0 2 1 without destroying the cell, allowing us to see minute biological structures that would otherwise be invisible,” they say. “The benefits are obvious; from a better understanding of living systems, to improved diagnostic technologies.” According to the researchers, there exist potentially boundless opportunities for quantum entanglement in technology. www.uq.edu.au. ENERGY CONSERVATION BASED ON BEES By studying bees, researchers from two universities in China found that tiny hairs reduce friction from their movements, saving energy for the insects’ daily activities while reducing wear and tear. This knowledge could help researchers design longer-lasting moving parts. A bee’s abdomen is divided into several tough outer plates that make up its exoskeleton. When the abdomen flexes and extends, these segments slide over each other, creating friction. However, the overlapping portions of the segments show very Tiny hairs on a honeybee’s abdomen reduce friction during bending, saving large amounts of energy during the bee’s daily activities. Courtesy of ACS Applied Materials & Interfaces. little wear and tear, a finding that has puzzled scientists. The researchers wanted to investigate the anti-friction mechanism of the honeybee abdomen, which could someday be used to extend the lifetime of engineered soft devices, such as actuators and hinges. To do this, they observed honeybee abdomens under a scanning electron microscope, finding numerous branched hairs on the outer surface. Then, using atomic force microscopy, they measured the friction caused by moving an exoskeletal segment across either a hairy or hairless surface. Under the same load, the friction for the hairy surfacewas lower than that for a smooth surface. As the load increased, friction for the hairless surface rose, whereas no obvious rise in friction was observed for the hairy surface. The researchers calculated that the hairy surface reduced abrasion during abdominal contraction by about 60% and also saved energy with each contraction, adding up to a large amount of conserved energy essential for conducting bees’ daily activities. https://english.bit.edu.cn.
A D V A N C E D M A T E R I A L S & P R O C E S S E S | J U L Y / A U G U S T 2 0 2 1 1 1 MAKING LIGHTWEIGHT DEVICES Scientists from the National University of Science and Technology MISIS, Russia, in collaboration with LG Electronics, South Korea, created new high heat conductivity magnesium alloys that differ from their counterparts in increased reliability and low cost— plus, the ability to reduce the weight of heat-removing elements by a thirdwithout losing efficiency. Reducing the temperature directly affects the prolongation of the devices’ life cycle. Based on the results of the work, LG Electronics registered patents for a high-heat-conducting magnesium alloy developed at NUST MISIS and a radiator incorporating it in the U.S., the European Union, Korea, and China. The researchers are working on new compositions of magnesium-based alloys, which can provide high strength and corrosion resistance along with low cost and high thermal conductivity. www.en.misis.ru; lg.com. COOLING FABRIC A type of fabric typically used for hiking gear was found to have remarkable heat- conducting properties on par with stainless steel. The discovery, made by a team of Purdue University, West Lafayette, Ind., engineers, could potentially lead to wearable electronics that successfully cool both the device and the wearer’s skin. The material is made of ultrahigh molecular weight polyethylene fibers, which are sold commercially under the brand name Dyneema. These polymer-based fabrics are marketed for their high strength, durability, and abrasion resistance, and are often used to create body armor, specialty sports gear, ropes, and nets. Purdue heat transfer researchers recently investigated other uses for the fabric, specifically as a cooling interface between human skin and wearable electronics. “This fabric has great flexibility and thermal properties. If you stitch it differently, weave it differently, or start blending the polymers with different materials, you could tailor the fabric’s properties to different applications,” the researchers say. “These polymer fabrics have amazing thermal properties that can keep these devices cooler and avoid low-degree skin burns.” The teamdiscovered these properties by benchmarking Dyneema against EMERGING TECHNOLOGY Interlink Electronics Inc., Irvine, Calif., opened a new materials science and research & development lab in Camarillo, Calif. The facility includes state-of-the-art materials characterization, printing, prototyping, and testing equipment for advanced research into novel sensing materials, devices, and applications. interlinkelectronics.com. BRIEF conventional cotton fabrics as well as polyethylene sheets in rigid nonwoven form. They obtained several different commercially manufactured fabric samples and even wove their own samples from rawDyneema fibers. The samples went into a small vacuumchamber, with a metal wire laid across the surface as a heat source. Using an infrared microscope, they generated detailed data about how much heat was being conducted through the fabric’s surface, and in which direction. They found that the Dyneema fabric has 20-30 times higher thermal conductivity than other fabrics—comparable with steel. The fabric naturally has these properties with no additional circuity or other equipment, but the researchers also have plans to test how weaving in different materials affects the fabric. According to the researchers, it’s also possible to integrate other types of fibers to achieve different combinations of properties. purdue.edu. A commercial fabric typically used for hiking gear has the heat-conducting properties of stainless steel, allowing the material to dissipate heat more effectively than other fabrics. Courtesy of Purdue University/Jared Pike. New alloys help reduce the weight of heat removal systems in electric vehicles, consumer electronics, and household appliances. Courtesy of NUST MISIS.
A D V A N C E D M A T E R I A L S & P R O C E S S E S | J U L Y / A U G U S T 2 0 2 1 1 2 D A T A M A N A G E M E N T *Member of ASM International UNLEASHING THE POTENTIAL OF ADDITIVE MANUFACTURING: FAIR AM DATA MANAGEMENT PRINCIPLES William E. Frazier, FASM,* Pilgrim Consulting LLC, Lusby, Maryland Yan Lu and Paul Witherell, NIST, Gaithersburg, Maryland Ray Fryan,* ASM International, Materials Park, Ohio Alex Kitt, EWI, Bu alo, New York Additive manufacturing workshop advocates the use of guidelines for data management to realize Materials 4.0 and achieve process qualification.
A D V A N C E D M A T E R I A L S & P R O C E S S E S | J U L Y / A U G U S T 2 0 2 1 1 3 We are at the dawn of Materials 4.0, a critical component of the digitally driven, data enabled epoch of research and manufacturing, Industry 4.0[1-4]. In this new era, every aspect of a product’s life cycle (research, development, engineering, design, manufacturing, deployment, sustainment, and sunsetting) is interconnected and interdependent. Concomitantly, digitally intense manufacturing technologies of significant importance have emerged. Additive manufacturing (AM) is one such manufacturing technology area that has demonstrated its potential to enhance innovation, accelerate product deployment, and reduce cost. AM is not a single technology, but instead refers to several layer-by-layer processes that fall within its scope. These layer-by-layer processes are com- monly defined as a “a process of joining materials to make parts from 3D model data, usually layer upon layer, as opposed to subtractive manufacturing and formative manufacturing methodologies”[5]. The flexibility offered by AM gives it a certain advantage over many traditional processes, such as the potential to produce components where and when they are needed. Part-defining technical data packages can be sent electronically to any global manufacturing site. Long lead time, complex components, such as aircraft forgings and castings, can be produced in days or weeks compared to months or years. However, the Achilles’ heel of this vision remains the inability to rapidly and cost effectively qualify AM processes and certify components. The traditional means of process qualification involves optimizing the materials technology process, “freezing” it, and then developing statistically substantiated design allowables[6]. Unfortunately, AM does not lend itself to thismethodology as key process parameters may be part-specific and a function of material, geometry, orientation, and proprietary processing. Because of the multitude of factors affecting part quality, the qualification process is time consuming and very costly. A great deal of effort has been devoted to overcoming this challenge. AM standards are Makes/DoD, Crystal City, Va., June 18, 2019). • Additive Manufacturing for Maintenance Operations (AMMO), (America Makes/DoD, Crystal City, Va., June 23, 2020). A fundamental tenet emerged that the challenge could be addressed by building upon the FAIR principles of data management[8]. Simply stated, AM data must be captured, curated, and managed in a form that allows the characteristics of Findability, Accessibility, Interoperability, and Reusability, i.e., FAIR. Details of these principles may be found at https://www.go-fair.org/ fair-principles/ and are summarized in Table 1[9]. THE COST OF NOT BEING FAIR The EuropeanUnionhas published compelling evidence of the impact on the research community of not having FAIR data[10]. They estimated the annual cost of not having FAIR data to be a minimum of €10.2bn per year. An additional cost to innovation was estimated at €16.9bn per year. Further, they stated, “The actual cost is likely to be much higher due to unquantifiable elements such as the value of improved research quality and other indirect positive spillover effects of FAIR research data.” They went on to conclude that about 80% of the duplicative funded work could be avoided with FAIR. Furthermore, the need for FAIR data extends beyond the research community in AM, to practitioners and developers as well. As Fig. 1 indicates, those who work primarily with data spend 80% of their time finding, filtering, reformatting, and integrating data[11,12]. FAIR AM DATA MANAGEMENT WORKSHOP Under the backdrop of this community alignment, the FAIR Additive Manufacturing (AM) Data Management Workshop was held virtually on October 27-28, 2020[13]. The workshop was organized and executed by NIST, ASM International, and Pilgrim Consulting LLC. A workshop assessment[14], speaker briefs, agenda, etc., may be found being developed. Integrated computational materials engineering (ICME) tools are being developed. Modeling and simulations tools, as well as artificial intelligence (e.g., machine learning, neural networks, etc.) are being employed, and new testing methodologies are being adopted. Application of these physics-based and data analytical tools requires the capture, transformation, curation, and analysis of data from across the product’s life cycle. Further, given the complexity of the processes, vast amounts of data are required to achieve any correlations of significance. Few have the necessary resources to attain the required amount of data. To reduce cost, time, and duplicative work, government, academic, and corporate organizations must be able to share data easily across organizational lines. Unfortunately, there are many obstacles to the facilitation of data sharing. Today most data are stored in a range of diverse formats, e.g., paper files, PDFs, spreadsheets, relational databases, etc. They are stored in an equally diverse set of containers including in engineers’ desk drawers, desktop computers, product life cycle management systems, and in the cloud. FAIR AM DATA MANAGEMENT PRINCIPLES Emerging from a series of additive manufacturing workshops held by the U.S. Navy, National Institute of Standards and Technology (NIST), America Makes, and U.S. Department of Defense (DoD) has come a community consensus for a transformational shift in AM process and part qualification and the imperative to adopt FAIR AM data management practices[7]. The workshops were held at these locations and dates: • Navy Additive Manufacturing Technology Interchange (NAMTI) 2018, (Navy, Quantico, Va., November 27, 2018). • AM Materials Database and Data Analytics Workshop, (NIST, Gaithersburg, Md., May 7, 2019). • Additive Manufacturing for Maintenance Operations (AMMO), (America
A D V A N C E D M A T E R I A L S & P R O C E S S E S | J U L Y / A U G U S T 2 0 2 1 1 4 lighted extant and ongoing work being done by standards development organizations and non-profit organizations. Dr. Mohsen Seifi, ASTM, and Kathryn Hyam, ASME, provided updates on their organizations’ datamanagement stand- TABLE 1 – FAIR GUIDING PRINCIPLES Findable Accessible Metadata and data should be easy to find for both humans and computers. Machine-readable metadata are essential for automatic discovery of datasets. F1. (Meta)data are assigned a globally unique and persistent identifier F2. Data are described with rich metadata (defined by R1 below) F3. Metadata clearly and explicitly include the identifier of the data they describe F4. (Meta)data are registered or indexed in a searchable resource After the user finds the required data, she/he needs to know how it can be accessed & authenticated. A1. (Meta)data are retrievable by their identifier using a standardized communications protocol A1.1. The protocol is open, free, and universally implementable A1.2. The protocol allows for an authentication and authorization procedure, where necessary A2. Metadata are accessible, even when the data are no longer available Interoperable Reusable The data must be integrated with other data. The data needs to interoperate with applications, etc. I1. (Meta)data use a formal, accessible, shared, and broadly applicable language for knowledge representation I2. (Meta)data use vocabularies that follow FAIR principles I3. (Meta)data include qualified references to other (meta) data In order to optimize the reuse of data, metadata and data must be well-described so that it can be replicated and/or combined in different settings. R1. (Meta)data are richly described with a plurality of accurate and relevant attributes R1.1. (Meta)data are released with a clear and accessible data usage license R1.2. (Meta)data are associated with detailed provenance R1.3. (Meta)data meet domain-relevant community standards at https://www.asminternational.org/ web/nist-asmdatamanagementworkshop. The purpose of the workshop was to: 1. Facilitate the establishment of a strategic path forward regarding needed AM data management standards and R&D, and 2. Accelerate AM part deployment and reduce the time and cost associated with AM process qualification and part certification. To do so, the thought leadership of an eclectic and diverse group of world-renowned experts were invited to participate. A total of 128 people participated in the event: 30% from government, 25% from academia, 33% from industry, and 12% from standards developing organizations (SDOs) and non-profit organizations. Since the FAIR Data Management Principles have not yet been substantively embraced by the materials engineering or the additive manufacturing communities, the workshop organizers elected to have FAIR experts (working in the biological community) deliver the Day 1 plenary addresses. The invited FAIR keynote speakers were Dr. Mark Wilkinson, University Politecnica de Madrid; Dr. Erik Schultes, Go-FAIR; and Matthew Trunnel, Pandemic Response Commons. The Day 2 plenary session high- Fig. 1 — How data scientists spend their time.
A D V A N C E D M A T E R I A L S & P R O C E S S E S | J U L Y / A U G U S T 2 0 2 1 1 5 taining machine-readable information from tribal/artisan knowledge sources be significantly reduced. • Ensuring that data is reusable and accessible requires that the generator of data be incentivized to collect, organize, and curate it in a manner suitable for reuse. Note, the data generator has all the burden and little to gain while the data user has none of the burden with everything to gain. • The principal impediment to data accessibility is the political, economic, and social resistance to data sharing. This is especially true for proprietary, confidential, and classified data. • Proprietary data formats impede the findability and accessibility of data. • The interoperability, reusability, and findability of data is hindered because of the lack of common data/metadata formats, metadata definitions, and missing data. PATH FORWARD Based upon the results of the work- shop, the critical elements of a strategic path forward, and toward a realization of Materials 4.0, were identified. See Fig. 2. Overcoming the PEST challenges ards development work. Dr. Brandon Ribic, America Makes, and Doug Hall, Battelle Memorial Institute, discussed the AM data management strategy of their non-profit organizations. Participants were divided into four working groups aligned to the FAIR Data Management Principles, i.e., 1. Findable, 2. Accessible, 3. Interoperable, and 4. Reusable. Each working group was co-led by NIST and industry personnel. Working groups identified and prioritized the challenges associated with achieving the workshop goals and recommended approaches to overcome those challenges. An abbreviated summary of the salient observations of the workshop are as follows: • There are political, economic, social, and technological (PEST) impediments to effective data management. The technological challenges were viewed as tractable; the political, economic, and social challenges will require cross-agency and government/private sector collaborative efforts. • Data scientists spend 80% of their time finding, filtering, reformatting, and integrating data, leaving only 20% of their time for data analysis. This 80/20 ratio (time to prepare data/time using data) needs to be changed to 20/80. • The current work to establish an AM common data dictionary (CDD) was highlighted. • The need for a common data exchange format (CDEF) for AM was validated. • Continued work is required to build and expand community consensus around the FAIR principles. • Utilization of WWW consortium standards was an implicit theme. Similarly, the use of JavaScript object notation (JSON), representational state transfer API (REST API), and web ontology language (OWL2) was implicit to the participants’ thinking. • Establishing a “Data Commons” for the facile, cost effective exchange of AM data, models, and tools deserves to be explored. The workshop identified challenges associated with implementing FAIR principles, which were: • Enhanced interoperability requires the establishment of a common data model and formal knowledge representation. • The ability to find and access data requires that the manual labor, difficulty, and cost associated with obFig. 2 — Critical elements of an additive manufacturing data management plan: A PEST problem.
A D V A N C E D M A T E R I A L S & P R O C E S S E S | J U L Y / A U G U S T 2 0 2 1 1 6 is viewed as central to success. Quantifying the value proposition is required to overcome the activation energy associated with concerns (e.g., IP rights, ROI, security, etc.), and provides a business rationale for investment in FAIR data management. Standards are needed to facilitate interoperability. These must include a common data dictionary, a domain specific AM ontology, and metadata formats. The foundational elements include many data standards and architectures developed by the World Wide Web Consortium (W3C). In addition, the aspirational goal of the Semantic Web must be embraced, i.e., to format data in such a way as to make it both machine and human readable. There are critical imperatives associated with implementing effective FAIR data management principles and being productive in Industry 4.0. The work before us will require cross disciplinary efforts. The knowledge, skills, and abilities of the materials scientist and engineermust expand to include that of data science. Further, there is a need for an organization, perhaps a public-private consortium, to serve as a focal point for prototyping data management technologies and serving as the steward for persistent data identifiers. EXAMPLE DATA MANAGEMENT CONCEPTS Technology Stack: When considering the development of a viable data management system, it is perhaps useful to view it in terms of a technology stack, Fig. 3. This permits a systems-level perspective. In this table, the FAIR principles, Semantic Web, the World Wide Web (WWW), etc., are viewed as the foundation upon which an effective data management structure must be built. The applications and platforms listed at the top of the table illustrate how the data might be used by the consumer. The wide breadth of applications underscores the need for the use of FAIR data management principles and a well-defined knowledge management architecture. AM generates large amounts of data, and effective knowledge man- agement is crucial to the advancement of AM. A well-structured and community accepted domain ontology supports knowledge sharing, i.e., interoperability. A pragmatist may characterize an ontology as a model constructed to describe reality that consists of a taxonomy, lexicon, concepts, and defines interrelationships. Here, the goal of an ontology is to support knowledge sharing and the electronic management of scientific information. R. Arp et al. state, “Ontology is a top-down approach to the problem of electronically managing scientific information,” and go on to say “Definitions are perhaps the most important component of ontologies, since it is through definitions that an ontology draws its ability to support consistent use across multiple communities and disciplines, and to support computational reasoning”[15]. Hence, the hard work of establishing components (i.e., dictionary, thesaurus, taxonomy, and ontology) of effective AM data management is critical to achieving innovation and accelerated product deployment[16,17]. The means of data curation and management is also very important. Data must be extracted, transformed, and loaded into the curation site in such a way as to make it usable to data consumers. Several common architectures are considered data repositories. Whether the data is physically curated at a “brick and mortar” location or in the cloud, its purpose and functionality is largely determined by political, social, and economic consideration. For example, a data commons typically supports precompetitive R&D and provides the community with access to both data and computational tools. A data warehouse, however, is typically employed by corporations to deliver specific, actionable business information. Data hubs have characteristics that may make them well suited for agile team formation, secure data curation, and collaboration. However, the sustainability of any of these repositories requires a viable long termbusiness model. One study[18] of 48 repositories in 18 countries assessing their business case concluded, “Yet good data stewardship is costly and research budgets are limited. So, the development of sustainable business models for research data repositories needs to be a high priority in all countries.” EWI AM Qualification: EWI and partners have shown proof of concept that data-enabled approaches can change the approach to qualification Fig. 3 — FAIR AM data management technology stack.
A D V A N C E D M A T E R I A L S & P R O C E S S E S | J U L Y / A U G U S T 2 0 2 1 1 7 of additive components. Currently, the qualification and certification of a production part is based on expensive and part-specific point-qualification datasets. As analternative approach, EWI, GE Research, Raytheon, and Youngstown State University showed proof of concept for feature-based qualification in an America Makes program entitled “Feature-Based Qualification Method for Directed Energy Deposition AM.” In this approach, feature specific datasets are used to train machine learning methods to predict microstructure and mechanical performance. This abstraction from part-specific to feature-specific qualification drastically extends the predictive power of a given dataset. The combination of techniques like these and the reusable nature of FAIR data will provide a paradigm change in qualification/certification. NIST & Data Hub: Figure 4 illustrates a fast AM qualification framework based on federated FAIR AM data. Five key components are identified to enable the fast AM qualification process including: a collaborative and federated AM data hub, advanced data analytics to leverage on heterogeneous datasets, integrated computational material engineering (ICME), a hybrid method to combine data-driven models with first principle-based models for better predictive accuracy, and an adaptive sampling mechanism for material test planning. A collaborative AM data management system combines community efforts and leverages on legacy FAIR data to turn the small data sets from individual material tests into vast amounts of data necessary for statistically sound process qualification. With advanced data analytics, such as transfer learning, heterogeneous data sets with a multitude of geometries, material types, and processes can be mined to develop empirical correlations between material properties, microstructure, part geometry and process parameters. Methods like transfer learning make machine learning systems more efficient and able to work with less data. In addition, combining physics-basedmodeling and toolsets like ICME can provide additional data sets based on simulations. AM qualification can also benefit from better design of experiments using physics-based models. Such advancements lead to less effort and time for material and process testing and promise to speed up AM process/material/part qualification. It is critical to develop and validate efficient and effective advanced data analytics, complemented by physics-based models, capable of undertaking rapid explorations of AM process-structure-property relationships with limited and diverse data sets. ASM International Ecosystem: ASM International has recognized the need to enable the digital capabilities of its membership and has embarked on an ambitious initiative to bring these capabilities to fruition. This initiative is tentatively labeled the ASM Data Ecosystem and is currently a “proof of concept” digital materials analytical environment. Ultimately, this proof of concept will be scaled into a fully featured digital “store” where members can access materials data, simulation tools, and use computational infrastructure with much lower barriers to entry. If targeted and executed properly, many of the FAIR data principle imperatives will be advanced, and some of the PEST challenges will be mitigated. The Data Ecosystem that ASM International is currently building will have many similarities with the data commons previously described. In addition to the digital environment, ASMwill join high-quality and pragmatic data management education to the core “table stake” of high-quality, useful materials data. The schematic of this initiative is provided in Fig. 5. Fig. 4 — A FAIR additive manufacturing framework for rapid qualification.
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