18 25 31 P. 12 OCTOBER 2023 | VOL 181 | NO 7 NDE of Ancient Silver Artifact NASA’s New Superalloy for Extreme Environments SMST NewsWire Included in This Issue BRIDGING MECHANICAL ENGINEERING AND MATERIALS SCIENCE NDT AND FAILURE ANALYSIS
18 25 31 P. 12 OCTOBER 2023 | VOL 181 | NO 7 NDE of Ancient Silver Artifact NASA’s New Superalloy for Extreme Environments SMST NewsWire Included in This Issue BRIDGING MECHANICAL ENGINEERING AND MATERIALS SCIENCE NDT AND FAILURE ANALYSIS
2024 INTERNATIONAL MATERIALS, APPLICATIONS & TECHNOLOGIES HUNTINGTON CONVENTION CENTER | SEPTEMBER 30–OCTOBER 3, 2024 | CLEVELAND, OHIO MATERIALS FOR ENERGY STORAGE IMAT, ASM International’s annual meeting will focus on membership and materials community needs, offering an industry-oriented conference and exposition. IMAT will target a broad range of materials, processes, and their applications, with an emphasis on advanced materials and manufacturing technologies. Traditional topics of interest will be explored, including metals, ceramics, composites, coatings, alloy development, microstructure/process/properties relationships, phase equilibria, mechanical behavior, joining, corrosion, and failure analysis. Emerging topics, instrumental in advancing materials development and cutting-edge technologies, will be covered. Technologies such as advanced manufacturing, including additive, Industry 4.0 and digitization of the materials industry, biomedical/multifunctional materials, power, and transportation industries, materials for energy, renewable and sustainable materials and processes, as well as materials to enable automation and robotics will be covered. Students will have the opportunity to showcase their research and connect with future materials scientists through various events and competitions. CALL FOR ABSTRACTS ORGANIZED BY: Shape Memory & Superelastic Technologies PARTNERED WITH: CO-LOCATED WITH: Abstracts are solicited in the following areas: • Additive Manufacturing • Archaeometallurgy and Ancient Metalworking • Characterization of Materials and Microstructure through Metallography, Image Analysis, and Mechanical Testing: Fundamental and Applied Studies • Corrosion and Environmental Degradation • Emerging Technologies • Failure Analysis • Functional Materials and Structures: Solving Barriers to Adoption • Joining of Advanced and Specialty Materials (JASM XXII) • Light Metal Technology • Materials 4.0: Materials Information in the Product Life Cycle • Materials Behavior & Characterization • Materials for Energy & Utilities • Medical / Biomaterials: Delivering Patient Value • Materials & Processes for Automation • Metals, Ceramics, and Composite Materials: Raw Materials, Processing, Manufacturing Methods, Applications, and Environmental Effects • Perspectives for Emerging Professionals • Processing and Applications • PSDK XV: Phase Stability and Diffusion Kinetics • Sustainable Materials & Processes ABSTRACT SUBMISSION DEADLINE: FEBRUARY 14, 2024 imatevent.org
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28 ISTFA 2023 SHOW PREVIEW The 49th International Symposium for Testing and Failure Analysis features the theme of “Moving Toward Reliable Power Electronic Devices” and will be held in Phoenix, Nov. 12-16. BRIDGING MECHANICAL ENGINEERING AND MATERIALS SCIENCE To learn about the important connection between mechanical engineering and materials science, we turned to five experts with backgrounds in both fields for insight. 12 ADVANCED MATERIALS & PROCESSES | OCTOBER 2023 2 An ancient silver object from Iran is noninvasively tested by micro-x-ray fluorescence spectroscopy. Courtesy of Omid Oudbashi, University of Gothenburg. On the Cover: 45 ASM NEWS The latest news about ASM members, chapters, events, awards, conferences, affiliates, and other Society activities. 10 MACHINE LEARNING Researchers are using artificial intelligence and machine learning tools to discover new magnetic materials and corrosion-resistant alloys.
4 Editorial 5 Research Tracks 10 Machine Learning 6 Metals/Polymers/Ceramics 8 Testing/Characterization 11 Surface Engineering 55 Editorial Preview 55 Special Advertising Section 55 Advertisers Index 56 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. 181, No. 7, OCTOBER 2023. Copyright © 2023 by ASM International®. All rights reserved. Distributed at no charge to ASM members 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 Kodi Collective, Lebanon Junction, Ky. 18 NONINVASIVE μ-XRF ANALYSIS OF ANCIENT SILVER OBJECT Omid Oudbashi, Federico Carò, and Jean-Francois de Lapérouse This case study details the noninvasive analysis of an ancient silver object from Iran, now in the collection of The Metropolitan Museum of Art. 22 ADDITIVELY MANUFACTURING MINING TOOLS Varun Kumar Kurapati Additive manufacturing techniques give the mining industry a chance to revolutionize the conceptualization, prototyping, and production of mining tools, including using WC-Fe, Ni-based matrix coatings that display exceptional properties. 25 TECHNICAL SPOTLIGHT: NASA’S NEW SUPERALLOY FOR EXTREME ENVIRONMENTS Hear from the co-inventors of NASA’s Alloy GRX-810, Tim Smith and Christopher Kantzos, about its exceptional high strength and durability for aerospace and other extreme conditions. FEATURES OCTOBER 2023 | VOL 181 | NO 7 ADVANCED MATERIALS & PROCESSES | OCTOBER 2023 3 18 25 31 22 31 SMST NewsWire The official newsletter of the International Organization on Shape Memory and Superelastic Technologies (SMST). This biannual supplement covers shape memory and superelastic technologies for biomedical, actuator applications, and emerging markets, along with SMST news and initiatives.
4 ADVANCED MATERIALS & PROCESSES | OCTOBER 2023 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 Anne Vidmar, Layout and Design Allison Freeman, Production Manager allie.freeman@asminternational.org Press Release Editor magazines@asminternational.org EDITORIAL COMMITTEE John Shingledecker, Chair, EPRI Beth Armstrong, Vice Chair, Oak Ridge National Lab Adam Farrow, Past Chair, Los Alamos National Lab Rajan Bhambroo, Tenneco Inc. Daniel Grice, Materials Evaluation & Engineering Surojit Gupta, University of North Dakota Michael Hoerner, KnightHawk Engineering Hideyuki Kanematsu, Suzuka National College of Technology Ibrahim Karaman, Texas A&M University Ricardo Komai, Tesla Bhargavi Mummareddy, Dimensional Energy Scott Olig, U.S. Naval Research Lab Christian Paglia, SUPSI Institute of Materials and Construction 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 ASM BOARD OF TRUSTEES Pradeep Goyal, President and Chair Navin Manjooran, Senior Vice President Elizabeth Ho man, Vice President David B. Williams, Immediate Past President Lawrence Somrack, Treasurer Amber Black Ann Bolcavage Pierpaolo Carlone Hanchen Huang André McDonald Christopher J. Misorski U. Kamachi Mudali James E. Saal Dehua Yang Sandra W. Robert, Executive Director STUDENT BOARD MEMBERS Kingsley Amatanweze, Karthikeyan Hariharan, Denise Torres Individual readers of Advanced Materials & Processes may, without charge, make single copies of pages therefrom for personal or archival use, or may freely make 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 from articles 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 (FA) ENGINEER Tucked away near the labyrinth of bridges, tunnels, and steel structures of downtown Pittsburgh is one of its unsung guardians. Matergenics Inc., a materials testing laboratory, provides corrosion risk assessment and failure analysis (FA) for the aging infrastructure of the Iron City and beyond. Recently, I met company founder, Dr. Mehrooz (Zee) Zamanzedeh, FASM, and received a tour of Matergenics and its Museum of Material Failures. The museum showcases his team’s accumulation of knowledge from decades of failure assessments. According to Dr. Zee, the two most common failure mechanisms are corrosion and vibration. The latter leads to fatigue cracks. As he described the steps involved in his team’s condition assessment of a new project, Dr. Zee interspersed what he sees as “the role of the new FA engineer.” The characteristics he enumerated as important in modern FA seem applicable to all engineers. In fact, we found connections between Dr. Zee’s description of the new FA engineer and some of the authors in this issue. Interdisciplinary thinking. An FA engineer must explore all dimensions of a case—the original design, materials used, manufacturing process, and wear during usage—to get to a root cause. That echoes the sentiment of our “Bridging Mechanical Engineering and Materials Science” article, which asks five experts to discuss the inherent connection between the two disciplines. Environmental consideration. Dr. Zee and his team have seen a dramatic increase in cases due to climate change and its impact on infrastructure and utilities. He has been called to the California wildfires to assess the damage that prolonged heat has on the steel lattice structures, which hold power lines. The extreme environment of space posed a different problem for two inventors from the NASA Glenn Research Center. Through an interview synopsis, learn about their challenges in finding an alloy that can hold up against the high temperatures of aeronautics and space missions. New technologies. The modern FA engineer embraces new technologies by using artificial intelligence (AI), satellites, and sensors to gather and analyze data. Likewise, an archaeometallurgist shows how the use of micro-x-ray fluorescence spectroscopy has become a helpful tool in his field for examining ancient museum pieces without causing harm to the precious artifact. Also, ASM’s Executive Director Sandy Robert outlines in her column how the Society is already using AI as a critical new partner in its operations. “Load bearing” members. Dr. Zee encourages his staff to be someone their team can rely on, to be a stalwart who carries their weight. Our ASM News section includes these workers. For example, meet Ed Cole, Jr., FASM, who is a pillar of ASM’s Electronic Device Failure Analysis Society (EDFAS) and co-founder of EDFA magazine. And by any condition assessment, Dr. Zee and Matergenics are more than carrying their weight in the FA industry. joanne.miller@asminternational.org Dr. Zee in his Museum of Material Failures.
ADVANCED MATERIALS & PROCESSES | OCTOBER 2023 5 NEW GLASS SPORTS SUPREME TOUGHNESS Researchers at the University of Bayreuth, Germany, along with colleagues in the U.S. and China, produced an oxide glass with unmatched toughness. Under high pressures and temperatures, they succeeded in “paracrystallizing” an aluminosilicate glass, with the resulting crystal-like structures creating a highly damage-tolerant material. The new approach begins with oxide glasses that have a disordered internal structure and are the most widely employed commercial glass materials. Using aluminosilicate, which contains silicon, aluminum, boron, and oxygen, the team created a new structure by employing high-pressure and high-temperature technologies. At pressures between 10-15 gigapascals and a temperature of roughly 1000°C, the silicon, aluminum, boron, and oxygen atoms grouped together to form crystal-like structures. These structures are called paracrystalline because they differ significantly from a completely irregular structure, but do not approach the clear regular structure of crystals. Even after a drop RESEARCH TRACKS in pressure and temperature to normal ambient conditions, the paracrystalline structures in the aluminosilicate glass remain. The penetration of the glass with these new structures results in toughness many times higher than be- fore paracrystallization. It now reaches a value of up to 1.99 ± 0.06 MPa (m)¹/², a toughness never before measured for oxide glasses. The team explains the extraordinary strengthening by the fact that forces acting on the glass from outside, which would normally lead to breakage or cracks, are now directed against the paracrystalline structures. They dissolve areas of these structures and transform them back into an amorphous random state. In this way, the glass acquires greater inter- nal plasticity so it does not suffer damage when exposed to strong forces. www.uni-bayreuth.de. BUILDING BETTER THIN-FILM BATTERIES Researchers at Empa, Switzerland, developed a lithium metal-based solid- state battery with some key advantages over today’s lithium-ion technology: It A new solid-state thin-film battery prototype features individual cells measuring just 1 x 3 mm. can be charged and discharged within one minute, lasts about 10 times as long as a lithium-ion battery, and is insensitive to temperature fluctuations. In addition, unlike lithium-ion batteries, it is not flammable. The team now plans to bring this technology to market and has founded a spin-off called BTRY to do so. The battery is a thin-film solid- state battery with a new approach— the researchers succeeded in stacking the thin-film cells on top of each other, increasing their capacity. The thin-film cells are manufactured using vacuum coating. The desired materials are atomized in a vacuum chamber to form individual atoms, which are then deposited in a precisely controlled layer on the target substrate. The high-precision manufacturing method has an additional advantage in that it does not require toxic substances. However, this also makes the thin-film battery more expensive. The researchers see its application primarily in products where the battery only accounts for a small portion of the overall cost, such as smartphones and satellites. Over the next two years, the team plans to increase both the surface area of the battery and the number of layers. www.empa.ch. Simulated structure of glassy (left) and paracrystalline (right) grossular. Oxygen, silicon, aluminum, and calcium atoms (from small to large) are colored lighter the higher the degree of order in the surrounding structure. Courtesy of Hu Tang.
ADVANCED MATERIALS & PROCESSES | OCTOBER 2023 6 METALS | POLYMERS | CERAMICS The University of Nebraska-Lincoln committed $40 million over four years to support its Grand Challenges Catalyst Competition. One of the 11 winning projects will use materials science and quantum technologies to plan, model, and engineer solutions to achieve climate resilience, quantum literacy, and sustainable agriculture. research.unl.edu. use in illuminated devices or solar energy conversion. The research team reports that the luminescent properties of new chromium materials are nearly as good as some of the osmium compounds used conventionally. Relative to osmium, however, chromium is about 20,000 times more abundant in the earth’s crust—and much cheaper. The new materials are also proving to be efficient catalysts for photochemical reactions, including processes that are triggered by exposure to light, such as photosynthesis. If the new chromium compounds are irradiated with a red lamp, the energy from the light can be stored in molecules which can then serve as a power source. To make the chromium atoms glow and enable them to convert energy, the researchers built them into an organic molecular framework consisting of carbon, nitrogen, and hydrogen. The team designed this organic framework to be particularly stiff, so that the chromium atoms are well packaged. This tailor-made environment MUSSELS INSPIRE RARE EARTH ELEMENT EXTRACTION METHOD Researchers at Penn State, University Park, Pa., recently developed a new mussel-inspired nanocellulose coating (MINC) that has demonstrated a surprising ability to recover rare earth elements (REEs) from secondary sources such as industrial wastewater without using a high amount of energy. Mussels have a remarkable ability to adhere to surfaces underwater thanks to the adhesive properties of catechol-based molecules found in mussel proteins. The MINC mirrors this by consisting of ultra-tiny hairy cellulose nanocrystals with uniquely sticky properties. The coating is applied to a substrate via a technique called dopamine-mediated ad-layer formation. A chemical reaction then enables the MINC to form a thin layer of molecules on a surface, making it capable of sticking to a broad range of substrates. The MINC coating is to neodymium what a magnet is to iron, pulling the REE out of water, even when the element is only present in amounts as limited as parts per million. This selectivity allows MINC to avoid recovering undesired elements like sodium and calcium. Next, the researchers plan to investigate how the MINC method may work to extract other REEs in a more sustainable way. psu.edu. REPLACING NOBLE METALS WITH CHROMIUM Scientists at the University of Basel, Switzerland, have successfully replaced rare and expensive noble metals with a significantly cheaper metal for Mussels’ unique ability to stick to underwater surfaces has inspired a more e icient, and environmentally friendly way to extract critical rare earth elements. Courtesy of Sheikhi Lab/Penn State. ISM Resources Corp., Canada, changed its name toDiscovery Lithium Inc. to reflect the company’s recent acquisition of the lithium prospective Serindac Lake and Vaubert Lake mineral claims. discoverylithium.com. BRIEFS State-of-the-art chromium compounds act as luminescent materials and catalysts. Courtesy of University of Basel/Jo Richers.
ADVANCED MATERIALS & PROCESSES | OCTOBER 2023 7 helps to minimize energy losses due to undesired molecular vibrations and to optimize the luminescent and catalytic properties. Encased in its rigid organic framework, chromium proves to be much more reactive than noble metals when exposed to light. This paves the way for photochemical reactions that are otherwise difficult to initiate. In the future, the group aims to develop their materials on a larger scale to allow broader testing of potential applications. They also want to further optimize the catalytic properties to advance toward the goal of converting sunlight into chemical energy for storage—as in photosynthesis. www.unibas.ch/en. NEXT-GEN SEMICONDUCTOR MATERIAL For the first time, a team of researchers from the University of Minnesota Twin Cities created a thin film of a unique topological semimetal material that has the potential to generate more computing power and memory storage while using significantly less energy. As evidenced by the United States’ recent CHIPS and Science Act, there is a growing need to increase semiconductor manufacturing and support research that goes into developing more efficient materials that power electronic devices everywhere. A class of quantum materials called topological semimetals is one such candidate for use in new and improved computer chips. The electron behavior in these materials contributes to properties that typical insulators and metals used in electronic devices do not have. They’re being explored for use in spintronic devices, an alternative to traditional semiconductor devices that leverage the spin of electrons rather than the electrical charge to store data and process information. The University of Minnesota researchers were able to successfully synthesize such a material as a thin film—and prove that it has the potential for high performance with low energy consumption. The researchers are the first to use a patented, industrycompatible sputtering process to create this semimetal in a thin film format. Because their process is industry compatible, the team says, the technology can be more easily adopted and used for manufacturing real-world devices. twin-cities.umn.edu. In response to the CHIPS and Science Act, new materials are being explored for use in the electronic chip industry. AM&P TECHNICAL ARTICLES NOW AVAILABLE IN THE ASM DIGITAL LIBRARY! Advanced Materials & Processes (AM&P) is the flagship magazine from ASM International. AM&P technical articles cover leading-edge developments in materials selection, processing, applications, and characterization, as well as emerging technologies of interest to engineers and scientists. Now, a collection of all of the technical articles plus ASM News sections from the past ten years of AM&P are available in the ASM Digital Library, making it easier than ever to discover and link to in-depth articles on materials technologies. ASM members get full free access. Learn more: dl.asminternational.org/amp-tech
8 ADVANCED MATERIALS & PROCESSES | OCTOBER 2023 CCQ research team’s new theory explains many oddities about strange metals, such as why the change in electrical resistivity is directly proportional to the temperature, even down to extreme lows. This correlation indicates that a strange metal resists the flow of electrons more than an ordinary metal such as gold or copper at the same temperature. The new theory is based on a combination of two strange metal properties. First, their electrons can become quantum mechanically entangled with one another, binding their fates, and they remain entangled even when distantly separated. Second, strange metals have a nonuniform, patchwork-like arrangement of atoms. The irregularity of a strange metal’s atomic layout means that the electron entanglements vary depending on where in the material the entanglement took place. The variety adds randomness to TESTING | CHARACTERIZATION DETERMINING METAL DUCTILITY WITH QUANTUM MECHANICS A new testing method for predicting metal ductility was created by a team of scientists from Texas A&M University and Iowa’s Ames National Laboratory. The quantum-mechanics-based approach fills a need for an inexpensive, efficient, high-throughput way to predict ductility. The team demonstrated its effectiveness on refractory multiprincipal-element alloys (RMPEAs). These are materials of interest for use in high-temperature conditions— however, they frequently lack necessary ductility for potential applications in aerospace, fusion reactors, and landbased turbines. Another advantage to this new high-throughput testing method is its efficiency. The speed and capacity make it possible to predict which material combinations are worth taking to the experimental level, and it can test thousands of materials rapidly. It also expands on the capabilities of current approaches. The researchers performed validation tests on a set of predicted RMPEAs, materials that have potential use in high temperature environments. Through their validation testing, the team found that the predicted ductile metals underwent significant deformation under high stress, while the brittle metal cracked under similar loads, confirming the robustness of their new quantum mechanical testing method. ameslab.gov. STRANGE METALS MECHANISM REVEALED A mechanism that explains the characteristic properties of strange metals has been revealed by researchers at the Flatiron Institute’s Center for Computational Quantum Physics (CCQ) in New York City. Strange metal behavior is found in many quantum materials, including some that, with small changes, can become superconductors. The Triangular holes make this material more likely to crack from le to right. Courtesy of N.R. Brodnik et al./Phys. Rev. Lett. A new scientific tool called the high-energy electron xtallography instrument (HeXI) combines the power of electron diffraction with x-ray beamline expertise. It is being built by a team at Diamond Light Source, the U.K.’s national synchrotron, and will enable highly precise structure determination. www.diamond.ac.uk. Researchers found that higher (increased) charge activity is responsible for improved ductility in bodycentered cubic metals. Courtesy of P. Singh et al., Acta Materialia, Vol. 257, 15 September, 2023. A new theory explains the unusual behavior of strange metals, considered one of the greatest open challenges in condensed matter physics. Courtesy of Lucy Reading-Ikkanda/Simons Foundation. BRIEF
ADVANCED MATERIALS & PROCESSES | OCTOBER 2023 9 the momentum of the electrons as they move through the material and interact with each other. Instead of all flowing together, the electrons knock each other around in all directions, resulting in electrical resistance. Since the electrons collide more frequently the hotter the material gets, the electrical resistance rises alongside the temperature. According to lead researcher Aavishkar Patel, a better understanding of strange metals could help physicists develop and fine-tune new super-conductors for applications such as quantum computers. simonsfoundation.org, harvard.edu. IMAGING LIGHT ELEMENTS IN GRAIN BOUNDARIES For the first time, scientists at the Max Planck Institute for Iron Research (MPIE), Germany, successfully imaged and analyzed light and heavy elements in the atomic motifs of grain boundaries in steel. Using atom probe tomography and a customized microscopy code, they developed a workflow to analyze and interpret grain boundaries in steels. They identified that certain ordered atomic motifs govern the most important chemical properties of grain boundaries. Engineering those atomic motifs paves the way to more durable, tailor-made materials. “We developed a workflow and code for transmission electron microscopy (TEM) that involves growing bicrystals of an iron-boron- carbon alloy with the same crystal orientation but changing grain boundary planes,” explains lead researcher Xuyang Zhou. “This way, we were able to control the interfering parameters.” The researchers showed that even the mere tilt in the grain boundary plane with identical misorientation impacts the chemical composition and atomic arrangement of the microstructure and makes the material more or less prone to failure. The team is now working with the computational materials design department at MPIE to use the developed code and experimental data for simulating how light elements like boron, carbon, or hydrogen behave in materials. www.mpie.de. TEM image resolving even light atoms (boron and carbon) as interstitial atoms in the center of the motif. Courtesy of X. Zhou/Max-Planck-Institut für Eisenforschung. STATEMENT OF OWNERSHIP, MANAGEMENT, CIRCULATION, ETC. Required by the Act of 23 October 1962, Section 4369, Title 39, United States Code, showing the ownership, management, and circulation of Advanced Materials & Processes®, publishes eight issues per year: January/February, March, April, May/June, July/August, September, October, and November/December at 9639 Kinsman Road, Materials Park, Ohio 44073, USPS # 762-080. Annual subscription rate is $499. The publisher and editor are Scott D. Henry and Joanne Miller, respectively, both of 9639 Kinsman Road, Materials Park, Ohio, 44073. The owner is ASM International®, Materials Park, Ohio, which is a not-for-profit educational institution, the officers being; President and Chair of the Board, Pradeep Goyal; Senior Vice President and Trustee, Navin J. Manjooran; Vice President and Trustee, Elizabeth Hoffman; Immediate Past President and Trustee, David B. Williams; Executive Director, Sandy Robert; Treasurer and Trustee, Lawrence Somrack; Trustees, Amber Black, Ann Bolcavage, Pierpaolo Carlone, Hanchen Huang, André McDonald, Christopher J. Misorski, U. Kamachi Mudali, James E. Saal, and Dehua Yang; Student Board Members Kingsley Amatanweze, Karthikeyan Hariharan, and Denise Torres. There are no known bondholders, mortgagees, and other security holders owning or holding 1% or more of the total amount of bonds, mortgages, or other securities. The issue date for circulation data below is July/August 2023. The average number of copies of each issue during the preceding 12 months is: (a) Total number of copies printed: 4,031; (b) Paid and/or requested circulation: (1) Paid/requested outside county mail subscriptions: 2,809; (2) Paid in-county subscriptions: 0; (3) Sales through dealers and carriers, street vendors, counter sales, and other non-USPS paid distribution: 426; (4) other classes mailed through the USPS: 0; (c) Total paid and/or requested circulation: 3,235; (d.1) Free distribution or nominal outside-county: 0; (d.3) Free distribution by mail: 61; (e) Total free distribution: 61; (f) Total distribution: 3,296; (g) Copies not distributed: 475; (h) Total: 3,771; (i) Percent paid: 98. 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ADVANCED MATERIALS & PROCESSES | OCTOBER 2023 10 MACHINE LEARNING | AI AI HELPS FIND NEW MAGNETIC MATERIALS Researchers from the DOE’s Ames National Laboratory, Iowa, developed a new machine learning (ML) model for discovering magnet materials that are free of critical elements. The model predicts the Curie temperature of novel material combinations—a vital step in using AI to predict new permanent magnet materials. This model adds to the team’s recently developed capability for discovering thermodynamically stable rare earth materials. High performance magnets containing critical materials such as cobalt and rare earth elements like neodymium and dysprosium are in high demand but have limited availability, thus motivating researchers to find ways to design magnets that require less critical materials. The Ames team used experimental data on Curie temperatures and theoretical modeling to train the ML algorithm. “Finding compounds with high Curie temperature is an important first step in the discovery of materials that can sustain magnetic properties at elevated temperatures,” explains researcher Yaroslav Mudryk. “This aspect is critical for the design of not only permanent magnets but other functional magnetic materials.” According to Mudryk, using an ML method can save time and resources. The team trained their model using experimentally known magnetic materials in order to establish a relationship between several electronic and atomic structure features and Curie temperature. These patterns then give the computer a basis for finding potential candidate materials. To test the model, the team used compounds based on cerium, zirconium, and iron. “The next super magnet must not only be superb in performance, but also rely on abundant domestic components,” says researcher Andriy Palasyuk. The team found that the ML model was successful in predicting the Curie temperature of material candidates, an important first step in creating a faster way to design new magnets for future applications. ameslab.gov. CORROSION-RESISTANT ALLOY DESIGN VIA AI Scientists at the Max Planck Institute for Iron Research, Germany, developed a machine learning (ML) model that enhances predictive accuracy by up to 15% versus existing frameworks for discovering corrosion-resistant alloys. The model’s power stems from fusing both numerical and textual data. “Every Magnet material. Courtesy of Ames Lab. alloy has unique properties concerning corrosion resistance. These properties do not only depend on the alloy composition itself, but on the manufacturing process. Current ML models are only able to benefit from numerical data. However, processing methodologies and experimental testing protocols, which are mostly documented by textual descriptors, are crucial to explain corrosion,” says researcher Kasturi Narasimha Sasidhar. The team used language processing methods similar to ChatGPT along with ML techniques for numerical data and developed a fully automated natural language processing framework. Including textual data in the ML framework enables identification of enhanced alloy compositions resistant to pitting corrosion. With the new ML program, Sasidhar and his team used manually gathered data as textual descriptors. Now, their objective is to automate the data mining process and seamlessly integrate it into the existing framework. Incorporating microscopy images will mark yet another milestone, as the researchers envision the next generation of AI tools that converge textual, numerical, and image-based data. www.mpie.de. Schematic of process-aware deep neural network model. Courtesy of Science Advances.
ADVANCED MATERIALS & PROCESSES | OCTOBER 2023 1 1 SURFACE ENGINEERING SUPERLUBRICITY COATING A new coating created by scientists at the Department of Energy’s (DOE) Oak Ridge National Lab (ORNL), Tenn., could significantly reduce friction in common load-bearing systems with moving parts, from vehicle drive trains to wind and hydroelectric turbines. Composed of carbon nanotubes, the new superlubricity coating reduces the friction of steel rubbing on steel at least a hundredfold. Superlubricity—the property of showing virtually no resistance to sliding—has a coefficient of friction less than 0.01. The ORNL coating reduced the coefficient far below the cutoff for superlubricity to as low as 0.001. According to the researchers, their main achievement is making superlubricity feasible for the most common applications. In the research, scientists grew carbon nanotubes on steel plates. With a machine called a tribometer, they made the plates rub against each other to generate carbon-nanotube shavings. The multiwalled carbon nanotubes coat the steel, repel corrosive moisture, and function as a lubricant reservoir. When first deposited, the vertically aligned nanotubes stand on the surface like blades of grass. Each blade is hollow but made of multiple layers of rolled graphene. The fractured carbon nanotube debris from the shaving is redeposited onto the contact surface, forming a graphene-rich tribofilm that reduces friction to nearly zero. As such, the lab-developed nanotubes do not provide superlubricity until they are damaged. Notably, the presence of even one drop of oil is crucial to achieving that superlubricity. According to the researchers, their coating’s superior slipperiness has staying power— superlubricity persisted in tests of more than 500,000 rubbing cycles. ornl.gov. SCALABLE LIQUID METAL ADHESION According to scientists at Tsinghua University in China, everyday materials such as paper and plastic could be transformed into electronic smart devices by using a simple new method to apply liquid metal to surfaces. The researchers demonstrated a technique for applying a liquid metal coating to surfaces that do not easily bond with liquid metal. The approach is designed to work at a large scale and may have applications in wearable testing platforms, flexible devices, and soft robotics. Exploring an alternative approach that would allow them to directly print liquid metal on substrates without sacrificing the metal’s properties, Bo Yuan and colleagues applied two different liquid metals—eGaln and BilnSn—to various silicone and silicone polymer stamps, then applied different forces as they rubbed the stamps onto paper surfaces. The researchers found that rubbing the liquid metal-covered stamp against the paper with a small amount of force enabled the metal droplets to bind effectively to the surface, while applying larger amounts of force prevented the droplets from staying in place. In the future, the team plans to build on their technique so that it can be used to apply liquid metal to a greater variety of surfaces, including metal and ceramic. “We also plan to construct smart devices using materials treated by this method,” adds Yuan. www.tsinghua.edu.cn/en. BRIEF Engineered Performance Coatings (EPC), U.K., and Flame Spray Technologies (FST), the Netherlands, have joined to form Surface Technology Services (STS). EPC provides in-house coating services including coating development and manufacturing of coated components, while FST designs and manufactures thermal spray equipment. Both firms will operate independently under STS. ep-coatings.com, www.fst.nl. Jun Qu shows stainless-steel disks before (silver) and a er (black) coating with carbon nanotubes that provide superlubricity. Courtesy of Carlos Jones/ ORNL, U.S. DOE. Liquid metal applied to paper provides new properties to this origami paper crane and collapsible box. Courtesy of Cell Reports Physical Science/Yuan et al.
12 ADVANCED MATERIALS & PROCESSES | OCTOBER 2023 BRIDGING MECHANICAL ENGINEERING AND MATERIALS SCIENCE To learn about the important connection between mechanical engineering and materials science, we turned to five experts with backgrounds in both fields for insight. Following are their perspectives on how the two disciplines informed their careers, which types of design challenges can be solved with materials information, and how ASM can improve that connection by leading with a “unity of disciplines” approach. ASM PANEL OF EXPERTS Scott Carpenter Senior Director of R&D Vactronix Scientific Bertrand Jodoin, FASM Professor, Mechanical Engineering Department Cold Spray Laboratory University of Ottawa Vistasp Karbhari, FASM Professor, Department of Civil Engineering Professor, Department of Mechanical and Aerospace Engineering The University of Texas at Arlington Marina B. Ruggles-Wrenn, FASME Professor of Aerospace Engineering Department of Aeronautics & Astronautics AFIT/ENY Air Force Institute of Technology Judith A. Todd, FASM, FASME Professor of Engineering Science and Mechanics Department of Engineering Science and Mechanics The Pennsylvania State University Image courtesy of Ehsan Ahi, Velan Inc., Montreal. INTERDISCIPLINARY PERSPECTIVES
13 ADVANCED MATERIALS & PROCESSES | OCTOBER 2023 Describe your education or career in relationship to the two disciplines of materials and mechanical engineering. Scott Carpenter: I graduated from the University of California, Berkeley with a double major in mechanical engineering and materials science and engineering; so these worlds were brought together for me through my education. In my professional career, I began working with shape memory alloys at Raychem in the late 1980s and continue to work with these materials today. I have worked with numerous other metals and alloys, as well as polymers, ceramics, and coatings throughout my career. My main focus has been on Nitinol processes and products. Nitinol is a highly non-linear, anisotropic, and path dependent material, and as such requires computer simulation for all but basic analyses. This material is sensitive to thermomechanical processing history; so, you cannot separate the processing and its impact on properties from the mechanical design. Understanding the mechanical aspects of these materials requires an understanding of how the crystallography works. Bertrand Jodoin: I have a bachelor’s degree in mechanical engineering with a specialization in aerospace and a Ph.D. in chemical engineering. As part of my undergraduate studies, I took two courses related to materials and numerous courses about mechanical engineering. While pursuing my Ph.D., I again took a few courses on materials. My dissertation was on the development of a DC plasma torch for coating development and that was when I was introduced to the thermal spray world and community. After my Ph.D., I started an academic career at the University of Ottawa and decided to push the link between materials and mechanical engineering further by working on the cold spray process, which was at the time more of an engineering/science curiosity than a real spray/coating process. I have been working on the development and use of this process ever since, combining both mechanical engineering and materials for interesting applications. Vistasp Karbhari: My career in academia has been at the interstices of structures, mechanics, and materials, building on the disciplines of mechanical and aerospace engineering, civil engineering, and materials. This has enabled me to conduct cutting-edge research in the areas of composite materials from the nano level to the structure, on the durability of materials and structures, and in terms of structural design, rehabilitation, and multi-threat mitigation. The ability to combine knowledge from the different disciplines allowed me to study effects during the processing of polymers and composites and to develop methods for handling large structural components using ambient and moderate temperature non-autoclave cure processes. This background also enables me to teach courses at the undergraduate and graduate levels linking materials details at the nano and constituent level (i.e., fiber, matrix, filler) with structural response and design. The ability to integrate the disciplines enables innovation across levels with a true understanding of how materials selection and processing affects design and structural responses. Marina Ruggles-Wrenn: My education (B.S. in mechanical engineering, M.S. in mechanics, and Ph.D. in mechanical engineering) focused primarily on mechanical engineering with little emphasis on materials science. During the early years of my professional career, I concentrated on experimental investigation and constitutive modeling of the inelastic deformation behavior of engineering alloys and on high-temperature structural design methods. My first significant (and exciting!) excursion into materials science occurred when I investigated effects of prior aging on rate sensitivity and cyclic hardening of a nuclear-grade stainless steel as part of my Ph.D. research. Thorough understanding of the microstructural nature of aging through the formation of precipitates was critical to selecting proper pretest heat treatments. Microstructural investigation of the samples with an SEM and a TEM was critical to determining that the precipitation heat treatments indeed produced the desired degrees of aging. Then some 20 years ago, my growing interest in the mechanical behavior and environmental durability of advanced ceramic matrix composites necessitated an aggressive study of the material microstructure and physical methods of materials characterization. Judith A. Todd: I completed my B.S. and Ph.D. degrees in materials science at Cambridge University with a strong emphasis on metallurgy and mechanical behavior. I then accepted a postdoctoral position at Imperial College of Science and Technology, London, to conduct research on the mechanical behavior of materials, advanced fracture mechanics, and fatigue. In this collaborative program between the materials science and engineering and mechanical engineering departments, I worked on the early development of the parameter C* (creep equivalent of the J contour integral) to predict creep crack growth in Cr-Mo steels (power plant steam pipe), and in aluminum alloy RR-58, (skin of Concorde). This began my life-long engagement with mechanical engineers. Except for my position as Department Head of Engineering Science and Mechanics at Penn State, I have held courtesy faculty positions in mechanical engineering departments throughout my academic career. What have you learned from a knowledge of mechanical engineering that helps in your materials career? Ruggles-Wrenn: My background in mechanical engineering has taught me to see the difference between the design of the material (typically a purview of materials scientists) and the design with the material (typically a purview of mechanical engineers). Both are extremely important. The best results are achieved through collaboration, when the design of the material goes hand-in-hand with the design with the
14 ADVANCED MATERIALS & PROCESSES | OCTOBER 2023 shoulder” transfer between design and manufacturing, and enables a better understanding of service life, durability, and damage tolerance. In the case of composite materials—my specialty— that background enabled a much better ability to understand and tailor failure modes, develop optimized load paths through configuration tailoring, and develop better processes, taking into account aspects of flow and cure at the micro and macro levels. This has allowed for design to be considered simultaneously at the materials and structural levels, especially in the development of ceramics through pre- ceramic polymer methods. What are the challenges mechanical engineers encounter that can be overcome by an increased knowledge of materials? Karbhari: Mechanical engineers are required to analyze structural response and design components that will withstand a range of thermo- mechanical loads and vibrations. A thorough understanding of materials leads to not just better, more effective, and cost-efficient materials selection, but also tailoring of the materials and configuration to best handle loads over material. We should aim to link the material behavior we observe on the macroscale (say in mechanical testing of laboratory sized specimens) to the phenomena we observe on the microscale. Improvements in material processing can be recommended and executed based on such observations. Todd: Mechanical engineers place a very strong emphasis on design of components and their integration into large systems—power plants, automobiles, electronics, medical devices, among many others. It is essential to know how all the parts fit together and how designs can be tuned to optimize the performance of the system. Mechanical engineers rely heavily on materials property data, codes, and standards to select appropriate materials compositions, component dimensions, and manufacturing processes that they expect suppliers to meet. It is essential for materials scientists and engineers to supply the highest quality materials information to ensure the integrity of our safety-critical and humanitarian infrastructures. Jodoin: Being primarily involved with surface and coatings technologies, the goal is always to produce the perfect coating that can withstand the specific environment it is exposed to as well as the various stresses. However, the production of these coatings usually involves complex equipment as well as complex interactions of the various process parameters. My training in mechanical engineering has been extremely beneficial to understanding the intricate interactions and various complexities of the processes to allow going beyond “turning knobs and seeing what happens.” Most coating technologies, especially thermal spray processes, involve heat transfer, fluid mechanics, gas dynamics, solid mechanics, and many other topics that are covered in mechanical engineering. As such, it has helped me understand the process fundamentals and be able to foresee the effect of various spray parameters ahead of time. Karbhari: The fundamentals of solid mechanics, thermodynamics, fluid mechanics, and analysis have helped me develop a better understanding of materials, configuration, and process interactions, and tailor materials for specific response modes using anisotropy to optimize design and failure modes at levels not possible with isotropic materials. Mechanical engineering helps in the appropriate selection and use of materials, obviating the “over the Many engineers point to Mechanical Metallurgy by George Dieter, a seminal text from their undergraduate education. Its third printing is still used today. Tensile testing is an essential tool in determining material properties related to strength.
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