20 24 28 P. 13 APRIL 2024 | VOL 182 | NO 3 Growing a Diverse Materials Science Workforce The Transformative Power of AM for Batteries SMST NewsWire and iTSSe Newsletter Included in This Issue EMPOWERING BUSINESSES THROUGH EFFECTIVE DATA MANAGEMENT ADDITIVE MANUFACTURING
20 24 28 P. 13 APRIL 2024 | VOL 182 | NO 3 Growing a Diverse Materials Science Workforce The Transformative Power of AM for Batteries SMST NewsWire and iTSSe Newsletter Included in This Issue EMPOWERING BUSINESSES THROUGH EFFECTIVE DATA MANAGEMENT ADDITIVE MANUFACTURING
MAY 6–8, 2025 | VANCOUVER, CANADA 36th AeroMat Conference and Exposition ORGANIZED BY INNOVATIONS IN MATERIALS ENGINEERING: SHAPING THE FUTURE OF THE AEROSPACE INDUSTRY Abstracts are currently being solicited for (but not limited to) the following topics: • Additive Manufacturing • Advanced Coatings for Aerospace and Industrial Gas Turbines • Advanced Forming and Thermomechanical Processing • Advances in Coatings and Surface Modification • Composite Materials & Structures • Emerging Materials & Processes • High Temperature & Gas Turbine Materials • Hydrogen Storage and Propulsion • Integrated Computational Materials Engineering • Light Alloy Technology • Low Cost Manufacturing and Affordable Structures • Material Compatibility in Aerospace Environments • Materials Characterization & Failure Analysis • Modeling & Simulation of Manufacturing Processes • Nondestructive Inspection Techniques • Space Materials & Applications • Sustainability and Recycling • Titanium Alloy Technology • Tribology and Wear of Aerospace Materials • Residual Stress of Aerospace Components • Welding & Joining 2025 CO-LOCATED WITH: SUBMIT TODAY! AeroMat 2025 will only accept online abstract submissions of 300 words or less in English via our online abstract service. Visit aeromatevent.org to begin your submission process. The system is self-explanatory and will allow you return access once you have signed up so that you may edit your abstract as needed before submitting. *To maintain the integrity of AeroMat, please obtain pre-approval to present your work at the conference before submitting your abstract. All costs associated with your participation will be at your expense (travel, housing, and registration fee). aeromatevent.org New innovations in materials engineering are required to deliver improvements in the performance, cost, and environmental impact of aerospace structures and engines. The 2025 technical program will focus on the latest aerospace materials and process developments, with keynotes and panels to feature Canadian-centric projects and collaborations with the global materials community. CALLING ALL AUTHORS Deadline is October 25.
61 ASM NEWS The latest news about ASM members, chapters, events, awards, conferences, affiliates, and other Society activities. HOW ADDITIVE MANUFACTURING EMPOWERS COMMERCE THROUGH EFFECTIVE DATA MANAGEMENT William E. Frazier, Yan Lu, and Paul Witherell This synopsis of an additive manufacturing workshop by NIST highlights the importance of data management in addressing issues such as compliance costs, technology needs, and leadership. 13 ADVANCED MATERIALS & PROCESSES | APRIL 2024 2 A 3D printing machine creates a colorful part. Courtesy of Dreamstime. On the Cover: 68 3D PRINTSHOP A new coating for telecom satellites and the formation of pores in DED are studied in this issue. MACHINE LEARNING Scientists are using machine learning to create new computational methods and to detect Bragg glass order. 10
4 Editorial 5 Feedback 5 Research Tracks 10 Machine Learning 6 Metals/Polymers/Ceramics 8 Testing/Characterization 11 Process Technology 12 Emerging Technology 67 Editorial Preview 67 Special Advertising Section 67 Advertisers Index 68 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 worldwide 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. 182, No.3, APRIL 2024. Copyright © 2024 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. 20 BEST PRACTICES FOR GROWING A DIVERSE MATERIALS SCIENCE WORKFORCE Viola L. Acoff For the U.S. to remain competitive in industry, materials science and engineering fields must find ways to increase persistence, reduce attrition, and successfully increase diversity in the STEM pipeline. 24 PERSPECTIVE THE TRANSFORMATIVE POWER OF ADDITIVE MANUFACTURING FOR BATTERIES Ana C. Martínez and Alexis Maurel The benefits and flexibility of using additive manufacturing opens up new possibilities for lithium-ion batteries beyond the limitations of traditional methods. 28 iTSSe: INCLUDES ITSC SHOW PREVIEW 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. FEATURES APRIL 2024 | VOL 182 | NO 3 ADVANCED MATERIALS & PROCESSES | APRIL 2024 3 20 28 45 24 45 SMST NewsWire: INCLUDES SMST SHOW PREVIEW The official newsletter of the International Organization on Shape Memory and Superelastic Technologies (SMST).
4 ADVANCED MATERIALS & PROCESSES | APRIL 2024 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 Vasisht Venkatesh, Pratt & Whitney ASM BOARD OF TRUSTEES Pradeep Goyal, President and Chair Navin Manjooran, Senior Vice President Elizabeth Ho man, Vice President Mark F. Smith, 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 Carrie Wilson, Interim 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. WELCOMING THE FUTURE WORKFORCE Professor Viola Acoff exudes a welcoming presence. I experienced it firsthand while attending her ASM/ TMS Distinguished Lecture last year at IMAT in Detroit. Maybe that explains why part of her role as dean of the School of Engineering at the University of Mississippi is meeting with undecided freshmen to help them envision a future as an engineer. She gently guides them by presenting various engineering degree options for their consideration. In doing so, Acoff likes to describe the breadth of materials science by using an airplane example. The body of the plane is made of aluminum, the engine uses titanium, brakes and bearings contain ceramics, and the cockpit’s circuit board employs silicon. She paints the picture that a materials science degree will give students access to work in any or all of these areas. But Acoff’s goal is not only to encourage underrepresented minorities to join the field of materials engineering. That’s just step one. An equally challenging task is to help them be successful during their academic years to ensure they stay in any STEM field. Her article in this issue outlines some best practices she and her colleagues at Ole Miss have employed that seem to do the trick. They include summer bridge programs, scholarly activities that build a sense of belonging, and faculty mentoring on how to develop a welcoming atmosphere. A key tactic is encouraging the students to see themselves in the field by experiencing success and a sense of community during their undergraduate years. If that is achieved, they are more likely to pursue advanced STEM degrees. That’s mission accomplished according to Acoff. We can thank her and others for filling the pipeline with a diverse and competent workforce, just in time to meet the increased need for materials engineering expertise in many sectors including additive manufacturing (AM). According to Market.us, the global 3D printing market size is set up for significant growth. The industry is expected to reach $135.4 billion by 2033. As a subset, the metal 3D printing market was $3.08 billion in 2022 and is now predicted to reach $15.94 billion by 2030—a CAGR of 22.8% in just eight years. Important drivers of this growth include the increased implementation of technologies including Industry 4.0, machine learning, robotics, and smart factories. All of these technologies rely on and generate materials data. William Frazier, FASM, and his co-authors from the National Institute of Standards and Technology know well that list of drivers and the importance of data in today’s digitized production environment. As they describe in the lead article, AM offers many benefits in an Industry 4.0 world. Yet many small and mid-sized companies need some guidance to learn proper AM data management and how to navigate AM process qualification and part certification. Helping more of these companies become capable of executing AM processes will lead to a more efficient and innovative supply chain overall. Small businesses as well as early engineering students need mentoring and guidance to succeed. Helping them builds our workforce capabilities and strengthens the wider engineering community. Let’s welcome them in. joanne.miller@asminternational.org
ADVANCED MATERIALS & PROCESSES | APRIL 2024 5 FEEDBACK / RESEARCH TRACKS SHAPE-SHIFTING PLASTIC A team of molecular engineers from several institutions developed a kind of plastic that can be shape- shifted. Researchers used a dynamic crosslinking approach based on the reversible addition of thiols to benzal cyanoacetates, a process known as a “Michael addition.” The resulting plastic is able to be modified by tempering— a process traditionally used for metalworking. The scientists found that by heating the plastic to temperatures ranging from 60-110°C, then transferring it to a standard food freezer, they could create several different objects from the same material. First they made a spoon sturdy enough to scoop peanut butter. They then used tempering to change the spoon to a fork, and then to an adhesive capable of joining two panes of glass together. However, testing showed that the plastic could only be changed seven times before degrading. Researchers from the University of Chicago, U.S. DEVCOM Army Research Laboratory, Aberdeen Proving Ground, NIST, and NASA Glenn Research Center comprised the team. DOI: 10.1126/ science.adi5009. ARGONNE HEADS MICROCHIP PROJECT The U.S. Department of Energy (DOE) awarded Argonne National Laboratory $4 million WRIGHT TECHNIQUES The recent editorial on the Wright brothers (AM&P, March 2024) mentioned that they used a wind tunnel to test out wing designs. Around 20 years ago, I visited their museum in Kitty Hawk, North Carolina. As I recall, this was the first “real” wind tunnel where lift and drag could be measured simultaneously. I believe they tested something like 2000 shapes and also invented the lab notebook, which was on display. At the time, I was dealing with an employee who had a horrible lab notebook, which made me take notice. The Wright brothers recorded their hypothesis, experimental results, conclusions, and thoughts on next steps. No one made them do this, it just made sense. It turns out that their notebook format is almost identical to that recommended by the American Chemical Society, probably to this day. There were many reasons they were successful. The wind tunnel and lab notebook were two important ones. Bill Hamm, FASM FEEDBACK We welcome all comments and suggestions. Send letters to joanne.miller@asminternational.org. Two applications from a single feedstock: a) batch of as-cast, dried N63; b) freestanding film of N63; and c) N6360 spoon and fork. (a) (b) (c) toward research that will use atomic layer deposition (ALD) to advance new materials and devices for creating microchips that use up to 50 times less energy than current chips. Argonne will partner with Stanford University, Northwestern University, and Boise State University on the project. The Argonne scientists will use ALD to redesign the microchip and eliminate the back-and-forth shuffling of data, which requires significant energy. Currently, silicon is the semiconducting material used to make memory chips and microprocessors, but the 3D integration necessary to stack the layers is difficult to achieve with silicon. Building on previous research, Argonne scientists are using ALD to create atomically precise molybdenum disulfide films to replace the bulky 3D silicon thin films used in today’s transistors. anl.gov. The DOE is funding energy efficient techniques for producing microchips. Courtesy of Sebastian Moss.
ADVANCED MATERIALS & PROCESSES | APRIL 2024 6 METALS | POLYMERS | CERAMICS Intek Plastics, Hastings, Minn., acquired a 72,000-sq-ft extrusion facility in Medford, Wis. With complementary equipment, the facility is structured to manufacture high-quality extrusion solutions for the fenestration market. The Medford equipment is equivalent to the company’s highvolume twin-screw extruders at the Hastings facility. intekplastics.com. With applications in aerospace and automotive industries, the research offers a path to promising materials that are lighter, stronger, and more corrosion-resistant, setting a new standard in composite material development with wide-reaching industrial implications. english.tyut.edu.cn. IMPROVED PADDING DESIGN A collaborative team of researchers led by the University of Colorado Boulder created a new design for padding that can withstand big impacts. The team’s innovations, which can be printed on commercially available 3D printers, could one day wind up in everything from shipping crates to football pads— anything that helps to protect fragile objects, or bodies, from outside forces and events. The group wrote computer algorithms to meticulously redesign the interior of cushioning materials— allowing them to buckle under force, but only following a careful pattern. To make a more versatile cushion, the researchers opted to rearrange the ALUMINUM MAGNESIUM LAMINATES Researchers at Taiyuan University of Technology, China, are developing Al/Mg/Al laminates, cladding magnesium with aluminum to combine their respective strengths—lightness and better corrosion resistance. They explored various methods such as co-extrusion, casting, and welding, with rolling emerging as a preferred technique for its flexibility and efficiency. The research team produced Al/Mg/Al laminates with large thickness ratios, presenting significant advancements in mechanical properties and interfacial bonding strength. Created through a hot-rolling process, the team’s Al/Mg/Al laminates exhibited varied initial thickness ratios (ITR). By experimenting with ITRs ranging from 5 to 40, they investigated how changing the ITR affects the stress, strain, microstructure evolution, and overall properties of the laminates. Findings indicated that an optimal ITR exists—specifically, an ITR of 20—where the laminates display the best comprehensive mechanical properties. This includes maximizing the ultimate tensile strength and yield strength while also achieving high interfacial bonding strength and optimal elongation. Beyond this optimal point, increases in ITR lead to a decrease in interface bonding strength, affecting the laminate’s overall performance. Nippon Steel Corp., Tokyo, remains committed to acquiring United States Steel Corp., Pittsburgh, by September, according to executive vice president Takahiro Mori. He stated that the acquisition is an “investment to strengthen U.S. Steel, and will also make the automobile and other related industries strong.” nippon.com. BRIEFS Schematic of large thickness ratio Al/Mg/Al laminate rolling process. Courtesy of TranSpread. In laboratory tests, a new design for padding, right, outperformed more conventional technologies like a foam, le , made out of the same springy material. Courtesy of Lawrence Smith.
ADVANCED MATERIALS & PROCESSES | APRIL 2024 7 interior of these objects, down to the scale of a millimeter or less. The group first used custom software to lay out a network of honeycombs, then tweaked them to include a few kinks, a bit like the bellows in an accordion. Those kinks help to guide the honeycombs as they crunch down during an impact, allowing for a much smoother collapse. Testing their design at a larger scale, the researchers used a 3D printer to create blocks the size of a small brick out of a springy material called thermoplastic polyurethane. Next, they squeezed them with an impact-testing machine. The group discovered that its blocks could absorb roughly six times more energy than standard foams made from the same material, and up to 25% more than other honeycomb designs. The team notes that engineers can make these kinds of designs out of many different types of materials, from bouncy plastics to harder substances like aluminum. colorado.edu. ICE REPELLENT POLYMER COATING Researchers at Graz University of Technology, Austria, developed a highly ice-repellent coating that adheres to a wide variety of materials and is very resistant to abrasion. Such coatings have been around for some time, but until now, they have been super sensitive and detach quite quickly from the surfaces they’re meant to protect. The researchers achieved this progress by using a manufacturing technology called initiated chemical vapor deposition (iCVD). This makes it possible for a strongly adhesive primer material to gradually transition into the ice-repellent compound. This stepless transition is accomplished by applying the two materials as a changing gas mixture to the intended surface. Initially, the gas mixture consists purely of the primer material, but the proportion of the ice-repellent material is continuously increased during application, from zero to 100 percent. The result is a coating with a strongly adhesive underside and a top side that prevents ice crystals from sticking. A wide range of applications are conceivable for this new type of coating, for instance, in the aviation industry. The researchers say their coating could speed up the deicing of aircraft and use less antifreeze. Sensors exposed to the weather that are disturbed by ice could also benefit from the coating. www.tugraz.at/en. Gabriel Hernández Rodríguez displays the wafer-thin ice-repellent coating. Courtesy of Lunghammer - TU Graz. ORDER TODAY! Visit asminternational.org or call 800.336.5152. ASM HANDBOOK VOLUMES 24 AND 24A ADDITIVE MANUFACTURING SET This set includes ASM Handbook, Volume 24: Additive Manufacturing Processes, and Volume 24A: Additive Manufacturing Design and Applications. Volume 24 provides essential knowledge in materials, processes, and applications of additive manufacturing. Volume 24A provides a comprehensive review of additive manufacturing design fundamentals and applications. Both volumes are written by the world’s leading additive experts in both research and industry. asminternational.org NOW AVAILABLE! Print: $680 / ASM Member: $510 Product Code: 06058G VOLUME EDITORS: MOHSEN SEIFI, DAVID L. BOURELL, WILLIAM FRAZIER, AND HOWARD KUHN
8 ADVANCED MATERIALS & PROCESSES | APRIL 2024 approach could ultimately allow scientists to synthesize only the very best MOF contenders. anl.gov. OBSERVING GRAVITATIONAL WAVES FROM SPACE In January, the European Space Agency in Paris voted to formally adopt the Laser Interferometer Space Antenna (LISA) as its next large mission, putting the space-based gravitational- wave observatory on track for construction and launch in 10 years. LISA’s discoveries will complement scientists’ knowledge about the beginning, evolution, and structure of the universe. The detector will be sensitive to gravitational waves of a lower frequency than those detected by Earthbound observatories. First predicted by Albert Einstein in 1916, gravitational waves are caused by the rapid motion of compact massive objects, such as neutron stars and black holes. LISA will TESTING | CHARACTERIZATION AI CAPTURES NEW CARBON MATERIALS Researchers from the DOE’s Argonne National Laboratory, Lemont, Ill., are using generative artificial intelligence (AI) to discover potential materials for use in emission-reducing carbon capture technology. A suitable material for effective carbon capture at low cost has yet to be found, though metal-organic frameworks (MOFs) are thought to be promising candidates, as they can selectively absorb carbon dioxide. MOFs have three kinds of building blocks in their molecules—inorganic nodes, organic nodes, and organic linkers, which can be arranged in different relative positions and configurations. As a result, there are countless potential MOF configurations for scientists to design and test. The Argonne Lab researchers are using generative AI and machine learning to speed up the discovery process of previously un- known building block candidates for these specific-use MOFs. Designing MOFs with optimal carbon selectivity and capacity is a significant challenge. By exploring the MOF design space with generative AI, the team was able to quickly assemble, building block by building block, over 120,000 new MOF candidates within 30 minutes. They ran these calculations on the Polaris supercomputer at the Argonne Leadership Computing Facility. Using only the most promising candidates, they then turned to the Delta supercomputer at the University of Illinois Urbana-Champaign to carry out time-intensive molecular dynamics simulations. The goal is to screen them for stability, chemical properties, and capacity for carbon capture. The team’s Triangular holes make this material more likely to crack from left to right. Courtesy of N.R. Brodnik et al./Phys. Rev. Lett. Hitachi High-Tech Corp., Tokyo, conducted a proof-of-concept trial using chemicals informatics and materials informatics to improve the efficiency of developing new metal thin film materials for electronic and other devices. The results showed an overall workload reduction of more than 80%. hitachi.com. According to a new report from MarketsandMarkets, Northbrook, Ill., the nondestructive testing and inspection market is forecast to grow from $11.6 billion in 2024 to $18.4 billion in 2029 at a 9.6% compound annual growth rate. marketsandmarkets.com. BRIEFS The proposed LISA mission will detect gravitational waves in space using a trio of satellites, separated by millions of kilometers. Lasers will measure minute changes in their relative distance. Courtesy of AEI/MM/exozet. Model of AI-guided assembly of a novel metal organic framework with high carbon dioxide adsorption capacity and synthesizable linkers. Courtesy of Xiaoli Yan/University of Illinois Chicago and the ALCF Visualization & Data Analytics Team.
ADVANCED MATERIALS & PROCESSES | APRIL 2024 9 be most sensitive to large-scale events such as massive black holes colliding in the centers of galaxies and smaller binary systems of dead stars made up of white dwarfs, neutron stars, or black holes. LISA will detect gravitational radiation in the yet-unexplored window between 0.1 mHz and 1 Hz, waves that cannot be identified by ground-based detectors. Unique to LISA will be the detection of gravitational waves from stellar black holes swirling around massive ones in galactic nuclei. The LISA instrument will consist of three spacecraft in a triangular configuration with 2.5-million-kilometer arms, moving in an Earth-like orbit around the sun. Gravitational waves from sources throughout the universe will produce slight oscillations in the arm lengths. LISA will capture these motions and measure the waves by using laser links to monitor the displacements of test masses free-falling inside the spacecraft. northwestern.edu, www.esa.int. TIME-RESOLVED MICROSCOPY TECHNIQUE Building on previous work, researchers at the University of Tsukuba, Japan, developed a new time-resolved atomic force microscopy (AFM) system, enhancing operability by merging AFM with their unique ultrashort laser pulse technology. The research team previously established a time-resolved scanning tunneling microscopy (STM) method, combining STM with laser technology, to attain nanolevel spatial resolution and femtosecond temporal resolution. This method has been instrumental in elucidating various photoexcited dynamics. However, STM’s reliance on electric current flow between the probe and sample limits its application to conductive materials. The new development allows researchers to measure high-speed dynamics in a broader range of materials, including insulators, with nanometer resolution. A new AFM technique enables the measurement of ultrafast photoexcitation phenomena observed through changes in the forces between the sample and the AFM probe tip a er an extremely short time irradiation of laser light. Courtesy of University of Tsukuba. Phone: 1-800-292-6141 | info@leco.com www.leco.com | © 2024 LECO Corporation EMPOWERING RESULTS Elemental Analysis | GC Mass Spectrometry | Metallography Glow Discharge Spectroscopy Microscopic Examination Sample Preparation Elemental Analysis Operate your lab with ease and use LECO's analytical solutions for smooth transitions from task to task. With high-quality instruments made to take on each step of the process, you can feel condent in your results. Whether you're a busy, high throughput laboratory, or challenged with infrequent, intensive analyses, LECO's solutions will work for you. A Smooth Process, From Start to Finish Hardness Testing A unique approach to counteract the thermal expansion of the probe and sample due to laser irradiation has enabled the acquisition of timeresolved signals with an exceptionally high signal-to-noise ratio. The ability of AFM to measure a diverse range of objects positions the new technology to have widespread applications. www. tsukuba.ac.jp/en.
ADVANCED MATERIALS & PROCESSES | APRIL 2024 10 MACHINE LEARNING | AI NEW CERAMICS HANDLE THE HEAT A multi-university team led by Duke University, Durham, N.C., developed a method to rapidly discover a new class of materials with heat and electronic tolerances tough enough to withstand extremely high temperatures— greater than several thousands of degrees Fahrenheit. These new materials are both harder than steel and stable in chemically corrosive environments. Potential applications include new wear and corrosion-resistant coatings, thermoelectrics, batteries, catalysts, and devices resistant to radiation. The recipes for these materials— ceramics made using carbonitrides or borides—were discovered by using a new computational method called disordered enthalpy-entropy descriptor (DEED). In its first demonstration, the program predicted the synthesizability of 900 new formulations of high-perfor- mance materials, 17 of which were tested and produced in laboratories. Professor Stefano Curtarolo’s group maintains the Duke Automatic-FLOW for Materials Database (AFLOW), a huge data reservoir of materials properties connected to various online tools for materials optimization. The information enables algorithms to accurately predict properties of unexplored mixtures without having to make them in a lab. For the past few years, Curtarolo’s group has been working to develop predictive powers for high-entropy materials that achieve enhanced stability from a chaotic mixture of atoms. DEED is specifically tailored to hot-pressed sintering, which involves taking powdered forms of the constituent compounds and heating them in a vacuum to as high as 4000°F while applying pressure for a few hours. The finished ceramics have a dark metallic appearance, feel like metal alloys such as stainless steel, and have a similar density— although they are hard and brittle like conventional ceramics. The group expects other researchers to begin using DEED to synthesize and test the properties of new ceramic materials for a wide range of applications. duke.edu. MACHINE LEARNING DETECTS ELUSIVE PHASE OF MATTER Researchers at Cornell University, Ithaca, N.Y., detected an elusive phase of matter called the “Bragg glass phase” using large volumes of x-ray data and a new machine learning data analysis tool. The discovery settles an enduring question of whether or not this particular state of matter can exist in real materials. Collaborators include scientists at Argonne National Laboratory and Stanford University. The team presented the first evidence of a Bragg glass phase detected by x-ray scattering in a systematically disordered charge density wave (CDW) Molecular structure of new ceramic materials for extreme temperature applications. Courtesy of Duke University. material, PdxErTe3. They used comprehensive x-ray data and a machine learning data analysis tool called x-ray temperature clustering (X-TEC). Theoretically, there is a sharp distinction between three phases: long-range order, Bragg glass, and the disordered state. In the disordered state, the CDW correlation decays within a finite distance. In the long-range ordered state, the CDW correlation continues indefinitely. In the Bragg glass phase, the CDW correlation decays so slowly that it will only completely vanish at infinite distances. X-TEC made it possible to analyze the massive volume of data with a scalable and automated approach. Beyond exploring the Bragg mystery, the study presents a new mode of research in the age of big data. The team reports that this detection of Bragg glass order and the resulting phase diagram significantly advances our understanding of the complex interplay between disorder and fluctuations. Moreover, using X-TEC to target fluctuations through a high- throughput measure of peak spread could revolutionize how fluctuations are studied in scattering experiments. cornell.edu. Crystal structure of pure ErTe3.
ADVANCED MATERIALS & PROCESSES | APRIL 2024 1 1 PROCESS TECHNOLOGY WELDING METAL FOAM WITHOUT BUBBLES Using an induction welding technique, researchers at North Carolina State University (NCSU), Raleigh, successfully joined composite metal foam (CMF) components together without impairing the properties that make CMF desirable. CMFs hold promise for a wide array of applications because the pockets of air they contain make them light, strong, and effective at insulating against high temperatures. CMFs are foams that consist of hollow, metallic spheres—made of materials such as stainless steel or titanium—embedded in a metallic matrix made of steel, titanium, aluminum, or other metallic separation, the MSX process is more efficient and uses much less energy, labor, and chemical solvents, and can be applied to a variety of critical material recovery efforts. The MSX system contains porous hollow fibers with a neutral extractant that creates a selective barrier, letting only REEs pass through. The REE-rich solution collected can then be further processed to yield rare earth oxides with purities exceeding 99.5%. “The Pea Ridge iron ore mine is the only fully permitted domestic source for heavy REEs critical for high operating temperature, high value neodymium magnets,” says Jim Kennedy, president of Caldera. “The Caldera mine has three distinct rare earth deposits, open at depth, containing 700,000 tons of REEs and significant levels of praseodymium, neodymium, terbium, dysprosium, holmium, and other heavy REEs. Caldera seeks to integrate ORNL’s technology into a domestic, vertically integrated value chain to produce neodymium magnets,” comments Kennedy. For ORNL researchers working on the MSX technique for the past decade, the license to Caldera provides a longsought opportunity to test their method on a mining source. The team is planning for a continued research relationship, which includes a demonstration of the technology. ornl.gov. alloys. The resulting material is both lightweight and remarkably strong, with potential applications ranging from aircraft wings to vehicle armor and body armor. In addition, CMF is better at insulating against high heat than conventional metals and alloys, such as steel. The combination of weight, strength, and thermal insulation means that CMF also holds promise for use in storing and transporting nuclear material, hazardous materials, explosives, and other heat- sensitive materials. However, in order to realize many of these applications, manufacturers would need to weld multiple CMF components together— which, until now, has been a challenge. “Because CMF is only 30-35% metal, the electromagnetic field is able to penetrate deeply into the material—allowing for a good weld,” explains researcher Afsaneh Rabiei. “The air pockets that make up the remaining 65-70% of the CMF serve to insulate the material against the heat. It’s essential to have a means of welding the CMF components without impairing the properties that make it attractive in the first place.” ncsu.edu. RARE EARTH ELEMENT SEPARATION TECHNOLOGY Oak Ridge National Laboratory (ORNL), Tenn., and Caldera Holding, St. Louis, the owner and developer of Missouri’s Pea Ridge iron mine, entered a nonexclusive research and development licensing agreement to apply a membrane solvent extraction technique, or MSX, developed by ORNL researchers to mined ores. MSX provides a scalable, efficient way to separate rare earth elements (REEs) from mixed mineral ores. Compared with other traditional separation methods such as hydrometallurgy and chemical On January 19, Bodycote acquired Lake City Heat Treating, Warsaw, Ind., a provider of hot isostatic pressing and vacuum heat treatment services for the aerospace and medical industries. bodycote.com. BRIEF Researchers use an induction coil to create an electromagnetic field that heats a metal for welding without compromising important CMF properties. Courtesy of NCSU. Syed Islam co-invented a process to recover rare earth elements from scrap magnets. Courtesy of Carlos Jones/ ORNL, U.S. Dept. of Energy.
ADVANCED MATERIALS & PROCESSES | APRIL 2024 12 SYNTHETIC SPIDER SILK In Japan, a group of interdisciplinary researchers at RIKEN successfully created a device that produces artificial spider silk. The artificial silk gland recreates the complex molecular structure of silk by mimicking the various chemical and physical changes that naturally occur in a living spider’s silk gland. Famous for its strength, flexibility, and light weight, spider silk has a tensile strength that is comparable to steel of the same diameter, and a strength-to-weight ratio that is unparalleled. In addition, it is biocompatible as well as biodegradable. However, the large-scale harvesting of spider silk has proven impractical for several reasons, leaving scientists with the challenge of synthesizing a similar material in the laboratory. Spider silk is a biopolymer fiber made from large proteins with highly repetitive sequences, called spidroins. Within the silk fibers are molecular substructures called beta sheets, which must be aligned properly for the fibers to possess their unique mechanical properties. Rather than trying to devise the process from scratch, RIKEN scientists took a biomimicry approach using microfluidics. The device developed by the researchers looks like a small rectangular box with tiny channels grooved into it. Precursor spidroin solution is placed at one end and then pulled toward the other end by means of negative pressure. As the spidroins flow through the microfluidic channels, they’re exposed to precise changes in the chemical and physical environment, which are made possible by the design of the microfluidic system. Under the correct conditions, the proteins self- assemble into silk fibers with their characteristic complex structure. The ability to artificially produce silk fibers using this method could provide numerous benefits, the researchers say, like reducing environmental impacts from current textile manufacturing practices. The silk material also has promising potential for biomedical applications such as sutures and artificial ligaments. www.riken.jp/en. VISUALIZING ATOMIC NUCLEI A new way to study the shapes of atomic nuclei and their internal building blocks was developed by a team of scientists from Brookhaven National Lab, Upton, N.Y., Wayne State University, Detroit, and the University of Jyvaskyla in EMERGING TECHNOLOGY Finland. The method relies on modeling the production of certain particles from high-energy collisions of electrons with nuclear targets. Such collisions will take place at the future Electron-Ion Collider (EIC) at Brookhaven. According to the researchers’ theoretical framework, results show that collisions that exclusively produce single mesons— a particle made of a quark and antiquark—offer insights into the largescale structure of the nucleus, such as its size and shape. Higher-momentum mesons can visualize nuclear structure at shorter length scales, including the arrangement of quarks and gluons within protons and neutrons. Because the measurements are done at much higher collision energy than traditional nuclear structure experiments, the interactions are sensitive to the gluon distributions inside the protons and neutrons of the nucleus. Measuring gluon distributions inside the nucleus—rather than the distribution of electric charge—will provide new insights into how these two distributions differ. This technique opens a new direction for research at the future EIC and could lead to important information that complements data from traditional nuclear structure experiments. It will help scientists understand how nuclear shapes evolve with energy and provide new information on nuclear structure that was previously inaccessible. bnl.gov, wayne.edu, www.jyu.fi/en. Mercury Systems Inc., Andover, Mass., signed a $96 million three-year subcontract with Raytheon. Mercury will deliver high-performance signal processing subsystems for the U.S. Army’s Lower Tier Air and Missile Defense Sensor, the latest air and missile defense sensor that will operate on the Army’s defense network. mrcy.com. BRIEF This microfluidic device is used for creating silk fibers. An electron collides with a deformed nucleus and produces a single vector meson (J/Psi).
ADVANCED MATERIALS & PROCESSES | APRIL 2024 13 William E. Frazier, FASM* Pilgrim Consulting LLC, Lusby, Maryland Yan Lu and Paul Witherell National Institute of Standards and Technology, Gaithersburg, Maryland This synopsis of an additive manufacturing workshop by NIST highlights the importance of data management in addressing issues such as compliance costs, technology needs, and leadership. *Member of ASM International Image courtesy of TWI Ltd. AM AND DATA MANAGEMENT HOW ADDITIVE MANUFACTURING EMPOWERS COMMERCE THROUGH EFFECTIVE DATA MANAGEMENT
ADVANCED MATERIALS & PROCESSES | APRIL 2024 14 Arobust and resilient economy depends on the health and active participation of small and medium sized enterprises (SMEs)[1-3]. SMEs are recognized as essential to achieving the full potential offered by Industry 4.0[4]. These companies tend to be innovative, flexible, adaptable, and entrepreneurial, and thus contribute to a healthy business ecosystem. Additive manufacturing (AM) has emerged as an important means of producing a wide range of products. Characteristics associated with the effective application of AM include rapid part production, part complexity, customizable components, and initial low capital cost of investment. Together, SMEs fully enabled with AM processes will provide a previously unseen level of resilience to industrial supply chains. Realizing this vision will require teamwork across supply chains and stakeholders and will be supported by effective data management. In June 2023, a workshop was held at the National Institute of Standards and Technology (NIST) to gather stake- holders and discuss necessary steps. The AM process generates large quantities of data especially for components used in critical applications when increased monitoring and inspection is in play[5]. Findings from prior work, including a NIST workshop entitled “Unleashing the Potential of Additive Manufacturing: FAIR AM Data Management Principles,” concluded that effec- tive data management throughout the lifecycle of an AM part would lead to cost reductions and accelerated deployments of these parts[6,7]. To constitute effective data management, data should be curated in a manner that captures its pedigree and provenance and organized in accordance with certain principles to make the data FAIR—findable, accessible, interoperable, and reusable[8]. Given the benefits of AM, the question arises as to why more SMEs have not embraced AM, especially for manufacturing critical components. To explore this matter, a workshop entitled “Empowering Small and Medium Size Enterprises Through Effective Additive Manufacturing Data Management” was held June 6-8, 2023, at the NIST National Cybersecurity Center of Excellence in Rockville, Maryland. The workshop was organized by NIST and Pilgrim Consulting LLC. The event was cohosted by the National Additive Manufacturing Innovative Institute (America Makes) and the Regional Additive Manufacturing Partnership of Maryland (RAMPMD). This article is a synopsis of the NIST Advanced Manufacturing Series 100 report that summarized the workshop and its findings[9]. Visit the following link to the event web page for additional information: https://bit.ly/49Y5ZNb. The complex, diverse, and frequently parochial relations between OEMs, SMEs, and customers tend to inhibit productive working relationships. This increases the cost and time required to bring a product to market along with inhibiting innovation and profitability. The workshop welcomed 86 participants from a variety of organizations. Of those registered, 38% were from SMEs and large system integrators (LSIs), 34% were from various government agencies, and 28% were from nonprofit organizations, universities, and the U.S. Department of Defense (DOD). Attendees were charged with exploring how best to empower the productive working relationship of SMEs with top tier manufacturers or LSIs through effective AM data management. In the context of AM-enabled supply chains, the goal was to examine pain points regarding SME interactions with LSIs and government procurement agencies, as well as how effective data management might help. SALIENT OUTCOMES AND THEMES The additive manufacturing industry is recognized as being essential to the supply chain resilience of the United States. Businesses with perhaps the greatest opportunity to drive economic growth are small and medium sized enterprises. Consequently, addressing barriers to SME entry into the marketplace is critical to economic wellbeing. During discussions, attendees were asked to take into consideration political, economic, social, and technological (PEST) aspects. In rooms full of scientists and engineers, this approach promoted “out of the box” thinking. In general, factors identified in this workshop that impede SME-LSI effectiveness may be categorized under cost of compliance, technology needs, or required leadership. These factors were indicative of many of the barriers meant to be overcome with effective data management. A summary of the results is provided below. Cost of Compliance. For SMEs, cost was identified as a significant pain point and barrier to working with LSIs and the government. The upfront investment to comply with regulations, policies, and procedures was identified as a noteworthy barrier to market entry. Generally speaking, the baseline requirements for an SME to be considered a qualified vendor include: • Having an established accredited quality management system/quality manufacturing system (e.g., ISO 9001, AS9100). • Demonstrating compliance with cybersecurity requirements (e.g., Cybersecurity Maturity Model Certification (CMMC) 2.0 Program). • Having an approved means of protecting controlled unclassified information (SP 800-171 Rev 2). • Cost of due diligence associated with SME compliance with LSI and government contractual flow down requirements. Requirements documents typically cite significant numbers of FAR/DFAR regulations by code, and each requirement document must be located, downloaded, and examined. Technology Needs. Uncertainty surrounding AM process qualification and part certification was voiced as a significant challenge to widespread adoption of AM and has stymied SME entry into the AM marketplace and the use of AM parts by LSI. The current qualification process takes too long, costs too much, and must be replicated for each part considered. Highlighted by SME-LSI interactions, a paradigm shift in the way AM
ADVANCED MATERIALS & PROCESSES | APRIL 2024 15 processes are qualified and components are certified is required, i.e., a move away from fixing and controlling key process parameters. Instead, the shift is toward qualifying a process control methodology that operates within a defined qualified processing envelope. This would require: • Maturation and development of feed-forward controls (FFC) and iterative learning controls (ILC). • Development and integration of in situ sensors and control systems. • Greater use of machine learning and ICME. • Development and use of virtual twin modeling and simulation tools for the entire AM part production line. Leadership. Workshop participants sent a clear message: Government leadership is required. The government (as a neutral or facilitating party) has a unique responsibility to catalyze, develop, and promote cooperation among stakeholders (e.g., SMEs, LSIs, and standards organizations) to address the difficult challenges facing the AM community. Specific areas include: • Agreement on an “80% Solution” as to what constitutes a qualified AM vendor by LSIs and the government. • Standardized Technical Data Package (TDP) content to convey AM part and process specifications. • Data curation and open data accessibility for reference and research. • Development of standards required to reduce entry barriers and support technology adoption. These three factors—cost of compliance, technology needs, and leadership—set the stage for investigating SME-LSI barriers and the empowering roles of AM data and data management. A more detailed discussion follows. JOURNEY WORKSHOP STRUCTURE The two-and-a-half-day event aimed to generate discussion from various perspectives and stakeholders. Two keynote presentations set the tone for each day’s discussions. Four panel discussions highlighted the perspectives of LSIs, SMEs, nonprofits, and AM software tool providers, respectively. On the first two days, participants— divided into six working groups—were asked to identify and rank challenges and approaches to enabling SMEs with data (Fig. 1). The six working groups held discussions about AM process develop- ment, AM part production, and delta qualification. On the last day, two larger working groups were formed to examine the top ranked challenges from the perspectives of the SME and LSI. Results provided new insights into the complexities of these relationships and opportunities afforded by effective data management. KEYNOTE SYNOPSIS Two keynote speakers delivered presentations each day of the event (Fig. 2). These talks were used to set the tone for the day’s discussions and inspire attendees regarding the importance of the efforts and the potential impact. Day One Keynotes. Chris DeLuca, OUSD(R&E), and Neal Orringer, ASTRO America, kicked off the first day. DeLuca’s brief examined three DOD priority areas: securing the data infrastructure, establishing requirements for an AM digital technology data package (TDP), and executing path- finding demonstrations of digital manufacturing. He emphasized, “We must work together from concept Fig. 1 — Working group methodology for identifying and ranking challenges and approaches. DeLuca Orringer Furrer Gardner Bridges King Fig. 2 — Keynote speakers at NIST event.
ADVANCED MATERIALS & PROCESSES | APRIL 2024 16 development through sustainment to create a resilient and agile supply chain.” Orringer’s presentation focused on a newly established program: AM Forward, a partnership of several LSIs and the Biden-Harris administration to advance supply chain resilience via AM adoption. The focus of AM Forward is to help SMEs address three challenges: accessing capital to procure industrial AM systems, workforce development, and qualifying AM processes. Day Two Keynotes. Presentations by David Furrer, FASM, Pratt & Whitney, and Slade Gardner, Big Metal Additive, set the tone. Furrer discussed community opportunities, standards for digital certificates of conformance data, and the development, validation, and deployment of physics-based models. During his brief, he said, “Data management through data analytics and modeling tools provides for a more complete means of knowledge capture.” Gardner stressed that, “Manufacturing is a key word…manufacturing goes way beyond just 3D printing” (Fig. 3). He went on to say that a business without a quality manufacturing system (e.g., ISO 9001, AS9100, API Spec Q1) is irrelevant in the manu- facturing world. Further, he said that the major pain points small business owners experience are complying with requirements for protecting controlled unclassified information and cyber- security maturity model certification. Day Three Keynotes. Presentations were given by Jason Bridges, Lockheed Martin, and Wayne King, The Barnes Global Advisors. Bridges emphasized, “Working with LSI is hard.” He went on to explain that a significant pain point is that qualification is not transferable across LSIs nor across LSI business units and the SME must spend significant additional money and time to be qualified across an LSI’s entire line of business. King posed the question, “How do we broaden the use of laser powder bed fusion additive manufacturing?” He pointed out that in a survey, 56% of the manufacturers indicated that uncertain quality of the final product was a barrier to adoption of AM. He stressed that, “Process optimization is costly and time consuming.” Consequently, he advocated for a demonstration and standardization of a process qualification methodology of feed forward control- iterative learning controls (FFC-ILC). PANEL DISCUSSIONS Panel discussions followed the presentations on the first two days. These discussions continued to set the stage for the breakout groups, providing important perspectives from key stakeholders. Four panel discussions examined the challenges faced by SME-LSIs from the perspectives of SMEs, LSIs, data consortiums and nonprofits, and software and data analytic tool providers. Panel 1: Small and Medium Sized Enterprise (SME) Perspective. Participants discussed the pain points from an SME perspective including: AM process qualification and part certification; access to machine vendor software; value proposition and price point for embedded solutions; and control of intellectual property. Panel members discussed the results of a survey of the aerospace and defense industry, which identified barriers to the adoption of the digital thread including: protection of intellectual property; system inter- operability; lack of real-time supplier and production data from different systems; and the high cost of curating, maintaining, and managing the data quality of information being shared. Panel 2: Large System Integrator (LSI) Perspectives. The moderator kicked off the discussion by stating that a paradigm shift in the way AM processes are qualified and com- ponents are certified is required to reduce cost, accelerate deployment, and allow AM TDP to be used across type, model, and series of AM equipment. He stated that we must move away from fixing key process parameters and instead embrace FFC and ILC. We must move toward process qualification based on standardizing “freezing” the FFC-ILC process methodology. LSIs expressed the desire to establish a distributed AM production Fig. 3 — It is all about manufacturing (based on Slade Gardener’s brief[9]).
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