14 25 37 P. 29 MAY/JUNE 2024 | VOL 182 | NO 4 AI and ML in Materials Science Formation of Metallic Glasses HTPro Newsletter Included in This Issue CYMBAL MAKING: THE ART OF BRONZE METALWORKING MATERIALS TESTING/CHARACTERIZATION
SAVE THE DATE OCTOBER 21–23, 2025 | DETROIT, MICHIGAN ORGANIZED BY: CO-LOCATED WITH: As the LARGEST gathering for heat treating professionals, materials experts, and industry leaders in North America, Heat Treat is a MUST-ATTEND event!
14 25 37 P. 29 MAY/JUNE 2024 | VOL 182 | NO 4 AI and ML in Materials Science Formation of Metallic Glasses HTPro Newsletter Included in This Issue CYMBAL MAKING: THE ART OF BRONZE METALWORKING MATERIALS TESTING/CHARACTERIZATION
2024 INTERNATIONAL MATERIALS, APPLICATIONS & TECHNOLOGIES HUNTINGTON CONVENTION CENTER | SEPTEMBER 28–OCTOBER 3, 2024 | CLEVELAND, OHIO MATERIALS FOR ENERGY STORAGE REGISTRATION NOW OPEN Register now at IMATevent.org Tuesday, October 1 2:30 p.m. Exhibit Hall – Industry Forum Joint Keynote Session with IFHTSE IMAT Keynote Gabriel Veith Distinguished Staff Scientist Chemical Sciences Division ORNL IFHTSE World Congress Keynote Professor Sabine Denis Université de Lorraine, France Design of Alloy Metals for Low-mass Structures Laboratory Special Sessions: Alpha Sigma Mu Lecture 9:00 – 10:00 a.m. Professor Brajendra Mishra 2024 Edward DeMille Campbell Memorial Lecture 10:30 – 11:30 a.m. Prof. Christopher A. Schuh, FASM 2024 IMS Henry Clifton Sorby Lecture 1:00 – 2:00 p.m. Prof. Luiz Henrique de Almeida PARTNERED WITH: ORGANIZED BY: Shape Memory & Superelastic Technologies IMAT AND IFHTSE ARE C Wednesday, October 2 10:30 a.m. – 12:00 p.m. Panel Discussion: Materials for Energy Storage The panel topic will focus on reviewing and discussing the state of science and industry involved in the development of advanced materials for energy storage. The discussion will include presenting challenges that various industries are facing to meet demand for these new technologies, and how these problems are being addressed and resolved. KEYNOTE SPEAKERS
SEPTEMBER 28–OCTOBER 3, 2024 | CLEVELAND, OHIO INNOVATIONS IN HEAT TREATMENT AND SURFACE ENGINEERING FOR A SUSTAINABLE FUTURE ORGANIZED BY: Monday, September 30 1:30 – 2:30 p.m. IFHTSE 2024 Medalist Professor Tadashi Furuhara Tohoku University, Sendai, Japan Tuesday, October 1 2:30 p.m. Joint Keynote Session with IMAT IFHTSE World Congress Keynote Professor Sabine Denis Université de Lorraine, France Design of Alloy Metals for Low-mass Structures Laboratory Heat Treatment Numerical Simulations: From the Early Works to Today’s Achievements and Perspectives IMAT Keynote Gabriel Veith Distinguished Staff Scientist Chemical Sciences Division ORNL Adventures in Interface Chemistry: From Atomic Organization to Bulk Powders and How These Determine the Future of Energy Storage CO-LOCATED THIS YEAR! Wednesday, October 2 8:00 – 8:45 a.m. IFHTSE World Congress Keynote Thomas L. Christiansen Center for Heat Treating Excellence (CHTE) Worcester Polytechnic Institute, Massachusetts Current Challenges and Future Opportunities within Heat Treatment of Steel IFHTSEevent.org REGISTRATION OPEN! Shape the future of heat treatment and surface engineering at the 29th IFHTSE World Congress. Join the ASM Heat Treating Society and IFHTSE for cutting-edge research, real-world applications, and an exhibition co-located with IMAT 2024. Network with global leaders, forge partnerships, and hear important updates from industry leaders during the dedicated keynote sessions listed below. Don’t miss out – register today!
50 ASM NEWS The latest news about ASM members, chapters, events, awards, conferences, affiliates, and other Society activities. ARTIFICIAL INTELLIGENCE AND MACHINE LEARNING IN MATERIALS SCIENCE Joshua Stuckner, S. Mohadeseh Taheri-Mousavi, and James E. Saal Several case studies show how the discovery, development, and deployment of novel materials are being dramatically accelerated through automation and data-driven models. 14 ADVANCED MATERIALS & PROCESSES | MAY/JUNE 2024 2 Bronze cymbals undergo a rigorous metalworking process to achieve their percussive sound and finished luster. Courtesy of Dreamstime. On the Cover: 64 3D PRINTSHOP Researchers are focused on using bio-based materials and plastic found in the ocean to make 3D printing more ecologically friendly. ASM PROGRESS REPORT: STRATEGIC PLAN HIGHLIGHTS Pradeep Goyal ASM International’s strong strategic plan now includes a focus on financials, to ensure that the Society is ready for the next generation, in addition to building and marketing digital-first products and forming collaborations across disciplines and continents. 33
4 Editorial 5 Research Tracks 10 Machine Learning 6 Metals/Polymers/Ceramics 8 Testing/Characterization 11 Process Technology 12 Emerging Technology 13 Surface Engineering 63 Editorial Preview 63 Special Advertising Section 63 Advertisers Index 64 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.4, MAY/JUNE 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. 21 ARCHAEOMETALLURGICAL AND NUMISMATIC STUDIES OF A 5-PESETA SILVER COIN FROM 1870 Patricia Silvana Carrizo A metallographic study of a Spanish silver coin verifies its authenticity and solidifies a collaboration between museum and university. 25 METALLIC GLASSES: MATERIALS FOR TODAY AND TOMORROW Nicholas Mauro A modern understanding of how glasses are formed along with an appreciation for the high ultimate yield strength of metallic glasses are leading to a boon in applications for these unique materials. 29 CYMBAL MAKING: THE ART OF BRONZE METALWORKING, PART I Joseph Paul Mitchell The initial steps in the art of manufacturing cymbals are discussed from ancient times through the modern era, including alloying copper and tin, pouring the molten metal into buns, and processing the ingots. FEATURES MAY/JUNE 2024 | VOL 182 | NO 4 ADVANCED MATERIALS & PROCESSES | MAY/JUNE 2024 3 21 29 37 25 37 HTPro The official newsletter of the ASM Heat Treating Society (HTS). This supplement focuses on heat treating technology, processes, materials, and equipment, along with HTS news and initiatives.
4 ADVANCED MATERIALS & PROCESSES | MAY/JUNE 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. MATERIALS CONNECT GENERATIONS A2021 film entitled “The Dig” recounts the fascinating discovery of an Anglo-Saxon ship found on private property in Suffolk, England, in the 1930s. The excavators also unearthed a chamber on board containing treasures dating back to the 6th century. These spectacular artifacts are now housed at the British Museum as the Sutton Hoo exhibit. The compelling film reflects on what remains from past generations and explores why later generations care about finding and preserving these unique relics. With regard to the remains of the past, what primarily stands the test of time and endures the elements are items made of metals and other durable materials: jewelry, swords, armor, spoons, cups, belt buckles, and coins. That’s good news for materials science. For archaeologists, these objects become the main storytellers of the past. In fact, they link us to our past. In this issue of AM&P, ASM’s Archaeometallurgy Technical Committee has served as an excavator of sorts, in finding two authors who offer up glimpses into past cultures through their research. Patricia Silvana Carrizo’s study of silver coins brings to life Spain in the 1870s. Her macroscopic examination reveals important symbols of the culture and politics as well as significant mottos of that time. The ancient art of cymbal making is described by another archaeometallurgist, Joseph Paul Mitchell, in Part I of a short series. Mitchell walks us through the alloying, casting, and hand-hammering steps involved in creating the bronze discs. He describes how each of those processes has evolved from the time of the first cymbal makers up to the modern era. Nothing could be more modern than ASM’s Materials Informatics Technical Committee. Authors from this newly formed group offer us a view into the near future with their article, “Artificial Intelligence and Machine Learning in Materials Science.” The authors describe how tools like algorithms, large language models, and computer vision modeling are significantly speeding up the discovery of new materials as well as slashing the time needed for many manufacturing processes. Through several case studies, the authors show what is possible on this front thus far and present exciting developments they see on the horizon. This committee is also developing an ASM Handbook on what are quickly becoming the new tools that all materials engineers will need going forward. Machine learning and artificial intelligence are surely pointing us to the future. Through archaeology, we can connect with the past. The materials created now and in the future will tell the next generations who we are. Let’s revisit the question, why do we care about unearthing artifacts? According to dialogue in “The Dig,” it is so the next generation can know where they came from, as can the generation after that. These precious objects create a line that joins us to our forebearers. We are all part of something continuous. Based on what’s already proven to endure the test of time, the through line is materials. joanne.miller@asminternational.org Sutton Hoo helmet at the British Museum, circa A.D. 600.
ADVANCED MATERIALS & PROCESSES | MAY/JUNE 2024 5 RESEARCH TRACKS SUPERALLOY COULD CUT POWER PLANT EMISSIONS Researchers at Sandia National Laboratories have shown that a new 3D-printed superalloy could help power plants generate more electricity while producing less carbon. Sandia scientists, working with colleagues at Ames National Laboratory, Iowa State University, and Bruker Corp., used a 3D printer to create a superalloy with an unusual composition that makes it stronger and lighter than the best materials now used in gas turbine machinery. The team’s experiments showed that the new superalloy was stronger at 1472°F than many other high- performance alloys—and even stronger when returned to room temperature. The alloy is comprised of 42% aluminum, 25% titanium, 13% niobium, 8% zirconium, 8% molybdenum, and 4% tantalum. The findings could have a broad impact across the energy sector as well as aerospace and automotive. “We’re showing that this material can access previously unobtainable combinations of high strength, low weight, and high-temperature resiliency,” explains Sandia scientist Andrew Kustas. “We think part of the reason we achieved this is because of the additive manufacturing approach.” Moving forward, the team is interested in exploring whether advanced computer modeling techniques could help researchers discover more members of what could be a new class of high- performance super- alloys designed for additive manufacturing. Kustas notes that challenges are ahead. For one, it could be difficult to produce the new superalloy in large volumes without microscopic cracks, a general challenge in additive manufacturing. He also said the materials that go into the alloy are expensive. “With all those caveats, if this is scalable and we can make a bulk part out of this, it’s a game changer,” he says. sandia.gov. U.S.-JAPAN PARTNERSHIP AIDS AI INNOVATION Carnegie Mellon University, Pittsburgh, and Keio University, Japan, will join forces with each other and industry partners to boost AI-focused research and workforce development Sandia’s laser engineered net shaping machine enables 3D printing of new superalloys. in the United States and Japan. The partnership is one of two new university partnerships between the two countries in the area of artificial intelligence. This work will center on multimodal and multilingual learning, AI for robots, autonomous AI symbiosis with humans, life sciences, and AI for scientific discovery. The partnerships between Carnegie Mellon and Keio universities and between the University of Washington and the University of Tsukuba will be supported by $110 million in combined private sector investment from several American companies and a consortium of nine Japanese companies. cmu.edu. INTERNSHIPS SUPPORT EXTREME MATERIALS RESEARCH The U.S. National Science Foundation (NSF) and the U.S. Army Combat Capabilities Development Command (DEVCOM) initiated a joint research training opportunity through the NSF INTERN program. Two DEVCOM organizations are participating: the Army Research Laboratory (ARL) and the Ground Vehicle Systems Center (GVSC). The program provides graduate students with sixmonth experiential learning oppor- tunities through research internships where they acquire core professional competencies and skills. The NSFDEVCOM INTERN opportunity will support research experiences at DEVCOM that align with ARL and GVSC research competencies including extreme materials, biotechnology, energy, robotics, and others. The opportunity will fund approximately 10 internships in 2024, providing up to $55,000 per student for a six-month period. nsf.gov. U.S. Secretary of Commerce Gina Raimondo and Japanese Minister of Science and Technology Moriyama Masahito. Courtesy of U.S. Department of Commerce.
ADVANCED MATERIALS & PROCESSES | MAY/JUNE 2024 6 METALS | POLYMERS | CERAMICS In March, SSAB Corp., Stockholm, introduced the first emission-free steel powder for commercial use, made of recycled SSAB Zero steel. The powder features the same properties as SSAB’s high-strength steel and is designed for use in 3D printing. ssab.com. NEW PROCESS TURNS ELECTRONIC TRASH INTO TREASURE Scientists at the University of Illinois Urbana-Champaign developed a new method to extract valuable metals from discarded electronics and low-grade ore. They say the process uses significantly less energy and fewer chemicals than current methods. Their research involves the first precious metal extraction and separation process fully powered by the energy of electrochemical liquid-liquid extraction (e-LLE). The new technique uses a reductionoxidation reaction to selectively extract gold and platinum group metal ions from a liquid slurry containing dissolved electronic waste. In the lab, the team used an organic solvent to dissolve catalytic converters, electronic waste such as old circuit boards, and simulated mining ores containing gold and platinum METALS CHALLENGE QUANTUM STATUS QUO A team of researchers led by James Rondinelli at Northwestern University, Evanston, Ill., unveiled a class of metals that challenges the status quo of how metals behave, opening a realm where quantum oddities abound. With the creation of the compound Ca3Co3O8, the traditional distinctions between metals, polar materials, and magnets blur, confronting the fundamental understanding of what interactions give rise to material properties. According to Rondinelli, “This achievement opens the door to a frontier of unique quantum phenomena never before seen in classical systems and conventional metals.” One of those phenomena is intrinsic magnetochiral anisotropy, where certain materials act in a special way when electricity flows through them. Unlike regular metals, where the resistance to electricity is the same no matter which way the current goes, in these materials, the resistance changes depending on the direction of the current. This discovery could improve the performance and architecture of electronic devices, giving researchers more control over how magnetism and electricity work together. The team used quantum mechanical simulations and collaborative experimentation to predict Ca3Co3O8—a polar metal devoid of inversion symmetry yet imbued with ferromagnetic properties. “This material and its derivatives will serve as an exemplary group to explore the diverse range of emergent states combining polarity, magnetism, and metallicity, paving the way for exciting functionalities in electronic and spintronic devices,” says Rondinelli. Moving forward, the team will dive deeper into understanding the intricate relationship between polarity and magnetism within metallic systems. This involves performing additional studies to investigate the nuanced mechanisms underlying these interactions and their implications for material properties and applications. northwestern.edu. Reliance Inc., Scottsdale, Ariz., acquired MidWest Materials, Perry, Ohio, a provider of hot-rolled, high strength hotrolled, coated, and cold-rolled steel used in trailer manufacturing, agriculture, metal fabrication, and building products. reliance.com. BRIEFS Northwestern University researchers identified a new class of materials that blurs the distinctions between metals, polar materials, and magnets. A newly developed process uses electrochemistry to extract precious metals from discarded electronics in an e icient and environmentally friendly manner. Courtesy of Fred Zwicky.
ADVANCED MATERIALS & PROCESSES | MAY/JUNE 2024 7 group metals. The system then streams the dissolved electronics and ores over specialized electrodes in three consecutive extraction columns designed for oxidation, leaching, and reduction. An economic analysis of the approach shows that the new method costs substantially less than current industrial processes. According to researcher Xiao Su, one of the many advantages of the new method is that it can run continuously in a green fashion and is highly selective in terms of how it extracts precious metals. “We can pull gold and platinum group metals out of the stream, but we can also separate them from other metals like silver, nickel, copper, and other less valuable metals to increase purity greatly—something other methods struggle with,” says Su. The team is now working to perfect their new process by improving the engineering design and the solvent selection. illinois.edu. URANIUM MINERAL DATABASE A first-of-its-kind dataset and corresponding analysis has been published by nuclear nonproliferation scientists at the DOE’s Oak Ridge National Laboratory (ORNL) in Tennessee. The Compendium of Uranium Raman and Infrared Experimental Spectra, or CURIES, is a public database and analysis of structure-spectral relationships for uranium minerals. It fills a key gap in the existing body of knowledge for mineralogists and actinide scientists. Laser-based vibrational spectroscopy methods such as Raman and IR are frequently employed by nonproliferation materials scientists because they are rapid, nominally nondestructive, and can give direct insight to what a material contains. Where spectral assignments may be difficult, the CURIES database uses structural information, subject matter expertise, and statistical analysis to determine key features of Raman spectra based on their structural origins. The ORNL team hopes that CURIES will support researchers who are looking for new relationships among various types of uranium materials and foster development of rapid characterization and analysis of spectra collected on new materials. ornl.gov. The CURIES database will help researchers better identify uranium samples. Courtesy of Tyler Spano/ U.S. Dept of Energy. To appear in the listings, visit AMPdirectory.com/addyourcompany Simplify Your Search for Vendors Find the right solutions for your business. Search for products, research companies, connect with suppliers, and make confident purchasing decisions all in one place. AMPdirectory.com www.masterbond.com Hackensack NJ, 07601 USA ∙ +1.201.343.8983 ∙ mainmasterbond.com TOUGHENED EPOXY RESISTS VIBRATION, IMPACT & SHOCK Supreme 33CLV Two Part, Room Temperature Curing Epoxy -100°F to +425°F [-73°C to +218°C] SERVICE TEMPERATURE RANGE EXCEPTIONAL TOUGHNESS Resists thermal cycling SUPERIOR STRENGTH PROFILE Tensile strength: 8,000-9,000 psi
8 ADVANCED MATERIALS & PROCESSES | MAY/JUNE 2024 SIMULTANEOUS MEASUREMENT OF NANOMATERIAL PROPERTIES Scientists at the Korea Research Institute of Standards and Science (KRISS) developed a hybrid nano-microscope capable of simultaneously measuring various nanomaterial properties. The new microscope combines the functions of atomic force microscopy, photo-induced force microscopy, and electrostatic force microscopy. This nano-microscope is essential for researching the properties of nanocomposite materials and is also suitable for commercialization. Instead of using lenses, it employs a fine functional probe to tap the sample, allowing simultaneous measurement of the optical and electrical properties as well as the shape of nanomaterials with a single scan. TESTING | CHARACTERIZATION RECORD BREAKING RESOLUTION Using electron ptychography on conventional transmission electron microscopes, researchers at the University of Illinois Urbana-Champaign achieved record-breaking resolution. This breaks the trend of increasing microscope prices with increasing resolution. They were able to achieve deep sub-angstrom spatial resolution down to 0.44 angstrom, which exceeds the resolution of aberration-corrected tools and rivals their highest ptychographic resolutions. Rather than using a stack of lens optics to remove aberrations, ptycho- graphy removes them computationally. With a new generation of detectors, called hybrid pixel detectors, that cost a few hundred thousand dollars (compared to aberration-corrected microscopes that cost up to $7 million) and computer algorithms, this method can double, triple, or even quadruple the resolution of what a microscope can achieve with its physical lenses. The team demonstrated that their approach quadruples the resolution of conventional transmission electron microscopes. Further, nearly any STEM can now be adapted to achieve state-of-the-art resolution at a fraction of the cost. “This is significant for the hundreds of institutions across the country and across the world who previously couldn’t afford the cutting edge. Now, all they need is a detector, some computers, and electron ptychography. And once you do that, you can see the atomic world with much more detail than anyone imagined even 10 years ago,” says team leader Pinshane Huang. grainger. illinois.edu. Triangular holes make this material more likely to crack from left to right. Courtesy of N.R. Brodnik et al./Phys. Rev. Lett. ASTM International, West Conshohocken, Pa., appointed Andrew G. Kireta, Jr., as the organization’s new president, effective May 1. He will succeed Katharine Morgan, who served in the role since 2017 during her 40-year career at ASTM. Kireta was most recently president and CEO of the Copper Development Association. astm.org. Allied High Tech Products Inc. moved its corporate headquarters to 16207 Carmenita Rd. in Cerritos, Calif. The 40-yearold company supplies products for metallographic sample preparation and analysis along with technical assistance. alliedhightech.com. BRIEFS Photo of the new hybrid nano-microscope. Courtesy of KRISS. A comparison of experimental annular dark field (ADF)-scanning transmission electron microscopy (STEM) and electron ptychography in uncorrected and aberration-corrected electron microscopes. Courtesy of The Grainger College of Engineering at University of Illinois Urbana-Champaign.
ADVANCED MATERIALS & PROCESSES | MAY/JUNE 2024 9 Bilayer graphene is one of the typical nanomaterials that benefit from using the hybrid nano-microscope. Depending on the voltage applied to each layer or the twisted angle between two layers, the bilayer graphene exhibits various properties, including superconductivity. The KRISS researchers elucidated the principles of the unique infrared absorption response observed in bilayer graphene with the hybrid nano-microscope and confirmed that this phenomenon is caused by the charge imbalance between the two layers of graphene. Conventional nano-microscopes can only measure a single property of a material at a time, making it challenging to measure and analyze composite properties. By expanding measurement capabilities to magnetic properties, in addition to optical and electrical properties, it will now be possible for researchers to observe all three properties simultaneously on the nanoscale. This is expected to accelerate research on the properties of various nanocomposite materials, including quantum materials, contributing to the development of nanomaterials, parts, and equipment. www.kriss.re.kr/eng. ROUGHNESS AND ADHESION OF SOFT MATERIALS It is widely known that adhesive contact is formed more easily than it is broken. Now, an international team of researchers discovered that this phenomenon, called adhesion hysteresis, is caused by the surface roughness of the adherent soft materials. The team, including researchers from the University of Pittsburgh, the University of Freiburg in Germany, and the University of Akron in Ohio, conducted a combination of experimental observations and simulations to demonstrate how roughness interferes with the This graphic shows the contact area of a so solid that is separated from a rough surface. The di erent color intensity shows how much energy is lost in the process. Courtesy of Antoine Sanner/Lars Pastewka. separation process. The materials detach in minute, abrupt movements, which release parts of the adhesive bond incrementally. “We have succeeded for the first time in calculating the adhesion hysteresis for realistic surface roughness. This is based on the efficiency of the numerical model and an extremely detailed surface characterization carried out by researchers at the University of Pittsburgh,” says Tevis Jacobs. The team’s findings may make it possible to control the adhesion properties of soft materials through surface roughness. It also may aid the development of new and improved applications in soft robotics or production technology, like grippers or placement systems. pitt.edu, uakron.edu, www.uni-freiburg.de/en. ORDER TODAY! Visit asminternational.org or call 800.336.5152. ASM HANDBOOK VOLUME 10: MATERIALS CHARACTERIZATION The 2019 edition of ASM Handbook, Volume 10: Materials Characterization provides detailed technical information that will enable readers to select and use analytical techniques that are appropriate for their problem. Each article describing a characterization technique begins with an overview of the method in simplified terms and lists common applications as well as limitations. The articles also describe materials characterization in general terms according to material type and serve as a jumping o point to the more specific technique articles. asminternational.org Print: $380 / ASM Member: $285 ISBN: 9781627082112 Product Code: 05918G ASM Digital Library: $102 / ASM Member: $79 EISBN: 978-1-62708-213-6 ASM Digital Library price is for one-year single user access. Pages: 807 VOLUME EDITORS: THOMAS J. BRUNO, RYAN DEACON, JEFFREY A. JANSEN, NEAL MAGDEFRAU, ERIK MUELLER, GEORGE F. VANDER VOORT, DEHUA YANG
ADVANCED MATERIALS & PROCESSES | MAY/JUNE 2024 10 MACHINE LEARNING | AI VISION TRANSFORMERS OPTIMIZE 3D PRINTING Researchers at Carnegie Mellon University, Pittsburgh, developed a new system that employs ultra-high-speed in situ imaging and vision transformers to optimize process parameters for 3D printing a variety of metal alloys. These parameters include critical process details such as printing speed, laser power, and layer thickness of the deposited material. Vision transformers are a type of machine learning that applies neural network architectures originally developed for natural language processing tasks to computer vision tasks such as image classification. Video vision transformers go even further by using video sequences instead of still images to capture both spatial and temporal relationships that enable the model to learn complex patterns from video data. “We are excited to have developed an AI method that leverages temporal features in AM imaging data to detect different types of defects. Demonstrating the generalizability of the AI method using different AM metals is groundbreaking and reveals that the same trained AI model can be employed without costly retraining using additional data,” explains Conrad Tucker, mechanical engineering professor. The team used funding from the Army Research Laboratory to develop a high-speed imaging setup to capture clear features of molten metal and a machine learning model that could see the patterns associated with the defects they were trying to detect and prevent. By using vision transformers to classify different kinds of defects that can occur during 3D printing, the algorithmic accuracy surpassed 90% depending on the material. The scientists developed an off- axial imaging setup using a high-speed video camera and magnification lens to capture high-frequency oscillation in the melt pool shape. Video was recorded with a temporal resolution of over 50,000 frames per second. The videos were classified into four categories: one desirable regime and three undesirable regimes that produced defects including keyholing, balling, and lack of fusion. These four printing regimes were then tested on 316L stainless steel, Ti-6AL-4V, and Inconel 718. The team found that video vision transformers with temporal embedding can enable in situ detection of melt pool defects with a simple off-axial imaging setup. Using this video data, researchers are able to generate process maps that could accelerate qualification of printability for newly developed metal alloys specifically designed for 3D printing. engineering. cmu.edu. AI TRAINING BOOSTS BRITISH METALS INDUSTRY A new training center at the University of Leicester in the U.K. plans to boost the metals industry by developing postgraduates with excellent skills in data and artificial intelligence. The new $22 million Molten pools of Ti-6Al-4V captured by videos of different printing regimes. Centre for Doctoral Training (CDT) in Digital Transformation of Metals Industry (DigitalMetal) was funded by the Engineering and Physical Sciences Research Council (EPSRC), five U.K. partner universities (Birmingham, Leicester, Loughborough, Nottingham, and Warwick), and 35 industrial members. The effort is part of the U.K.’s largest investment ever in engineering and physical sciences doctoral skills, totaling more than $1 billion. Sixty-five CDTs will support leading research in AI, quantum technologies, semiconductors, telecommunications, and engineering biology. The DigitalMetal CDT is designed to meet a national strategic need for training a new generation of technical leaders able to guide the digital transformation of the metals industry and its supply chain with the objective of increasing agility, productivity, and international competitiveness. The pro- gram will provide postgraduate training that combines metals and alloys engineering with digital technology and AI skills, to help the U.K.’s domestic metals and manufacturing industries reap the benefits of big data. The goal is to develop future industry leaders who can rapidly take advantage of the latest discoveries in manufacturing processes through digital twinning to enable defect-free manufacturing at reduced costs. le.ac.uk. Enhanced AI training aims to boost the U.K. metals industry. Courtesy of www.vpnsrus.com.
ADVANCED MATERIALS & PROCESSES | MAY/JUNE 2024 1 1 PROCESS TECHNOLOGY CHEMICAL ETCHING WIDENS PORES An international team of scientists led by Nagoya University in Japan and East China Normal University developed a new chemical etching method for widening the pores of metal-organic frameworks (MOFs). The new technique could improve various applications of MOFs, including in fuel cells and as catalysts. The researchers used chemical mixtures to etch a more open structure throughout a MOF. After an initial cycle of etching, the interior of the MOF became more porous, meaning it could be loaded with iron ions that are crucial for catalysis. This MOF has individual iron ions anchored throughout its open structure, allowing each ion to be individually catalytically active. The final catalysts, known as OP-Fe-NC, were obtained by subjecting the final MASS PRODUCING POLYMER SOLID ELECTROLYTES Researchers at Ulsan National Institute of Science and Technology, South Korea, debuted a new technique for mass-producing polymer solid electrolytes, crucial components in batteries. Departing from the traditional melt casting method, the team introduced a horizontal centrifugal casting method to overcome existing limitations. Drawing inspiration from the casting technique used in producing iron pipes, the research team successfully achieved a uniform polymer solid electrolyte by rotating the solution horizontally during manufacturing. This method ensures minimal raw material wastage and offers superior electrochemical performance, economic feasibility, and effectiveness compared to conven- tional methods. The newly developed technology enables a remarkable 13-fold increase in production speed by eliminating the need for drying polymer solutions and vacuum heat treatment, thereby streamlining the manufacturing process significantly. Moreover, the production volume can be easily adjusted by varying the size of the horizontal centrifugal casting cylinder, ensuring consistent thickness and surface quality of polymer solid electrolytes—ideal for battery production. www.unist.ac.kr. MOF to calcination treatment in an inert atmosphere. Preliminary simulations suggest that this structure will greatly improve the movement of oxygen through the material, which should significantly enhance its activity and stability. The promising results highlight the potential of OP-Fe-NC as an effective electro- catalyst for various energy storage and conversion devices. For this work, using OP-Fe-NC as a cathode catalyst delivered extraordinary oxygen reduction reaction (ORR) activity and excellent stability in acidic media, which is even better than the commercial platinum and carbon catalyst. In the fuel cell, OP-Fe-NC showed a high current density, which was close to the DOE’s 2025 target. “This work provides a new approach for designing and optimizing high-efficiency catalysts for ORR by simultaneously increasing the intrinsic catalytic activities of the active sites and effectively utilizing the active sites in the catalyst layer,” says researcher Wei Xia. Having demonstrated the potential of their method in principle, the team now plans to explore how other chemical modifications could optimize the approach to produce materials suited to different real-world situations, like contributing to the drive toward sustainable energy solutions. en.nagoya-u.ac.jp, english.ecnu.edu.cn. KULR Technology Group Inc., San Diego, received a sixfigure contract from Lockheed Martin Corp., Bethesda, Md., to develop phase change material heat sinks critical for thermal regulation of essential electronics inside long-range precision missiles. kulrtechnology.com. BRIEF Structure of the etched open-pore MOF. Courtesy of Wei Xia. Depiction of the fabrication process for solid polymer electrolytes, utilizing a custom horizontal centrifugal casting apparatus. Courtesy of Energy Storage Materials, 2024.
ADVANCED MATERIALS & PROCESSES | MAY/JUNE 2024 12 LIGHT RESPONSIVE MATERIAL FOR SOFT MACHINES Scientists developed a type of soft material that can change shape in response to light, a discovery that could innovate soft machines for a variety of fields spanning robotics to medicine. Researchers at Lawrence Livermore National Laboratory (LLNL), Calif., created the novel material, a liquid crystal elastomer (LCE), by incorporating liquid crystals into the molecular structure of a stretchable material. Adding gold nanorods to the LCE material, scientists and engineers created photo-responsive inks and 3D-printed structures that could be made to bend, crawl, and move when exposed to a laser that causes localized heating in the material. The LLNL team used a direct ink writing technique to build a variety of light-responsive objects, including cylinders that could roll, asymmetric crawlers that could move forward, and lattice structures that oscillated. Researchers report the movement of the LCE material is driven primarily by a process known as photothermal actuation. Activated by the interaction between light, gold nanorods, and the LCE matrix, the process enables the printed structures to exhibit dynamic and reversible movements in response to external stimuli. Combining shape morphing with photoresponsivity, researchers say their new material could be used to create a soft machine capable of mimicking the movements and behaviors of living organisms. The team is now looking at starting a new strategic initiative at the lab to focus on autonomous materials and make advancements toward sentient materials. llnl.gov. INSECTS INSPIRE INVISIBILITY DEVICES Researchers at Penn State, State College, Pa., are looking to a common backyard insect for both inspiration and instruction for developing nextgen technology. The team precisely replicated the complex geometry of the tiny particles that leafhoppers secrete and use as a coating. Through the replication of these particles, called brochosomes, scientists elucidated a better understanding of how they absorb both visible and ultraviolet light. This could enable the development of bioinspired optical materials with applications ranging from invisible cloaking devices to coatings that can EMERGING TECHNOLOGY harvest solar energy, according to the researchers. The team found that the size of the holes in the brochosome that give it a hollow, soccer ball-like appearance is extremely important. The size is consistent across leafhopper species, regardless of body size. The brochosomes are roughly 600 nanometers (nm) in diameter, about half the size of a single bacterium, and the brochosome pores are around 200 nm. The researchers found the unique design of brochosomes serves a dual purpose— absorbing ultraviolet (UV) light, which reduces visibility to predators with UV vision, and scattering visible light, creating an anti-reflective shield against potential threats. Using advanced 3D-printing technology, researchers produced a scaledup version that was 20,000 nm in size. They accurately replicated the shape and morphology, as well as the number and placement of pores, to produce synthetic brochosomes that were large enough to characterize optically. Next, the researchers plan to explore additional applications for synthetic brochosomes, such as information encryption, where the structures could be used as part of an encoded system where data is only visible under certain light wavelengths. psu.edu. Liberty Reach Inc., Dexter, Mich., a supplier of 3D volumetric vision guidance systems for robot applications, changed its name to Liberty Robotics Inc. This reflects the company’s focus on machine vision and robotic guidance technologies. liberty-robotics.com. BRIEF Photo-responsive inks and movable 3D-printed structures were created by combining LLNL’s new liquid crystal elastomer with gold nanorods. Courtesy of Michael Ford. Brochosomes are hollow, nanoscopic, soccer ball-shaped spheroids with through-holes produced by a leafhopper. Courtesy of Lin Wang and Tak-Sing Wong/Penn State.
ADVANCED MATERIALS & PROCESSES | MAY/JUNE 2024 13 SURFACE ENGINEERING COLD SPRAY TANTALUM COATING Researchers at the University of Wisconsin-Madison are using a new coating technology to produce a hardworking material that can withstand the harsh conditions inside a fusion reactor. The team used a cold spray process to deposit a coating of tantalum on stainless steel, then tested it in extreme conditions. Notably, they found that the material is exceptionally good at trapping hydrogen particles, which is beneficial for compact fusion devices. “We discovered that the cold spray tantalum coating absorbs much more hydrogen than bulk tantalum because of the unique microstructure of the coating,” says Professor Kumar Sridharan, FASM. “The simplicity of the cold spray process makes it very practical for applications.” Over the past decade, Sridharan’s research group has introduced cold spray technology to the nuclear energy community by implementing it for multiple applications related to fission reactors. In fusion devices, plasma is heated to extremely high temperatures, and atomic nuclei in the plasma collide and fuse, producing energy. However, some hydrogen ions may get neutralized and escape from the plasma. To avoid this, the researchers aimed to create a new surface for plasma-facing reactor walls that could trap hydrogen particles as they collide with the walls. Tantalum is inherently good at absorbing hydrogen— and the team suspected that creating a tantalum coating using a cold spray process would boost its hydrogentrapping abilities even more. During testing, it was discovered that when heating the material to a higher temperature, it expelled the trapped hydrogen particles without modifying the coatings, a process that essentially regenerates the material so it can be used again. Another major benefit of the cold spray method is that it allows repair of reactor components on site by applying a new coating rather than requiring a completely new part. The team plans to use their new material in the Wisconsin HTS Axisymmetric Mirror, an experimental device under construction near Madison, which will serve as a prototype for a next-generation fusion power plant that UWMadison spinoff Realta Fusion plans to develop. wisc.edu. CHEMICAL FREE VIRUCIDAL SURFACE An international team of researchers from Australia’s RMIT University and the University of Rovira i Virgili (URV) in Spain created a surface that uses mechanical means to mitigate the infectious potential of viruses. Made of silicon, the artificial surface consists of a series of tiny spikes that damage the structure of viruses they encounter. The process of making the virucidal surfaces starts with a smooth metal plate, which is bombarded with ions to strategically remove material. The result is a surface full of needles that are 2 nm thick and 290 nm high. “In this case, we used silicon because it is less complicated technically speaking than other metals,” explains URV researcher Vladimir Baulin. The findings show that this method is extremely effective and incapacitates 96% of viruses that come into contact with the surface within a period of six hours. The study confirmed that the surfaces have a virucidal effect because of the ability of the needles to destroy or incapacitate viruses by damaging their external structure or piercing the membrane. Using this technology in high-risk environments such as laboratories or health centers in which there is potentially dangerous biological material would make it easier to contain infectious diseases and make these environments safer for researchers, health workers, and patients. www.urv. cat/en, www.rmit.edu.au. From le : Engineer Jeremiah Kirch, postdoctoral researcher Mykola Ialovega, and assistant scientist Marcos Xavier Navarro-Gonzalez work on the implementation of tantalum coatings as a plasma-facing material for the WHAM device, pictured in the background. Courtesy of Mykola Ialovega. Graphical depiction of artificial surface with spikes used to pierce and kill viruses. Courtesy of URV and RMIT University (Australia).
ADVANCED MATERIALS & PROCESSES | MAY/JUNE 2024 14 Several case studies show how the discovery, development, and deployment of novel materials are being dramatically accelerated through automation and data-driven models. *Member of ASM International Pacific Northwest National Laboratory (PNNL) created a new AI model for materials science that can identify patterns in electron microscope images without human guidance. Illustration courtesy of Cortland Johnson/PNNL. ARTIFICIAL INTELLIGENCE AND MACHINE LEARNING IN MATERIALS SCIENCE Joshua Stuckner* NASA Glenn Research Center Cleveland S. Mohadeseh Taheri-Mousavi Departments of Materials Science and Engineering and Mechanical Engineering Carnegie Mellon University, Pittsburgh James E. Saal* Citrine Informatics Redwood City, California MATERIALS INFORMATICS
ADVANCED MATERIALS & PROCESSES | MAY/JUNE 2024 15 Artificial intelligence (AI) and machine learning (ML) are advancing at a rapid pace and having an ever-larger impact on our daily lives. Equally so, AI and ML are increasingly affecting the way materials are researched and developed. Data- driven ML models are being used to establish complex processing-structure- property (PSP) relationships and paired with optimization to design and discover better materials faster than ever before. Computer vision models are being used to automatically quantify images of materials allowing for unbiased high throughput analysis and enabling in situ process monitoring. Advanced ML models are being implemented as the brains for robotic labs to automatically determine optimal experiments and work tirelessly to discover new materials without human input. These models are integrating with and empowering existing integrated computational materials engineering (ICME) tools to further accelerate materials design. This article provides a brief overview of the many ways that AI and ML are being used for materials and manufacturing research and highlights a few early applications of the technology in industry. The specific cases discussed here are illustrative examples and their inclusion in this article in no way indicates that they are better or more advanced than the many unmentioned examples of AI and ML in the field. AUTOMATIC IMAGE ANALYSIS Establishing processing-structure- property relationships is the fundamental framework for developing materials. However, quantifying microstructure is difficult, time-consuming, and prone to bias. Therefore, it’s no surprise that ML-based image analysis that has been used to enable self-driving cars and analyze satellite and medical images is being applied to automatic microstructure analysis and process monitoring. Foundational ML models that can be applied to a variety of microstructure quantification tasks were created by training convolutional neural network (CNN) encoders on a large dataset of over 100,000 microscopy images called MicroNet[1]. CNNs have two parts: (1) an encoder which identifies the features contained within the image, and (2) a task-specific decoder, which uses the extracted features to perform a desired analysis task such as classification, property prediction (regression), segmen- tation, and many more. Traditionally, encoders are trained on millions of pictures of everyday life. By seeing these images, the encoders learn to detect simple features like edges, textures, and high-level features such as dog ears and human faces. Then, through transfer learning, the pre-trained model is copied into larger more complex models for other tasks, providing improved performance. This process is illustrated in Fig. 1. But learning to detect high- level features like dog ears isn’t useful for microscopy analysis. By pre-training on a large microscopy dataset, MicroNet models learn to detect high-level features like grain boundaries and precipitates and perform much better in downstream microstructure analysis tasks. MicroNet models have been used by NASA for the segmentation and subsequent analysis of Ni-base superalloys[2] and environmental barrier coatings[3], direct strength prediction of Artemis core stage welds, and in a collaboration with the University of Pittsburgh, embedded within an instance seg- mentation model to analyze additive manufacturing (AM) individual laser path microbead morphology. Clemex is integrating MicroNet models into Clemex Studio to produce superior segmentation models with sparse Fig. 1 — Illustration of convolutional neural network models and transfer learning from MicroNet. By initially pre-training a classification model on a massive microscopy dataset from various materials and microscopes, the encoder learns to identify relevant microscopy features. Then, through a process called transfer learning, the encoder can be reused to perform more complex tasks such as segmentation with higher accuracy through a process called transfer learning. Figure adapted from Ref. 1.
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