18 27 32 P. 13 Weld Penetration Monitoring Damage Caused by Stress Corrosion Cracking SMST NewsWire Included in This Issue NOVEL NDT TECHNIQUE FOR CAST-IRON WATER MAINS NDT AND FAILURE ANALYSIS OCTOBER 2024 | VOL 182 | NO 7
18 27 32 P. 13 Weld Penetration Monitoring Damage Caused by Stress Corrosion Cracking SMST NewsWire Included in This Issue NOVEL NDT TECHNIQUE FOR CAST-IRON WATER MAINS NDT AND FAILURE ANALYSIS OCTOBER 2024 | VOL 182 | NO 7
3 EVENTS • 1 LOCATION SUSTAINABLE INNOVATIONS IN THERMAL SPRAY TECHNOLOGY: PIONEERING A GREENER FUTURE INNOVATIONS IN MATERIALS ENGINEERING: SHAPING THE FUTURE OF THE AEROSPACE INDUSTRY 2025 MAY 5–8, 2025 VANCOUVER CONVENTION CENTER | VANCOUVER, CANADA SAVE THE DATE ITSCevent.org QDEevent.org AeroMatevent.org CO-LOCATED WITH: OFFICIAL MEDIA SPONSOR: 3RD INTERNATIONAL CONFERENCE ON QUENCHING AND DISTORTION ENGINEERING ORGANIZED BY:
27 DAMAGE CAUSED BY STRESS CORROSION CRACKING Frank N. Smith Stress corrosion cracking is an insidious form of damage that can occur when a susceptible metal is subjected to a tensile stress in a specific environment. NDT TECHNIQUE TO CHECK GRAPHITIZATION OF DUCTILE AND CAST-IRON WATER MAINS Mehrooz Zamanzadeh and Anil Kumar Chikkam An advanced, patented probe sensor provides early detection of water infrastructure problems caused by corrosion and harsh atmospheric conditions. 13 ADVANCED MATERIALS & PROCESSES | OCTOBER 2024 2 An ultrasonic test detects imperfections and defects in a steel plate. Courtesy of Dreamstime. On the Cover: 49 ASM NEWS The latest news about ASM members, chapters, events, awards, conferences, affiliates, and other Society activities. ADVANCES IN MATERIALS CONFERENCE PREVIEW Join us for the 10th International Conference on Advances in Materials, Manufacturing & Repair for Power Plants, scheduled from October 15 to 18 in Bonita Springs, Florida. 12
4 Editorial 5 Machine Learning 6 Metals/Polymers/Ceramics 8 Testing/Characterization 10 Process Technology 11 Energy Trends 59 Editorial Preview 59 Special Advertising Section 59 Advertisers Index 60 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. 7, OCTOBER 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. 18 TECHNICAL SPOTLIGHT ADVANCED TECHNIQUES IMPROVE WELD PENETRATION MONITORING In the quest to improve reliability of partial penetration welding validation, advanced ultrasonic testing techniques have replaced other less accurate methods. 22 MATERIAL SELECTION OF 316 STAINLESS STEEL FOR HIGH- PRESSURE HYDROGEN SYSTEMS Xiaoli Tang Selecting materials for high-pressure hydrogen systems requires balancing technical understanding of hydrogen embrittlement and business considerations. 30 ISTFA 2024 SHOW PREVIEW The 50th International Symposium for Testing and Failure Analysis features the theme of “Riding the Wave of Artificial Intelligence” and will be held in San Diego, Oct. 28 to Nov. 1. FEATURES OCTOBER 2024 | VOL 182 | NO 7 ADVANCED MATERIALS & PROCESSES | OCTOBER 2024 3 18 30 32 22 32 SMST NEWSWIRE The official newsletter of the International Organization on Shape Memory and Superelastic Technologies (SMST). This biannual supplement covers shape memory and superelastic technologies for biomedical, actuator applications, and emerging markets, along with SMST news and initiatives.
4 ADVANCED MATERIALS & PROCESSES | OCTOBER 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 EDITORIAL COMMITTEE John Shingledecker, Chair, EPRI Beth Armstrong, Vice Chair, Oak Ridge National Lab Adam Farrow, Past Chair, Los Alamos National Lab Yun Bai, Ford Rajan Bhambroo, Tenneco Inc. Punnathat Bordeenithikasem, Machina Labs 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 Krassimir Marchev, Northeastern University Bhargavi Mummareddy, Dimensional Energy Scott Olig, U.S. Naval Research Lab Christian Paglia, SUPSI Institute of Materials and Construction Satyam Sahay, John Deere Technology Center India Abhijit Sengupta, USA Federal Government Kumar Sridharan, University of Wisconsin Vasisht Venkatesh, Pratt & Whitney ASM BOARD OF TRUSTEES Navin Manjooran, President and Chair Elizabeth Ho man, Senior Vice President Daniel P. Dennies, Vice President Pradeep Goyal, Immediate Past President Lawrence Somrack, Treasurer Amber Black Pierpaolo Carlone Rahul Gupta Hanchen Huang André McDonald Victoria Miller Christopher J. Misorski Dehua Yang Fan Zhang Veronica Becker, Executive Director STUDENT BOARD MEMBERS Gladys Duran Duran, Amanda Smith, Nathaniel Tomas 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. SUPERHEROES AMONG US Engineering and failure analysis, at their core, solve problems. Behind every new invention, process improvement, or solution to one of those problems is a superhero of sorts. And superheroes are known for harnessing their unique abilities or superpowers to make any situation better. The engineering team at Matergenics Inc. in Pittsburgh has the superpower of developing sensors to aid materials inspections in challenging environments. They have designed a trio, in fact. During this year’s ASM awards banquet at IMAT in Cleveland, the Matergenics team received the Engineering Materials Achievement Award for their patented sensor that can safely be used for real-time monitoring of temperature and corrosion of assets that have been exposed to wildfires. In the lead article of this issue, they provide a case study on the use of another one of their sensors, the Zee Probe, which can nondestructively test water mains. And a third feat of ingenuity, their newest Sentry sensor, detects hydrogen embrittlement in gas lines and storage vessels and is also described. The team knows that hydrogen will be increasingly called upon in our clean energy future. Yet, it comes with its own perilous issues. This sentiment is echoed by the author of our “Material Selection of 316 Stainless Steel for High-pressure Hydrogen Systems” article. Xiaoli Tang of Swagelok is working on the front end of the problem to design containers less likely to develop fatigue property degradation. Her super solution is to refine the material selection criteria to include a Goldilocks percentage of nickel content, as found in 316. To hone your own abilities for performing materials inspections and solving fatigue issues, we’re here to help. ASM just launched a new Failure Analysis Certificate of Achievement program. Earn the credential by completing two required courses plus an additional three courses from a selection of electives that fit your needs. Flip to the inside back cover of this issue to read more about this unique opportunity to sharpen your skills. Another helpful resource for budding superheroes is the Journal of Failure Analysis and Prevention (JFAP). You’ll find case studies, tips for determining causes of failures, testing techniques, new inspection processes, and reviews of classic failures. Speaking of ASM’s periodical program, this month marks the retirement of Mary Anne Fleming, the longtime ASM director of journals. During her 35 years on ASM’s staff, she has shepherded the journal program and brought it to new heights by launching four new journals, JFAP among them. Also, under her tutelage, an illustrious group of editors along with her staff have worked to achieve an increase in the papers published, Journal Impact Factors, and of course, revenue. As Mary Anne shifts her focus to reading more novels—no impact factor required—we hope she knows that she made a big impact on us. She’s our superhero. joanne.miller@asminternational.org JFAP editor Elvin Beach and family with Mary Anne Fleming, 2017.
ADVANCED MATERIALS & PROCESSES | OCTOBER 2024 5 MACHINE LEARNING | AI MACHINE LEARNING PREDICTS POLYMER BEHAVIOR Researchers from the National Institute for Materials Science (NIMS), Japan, are using machine learning to predict the material properties of polymers. The team developed their new method on homo-polypropylenes, using x-ray diffraction patterns of the polymers under different preparation conditions to provide detailed information about their complex structure and features. Scientists then analyzed two datasets using Bayesian spectral deconvolution to extract patterns from the complex data. The first dataset was x-ray diffraction data from 15 types of homo-polypropylenes subjected to a range of temperatures, and the second was data from four types of homo-polypropylenes that underwent injection molding. The mechanical properties they analyzed included stiffness, elasticity, the temperature at which the material starts to deform, and how much it would stretch before breaking. The team found that the machine learning analysis accurately linked features in the x-ray diffraction imagery with specific materials properties of the polymers. Some of the mechanical properties were easier to predict from the x-ray diffraction data, while others, such as the stretching break point, were more challenging. The researchers believe their Bayesian spectral deconvolution approach could be applied to other data, such as x-ray photoelectron spectroscopy, and used to understand the properties of other inorganic and organic materials, too. www.nims.go.jp/eng. MACHINE LEARNING EXPLORES PHASE-CHANGE MATERIALS Cornell University researchers, Ithaca, N.Y., are using a combination of machine learning and x-rays to explore the unusual behavior of phase-change materials. Scientists have long known that the cubic phase of germanium telluride (GeTe) exhibits an unexpected rise in lattice thermal conductivity as its temperature increases, but they did not understand why. The researchers found that as a sample of GeTe is heated to the point where its phase changes from a rhombohedral structure to a cubic structure, the bonds between second-nearest neighbors Flow diagram of the procedure used to provide a highly accurate machine learning prediction model using only the XRD results of polymer materials. Courtesy of NIMS. of like atoms (Ge-Ge and Te-Te) strengthen considerably. Ge-Ge bond strength increased by 8.3% and the strength of Te-Te bonds increased by a remarkable 103% as the sample’s temperature rose from 693 to 850 K. The team used machine learning- assisted first-principles calculations corroborated by x-ray scattering measurements to computationally reproduce the increasing thermal conductivity trend for the first time. They then borrowed a chemistry technique to perform the bonding analysis and confirmed that these increasingly strong second-nearest neighbor bonds play a major role in GeTe’s previously unexplained increase in lattice thermal conductivity. Phase-change materials such as GeTe are valued for their usefulness in a range of optical and electronic applications. Their optical and electrical properties change significantly depending on which of several stable phase states they are in, and these phase states can be easily reversed. The research demonstrates an efficient pathway toward accurate modeling of materials near phase transitions or at high temperatures that have promise for phase change, thermoelectric, and other energy applications. cornell.edu. Overview of methodology for studying GeTe phase-change materials. Courtesy of Nature Communications. (a) (b)
ADVANCED MATERIALS & PROCESSES | OCTOBER 2024 6 METALS | POLYMERS | CERAMICS POLYMER FOAM SOAKS UP OIL SPILLS Researchers at the University of Waterloo, Canada, developed a polymer material that can absorb more than eight times its weight in oil, offering a new method to clean up spills and accidents. The polymer foam turns into a gel upon contact with oil, thereby preventing groundwater contamination. Applications include use around electric transformers and oil storage facilities that face groundwater leak risks due to accidents or natural disasters such as earthquakes and hurricanes. To determine which material would work best for oil absorption, researchers measured various gel densities and tested their mechanical properties and capacity to hold as much liquid as possible without becoming saturated. Each polymer foam is designed to allow water to pass freely through its porous structure, but triggers a chemical reaction once it comes in contact with oil. The polymer that the team developed features a spongy texture but becomes a semisolid, gel-like substance that seals in oil and prevents leaks. The material is also lightweight and easy to transport. Any oil trapped in the gel can be recovered through a secondary process. The team will now work with industry partner Albarrie Canada to apply their research ADHESIVE-FREE METHOD JOINS WOOD AND METAL Researchers at Graz University of Technology, Austria, achieved an extremely strong bond of wood with both metal and polymer composites by using 3D printing and an ultrasonic joining technique. The team has now successfully tested two methods by which strong joints can be achieved without using adhesives or screws. Applying the new techniques to wood holds promise for the aircraft, automotive, and furniture industries. Beech, oak, carbon fiber-reinforced polyamide and polyphenylene sulfide, 316L stainless steel, and Ti-64 alloys, were used as test materials. With the AddJoining technique, a component made of polymer composite is affixed to and printed directly onto a surface, in this case wood, using 3D printing. The printed material penetrates into the wood pores and causes a chemical reaction, similar to the reaction of glue with wood. The resulting connections were highly successful in mechanical load tests, which were conducted on the untreated wood surface. Even more durable joints could be achieved by introducing a micro- or nano-structure into the wood through laser texturing or etching, which increases the pores and enhances the bonding surfaces. The new technology works especially well with complicated 3D geometries because the components are printed directly onto the surface in whatever geometry is required, say researchers. In ultrasonic joining, highfrequency vibration with low amplitude is applied to the wooden component using a sonotrode. In contact with the base component—in this case, polymer or a polymer composite material—the friction generates heat at the interface, melting the surface of the polymer part. Molten polymer infiltrates the naturally porous wood surface, resulting in a very stable spot joint from a mixture of mechanical interlocking (due to melted plastic solidifying again in the wood) and adhesion forces. Joints could be further strengthened by pretreatment of the wood surface with laser texturing. www.tugraz.at. In ultrasonic joining, wood and the base component are joined by frictional heat. Courtesy of Wolf/TU Graz. Novelis Inc., Atlanta, recently completed its Green Bond financial commitments. Projects include a $2.4 million solar installation in Pieve, Italy, commissioning of a third recycling furnace in Neuss, Germany, and construction of a new recycling plant for beverage cans in Bay Minette, Ala. novelis.com. BRIEF
ADVANCED MATERIALS & PROCESSES | OCTOBER 2024 7 to the company’s transformer oil containment services where larger volumes of oil spills will be examined. www.uwaterloo.ca. BETTER MEMBRANES RECOVER CRITICAL MATERIALS Membrane technology shows great promise for extracting critical materials such as lithium and cobalt from sources other than raw material mining. Featuring nanosized pores, membranes can be tuned to filter specific materials from water and other sources. Researchers from Yale University, New Haven, Conn., and MIT, Cambridge, Mass., are drawing inspiration from living organisms to outline a way to improve this technology. “There’s a recent movement in membrane science to design at a more precise level,” says researcher Camille Violet. For example, cobalt and nickel are next to each other on the periodic table. That makes it difficult for conventional membranes, which separate species based on differences in size or charge, to separate these nearly identical species. “Some of these really important metals that we need to separate only differ by one atomic number,” says Violet. To locate more of today’s valuable materials—beyond mining—scientists are turning to the untapped resources in waste streams. Electronic waste contains rare earth elements and precious metals while used lithium-ion batteries contain cobalt and lithium. One goal of the new research is to get membrane scientists to think more like biochemists. “If we look to the biological ion channel as a model, then we can start to mimic that design in membrane science,” says Violet. seas.yale.edu. Cobalt, nickel, manganese, and lithium are some of today’s most valuable materials. thermcraftinc.com • (336) 784-4800 Industrial& Laboratory Furnaces, Ovens& Heaters • Batch or Continuous Processing • Durable Construction • Standard or Fully Customizable • Up to 1800ºC, 3272ºF • Single or Multi-Zone • PLC Controls Available • Made in the USA Since 1971 thermcraftinc.com • (336) 784-4800 STAY AHEAD OF YOUR PROFESSIONAL JOURNEY WITH ASM EDUCATION & TRAINING. EARN CEUs, ENJOY DISCOUNTS, NETWORK, AND LEARN FROM INDUSTRY EXPERTS. SCAN TO ENROLL TODAY Education
8 ADVANCED MATERIALS & PROCESSES | OCTOBER 2024 devices. The research team employed a novel near-field transient nanoscopy technique to probe the behavior of materials at the nanoscale with both high spatial and temporal resolution. This approach overcomes the limitations of traditional optical methods, allowing researchers to directly visualize and analyze phenomena that were previously difficult to observe. The team focused on atomically thin transition metal dichalcogenides (TMDCs), materials known for their unique optical and electronic properties. They also examined vanadium dioxide (VO2), a material celebrated for its remarkable phase-change properties. Using their advanced imaging techniques, the researchers mapped out the nanoscale distribution of metallic and insulating phases in bent VO2 nanobeams. The team observed slower carrier recombination but faster diffusion in the metallic phase of VO2 compared to its insulating phase. This finding provides new insights into the material’s behavior during phase transitions, which could be crucial for developing advanced switching and memory devices. The research also highlighted the impact of local material properties, such as strain and interfaces, on exciton and carrier dynamics in both TMDCs and VO2. These discoveries have significant implications for the development TESTING | CHARACTERIZATION FASTER IMAGING FOR ATOMIC BEAM MICROSCOPES Researchers at Swansea University created a new imaging method for neutral atomic beam microscopes that could lead to much faster results for engineers and scientists when scanning samples. Existing neutral atomic beam microscopes obtain images by illuminating the sample through a microscopic pinhole. Now, the Swansea researchers developed a new—and faster—alternative method to pinhole scanning. They demonstrated the new method using a beam of helium-3 atoms, a rare light isotope of regular helium. The technique works by passing a beam of atoms through a non- uniform magnetic field and using nuclear spin precession to encode the position of the beam particles, which interact with the sample. The team used numerical simulations to show that the new magnetic encoding method should be capable of improving image resolution with a significantly smaller increase in time. “The method we have developed opens up various new opportunities in the field of neutral beam microscopy,” lead researcher Gil Alexandrowicz says. “In the immediate future, the new method will be further developed to create a fully working prototype magnetic encoding neutral beam microscope. In the more distant future, this new type of microscope should become available to scientists and engineers to characterize the topography and composition of sensitive and delicate samples they produce or study.” www.swansea.ac.uk. A CLOSER LOOK AT ULTRAFAST CARRIER DYNAMICS Scientists are achieving extra- ordinary insights into ultrafast carrier dynamics in advanced materials thanks to cutting- edge nanoscale optical imagining techniques developed by researchers at the University of California, Berkeley. Their work shows significant progress in understanding the carrier behaviors in 2D and phasechange materials, with implications for next-generation electronic and optoelectronic The Giant Magellan Telescope and Ingersoll Machine Tools Inc. have started manufacturing the largest telescope mount ever built in the U.S. Once fully assembled in Rockford, Ill., the mount will undergo testing before being shipped to Chile for reassembly and use by the early 2030s. Magellan will be 200 times more powerful than today’s best telescopes. giantmagellan.org. BRIEF Schematic shows transient s-SNOM, which measures exciton dynamics in MoS2. Courtesy of Advanced Materials, 2024, doi.org/10.1002/adma.202311568. A magnetic encoding device is lifted by a crane before being attached to the beam line. Courtesy of Morgan Lowe.
ADVANCED MATERIALS & PROCESSES | OCTOBER 2024 9 of next-generation electronic and optoelectronic devices, including high- performance sensors, memory devices, and adaptive optical components. berkeley.edu. VISUALIZING NANOSTRUCTURES AND METAMATERIALS Scientists at the Max Planck Society in Munich developed a new microscopy method that allows for the unprecedented visualization of nanostructures and their optical properties. Metamaterials, engineered at the nanoscale, exhibit unique properties not found in naturally occurring materials. These properties arise from their nanoscale building blocks—which, until now, have been challenging to observe directly due to their size being smaller than the wavelength of light. The team’s research overcomes this limitation by employing a new microscopy technique that can simultaneously reveal both the nano and macrostructures of these materials. The key finding of this research is a methodological breakthrough that enables the visualization of structures previously too small to be seen with traditional microscopy. Using light in innovative ways, the scientists discovered how to trap one color of light within the structure and mix it with a second color that can leave the structure to visualize this trapped light. This trick reveals the hidden world of nanoscale optical metamaterials. The breakthrough is the result of more than five years of dedicated research and development, utilizing the unique features of the Free Electron Laser at the Fritz Haber Institute. This type of microscopy Graphical representation of sum-frequency spectro-microscopy of phonon polaritons in SiC micropillar arrays. Courtesy Fritz Haber Institute. is particularly special because it allows for a deeper understanding of meta- surfaces, paving the way for advancements in technologies such as lens design, and opening the door to the development of novel light sources and the design of coherent thermal light sources. www.mpg.de/en. STATEMENT OF OWNERSHIP, MANAGEMENT, CIRCULATION, ETC. Required by the Act of 23 October 1962, Section 4369, Title 39, United States Code, showing the ownership, management, and circulation of Advanced Materials & Processes®, publishes eight issues per year: January/February, March, April, May/June, July/August, September, October, and November/December at 9639 Kinsman Road, Materials Park, Ohio 44073, USPS # 762080. Annual subscription rate is $499. The publisher and editor are Scott D. Henry and Joanne Miller, respectively, both of 9639 Kinsman Road, Materials Park, Ohio, 44073. The owner is ASM International®, Materials Park, Ohio, which is a not-for-profit educational institution, the officers being; President and Chair of the Board, Navin J. Manjooran; Senior Vice President and Trustee, Elizabeth Hoffman; Vice President and Trustee, Daniel P. Dennies; Immediate Past President and Trustee, Pradeep Goyal; Executive Director, Veronica Becker; Treasurer and Trustee, Lawrence Somrack; Trustees, Amber Black, Pierpaolo Carlone, Rahul Gupta, Hanchen Huang, André McDonald, Victoria M. Miller, Christopher J. Misorski, Dehua Yang, and Fan Zhang; Student Board Members Gladys Duran Duran, Amanda Smith, and Nathaniel Tomas. There are no known bondholders, mortgagees, and other security holders owning or holding 1% or more of the total amount of bonds, mortgages, or other securities. The issue date for circulation data below is April 2024. The average number of copies of each issue during the preceding 12 months is: (a) Total number of copies printed: 2,146; (b) Paid and/or requested circulation: (1) Paid/requested outside county mail subscriptions: 1,514; (2) Paid in-county subscriptions: 0; (3) Sales through dealers and carriers, street vendors, counter sales, and other non-USPS paid distribution: 206; (4) other classes mailed through the USPS: 0; (c) Total paid and/or requested circulation: 1,720; (d.1) Free distribution or nominal outside-county: 13; (d.3) Free distribution by mail: 35; (e) Total free distribution: 48; (f) Total distribution: 1,768; (g) Copies not distributed: 401; (h) Total: 2,169; (i) Percent paid: 97. The actual number of copies of single issue published nearest to filing date is: (a) Total number of copies printed: 3,260; (b) Paid and/or requested circulation: (1) Paid/requested outside-county mail subscriptions: 2,447; (2) Paid in-county subscriptions: 0; (3) Sales through dealers and carriers, street vendors, counter sales, and other non-USPS paid distribution: 339; (4) other classes mailed through the USPS: 0; (c) Total paid and/or requested circulation: 2,786; (d.1) Free distribution or nominal outside-county: 21; (d.3) Free distribution by mail: 56; (e) Total free distribution: 77; (f) Total distribution: 2,863; (g) Copies not distributed: 392; (h) Total: 3,255; (i) Percent paid: 97. I certify that the statements made by me above are correct and complete. Scott D. Henry Publisher
ADVANCED MATERIALS & PROCESSES | OCTOBER 2024 10 PROCESS TECHNOLOGY ADVANCED ALLOY ATOM ARRANGEMENT A group of researchers from Penn State University, University Park, Pa., uncovered new findings about how atoms arrange themselves to find their preferred neighbors in multi-principal element alloys (MPEAs). The scientists say their discovery could enable engineers to customize these unique and useful materials for enhanced performance in specific applications ranging from advanced power plants to aerospace technologies. One of the major gaps in understanding MPEAs has been the formation tory in Iowa developed a new recycling process that eliminates the need for chemicals and high heat. The battery recycling and water splitting (BRAWS) technology uses only water and carbon dioxide to complete the process. It doesn’t require chemicals or heat and allows scientists to recover more lithium from spent batteries than other recycling methods. When lithium-ion batteries undergo fast charging, they don’t last as long because the fast charging causes the lithium to build up on the anode. Over time, the lithium build-up causes the battery to fail. The first step in the BRAWS technology is to use a set of protocols that includes fast charging to force as much additional lithium as possible to build up on the battery anode. After the battery is dismantled, the anode—typically made of graphite— is then immersed in water, and CO2 is added to recover lithium as lithium carbonate. This step results in recovery of almost all the lithium from the original battery and produces green hydrogen as a byproduct. And since the technology doesn’t rely on chemicals or extreme temperatures, other materials can be extracted in a form that can be directly reused. The scientists say their recycling process is sustainable not only environmentally but economically as well. ameslab.gov. and control of short-range order (SRO), which refers to a non-random arrangement of atoms over short distances— typically only a few atoms wide. The researchers discovered that SRO is an inherent characteristic in MPEAs, forming during the solidification process when fabricating such materials, which involves the liquid components hardening. Instead of being completely random, SRO features atoms clustering in a specific order. This clustering can affect MPEA properties, such as strength or conductivity. The researchers’ findings challenge the previous notion that, if the cooling rate during solidification is rapid, elements in MPEAs randomly arrange themselves in the crystal lattice. It also confronts the idea that SRO primarily develops during annealing, where heating and gradual cooling enhance the material’s microstructure to improve properties like strength, hardness, and ductility. The team used an improved semi-quantitative electron microscopy method to study SRO in cobalt/chromium/nickel-based MPEAs. They were surprised to find that SRO forms during the solidification process, regardless of cooling rates or thermal treatments applied. Understanding that SRO is inherent and forms during solidification means that traditional methods of thermal processing methods may not effectively control it. The researchers also discovered that the pervasive nature of SRO enabled them to tune MPEAs for particular properties, opening new possibilities for material design and engineering. psu.edu. RECYCLING LITHIUM-ION BATTERIES WITHOUT HEAT OR CHEMICALS A team of scientists from the DOE’s Ames National LaboraHeidelberg Materials North America, Irving, Texas, converted its Speed, Indiana, cement plant to a slag grinding facility to support increased demand for more sustainable cementitious products in the Midwest market. heidelbergmaterials.us. BRIEF The cloud blocking the view in this illustration indicates that the transformation mechanism from liquid metal to a high-entropy alloy solid is unclear. Courtesy of Yang Yang/Ying Han. Materials extracted using the BRAWS technology. Courtesy of Ames National Laboratory.
1 1 ADVANCED MATERIALS & PROCESSES | OCTOBER 2024 EMERGING TECHNOLOGY TIN LAYER FORTIFIES LITHIUM-ION BATTERIES Researchers from the University of Alberta developed a promising new approach to prevent formation of dendrites in solid-state lithium-ion batteries. Using the Canadian Light Source at the University of Saskatchewan, scientists were able to see at a structural level what was happening on the surface of the lithium in an operating battery. They found that adding a tin-rich layer between the electrode and the electrolyte helps spread the lithium around when it’s being deposited on the battery, creating a smooth surface that suppresses the formation of dendrites. The team also found that the cell modified with the tin-rich structure can operate at a much higher current and withstand many more chargingdischarging cycles than a regular cell. The novel method holds considerable potential for industrial applications, according to the researchers, who say their next step is finding a sustainable, cost-effective approach to applying the protective layer in battery production. www.lightsource.ca. BIOBASED AND RECYCLABLE WIND TURBINE BLADES A new method to produce biobased, reusable, and chemically recyclable wind turbine blades was created by researchers at the DOE’s National Renewable Energy Laboratory (NREL) in Golden, Colo., and could end the practice of old blades winding up in landfills at the end of their useful life. The new resin, which is made of materials produced using bio-derivable resources, performs on par with the current industry standard of blades made from a thermoset resin and outperforms certain thermoplastic resins intended to be recyclable. The researchers built a prototype nine-meter blade to demonstrate the manufacturability of an NREL-developed biomass-derivable resin nicknamed PECAN. The acronym stands for PolyEster Covalently Adaptable Network, and the manufacturing process integrates with current methods. Under existing technology, wind blades last about 20 years, and afterward they can be mechanically recycled—for example, shredded for use as concrete filler. PECAN marks a leap forward because EMEREGNEINRG YTETCRHENDOSLOGY The DOE’s Oak Ridge National Laboratory, Tenn., is the lead partner on five research collaborations with private fusion companies in the 2024 cohort of the Innovation Network for FUSion Energy (INFUSE) program. Projects aim to develop technologies to accelerate fusion energy research in the private sector. ornl.gov. BRIEF Interfacial tin-rich layer suppresses dendrite formation. Courtesy of ACS Applied Materials & Interfaces, 2024, doi.org/10.1021/acsami. 4c05227. An NREL scientist holds small cubes of the PECAN resin. Courtesy of Werner Slocum/NREL. of the ability to recycle the blades using mild chemical processes. The chemical recycling process allows the components of the blades to be recaptured and reused again and again, allowing the remanufacture of the same product. The researchers say the process was able to completely break down the prototype blade in six hours. The research into the PECAN resin began with the end. The scientists wanted to make a wind blade that could be recyclable and began experimenting with what feedstock they could use to achieve that goal. The resin they developed using bio-derivable sugars provided a counterpoint to the conventional notion that a blade designed to be recyclable will not perform as well. Composites made from the PECAN resin held their shape, withstood accelerated weatherization validation, and could be made within a timeframe similar to the existing cure cycle for how wind turbine blades are currently manufactured. nrel.gov.
OCTOBER 15–18, 2024 | BONITA SPRINGS, FLORIDA 10TH INTERNATIONAL CONFERENCE ON ADVANCES IN MATERIALS, MANUFACTURING & REPAIR FOR POWER PLANTS SHOW PREVIEW KEYNOTE LECTURES Practical Realities of the Global Energy Transformation Steve Chengelis Sr. Director Future Nuclear, EPRI Democratization of Advanced Manufacturing Dr. Suresh Babu, FASM, FAWS UT/ORNL Governor’s Chair of Advanced Manufacturing Professor, University of Tennessee For event details and to register, visit www.asminternational.org/epri-2024. Join us at the 10th International Conference on Advances in Materials, Manufacturing & Repair for Power Plants for a four-day event, October 15-18. As the world undergoes an energy transformation, the safe, reliable, a ordable, and environmentally responsible operation of today’s and tomorrow’s power plants requires continued advancement in high-temperature materials technology. Materials serve as the key enabling technology driving the development of high-e ciency power conversion technologies. The Electric Power Research Institute (EPRI) is proud to continue its partnership with ASM for its 10th Advances in Materials Conference, building on EPRI’s inaugural event in 1987 and rotating between the UK, Europe, North America, and the Pacific, with the most recent conference (2019) held in Nagasaki, Japan. For more information, visit www.asminternational.org/epri-2024. ORGANIZED BY: SPONSORS: MONDAY, OCTOBER 14 8:30 a.m.– 5:00 p.m. Pre-Conference Workshop: Case Studies in High Temperature Damage in Power Plant Components TUESDAY, OCTOBER 15 8:30 – 10:00 a.m. Welcome Address: John Shingledecker; Keynote: Steve Chengelis; Keynote: Suresh Babu 10:30 a.m. – 4:55 p.m. Technical Sessions: Component Manufacturing; Stainless Steels; Welding & Weld Repair; Advanced Manufacturing; Quantification/Codes & Standards 10:20 – 11:40 a.m. Poster Session and Reception WEDNESDAY, OCTOBER 16 8:30 – 10:00 a.m. Plenary: Materials & Manufacturing Innovations for Nuclear 10:30 a.m. – 4:45 p.m. Technical Sessions: Advanced Manufacturing; Welding & Weld Repair; Environmental Degradation; Materials Modeling; Life Assessment Ferritic Steel/ CSEF; High-Temperature Advanced Materials THURSDAY, OCTOBER 17 8:30 – 10:00 a.m. Plenary: Materials Performance in Thermal Power Plants 10:30 a.m. – 3:10 p.m. Technical Sessions: Damage Mechanisms; Ferritic Steel/CSEF; High-Temperature Advanced Materials; Claddings, Coatings, and Surface Modification; Nickel-based/Superalloy 5:30 – 7:30 p.m. Conference Dinner and Awards Banquet FRIDAY, OCTOBER 18 8:30 – 10:00 a.m. Plenary: Superalloys and Advanced Manufacturing for Gas Turbines 10:30 a.m. – 12:10 p.m. Technical Sessions: Ferritic Steel/CSEF; Nickelbased/Superalloy SCHEDULE-AT-A-GLANCE
ADVANCED MATERIALS & PROCESSES | OCTOBER 2024 13 *Member of ASM International NDT TECHNIQUES An advanced, patented probe sensor provides early detection of water infrastructure problems caused by corrosion and harsh atmospheric conditions. NDT TECHNIQUE TO CHECK GRAPHITIZATION OF DUCTILE AND CASTIRON WATER MAINS Mehrooz Zamanzadeh, FASM* and Anil Kumar Chikkam* Matergenics Inc., Pittsburgh
ADVANCED MATERIALS & PROCESSES | OCTOBER 2024 14 Annually, the United States faces over 250,000 water main failures, leading to extensive flooding, property damage, and significant financial repercussions, including costly legal disputes and operational delays. These failures impose enormous financial burdens on municipalities, covering repair costs, mitigating flood damage, lost commercial revenue, and interruptions to essential services such as healthcare and firefighting. The economic toll on industries and municipal govern- ments is substantial, necessitating a forward-thinking approach to infrastructure maintenance (Figs. 1 and 2). DETECTING GRAPHITIZATION The core issue lies in the aging gray and cast-iron pipelines susceptible to graphitization—a form of corrosion that weakens the pipes’ structural integrity (Fig. 3). Traditional maintenance methods are largely reactive, addressing problems only after failures occur, leading to high expenses associated with emergency repairs and collateral damage. This highlights the critical need for proactive strategies to identify and address potential issues before they become catastrophic. An innovative solution to these challenges is the “Zee Probe” (Fig. 4). Designed to detect graphitization in active pipelines, it identifies areas at risk of major failures early on. By using indirect methods like GIS mapping, in-situ soil resistivity testing, and structure-to-soil potential measurements, high-risk zones can be pinpointed. Once these areas are identified, the probe assesses the severity and depth of graphi- tization, providing a comprehensive evaluation of the pipeline’s condition. This allows for the implementation of effective corrosion management strategies, including cathodic protection systems, to prevent critical failures. The Zee Probe operates on the principle of inductance variation. It features a compact inductor with a ferrite core, wrapped in multiple layers of magnet wire. This configuration is adept at detecting changes in graphitization levels within cast-iron pipes by accurately measuring inductance shifts during surface scans (Fig. 5). The adoption of advanced diagnostic tools like this unique probe marks a significant shift from reactive to proactive maintenance strategies for municipalities. This approach optimizes resource utilization and enhances the reliability of water supply systems, ensuring public health and safety. Developed by engineers and researchers at Matergenics, which focuses on infrastructure resilience and public safety, this novel probe represents a significant advancement in water infra- structure maintenance. Its proactive approach aims to shift the paradigm from reactive to preventive maintenance, promising to improve the safety and reliability of water supply systems while reducing economic impacts associated with water main corrosion. Fig. 1 — Photograph showing water main break. Fig. 2 — Photographs showing the pieces of a broken water main. Fig. 3 — Photographs showing the depth of corrosion. Fig. 4 — Photograph showing the Zee Probe.
ADVANCED MATERIALS & PROCESSES | OCTOBER 2024 15 The Zee Probe offers several technological advancements: Nondestructive testing (NDT) advancement. It provides a specialized, nondestructive means to detect graphitization within cast/gray iron pipelines. Unlike traditional NDT methods, the probe offers a targeted approach, specifically designed to identify and assess the extent of graphitization, representing a leap forward in precision and utility for infrastructure maintenance. Preventive maintenance enhance- ment. By enabling early detection of graphitization, the probe facilitates a proactive maintenance strategy. This shift allows for timely intervention before catastrophic failures occur, enhancing the safety and reliability of water distribution networks and contributing to substantial cost savings by reducing the need for emergency repairs and extending the lifespan of existing infrastructure. Advanced sensing technology integration. The probe incorporates sophisticated sensing technology based on the principle of inductance variation, demonstrating an innovative application of electromagnetic principles to solve real-world problems. This integration represents a significant technological gain, pushing the boundaries of sensor capabilities and expanding their application to critical areas of public infrastructure. Infrastructure resilience contribution. The deployment of the probe significantly contributes to the resilience of water infrastructure. By providing a tool for early detection of graphitization, it directly impacts the longevity and reliability of critical water supply systems, ensuring the continued delivery of safe water services and the protection of public health. CASE STUDY A 54-inch cast-iron water main was exposed to atmospheric conditions and had been in service since the 1940s. The purpose of the investigation was Fig. 5 — Photograph showing the working principle of the sensor. Fig. 6 — Three sections selected for condition assessment. Fig. 7 — Section 2 was prepared for focus measurements. Fig. 8 — Pack layers of rust and dark graphitic-looking surface underneath. Fig. 9 — Cast-iron flange exhibiting extensive graphitization and cracking. Fig. 10 — Typical magnetic flux measurement using Zee Probe. Fig. 11 — Electrochemical potential measurement indicating graphitic corrosion.
ADVANCED MATERIALS & PROCESSES | OCTOBER 2024 16 to evaluate the condition of the pipe without causing any damage. To achieve this, various nondestructive techniques were employed, including visual examination, electrochemical potential measurements, magnetic flux measurements using the patented Zee Probe, hardness measurements, and onsite replication or field metallography replication (FMR) (Figs. 6-11). For a better understanding of the results, the test findings are tabulated and shown in Table 1. Both onsite replication and hardness measurements indicated the presence of graphitic corrosion. See the photo- micrographs in Figs. 12-14, and hardness measurements (Table 2). Field metallography clearly showed that the castiron pipe section is partially graphitized (Figs. 12 and 13), and the flange section is graphitized at the surface (Fig. 14). By conducting this comprehensive assessment of the cast-iron water main that was exposed to atmospheric conditions, the goal was to gain valuable insights into the condition of the castiron water main and identify any potential issues or areas that might exhibit accelerated corrosion. A nondestructive approach gathered crucial data without causing any harm to the pipe, ensuring its continued functionality and reliability. All indications from testing are that accelerated surface corrosion is occurring. There is a graphitic layer and graphitic corrosion present on this cast-iron pipe. It is essential to emphasize that if the cast-iron pipe, which is exposed to the atmosphere, is showing evident signs of graphitic corrosion, the buried section of the pipe exposed to corrosive soil and reducing conditions is likely experiencing even more severe external corrosion. The internal corrosion of the pipe section would be comparable in both the segments exposed to the soil and the atmosphere since the internal surface is exposed to the same water in both cases. To understand graphitic corrosion, it is essential to grasp the structure of cast iron. Cast iron is an alloy of iron, carbon, silicon, and other elements. The microstructure of cast iron consists of graphite flakes embedded in a matrix of iron. The presence of graphite imparts desirable properties to cast iron, such as improved machinability and damping capacity. However, when exposed to corrosive conditions, the iron (ferrite and or pearlite phase) in the cast-iron material can react with certain elements, most notably oxygen TABLE 1 — CAST-IRON PIPE INSPECTION DATA Cast-iron pipe section Visual Electrochemical potential readings, V Zee Probe readings Observations 1 Brown surface -0.13 7 Graphitic corrosion 2 Dark brown surface -0.032 9 Graphitic corrosion 2 Dark surface -0.031 8 Graphitic corrosion 2 Brown surface -0.140 7 Graphitic corrosion 3 Brown and dark surface -0.028 8 Graphitic corrosion TABLE 2 — VICKERS HARDNESS DATA Reading Location Hardness values, HV 1 Unaffected CI pipe 256 2 282 3 311 4 268 5 Graphitized area 161 6 108 Fig. 12 — Non-affected structure. Fig. 13 — Partial graphitization of the iron/ pearlite phase can be clearly seen. Fig. 14 — Flange graphitized at the surface.
ADVANCED MATERIALS & PROCESSES | OCTOBER 2024 1 7 and various ions, present in the surrounding environment. The corrosion process leads to the conversion of the iron into corrosion products (rust). This results in degradation of the material, which can compromise the structural integrity of the cast-iron pipe over time. A summary of the inspection of selected cast-iron pipe sections exposed to the atmospheric conditions follows: • Visual inspection: Corrosion products of iron and graphitized layers. • Potential measurement: Positive potential readings indicating graphitization. • Magnetic flux measurements: Low flux numbers indicating graphitization. • FMR: Graphitization was clearly observed. • Hardness measurements: Graphitized areas had lower Vickers hardness numbers. SUMMARY In conclusion, the Zee Probe graphitization detection sensor represents a significant leap forward in the management and maintenance of water infrastructure. Its technological advancements and proactive approach to maintenance offer substantial benefits, including enhanced public health and safety, economic stability, resource conservation, and ecological preservation. By shifting the maintenance paradigm from reactive to preventive, the probe not only improves the reliability and longevity of water distribution systems but also fosters a more sustainable and resilient infrastructure for the future. ~AM&P For more information: Mehrooz Zamanzadeh (Dr. Zee), technical director, Matergenics Inc., 100 Business Center Dr., Pittsburgh, PA 15205, 412.788.1263, zee@matergenics.com. HYDROGEN EMBRITTLEMENT AND SENTRY SENSOR Michael McGuire, Mehrooz Zamanzadeh, FASM, Anil Kumar Chikkam, and Farzan Zolfaghari Matergenics Inc. Hydrogen embrittlement (HE) is a mechanical degradation phenomenon that affects metals, particularly high-strength steels and other alloy materials. It occurs when hydrogen atoms are absorbed into the metal, leading to a reduction in the ductility and toughness of the material. This absorption can cause the material to become brittle and susceptible to cracking under stress, even if the stress is below the yield strength of the material. Hydrogen embrittlement is a critical concern in industries such as aerospace, automotive, and construction, where material integrity is paramount. Based on a breakthrough in hydrogen embrittlement theory, Matergenics has developed a sensor that measures hydrogen in a steel in real time and transmits the data wirelessly. The sensor also allows for warning levels to be set before a critical combination of hydrogen content and stress intensity is reached, generally in the 100 to 200 wppm level for crack tip regions. Traditionally, total hydrogen is only measured destructively, by collecting the gas in a heated sample. Even this method is too gross to sense hydrogen concentration in critical regions, such as local stress concentrations. Measuring it at a specific site is itself a breakthrough, and with Matergenics monitoring the output, incipient hydrogen cracking can be alarmed in time to take preventive action. The new sensor was designed with traditional areas of hydrogen embrittlement in mind: storage vessels, gas transmission lines, and any structure with cathodic protection. Now, the advent of hydrogen as the clean fuel of the future opens up a new range of needs to monitor hydrogen and prevent its damage. Matergenics plans to have prototypes in the United States and Italy later this year, while it works with partners in key industries. Sentry sensor. ENGINEERING MATERIALS ACHIEVEMENT AWARD Dr. Mehrooz Zamanzadeh, FASM, Mr. Anil Kumar Chikkam, Ms. Carolyn Tome, Mr. Nathan Pace, Mr. Chris Desmond, Mr. Farzan Zolfaghari, and Dr. Peyman Taheri, from Matergenics Materials and Energy Solutions, Pittsburgh, received the 2024 Engineering Materials Achievement Award (EMAA) from ASM International for one of their patented sensors. Specifically, the team was recognized for their “Advanced Sensor for Real-Time Monitoring of Temperature and Corrosion, Capable of Withstanding 2000°F and Delivering Essential Data Before, During, and Following Exposure to Wildfires.” Established in 1969, the EMAA recognizes an outstanding achievement in materials or materials systems relating to the application of knowledge of materials to an engineering structure or to the design and manufacture of a product.
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