20 25 29 P. 14 ASM Welcomes New President Advanced Characterization of High Entropy Alloys Using AI to Enhance Computed Tomography CYMBAL MAKING PART II: THE ART OF BRONZE METALWORKING EMERGING ANALYSIS METHODS JANUARY/FEBRUARY 2025 | VOL 183 | NO 1
INTERNATIONAL CONFERENCE ON ADVANCES IN MATERIALS, MANUFACTURING & REPAIR FOR POWER PLANTS (EPRI) FEBRUARY 25 – 28, 2025 | INDIAN WELLS (PALM SPRINGS), CALIFORNIA As the world undergoes an energy transformation, the safe, reliable, affordable, 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-efficiency power conversion technologies. INTERNATIONAL THERMAL SPRAY CONFERENCE & EXPOSITION (ITSC) MAY 5 – 8, 2025 | VANCOUVER, CANADA ITSC is the world’s foremost international conference and exhibition for thermal spray technologists, researchers, manufacturers, and suppliers. This conference rotates between North America, Europe, and the Pacific Rim and is organized by the ASM Thermal Spray Society, the German Welding Society (DVS), and International Institute of Welding (iiw). 3RD INTERNATIONAL CONFERENCE ON QUENCHING & DISTORTION ENGINEERING (QDE) MAY 6 – 7, 2025 | VANCOUVER, CANADA This event is the global gathering for professionals and researchers in the field of quenching and distortion engineering. Join us for an immersive experience filled with cutting-edge research presentations, insightful discussions, and unparalleled networking opportunities. AEROMAT MAY 6 – 8, 2025 | VANCOUVER, CANADA AeroMat focuses on innovative aerospace materials, fabrication, and manufacturing methods that improve performance, durability, and sustainability of aerospace structures and engines with reduced life-cycle costs. 2ND SHAPE MEMORY & SUPERELASTIC TECHNOLOGIES (SMST) IRELAND MAY 22, 2025 | GALWAY, IRELAND The 2nd SMST Ireland event will be a pivotal gathering in the MedTech industry, spotlighting the dynamic role of Nitinol in design and manufacturing. With the theme “Engaging and Enabling Irish MedTech for Design and Manufacturing with Nitinol,” the conference aims to explore the transformative potential of this unique alloy in advancing medical technology. INTERNATIONAL CONFERENCE ON RESIDUAL STRESSES (ICRS) OCTOBER 20 – 23, 2025 | DETROIT, MICHIGAN Discover the forefront of residual stress research and its impact on material behavior at this enriching event. Engage with experts and practitioners across diverse fields through our symposium topics, networking opportunities, and technical programming. INTERNATIONAL MATERIALS, APPLICATIONS & TECHNOLOGIES (IMAT) OCTOBER 20 – 23, 2025 | DETROIT, MICHIGAN IMAT, ASM’s annual event, is the only targeted conference on advanced materials, applications, and technologies in key growth markets that will have a focus on economic trends and business forecasts. The event will include a diverse group of materials experts, including the ASM Programming Committees and all six of ASM’s Affiliate Societies, who are heavily involved in building the technical symposiums, which will have a strong focus on realworld technologies that can be put to use today. HEAT TREAT 2025 OCTOBER 21 – 23, 2025 | DETROIT, MICHIGAN Discover the unrivaled opportunities awaiting you at Heat Treat Conference/Expo! As the LARGEST gathering for heat treating professionals, materials experts, and industry leaders in North America, Heat Treat is a MUST-ATTEND event! INTERNATIONAL SYMPOSIUM FOR TESTING AND FAILURE ANALYSIS (ISTFA) NOVEMBER 16 – 20, 2025 | PASADENA, CALIFORNIA ISTFA is the only North American event devoted to the semiconductor, electronic sample preparation, and imaging markets. ISTFA offers the best venue for failure analysts and the FA community for sharing challenges and acquiring the technical knowledge and resources needed to take them on. Showcase your thought leadership and innovations at one of ASMʼs 2025 conferences and expositions, which offer unparalleled access to highly engaged audiences of industry leaders and decision-makers. Learn more about each event and related exhibit and sponsorship opportunities at asminternational.org/events
20 25 29 P. 14 ASM Welcomes New President Advanced Characterization of High Entropy Alloys Using AI to Enhance Computed Tomography CYMBAL MAKING PART II: THE ART OF BRONZE METALWORKING EMERGING ANALYSIS METHODS JANUARY/FEBRUARY 2025 | VOL 183 | NO 1
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:
WHAT’S IN YOUR 2025 MARKETING MIX? ASM INTERNATIONAL’S 2025 MEDIA KIT is YOUR GATEWAY to reaching a targeted audience of materials science and engineering professionals. ARE YOU READY TO EXPLORE HOW ASM CAN HELP YOU ACHIEVE YOUR 2025 GOALS? VIEW THE 2025 MEDIA KIT AT: WWW.ASMINTERNATIONAL.ORG/ADVERTISE-WITH-US-RESULTS/ ASM generates measurable impact by offering unparalleled access to engaging with a unique and motivated audience through integrated, omnichannel marketing capabilities. Develop a comprehensive campaign through sponsored emails, webinars, web and mobile ad placements, in-person event sponsorships, and more to target sizable audiences of decision makers in industries such as: Aerospace Automotive Heat Treating Materials Characterization & Testing Failure Analysis Shape Memory & Medical Devices Thermal Spray And more! KELLY “KJ” JOHANNS BUSINESS DEVELOPMENT MANAGER CONTACT KJ TODAY AT: KJ.JOHANNS@ASMINTERNATIONAL.ORG OR 440.671.3851
34 AEROMAT PROGRAM HIGHLIGHTS AeroMat brings together hundreds of aerospace professionals and exhibiting companies to discuss and display the latest advancements in aerospace materials and processes. CYMBAL MAKING: THE ART OF BRONZE METALWORKING, PART II Joseph Paul Mitchell This article, the second in a two-part series, examines the finishing processes in the manufacturing of bronze cymbals as well as technological advances incorporated in the modern age. Part I, which appeared in the May/June 2024 issue, described the first steps in the art of cymbal making. 14 ADVANCED MATERIALS & PROCESSES | JANUARY/FEBRUARY 2025 2 Close-up of cymbals engraved with the year 2025; Engraving AI generated. Courtesy of Dreamstime. On the Cover: 35 ASM NEWS The latest news about ASM members, chapters, events, awards, conferences, affiliates, and other Society activities. ARCHAEOMETALLURGICAL MATERIALS CHARACTERIZATION Omid Oudbashi and Russell Wanhill Combinations of descriptive and analytical techniques with case studies provide essential information about ancient metallic objects. 22
4 Editorial 5 Research Tracks 10 Machine Learning 6 Metals/Polymers/Ceramics 8 Testing/Characterization 11 Process Technology 12 Emerging Technology 13 Nanotechnology 47 Editorial Preview 47 Special Advertising Section 47 Advertisers Index 48 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. 183, No. 1, JANUARY/FEBRUARY 2025. Copyright © 2025 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: 13487 S. Preston Hwy, Lebanon Junction, KY 40150. 20 NAVIN MANJOORAN 2024-2025 PRESIDENT OF ASM INTERNATIONAL Meet Navin Manjooran, the new president of ASM, and learn about his professional background, service, and contributions as an industry leader. 25 UNLOCKING THE POTENTIAL OF HIGH-ENTROPY ALLOYS WITH ADVANCED CHARACTERIZATION TECHNIQUES Raja Gopala Chary Thipparthi and R.J. Immanuel As high-entropy alloys become more complex in terms of microstructure, phase stability, and complex intermetallics, the advent of sophisticated analytical instruments is helping scientists to develop new materials with the most desirable properties. 29 TECHNICAL SPOTLIGHT HOW AI CAN MAKE A DIFFERENCE IN THE REAL WORLD OF MANUFACTURING Industrial computed tomography data analysis is harnessing deep learning to both accelerate in-line inspection and build better products. FEATURES JANUARY/FEBRUARY 2025 | VOL 183 | NO 1 ADVANCED MATERIALS & PROCESSES | JANUARY/FEBRUARY 2025 3 20 29 32 25 32 PERSPECTIVE 50 YEARS OF ARCHAEOMETALLURGY World-renowned archaeometallurgist Peter Northover reflects on his career within the industry and the technological advancements he witnessed during five decades out in the field and at the microscope.
4 ADVANCED MATERIALS & PROCESSES | JANUARY/FEBRUARY 2025 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. TOP 10 MATERIALS TRENDS FOR 2025 What will 2025 have in store for us? For one, this year marks the 50th anniversary of the Henry Clifton Sorby Award, presented annually by ASM’s International Metallographic Society. Its namesake is widely considered the father of metallography and the modern-day microscope. Watch for more updates later this year on the celebration at IMAT in Detroit, including cameo appearances of many past Sorby winners. Beyond that, which materials will be paving the way in 2025? In lieu of a crystal ball, StartUs Insights uses data science to watch trends in emerging technologies. They forecast that the Top 10 advanced materials technologies most likely to lead to innovations in 2025 include: sustainable materials (reducing waste and carbon footprints with recyclable and biodegradable options); smart and responsive materials (reacting to environmental stimuli); nanotechnology (enhancing product performance at the atomic level); additive manufacturing (revolutionizing production with 3D printing); lightweighting (reducing weight with materials like carbon fiber); materials informatics (using artificial intelligence and data to accelerate materials discovery); advanced composites (offering superior properties through materials combinations); graphene and 2D materials (enhancing conductivity and strength); surface engineering (improving durability with advanced coatings); and materials management 4.0 (integrating industry 4.0 technologies for optimized material handling). Happily, this list coincides directly with the content provided in AM&P magazine. All 10 of these topics can be found in our news sections, technical articles, and the supplements on shape memory alloys and surface engineering. We also devote a whole issue to some of these topics, such as our March issue on additive manufacturing and our sustainability coverage in the July/August green materials engineering issue. AM&P will keep you abreast of the latest developments on these materials trends throughout the year. Starting with this January/February issue, the emerging technologies of sustainability and AI are covered in our technical articles. The author of “Unlocking the Potential of High-Entropy Alloys with Advanced Characterization Techniques” reviews various modern methods that allow us to make more sustainable materials. He predicts, “Within the next few decades, more advanced, stable, and greener alloy compositions will likely compete with conventional alloys for use in a broad range of engineering applications.” Addressing the artificial intelligence front, Volume Graphics provides an article on “How AI Can Make a Difference in the Real World of Manufacturing.” They cite industrial computed tomography (CT) as a helpful data tool for advanced manufacturing. Peter Northover also refers to CT and micro-CT as techniques providing results that are “simply jaw-dropping.” His article, “50 Years of Archaeometallurgy,” provides a refreshingly frank, personal reflection on the changes he has witnessed in technique and technology during five decades in the field. Just think, in another 50 years, we’ll be celebrating the centennial of the Sorby Award and ushering in a new Top 10 list of materials innovations. Wonder what will be trending then? joanne.miller@asminternational.org Henry Cli on Sorby, age 25.
ADVANCED MATERIALS & PROCESSES | JANUARY/FEBRUARY 2025 5 RESEARCH TRACKS Oak Ridge National Laboratory, Tenn., launched its Neutron Nexus pilot program with Florida Agricultural & Mechanical University and Florida State University. The program aims to broaden the scientific user community with outreach to universities and colleges to increase both collaboration and scientific advancement. ornl.gov. BRIEF DECODING COPPER DEPOSIT FORMATION A research consortium that includes The University of Western Australia (UWA), the University of Bristol, natural resources company BHP, and others is making progress on its “High Grade Hypogene Copper” initiative. The work proposes a new model for the formation of large copper deposits by decoding the metal’s origins, a discovery that could determine the future of copper mining and help meet surging global demand. Tony Kemp, associate professor at UWA, says researchers focused on the formation of copper deposits beneath volcanic chains where tectonic plates converge, a process known as flat slab subduction. “This phenomenon causes the sinking plate to heat up and release fluids, which then percolate into the overlying plate, melting it and channeling copper and other metals upwards to form ore deposits,” he explains. “Recognizing areas where flat slab subduction has occurred in the past is crucial for discovering new copper resources.” The study also highlighted the importance of precise dating of copper deposits using a radiometric laser- based technique developed by UWA research fellow Dan Bevan while he was at the University of Bristol. The method, which is now being implemented at UWA, allows researchers to link copper deposits to specific geological events, providing a clearer understanding of their formation. www.uwa.edu.au. SPECIAL TRANSISTORS LISTEN FOR DEFECTS A research team led by NYU Tandon School of Engineering and KAIST (Korea Advanced Institute of Science and Technology) developed a new technique to identify and characterize atomic-scale defects in hexagonal boron nitride (hBN), a 2D material often called “white graphene” due to its impressive properties. The team believes this advance could accelerate de- velopment of next- generation electronics and quantum technologies. The researchers report they A new technique is able to characterize atomic-scale defects in hBN. Courtesy of ACS Nano, doi.org/10.1021/acsnano.4c06929. were able to detect the presence of individual carbon atoms replacing boron atoms in hBN crystals, a discovery made possible by listening to the electronic noise in specially designed transistors. “In this project, we essentially created a stethoscope for 2D materials,” explains NYU’s Davood Shahrjerdi. “By analyzing the tiny and rhythmic fluctuations in electrical current, we can ‘perceive’ the behavior of single atomic defects.” The NYU team built a transistor using a few-layer thin molybdenum disulfide sandwiched between layers of hBN. By cooling this device to cryogenic temperatures and applying precise electrical voltages, researchers were able to observe discrete jumps in the current flowing through the transistor. By carefully analyzing these signals at different temperatures and voltages, the team was able to determine the energy levels and spatial locations of the defects. The KAIST team then used advanced computer simulations to clarify the atomistic origins of the experimental observations. nyu.edu. Dan Bevan developed a radiometric laser-based technique for precise dating of copper deposits. Courtesy of UWA.
ADVANCED MATERIALS & PROCESSES | JANUARY/FEBRUARY 2025 6 METALS | POLYMERS | CERAMICS Constellium concluded its “ISA3” R&D project, initiated in 2021 to enhance automotive lightweighting. Renault Group, ESI Group, the Institut de Soudure, and the University of Lorraine contributed to the research. A major outcome of ISA3 is a lightweight aluminum door, co-developed with Renault, using Constellium’s uni-alloy 6xxx products. constellium.com. MORE ACCURATE FATIGUE LIFE PREDICTION FOR METALS A team of researchers from Pusan National University, South Korea, developed a method to more accurately predict the fatigue life of magnesium alloys by integrating machine learning with energy-based physical modeling. The model was built using a large dataset of hysteresis loops—the stress-strain behaviors observed during repeated loading and unloading of the material— collected from low-cycle fatigue tests of the AZ31 magnesium alloy. Instead of predicting fatigue life directly, the neural network estimates hysteresis loops for the material under different conditions. By reconstructing these loops, it can more accurately assess how the material’s energy is dissipated during each cycle of loading and unloading, which is directly related to how quickly fatigue will accumulate. Then, the physics-based model converts these stress cycle predictions into a reliable estimate of the number of cycles to failure, or the fatigue life of the alloy. With the advent of this new approach, manufacturers could soon benefit from greater predictive reliability when working with magnesium alloys, enabling safer, lighter, and more cost-effective designs in high-stakes environments. The model offers a more streamlined and accurate approach to the fatigue life prediction of MAKING HIGH-VALUE ALLOYS WITH METAL SCRAP Researchers at the DOE’s Pacific Northwest National Laboratory (PNNL), Richland, Wash., found a way to directly transform and upgrade metal scrap into high-performance, high-value alloys without the need for conventional melting processes. They demonstrated that upcycled aluminum from industrial waste streams performs on par with identical materials produced from primary aluminum, indicating that this approach can provide a low-cost pathway to bringing more high-quality recycled metal products to the marketplace. The innovative solid phase alloying process converts aluminum scrap blended with copper, zinc, and magnesium into a precisely designed high-strength aluminum alloy product in a matter of minutes, compared to the days required to produce the same product utilizing conventional melting, casting, and extrusion. The research team used a PNNL-patented technique called Shear Assisted Processing and Extrusion, or ShAPE, to achieve their results. They say that the findings should be reproducible with other solid phase manufacturing processes. The team used both mechanical testing and advanced imagery to examine the internal structure of the upcycled materials produced by solid phase alloying. Their results showed that the ShAPE upcycled alloy is 200% stronger and has increased ultimate tensile strength when compared with conventional recycled aluminum. The solid phase alloying process could be used to create custom metal wire alloys for various 3D printing technologies, the researchers say. pnnl.gov. Cleveland-Cliffs Inc., Cleveland, acquired Stelco Holdings Inc., Hamilton, Ontario, expanding Cliffs’ presence in Canada as the top flat-rolled steel producer. Stelco will continue operations as a subsidiary of Cliffs, preserving Stelco’s name and Canadian legacy. clevelandcliffs.com. BRIEFS New aluminum car door achieves 14% weight reduction. Courtesy of Constellium. An innovative solid phase alloying process eliminates the costly and energy-intensive melting, casting, and extrusion process currently used in aluminum recycling. Courtesy of PNNL.
ADVANCED MATERIALS & PROCESSES | JANUARY/FEBRUARY 2025 7 magnesium alloys that could lead to enhanced safety and longevity of critical components in real-world applications. www.pusan.ac.kr/eng. SHAPE-CHANGING POLYMER BEHAVIOR SHIFTS WITH TEMPERATURE Using a liquid crystalline elastomer (LCE), scientists at The Ohio State University (OSU) in Columbus created a new shape-changing polymer that could transform how future soft materials are constructed. The LCE material, or mesogen, is a soft rubberlike material that can be stimulated by external forces like light or heat, and the polymer is so versatile that it can move in several directions. Resembling animal-like movements, its behavior includes the ability to twist, tilt left and right, shrink, and expand, the researchers report. The new polymer’s ability to change shapes could make it useful for creating soft robots or artificial muscles, among other high-tech applications in various fields. Today, liquid crystals are most often used in TVs and cellphone displays, but these materials often degrade over time. With the expansion of LEDs, many researchers are focused on developing new uses for liquid crystals. Unlike conventional materials that can only bend in one direction or require multiple components to create intricate shapes, the team’s polymer is a single component that can twist in two directions. According to the team, one of the study’s most important findings reveals the three phases that the material goes through as its temperature changes. Throughout these phases, molecules shift and selfassemble into different configurations. If scaled up, the polymer in this study could potentially advance several scientific fields and technologies, including controlled drug delivery systems, biosensor devices, and as an aid in complex locomotion maneuvers for next-generation soft robots. osu.edu. An all-atom representation of the initial system with mesogens randomly placed in a simulation box. The mesogen repack in various way during subsequent phases. Courtesy of OSU. www.masterbond.com WHY USE A NANOREINFORCED EPOXY? KEY BENEFITS of nanosilica filled EPOXY EP30NS Optically clear | Refractive index: 1.56 NASA low outgassing | ASTM E595 Dimensionally stable | Hardness: 80-90 Shore D Abrasion resistant | ASTM D466-14 Hackensack, NJ 07601 USA ∙ +1.201.343.8983 ∙ mainmasterbond.com 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
8 ADVANCED MATERIALS & PROCESSES | JANUARY/FEBRUARY 2025 studying the fiber-scale properties of parachute textiles. The team says that if the parachute’s performance is considered the macro scale, a bundle of fibers is the mesoscale, and an individual fiber represents the microscale. The goal was to quantify what was going on at those smaller scales and link that behavior to the forces happening on the larger scale. At each new level of force, micro-CT scans were taken while samples were kept under stress. Tensile testing showed how fibers stretched, straightened, and reorganized with increasing loads. As the fiber bundles changed shape, the pores between them widened, thus altering how air would flow through and around the parachute. When a textile has the same number of the same type of fibers going both directions, it is expected to be isotropic. However, the researchers observed that the textiles had different properties in different directions. During weaving, the fibers running in one direction (the warp) are held in tension on a loom, while the fibers running perpendicular to them (the weft) are slid in between the first set of fibers. Even after the textile is removed from the loom, the differences in tension TESTING | CHARACTERIZATION FASTER FAILURE DETECTION IMPROVES EV SAFETY Electric vehicles (EVs) have systems to detect performance issues with lithium-ion batteries. However, these systems are not focused on imminent safety concerns—like when the battery is about to catch on fire. Now, researchers at Sandia National Lab, Albuquerque, are working to detect these failures early and provide sufficient warning to vehicle occupants. Current measurements in battery management systems capture temperature and voltage, but these are lagging indicators of safety issues. The researchers are working on a diagnostic system that extends the warning period, allowing time to park and exit the vehicle. Their goal is to integrate this system into the car’s dashboard. To this end, the team is testing commercial off-the-shelf diagnostics on single cells and battery packs at the Battery Abuse Testing Laboratory. Beyond warning systems for EV batteries, the team says their techniques to detect failure markers have potential applications in grid energy storage systems. For now, researchers will continue to the next phase of their EV battery failure detection research—understanding the limitations and applying machine learning algorithms to datasets. Another focus area is advancing sensor technology to the point that the sensors issue more than warnings. “These tools can also activate mitigation measures,” explains researcher Loraine Torres-Castro. “For instance, upon receiving a warning, the system could trigger the thermal management system of the battery to start cooling it down.” sandia.gov. CT SCANS PROBE PARACHUTES Using computed tomography (CT) scans, researchers at the University of Illinois Urbana-Champaign are Triangular holes make this material more likely to crack from left to right. Courtesy of N.R. Brodnik et al./Phys. Rev. Lett. Tescan Group reopened its R&D facility in Tempe, Ariz., adding space to showcase the company’s latest electron microscopy technologies. The lab features the Tescan Tensor STEM and the new Solaris 2 FIB-SEM. Equipment demonstrations and support are available to customers in materials science and semiconductor R&D, failure analysis, and process monitoring. tescan.com. BRIEF From left: Francesco Panerai, Cutler Phillippe, and Laura Villafañe Roca utilize a micro-CT scanner at the Beckman Institute in their study of parachutes. Courtesy of Lauren Otolski/Beckman Communications Office. Sandia’s Alex Bates and Loraine Torres-Castro discuss the positioning of a battery that is being examined at the Battery Abuse Testing Lab. Courtesy of Craig Fritz.
ADVANCED MATERIALS & PROCESSES | JANUARY/FEBRUARY 2025 9 during manufacturing result in it not being isotropic. Specifically, the fabric is more resistant to being stretched in the direction of the warp fibers. Parachutes are made of different textile pieces attached to each other, and the orientation of these pieces influences the overall properties. This research informs models that will be used to identify promising textiles. illinois.edu. LIQUID REPELLENT MICROSTRUCTURES Scientists at Griffith University, Australia, are exploring the potential of re-entrant microstructures to repel water and other liquids from their surfaces, making new strides in understanding the behaviors of these advanced surface structures. The breakthrough could impact a wide range of industries, from self-cleaning materials to medical devices. The research revealed how factors such as shape, material, and spacing of these microstructures influenced their ability to resist wetting or liquid spreading. The team focused on two materials, silicon dioxide (SiO ) and silicon carbide (SiC), which each offered unique properties. While SiC is known for its inherent hydrophobic nature, the researchers found the overall geometry—especially the spacing and shape of these tiny cap-like structures—played a more significant role in influencing liquid behavior than the type of material itself. They found re-entrant structures with larger gaps between them effectively trapped air pockets, enhancing water repellence and preventing the liquid from fully wetting the surface. This balance between material properties and structure provided new insight on designing liquid-repellent surfaces. Researchers say these findings could open doors to creating materials that can withstand extreme conditions, such as high temperatures or harsh chemicals, using materials like silicon carbide. www.griffith.edu.au. SEM image of a single re-entrant structure with a circular SiO2cap; scale bar: 5 µm. Courtesy of Gri ith University. 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
ADVANCED MATERIALS & PROCESSES | JANUARY/FEBRUARY 2025 10 MACHINE LEARNING | AI The new “Chatbots Decoded: Exploring AI” exhibit at the Computer History Museum, Mountain View, Calif., explores why chatbots matter. Ameca, a robot from Engineered Arts that uses hardware, sensors, and large language models like Open AI’s GPT-4, will interact with visitors. computerhistory.org. BRIEF MACHINE LEARNING ENHANCES DEFECT DETECTION Researchers from Northwestern University, University of Virginia, Car- negie Mellon University, and Argonne National Laboratory made a signi- ficant advancement in defect detec- tion for laser powder bed fusion (LPBF) additive manufacturing. By using sensors such as microphones and photodiodes along with machine learning, they achieved over 90% accuracy with a temporal resolution of 0.1 ms in detecting keyhole pore formation. This breakthrough could lead to a faster certification process for metal AM parts. Detecting keyhole pores in real- time during the printing process has been challenging due to the speed and complexity of LPBF. To address this, the team developed a machine learning-based approach that uses light and sound sensors to monitor the printing process and accurately detect when and where keyhole pores form. The key to this method lies in measuring the oscillations of the keyhole, a vapor depression formed in the melt pool during printing. High-speed synchrotron x-ray imaging was used to help train the machine learning model to recognize conditions that lead to pore formation. With this approach, manufacturers could detect defects during printing, allowing for adjustments to prevent production of flawed parts. northwestern.edu. AI LISTENS FOR BATTERY ABOUT TO CATCH FIRE Researchers at the National Insti- tute of Standards and Technology (NIST) are using sound to detect when lithium- ion batteries are about to catch fire— especially dangerous because a battery can emit a flame up to 2012°F in about a second. “While watching videos of exploding batteries, I noticed something interesting,” says researcher Andy Tam. “Right before the fire started, the safety valve in the battery broke and it made this little noise. I thought we might be able to use that.” Tam was A new method detects keyhole pore formation in laser powder bed fusion. Courtesy of Northwestern University. not the first to make this observation, but he wanted to see what he could do with it. Many of the hard casings used on Li-ion batteries contain a safety valve designed to break and release pressure when needed. This breaking valve is the sound Tam heard in the videos, a distinctive click-hiss. The researchers needed software that could recognize this sound and not detect other noises, so they trained a machine learning algorithm. Through a collaboration with Xi’an University of Science and Technology, they recorded audio from 38 exploding batteries. Then they tweaked those recordings into more than 1000 unique audio samples to teach the software what a breaking safety valve sounds like. Using a microphone mounted on a camera, the team detected the sound of an overheating battery 94% of the time. nist.gov. An experiment records the sounds a Li-ion battery makes before and during thermal runaway. Courtesy of Xi’an University.
ADVANCED MATERIALS & PROCESSES | JANUARY/FEBRUARY 2025 1 1 PROCESS TECHNOLOGY RECYCLING RESTORES SPENT CATHODE MATERIALS Researchers at the Korea Institute of Energy Research (KIER) developed a new technology to directly recycle spent cathode materials from lithium- ion batteries through a simple process that addresses the limitations of conventional recycling methods. Their approach restores the spent cathode to its original state by immersing it in a restoration solution under ambient temperature and pressure, effectively replenishing lithium ions. The bromine in the restoration solution initiates spontaneous corrosion upon contact with the aluminum in the spent battery. During this process, work could help meet the surging demand for lithium and paves the way for more sustainable extraction practices. Studies conducted on brines from China’s Longmu Co Lake and Dongtai Lake show how the method could efficiently extract lithium from lowgrade brines with high magnesium content. Key to the innovation is a type of nanofiltration that uses a selective chelating agent to separate lithium from other minerals, especially magnesium, which is often present in brines and difficult to remove. “Our technology achieves 90% lithium recovery, nearly double the performance of traditional methods, while dramatically reducing the time required for extraction from years to mere weeks,” says researcher Zhikao Li. The process also turns leftover magnesium into a high-quality product that can be sold, reducing waste and environmental impact. monash.edu. electrons are released from the corroded aluminum and subsequently transferred to the spent cathode material. To maintain charge neutrality, lithium ions in the restoration solution are inserted into the cathode material. This recovery of lithium ions restores the cathode material to its original state. In addition, unlike conventional methods that require disassembly of the spent battery, the restoration reaction takes place directly within the cell, significantly enhancing the efficiency of the recycling process. After testing the electrochemical performance, researchers confirmed that the restored cathode achieved a capacity equivalent to that of new materials. www.kier. re.kr/eng. MINING LITHIUM FROM HARSH ENVIRONMENTS Engineers at Monash University, Australia, developed a new method that enables direct lithium extraction from difficult-to-process sources such as salt water. The innovative technology, called EDTA- aided loose nanofiltration (EALNF), extracts both lithium and magnesium simultaneously, unlike traditional methods that treat magnesium salts as waste. Researchers say the Alloy Enterprises, Burlington, Mass., expanded its headquarters and fabrication facility. The production area features new stack forging equipment to meet increasing demand for complex aluminum components. More testing, inspection, and machining capabilities were also added. alloyenterprises.co. Asahi Kasei Corp., Tokyo, broke ground on its new lithium-ion battery separator manufacturing facility in Port Colborne, Canada. The plant will operate as a joint venture with Honda Motor Co. Ltd. and will begin production in 2027. asahi-kasei.com. BRIEFS The research team conducts an experiment by immersing spent cathode material in a restorative solution. Courtesy of KIER. Graphical depiction of selective binding and filtration of binarycation brine. Courtesy of Nature Sustainability, 2024, doi.org/ 10.1038/s41893-024-01435-2.
ADVANCED MATERIALS & PROCESSES | JANUARY/FEBRUARY 2025 12 MATERIAL CONVERTS VIBRATIONS INTO ELECTRICITY Researchers at Rensselaer Polytechnic Institute (RPI), Troy, N.Y., are developing environmentally friendly materials that produce electricity when compressed or exposed to vibrations— think streetlights powered by the rumble of passing traffic or skyscrapers that generate electricity as they sway in the wind. The team developed a polymer film infused with a special chalcogenide perovskite compound that produces electricity when squeezed or stressed, a phenomenon known as the piezoelectric effect. While other piezoelectric materials currently exist, this is one of the few high performing ones that doesn’t contain lead, making it an excellent candidate for use in machines, infrastructure, and biomedical applications. The energy-harvesting film—only 0.3 millimeters thick—could be integrated into a wide variety of devices, machines, and structures, the scientists say. “Essentially, the material converts mechanical energy into electrical energy—the greater the applied pressure load and the greater the surface area over which the pressure is applied, the greater the effect,” explains researcher Nikhil Koratkar. The piezoelectric effect occurs in materials that lack structural symmetry. Under stress, piezoelectric materials deform in such a way that causes positive and negative ions within the material to separate. This dipole moment can be harnessed and turned into an electric current. Once they synthesized their new material, which contains barium, zirconium, and sulfur, the researchers tested its ability to produce electricity by subjecting it to various bodily movements, such as walking, running, clapping, and tapping fingers. The researchers found that the material generated electricity during these experiments, enough to power banks of LEDs that spelled out RPI. Moving forward, Koratkar’s lab will explore the entire family of chalcogenide perovskite compounds in the search for those that exhibit an even stronger piezoelectric effect. They’re also aiming toward implementing these materials at scale, where they can make a difference in more sustainable energy production. rpi.edu. EMERGING TECHNOLOGY IMPROVING SEMICONDUCTOR FUNCTIONALITY At the City University of Hong Kong, researchers are enhancing the mobility of positively charged carriers, known as holes, in inorganic semiconductors. The research team achieved this breakthrough by employing an innovative inorganic blending strategy, combining various intrinsic p-type inorganic materials into a single compound, called tellurium-selenium- oxygen (TeSeO). The TeSeO materials have shown remarkable adaptability and reliability, positioning them as a promising solution to address challenges with current semiconductors. According to lead researcher Johnny Ho, the team successfully developed air-stable, high-mobility TeSeO thin-film transistors and flexible photo- detectors that surpass conventional p-type semiconductors, such as metal oxides, metal halides, and organic materials. Ho says these new devices exhibit remarkable durability and performance, setting a new benchmark in the field, and opening new possibilities for creating high-performance and cost-effective devices and circuits in the future. www.cityu.edu.hk. ASTM International will launch a center of excellence to support standardization of critical and emerging technologies. Through a competitive process, the National Institute of Standards and Technology chose ASTM to lead this center along with several other partners. The $15 million grant will be used to focus on standards that support U.S. competitiveness and national security. astm.org. BRIEF The RPI team’s device that produces electricity when stressed could be used in a shoe that lights up when the user walks. Courtesy of RPI. Inorganic blending strategy of TeSeO semiconducting materials. Courtesy of Y. Meng et al.
ADVANCED MATERIALS & PROCESSES | JANUARY/FEBRUARY 2025 13 UNDERSTANDING DEGRADATION IN MICROELECTRONICS Researchers at the University of Minnesota Twin Cities, Minneapolis, gained new insights into how next-generation electronics, including memory components in computers, breakdown or degrade over time. Understanding the reasons for degradation could help improve efficiency of data storage solutions, which are increasing in demand as computing technology continues to rapidly advance. Spintronic magnetic tunnel junctions (MTJs)—nanostructured devices that use the spin of the electrons to improve hard drives, sensors, and other microelectronics systems, including magnetic random access memory (MRAM)—create promising alternatives for the next generation of memory devices. MTJs have been the building blocks for the nonvolatile memory in products like smart watches and in-memory computing with promise for applications to improve energy efficiency in AI. Using a sophisticated electron microscope, researchers looked at the nanopillars within these systems, and ran a current through the device to see how it operates. As researchers increased the current, they were able to observe how the device degrades and eventually dies in real time. They discovered that over time with a continuous current, the layers of the device get pinched and cause the device to malfunction. Previous work theorized this, but this is the first time researchers have been able to observe the phenomenon. Once the device forms a pinhole—the pinch—it’s in the early stages of degradation. As the researchers add more and more current to the device, it melts down and completely burns out. Looking more closely at the device at the atomic scale, researchers realized materials that small have very different properties, including melting temperatures. This means that the device will completely fail at a very different time frame than anyone has known before. “There has been a high demand to understand the interfaces between layers in real time under real working conditions, such as applying current and voltage, but no one has achieved this level of understanding before,” says researcher Jian-Ping Wang. twin-cities.umn.edu. TECHNIQUE TO MASS PRODUCE METAL NANOWIRES A new technique for growing tiny metal nanowires (NWs) for use in next-generation electronics was NANOTECHNOLOGY A pinhole’s degradation within a device is now observable. Courtesy of Mkhoyan Lab/University of Minnesota. developed by a group of researchers from Nagoya University in Japan. Their results suggest a way to mass produce pure metal NWs. The new method promises to enhance the efficiency of electronics production, including circuitry, LEDs, and solar cells. Until now, mass production of pure metal NWs has been challenging because of the difficulties of scaling production while maintaining quality and purity. NWs are so small that they are made by transporting atoms—typically in a gas phase state. However, this process is difficult to apply to metals, hindering the production of these important electronic components. To overcome this problem, the researchers used atomic diffusion in a solid phase state enhanced by ion beam irradiation to create aluminum NWs from single crystals. Using ion beams, the crystal grains were irradiated inside the thin aluminum film to coarsen them at the surface layer. This caused changes in stress distribution, guiding atomic flow, and was used as a means of supplying mass atomic feedstocks for NW growth to specific locations. In practice, when heat was applied, there was an upward flow of atoms through the gradient from the fine grains on the bottom to the coarse ones on top, resulting in mass growth of NWs. en.nagoya-u.ac.jp. Scientists at the DOE’s Pacific Northwest National Laboratory, Richland, Wash., achieved a uniform 2D layer of silk protein fragments on graphene. They say the discovery provides a reproducible method for silk protein self-assembly essential for designing and fabricating silk-based electronics. pnnl.gov. BRIEF Metal atom di usion leads to the growth of aluminum nanowires. Courtesy of Nagoya University.
ADVANCED MATERIALS & PROCESSES | JANUARY/FEBRUARY 2025 14 METALWORKING *Member of ASM International This article, the second in a two-part series, examines the finishing processes in the manufacturing of bronze cymbals as well as technological advances incorporated in the modern age. Part I, which appeared in the May/June 2024 issue, described the first steps in the art of cymbal making. CYMBAL MAKING: THE ART OF BRONZE METALWORKING, PART II Joseph Paul Mitchell* Avedis Zildjian Co. Inc., Norwell, Massachusetts
ADVANCED MATERIALS & PROCESSES | JANUARY/FEBRUARY 2025 15 This article concludes a two-part series on the bronze cymbal making process as performed by ancient metalworkers and modern cymbalsmiths. The process is described and examined through both historical context and cymbal metallurgy. The culture and metalworking traditions of a country influence the type of cymbals made, the manner in which musicians play them, and how these instruments are used in society. The cymbals examined for this article are of Turkish origin and manufactured using ancient practices, which remain largely unchanged. The Turkish process of cymbal making begins by melting a tin-copper combination and pouring the molten metal into open molds (bowls)—one casting per mold. The chemical composition of the bronze is ~20% Sn and ~80% Cu. The basic process of casting, rolling, hammering, and lathing (metal turning) remains customary practice in modern times with only minor changes, for example, the use of machinery powered by electrical, pneumatic, or hydraulic technology. Beginning in the late 18th century, at which time modern rolling methods appear, the introduction of two-high rolling mills (i.e., two horizontal rolls, one over the other, each roll turning opposite the other) for hot rolling iron would eventually be adapted by cymbalsmiths, who used the two-high mills for reducing bun castings into specific sized blanks. This new practice of hot rolling, working the hot metal above crystallization temperature, provided much improved gauge-thickness consistency as well as accurate dimensional tolerances and allowed development of specific reduction schedules. The applied force of the rolls reduced material thickness with each successive roll-pass, changing both the shape and internal microstructure of the castings. Following the reduction steps, cold working begins (hammering, forming, and bending). The metallurgy of two samples examined at this point in the process indicates equiaxed grain structure. The microstructure consists of copper-rich metallic grains and tin-rich grains with fine inter- metallic precipitates. Microstructure shows twinning and signs of light cold working in the metallic grains. Both samples have inclusions of varying morphologies. Using color thresholding, analysis of the phase constituents of the microstructure revealed a copper-rich alpha phase composition of 50% and 52%, respectively. The remainder of the microstructure is composed of tin-rich grains with fine intermetallic precipitates, pro- ducts of decomposition of the high-temperature Cu-Sn phase. Analysis confirms an insignifi- cant volume fraction of inclusions[1]. This type of micro- structure contributes to the ease of cold working and eventually the sound of a cymbal. FORMING PRESS Another late 18th century manufacturing advancement that helped the efficiency of cymbalsmiths and integrated into the cymbal making process is the metal forming press. The use of a machine press for hot forming a bell onto a blank, versus hammering the bell, saved much time and offered advantages including extended production runs and a consistent, if not precise bell shape, allowing a given cymbal line (same model) uniform and repeatable bell shape and, surmising downstream operations adhered to standard manufacturing practices, sound characteristics within an expected range (Table 1). For efficiency, metalworkers perform the Zildjian workers outside of early manufacturing facility, circa 1929. Seated from left: Puzant Zildjian, Aram Zildjian, Avedis Zildjian III, and Avedis Varteresian. TABLE 1 — BELL SIZE AND ASSOCIATED SOUND CHARACTERISTICS Bell shape Sound characteristics Small High pitch, short sustain Large Low pitch, long sustain Low profile Less sustain High profile Bright Thin walled Low pitch, less sustain Thick walled High pitch, more sustain
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