13th Symposium on Green and Sustainable Technologies for Materials Manufacturing and Processing: On-Demand Novel Approaches to Sustainable Manufacturing
Sponsored by: ACerS Engineering Ceramics Division
Program Organizers: Surojit Gupta, University of North Dakota; Rajiv Asthana, University of Wisconsin; Hisayuki Suematsu, Nagaoka University of Technology; Mritunjay Singh, Ohio Aerospace Institute; Enrico Bernardo, University of Padova; Yiquan Wu, Alfred University; Zhengyi Fu, Wuhan University of Technology; Allen Apblett, Oklahoma State University; Tatsuki Ohji, National Institute of Advanced Industrial Science and Technology
Friday 8:00 AM
October 22, 2021
Room: On-Demand Room 12
Location: MS&T On Demand
Invited
Sustainable Processing of Composite Materials: Daniel Kopp1; Kevin Blinn2; Jun Wang2; Daniel McMullen2; Surojit Gupta3; Richard Riman1; 1Rutgers University; 2RRTC Inc.; 3University of North Dakota
Utilization of captured carbon dioxide (CO2) by converting it into valuable products, such as fuels, chemicals, plastics, and building materials is needed to offset the >36 GT/y of anthropogenic emissions. This presentation will describe two breakthrough processes invented and patented by Rutgers University for the production of low-carbon and carbon-negative composites. The first process, namely, Hydrothermal Vapor Synthesis (HVS), enables the production of feedstock anhydrous inorganic oxides, an essential precursor for carbonate ceramics, at temperatures <500˚C, which is up to 1000˚C lower than the temperatures of traditional pyrothermal reactions. The second process, called Gas-assisted Reactive Hydrothermal Liquid Phase Densification (g-rHLPD), enables low temperature (<100˚C) densification by using CO2 as a reactant with anhydrous oxides for creating strong, dense carbonate-bound ceramics with outstanding physical and chemical properties. Materials produced with these technologies will be presented and compared with the incumbent materials to demonstrate the outstanding low-carbon future awaiting materials manufacturing.
Invited
Gelation-freezing Derived Mullite Thermal Insulators Prepared by Reaction Sintering with Various Types of Alumina Nanofibers and Silica: Manabu Fukushima1; 1National Institute of Advanced Industrial Science and Technology
Thermal conductivity and strength of porous mullite prepared by freezing gels containing nano-sized powders. Mullite thermal insulators were fabricated by freezing gelatin gels containing nano-sized powders, drying under vacuum. followed by sintering. Various types of alumina nano-powders mixed with fumed silica or kaolin resulted in controlled strength and thermal conductivity, depending on the solid loading in the initial gel. The relationship between the microstructure, mechanical and thermal properties of the resulting ceramics was discussed using a multiscale modeling technique, in which a homogenization method was conducted with microscopic models created from three dimensional images, global stress distributions in macroscopic samples by finite element method and local stress distributions. The simulation results were consistent relatively with the experimental results. The overall morphology and properties of the insulators prepared by gelation–freezing route were investigated.
Invited
Addressing Advanced Sustainability with Materials Selection: Luca Masi1; Mauricio Dwek1; 1Ansys Inc.
The focus on sustainability and associated subjects such as ecodesign, critical materials and circular economy is growing, both in industry and in public opinion. From an education standpoint, this means that more scientists and engineers will have to acquire skills that connect technological problems with their respective environmental, social and economic issues. This is not easy and generally more successful through interdisciplinary projects.In this talk, we will present Ansys Granta EduPack, a software solution composed of a large materials database, multiple analytical models as well as visualization and selection tools that support the introduction of sustainability in students’ projects. We will showcase how materials property charts are used to select best candidates based on their CO2 footprint, how we can estimate and compare the performance of composites such as sandwich panels for aircrafts’ lightweighting , and how we can increase material circularity by identifying applications for secondary raw materials.
Invited
Sustainable Synthesis of Non-oxide Ceramics in Air: Jesus Gonzalez-Julian1; Apurv Dash1; Sylvain Badie1; Robert Vassen1; Olivier Guillon1; 1Forschungszentrum Jülich
Synthesis of non-oxide ceramics typically requires high temperature (> 1000 °C) and protective atmosphere – commonly argon or vacuum – to avoid the oxidation of the precursors. Furthermore, conventional synthesis routes typically entail a milling step to produce fine powders, increasing operating costs and introducing potential impurities. Nowadays, industry and society are demanding novel sustainable processes, where less energy is consumed and sustainable compounds are used. In this work, we will present a novel synthesis route for non-oxide ceramic powders, which is referenced as Molten Salt Shielded Synthesis or MS3. MS3 is carried out at lower temperatures than conventional synthesis routes, in air instead inert atmospheres, and does not require any milling step to obtain fine and loose powders. Synthesis of different ternary transition metal compounds (MAX phases such as Ti3SiC2, Ti2AlC and Cr2AlC) will be shown, as well as the possibility for other non-oxide ceramics such as TiC.
Invited
Preparation of Tin Nanosized Powder by Pulsed Wire Discharge: Hisayuki Suematsu1; Souma Yamamoto1; Thi Do1; Tadachika Nakayama1; 1Nagaoka University of Technology
Sn has a low melting point and has been used in lead-free solder alloys. Because of the needs to decrease the soldering temperature, sintering rather than melting has been attempted. For this applications, preparation of Sn and its alloy nanosized powders is required. Pulsed wire discharge (PWD) is known as a physical evaporation method in which a thin metal wire is evaporated by pulsed large current and cooled in ambient gas. In this research, to simplify the effect of the crystal structure to the particle formation, nanosized powder of Sn with a tetragonal unit cell was to be prepared by PWD.From TEM bright field images and XRD patterns, Sn nanosized power was successfully prepared. Geometric mean diameter was decreased with increasing the charging voltage and decreasing the pressure. The particle size control method for Sn nanosized powder preparation by PWD was successfully developed.
Invited
Room-temperature Densification of MgO Ceramics with Nitride Phosphor Particles: Junichi Tatami1; Emi Takahashi1; Takuma Takahashi1; 1Yokohama National University
Wave conversion materials with high thermal conductivity are required for high-power semiconductor lighting. Ceramics have higher thermal conductivity than existing matrices such as resin or glass in which phosphor particles are dispersed. However, the high densification of ceramics generally requires high-temperature sintering, which degrades and alters the phosphor particles. In this study, we aimed to achieve the high densification of MgO ceramics at room temperature. Applying high hydrostatic pressure with water addition improved the sample packing ratio and promoted the formation of Mg(OH)2. As a result, the relative density was ≥95%. Additionally, various nitride phosphor particles (CaAlSiN3:Eu2+, β-SiAlON:Eu2+, and α-SiAlON:Eu2+) were dispersed in the MgO matrix at room temperature without degrading the luminescence property. The thermal conductivity of the obtained sample was about 8 W m−1K−1, 40 times higher than that of the epoxy matrix.
Invited
Smart Powder Processing for Sustainable Society: Makio Naito1; Takahiro Kozawa1; Akira Kondo1; 1Osaka University
Recently, various novel powder processing techniques were rapidly developed for advanced material production due to the growth of high-tech industry, especially the fields of green and sustainable manufacturing. Particle bonding technology is the typical powder processing technique that creates advanced materials with minimal energy consumption and environmental impacts. It creates direct bonding between particles and particle synthesis without any heat support or binders of any kind in the dry phase. In this talk, its applications for fibrous nanoporous compacts formed by nanoparticle bonding will be explained. The compacts are very effective for energy-saving issues. Besides, particle bonding technology is also applied for separation of composite structure into elemental components, which leads to the development of novel recycling of composite materials and turns all of them to highly functional applications. As an example, novel recycling methods of GFRP will be introduced.
Invited
Polymer Derived Coatings for Corrosion Protection of Steels: Kathy Lu1; 1Virginia Polytechnic Institute and State University
Due to its vast industrial applications, steel is often exposed to a wide variety of harsh environments leading to corrosion/oxidation damage. In this work, polymer derived ceramic coatings for steels have been explored for low temperature and high temperature uses in corrosive environments. The microstructure evolution, pyrolysis behaviors, and corrosion properties were investigated. The coatings change from being hydrophobic to being hydrophilic above 200oC pyrolysis temperature. Higher pyrolysis temperature leads to higher hardness and Young’s modulus coatings. The high-temperature oxidation behaviors of SiON coated AISI 441 substrates were studied in Ar+O2, Ar+H2O, and Ar+CO2 atmospheres at 800oC for 100 hours. The SiON coated AISI 441 substrates showed better performance in all three atmospheres.
Invited
First-principles Studies of Adsorption and Diffusion of Metal on α-Al2O3 for Advanced Manufacturing Applications: Austin Biaggne1; Lan Li; 1Boise State University
Advanced manufacturing has been shown to be an alternative method for the development of sensors for in-pile nuclear reactor applications. Mo and Nb printed on alumina substrates are candidates for the construction of thermocouples that can monitor temperature due to their balance of temperature and irradiation resistance. However, the surface diffusion mechanisms of Mo and Nb adatoms on alumina, which play a critical role in the printing process, have not been fully addressed. We performed density functional theory-based calculations to study the adsorption and surface diffusion of Mo and Nb adatoms on the α-Al2O3(0001) surface. Nb adatoms have stronger adatom-surface interactions, and both Mo and Nb prefer to occupy the same adsorption sites. Nudged elastic band methods were used to calculate surface diffusion paths. Mo has a smaller diffusion energy barrier than Nb, resulting in a larger diffusion coefficient. Mo and Nb follow similar diffusion paths, potentially leading to site-blocking.
Invited
The Printability of Ternary Metal Boride (MAB) Materials Using Laser Powder Bed Fusion: Samuel Hocker1; Mackenzie Geigle2; Taylor Riedl2; Christian Forsberg2; Maharshi Dey2; Karen Taminger1; Lopamudra Das3; Surojit Gupta2; Valerie Wiesner1; Daniel Trieff2; 1NASA Langley Research Center; 2University of North Dakota; 3National Institute of Aerospace
Dust threatens long-term durability of vehicles and structures operating on Lunar and Martian surfaces. Abrasion, erosion and jamming of mechanisms with mating surfaces, such as gears, hinges and other mechanical joints, were documented due to lunar dust incursion in Apollo missions. Furthermore, corrosion has been identified as another hazard to materials durability and performance of Martian rovers due to the presence of water and brine. Materials resistant to abrasive particles and corrosive environments are needed to enable human/robotic exploration of the Moon and ultimately Mars. Ternary metal boride (MAB) phase materials, such as molybdenum aluminum boride (MoAlB), are novel ceramics that possess high toughness and hardness, exceptional thermal conductivity and shock resistance with enhanced corrosion resistance observed in some MAB systems. Due to processing limitations, it is difficult to produce MAB parts via traditional fabrication methods. The feasibility of laser powder bed fusion additively manufactured MAB parts will be presented.
High Temperature Interaction of IN718 on Heated Buildplate: Nicolas Tan1; 1University of Arizona
High-temperature build plate preheating is an effective method to reduce part distortion in the laser powder-bed fusion (LPBF) process. It also leads to changes in the powder quality, including sintering which is expected to alter the thermal conductivity in the powder bed. This presents a challenge for part-scale distortion modeling where convection is often used to represent heat loss into the powder bed to reduce computational load. In this work, experimental measurements of the temperature profile in a powder bed are taken at build plate temperatures up to 500°C. Oxidation and sintering of Inconel 718 powder are measured over a period equivalent to a LPBF build. Through calibration of thermo-mechanical models to experimental temperature measurements, time and temperature dependent convection coefficients are used to improve distortion predictions. This provides a comprehensive view of the effect of build plate preheating on thermal history, part distortion, and powder quality in LPBF builds.
Preparation of BaZrO3/Y2O3 Composite Refractory and Study on Its Interface Reaction with Ti2Ni Alloy: Xiao Hou1; Feihai Yu1; Yucheng Yang1; Guangyao Chen1; 1Shanghai University
The addition of Y2O3 refractories can significantly improve the stability of barium zirconate refractories. This paper studies the corrosion of fused barium zirconate to yttrium oxide molar ratios of 2:1 and fused barium zirconate crucible induction smelting to prepare Ti2Ni alloy. The phase structure and microstructure of composite crucible refractories were analyzed by X-ray diffractometer (XRD), scanning electron microscope (SEM) combined energy spectrometer (EDS) and oxygen/nitrogen analyzer. Ti2Ni alloy melt interface reaction. The results show that the composite crucible refractory is composed of two phases: Zr solid solution Y2O3 and Y-doped BaZrO3. As the doping content of yttrium oxide increases, the erosion layer decreases and the oxygen content of the alloy decreases.
Study on the Interfacial Reaction between BaZrO3 Refractories and Zr Amorphous Alloys: Feihai Yu1; Guangyao Chen1; Xiao Hou1; Yuchen Yang1; Chonghe Li1; 1Shanghai University
In this study, the (Zr, Hf)68.46Cu12.99Ni9.79Al3.66Nb4.59Y0.5 alloy was prepared using vacuum induction melting with the BaZrO3 crucible. The microstructure and oxygen content of the alloy were analyzed, and the interaction was investigated using optical microscope, scanning electron microscope and X-ray diffraction. The results showed no obvious melt erosion layer was found at the bottom of BaZrO3 crucible, and a large number of Y2O3 particles were found attached to the bottom. With the increase of smelting times, the oxygen content in the alloy showed a decreasing trend, and the Y element content in the alloy was significantly lower than the proportion content. It indicated that O generated by the decomposition of the crucible after contact with the melt combines with the free Y in the melt to generate Y2O3 particles deposited at the bottom of the crucible, which hinders the further contact between the melt and the crucible.