14th Symposium on Green and Sustainable Technologies for Materials Manufacturing and Processing: Application of Sustainable Materials for Functional Applications I/Novel Manufacturing Methods
Sponsored by: ACerS Engineering Ceramics Division
Program Organizers: Surojit Gupta, University of North Dakota; Mritunjay Singh, Ohio Aerospace Institute; Tatsuki Ohji, National Institute of Advanced Industrial Science and Technology; Hisayuki Suematsu, Nagaoka University of Technololgy; Enrico Bernardo, University of Padova; Rajiv Asthana, University of Wisconsin; Yiquan Wu, Alfred University; Zhengyi Fu, Wuhan University of Technology; Allen Apblett, Oklahoma State University

Monday 8:00 AM
October 10, 2022
Room: 414
Location: David L. Lawrence Convention Center

Session Chair: Huong Le, Faraday Technology; Junichi Tatami, Yokohama National University; Bai Cui, University of Nebraska Lincoln; Hisayuki Suematsu, Nagaoka University of Technology


8:00 AM  Invited
A Computationally Engineered Sustainable Approach for Tuning Nanoclays for Biomaterials Applications: Kalpana Katti1; Krishna Kundu1; Hanmant Gaikwad1; Dinesh Katti1; 1North Dakota State University
    Clay-based materials have been extensively used in medicine for wound dressings, drug delivery and regenerative medicine. Our group developed the ‘Altered-Phase-Theory’ for polymer-clay-nanocomposites (PCNs) that elucidates methodology for a simulation-based design of PCNs. We report here the use of different amino acids as modifiers for design of PCNs for scaffolds for bone tissue engineering. The amino acids enable a biomimetic mineralization of hydroxyapatite inside the nanoclay galleries. In addition, molecular dynamics simulations indicate extensive interaction energies in the novel PCNs. The variation of amino acids enables tuning of both the mechanical properties of the scaffolds for bone tissue engineering as well as biological activity for the design of environmentally benign and sustainable nanocomposites. Unlike several other nanomaterials that exhibit toxicity, the engineered nanoclays elicit favorable response such as enabling stem cell differentiation. Thus, biomolecule modified nanoclays represent a next generation tunable nanocomposite for biomedical applications with far reduced environmental footprint.

8:30 AM  
Capture of Plant Nutrients by Ceramics for Subsequent Use as a Slow Release Fertilizer: Allen Apblett1; Russel Rahman1; Ciara Kelley1; Patrick Kitzel1; 1Oklahoma State University
    Nutrient pollution is a costly problem with widespread negative health and ecological effects. Similarly, build-up of nutrients in aquaria water leads to algal growth and toxicity to aquatic organisms and fish. An ideal solution to these problems is capturing such nutrients in a form that is amenable to application as a fertilizer, thus turning a pollutant into a valuable resource. We have developed magnesium aluminum oxide and magnesium iron oxides from calcining a layered double hydroxide that are good adsorbents for both phosphate and nitrate. The material possesses excellent capacity for sorption of the highly difficult to capture nitrate ions due to a molecular imprinting process. These materials can capture plant nutrients from municipal wastewater and aquaria and can then be utilizes as time release fertilizer. The possibility of using this low-cost material as a soil additive to prevent fertilizer runoff will also be discussed.

8:50 AM  
Change in the Density Distribution during Sintering of Alumina Ceramics Visualized by In-situ OCT Observation: Junichi Tatami1; Mitsuki Tajima1; Motoyuki Iijima1; Takuma Takahashi2; 1Yokohama National University; 2Kanagawa Institute of Industrial Science and Technology
     The density distribution of ceramics develops during the firing process. However, the density distribution and its changes have not been fully elucidated. In this study, the change in the density distribution of alumina ceramics during sintering was clarified by in-situ optical coherence tomography (OCT) observation of the internal structure.First, a calibration curve was obtained for the relationship between density and the attenuation rate of the OCT signal. Mapping of the attenuation rate inside alumina ceramics was obtained through in situ and 3D OCT observations at high temperatures using an infrared heating furnace. Density distribution was estimated from the attenuation rate mapping and calibration curves. It was shown that the density distribution developed during sintering and became narrower in more homogeneous green bodies.

9:10 AM  
Electrochemical Remediation of PFAS-Contaminated Aqueous Waste Streams: Huong Le1; Brian Skinn1; Katherine Lee1; Stephen T. Snyder1; Maria Inman1; 1Faraday Technology
    This talk will present recent progress toward development of an economical and energy-efficient process to pretreat waste streams for removal of per-/polyfluorinated alkyl species (PFAS). PFAS have historically been used across a broad range of industries for a wide variety of applications,but are highly refractory and bio-accumulative and have the potential to cause numerous adverse health effects. Thus, multiple regulatory agencies, including the U.S. and various state EPAs, are in the process of defining actionable maximum contaminant limits for numerous PFAS. Faraday has recently demonstrated a pulsed-waveform electrocatalysis approach for PFAS destruction with clearly superior performance to direct-current methods, enhancing destruction of more-challenging short-chain PFAS and enabling PFAS destruction even in complex matrices. Cost analysis estimates indicate that the use of pulsed waveforms has the potential to provide appreciable reductions in OPEX and favorable overall CAPEX/OPEX.

9:30 AM  
Critical Metals Recovery from Recycled Lithium-ion Batteries: Meng Shi1; Luis Diaz1; John Klaehn1; Aaron Wilson1; Tedd Lister1; 1Idaho National Laboratory
    Aiming to recover critical materials from waste lithium-ion batteries (LIB), we have developed a series of operations to extract individual metals from the end-of life LIB based on their electrochemical (EC) and chemical properties. The EC-Leach process generates a metal-rich Cu-free leachate solution while isolating graphite and metallic copper. This leachate contains critical metals such as Li, Mn, Co, and Ni as well as impurities such as Al and Fe. A precipitation step was developed to effectively remove the impurities in preparation for separation stages such as solvent extraction or ion-exchange. A process has also been developed using electrodialysis coupled with a CO2 capture agent to recover lithium carbonate. In total, these activities have produced high purity NiSO4, CoSO4, MnCO3, and Li2CO3. Through these methods, we have developed and demonstrated options which can be coupled with traditional methods used in mining to recover critical materials from LIBs.

9:50 AM Break

10:10 AM  Invited
Direct Selective Laser Sintering for Additive Manufacturing of Advanced Ceramic Materials: Bai Cui1; Xiang Zhang1; Fei Wang1; Zhipeng Wu1; Michael Nastasi2; Yan Chen3; Yongfeng Lu1; 1University of Nebraska-Lincoln; 2Texas A&M University; 3Oak Ridge National Laboratory
    A direct selective laser sintering (SLS) process has been successfully developed by our team, which has been demonstrated as a novel and promising approach for additive manufacturing of various ceramic materials such as BaTiO3 and ZrC. Without use of polymer binders or resins, a dense ceramic layer could be formed with a thickness of several hundred of micrometers depending on the laser parameters and a relative density of higher than 97%, in which pores or microcracks are absent. The phase transformation during SLS has been investigated by X-ray and neutron diffractions. SLS can result in the formation of the metastable high-temperature phase, such as hexagonal BaTiO3, which is retained at room temperature possibly due to the ultrahigh cooling rate. The processing-microstructure-property relationship of the SLSed ceramics is revealed and discussed.

10:40 AM  Invited
Green Routes to Materials Via Reaction of Metal Oxides with Aqueous Reagents: Allen Apblett1; 1Oklahoma State University
    The reaction of metal oxides with an aqueous salt of another metal is a hybrid method that can have significant advantages for synthesis of bimetallic metal oxides. For example, the reaction of lanthanum oxide with aqueous vanadyl sulfate provides a simple pathway to LaVO4 or VO(OH)2 depending on stoichiometry. A similar reaction can be used to derivatize the surface of alumina catalyst support pellets to produce catalytic materials. Reaction of MoO3 with aqueous metal salts can be used to produce a myriad of metal molybdates. Indeed, these reactions can be used to remove heavy metals and uranium from contaminated waters. Replacement of MoO3 in these reactions by tungstic acid, H2WO4, provides low-temperature routes to metal tungstates. Examples of these reactions will be provided and the potential for these reactions will be discussed including a recent method for direct preparation of Na2Fe(MoO4), a promising battery electrode material.

11:10 AM  
Effect of Hydrolysis on Mechanical Properties of Rice Husk Reinforced Composites for 3D Printing: Athira Nair Surendran1; Sreesha Malayil1; Kunal Kate1; Jagannadh Satyavolu1; 1University of Louisville
    Rice husk is a residual biomass that results from rice grain processing and disposing it is a challenging task. Currently rice husk is being used for gasification and combustion purposes, but these methods increase carbon footprint and contribute towards greenhouse gas production. We developed a method to utilize rice husk fibers in producing natural fiber composite filaments (NFRC). Two pretreatment methods, dilute acid hydrolysis and ethanol drying, were investigated. The treated fibers were mixed with thermoplastic copolyester elastomer matrix with 10 wt.% loading. The compounded mixture was chopped and extruded into 3D printing filaments which were then analyzed for mechanical properties and surface morphology. Printing parameters of the filament were optimized and mechanical properties of printed parts were investigated. This reinforcement composite was investigated to enhance the mechanical properties of composite filaments while increasing sustainability and decreasing carbon footprint of printed parts.

11:30 AM  
Enabling Sustainability and Circularity Through Big Area Additive Manufacturing: Soydan Ozcan1; 1Oak Ridge National Laboratory
    Big area additive manufacturing (BAAM) is an energy-efficient additive manufacturing (AM) approach that enables the production of complex parts at rates 200 times faster than conventional polymer AM. Through BAAM, sustainable, bio-based feedstocks can be printed into large-scale products for a variety of applications in the wind energy, automotive, marine, etc. industries. By incorporating, bio-based fillers into these feedstocks’ material properties can be enhanced furthering the application space of BAAM of bio-based feedstocks. Alternatively, BAAM can be used for re-manufacturing of large end-of-life (EoL) parts such as composite door panels, molds, etc. In this case, EoL composite materials, are given opportunities to either be recycled into the same product, a different product, or down-cycled. BAAM can create avenues for the industry to incorporate bio-based composites into everyday practice and provide the opportunity to re-use EoL composites, both of which are adoptable strategies to improve sustainability and circularity within industrial operations.