Design and Manufacturing Approaches for the Next Generation of Sustainable Materials: The 2021 Student-led Symposium: Challenges in Sustainable Materials: Novel Processing and Recycling
Sponsored by: TMS Extraction and Processing Division, TMS Light Metals Division, TMS: Recycling and Environmental Technologies Committee
Program Organizers: Mary Dougherty, Colorado School of Mines; Christopher Finfrock, Sandia National Laboratories; Brady McBride, Colorado School of Mines; Jaden Zymbaluk, Colorado School of Mines; Desmond Mills, Colorado School of Mines; Casey Gilliams, Colorado School Of Mines
Monday 8:30 AM
March 15, 2021
Room: RM 5
Location: TMS2021 Virtual
Session Chair: Mary Dougherty, Colorado School of Mines; Christopher Finfrock, Colorado School of Mines; Casey Gilliams, Colorado School of Mines; Brady McBride, Colorado School of Mines; Desmond Mills, Colorado School of Mines; Jaden Zymbaluk, Colorado School of Mines
8:30 AM
Introductory Comments: Design and Manufacturing Approaches for the Next Generation of Sustainable Materials: The 2021 Student-led Symposium: Christopher Finfrock1; 1Colorado School of Mines
Introductory Comments
8:35 AM Invited
Research with a Sustainable Materials Science and Engineering Approach: Bryan Boudouris1; Lynnette Madsen1; 1National Science Foundation
Funding agencies are positioned to deliver a message – (i) a sustainable approach is expected, (ii) sustainability is a priority for funding, (iii) industry wants to embrace sustainable practices, and (iv) the world wants to make the best use of its resources. Sustainable development continues to be a high priority for the European Commission, and it has helped develop and then adopt the 2030 Agenda including the 17 Sustainable Development Goals. Similarly, the Natural Sciences and Engineering Research Council of Canada has embraced Canada's sustainable development priorities and their Departmental Sustainable Development Strategy describes actions in support of achieving a smaller environmental footprint. Recently, the U.S. National Science Foundation (NSF) developed a program on the Critical Aspects of Sustainability. Many sectors of NSF are involved: chemistry, materials, systems engineering, manufacturing innovation, and earth sciences. Sustainability efforts go beyond research priorities and stand to impact standards, exchange/trade, and industrial development.
8:55 AM Invited
Research Requirements for Sustainable Materials: Daniel Cooper1; 1University of Michigan
Anthropogenic greenhouse gas emissions must be cut by at least half by 2050 in order to avoid the worst consequences of climate change. Industry already accounts for one-third of global emissions and these emissions are growing quickly as the developing world industrializes. We need sustainable material production and (re)manufacturing solutions that fit the scale of the challenge and can be deployed in the short as well as the medium-long term. This talk first highlights the sources of industry emissions both now and in the future. We then identify two key challenges that form the focus of the talk: (renewably sourced) electrification of atom efficient material synthesis and downstream manufacturing; and, high-value restoration of end-of-life materials by the design of materials, components, and products for circularity, and by the design and control of manufacturing processes resilient to time-varying heterogeneous feedstocks. We explore basic and applied research directions that address these challenges.
9:15 AM Invited
Creating New Green Jobs Starts at the Product Design Stage: Justine Burt1; 1Appraccel
Switching to a circular economy in which consumer products and packaging last longer and can be upcycled into new products will require designing them differently up front. The environmental impact of products and packaging over their lifetime is determined during the design phase. Reducing environmental impact by applying design criteria such as: o durability o reusability o repairability o upgradability o recycled content o regional materials will help society transition to a circular economy that can bounce back from future pandemics and natural disasters. Pushing back against planned obsolescence and extending the life of electronics, appliances, clothing, and packaging will expand green jobs available in reverse logistics, repair, and recycling. This presentation will provide case studies about the kinds of work green design enables for: o Reusable transportation packaging o Repair cafes o Electronics recycling o Thrift store donation upcycling o Fishing net reclamation and recyclingo Building deconstruction
9:35 AM Invited
Materials Innovations Towards Decarbonization of Industrial Processes: Elsa Olivetti1; 1Massachusetts Institute of Technology
Materials have long played a role in transitioning between eras. Now the materials community’s most pressing task is to decarbonize society. For the past several decades, materials science has played a key role in lowering carbon dioxide emissions from the electricity sector through development of renewable energy generation and high performing energy storage technologies. However, outside of the energy sector there remain significant greenhouse gas emissions linked to materials production, particularly in the form of infrastructure and chemicals production. This presentation focuses on the significant challenge of reducing the burden of materials production itself. I will review recent progress in understanding the potential for decarbonization in the materials production sector and describe where and how the material science community can have significant impact.
9:55 AM Invited
Genomic Computational Design: Materials for Sustainability: Gregory Olson1; 1Massachusetts Institute of Technology
Sixty years of academic collaboration and thirty years of commercialization by a network of small businesses have delivered a mature technology of computational materials design and accelerated qualification, grounded in the CALPHAD system of fundamental databases now known as the Materials Genome. Two computationally designed aircraft landing gear steels have already been taken to full flight qualification employing this technology. The announcement in 2011 by the US President of a national Materials Genome Initiative acknowledging the reality of this technology has spurred global interest and rapid adoption by US apex corporations with broad market impact spanning a range from consumer electronics to space exploration. The technology provides a system for affordable change of materials technology supporting sustainability through reduced pollutants, energy efficiency and reduced emissions over a range of application sectors.
10:15 AM Invited
Additive Manufacturing of High Temperature Materials: New Alloys and Sustainability Considerations: Tresa Pollock1; 1University of California, Santa Barbara
New high temperature metallic alloys for propulsion, energy and automotive applications can address materials sustainability challenges through energy savings in production, improvements in performance that reduce fuel consumption or by lightweighting. In this talk the performance benefits of new superalloys and their coatings and multi-principal element alloys will be discussed. Tradeoffs in the use of elements that are subject to supply risk and large price fluctuations are a major consideration. Design tools and approaches that address these challenges are emerging and examples will be given. While the performance benefits may be significant, the compositional complexity of these alloys also poses some contrasting challenges with respect to recycling. Finally, the benefits of additive manufacturing for the production of these high value classes of materials will be discussed.
10:35 AM Invited
Challenges in Optimizing Structural Metamaterials: Brad Boyce1; Anthony Garland1; Benjamin White1; Ryan Alberdi1; 1Sandia National Laboratories
Lattice metamaterials have been shown to exhibit several beneficial properties, ranging from structural lightweighting to acoustic damping. Now, with the proliferation and maturation of additive manufacturing technologies, such structures are becoming more accessible and cost-effective. However, to best use metamaterials to their fullest extent, several challenges must still be addressed. During manufacturing, residual stress and warpage, location-dependent microstructure, orientation-dependent surface roughness and lack-of-fusion porosity all remain outstanding challenges. Design optimization methods rarely consider these manufacturability tradeoffs. Furthermore, existing topology optimization algorithms generally can only address linear problems such as elastic behavior, while nonlinear optimization of elastoplastic behavior and fracture resistance is only recently emerging. Finally, the computational expense of finite element representations for large-scale lattice structures requires innovative approaches, typically in the form of reduced order models. We will explore the use of convolutional neural networks, which provides one potential path to address several of these issues simultaneously.
10:55 AM Invited
Microstructural Development and Powder Feedstock Recyclability in Additive Manufacturing by Laser Powder Bed Fusion: Yongho Sohn1; Sharon Park1; Holden Hyer1; Nathalia Diaz Vallejo1; Thinh Huynh1; Asif Mahmud1; Kevin Graydon1; Cameron Lucas1; Nicolas Ayers1; Abhishek Mehta1; Le Zhou1; 1University of Central Florida
Additive manufacturing of metallic alloys is a disruptive technology that can produce net-shape components with nearly unlimited geometrical complexity and on-demand customization. This technology also brings an unprecedented opportunity to design new and modified alloys based on robust understanding of materials science. Important challenges lie ahead to desensitize dependent process variables, take advantage of thermo-kinetic process environments, and recycle feedstock for sustainable manufacturing ecosystem. In this presentation, experimental research efforts using gas atomization and laser powder bed fusion for metallic alloy development will be introduced. Progress towards fundamental understanding of microstructural development in Al-, Mg-, Ti-, Ni-, and Fe-base alloys will be documented for both commercially available and new/modified compositions. Effects of using recycled powders will be highlighted with due consideration for characteristic alloy compositions. Manufacturing ecosystem based on additive technologies is deliberated for sustainable future, wherein knowledge of thermodynamics and kinetics will play an important role.
11:15 AM Invited
Shaping a Sustainable World Together – Delivering Novelis’ Commitment to Sustainability: James Fekete1; 1Novelis Global Research and Technology Center
Novelis, as the world’s leading producer of sheet aluminum, believes that sustainability is a core attribute of its business objectives and its commitment its customers, stakeholders and the world. This is reflected in the Company’s stated purpose, “Shaping a Sustainable World Together”. Novelis’ approach to product and process development has a strong emphasis on increasing the recycled content of its products, and the Company works closely with its customers and community partners to further close the aluminum recycling loop. This presentation will discuss Novelis’ efforts in using its science and engineering acumen to move towards an increasingly circular economy.
11:35 AM Invited
Using Rapid Alloy Prototyping to Investigate the Effects of Increased Levels of Residual Elements from Recycled Scrap on DP800 Steel: Caroline Norrish1; Carlos Llovo-Vidal2; Richard Underhill2; Cameron Pleydell-Pearce1; Nicholas Lavery1; 1Swansea University, Bay Campus; 2Tata Steel Europe
This work presents a DP800 automotive steel produced using rapid alloy prototyping with varying levels of copper, tin and nickel, which are three common residual elements introduced into new steels by recycling steel scrap. Manufacturers have increasing responsibilities to be environmentally responsible and although recycling is a huge part of this, it is not without issue; residual elements can be detrimental to the mechanical properties of the steel. Here, the mechanical impacts of higher residual elements are presented and compared to industrially produced versions of the same grade to predict what could be expected if the scrap content in new steel were to be increased. These results aim to show that higher levels of scrap can be used without comprising the quality of the steel. This move would have the potential to preserve valuable iron ore, lime and coal resources, reduce water and energy use, and lower carbon dioxide emissions.