AMP Vol 171 - N°08 - August 2013

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AUGUST 2013 VOL 171, NO 8
Failure Analysis/Testing
Simulation Validates Weld Designs
Failure Analysis of a Pipeline Rupture
Stress Corrosion Cracking in Aluminum
AN ASM INTERNATIONAL PUBLICATION
contents
19
ON THE COVER:
A modern MAN B&W two-stroke
diesel engine for oceangoing
vessels. Engines can weigh up to
2800 metric tons and reach
16 meters high. Courtesy of
MAN Diesel & Turbo, marine
low-speed business unit,
Copenhagen, Denmark.
www.mandieselturbo.com.
2
4
4
6
DEPARTMENTS
Editorial
Market Spotlight
Feedback
Of Material Interest
10 Industry News
10 Metals/Polymers/Ceramics
12 Testing/Characterization
14 Emerging Technology
15 Process Technology
16 Energy Trends
17 Surface Engineering
18 Nanotechnology
60 Products/Literature
6 1 Classifieds
6 1 Advertisers Index
6 1 Special Advertising Section
62 Editorial Preview
63 Pastimes
64 Stress Relief
Check out the

Digital Edition online at
http://amp.digitaledition.
asminternational.org
Scanning Vibrating Probe Monitors

Al Stress Corrosion Cracking
K. Williams, R. Bayles, and D.D. Macdonald

Although specifics of stress corrosion cracking in certain
metal alloys remain elusive, a new probing process holds
promise for a deeper understanding of crack
mechanisms.
TECHNICAL SPOTLIGHT
24
Detailed Simulation Helps Validate Weld

Designs in Large Marine Engines
Finite element analysis and other techniques verify that a

new weld design is safe for both repair of existing
engines and use in future engines.
26
Failure Analysis
of a Natural Gas Pipeline Rupture
Frances Richards
From aviation accidents to pipeline explosions, the
National Transportation Safety Board is often called to
determine probable cause and make safety
recommendations, as they did in the aftermath of the
2010 San Bruno pipeline explosion.
29
Selective-Melt Sintering
Brings Speed and Efficiency
to Creating High-Density Ceramics
J. Narayan
Selective-melt sintering can occur at lower overall
temperatures and with much lower energy consumption
compared to conventional sintering involving solid-state
diffusion.
ASM ANNIVERSARY
34
Celebrating ASMs First 100 Years in

Supporting Materials Innovation
37 International Thermal Spray

and Surface Engineering
This is the official newsletter of the ASM Thermal Spray Society (TSS).
The quarterly supplement focuses on thermal spray and related
surface engineering technologies.
53 ASM News
The monthly publication about ASM members, chapters, events,

awards, conferences, affiliates, and other Society activities.
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) is published monthly, except bimonthly 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. 171, No. 8, August 2013. Copyright 2013 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: $461. Single copies: $45. POSTMASTER: Send 3579 forms to ASM International, Materials Park, OH 440730002.
Change of address: Request for change should include old address of the subscriber. Missing numbers due to change of address cannot
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ADVANCED MATERIALS & PROCESSES AUGUST 2013
materials witness
9639 Kinsman Road
Materials Park, OH 44073
Tel: 440/338-5151 Fax: 440/338-4634
Materials lifecycle issues

open to funding and debate
re you working on a materials research project that could use

additional funding? If so, new opportunities are available in
2014 through the National Science Foundation (NSF). As part of
NSFs Sustainable Chemistry, Engineering, and Materials (SusChEM)
initiative, two areas offering support include the Materials Research
(DMR) division and the Materials Engineering and Processing
program in the Division of Civil, Mechanical and Manufacturing
Innovation (CMMI).
Topics of interest include replacing rare, expensive, and toxic chemicals or materials with
abundant, inexpensive, and benign chemicals or materials; recycling chemicals or
materials that cannot be replaced; developing non-petroleum-based sources of important
raw materials; discovering new separation methods to facilitate recycling and production
of valuable chemicals or materials; and developing and characterizing low cost,
sustainable materials with improved properties.
Of particular interest to DMR are proposals that promote preservation of natural resources
via improved material usage and overall lifecycle management. Relevant topics include
enhanced recyclability, materials designed to be reclaimed, reused, or repurposed, and new
approaches to extend the lifetime of materials. For CMMI, proposals addressing sustainable
materials processing are welcome. Of interest are processes with reduced use of toxic
components, processes under ambient conditions, and increased conservation of natural
resources. To see examples of 2013 SusChEM awards, visit the NSF Awards Abstracts
Database at http://nsf.gov/awardsearch and search SusChEM.
With regard to lifecycle management, this makes perfect sense. In fact, support for a holistic
approach to materials production and usage was the subject of the Steel Market
Development Institutes (SMDI) recent criticism of the Obama Administrations Climate
Action Plan. Lawrence Kavanagh, president of SMDI, points out that the new vehicle
regulations in the plan only consider tailpipe emissions that occur when a vehicle is being
driven. According to SMDI, as vehicles get lighter and engine technologies advance,
emissions from driving become a much smaller portion of total vehicle emissions. Citing
studies by the University of California, Davis and Santa Barbara campuses, Kavanagh notes
that emissions from materials and vehicle manufacturing can account for half of a vehicles
total emissions. He adds that regulatory systems that ignore this significant portion of a
vehicles total emissions may not achieve the desired environmental result, especially as
vehicles become more fuel-efficient. SMDI supports vehicle regulations that consider
emissions from all phases of a vehicles lifemanufacturing, use, and end-of-life disposal.
Many materials used for vehicle lightweighting and in alternative drivetrains produce
such high emissions when they are made that they may not be overcome by savings
during the driving phase, says Kavanagh. Considering only tailpipe emissions may result
in a net increase in vehicle emissions, which is why the only way to ensure a reduction in
emissions is to regulate total, or lifecycle, vehicle emissions.
We agree. In everything from automotive applications to power generation, a
comprehensive lifecycle approach to materials and processes is the only authentic way to
make apples-to-apples comparisons between competing technologies. Looking at only
one aspect of product usagesuch as vehicle tailpipe emissionsis shortsighted indeed.
We welcome your opinions on these matters.
frances.richards@asminternational.org
2
Frances Richards, Senior Editor

frances.richards@asminternational.org
Julie Kalista, Editor
julie.kalista@asminternational.org
Barbara L. Brody, Art Director
Joanne Miller, Production Manager;
Editor, ASM News
joanne.miller@asminternational.org
Press Release Editor
magazines@asminternational.org
EDITORIAL COMMITTEE
Ellen Cerreta, Chair, Los Alamos National Lab
Mario Epler, Vice Chair, Carpenter Technology Corp.
Scott Olig, Past Chair, Vision Point Systems
David Furrer, Board Liaison
Laura Addessio, PCC Structurals Inc.
Arvind Agarwal, Florida International University
David Bowden, The Boeing Co.
Adam Farrow, Los Alamos National Lab
Jaret Frafjord, IMR KHA Portland
Jacob Goldsmith, University of Michigan
Alan Luo, General Motors
Thomas Murphy, Hoeganaes Corp.
Roger Narayan, UNC-NCSU
Nina Pang, Boston University
Somuri Prassad, Sandia National Laboratories
Fei Ren, Oak Ridge National Laboratory
Satyam Sahay, John Deere Technology Center India
Jaimie Tiley, U.S. Air Force Research Lab
Cong Wang, Saint Gobain High Performance
Materials
Yu-Ping Yang, Edison Welding Institute
ASM BOARD OF TRUSTEES

Gernant E. Maurer, President
C. Ravi Ravindran, Vice President
Robert J. Fulton, Treasurer
Christopher C. Berndt, Immediate Past President
Diana M. Essock
David U. Furrer
Vilupanur A. Ravi
Jeffrey A. Hawk
William J. Lenling
Linda S. Schadler
Iver Anderson
Mitchell Dorfman
James C. Foley
Thomas S. Passek, Secretary and Managing
Director
STUDENT BOARD MEMBERS
Jennifer Breidenich, Gregory Vetterick, Blake Whitley

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.
market
spotlight
Machine tools market
set for growth
ew analysis from market researcher Frost & Sullivan regarding the

global machine tools and cutting tools market finds revenue earnings of $15.72 billion in 2012 with estimates reaching $21.18 billion in
2017. The research covers metal cutting, forming, and finishing segments
across North America, Europe, Middle East, and Africa (EMEA), Asia-Pacific (APAC), and Latin America.
Despite the economic downturn, demand for machine tools and cutting tools is expected to grow in emerging economies such as China,
India, Brazil, and Russia, says analyst Guru Mahesh. Increased investments in the automobile, aerospace, and defense industries that incorporate these tools in their production
Machine Tools and Cutting Tools Market:
processes
will boost uptake levels.
Revenue Forecast % by Region
Aerospace and defense industry
North
Latin
growth in Europe, Russia, China, and
America
America
16.1%
India,
with its widespread use of
8.3%
high-precision cutting tools, super
abrasives, and metal forming and
fabrication tools, is good news for market
prospects. In addition, increased demand
for advanced materials such as nickel and
titanium alloys by the aerospace industry
APAC
is set to further spur the use of machine
26.7%
tools and cutting tools.
The biggest challenge tool manufacturers face is that these advanced maNote: All figures
terials are very difficult to machine and
EMEA
are rounded.
tend to increase tool deformation,
Base year 2012.
48.9%
Source: Frost &
says
Mahesh. Investments in R&D are
Sullivan analysis.
likely to address this challenge, aiding market growth.
Tool manufacturers are investing in research to develop tools that are
coated with materials like titanium carbide, titanium nitride, and aluminum oxide. The coating process is done either by chemical vapor deposition or by physical vapor deposition and such tools are capable of
withstanding excessive temperatures, preventing deformation.
Despite being the leading manufacturers of machine tools and cutting tools, China and India have been unable to address increased demand for technologically advanced, high-quality products due to a
lack of local expertise. Instead, this need has been met by German
manufacturers.
As part of their research process, Frost & Sullivan also gathers insight
from CEOs. From their perspective, increased demand for machine tools
and cutting tools in China and India is expected to compensate for the
drop in sales across Europe and North America. Many also believe that
demand for alternate technology such as laser and water jet cutting in the
aerospace and defense industries will likely replace the need for conventional cutting tools. Finally, mining activity, infrastructure development,
and oil and gas exploration in Brazil and Africa are projected to boost the
market as well. www.industrialautomation.frost.com.
4
feedback
Welcome to AM&Ps new
Feedback department!
We encourage all comments and
suggestions. Send letters to
frances.richards@asminternational.org.
Reader seeks fastener data
Thank you for your editorial in the
June issue. I am interested in reading
The Toaster Project because of it. The
end of the column mentioned contacting
you about potential article ideas. I am a
mechanical engineer with only one undergraduate metallurgy/materials science class under my belt. One project I
am working on involves looking into fastener options for use in dental hand
tools. I am interested in learning about
the effect that material hardness plays
with respect to surface wear and the effect repeated thermal cycling (sterilization) plays on the materials fatigue
strength and other properties. Id like to
find some information on these topics,
as they may play important roles in mitigating risk as it applies to failure modes,
product improvements, and cost impact.
Name withheld by request
Honoring Krivsky
In the May issue, p 40, the name of the
AOD process inventor was misspelled.
He was Dr. William A. Krivsky. The MIT
directory reports him deceased; last position, president of Keyson Airways,
Nashua, N.H. I was working at the same
laboratory in 1954 and am aware of the
importance of his invention.
Italo S. (Al) Servi, FASM
P.S. I have been a member of ASM since
1948 and still enjoy reading every issue
of AM&P, though not fully understanding
the mysteries of nanotechnology.
Missing markers
Overall, the monthly issues are high
quality, but Ive noticed a few instances
where images could be better. As materials scientists, we rely on characterization
to gain a more thorough understanding
of material behavior. I have noticed
some cases where micrographs and
data plots are not printed in a high
enough resolution and become difficult
to read. Additionally, there have been
instances of missing micron/scale
markers. Without these, micrographs
lose much of their value.
Mario Epler
[Noted. We promise to keep a close eye
on image details.Eds.]
of material
interest
Concrete solution from Roman ruins
The chemical secrets of a concrete Roman breakwater that spent
the last 2000 years submerged in the Mediterranean Sea were recently
uncovered by an international team of researchers led by Paulo Monteiro of the U.S. Department of Energys Lawrence Berkeley National
Laboratory, Calif.
Portland cement is the source of the glue that holds most modern
concrete together in an energy-intensive process. In contrast, the team
found that Romans used much less lime and made it from limestone
baked at 900C (1652F) or lower, using far less fuel than modern methods. Lime reacting with aluminum-rich pozzolan ash and seawater
formed highly stable calcium-aluminum-silicate-hydrate (C-A-S-H) and
Al-tobermorite, ensuring strength and longevity. Both the materials and
the way the Romans used them hold lessons for the future.
It could replace 40% the worlds demand for Portland cement. And
there are sources of pozzolan all over the world, says Monteiro.
Stronger, longer-lasting concrete, made with less fuel and spewing fewer
carbon particles into the atmosphere, may be the legacy of a deeper understanding of how the Romans made their remarkable concrete. For
more information: Paulo Monteiro, monteiro@ce.berkeley.edu, 510/6438251, www.als.lbl.gov.
Drill core of volcanic ash-hydrated lime mortar

from the ancient port of Baiae in Pozzuloi Bay.
Yellowish inclusions are pumice, dark stony
fragments are lava, gray areas consist of other
volcanic crystalline materials, and white
spots are lime. Inset is a scanning electron
microscope image of the special Al-tobermorite
crystals that are key to the superior quality of
Roman seawater concrete.
Houses stick together with glue
WKI came up with a way of bonding

components of prefabricated houses
together with adhesive, allowing greater
flexibility in component design. Courtesy
of Fraunhofer WKI.
Researchers from the Fraunhofer Institute for Wood Research, Wilhelm-Klauditz-Institut (WKI), Braunschweig, Germany, developed an adhesive tape to hold the individual
components of prefabricated houses together. The secret is inside the material itself: Unlike ordinary adhesive tape, it does not consist merely of a backing material and adhesive
it also has its own heating system, a metal strip coated with adhesive on both sides. To
make two pieces of wood stick together, the adhesive tape is placed in the right position, and
an electrical current is flowed through the metal strip. As the metal heats up, the adhesive
melts and binds to the wood. It then sets very quickly once it cools.
Researchers are testing different adhesives and metal strips. They discovered the optimum adhesive, but still have work to do to find the right metal. Brass shows a lot of promise, while stainless steel and aluminum will also be investigated. Scientists plan to test the
adhesive tape in practical applications later this year. www.wki.fraunhofer.de/en.html.
Look up, lookdown, you wont see this fish around
Researchers found the lookdown fish

hide themselves through a complex
manipulation of polarized light after it
strikes their skin. This technique
outperforms by up to 80% the mirror
strategy, previously thought to be stateof-the-art in fish camouflage. Courtesy
of Jeff Kubina/Creative Commons.
Researchers at the University of Texas, Austin, found that lookdown fish disguise themselves through a complex manipulation of polarized light after it strikes their skin. In lab
studies, researchers show that this camouflage outperforms the mirror strategypreviously thought to be state-of-the-art in fish camouflageby up to 80%.
Contours of the polarized light field in the open ocean environment are constantly
changing except at noon, when the sun is directly overhead. A fish needs to do more than
deploy the straight mirror strategy in order to stay hidden. Researchers used lookdowns,
which are known as good camouflagers, simulated the sun passing over the ocean during
the course of a day, and used a custom-built polarimeter to measure how the fish reflect
polarized light. The fish are able to manipulate their reflective properties in ways that were
close to the theoretical optimum and far better than a standard mirror. What researchers
discover about these mechanisms will be of particular interest to the Navy, which at present is not as good as lookdowns at open ocean camouflage. For more information: Molly
Cummings, 512/232-6243, mcummings@mail.utexas.edu, www.bio.utexas.edu/research/
cummingslab.
industry
news
briefs
A. Schulman Inc., Akron, Ohio,
purchased Network Polymers
Inc., also in Akron, a niche
engineered plastics compounding
and distribution business, for
approximately $50 million. The
purchase is subject to completion
of due diligence. Network Polymers
offers custom resins and alloys
and exclusively produces the
Centrex ASA family of products as
well as the Diamond Polymer
brand of ABS, ABS/PC, ASA, and
ASA/PC thermoplastic products.
The company operates a 72,000sq-ft manufacturing facility and
has 70 employees.
www.networkpolymers.com,
www.aschulman.com.
Century Aluminum Co.s
(Chicago) wholly owned subsidiary
completed the transaction with Rio
Tinto Alcan Inc., Montreal,
Quebec, to acquire all assets of the
Sebree aluminum smelter,
Henderson County, Ky. The smelter
employs more than 500 people
and has an annual production
capacity of 205,000 metric tons of
primary aluminum.
www.centuryaluminum.com,
www.riotintoalcan.com.
Corning Inc.s durable Gorilla
Glass, used in the displays of
iPhones and other mobile devices,
can be found in 1.5 billion
electronic devices today. But the
next market for the lightweight
material might be literally larger
replacing some of the standard
glass used for automobile
windows. It would help reduce a
vehicles weight and lower its
center of mass, boosting fuel
economy by a few percentage
points depending on how much of
the glass is used, according to
senior vice president Jeffrey
Evenson. Cars that use the
material will also be quieter inside,
he said. Evenson expects at least
one high-end automaker to start
producing cars that use some
Gorilla Glass within the next year.
www.corninggorillaglass.com.
10
METALS POLYMERS CERAMICS

Nanoclays birth bone
Researchers at North Dakota State University, Fargo, are making strides in tissue engineering, designing scaffolds that may lead
to ways to regenerate bone. The 3D mesh
scaffold is comprised of degradable materials
that are compatible with human tissue. Over
time, the cells generate bone and the scaffold
deteriorates. The nanoclays enhance the mechanical properties of the scaffold by enabling
it to bear load while bone generates.
Biomineralized nanoclays impart osteoFormation of large bone nodule (indicated by
genic or bone-forming abilities to the scaffold
deep red color) on nanoclay scaffold.
to enable birth of bone, said Kalpana Katti,
professor of civil engineering. Our research studies involve the use of bioreactors that
mimic fluid/blood flow in the human body during bone tissue regeneration. For more information: Kalpana Katti, 701/231-9504, kalpana.katti@ndsu.edu, www.ndsu.edu/research.
Hydroformed aluminum drives down weight of Corvette
Vari-Form, Troy, Mich., began production of all-aluminum hydroformed frame rails

for the 2014 Corvette Stingray. The technology yields greater design strength, torsional
stiffness, and vehicle durability. Fuel economy will get a boost as well, due to lower weight
and reduced complexity.
For 2014, the Corvette Stingray incorporates substantial structural changes, resulting in
a 99-lb weight reduction and a 57% stiffness increase compared to the steel structure of the
previous model. The backbone of the body structure is a new frame concept that features left
and right hydroformed aluminum tube center sections, bridging the gap between two pairs
of connecting nodes and front/rear crush zones. Hydroformed frame rails are optimized for
light weight and superior strength, delivering classic Corvette handling and improved mileage
for the driver. www.vari-form.com, www.chevrolet.com/new-2014-corvette.
Backbone of the lightweight
aluminum 2014 Corvette
Stingray frame is a set of
hydroformed aluminum tube
center sections (blue highlight),
bridging the gap between two
pairs of connecting nodes and
front/rear crush zones.
Courtesy of PRNewsFoto/
Vari-Form.
Collaboration on Structural Materials Data Demonstration Project
The NIST Material Measurement Laboratory, Gaithersburg, Md., and ASM International, Materials Park, Ohio, through its Computational Materials Data Network, formed
a collaboration: the Structural Materials Data Demonstration Project. The project established a data repository focused on metallic structural materials. The repository, housed
in the Materials Data Laboratory of the Computational Materials Data Network, supports data for use at a number of length scales, including first principles and phase-based
information, quantitative microstructural descriptions, process information, and property and materials performance data. Open access to the data repository provides the
materials digital data community with a resource for data analytics and informatics, modeling and simulation, and for educational purposes. In addition, it provides the opportunity to develop data input and output protocols as well as to explore data schema and
ontology development for this class of materials. For more information: Scott Henry,
scott.henry@asminternational.org, www.asminternational.org.
Light-manipulated hydrogel
suitable for soft robotics
University of California, Berkeley, researchers created a hydrogel that can be manipulated by light, which could have future
applications in the emerging field of soft robotics. Synthetic, elastic proteins were combined with sheets of
graphene that generate heat when exposed
to near infrared light. The heat affects the
synthetic proteins, which absorb water
when cooled and release it when hot. The
two materials together formed the
nanocomposite biopolymer, or hydrogel,
designed so that one side was more porous
than the other. The side that was more
porous allowed faster absorption and release of water than the other side.
By combining these materials, we
were able to mimic the way plant cells expand and shrink in response to light in a
much more precisely controlled manner,
said Seung-Wuk Lee, associated professor
of bioengineering. Because the gels
shrank unevenly, the material bent when
the light hit it. We used these bending motions to demonstrate a hand-shaped hydrogel that exhibited joint-like articulation
when exposed to light. For more information: Seung-Wuk Lee, 510/486-4628, leesw
@berkeley.edu, www.lbl.gov.
GKN Sinter Metals, Auburn Hills, Mich., will spend $10 million to expand its Gallipolis production facility in southeastern Ohio. The expansion includes installation of a new 750-metric-ton, powder-compaction
press along with other capital equipment to launch production of differential-gear components developed at the plant. The 175,000-sq-ft
facility has more than 160 employees and produces gears, clutch pressure plates, and torque-converter components for a variety of customers, including Chrysler, General Motors, EXEDY, LuK USA, and Allison
Transmission. Production of the new components is expected to begin
during the second half of 2013. www.gkn.com/sintermetals.
Safer circuit breakers made

with specialized plastics
Royal DSM, Heerlen, the Netherlands,

offers materials that can replace thermosets
in demanding molded-case circuit breakers
(MCCBs) with open arc extinguishing
chambers. The company provides advanced
materials for these housing components, as
well as for the functional internal parts in
the arc extinguishing chamber of the circuit
breaker, reportedly resulting in a 100% safe
and cost-effective solution. MCCBs are
heavy-duty circuit breakers operating at far
higher electrical ratings than residential versions. Materials such as Stanyl polyamide
46 rangeincluding Stanyl CR new-generation, halogen-free UL94 V-0 flame retardant typesas well as new halogen-free FR
grades of Akulon polyamide 6 and 66 enable production of parts with improved
electrical endurance and reduced wall
thicknesses compared with those made of
traditional thermoset compounds.
www.dsm.com, www.stanyl.com.
11
industry
news
briefs
MSC Software Corp., Santa Ana,
Calif., released MaterialCenter,
materials lifecycle management
system software that manages
materials processes and data with
traceability across the enterprise
and throughout the product
lifecycle. The software is designed
to meet the integration and
scalability requirements of ICME
(Integrated Computational
Materials Engineering), the
interface between materials
engineering and virtual product
development. Through integration
with other MSC software and third
party simulation tools,
MaterialCenter aims to drive down
the cost of physical testing by
enabling virtual engineering of
next-generation materials.
www.mscsoftware.com.
Applied Materials Inc., Santa
Clara, Calif., introduced a suite of
new defect review and
classification technologies for its
SEMVision product family to
accelerate time to yield for chip
manufacturing at 1Xnm and
beyond. The SEMVision G6 defect
analysis system combines highresolution, multidimensional
imaging capabilities with the
machine learning intelligence of
the Purity Automatic Defect
Classification (ADC) system. G6
system resolution is a 30%
improvement over the previous
generation, reportedly making it
the highest available in the
industry. This capability and the
systems e-beam tilt angle allow
the G6 to find, identify, and analyze
defects in 3D FinFET and high
aspect ratio structures at 1Xnm
nodes. www.appliedmaterials.com.
SEMVision
G6 defect
analysis
system.
Courtesy of
Applied
Materials.
12
TESTING CHARACTERIZATION
Research reveals structure of liquid metal
Experimental work performed at the German

Electron Synchrotron Facility (DESY) in Hamburg
involved levitating hot metal droplets and observing
them as they cooled by irradiating them with one of
the worlds strongest x-ray sources.
We were able to show for the first time that a liquid that is being cooled transforms into a liquid of the
same concentration but of greater order, before further cooling initiates crystallization, says Shuai Wei,
a doctoral student in the metallic materials group
headed by Professor Ralf Busch at Saarland University
in Germany. Busch and his team are particularly interested in liquid metals that, when cooled, eventually
freeze to form bulk metallic glasses.
An electrostatically levitated metal
In order to study the liquid-liquid transition of
droplet is suspended in a vacuum
metals in detail, scientists used the experimental fabetween two electrodes. While the
cilities at DESY to create positively charged metal
droplet cools or is heated, its
structure is continuously monitored
droplets about 2-3 mm in diameter. Droplets were
by exposing it to radiation from the
then levitated in vacuum between two electrodes.
synchrotron source. Courtesy of
When the droplet is suspended in an electric field, it
Institute of Materials Physics in
Space, German Aerospace Center,
has no contact with its environment, so no crystal
Cologne.
nucleation can occur and the process of crystallization is slowed, explains Wei. Suspended droplets were then cooled by several hundred
Kelvin, during which time they were illuminated with particularly intense x-rays from the
Doris III synchrotron beamline at DESY.
Each image was completed within one second, whereas in a traditional x-ray device,
the image would have taken several hours to record, notes Busch. This allowed the team
to continuously monitor the cooling process and detect phenomena within the metal
droplets that otherwise would have been invisible. For more information: Shuai Wei, +49
(0)681/302-3208, shuai.wei@mx.uni-saarland.de, www.uni-saarland.de.
Coatings database under development
Due to stresses on internal coatings of oil production facilities, coatings of tanks, separators, and pipelines must be renewed on a regular basis. However, a lack of systematic
analysis is available to help operators assess a materials suitability for different stresses.
Researchers at the Fraunhofer Institute for Mechanics of Materials IWM, Germany, are
working to close this gap. In a project sponsored by the DGMK German Society for Petroleum and Coal Science and Technology, researchers in Freiburg developed a test program
to assess corrosion resistance under several scenarios.
In different sections of the plant, coating materials are exposed to completely different conditions, says IWMs Matthias Gurr. For example, sand or stone particles are present in the extracted mix in the immediate vicinity of the drilling hole. In this plant area, it
is especially important for the coating to withstand mechanical stress caused by abrasion.
Chemical factors also put the material under stress, among them saline solutions such as
reservoir water pumped out of the ground during crude oil extraction.
To protect the underlying steel, coatings exposed to this solution require high chemical resistance and a good level of impermeability. For plant areas downstream, resistance
to saline is not as important.
To assess corrosion resistance in a laboratory environment, researchers use several
tests. In the autoclave test, a material sample is placed in a medium such as an oil-saline mix
within a gas-tight container and exposed to temperatures to 150C. For most materials,
the critical temperature limit for corrosion susceptibility is much lower. The team is compiling results in a comprehensive table so plant operators can easily determine which ma-
terials are best suited to specific stresses. Researchers will also

test coating materials at treatment plants. Gurr plans to have
initial results in about two years. For more information:
Matthias Gurr, +49 (0)761/514-2137, matthias.gurr@iwm.
fraunhofer.de, www.iwm.fraunhofer.de.
Novel microscope
enables closer look at lithium
Reza Shahbazian-Yassar, associate professor of mechanical

engineering at Michigan Technological University, Houghton,
developed a device to allow researchers to eavesdrop on individual lithium ions and potentially develop the next generation
of batteries.
You might get eight hours out of your iPhone on one
charge. This is not enough for many of us, says Yassar. An
electric car can go up to 100 miles on a single charge, but it
should really be about 300 miles. We want to increase the
power of these systems.
In lithium-ion batteries, lithium ions travel back and forth
between the anode and cathode as the battery discharges and
charges. Anodes are usually made of graphite, but scientists are
testing other materials to see if they can last longer. As soon as
lithium moves into an electrode, it stresses the material, eventually resulting in failure, explains Yassar. If changes could be
observed in the host electrode, strategies could be developed to
address this problem. Ten years ago, observing light elements
such as lithium or hydrogen at the atomic level was unfeasible.
Now, it is possible to see light atoms with an aberration corrected scanning transmission electron microscope (ACSTEM). Yassars team was able to use one at the University of
Illinois at Chicago, where he is a visiting professor.
To determine how the
host electrode changes as
Los Alamos National Laboratory,
N.M., and Tribogenics Inc., Marina
lithium ions enter it, the
Del Rey, Calif., partnered to create
team built a nanobattery
a lightweight, compact, and low
within the AC-STEM microcost x-ray system that uses the
scope using a promising elecMiniMAX (miniature, mobile, agile,
trode material, SnO2, and
x-ray) camera to provide real-time
watched it charge. Lithium
inspection of sealed containers and
ions moved along specific
facilities. The system could lead to
new applications in security inchannels as they flowed into
spection, field medicine, specimen
the tin oxide crystals instead
radiography, and industrial inspecof randomly entering the
tion. Los Alamos developed Minihost atoms. Based on that
MAX as an alternative to the large,
data, researchers calculated
fixed facilities now required for sethe strain the ions were placcurity inspections using x-ray. The
MiniMAX portable radiography sysing on the electrodes. This
tem weighs less than five lb. Los
discovery prompted inAlamos physicists demonstrated
quiries from industries and
MiniMAX using a conventional ranational labs interested in
dioisotopic x-ray source and a prousing the atomic-resolution
totype source from Tribogenics
capability in their own batoperating at 90 keV. www.lanl.gov,
tery development work.
www.tribogenics.com.
www.mtu.edu.
13
industry
news
briefs
Researchers at the University of
Pennsylvania, Philadelphia, are
combining origami with materials
engineering. Working with
colleagues at Cornell University,
Ithaca, N.Y., the Penn team will
share a $2 million grant from the
National Science Foundations
program, Origami Design for the
Integration of Self-assembling
Systems for Engineering
Innovation. The program draws
inspiration from paper folding, but
adds a variety called kirigami in
which paper can be cut as well as
folded, making it easier to form
rigid 3D structures.
www.upenn.edu, www.nsf.gov.
Innovnano, Lisbon, Portugal,
developed nanostructured
Aluminum-doped Zinc Oxide (AZO)
for improved thin-film solar cell
efficiency. The AZO sputtering
targets are suitable for developing
next-generation transparent
conducting oxide (TCO) films,
allowing researchers to investigate
optimal materials and
manufacturing conditions. An
emulsion detonation synthesis
process produces highly pure,
nanostructured AZO powder with
enhanced density and chemical
homogeneity compared to
conventional microstructured AZO
ceramics. Resulting
nanostructures can be sintered at
lower temperatures to produce
sputtering targets with minimal
grain growth.
www.innovnano-materials.com.
EMERGING TECHNOLOGY
Carbon wiring replaces copper
Super-strong wires made of carbon nanotubes (CNTs) were developed in a usable

form for the first time by researchers at the University of Cambridge, UK. The wires are
10% the weight of copper and can be joined to conventional metal wires, raising the
prospect of hybrid energy networks. The angle, or chirality, at which sheets of graphene
are rolled determines the properties of CNTs and whether they are metallic, semi-metallic,
or semiconductors.
The catalytic continuous synthesis process of CNTs, originally developed by Alan Windle of the materials science and metallurgy department, uses chemical vapor deposition to
spin out nanotubes in long threads from what resembles a candy floss machine. The
process was further developed by Krzysztof Koziol and Windle for electrical applications,
achieving very selective synthesis and producing highly pure material consisting of single,
double, or multi-wall nanotubes. While most CNTs are grown in forests on a substrate
using a catalyst, the Cambridge team grows them by injecting the precursor materials (usually methane) and the catalyst in the gas phase into the reactor.
By controlling CNT diameter, the team can indirectly control the chirality. The nanosize catalyst particles act as a template for growing the nanotubes. Adding sulphur or selective carbon species results in a cloud of nanotube fibers with enough mechanical
integrity to be pulled as continuous strands at a rate of roughly 20 meters per minute. CNT
threads are twisted together to form wires 1 mm thick, which can be insulated and used
as electrical wiring. The team also developed an alloy that can solder carbon wires either
to each other or to metal wires. For more information: Sarah Collins, sarah.collins@admin.
cam.ac.uk, www.cam.ac.uk.
NIST announces Advanced Materials Research Center
The National Institute of Standards and Technology (NIST), Gaithersburg, Md., will establish an Advanced Materials Center of Excellence to facilitate collaboration between NIST
and researchers from academia and industry. The center, which NIST plans to fund at approximately $25 million over five years, will emphasize innovations in measurement technology, modeling, simulation, and data and informatics tools related to advanced materials.
The center will play a major role in NISTs support for the Materials Genome Initiative (MGI). Launched two years ago, MGI is a multiagency effort in materials research with a goal of cutting development times in half while reducing the cost of
discovering and deploying advanced materials. Typically, it takes 10 to 20 years for a
new material to go from initial research to first use. Advanced materials and products,
from tough glass used in smartphone screens to biomaterials used to repair damaged
tissues, are critical for the U.S. to fuel innovation,
create jobs, and spur economic growth, says NIST.
www.nist.gov, www.whitehouse.gov/mgi.
Magnetic phenomenon enables better data storage
A magnetic phenomenon discovered by researchers at Massachusetts Institute of Technology, Cambridge, could lead to faster, denser, and more energy-efficient chips for memory and computation. This
could reduce the energy needed to store and retrieve one bit of data by a factor of 10,000, says Geoffrey Beach, assistant professor of materials science and engineering. The results could overcome fundamental limitations in the use of magnetic materials, leading to an entirely new design approach.
The key to this phenomenon lies not in the magnetic materials, but in what is next to them: The
team used very thin films of a ferromagnetic material deposited on a metal base and with a layer of
an oxide material on top. The behavior of the ferromagnetic layer depends on the metal that layer rests
upon. In these thin-film sandwiches, spin rotations are aligned, consistently turning clockwise or
counterclockwise. Because of this peculiar effect, current can push domains with much more force
than in conventional materials, and the direction that the domains move can be engineered by simply selecting the nonmagnetic metal underneath the magnet. www.web.mit.edu.
14
Molecular dynamics simulation from

NIST shows interactions in a polymer
mixture as it solidifies. It has
applications in fields such as protein
preservation, batteries, and polymer
nanocomposites. Courtesy of
Douglas/NIST.
PROCESS TECHNOLOGY
industry
news
NASA and Boeing develop massive welding tools for new rocket
Engineers at NASAs Michoud Assembly Facility, New Orleans, are installing massive tools designed to weld together
pieces of the core stage of the Space Launch System
(SLS)NASAs new 321 ft, 5.5 million lb heavy-lift rocket
that will send humans to deep space destinations including Mars. Six substantial welding tools will be
used to handle assembly of the new cryogenic core
stage. Suppliers worked with NASA and The Boeing Co., Huntsville, Ala., over the course of a year to
Illustration of the
circumferential dome
design and build the tools.
The circumferential dome weld tool is used to perform cir- weld tool. Courtesy of
NASA/MAF.
cumferential friction stir welds in the production of dome assemblies for the core stage cryogenic tanks, while the gore weld tool performs vertical
conventional friction stir welds in the production of gore assemblies for the core stage
tanks. The vertical weld center is a friction-stir-weld tool for wet and dry structures on the
core stage; it welds barrel panels together to produce whole barrels for two pressurized
tanks and the intertank, forward skirt, and aft engine section. The segmented ring tool
uses a friction-stir-weld process to produce segmented support rings for the core stage.
Finally, the vertical assembly center is where domes, rings, and barrels join together to
complete the tanks or dry structure assemblies. It is expected to be
complete in 2014. www.nasa.gov/exploration/systems/sls/.
3D printed shoes tiptoe onto Parisian catwalks
Stratasys Ltd., Minneapolis, unveiled 12 pairs of 3D printed

shoes during Paris Fashion Week. In collaboration with Dutch designers Iris van Herpen and Rem D Koolhaas, Stratasys printed the
shoes with a number of intricate geometries designed to mimic elements of nature. Following the success of van Herpens recent collaboration with Stratasys, which included the creation of an elaborate
3D printed dress, she teamed up with Koolhaas to design a tree-rootinspired shoe. Shoes were 3D printed using Stratasys rigid opaque
black and white materials on the multi-material Objet Connex and
Objet Eden 3D printers.
Iris is very dramatic with her concepts and the shapes she
wanted were only possible with 3D printing, says Koolhaas. Working with Stratasys enabled us to quickly test the shoes during the
design process and adjust our concepts for optimal function and
form. Once we locked down the perfect design, we printed 12 pairs
of shoes in less than a week. www.stratasys.com.
briefs
Precision Castparts Corp.,
Portland, Ore., will acquire
Permaswage SAS, Gardena,
Calif., a designer and
manufacturer of aerospace fluid
fittings, for $600 million. The
company operates from
manufacturing locations in
Gardena, Les Clayes-sous-Bois,
France, and Suzhou, China, with
680 employees. The transaction is
expected to be complete during
the third quarter of 2013.
www.precast.com.
Diversified metal component
manufacturer JD Norman
Industries Inc., Addison, Ill.,
acquired two subsidiaries of
Federal-Mogul Corp., Southfield,
Mich. The business units include a
machining operation in Windsor,
Ontario, which makes connecting
rods and a foundry in Lydney,
England, that manufactures chilled
iron camshaft castings. Both
supply engine platforms for global
OEMs in the automotive and
transportation industries.
www.jdnorman.com.
Watts Water Technologies Inc.,

North Andover, Mass., cut the
ribbon on a multimillion dollar,
30,000-sq-ft foundry in June, an
expansion to the Franklin, N.H.,
Featuring intricate
facility of one of its subsidiaries
lattices that wind
that makes products for many of
around the foot,
its brands. The lead-free foundry
these 3D printed
reflects the companys
shoes mirror the
natural growth of
commitment to meet the
tree roots. Courtesy
requirements of the Reduction of
of Stratasys Ltd.
Lead in Drinking Water Act, which
goes into effect
January 2014. The law
Alcoa and Boeing to boost aluminum recycling efforts
establishes new limits
During the recent Paris Air Show in Le Bourget, France, Alcoa Inc. and The Boeing Co. announced a closed-loop
on the lead content in
every pipe, fixture, and
program to increase recycling of internal aluminum aerospace alloys used in production of Boeing airplanes. The profitting used to convey
gram entails intermodal transport of aluminum alloy scrap material including advanced alloys from Boeing facilities
water for human
in Auburn, Wash., and Wichita, Kan., as well as third-party processors in Auburn, to Alcoas Lafayette, Ind., facility for
consumption.
melting and recycling into new aerospace materials. The program calls for recycling of 2XXX and 7XXX-series aluwww.wattswater.com.
minum alloys used in production of wing and fuselage components. Forms include aluminum extrusions, sheet, and
plate products. Approximately eight million pounds of aluminum is expected to be recycled annually.
The program also lays the groundwork for capturing scrap from Boeing subcontractors and could be expanded
to include other aluminum scrap forms, including chips that remain after parts machining. Aluminum, unlike other
materials, does not lose any of its characteristics when recycled. Approximately 75% of all aluminum ever produced
since 1888 is still in use today, say Alcoa sources. www.alcoa.com, www.boeing.com.
15
industry
news
briefs
University of Michigan, Ann
Arbor, researchers took a step to
make high-performance
thermoelectric materials that
convert waste heat to electricity. A
semiconducting material was
engineered at the level of its
individual atoms, boosting its
ability to convert heat into power
by 200% and its electrical
conductivity by 43%. An alloy of
titanium, zirconium, nickel, and tin
was used. While it is not a
particularly effective
thermoelectric material at this
point, researchers say it made a
good testbed. www.umich.edu.
The U.S. Department of Energy
recognized the nations first gridconnected offshore floating wind
turbine prototype off the coast of
Castine, Maine. Led by the
University of Maine, Orono, the
project represents the first
concrete-composite floating
platform wind turbine to be
deployed in the world. The
university and its project partners
will conduct extensive design,
engineering, and testing of floating
offshore wind turbines, followed by
construction and deployment of its
65-ft-tall VolturnUS prototype. Data
will be collected to validate and
improve designs, and help reduce
costs. www.wind.energy.gov,
www.umaine.edu.
BASF New Business GmbH
acquired Deutsche Nanoschicht
GmbH, Rheinbach, Germany, who
recently developed an innovative
process to produce thin films by
chemical solution deposition. The
process allows high-temperature
superconductors to be
manufactured in a much more
efficient and resource-conserving
manner, say company sources. The
technique is also important for
manufacturing thin layers of a
broad range of materials. Such thin
layers, key elements in many
electrical components, can be
produced in a more energyefficient manner to feature
improved properties.
www.basf.com, www.d-nano.com.
16
ENERGY TRENDS
Printing innovations improve organic electronics
A team from Stanford University, Calif., and

the U.S. Department of Energys SLAC National
Accelerator Laboratory developed a printing
process called Fluence (fluid-enhanced crystal
engineering) that, for some materials, results in
thin films capable of conducting electricity 10
more efficiently than those created using conventional methods. Stefan Mannsfeld, a SLAC mateArray of 1-mm-wide by 2-cm-long
rials physicist, said the key was to focus on the
single-crystal organic semiconductors.
The neatly-aligned blue strips provide
physics of the printing process rather than the
greater electric charge mobility. The
chemical makeup of the semiconductor. The
Stanford logo is the size of a dime.
process produces strips of big, neatly aligned
Courtesy of Y. Diao, et al.
crystals that electrical charges can flow through
easily, while preserving the benefits of the strained lattice structure and solution shearing printing technique previously developed.
The printing blade has tiny pillars embedded in it that mix the ink forming a uniform
film. A series of cleverly designed chemical patterns on the substrate suppresses formation of unruly crystals that would otherwise grow out of alignment with the printing direction, resulting in a film of large, well-aligned crystals. www.slac.stanford.edu.
Advanced batteries boast 10,000 charge cycles
Scientists at the Center for Solar Energy and Hydrogen Research Baden-Wrttemberg
(ZSW), Ulm, Germany, developed lithium-ion batteries that reportedly exceed the current
international state of technology: Researchers say their improvements allow a single battery to be recharged up to 10,000 times while retaining 85% percent of its charging capacity. If used in an electric vehicle, this would allow battery recharging every
day for 27.4 years.
With other values, such as power density of 1100 watts per kg, the batteries are equivalent to those produced by leading Asian manufacturers.
The active materials for the batteries originate exclusively from German
companies. ZSW designed the cells, developed the manufacturing process,
and produced a small sample series in the 18650 format. Researchers say the
technology creates the basis for manufacturing large size pouch cells and
large size prismatic cells, intended for use in electric vehicles and as solar
18650 cells
made by
power storage systems. For more information: Tiziana Bosa, +49 731/9530ZSW.
601, tiziana.bosa@zsw-bw.de, www.zsw-bw.de.
Investments drive next-generation efficient lighting
The U.S. Department of Energy announced five manufacturing research and development projects to support energy efficient lighting products. They focus on reducing manufacturing costs, while improving the quality and performance of light-emitting diodes
(LEDs) and organic light-emitting diodes (OLEDs). Cree Inc., Durham, N.C., received $2.3
million to develop a modular design for LED lights that can link together multiple units to
fit larger areas. Eaton Corp., Menomonee Falls, Wis., received $2.4 million to develop an
innovative manufacturing process that streamlines the LED fixture design and removes
unnecessary materials and parts. OLEDWorks LLC, Rochester, N.Y., received $1 million to
develop and demonstrate new spray printing equipment that reduces overall manufacturing costs and could help support cost-competitive mass production. Philips Lumileds, San
Jose, Calif., received a $1.8 million DOE investment to develop an alternative to the standard flip-chip device that grows an LED face-down on the sapphire substrate. PPG Industries Inc., Pittsburgh, received $2.3 million to develop a cost-effective manufacturing
process to help commercialize an integrated substrate that includes the glass foundation as
well as the other necessary layers. www.energy.gov/lighting.
SURFACE ENGINEERING
industry
news
Filmmaking magic with polymers
A self-assembled copolymer block film

is being fabricated with intricately organized nanostructures, giving them multiple
functions and flexibility on a macroscale
level never before seen. A team of researchers from the University of Akron
College of Polymer Science and Polymer
Engineering, Ohio, devised a method that
enables the films to assemble themselves
and serve as templates or directly as end
products. The films can be embedded with
nanoparticles that enable everything from
data storage to water purification. Superimposed with nanopatterns that allow
them to be implanted with a variety of
functionselectronic, thermal, or chemiA strip of polymer thin film can now be
calthe films can be produced at an indusproduced at an industrial scale for use in a
trial level, which is no small feat in the
wide range of applications.
world of science, says a researcher.
We moved films manufacturing from microns to meter scale, opening pathways from
the lab to fabrication, says Alamgir Karim, associate dean of research for the college. Fundamentally, it allows us to practice nanoscience on a large scale. We can now produce these films
quickly and inexpensively, with precision and without compromising quality. For more information: Alamgir Karim, 330/972-8324, alamgir@uakron.edu, www.uakron.edu/cpspe.
Nanocoating protects electronics from moisture
briefs
arpenter Technology Corp.,
Reading, Pa., is pursuing

environmental permits that will
allow for $20 million in equipment
replacements proposed by the
specialty metals manufacturer.
They would like to replace the
current cleaning linea sequence
of tanks filled with brine or acid
used to rid steel coils of a rustlike
crustwith an automated system.
The primary emission stemming
from the cleaning line is nitrogen
oxide, which the company projects
will increase to 12 tons annually.
www.cartech.com.
Honeywell, Morris Township, N.J.,
received final approval from the
U.S. EPA on its new low-globalwarming-potential solvent for
precision cleaning of metal and
electronics components. It allows
Solstice Performance Fluid (PF) to
be used in precision cleaning
applications such as metal
cleaning, electronic components,
and others, as well as a carrier
solvent for adhesives, coatings,
and inks. Solstice PF exhibits
excellent solvency for a wide
variety of solutes including
hydrocarbon oils, silicone oils and
greases, fluorinated oils, mineral
oils, solder fluxes, hydraulic fluids,
and others. Solstice PF can be
used in vapor degreasing,
immersion cleaning, or as a spray
cleaner. http://honeywell.com.
Semblant Ltd., Cambridgeshire, UK, created a plasma conformal coating process that
delivers environmental protection without the expenses of material cost and manufacturing complexity. Called PlasmaShield, the process prevents solids and liquids from contacting electronics, protects against vapor damage (moisture, pollutant gasses, salts), and can
mitigate tin whiskers. This plasma deposition process can reduce or eliminate the need to
mask sensitive electronics and simplifies the manufacturing process, producing a continuously uniform and pinhole-free coating. Coating continuity is crucial in delivering the
best protection against moisture, salts, harmful liquids, destructive gasses, tin whiskers,
creep corrosion, and other contaminants. Plasma deposition of a thin coating simplifies
reworkcoating removal is no longer required before repairing or replacing components,
reducing the risk of damaging the printed circuit board (PCB) during removal. Concerns related to shelf life, potting life, curing time, and operator safety are eliminated.
At Southwest Research Institute, San AntoThe low total manufacturing cost of the process enables high-volume electronics
nio, a $1.5 million, three-year project awarded
manufacturers to incorporate moisture protection. www.semblant.com.
Collaboration on advanced
nanointerconnect technologies
Alchimer S.A., Massy, France will join Imec, Belgium, to evaluate and implement copper filling solutions for advanced nanointerconnect technologies. The focus
is on Alchimers Electrografting (eG) products that demonstrate void-free filling on
7 nm node devices and allow direct Cu fill on barrier with no seed layer required for
damascene processes. The goal is to obtain reliability data and electrical performance
for eG wet deposition processes in a 300 mm manufacturing environment for sub22 nm technologies. The companies will assess the plating chemistry and work to
identify optimal process conditions for 300 mm wafer-level advanced damascene
plating applications. www2.imec.be/be_en, www.alchimer.com.
by the Defense Advanced Research Projects

Agency (DARPA) aims to develop novel technologies for depositing thin films. The award is
under DARPAs Local Control of Materials Synthesis (LoCo) program, which is investigating
non-thermal approaches for depositing thinfilm coatings onto the surfaces of a variety of
materials. The goal is to overcome reliance on
high-thermal energy input by examining the
process of thin-film deposition at the molecular component level. www.swri.org.
17
industry
news
briefs
Researchers at five Fraunhofer

Institutes, Germany, are developing
production methods to improve the
tribological performance of
combustion engines. The focus is
on components exposed to
particularly high levels of friction,
such as running surfaces of engine
cylinders. The new process is
designed to improve the influence
on friction and wear in engine
components in the futuretaking
the automotive industry a significant
step closer to using energy more
efficiently and reducing CO2
emissions.
www.fraunhofer.de/en.html.
Columbia University, New York,
engineers demonstrated that
graphene, even if stitched together
from many small crystalline grains,
is almost as strong as graphene in
its perfect crystalline form. Their
work resolves a contradiction
between theoretical simulations,
which predict that grain boundaries
can be strong, and earlier
experiments, which indicated that
they were much weaker than the
perfect lattice. Commonly used
methods for post-processing CVDgrown graphene weaken grain
boundaries, resulting in the
extremely low strength seen in
previous studies. The team
developed a new process that
prevents graphene damage during
transfer.
http://engineering.columbia.edu.
Scientists at Contipro Biotech,
Czech Republic, developed a jet for
efficient coaxial nanofiber
production at the industrial scale.
The fiber coating can be made from
quickly soluble material, which
releases a large amount of
substance from the huge surface of
nanofibers in a short time.
Conversely, the middle of a fiber can
retain its mechanical properties and
release only small quantities of
substance over an extended period.
Timing can be controlled for all of
these processes, useful in medical
and other applications.
www.contipro.com.
18
NANOTECHNOLOGY
Antiwear nanocoating for oil and gas market
Alcoa, Pittsburgh, and RUSNANO, Moscow, will produce advanced oil and gas aluminum drill pipe finished with a life-extending antiwear coating under a Memorandum of
Understanding (MOU) signed by the companies. They will investigate potential application of a nanotechnology-based coating for aluminum drill pipes to enhance its wear resistance in corrosive drilling environments. Under terms of the MOU, Alcoa will use its
Samara facility in Russia to produce aluminum drill pipe with hot fit tool joints for the
countrys oil and gas market. RUSNANO Capital, a subsidiary of OJSC RUSNANO, will
contribute capital. The antiwear nanocoating is expected to extend the life of aluminum
pipe by approximately 30-40% in corrosive drilling environments compared to uncoated
aluminum pipe. www.alcoa.com, http://en.rusnano.com.
Graphene enhances substrates for CNT growth
A diamond film/graphene/nanotube
structure was the result of new research carried out by scientists at Rice University,
Houston, and the Honda Research Institute
USA, Mountain View, Calif. When graphene
is used as a middleman, surfaces considered
unusable for carbon nanotube (CNT)
growth now have the potential to do so. Diamond is a good example, according to the
team. Diamond conducts heat very well, but
has a low surface area. A vertically aligned
forest of CNTs grown on diamond would
disperse heat like a traditional heat sink, but Single-layer graphene is used to grow
with millions of fins. Such an ultrathin array forests of nanotubes on virtually anything.
Freestanding CNTs on graphene lifted off of a
could save space in small microprocessor- quartz substrate are shown. One hybrid
material created by the labs combines three
based devices.
The team grew various types of graphene allotropes of carbongraphene, nanotubes,
and diamondinto a superior material for
on copper foil by standard chemical vapor thermal management. Courtesy of Honda
deposition. The tiny graphene sheets were Research Institute.
transferred to diamond, quartz, and other
metals for further study. Researchers found that only single-layer graphene worked well,
and sheets with ripples or wrinkles worked best. Defects appeared to capture and hold the
airborne iron-based catalyst particles from which the nanotubes grow. Researchers think
graphene facilitates nanotube growth by keeping the catalyst particles from clumping. The
graphene layer remains intact between the nanotube forest and the diamond or other substrate. On a metallic substrate like copper, the entire hybrid is highly conductive. Such
seamless integration through the graphene interface would provide low-contact resistance
between current collectors and the active materials of electrochemical cells, a step toward
building high-power energy devices. www.honda-ri.com/HRI_Us, www.rice.edu.
Agreement to work on graphene
National Graphite Corp. (NGRC), Las Vegas, entered an agreement with American
Graphene LLC to explore joint business opportunities in the promising graphene market. NGRC supplied high grade graphite samples from its Chedic Graphite mine near
Carson City, Nev., to the laboratory facilities of American Graphene LLC near Phoenix.
Through a sonication process, graphite ore from the mine was reduced to a nanomaterial that has subsequently been sent to a metallurgical facility to determine its grade and
commercial viability. The companies will explore an exclusive supply agreement where
NGRC will supply high grade graphite to American Graphene, as well as cost effective
and scaleable processing facilities and commercial markets for the graphene product.
www.nationalgraphitecorp.com.
Scanning Vibrating Probe

Monitors Al Stress Corrosion Cracking
K. Williams
R. Bayles
Center for Corrosion

Science and
Engineering,
Naval Research
Laboratory
Washington, D.C.
D.D. Macdonald,
FASM*
Departments of
Nuclear Engineering
and Materials Science
and Engineering,
University of
California, Berkeley
Although
specifics of
stress corrosion
cracking in
certain metal
alloys remain
elusive, a new
probing process
holds promise
for a deeper
understanding
of crack
mechanisms.
he exact mechanisms of stress corrosion

and hydrogen induced cracking (SCC and
HIC) in specific metal alloys remain elusive, due to the way these phenomena differ for
each alloy, environment, or loading characteristics.
In addition, some alloys undergo sensitization,
where after exposure to certain temperature-time
profiles, they become susceptible to intergranular
attack. For example, in sensitized stainless steels
cooled through the 550-850C temperature range,
Cr carbides are formed at the grain boundaries
tying up the corrosion-resistant alloying element,
Cr. 5XXX Al alloys, such as 5083 (AA5083), also
experience sensitization when exposed to moderate temperatures (50C) for long periods of time
or to higher temperatures (175C) for shorter periods[1-5]. The ability to probe the SCC process
electrochemically in siturather than with mechanical instruments and electron microscopes
alonecould prove valuable in revealing specific
cracking mechanisms.
In the past, a technique was developed to interrogate the SCC process in-situ, through timebased measurement of the coupling current
(CC)[6]. CC flows from an inherently anodic crack
tip, or any other localized anode not related to a
crack (e.g., pits and crevices), to an alloys external
surfaces. This CC demonstrates strong coupling
between the cracks internal and external environment (the solution). The experimental setup for
measuring CC involved mounting cathodes close
to the sides (within a few microns) of an electrically insulated fracture mechanics specimen, to
only monitor CC from the crack tip. After load
was applied to the specimen, current flowed from
the freshly created crack tip to the mounted cathode (in the case of an insulated specimen) as predicted by the differential aeration hypothesis[7].
CC was measured using a zero resistance ammeter (ZRA) and a piezoelectric sensor, employed to
monitor acoustic emissions. These procedures
helped define the mechanism of crack growth in
sensitized Type 304 stainless steel[8-10].
The present study expands on recent research on AA5083 by introducing new experimental techniques to examine crack growth in
situ. Position-based maps of coupling
current/potential gradients around the crack tip,
mouth, and surrounding external surfaces were
collected to further characterize coupling between the crack and external surface. A scanning
vibrating electrode technique (SVET) examines
the position dependence of CC magnitude, while
a custom, horizontally-oriented fracture mechanics setup is designed for simultaneous mechanical and electrochemical evaluation.
Given a solution conductivity of about 4.4
mS/cm (in a typical experiment), this probes estimated resolution is near 100 m. Resolution
can be improved by an order of magnitude by decreasing the conductivity by an order of magnitude. However, the selected concentration is
closer to those found in real-world applications.
Although results apply specifically to AA5083
samples, these techniques can be used to investigate crack growth mechanisms in other alloys.
Horizontal fracture mechanics apparatus
As-received and sensitized AA5083-H116 bars
manufactured by Alcoa, Pittsburgh, were pre-
Applied load
10 in.
Plan view
AA5083
specimen
(laying on
its side)
Machined notch
and crack tip
Notch view
SVP probe
Waterline in cell
*Fellow of
ASM International
Load pins
Fig. 1 A portion of the

combined fracture
mechanics, crack mouth
opening extension device,
acoustic emission, and
scanning vibrating probe
(SVP). The AA5083
specimen is in contact with
two outer loading pins/
bolts (right) connected to
the sliding stage and load
cell (left) and two inner
stationary loading pins
(left). A plastic electrolyte
container is glued to the
sample and located
between the two inner
loading pins.
Load pins
19
pared for SCC analysis in the horizontal

four-point bend fracture mechanics setup.
Sensitized 0.75 in. thick 10 in. long 1.5
-0.03480
in. wide bars were prepared by heat treat-0.02417
ment in a 175C oven for 14 days. Sensi-0.01355
tized samples were heat treated to a degree
0.04
-0.002925
of sensitization (DOS) of 40-50 mg/cm2, as
defined
by the ASTM G-67 mass loss
0.007700
[11]
test
.
Both
sample types were tested to
0.01832
0.02
compare SCC behavior between high and
0.02895
low DOS values. As-received specimens of
0.03957
AA5083 exhibited a DOS of 4 mg/cm2,
0.00
0.05020
whereas the sensitized samples showed a
DOS of 30 mg/cm2.
In a separate study, other fracture me-0.02
chanics experiments (not designed for simultaneous CC detection) were carried
out
to identify subcritical crack growth in
4000
Cathodic
Al matrix
a
0.125
in. thick wedge-opening-load
IMC location
location
2000 m)
Po
(WOL)
sample,
an elongated version of
5000
sit
(
ion
n
the
compact
tension
sample. AA5083o
(m
i
sit
) Galvanic
H116 fracture mechanics specimens were
Po
potential drop
prepared for analysis in a horizontal fracture mechanics load frame[13]. Orientation
Fig. 2 SVP map of activity above an insulated 2-mm Cu rod embedded in an AA2024 matrix
that simulates the behavior of an intermetallic compound (IMC) in an aluminum matrix. The
was chosen so clevises of the fracture meregion with the lowest potential (green to black colors also shown towards top of legend) is
chanics device were not exposed to the
due to the coupling current passing between anodic and cathodic regions.
solution, which could lead to galvanic
couples when the materials were dissimilar.
Load (lb)
12
In the present study, a customized fracture mechanics
KISCC determined
Failure at
load
frame was designed for a horizontally-oriented fourlow load
300 here on step just
10
before load drop
indicative
point
bend bar that was oriented on its side with the largest
with ext. increase
of SCC
8
surface area, to expose the limited region around the notch
200 KISCC = 2.4 ksi in.
and growing crack to the 0.06 M saltwater solution, with6
out exposing the contacting mechanical components. This
4
relatively new approach to orientation was ideal for adding
100
a
moveable scanning probe platform to obtain localized
2
corrosion maps during load application. A schematic of the
0
//
0
setup is shown in Fig. 1.
0
100,000 400,000 600,000 800,000
To test AA5083 specimens in the fracture mechanics
Time (s)
setup,
an adaptation of incremental step loading, ASTM
Fig. 3 Load (blue) and crack mouth opening displacement
F162409 was used, in which load is increased to a certain
(CMOD) behavior (red) during the incremental step loading
procedures with a wedge-opening-load sample on another
value and held there for a period of time[12]. During the exfracture mechanics apparatus. Onset of subcritical crack
periment, actual applied load was determined by using
growth is identified when a load drop occurs with a
load
cell and data acquisition components. Crack mouth
simultaneous CMOD increase. The load holds provide a place
opening displacement (CMOD) values were collected by
to determine crack growth rate and to perform electrochemical
evaluation with the SVP.
placing a clip gauge in a notch cut through the specimens
top plane to start the crack.
Fig. 4 Section of the
Load (lb)
CMOD (milli-in.)
Potential (V)
Potential levels
10-in. bar sample that

contains the region of
interest for scanning and
the Mg insert, machined
notch, and growing crack.
The red arrow indicates
scanning direction.
20
0.039-0.0787 in. /1-2 mm
Scanning vibrating electrode technique

Preliminary feasibility studies spatially resolve the galvanic currents in a Cu-Al model system in a 0.06 M saltwater solution. SVET was used to analyze galvanic coupling
between a 2-mm cylindrical copper wire embedded (in
electrical contact, but separated by a spacer) through the
top surface of a rectangular aluminum alloy 2024 (AA2024)
electrode approximately 10 5 mm with a thickness of approximately 4 mm (macro-galvanic couple). This experiment was designed to demonstrate the type of localized
corrosion that would occur between an intermetallic compound (IMC) and its surrounding metal alloy matrix
(micro-galvanic couple). Potential maps were acquired as
the scanning vibrating probe (SVP) vibrated 30 m in a direction perpendicular to the sample surface (above the top
surface). ZRA was used to couple Al and Cu in these experiments and measure coupling current.
The experimental setup for the fracture mechanics
study combines electrochemical analysis using SVP with
mechanical analysis via fracture mechanics techniques. To
analyze fracture toughness in the presence of corrosive
media, a four-point bend apparatus applied a load to a precracked sample positioned on the side of the sample with
the largest surface area parallel to the bench (see Fig. 1).
Load was applied normal to the surface of the laboratory
bench. A steel platform was also designed to allow the sample to be subjected to load and for potential maps to be
gathered simultaneously.
Test results
Initial SVP scans performed on Al electrodes with embedded Cu were successful in detecting and quantifying
galvanic current flowing between the metals. 3D SVP potential scans were obtained, where, typically, the x and y
axes represent the probes location and the z axis represents the intensity of the measured potential at the corre-
sponding location. SVP scans of the AA2024/Cu sample

yielded intensity plots with two variations. The first scan
revealed the nature of the galvanic currents passing between dissimilar IMCs in an alloy matrix. According to the
settings of the electrometer and amplifier, the probe
records a spike in potential/current above the Cu, representing a cathodic region in the couple. A potential depression immediately follows in the surrounding spacer region
where anodic current flows from the Al to the Cu. In noninterfacial regions, away from the Cu-Al interface, baseline
potential was obtained with exception of a few spikes,
which may have been related to random errors from the
instrumentation or other local corrosion events such as
pitting (see Fig. 2). These initial experiments demonstrate
the feasibility of detecting the coupling current that flows
between dissimilar metals in an electrolyte.
In initial testing of AA5083 WOL fracture mechanics
specimens, the onset of subcritical crack growth was determined by identifying the load step where a load drop corresponds to an increasing CMOD value[13]. The load and
CMOD signals for two different DOS values are shown in
Fig. 3. Computing the change of CMOD divided by the
change in load (CMOD/P) yields values whose average
is nonzero when the crack starts growing. The value of the
load on the load step prior to subcritical crack growth is
used to determine the critical value of the fracture tough-
21
0.01000
0.01000
-0.008667
-0.008667
-0.3200
-0.3200
-0.5533
-0.5533
-0.7867
8000
n (m)
Positio
10000
5000
1000
Dominant signal from the
scanning above the Mg insert
-0.10
-0.1253
-0.1487
-0.1720
-0.2000
4000
-0.15
6000
8000
-0.20
Load = 0 lb
-0.025
-0.030
10000
-0.040
-0.7867
-0.1029
-0.1253
-0.1487
-0.1720
-0.2000
-0.045
(m)
tion
Posi
5000
1000
-0.050
Load = <100 lb
Fig. 5 Initial SVP scan taken 0.5 hours after exposure to 0.06
M saltwater. A strong anodic potential dominates any additional
anodic signals elsewhere above the region of interest. Faint
blue lines represent approximate size and location of the Mg
insert, notch, and final crack.
Fig. 6 SVP scan approximately two hours after exposure to

saltwater. The Mg has mostly dissolved and active signals
appear in the notch region. Faint blue lines represent approximate size and location of the Mg insert, notch, and crack.
ness for stress corrosion cracking under Mode I loading

(KISCC). This KISCC value, according to Saxena and Hudak,
can be calculated using this formula:
Summary
A unique horizontal fracture mechanics device was developed to examine AA5083 bend bars mechanically and
electrochemically using a scanning vibrational probe to detect and characterize the coupling current flowing from
the crack to external surface, where it is annihilated by a
cathodic charge transfer reaction (e.g., hydrogen evolution
or oxygen reduction). Hence, the coupling current from
the crack was spatially resolved while the specimen was actively loaded. The notch is active during loading and becomes more passive toward the end of the experiment.
With knowledge from previous fracture mechanics studies
on wedge-opening-load samples, the onset of subcritical
crack growth was verified with the aid of an extensometer
or clip gauge. Together with results of studies now underway, crack growth mechanisms may be more fully understood with regard to different sensitized alloys that
undergo stress corrosion cracking.
where KI
is the fracture toughness, W is the width of the specimen, a is
the crack length, and B is the specimen thickness[13].
The customized horizontal device used for the spatial
determination of the CC verified sources of the current as
being the notch and crack. Resulting potential maps from
an unsensitized specimen were obtained and are reported
in this study; potential maps for higher DOS levels will be
published in the future. To establish current flow direction,
a portion of Mg wire was embedded in the alloy near the
notch to act as a known source of anodic current. This
sample configuration is shown schematically in Fig. 4. During dissolution of Mg, a strong anodic depression dominated the SVP potential map, as shown in Fig. 5. As more
of the Mg dissolved, the potential recorded above the Mg
insert diminished toward the baseline (although not completely), as seen in the corners of the map in Fig. 6. The region above the notch starts to show an anodic potential, as
it is also a source of the coupling current.
As the load increased and the crack grew, the anodic
region became more confined to the notch and crack
alone, with a significantly lower contribution from the
nearly depleted Mg. This is shown in Fig. 7, where the bottom contour of the map reveals a more concentrated dark
coloring (lower potentials) around the notch and crack.
Eventually, the notch region away from the crack became
less anodic as the crack arrested, due to cessation of electrochemical crack growth and lack of energy for continuing crack growth by mechanical means, as shown in Fig. 8.
22
2000
-0.020
-0.035
m)
n (
itio
Pos
6000
m)
ion (
Posit
4000
-0.05
Poten
tial 2 (V
)
2000
Poten
tial (V
)
0.00
-0.1029
Acknowledgments
The author acknowledges NRL and the NRL SCEP program for
financial support and Ronald Holtz for technical assistance.
For more information: Krys Williams is an NRL SCEP student,
Center for Corrosion Science and Engineering, U.S. Naval Research Laboratory, 4555 Overlook Ave. SW, Washington, DC
20375, krystaufeux.williams@nrl.navy.mil, www.nrl.navy.mil.
References
1. R.H. Jones, et al., Metall. Mater. Trans. A, Vol 32A, 2001.
2. R. Goswami, et al., Mater. Sci. Eng. A, 527:1089-1095, 2010.
3. J. Gao and D.J. Quesnel, NACE Corrosion 2010 Conference
Proceedings, Houston, 2010.
4. J.R. Searls, The Electrochemical Characteristics of Al2Mg3 and
Stress Corrosion Cracking of AA5083 (Al-4.5, Mg-1.0, Mn), MS
Thesis, The Ohio State University, 2000.
5. K. Yasakau, et al., Electrochim. Acta, Vol 52, No. 27, p 7651-7659,
2007.
6. D.D. MacDonald and M. Urquidi-MacDonald, Corros. Sci., Vol
32 (1), p 51-81, 1991.
7. U. R. Evans, et al., Proceedings of the Royal Society of London,
Series A, Containing Papers of a Mathematical and Physical Char-
0.01000
0.01000
-0.008667
-0.008667
-0.3200
-0.3200
-0.5533
-0.5533
6000
8000
10000
-0.1253
-0.1487
-0.030
-0.1720
-0.035
-0.2000
-0.040
(m)
tion
Posi
5000
1000
Poten
tial 9
(V)
-0.025
-0.015
-0.1029
-0.045
~ 600 lb
Load ~
2000
4000
6000
-0.020
-0.025
-0.030
(m)
tion
Posi
4000
m)
n (
itio
Pos
2000
Poten
tial 3
(V)
-0.7867
-0.020
8000
10000
-0.7867
-0.1029
-0.1253
-0.1487
-0.1720
-0.2000
-0.035
-0.040
n (m)
Positio
5000
1000
-0.045
~ 3400 lb
Load ~
Fig. 7 SVP scan after approximately 22 hours of exposure to

saltwater. The region above the notch and the crack become
sources of anodic potentials, and therefore are sources of
coupling current. Faint blue lines represent approximate size
and location of the Mg insert, notch, and crack.
Fig. 8 Scan after approximately 70 hours of exposure to

saltwater. The potential from the upper region of the notch and
Mg insert decreased, and the anodic areas became more
confined as shown by the darker coloring being more restricted
to the middle of the map. Faint blue lines represent approximate
size and location of the Mg insert, notch, and crack.
acter, Vol 131, No. 817, p 355-375, 1931.

8. M.P. Manahan, Sr., D.D. MacDonald, and A.J. Peterson, Jr.,
Corros. Sci., Vol 37 (1), p 189-208, 1994.
9. M. Gomez-Duran and D.D. Macdonald, Corros. Sci., Vol 45 (7),
p 1455-1471, 2003.
10. M. Gomez-Duran and D.D. Macdonald, Corros. Sci., Vol 48
(7), p 1608-1622, 2005.
11. ASTM Standard F162409, ASTM International,
W. Conshohocken, Pa., 2003.

12. ASTM Standard G6704, Test Method for Determining the
Susceptibility to Intergranular Corrosion of 5XXX Series Aluminum Alloys by Mass Loss After Exposure to Nitric Acid
(NAMLT Test), ASTM International, W. Conshohocken, Pa., 2003.
13. Ashok Saxena and S.J. Hudak, Review and Extension of Compliance Information for Common Crack Growth Specimens,
Int. J. Fracture, Vol 14 (5), p 453-468, 1978.
23
TECHNICAL SPOTLIGHT
Detailed Simulation Helps Validate

Weld Designs in Large Marine Engines
FEA and
XFEM verify
that a new
weld
design is
safe for
both repair
of existing
engines and
use in
future
engines.
urmeister & Wain (B&W), with nearly a century of expertise in shipbuilding, is now part of
MAN Diesel & Turbo whose marine low-speed
business unit is located in Copenhagen, Denmark. The
unit produces new engines that can weigh up to 2800
metric tons and reach 16 m high. Once such giant engines are installed, they must be serviced in place as infrequently as possible.
Reliability and durability are crucial to marine engines. They are built to perform for more than 30 years,
roughly 6000 hours per year, and at a constant speed
of about 100 rpma billion revolution cycles on full
design load. Under these grueling conditions, fuel combustion and inertia of moving components can potentially cause high-cycle fatigue failure.
Every part of our engines must be designed and analyzed with sufficient safety margins against fatigue
loadsright down to the welds, says Tore Lucht, an industrial researcher in MAN Diesels R&D department.
Simulating cracks to prevent weld fatigue
Paying full attention to every weld detail in complex engine structures became a focus when a butt
Top: A diesel
engine on the
MS Selandia,
built by B&W in
1911-12 and
launched in 1912.
Right: A modern
MAN B&W
two-stroke diesel
engine.
24
weld on a low-speed marine diesel engine developed a

crack. The weld was located on the face of a second
order compensator, a large rotating component that
dampens engine vibration for greater crew comfort.
While the compensator was designed to withstand
large loads and stresses, the engine had only been in
service for two years, logging 13,000 hours and approximately 78 million revolutions of the crankshaft when
the crack was observed.
A preliminary investigation used Abaqus finite element analysis (FEA) from Simulia, Dassault Systmes,
France, for realistic simulation. In the initial investigation, a small cut-out from the engine undergoing centrifugal force from the flyweights was modeled (Fig. 2).
The centrifugal force was that of a MAN B&W 5S60MCC diesel engine at 100% rpma 16-metric-ton load.
All of these loads were accurately simulated based
on decades of field data from operating engines. The initial simulation showed that small areas of the weld root
had stress levels above a reasonable design limit. A different weld design might significantly reduce stress amplitude and solve the problem, but engineers needed to
make sure that the improvement was sufficient.
The International Institute of Welding (IIW) recommends three different methods to analyze welds:
hot spot stress, effective notch stress, and fracture mechanics. The first method compares structural stress
at the hot spot with the FAT (fatigue) class of different
weld details. Effective notch stress analysis can assess
both toe and root stress level, again comparing each to
a special FAT class. Fracture mechanics can simulate
typical weld defects on any part of the weld, using linear elastic fracture mechanics (LEFM).
Analysts decided that LEFM would give them the
most accurate answers, even though it potentially involved a great deal of model preparation. The team used
Abaqus eXtended Finite Element Method (XFEM) technology to reduce modeling time while offering an enriched environment for exploring fracture failure, even
when the crack does not follow element boundaries.
Other advanced numerical models of engines in Abaqus
cut simulation time further.
The area of the crack in XFEM was submodeled
with a fine mesh. Investigating a crack of a few millimeters growing in a four-story engine requires some mesh
refinement in the pertinent area and the submodeling
strategy made the task easier and less time-consuming.
Opting to model the most severe dynamic loading
on the crack, contact in the crack definition was excluded, leaving a weld gap (Fig. 2). Weld gaps can occur
in such a structure due to either residual stresses from
welding or a slight misalignment between parts that
join the weld. After calculating the stresses on the
Fig. 1 Cutaway model of a second order

moment compensator for a marine diesel
engine, showing the dual flyweights.
Fig. 2 Left to right: A section of the global model of the compensator, a cut view of the weld
gap, and an XFEM submodel of the crack in the weld.
original design, similar analysis was performed on proposed welds for the engine repair and for weld designs
on new engines going forward.
Residual stress
and modeling the welding process
One final load check was required to confirm that
the repair was sufficiently strongthe residual stress
state caused by the welding process itself. This stress
was not included in the other LEFM calculations, and
could potentially alter the strength of the final weld.
To determine the welds residual stress state, a previously developed weld simulation tool for Abaqus was
useda specialized modeling principle for simulating
a moving heat source by weld filler, body flux, and surface flux. The simulation adds the weld filler incrementally, with elements representing the weld filler
assigned a temperature above its melting point.
Elements were activated in groups using the model
change command and predefined values for temperature, body flux, and surface flux. New groups were automatically activated in subsequent steps as the old
groups cooled as a function of the heat transfer. Realistic simulation of the moving heat source of the weld
is key to this type of simulation. By adjusting active parameters like weld sequence, heat, and flux, obtaining
a high level of validation was possible by making comparisons to experiments using methods such as neutron diffraction measurements.
Simulation helped illustrate the result of welding an
additional supporting structure onto an engine. This predicted both the deformation of the existing engine structure and the size of the residual stress field around the
crack front. Analysis assumed that filler material was
welded in only three strings, and welding was simulated
along the side of the model, where it would introduce
residual stresses perpendicular to the only critical weld
defect that could cause an opening or closing of the crack.
Final simulation results enabled engineers to relate
both residual welding stress fields and crack simulation to
obtain realistic fatigue assessments (Fig. 3). As expected,
large tensile residual stresses remained at the toes of the
weld, but the stress level was close to zero at the welds
Fig. 3 Step-by-step simulation of the welding process, adding weld

filler under incremental passes of heat.
root, meaning that the stress intensity factor evaluation

of the critical root of new weld designs would only be
marginally influenced by the residual stresses of welding.
Despite this, it is good practice to take precautions
such as adding a peening step to the weld toes, to limit
the influence of high tensile stresses on the safety margin
against fatigue failure, so that a new problem with the repair is not introduced.
Results show clear sailing ahead
Realistic simulation revealed why the original weld
design performed as it did and confirmed that the new
design would be safely within the recommended limit
curve. The demonstrated lack of tensile stress in the
weld root proved out the integrity of the new design.
This combined method of weld process simulation
and fracture mechanical evaluation of weld defects
with XFEM is a strong tool to evaluate the structural
integrity of complex welded structures, says Lucht.
From this analysis, we were able to verify that our new
weld design is safe, both for repair of existing engines
and for use in future engines.
For more information: Tore Lucht is an industrial researcher in the R&D department of the marine low-speed
business unit of MAN Diesel & Turbo, Teglholmsgade
41, DK-2450 Copenhagen SV, Denmark, +45 3385-1100,
Tore.Lucht@man.eu, www.mandieselturbo.com.
25
Failure Analysis of a
Natural Gas Pipeline Rupture
Frances Richards
ASM International
Materials Park, Ohio
From aviation
accidents to
pipeline
explosions,
the National
Transportation
Safety Board
is often called
to determine
probable
cause and
make safety
recommendations, as they
did in
the aftermath
of the 2010
San Bruno
pipeline
explosion.
n September 10, 2010, one of Pacific

Gas and Electric Companys (PG&E)
natural gas transmission pipelines
ruptured in San Bruno, Calif., killing eight people and causing multiple injuries. In addition,
38 homes were destroyed and another 70 were
damaged. San Bruno, population 40,000, is located just 12 miles south of San Francisco. Soon
after the rupture occurred, the National Transportation Safety Board (NTSB) sent a team to
investigate.
As part of the investigation, a 28-ft section
of ruptured pipe along with the exposed ends
of the pipe still underground were sent to the
NTSB Materials Laboratory in Washington,
D.C., for examination. The materials engineer
in charge of the examination was Donald
Kramer, Ph.D., who discussed the investigation
during a recent ASM Emerging Professionals
webinar series.
As part of the failure analysis, NTSB investigators worked together with experts from
PG&E, the California Public Utilities Commission, and the Pipeline and Hazardous Materials Safety Administration. Microscopy, along
with other data and historical information,
was used to help determine the probable cause
of failure. Line 132, part of a larger natural gas
transmission network, begins in Milpitas, near
San Jose, and runs north to Martin Station,
south of San Francisco, passing through San

Bruno on its route. The line was originally
constructed in two phases, the first in 1944
and the second in 1948. The portion through
San Bruno was originally built during the 1948
phase using new pipe from Consolidated
Western Steel Corp., a steel mill in the Los Angeles area.
The original Consolidated Western materials consisted of double submerged arc
welded (DSAW) pipe, with each piece approximately 31 ft in length. Original pipe was
slightly undersized and then hydraulically expanded to a 30-in. diameter using cold expansion, a state-of-the-art method for the time.
Minimum yield strength was 52,000 psi, or
X52 according to American Petroleum Institute (API) specifications. The X means that
the pipe was hydrostatically tested by pumping it full of water at pressures corresponding
to 90% of yield strength.
Eight years later, a PG&E construction crew
was working on Line 132 in the future San
Bruno neighborhood. In 1956, a segment of
pipeline needed to be relocated by PG&E due
to a subdivision development project. Segment
180, the relocated pipeline section, was constructed mainly from surplus and reconditioned DSAW pipe and involved roughly 1851
ft of Line 132 being moved west about 10 ft.
However, at one location, the
pipeline was constructed from
six short lengths of pipe, often
referred to as pups. Five of
those pups, including the pup
where the rupture would initiate, had properties that differed from DSAW pipe.
As part of the San Bruno investigation, a 28-ft section of ruptured pipe along with the exposed ends
of the pipe still underground were sent to the NTSB Materials Laboratory in Washington, D.C.,
for examination. Shown here are the ejected pipe section and crater.
26
Comparing pipe properties

As part of the failure analysis, multiple attributes of the
pups were evaluated and compared to X52 DSAW pipe. A
few of those attributes included the seam weld morphology, rolling direction of
the steel, and mechanical
properties of the steel. The
seam welds on five of the pups
were not only dissimilar to
DSAW pipe, but also differed
among themselves. Most im-
portantly, the seam on the pup where the rupture would initiate was welded from the outside
only, leaving a crack-like defect that was about
half of the wall thickness on the inside of the
pipe. Other notable differences included removal of the weld reinforcement and the fit-up
angle. Using 2D finite element models, investigators showed the role that the weld morphology had on increasing the stresses and reducing
the strength of the seam.
The rolling direction of the pipe was determined by analyzing stringer orientation on
metallographic cross sections. Stringers are
manganese-sulfide inclusions that elongate in
the direction that steel plate is rolled, which is
in the longitudinal direction for line pipe. However, for four of the pups, including the pup that
ruptured, stringers were elongated in the circumferential direction, proving that they were
made as short segments.
With regard to tensile yield strengths, none
of the pups met the X52 requirement. Of note,
the ruptured pup had a yield strength of 36.6 ksi.
Based on the differences in pipe attributes,
NTSB concluded that five of the pups, including the ruptured pup, had qualities inconsistent
with the DSAW pipe, and were made at an unknown facility to unknown specifications. Furthermore, four of those pups were originally
fabricated as short pipe lengths and not cut
from longer pipes.
Analyzing system pressure
On the day of the accident, electrical work
was being performed on the transmission network at Milpitas Terminal. An electrical failure caused the loss of primary pressure
regulation, which lead to a rise in overall system pressure. When the pressure inside Line
132 reached 386 psi in San Bruno, the pup
with the partially welded seam, described
above, ruptured. The team examined the seam
by optical and electron microscopy and found
the rupture initiated at a preexisting crack in
the weld that had grown first by ductile fracture and then by fatigue.
Although Line 132 can legally operate to
400 psi, it typically runs below 375 psi. When
NTSB looked at historical pressure data for the
11 years preceding the accident, only two instances of pressures above 375 were ever
recorded; in 2003, 383 psi was reached, and in
2008, 382 psi was recorded.
Overview of Line 132.
Cross section of longitudinal seam in

typical DSAW pipe.
Cross section of longitudinal seam in the

pup where the rupture initiated.
Quality control
The Safety Board concluded that the San
Bruno pipeline rupture was due in part to inadequate quality assurance, as there were a
number of materials and construction quality
measures thathad they been usedwould
have or could have detected the deficient
pups. With regard to materials, in addition to
lot-level quality checks, the specification for
X52 pipe stated that each piece of pipe must
pass a proof test. The NTSB determined that
the ruptured pup would not have passed the
This schematic shows the

pipeline segment that was
constructed from six short
lengths of pipe, often referred to
as pups. Five of those pups,
including Pup 1 where the
rupture initiated, had properties
that differed significantly from
the DSAW pipe used on the rest
of the transmission line.
27
90% proof test for X52 pipe, requiring the pipes to withstand 1170 psi.
With regard to pipeline construction, there were several quality assurance methods available at the time including visual inspection, hydrostatic testing, and radiographic
inspection. The visual appearance of a typical DSAW longitudinal seam was quite different from the ruptured pups
longitudinal seam. NTSB concluded that a simple visual
inspection should have caught the deficient seam weld,
thus indicating that either the deficiencies were known and
ignored or the visual inspection was not done correctly,
thoroughly, or perhaps not at all.
Hydrostatic testing is also commonly used to ensure
pipeline integrity by pumping pipes full of water at elevated pressures and is mandatory for new pipeline construction today. In unpopulated areas, testing generally
stresses pipes to 10% above maximum allowable operating pressure. In residential areas, such as present-day San
Bruno, pipelines must be tested to 50% above the maximum allowable operating pressure. However, at the time
Segment 180 was constructed, hydrostatic testing was
not required. The NTSB determined that, depending on
the test pressure used, hydrostatic testing might have
caught some of the deficient pups.
Similarly, radiographic inspection is routinely used
today on new pipeline construction and is required to
ensure the integrity of field welds. However, at the time

that Segment 180 was constructed, radiographic inspection was not required. Had the welds been inspected by
radiography, the ends of the deficient seam welds likely
would have been detected.
Probable cause
The NTSB determined that PG&Es inadequate quality assurance and quality control in 1956 during its Line
132 relocation project allowed the installation of a substandard and poorly welded pipe section. The section included a visible seam weld flaw that over time grew to a
critical size, causing the pipeline to rupture during a
pressure increase stemming from poorly planned electrical work at the Milpitas Terminal. Further, an inadequate pipeline integrity management program failed to
detect and repair or remove the defective pipe section.
As a result of this accident investigation, the NTSB issued 29 safety recommendations, including a recommendation to require hydrostatic pressure testing of
lines like 132, and to make gas transmission lines
amenable to inline inspection methods.
For more information: Visit www.ntsb.gov/investigations/
2010/sanbruno_ca.html.
Selective-Melt Sintering
Brings Speed and Efficiency
to Creating High-Density Ceramics
J. Narayan, FASM*
North Carolina State
University, Raleigh
Selective-melt
sintering can
occur at lower
overall
temperatures
and with much
lower energy
consumption
compared to
conventional
sintering
involving
solid-state
diffusion.
*Fellow of
ASM International
oth dc and ac electric fields significantly affect ionic conduction and

diffusion transport in ceramics[1-4]. In
the late 1970s and early 1980s, researchers
from Oak Ridge National Laboratory (ORNL)
and others extensively studied characteristics
of electrical conductivity in pure and impurity-doped MgO single crystals as a function
of temperature and applied field. They also
analyzed the role of defects and impurity
clusters in enhancing the electrical conductivity and mass transport, which led to an avalanche and thermal electric breakdown.
These studies establish the presence of high
concentrations of intrinsic (anion and cation
vacancies) defects and impurity precipitates
in highly conductive regions between electrodes after cooling. Enhanced conductivity
at high temperatures exhibits an avalanche
effect, which, if uncontrolled by limiting current flow, leads to melting and eventually
evaporation of materials between electrodes.
These results suggest a predominant role of
vacancies and impurities in electronic conduction and diffusion transport.
Although the ORNL work was done at
higher fields (>1000 Vcm-1) and higher temperatures (>1000C), other researchers [5-15]
found interesting results on mechanical
properties and sintering at lower fields,
which can be correlated with earlier results
at higher fields. At lower fields, effects occurred on polycrystalline NaCl, MgO, and yttria-stabilized zirconia materials related to
grain growth retardation, reduction in flow
stress, and enhanced ductility [5-8]. Applied ac
and dc electric fields produce a host of interesting phenomena related to sintering of
solid-state materials[9-15].
More recently[13-16], the application of dc
electric fields in the intermediate range of
about 30-100 Vcm -1 was found to produce
sintering of polycrystalline yttria-stabilized
zirconia in mere seconds at furnace temperatures of 850C, well below the normal sintering temperatures around 1450C[16].
Remarkably, these field-treated samples did
not exhibit grain growth. In a recent paper[17],
a unified mechanism to explain critical elements of the field-assisted phenomena, ranging from reducing flow stress to lowering the
overall effective sintering temperatures of

materials was proposed. A new grain growth
model was also proposed to take into account
defect generation under field-assisted conditions and it explained reduction in grain
growth rate, with the rate eventually reaching zero [18].
This article focuses on selective melting
of grain boundaries as a result of field-assisted generation of defects and their segregation at grain boundaries. Defect generation
is enhanced via field-assisted electron trapping by cations and it is further enhanced in
the presence of impurities, which can trap
electrons and create charge imbalance. Electrical-field induced defect creation has interesting parallels with pulsed laser annealing,
internal reduction, and vacuum annealing[19-20].
Field-induced defects interact with and segregate at dislocations and grain boundaries,
leading to higher currents and joule heat along
grain boundaries, which further enhances defect concentration. This leads to an avalanche
and melting of grain boundary regions. In the
case of microwaves, enhanced coupling with
grain boundaries occurs due to presence of
defects and impurities, which leads to selective heating of grain boundaries. This process,
referred to in this article as selective-melt sintering, can lead to fully dense grain boundary
regions in a short time, as diffusivities in liquid
state (10-4 to 10-5 cm2s-1) are substantially
higher (6-10 orders) than those in solid state at
normal sintering temperatures. This article
explores five critical issues related to fieldassisted sintering, leading to selective grain
boundary melting and the process of selectivemelt sintering (SMS).
Field-assisted generation of defects
When ceramics (wide bandgap materials)
are subjected to a field at high temperatures,
there is some thermal generation of free carriers, depending on the bandgap, trap density
(defects), dopant concentration, and Fermi level
position. The applied field transports these free
electrons, which can be trapped by cations and
defects such as anion vacancies. The electron
trapping by cations (Mn+>M(n-1)+) leads to internal reduction and creation of anion vacancies. This electron trapping can lead to
29
formation of M0 defects eventually (Mn+>M(n-1)+>M0),

which can cluster to form metallic precipitates. These
reduced cations often get kicked into interstitial sites,
leaving behind cation vacancies. Thus, applied field
promotes electron trapping, which generates anion
and cation vacancies, and M0 defects, which cluster to
form metallic precipitates. Certain impurities, such as
yttrium in zirconia and nickel in magnesium oxide,
provide more efficient traps and enhance the generation of defects and formation metallic precipitates.
This reduction process induced by applied field is
equivalent to high-temperature annealing in vacuum
and pulsed laser annealing [19-20].
Segregation of defects and impurity precipitation
at dislocations and grain boundaries
As just discussed, the applied field primarily generates
anion and cation vacancies, in addition to electron trapped
M(n-1)+>M0 cation and impurity defects. Neutral defects
can get into interstitial sites with lower activation energy
for diffusion and cluster to form impurity metallic precipitates. These cation and anion vacancies and M0 defects
can interact with dislocations and grain boundaries
through elastic and electronic (space charge) potentials.
Fig. 1
(a) Bright-field
electron
micrograph
under
kinematical
diffraction
conditions
optimized for
strain contrast
(Bragg deviation
parameter
= 0.6), showing
mostly a<100>
loops and
occasionally
a/2<110>
loops near an
edge dislocation.
Arrow indicates
direction of
diffraction
vector [200].
(b) Bright-field
electron
micrograph
under
kinematical
diffraction
conditions
optimized for
strain contrast
(Bragg deviation
parameter
= 0.6). Arrow
indicates
direction of
diffraction
vector [200].
30
(a)
1.00 m
(b)
0.20 m
Detailed studies on segregation of defects at dislocations

show the formation of vacancy loops around dislocations,
as shown in Fig. 1(a), where vacancy loops of a<100> Burgers vector are preferentially associated with an edge
a/2<110> edge dislocation. In MgO, which has NaCl structure, the formation of a<100> dislocation loops can occur
only as a result of clustering of vacancies [21]. The average
size of these dislocations is 50 nm (500 A) and number
density 1.0 x 1014 cm-3. From the number density and average loop size, the density of point defects is determined as
1.0 x 1019 cm-3. Assuming the formation energy of vacancy
around 4.0 eV, local temperature around dislocations from
which defects are quenched is estimated to be approximately 3000K. Note that vacancy dislocation loops lie only
on one side as expected for an edge dislocation, which has
a compressive stress field above the half-plane and a tensile
stress below it.
Results on grain boundaries after field treatment show
that point defects were absorbed by dislocation climb, and
there is a high density of impurity precipitatesas shown
in Fig.1(b)whose average size and number density were
estimated to be 10 nm (100 A) and 2.5 x 1015 cm-3, respectively. These results from field-treated samples clearly establish the role of high density of intrinsic anion and cation
vacancies and a small fraction of interstitials in addition to
impurities, which were present in small amounts in both
ORNL samples and nominally pure MgO crystals from
other studies. Note that these segregation effects of intrinsic defects and impurities are observed only in field-treated
samples; they disappear on subsequent thermal annealing
without the applied field. Also, such segregation effects are
not observed in samples quenched from high temperatures
in the absence of applied field.
Selective Joule heating and melting
of grain boundaries
It is argued that applying an electrical field assists
the generation of defects, where electrons take part in
the reduction of cations, and this reduction process
(Mn+>M(n-1)+>M0) eventually results in the formation of
M0 defects, which are kicked into interstitial sites[21]. The
concentration of M0 defects is determined by the efficiency of electron trapping and the gain in free energy,
G (= RT ln K), where K is the reaction constant. These
defects can migrate rapidly and contribute to electronic
conduction, and are also responsible for the formation of
metallic impurity precipitates upon cooling. M(n-1)+ and M0
defects segregate preferentially at dislocations and grain
boundaries through elastic interaction. This field-induced
reduction creates anion vacancies, which can trap electrons, leading to V-(V0 >V-) defects[22]. Electron trapping
is known to reduce migration energy of vacancies. These
defects segregate at dislocations and grain boundaries
through elastic and electronic interactions. The preferential ionic and electronic conduction along dislocations and
grain boundaries results in selective joule heating, which
can lead to avalanche heating and selective melting of grain
boundary regions.

= bvds exp(--Gk(1)
(a)
(b)
A
Free energy G
Role of defects
in mechanical properties
and grain growth retardation
Segregation and field-assisted migration of defects around dislocations and
grain boundaries causes enhanced ionic
and electronic conduction, which leads to
selective joule heating. Selective heating of
dislocations enhances their mobility and reduces flow stress. Temperature dependence
of strain rate can be expressed as [23],
1
V
gb
3
A
V
A 2
V
A
re
ri
Distance X
where is the mobile dislocation density, b Fig. 2 (a) Change in free energy with distance across the grain boundary with jump
is the magnitude of the Burgers vector of distance, . (b) Vacancy jumps (for vacancy-atom exchange) across the interior (radius ri) and
dislocation, d is the frequency of vibration exterior (radius re) of a grain boundary.
of the dislocation segment involved in the
Below the melting point, G=Sm. T, where Sm is the
thermal activation, and s is the average distance dislocachange in entropy and T is the undercooling. This thertion moves after the successful jump. The presence of demodynamic driving force will make external and internal
fects and joule heating increase the dislocation mobility
[7-8]
melt
boundaries move toward each other, resulting in zero
and reduce the flow stress . This reduction will saturate
net
grain
growth [16].
once all the impurities are reduced and the supply of vacancies is exhausted[17-18].
Grain boundary melting
Field-assisted generation and segregation of defects
and selective-melt sintering
at grain boundaries retards grain growth by promoting
The most interesting aspect of applied field is that
inverse vacancy jumps and reducing the thermodydefect segregation and an avalanche in field-assisted
namic driving force for grain growth, as shown in Fig 2.
transport can lead to selective melting of grain boundConsidering both kinetic and thermodynamic factors
aries while the bulk of the material within the grains is
under field-assisted conditions, grain growth rate is
at a much lower temperature transiently for a short pederived as[18],
riod of time, depending on thermal diffusivity of the ma
dr
G
G
(2)
dt = f c v D exp(-- kT )[1-- exp(+ kT )],
terial. Thus, selective-melt sintering can lead to a huge
reduction in energy for materials processing. The p
ratio of energy consumption under SMS to normal sinwhere Cv is vacancy concentration, D is Debye frequency,
tering can be estimated by,
f is the geometrical factor for vacancy jumps, G is the activation barrier for vacancy diffusion across the boundary,
p = TSMS/TN + 3gb/d(1 + Lm/TmCv),
(4)
and G is the gain in free energy as shown in Fig. 2, which
should be negative for the reaction to proceed.
where gb is the width of the grain boundary melted reGrain growth rate has two terms; f c v D exp(-- kTG ) is
gion, d is the grain size, Lm is latent heat of fusion meltG
the kinetic or diffusion term and [1-- exp(+ kT
)] is the ther- ing, Tm is the melting temperature,
Cv is the specific
modynamic term, which is associated with phase transforheat, TSMS is reduced temperature for sintering, and TN
mation or gain in energy with the movement of the grain
is the normal sintering temperature. Research shows a
boundary.
drastic reduction in sintering temperature from 1450C
Assuming G<< kT, grain growth rate can be expressed
to 850C in 3 mole% yttria-stabilized zirconia[16] with apas,
plied field of 40 Vcm-1. Using L m = 700 J/g, Cv = 420
J/gK, and Tm for 3YSZ as 2823K, a drastic 40% reducdr
- G
G
(3)
tion (for grain size, d = 60 nm, assuming gb = 4 nm in
dt = f c v D ( kT )exp(-- kT ),
equation 4) in energy consumption in materials processing by selective-melt processing. Because diffusivities in
The field-assisted defect segregation at grain boundliquid state are substantially higher (6-10 orders) than
aries promotes inverse vacancy jumps against grain
those in solid state at normal sintering temperatures,
growth, as shown in Fig. 2 (step 3). In addition,
fully dense materials are obtained in a much shorter
thermodynamic driving force G is reduced with applied
time. Because melting involves a first-order phase transfield and it can be driven to zero during the melting of
formation, all the porosity and impurities are redistribgrain boundaries. When there is a first-order phase transuted rapidly in the liquid phase, giving the appearance of
formation such as melting, the free energy at the melting
clean boundaries[24].
point is zero and grain growth rate will be driven to zero.
31
Summary
Applied electrical field assists generation anion and
cation vacancies and promotes reduction of cations and
impurities. The generation of defects is greatly enhanced
by impurities, which trap electrons supplied by the applied
field. Upon cooling, these vacancies cluster into dislocation loops and impurities into precipitates. Enhanced defect segregation coupled with field-assisted current flow
leads to selective joule heating of dislocations and grain
boundaries. The primary mechanism for selective joule
heating of dislocations and grain boundaries is the segregation and transport of defects, which are generated as a
result of applied field.
These effects reduce flow stress and retard grain growth
in the solid state. Selective joule heating, if not controlled by
limiting the current flow, generates more defects and sets
up an avalanche resulting in selective and localized melting
of grain boundaries, while keeping the bulk of the grain at a
much lower temperature. Selective melting removes porosity at grain boundaries and provides more efficient sintering due to first-order phase transformation and fast
diffusivities (10-4 to 10-5 cm2s-1) in the liquid. This sintering
mode is referred to as selective-melt sintering, which can
occur at lower overall temperatures and with much lower
energy consumption compared to conventional sintering
involving solid-state diffusion.
32
Acknowledgements: The author acknowledges useful discussions with Rishi Raj and comments by Hans Conrad.
For more information: Jay Narayan is The John C. Fan
Distinguished Chair Professor, Department of Materials
Science and Engineering, North Carolina State University,
Centennial Campus, EB-1, Raleigh, NC 27695-7907,
919/515-7874, j_narayan@ncsu.edu, www.ncsu.edu.
References
1. J. Narayan, R.A. Weeks, and E. Sonder, Aggregation of
Defects and Thermal-Electric Breakdown in MgO, J. Appl.
Phys., 49:5977-81, 1978.
2. R.A. Weeks, J. Narayan, and E. Sonder, Electric Breakdown in MgO Crystals at Elevated Temperature, Phys. Status Solidi, 70:631-39, 1982.
3. E. Sonder, et al., The Effect of Electric Current on the
Conductivity of MgO Single Crystals at Temperatures
above 1300K, J. Appl. Phys., 49:5971-76, 1978.
4. K.L. Tsang and Y. Chen, Suppression of Dielectric Breakdown in MgO Crystals at High Temperatures by Impurity
Doping, J. Appl. Phys., 54:4531-35, 1983.
5. D. Yang and H. Conrad, Influence of an Electric Field on
the Superplastic Deformation of 3Y-TZP, Scripta Mater.,
36:1431-35, 1997.
6. D. Yang and H. Conrad, Influence of an Electric Field on
Grain Growth in Extruded NaCl, Scripta Mater., 38:144348, 1998.
7. H. Conrad and D. Yang, Influence of an Applied DC

Electric Field on the Plastic Deformation Kinetics of Oxide
Ceramics, Philos. Mag., 90:1141-57, 2010.
8. H. Conrad and D. Yang, Dependence of the Sintering
Rate and Related Grain Size of Yttria-Stabilized Polycrystalline Zirconia on the Strength of an Applied DC Electric
Field, Mater. Sci. Eng. A, 528:8523-29, 2011.
9. J.R. Groza and A. Zavaliangos, Sintering Activation by External Electrical Field. Mater. Sci. Eng. A, 287:171-77, 2000.
10. Z.A. Munir, et al., The Effect of Electric Field and Pressure on the Synthesis and Consolidation of Materials: A
Review of the Spark Plasma Sintering Method, J. Mater.
Sci., 41:763-77, 2006.
11. S.H. Risbud, J.R. Groza, and M.J. Kim, Clean Grain
Boundaries in Aluminum Nitride Ceramics Densified
without Additives by a Plasma-Activated Sintering
Process, Philos. Mag., 69:525-33, 1994.
12. J. Wan, M.J. Gasch, and A.K. Mukherjee, Silicon NitrideSilicon Carbide Nancocomposites Fabricated by ElectricField-Assisted Sintering, J. Am. Ceram. Soc., 86:526-28, 2003.
13. R. Raj, M. Cologna, and J.S.C. Francis, Influence of Externally Imposed and Internally Generated Electrical Fields on
Grain Growth, Diffusional Creep, Sintering and Related Phenomena in Ceramics, J. Am. Ceram. Soc., 94:1941-65, 2011.
14. M. Cologna, J.S.C. Francis, and R. Raj, Field Assisted
and Flash Sintering of Alumina and its Relationship to
Conductivity and MgO-Doping, J. Eur. Ceram. Soc.,
31:2827-37, 2011.
15. J.S.C. Francis and R. Raj, Flash-Sinterforging of

Nanograin Zirconia : Field Assisted Sintering and Superplasticity, J. Am. Ceram. Soc., 9:1-9, 2011.
16. M. Cologna, B. Rashkova, and R. Raj, Flash Sintering
of Nanograin Zirconia in <5 s at 850C, J. Am. Ceram. Soc.,
93:3557-9, 2010.
17. J. Narayan, New Mechanism for Electric-Field Assisted
Processing and Flash Sintering of Materials, Scripta Mater.,
69:107-111, 2013.
18. J. Narayan, Grain Growth Model for Electric-Field Assisted Processing and Flash Sintering of Materials, Scripta
Mater., 68:785-788, 2013.
19. S. Mal, et al., Thin Film Epitaxy and Magnetic Properties of STO/Tin Buffered Zno On Si (001) Substrates, Acta
Mater., 59:2526-2534, 2011.
20. P. Gupta, et al., Controlled P-Type to N-Type Conductivity Transformation in Nio Thin Films by UltravioletLaser Irradiation, J. Appl. Phys., 111:013706-1-7, 2012.
21. J. Narayan, Physical Properties of A100 Dislocations in Magnesium Oxide, J. Appl. Phys., 57:2703-8, 1985.
22. J. Narayan, Y. Chen, and R.M. Moon, Nickel Colloids in
Reduced Nickel-Doped Magnesium Oxide, Phys. Rev. Lett.,
46:1491-94, 1981.
23. J.P. Hirth and J. Loathe, Theory of Dislocations, McGraw-Hill, New York, 2002.
24. C.W. White, J. Narayan, and R.T. Young, Laser Annealing of Ion Implanted Semiconductors, Science, 204:461-8,
1979.
33
Celebrating ASMs First 100 Years

in Supporting Materials Innovation
A
s we celebrate the 100-year anniversary of ASM International (1913-2013), we look at the many notable advancements in materials and
processes technology that occurred along the way. ASM has played a significant role in this by providing a forum for bringing together
engineers, scientists, and practitioners to exchange information on these advancements, and by disseminating information about them to
the engineering community in general. The society, which began in 1913 as the Steel Treaters Club, also went through several changes over
the years to its present ASM International. In each issue of AM&P in 2013, we are highlighting in 10-year increments significant advancements
in technology, as well as advancements in the society.
September cover of
Metal Progress, the final
issue. Beginning in
October, Metal Progress
is incorporated into
Advanced Materials &
Processes.
The Iron Bridge over the River Severn in England

is designated an ASM Historic Landmark. Built in
1779, it is the first arch bridge to be made of cast
iron. Heat for smelting the iron ore was generated
by burning coke rather than charcoal, reducing
costs and greatly expanding iron applications.
1984
1985

Processes debuts in
September. The new
magazine is part of ASMs
effort to expand coverage of
materials beyond metals.
Editors Timothy Gall (left) and
Howard Boyer showcase the
first edition of the Metals
Handbook Desk Edition, the
largest Handbook ever. Over
30% of this nearly 1400-page
handbook is brand new
information, added to
thoroughly revised and
updated materials from the
Eighth and Ninth Editions of
Metals Handbook.
34
1986
ASM name
change
ASM officially
changes its
name from
American
Society for
Metals to ASM
International.
This image in
the November
1986 issue of
ASM News is
the first time the
new logo
appears in print.
ASM celebrates 75th anniversary

ASM celebrates its 75th anniversary
by sponsoring the first World
Materials Congress. Held in Chicago,
more than 12,000 people attend the
September event, representing 65
countries. Special issue cover of
Advanced Materials & Processes
features Claude Monets 1877
painting of a locomotive, one of the
first artistic works to depict a product
of the Industrial Revolution.
1987
1988
Two ASM members, Lawrence Murr and

Alan Hare, examine an explosively
consolidated superconducting ring as it cools
in liquid nitrogen. This breakthrough composite
material is announced exclusively in an article
in the October issue of Advanced Materials
& Processes. The authors reveal how
explosive consolidation can create an oxide
superconductor in a copper matrix to produce
a useful superconducting material.
ASM librarian Eleanor Baldwin stands in

front of a special atmosphere-controlled
cabinet housing some of ASMs William
Hunt Eisenman rare book collection. The
collection includes 63 titles, including such
treasures as De Re Metallica, written by
Georgius Agricola in 1556. The oldest book
in the collection is Stahel und Eysen
Kunstbchlein, published in 1539.
The 800-ft
Canary
Wharf Tower,
the tallest
building in
the UK, is
completed.
Designed by
architect
Cesar Pelli, it
is the first
skyscraper
to be clad in
stainless
steel.
Artists conception of the

National Aerospace Plane
(NASP), a U.S. project to build a
single-stage-to-orbit spacecraft
and passenger spaceliner. Its
materials and construction are
major topics during the first
ASM Advanced Aerospace
Materials and Processes
(AeroMat) Conference and
Exposition held in Long Beach,
Calif., though the project is
canceled soon after.
1989
1990
The Ninth edition of

the Metals Handbook
is completed with the
publication of Volume
16 Machining and
Volume 17
Nondestructive
Evaluation and Quality
Control. The number of
pages for all 17
volumes totals 14,919.
More than 220,000
copies of the Ninth
edition have been
distributed worldwide.

1991
The National Institute of

Standards and Technology
releases version 1.0 of its
Structural Ceramics
Database, containing
state-of-the-art thermal
and mechanical property
data for silicon carbides
and silicon nitrides.
The database is available
on 3.5 or 5.25 in.
diskettes.
Microstructure of an advanced ceramic

composite. Called Qualitative Analysis
of Color Metallography, the entry was
prepared by a team from NASA Lewis
Research Center: It is the 1993 winner
of the Jacquet-Lucas Award, the first
after the International Metallographic
Society (IMS) becomes an affiliate
society of ASM in September.
1992
1993
Processes publishes its
first Heat Treating ShowIn-Print, a product
showcase designed to
bridge the gap between
the 1991 and 1993 Heat
Treating Expos. Lead
photo shows an induction
hardening and tempering
system developed by Ajax
Magnethermic Corp.
35
36
AUGUST 2013 VOL 8 ISSUE 3
TM
INTERNATIONAL THERMAL SPRAY & SURFACE ENGINEERING

T H E O F F I C I A L N E W S L E T T E R O F T H E A S M T H E R M A L S P R AY S O C I E T Y
Ther mal Spray

Coatings in the
Automotive Industr y/
Industrial
Applications
JTST Highlights
Society News
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AUGUST 2013 VOL 8 ISSUE 3
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CONTENTS
INTERNATIONAL THERMAL SPRAY & SURFACE ENGINEERING
T H E O F F I C I A L N E W S L E T T E R O F T H E A S M T H E R M A L S P R AY S O C I E T Y
5 Thermal Spray Applications

in the Steel Industry
Editors Robert Gansert

William Jarosinski
Managing Editor Julie Kalista
Art Director Barbara L. Brody
Production Manager Joanne Miller
7 Application of Automotive
Thermal Spray Coatings
8
Electric Arc Spray

Coatings Increase
Cost and Reliability
of Power Generation
Systems
National Account Manager

Kelly Thomas, CEM.CMP
Materials Park, Ohio
tel: 440/338-1733
e-mail: kelly.thomas@asminternational.org
Thermal Spray Society
Executive Committee
Luc Pouliot, President
Charles M. Kay, Immediate Past President
John O. Hayden, Vice President
Douglas G. Puerta, Secretary/Treasurer
Randall S. Barnes, Executive Director
TM
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About the cover
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International Thermal Spray & Surface Engineering
does not imply that the editors or ASM International

accept, approve, or endorse the data, opinions, and
conclusions of the authors. Although manuscripts
published in International Thermal Spray & Surface
Engineering are intended to have archival significance,
authors data and interpretations are frequently
insufficient to be directly translatable to specific design,
production, testing, or performance applications
without independent examination and verification
of their applicability and suitability by professionally
qualified personnel.
The editorial focus for iTSSe in 2013 reflects established applications of

thermal spray technology such as power generation and transportation, as well as new applications representing new opportunities for
coatings and surface engineering.
November Emerging Technologies
To contribute an article to one of these issues, please contact the
editors c/o Julie Kalista at Julie.Kalista@asminternational.org.
To advertise, please contact Kelly Thomas,
Kelly.Thomas@asminternational.org.
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Highlights from a Successful

ITSC 2013
fter much handwringing, ITSC 2013 was held May 13-15 in Busan, Republic of Korea.
Despite the intense geopolitical situation in the months preceding the event and its inevitable impact on attendance, ITSC was a great success. Close to 1000 attendees enjoyed
196 presentations, including many about applications in the automotive industry.
Forty-three posters were also presented during the conference, and the exposition featured 81 booths from 58 companiesa record for an ITSC held in the Pacific Rim. The
week started with a well-attended plenary session on Monday morning. After opening remarks, several important awards were presented including:
Christian Moreau (National Research Council of Canada) and Brad Beardsley
(Caterpillar) were inducted into the Thermal Spray Hall of Fame
Joachim Heberlein (University of Minnesota) received the 2013 TSS Presidents Award
JTST and ITSC Best Paper Awards
The opening session ended with an excellent plenary talk by Jennifer Sun (Applied Materials Inc.) about Integrated Total Solution of Plasma
Spray for Semiconductor Equipment Applications
Past & Future.
ITSC featured another plenary talk on Tuesday by H.J.
Kim (RIST), in which he gave a comprehensive overview
of thermal spray in Korea and R&D activities at RIST.
On Tuesday evening, ITSC attendees went to the Nurimaru APEC House, a breathtaking venue by the sea, for
a networking gala dinner followed with a lovely traditional Korean entertainment performance.
ITSC concluded on Wednesday with the Sulzer Metco
Young Professional Competition, organized and led by
Sanjay Sampath (SUNY). This years winner was Emine
Bakan from Jlich, Germany. For the benefit of those
Located on Dongbaekseom Island, Nurimaru APEC House is a who could not join us in Busan, I can confirm that there
modernistic expression of jeongja, a pavilion in traditional are a lot of promising young talents out there!
Korean architectural style. ITSC attendees enjoyed
Of course, such a successful event would not be posa networking gala here on May 14.
sible without the hard work and dedication of several
people as well as the support from many organizations, so please allow me to extend very
special thanks to:
Our distinguished Korean hosts, Drs. Kim and Lee, and the entire KTSA
Our partners, DVS and IIW
Dedicated ASM and DVS staff
Many TSS volunteers led by John Hayden, TSS vice president
Exhibitors and sponsors
All attendees
On behalf of the ASM Thermal Spray Society, DVS, and IIW, I thank you again for your
participation and support, and I look forward to seeing you all again next year in Barcelona.
EDITORIAL
Luc Pouliot, president,

Thermal Spray Society
Nominations Sought for

Thermal Spray Hall of Fame
The Thermal Spray Hall of Fame recognizes and honors outstanding leaders who have made significant contributions to the science, technology, practice, education, management, and advancement
of thermal spray. For a copy of the rules, nomination form, and list of previous recipients, visit www.
asminternational.org/tss. Click on networking and membership followed by TSS Awards. Or contact
Sarina Pastoric at sarina.pastoric@asminternational.org. Nominations are due September 30.
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Two Inducted into the Thermal Spray Hall of Fame
entific and control diagnostics,

advanced coating materials systems, and for leadership in thermal spray communications.
Beardsley joined Caterpillar
Inc. in 1977 and worked in the
areas of heat treat, gear technology, casting, fatigue, fracture,
and thermal spray technology
prior to his retirement in April
2013. He developed thermal
spray coating applications including coatings for remanufac- Christian Moreau (right) accepts the
Thermal Spray Hall of Fame plaque
turing as well as chrome plate from
Luc Pouliot (left), president of
replacement. His leadership re- TSS, at the International Thermal
sulted in significant growth in Spray Conference in Busan, South
Caterpillars Remanufacturing Korea.
Division using twin wire arc and plasma transferred arc bore
spray technologies. He also led the implementation of HVOF
coatings to replace thick chrome platings used on Caterpillar
large mining truck suspensions.
TSS NEWS
Christian Moreau and Brad Beardsley were both inducted

into the Thermal Spray Hall of Fame at ITSC 2013. Christian
Moreau, FASM, and the Editor-in-Chief of Journal of Thermal Spray Technology since 2004, was inducted into the Thermal Spray Hall of Fame for advancing thermal spray science
and technology through the development of innovative scientific and control diagnostics, advanced coating materials systems, and for leadership in thermal spray communications.
Moreau was selected based on both his personal contributions to thermal spray technology, as demonstrated by his seven
patents and many publications, as well as for his management
of an internationally recognized research organization. He has
advanced the understanding and development of thermal spray
technology through his significant role in the development of
optical systems for the measurement of the plasma effluent and
particle temperature, velocity, and their distributions.
Moreau is an active member of the Thermal Spray Society
and ASM International and served on the Thermal Spray Society Advisory Council from 2011 to 2013, the TSS Nominating
Committee from 2010 to 2012, and is a
member of both TSS Publications and Communications as well as the TSS Program
Committee from 1999 to 2013.
Along with Moreau, Brad Beardsley of
Caterpillar Inc. was also inducted into the
TSS Hall of Fame during ITSC for advancing thermal spray science and technology
through the development of innovative sci- Beardsley
ITSC 2013 Best Paper Award
The ITSC 2013 Best Paper Award was presented to Navid

Sharifi, Fadhel Ben Ettouil, Milad Mousavi, Martin Pugh,
Christian Moreau, and Ali Dolatabadi for their paper, Superhydrophobicity and Water Repelling Characteristics of Thermally
Sprayed Coatings.
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Handbook of Thermal Spray Technology

hits bookshelves this month
A new addition to the ASM Handbook Series hits bookshelves this month. Based on the success
of Handbook of Thermal Spray Technology, Dr. Robert C. Tucker, Jr. took the lead as editor to update and expand this book into what is now ASM Handbook, Volume 5A, Thermal Spray Technology. It is written for those new to the industry, design engineers, thermal spray job shops,
management and sales, and as a knowledge springboard for scientists and universities.
ASM Handbook Volume 5A contains core fundamentals, insights from experts, and an expanded
section on application stories. Every page contains information that may help solve problems. Visit
the bookstore at asminternational.org to purchase your copy today.
TSS NEWS
Reliability, Durability
and Performance Assessment
of Thermal Spray Coatings
Conference
This conference features invited talks and keynote presentations by technical experts in a variety of industries who will share
their knowledge and experience. Sign up for the Introduction to
Advanced Diagnostic Techniques Applied to Thermal/Cold Spray
Processes education course or sign up to tour the GE Power
& Water Factory or Test Solutions Industry (ITS). Visit www.
asminternational.org/content/Events/tscoatings to learn more.
42
ITSC 2014
Call for Papers
This annual event is jointly organized by the

German Welding Society (DVS), ASM Thermal Spray Society (TSS), and the International
Institute of Welding (IIW). ITSC 2014 presents
the latest applications, research, and developments in the field of thermal spray.
All oral/poster manuscripts must be written
in English and submitted electronically. The
manuscript deadline for all contributions is December 13, 2013. Selected conference contributions (oral and poster) will be published
in the conference proceedings. Visit www.
dvs-ev.de/itsc2014 to submit today.
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Thermal Spray Applications

in the Steel Industry
ASB Industries Inc.

Barberton, Ohio
roduct quality, maintenance costs, and production requirements drive engineering

improvements where surfacing technologies play an important role in steel production. To enhance product quality, the steel
industry employs various surface-modification technologies. Thermal spray is one such
process. This article reviews both thermal
spray materials and equipmentand provides examples of where coated components
result in improved performance.
High-velocity oxyfuel (HVOF) and detonation gun technology are considered mainstream thermal spray techniques in steel
manufacturing plants. Applications ranging from
melting and transferring steel to end product integration require all types of coatings, with WC-Co
and Cr3C2-NiCr cermets playing important roles. Properly applied coatings can withstand extreme
Excerpt from
wear and corrosion, resulting in longer proASM Handbook,
duction life and better quality steel strip, bars,
Volume 5A,
and billets.
Thermal Spray
During steel production, components are
Technology
exposed
to a combination of high temperaR.C. Tucker,
tures, corrosive environments, and various
editor
wear mechanisms, resulting in a wide range
of degradation mechanisms. This leads to reduced product quality and operating efficiencies, and greater maintenance costs and downtime. Recent advances in
materials, equipment, and processes, along with growth
in the automotive sector in traditional and developing
countries, should expand the use of thermal spray technologies. Dramatic growth has occurred in HVOF technology and in key cermets such as WC-Co(Cr) and
NiCr-Cr3C2 for many different roll applications.
Areas of concern during steel manufacturing include
heat, corrosion, and wear. To enhance equipment life, a
number of thermal spray coatings are being used. Figure 2
shows a hot coil wound from strip steel. Wrapper rolls,
which force the strip to turn into a coil, use a nickel-base
self-fluxing alloy that is combustion sprayed and fused.
This is one of a select group of coatings that works well in
this extreme environment. The temperature of the steel
strip shown in Fig. 2 is estimated at over 1400C (2500F);
note the high-pressure cooling water flowing onto the coil
as it is being wrapped. This is one of the harshest environments in strip steel manufacturing. Other surface-modification processes, such as submerged arc or welded
coatings, can also be used in this demanding environment.
*Member of ASM International
and ASM Thermal Spray Society
Fig. 1 The
making, shaping,
and treating of steel.
Many surface-modification processes

are proprietary to steel manufacturers or
coating applicators, but basic thermal spray coating applications are well understood. The desired quality and
surface finish of the final product are critical to process
and material selection. Wires, rods, sheet, and billets are
just a few forms that steel can take before its release to
second-tier industries. Specific areas of steel production
where coatings are used include:
Gas ducting system from molten metal
Gas injection tuyeres, lances, and nozzles
Molten steel processceramic nozzles
Continuous casting molds
Continuous casting rolls
Various processing rolls (i.e., bridle, deflection,
and annealing furnace rolls)
Following are a few important applications where
coatings extend equipment life in the steel industry:
Continuous casting molds: Casting molds control the
rate of solidification and shape of resulting billets. Mold
life (gaged by the number of pours and tonnage) is limited by the coatings ability to withstand wear that could
transfer marks onto the slab or billet. Coating materials
for this type of application include carbides, cermets, and
ceramics.
Coiling mandrels: In steel applications, hot mill strip
products typically require further processing. The transfer of coils to other continuous process lines requires the
coil to be unwound then rewound, holding the core
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Fig. 2 Winding of hot

steel coil, showing the
harsh conditions of steel
manufacturing.
tightly wrapped. Friction, grip, and long-wearing surfaces

allow proper strip tension from the initial weld joining to
final trimming and wrapping. Rolls with HVOF-applied carbide coatings have harder surfaces than strip materials. Optimized surface profiles and high friction coefficients support
gripping of strips to rolls without harming the strips surface
finish properties.
Todays production rolls use either
HVOF or detonation gun coatings. Proprietary coatings with
oxidation-resistant MCrAlY cermets are used for extremely
high furnace temperatures. For lower-temperature heat treatment of low-manganese steels, NiCr-Cr3C2 coatings are
44
used. For high-temperature annealing of low-manganese

steels, oxides and/or borides, or cermets of MCrAlY and alumina have been used in production. High-manganese steels
cause more severe problems for rolls. Corrosion and oxidation products, typically in the form of oxides of chromium
and aluminum on MCrAlY coatings, react with manganese
from the steel, reducing coating service life and steel sheet
quality. Many proprietary coatings feature optimized
MCrAlY chemistries, along with additions of alternative oxides and/or carbides.
Degradation of sink rolls and
other rolls associated with continuous galvanizing lines is
due to zinc and/or aluminum reactions with iron from the
steel rolls. These reaction productssometimes called dross
particlesdegrade rolls and affect the surface of steel products. The most commonly used zinc baths consist of galvanized zinc with minor concentrations of aluminum. Coatings
use tungsten carbide/cobalt powders applied via HVOF or
detonation gun technology. Success of these coatings depends on the spray parameters, powder manufacturing
method, and sealant system. The key to increased life is to reiTSSe
duce the amount of free cobalt in the coating.
Charles Kay is vice president of marketing at ASB Industries Inc., 1031 Lambert St., Barberton
OH, 44203, 330/753-8458, cmkay@asbindustries.com, www.
asbindustries.com.
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Application of Automotive
Thermal Spray Coatings
AMT AG
Dttingen, Switzerland
Advanced Materials & Technology Services

Simi Valley, Calif.
hermal spray coatings play an important role in

the automotive industry from the high-performance racing sector to domestic automotive proFig. 1 Production thermal spray cell for automotive parts.
duction. In North America alone, an estimated 15.6
million light-vehicle automobiles will be produced in
2013, representing a considerable market opportunity
for the coatings industry.
Thermal sprayed parts and
components for these vehicles involve a large network
of organizations including
automotive manufacturers,
tier one suppliers, thermal
spray companies, equipment
producers, and materials Fig. 2 Multi-station cell with loading, grit blasting,
Fig. 3 MP 200, multi-process
control system.
suppliers. Equipment manu- cleaning, metallizing, cooling, and unloading points.
facturers such as AMT AG design, build, and supply
Multiple wire feed control
high-volume production thermal spray coating cells for
Automatic flame control
this vast network.
Indexing turntable with 24 spindles and two handlings
Figure 1 shows a production spray cell provided to the
Integrated blasting, coating, and cooling sections
European market for synchronizer rings and shifter forks.
Acoustical spray booth
This particular application is used to apply molybdenum
Dry filter system
coatings. The combustion wire spray guns use acetylene,
One prominent component of these production cells
oxygen, and air. While newer wire-arc systems have been
is a sophisticated multi-process control system, AMTs
developed since the early days of the combustion
MP 200 system (Fig. 3). This control module features inprocess, the flame spray process is still used to impart
tuitive, color touch screens that allow operators to proessential mechanical properties such as hardness.
gram all process parameters involved in controlling the
High-volume coating cells consist of multiple stations
coating process. A separate gas module for the thermal
including load, grit blasting, cleaning, thermal spray
spray guns controls the process gases used in production.
coating, cooling, and unloading points. These stations
This particular cell was provided to a European car mancan be seen in Fig. 2.
ufacturer and sprays three parts per minute, enabling
This turnkey system was specifically designed to mass
3500 coated parts per day, in a three-shift operation.
produce a coating for certain automotive parts. The proVarious manufacturers provide other thermal spray cells
duction cell is based on a MP 200 wire flame spray sysfor coating automotive parts in North America and Europe
tem, and simultaneously controls three wire flame spray
as well. As automotive manufacturers continue to build
guns. The complete cell consists of:
vehicles to satisfy consumers and meet federal regulations
Wire flame spray system, with three thermal spray
for higher fuel efficiency, the thermal spray industry will
guns
continue to design and supply thermal spray cells and ad Control module (MP 200)
vanced coatings to address these needs.
iTSSe
Gas module (MP 200) for three simultaneous gun
operations
Danilo Lazzeri, AMT AG Badstrasse 34, CH-5312 Dttingen, Switzerland, 41 56/245*Member of ASM International
9010, danilo.lazzeri@amt-ag.net, www.amt-ag.net.
and ASM Thermal Spray Society
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8
Electric Arc Spray Coatings

Increase Cost and Reliability
of Power Generation Systems
Praxair TAFA Inc.

Concord, N.H.
ncreased power with decreased downtime is a constant

challenge for power producers. Thermal spray technologies, such as HVOF and arc spray, are now widely accepted in the power generation repair community. The
electric arc spray process in particular offers low cost, viable
coatings that boost both cost savings and reliability of power
generation systems, which run at 100% capacity for months
at a time.
Thermal spray coatings extend operating time and increase

the lifespan of stationary boiler steam driven power plants
(Fig. 1). Generating (water wall tubes) and super heater
banks, which suffer from ravages of sulfuric and vanadium
gases in coal-fired boilers, see vast increases in longevity
when sprayed with CrC-NiCr coatings using the liquid-fueled HP/HVOF process (Fig. 2)[1]. Where application requirements permit use of the electric arc spray process, the
coatings effectively increase service life. Arc sprayed materials successfully in use in global boiler applications include:
TAFA 45CT, a high chromium content nickel alloy for prolonging the life of coal fired boiler tubes; TAFA 95MXC, an
FeCr based alloy that exhibits a very high hardness not typ-
Fig. 2 Generating and super heater banks see increases in

longevity when sprayed with CrC-NiCr coatings using the
liquid-fueled HP/HVOF process.
Fig. 1 Thermal spray coatings extend operating time and increase the lifespan of stationary boiler steam driven power plants.
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9
ically found in most arc spray coatings (as high as 1180 DPH
Vickers), ideal for the coal fired boiler environment; and
TAFA 140MXC, an amorphous matrix nanocomposite material proven effective in wear and high temperature corrosion protection in the flu gas path of the boiler[2].
Development and application of thermal spray technologies is widely accepted for use in the main tube banks of
boilers. An effort to promote these same benefits to critical
secondary systems is now underway. By expanding the
scope of thermal spray applications, the overall lifecycle of
the entire boiler can be improved. Boiler systems include
the fly ash handling system, induced draft fan, and the fuel
handling system.
A variety of solid fuels are used in stationary power plants,
with coal being the most prevalent. As the quest for fossil
fuel alternatives continues, wood and trash fuel sources are
gaining wider popularity. The main problem with solid
fuelswhether coal, wood, or trashis the large amount of
particulate matter that carries through the entire flu gas path,
from the fire box to the exiting stack, causing significant erosion of many components. This aspect of the process creates
unique challenges.
Fig. 3 Amorphous work

hardening coatings produced
with materials such as TAFA
95MXC and TAFA 140MXC
display favorable results with
the electric arc spray process.
A critical task in any power generation facility is to maintain environmental discharges at acceptable limits. One
such emissions factor is limit of opacitythe amount of
particulate matter that passes through the entire flu path and
is discharged into the atmosphere via smoke stacks. In order
to keep the opacity level within a specific mandated level
and reuse as much potential energy from the fuel source as
possible, fly ash is re-injected back into the boiler prior to
the induced draft fan using a classifier, which separates the
exiting char. The re-injected char goes back into the hottest
part of the furnace and passes through the rest of the flu gas
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path until it is burned into a small enough size to pass beyond the classifier, and into the exiting particulate scrubber system prior to (or within) the plants exit stack.
In wood fire systems, the re-injected char is highly
abrasive. It can severely erode classifier componentry
and cut deep grooves into the re-injection piping, causing insufficient flow which, in turn, creates unacceptable
limits in opacity discharge. This can lead to premature
outages during the power stations run schedule. Electric arc spray coatings considerably extend the operating
life of these systems. Materials used to manufacture char
re-injection systems and flu gas duct work are generally
inexpensive low carbon steels which, while cost effective, cannot withstand the abrasive nature of the material passing through them.
Amorphous work hardening coatings produced with materials such as TAFA 95MXC and TAFA 140MXC display
favorable results with the electric arc spray process in applications within both the firebox of boilers (on the generating and super heater tubes) and induced draft fans (Fig.
3). These same materials can be used with comparable results within the fly ash system.
Another material to consider is TAFA 97MXC Ultra Hard
Duocor Wire. It uses titanium and tungsten carbide within an
amorphous matrix, providing high abrasion resistance. For
example, the material successfully coats blades of induced
draft fans to prevent the erosion and resulting imbalance that
occurs from contact with particulate matter traveling within
the high volumes of gasses exiting the boiler.
10
48
The last critical system to impact boiler uptime and reliability is the fuel handling equipment. These systems
have many points of contact that cause extreme wear, such
as conveyor rollers and bucket elevators. Additionally,
auger screws and the troughs in which they rest can experience high rates of wear as fuel passes through the screws
at high feed rates. The same amorphous arc spray coatings used in the boiler and fly ash system can be applied
to improve wear resistance in the fuel handling system.
Users of thermal spray technology in the boiler repair field
are encouraged to seek applications beyond coating boiler
tubes to prolong the overall life of power stations. iTSSe
Richard Luding is arc spray product
manager at Praxair TAFA Inc., 146 Pembroke Rd., Concord,
NH 03301, 603/223-2161, richard_luding@praxair.com,
www.praxair.com.
TAFA with Flame design and the Flame design, 45CT, 95MXC,
97MXC, 140MXC, Duocor, and HP/HVOF are trademarks or
registered trademarks of Praxair Surface Technologies Inc., in
the U.S. and/or other countries.
1. Y. Shimizu, et al., HVOF Sprayed Cr2C3 Cermet Coating to

Improve Erosion Resisting Performance of the Coal Burning
Boiler Tube, Proceedings of ITSC 2004, p 6.
2. D.J. Branagan, et al., High Performance Nanoscale Composite Coatings for Boiler Applications, J. Therm. Spray Technol.,
Vol 14, No. 2, 2005.
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The
()the official
journal of the ASM Thermal
Spray Society, publishes contributions on all aspects
fundamental and practical of
thermal spray science, including
processes, feedstock manufacture, testing, and characterization. As the primary vehicle for
thermal spray information transfer, its mission is to synergize
the rapidly advancing thermal
spray industry and related industries by presenting research
and development efforts leading to advancements in implementable engineering applications of the technology. Articles from the June and August issues, as selected by
Editor-in-Chief Christian Moreau, are highlighted. June is a
special issue on Coatings for Energy Applications, organized by guest editors Armelle Vardelle and Robert Vassen.
The first three articles highlighted below are from that issue.
In addition to the print publication, is available online
through www.springerlink.com. For more information, visit
www.asminternational.org/tss.
JTST HIGHLIGHTS
12
Advances in Thermal Spray Coatings

for Gas Turbines and Energy Generation:
A Review
Canan U. Hardwicke and Yuk-Chiu Lau

Functional coatings are widely used in energy generation equipment in various industries. Intelligent thermal spray processing is
vital in many of these areas for efficient manufacturing. Advanced
thermal spray coating applications
include thermal management,
wear, oxidation, corrosion resistance, sealing systems, vibration
and sound absorbance, and component repair. This paper reviews
the current status of materials,
equipment, processing, and properties aspects for key coatings in
the energy industry, especially the
developments in large-scale gas
turbines. In addition to the most recent industrial advances in thermal
spray technologies, future technical needs are highlighted.
Air plasma spray (APS) in action,
showing the gun end of the spray
robot, plasma plume, part being
sprayed, and controls.
Schematic shows the setup for plasma spray of composite

coatings using both radial and axial feedstock injection
(PF-powder feeder; PP-peristaltic pump; CM-coriolis meter;
PD-pulse dampener; SH-substrate heater; INJ-radial injector).
efficiencies of both feedstock types depend strongly on nozzle diameter. Plasma-spray metal-supported solid oxide fuel cells using
anodes fabricated with this technique demonstrate power densities
at 0.7 V as high as 366 and 113 mW/cm2 in humidified hydrogen
and methane, respectively, at 800C.
Flexible and Conducting Metal-Fabric

Composites Using the Flame Spray
Process for the Production
of Li-Ion Batteries
Joel Voyer
Wire flame spray was used to produce electrically conductive
and flexible Al coatings on diverse textile fabrics. The influence
of spray parameters and fabric materials on the electrical conductivity of the metal-fabric composites was studied. Production of flexible Li-ion batteries with good electrical properties
based on the use of such flame-sprayed aluminum cathode current collectors was shown to be viable. A coating quantity
threshold of about 20 mg/cm2 exists to obtain a sufficient electrical surface conductivity for commercial use of the produced
metal-fabric composites. Excellent electrical surface conductivity of the composites (about 500 SA) could be achieved through
an adequate optimization of spray parameters. Production of
electrically conductive and flexible metal-fabric composites having sufficient electrical conductivity for the manufacture of flexible Li ions batteries is possible.
A Novel Hybrid Axial-Radial Atmospheric

Plasma Spraying Technique for the
Fabrication of Solid Oxide Fuel Cell
Anodes Containing Cu, Co, Ni, and
Samaria-Doped Ceria
Mark Cuglietta, Joel Kuhn, and Olivera Kesler

Composite coatings containing Cu, Co, Ni, and samaria-doped
ceria (SDC) were fabricated using a novel hybrid atmospheric
plasma spraying technique. A multi-component aqueous suspension of CuO, Co3O4, and NiO was injected axially simultaneously
with SDC injected radially in a dry powder form. Coatings were
characterized for their microstructure, permeability, porosity, and
composition over a range of plasma spray conditions. Deposition
efficiency of the metal oxides and SDC was estimated. Depending on conditions, coatings displayed either layering or high levels of mixing between the SDC and metal phases. Deposition
50
Cross-section of flame-sprayed Al cathode current collector of a

typical Li-ion battery.
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change from brittle to ductile features on the fracture surface. The

highest strength coating produced was a helium-sprayed coating
annealed at 600C, which featured a tensile strength ~85% of the
minimum required bulk value and coating/substrate microstructures similar to the as-received powder/substrate microstructures.
Introduction to
Thermal Spray Course
(a) Torch testing of a tungsten rod coated with Mo-Si-B, where

Mo was applied through the use of plasma spraying. (b) The same
tungsten rod after torch testing at 1723 K for 15 min. There was
no significant or catastrophic mass loss.
Application of Plasma Spraying as a

Precursor in the Synthesis of OxidationResistant Coatings
Instructor: Richard Sayman

October 1-2
ASM Headquarters, Materials Park, Ohio
ASM International invited Thermal Spray Society leaders to compile
their knowledge and experience in a comprehensive, easy-to-understand course. Visit www.asminternational.org/portal/site/www/
education to learn more.
P. Ritt, O. Lu-Steffes, R. Sakidja,

J.H. Perepezko, W. Lenling, D. Crawmer,
and J. Beske
A novel application of thermal spray coating is demonstrated
by incorporating a plasma-sprayed Mo layer coating as a precursor step within an integrated costing design. The effectiveness of
the two-step design is illustrated for aluminoborosilica coatings
on SiC/C composites and W substrates based on the plasmasprayed Mo precursor and subsequent codeposition of Si and B by
a pack cementation method. Even with incomplete precursor coverage, an aluminoborosilica coating is developed due to the high
initial fluidity of the as-pack coating. Effective oxidation resistance is achieved following exposure at elevated temperatures
(1373-1673 K) in ambient air and during torch testing at 1773 K,
providing clear evidence that plasma spraying of Mo is a viable
precursor step in the formation of the oxidation-resistant Mo-Si-Bbased coating.
Mechanical and Microstructural

Characterization of Cold-Sprayed
Ti-6Al-4V After Heat Treatment
P. Vo, E. Irissou, J.-G. Legoux, and S. Yue

Cold spray of Ti-6Al-4V coatings deposited on Ti-6Al-4V substrates was investigated. Coatings were produced using nitrogen
and helium as propellant gases and subsequently heat treated with
various temperature-time conditions. The microstructure was characterized by SEM and optical microscopy while mechanical properties were measured by microhardness and tensile testing.
Coatings sprayed with nitrogen gas were relatively porous in comparison to the nearly completely dense coatings made with helium
gas. In the as-sprayed condition, coatings display high hardness
but low tensile strength. Heat treatments at temperatures of 600C
and higher result in a decrease in hardness due to microstructural
changes within the particles including recovery, recrystallization,
and/or phase transformation. An increase in tensile strength is attributed to improved inter-particle bonding due to an observed
51
JTST HIGHLIGHTS
Typical stress-strain curves for Ti-6Al-4V substrate, He-sprayed Ti-6Al-4V

coatings (as-sprayed and annealed at 600C for 2 h), and N2-sprayed
Ti-6Al-4V coatings (as-sprayed and annealed at 1000C for 4 h).
ASMnews
www.asminternational.org/ASMnews
2013 ASM Award Program Recipients

The ASM International Board of Trustees has named award
program recipients for 2013. The awards program recognizes
achievements of members of the materials science and engineering community. Awards will be presented at ASMs annual Awards Dinner, October 29 in Montral, Canada, during
Materials Science & Technology 2013 (MS&T13). Individual
tickets cost $90 and can be ordered using the MS&T registration form. Those interested in purchasing a table should contact Christine Hoover, Administrator, Awards Program, ASM
International, 440/338-5151, ext. 5509, fax: 440/338-6614,
christine.hoover@asminternational.org.
Honorary Membership
Dr. H.M. Mehta, chairman, NHB Ball
& Roller Ltd., Mumbai, India, will receive
this years award for distinguished service to the materials science and engineering professions, and for leadership in
establishing the ASM presence, vision,
professional excellence, and entrepreneurship in India. Honorary Membership in the Society was established in 1919 to recognize
distinguished service to the materials science and engineering community, ASM strategic plan and initiatives,
and the progress of mankind.
Official Notice:
ASM Annual Business Meeting
The Annual Business Meeting of members of
ASM International will be held in conjunction with
MS&T13 on:
Monday, October 28, 2013
4:00 5:00 p.m.
Palais des congre`s de Montral, Canada
The purpose of the ASM Annual Business Meeting
is the election of officers for the 2013-14 term
and transaction of other society business.
Distinguished Life Membership

Mr. William J. Bernard, Jr., FASM,
president and CEO, Surface Combustion
Inc., Maumee, Ohio, will receive this years
award in recognition for unwavering dedication to the advancement of the metallurgical/heat treating industry and
exemplary leadership, vision, and professional service supporting industry organizations and professional societies. Distinguished Life
Membership was established in 1954 and is conferred on
leaders who have devoted their time, knowledge, and abilities to the advancement of the materials industries.
Gold Medal
Dr. Enrique J. Lavernia, FASM, distinguished professor, provost, and executive

vice chancellor, University of California,
Davis, will receive this years Gold Medal
award for his pioneering contributions
and leadership in the materials science of
thermal spraying, spray deposition, and ultrafine-grained and nanocrystalline materials. The medal was established in 1943 to recognize
outstanding knowledge and great versatility in the application of science to the field of materials science and engineering, as well as exceptional ability in the diagnosis and
solution of diversified materials problems.
Medal for the Advancement of Research
Dr. Taylor W. Lawrence, president,
Raytheon Missile Systems, Tucson, Ariz.,
will receive this years award for leadership, dedication, and continuous support
for advancing the area of materials research for lasers, missiles warning, and
electro-optic systems. The award was established in 1943 to honor an executive in
an organization that produces, fabricates, or uses metals
and other materials. The recipient, over a period of years,
...in this issue

53 2013 ASM Awards Program Recipients
57 Emerging Professionals
55 Historical Landmark Designations
58 Members in the News
56 Celebrating Superstars of Longevity and Service
59 IMS Salutes Sponsors
Submit news of ASM and its members, chapters, and affiliate societies to
Joanne Miller, editor, ASM News ASM International, 9639 Kinsman Road, Materials Park, OH 44073
tel: 440/338-5151, ext. 5662 fax: 440/338-4634 e-mail: joanne.miller@asminternational.org
Contact ASM International at 9639 Kinsman Road, Materials Park, OH 44073 tel: 440/338-5151, ext. 0, or 800/336-5152, ext. 0
(toll free in U.S. and Canada) fax: 440/338-4634 e-mail: MemberServiceCenter@asminternational.org website: www.asminternational.org
53
ASMnews
HIGHLIGHTS...Award Recipients
will have consistently sponsored research or development,

and by foresight and actions, will have helped substantially
advance the arts and sciences relating to materials science
and engineering.
Engineering Materials Achievement Award (EMAA)
Mr. David L. Joyce, president and CEO,
GE Aviation, Cincinnati, along with M.J.
Weimer, Thomas J. Kelly, John Heyward,
all of GE Aviation, and Bernard P. Bewlay,
of GE Global Research, will receive this
years award for the worlds first successful
implementation of TiAl in aero engines.
Established in 1969, this award 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.
Albert Sauveur Achievement Award
Dr. Reza Abbaschian, FASM, William
R. Johnson Jr., Family Professor, distinguished professor, and dean of Bourns College of Engineering at the University of
California, Riverside, will receive this years
award for outstanding scientist and researcher in solidification fundamentals and
materials processing, educator, and leader
in advancing the materials profession. Established in 1934 in
honor of a distinguished teacher, metallographer, and metallurgist, the award recognizes pioneering materials science
and engineering achievements that stimulated organized
work along similar lines to such an extent that a marked
basic advance was made in the knowledge of materials science and engineering.
William Hunt Eisenman Award
Dr. Mark L. Robinson, FASM, vice president of technology (retired), Hamilton
Precison Metals, Lancaster, Pa., will receive
this years award for sustained contributions in cast, powder metallurgy, and
wrought products over a career in industrial product development, and technical
leadership in industrial R&D. The award
was established in 1960, in memory of a founding member
of ASM, and its first and only secretary for 40 years. It recognizes unusual achievements in industry in the practical
application of materials science and engineering through
production or engineering use.
J. Willard Gibbs Phase Equilibria Award
Prof. Peter W. Voorhees, FASM, Frank
C. Engelhart Professor and chair, Northwestern University, Evanston, Ill., is the recipient of this years award. He is cited for
numerous fundamental contributions that
have advanced the theories of phase equilibria to incorporate stress and capillarity
related phenomena. The award was established in 2007 to recognize outstanding contributions to the
54
field of phase equilibria. The award honors J. Willard Gibbs,

one of Americas greatest theoretical scientists. In addition to
many other contributions, Gibbs laid the thermodynamic
foundations of phase equilibria theory with his brilliant
essay, On the Equilibrium of Heterogeneous Substances,
published in 1876 and 1878 in the Transactions of the Connecticut Academy.
Allan Ray Putnam Service Award
Mr. Rodney R. Boyer, FASM, technical
fellow, Boeing Co., Seattle, will receive the
2013 Putnam award for continued service to ASM and the materials community
through his research and publications furthering the understanding of titanium
metallurgy, and continuous service to
ASM through committee activities. Established in 1988, the award recognizes the exemplary efforts
of outstanding members of ASM International on behalf of
the Society to further its objectives and goals. The purpose
of this award is to recognize those individuals whose contributions have been especially noteworthy and to whom the
Society owes a particularly great debt of appreciation.
Albert Easton White Distinguished Teacher Award
Dr. Subhash Mahajan, FASM, distinguished professor and special advisor to the
chancellor, University of California, Davis,
will receive this years award. His citation
reads an inspiring teacher who develops
critical thinking in classrooms and deftly
guides his research students. The award was
established in 1960 in memory of an outstanding teacher and research engineer, who was a founding
member and president of ASM in 1921. It recognizes unusually long and devoted service in teaching, as well as significant
accomplishments in materials science and engineering, and an
unusual ability to inspire and impart enthusiasm to students.
Silver Medal Award
Established in 2010, the honor of Silver Medal of the Society is to recognize members who are in mid-career positions (typically 5 to 15 years of experience), for
distinguished contributions in the field of materials science
and engineering, and the Society. The
purpose of this award is to recognize
leadership at an early stage and encourage individuals to grow, nurture, and further contribute to the growth of the
profession, as well as the Society. Winners
of the 2013 award are:
Dr. Matthew J. Perricone, principal inPerricone
vestigator and technical consulting group
manager, RJ Lee Group Inc., Monroeville,
Pa., is cited for exemplary leadership in
service to ASM International and for diverse contributions to the fields of materials science, corrosion, welding, and failure
analysis in support of manufacturing and
product development.
Dr. Nikhil Gupta, associate professor, Gupta
Polytechnic Institute of New York University, Brooklyn, is

cited for exceptional combination of professional achievements in the area of lightweight composite materials and
public education of materials science through scientific and
news media.
Bradley Stoughton Award for Young Teachers
Prof. Michele Viola Manuel, assistant
professor, University of Florida,
Gainesville, is cited for her commitment
to fostering and advancing design education in materials science and engineering
through the integration of research,
teaching, and innovation. This award,
accompanied by $3000, was established
in 1952 in memory of an outstanding teacher in metallurgy
and dean of engineering who was president of ASM in
1942. The award recognizes young teachers of materials
science, materials engineering, and design and processing,
by rewarding them for their ability to impart knowledge
and enthusiasm to students. The recipient must be 35
years of age or younger by May 15 of the year in which the
award is made.
Henry Marion Howe Medal
Horike
Morita
Okabe
Ms. Chiyoko Horike, researcher, Kanto Chemical Co.

Inc., Tokyo, Prof. Kazuki Morita, Institute of Industrial
Science, The University of Tokyo, and Dr. Toru H. Okabe,
professor, Institute of Industrial Science, The University of
Tokyo, are recipients of the 2013 award and are being cited
for their paper entitled, Effective Dissolution of Platinum
by Using Chloride Salts in Recovery Process. The award
was established in 1923 in memory of a distinguished
teacher, metallurgist, and consultant, to honor the author(s)
whose paper has been selected as the best of those published in a specific volume of Metallurgical and Materials Transactions.
Jung
Sohn
Marcus A. Grossmann
Young Author Award
Sung Suk Jung, graduate student, and Il
Sohn, associate professor, of Yonsei University, Seoul, South Korea, are 2013 award
recipients for their paper entitled, Crystallization Behavior of the CaO-Al2O3MgO System Studied with a Confocal
Laser Scanning Microscope. The award
was established in 1960 in recognition of
Dr. Grossmanns accomplishments, especially his abiding interest in and encouragement of younger metallurgists and
materials engineers.
ASMnews
HIGHLIGHTS...Award Recipients
ASM Historical Landmark Designations

In 1969, the ASM Historical Landmarks Designation was
established to permanently identify the many sites and
events that have played a prominent part in the discovery,
development, and growth of metals and metalworking. In
1987, the scope of this award broadened to include all engineered materials.
U.S. Department of
Energy Savannah River
Site, Aiken, S.C., has
been selected for the
2013 Historical Landmark Award. The citation
reads,
For
advancing the materials
technologies necessary
to produce tritium, plutonium, and other isotopes
for
national
defense, research and
medical applications.
The Delhi Pillar,
New Delhi, was also selected to receive one of the
2013 Landmark Awards. The
citation reads, Delhi Iron
Pillarthe rustless metallurgical marvel dedicated to ancient iron-making traditions
and blacksmiths of ancient
India.
Historic Heavy Hydraulic
Closed Die Forging Presses
of the World Alcoa, Cleveland; Alcoa Samara, Russia;
Wyman Gordon, Grafton,
Mass.; Aubert Duval, Issoire,
France; Weber Metals, Paramount, Calif.; and VSMPO,
Russia, were also selected to
receive 2013 Historical Landmark Awards. The citation reads, The large (>35,000 tones)
hydraulic forging presses of the world provided significant
advancements in metals processing technology, enabling
large monolithic structures especially for efficient aircraft
performance through weight savings, improved safety and
reduced assembly costs.
Emerging Professional Achievement Award
Ms. Anne M. Stockdale, of General
Atomics Aeronautical Systems Inc., Victorville, Calif., has been selected as the
2013 recipient of the Emerging Professional Achievement Award. The award
was established in 2010 to recognize extraordinary ASM volunteers with 0-5 years
of post-graduation experience who have
made a significant impact on ASM International through devoted service and dedication to the future of the Society.
55
ASMnews
HIGHLIGHTS...Celebrating Superstars
Celebrating ASMs Superstars of Longevity and Service

ASMs 100th Anniversary is not only a celebration of the
rich history of the Society, but also provides an opportunity
to honor some of its most enduring members. The dedication and commitment of some of our most senior members
is both astounding
and commendable.
These superstars are
representative of the
many thousands of members and volunteers of all ages
who continue to work diligently for the Society, leading it
into the next 100 years. High accolades go to four venerable ASM members.
W. William Dyrkacz, FASM
Most Consecutive Years of Membership
Ask Bill Dyrkacz, age 94,
about the old days of
ASM and he undoubtedly
could share many stories.
With 74 years of consecutive membership, this earns
Dyrkacz the top spot as
ASMs member with the
most longevity. He joined
ASM as a student member
in 1939 while studying
metallurgical engineering
Bill and Mary Dyrkacz, circa 2009
at Carnegie Institute of
Technology (now Carnegie Mellon University) in Pittsburgh.
Dyrkacz became a Fellow in 1976. He spent 22 years as an
independent consultant in metallurgy and manufacturing
technology. Wanting to give back and see more young people get into metallurgy, he and his wife, Mary, made a
planned gift to the Foundation, which includes annual
scholarships for undergraduate students in metallurgy or
materials science. The William & Mary Dyrkacz Scholarships, established in 2011, are awarded to several outstanding undergraduates each year at the MS&T Leadership
Awards Luncheon.
ASM 100th Anniversary Gala
Join us for an epic celebration of ASMs 100th year anniversary

with a spectacular gala on October 27 in Montral at MS&T.
The gala will feature an exceptional lineup of events including
a cocktail reception, Gala Jubilee dinner, Presidents Reception
(by invitation only), distinguished awards ceremony, historical
tributes, keynote speaker, live entertainment, mementos,
and much more!
Gala Featured Speaker
A Keynote on Optimism
by Peter Diamandis
Chairman and CEO of the X Prize Foundation
New York Times bestselling author of
Abundance The Future is Better
Than You Think
Register today for this invaluable opportunity to network
and support the future path of the materials world.
Tickets are $125 per person.
Visit www.asminternational.org/100.
56
Raymond L. Smith, FASM

Oldest Member and Past President
Born in 1917, Ray Smith is the oldest
ASM member and oldest past president.
He has 64 years of membership and served
as the Societys president in 1980. He became a Fellow in 1972 and received Honorary Membership in 1984. Smith received
Ray Smith,
circa 1975
the Distinguished Alumnus Award from
the University of Alaska, where he received B.S. and M.S. degrees in mining engineering and later became a faculty member. He received a Ph.D. in metallurgical engineering from
the University of Pennsylvania (1951-53). Much of his early
career was devoted to laboratory research and teaching at
the university level before becoming a college administrator.
He retired as president of Michigan Technological University
(Houghton) in 1979. Smith resides in Green Valley, Ariz.
David Krashes, FASM
Oldest Past President with
Continuous Service
Serving as ASM president in 1982 was
just one of the many volunteer efforts of
David Krashes. Prior to his presidency, he
served as trustee and treasurer and extended his treasurer duties past the reDave Krashes,
circa 1980
quired term. Later he served as ASM
Foundation board member for nearly a decade (2001-2010).
He was the 2001 recipient of ASM Honorary Membership.
Krashes received a physics degree (1949) from Rensselaer
Polytechnic Institute and a Ph.D. in metallurgy (1995). He
was a professor at Worcester Polytechnic Institute before
forming Massachusetts Materials Research Inc. (MMR) in
West Boylston in 1962. Before retiring as chief executive,
Krashes grew the company from an initial part-time consulting operation for failure analysis and metallurgical testing
services into a thriving corporation. MMR evolved into The
MMR Group Inc., which now operates three laboratories
with more than 50 employees.
Robert D. Halverstadt, FASM
Oldest Past Trustee
The ASM Materials Education Foundation
has reaped many benefits from the dedicated
service of Bob Halverstadt. Amazingly, at 94
years young, he continues to serve on the
ASM Foundation board, having started in
Bob Halverstadt, that role in 2007. He attended Case Institute
circa 2006
of Technology (now Case Western Reserve
University) in Cleveland. Halverstadt spent his career in the specialty metals industry and is retired chairman emeritus from
Special Metals Corp. In addition to serving on ASMs board, he
also was a board member of Special Metals Corp. and Carus
Chemical Co. He received the ASM Distinguished Life Member award in 2002. A permanently endowed scholarship enabling
one student a year to attend Eisenman Materials Camp was established in the name of Maryella and Bob Halverstadt. Through
his generosity and dedication, Halverstadt continues to impact
future generations of engineers.
Editors note: Data is based on ASM records at the time of publication.
ASMnews
HIGHLIGHTS...Profile of a Volunteer
Chapter News
LA Student Night
The ASM Los Angeles Chapter held their annual Student
Night meeting at Don Bosco Technical Institute in Rosemead, Calif., on April 16. The ASM Student Chapter at the
school helped organize the program.
Students and ASM Chapter members were given tours of the

Don Bosco Tech laboratory facilities by enrolled pupils, including
facilities for casting, machining, mechanical testing,
metallography, and nondestructive testing.
Professor Vilupanur A. Ravi, FASM and ASM Trustee, from

California State Polytechnic University (Pomona), chats with
students at the poster session.
EMERGING PROFESSIONALS
MS&T 2013 Symposium for Emerging Professionals:
Career Opportunities and Experiences

in Materials Science and Engineering
Mark A. Tschopp
Army Research Laboratory
hose attending the MS&T13 Conference and Exhibition in Montral,

Canada, (October 27-31), will have the
opportunity to hear from materials professionals who have taken many different
career paths. The speakers will share the narrative of their
careers so that early career professionals can make informed decisions about their own employment choices.
The ASM Emerging Professionals Committee is excited
to announce the 6th Annual Symposium, Perspectives for

Emerging Materials Professionals: Career Opportunities
and Experiences in Materials Science and Engineering.
The symposium is specifically designed for the emerging
professionals community and is part of Tuesdays programming. The early career professional programming includes keynote lectures from Dr. George T. Rusty Gray,
FASM, and Dr. C. Ravi Ravindran, FASM and ASM vice
president. We would like to personally extend an invitation to attend this symposium and interact with both
emerged and emerging professionals alike. We hope to see
you there!
VOLUNTEERISM COMMITTEE
Profile of a Volunteer
Michael B. Connelly, FASM

Casey Products Inc.
ew people can claim ASM as their alma

mater. But Mike Connelly, vice president of Casey Products in Chicago, received
his entire metallurgical education through
ASM courses. Mike jokes, In 1972, my
mother threw me out and I had to get a job. I liked science and
applied for a lab tech trainee job at a heat treating equipment
manufacturer. That was the start of a career.
In 1979, Mike became a member of ASM and travelled to
the Dome for his first class, Interpretation of Ferrous Microstructures. He still uses material from his 1980 Principles
of Failure Analysis coursepart of the ASM Metals Engineering Institute that subsequently became the ASM Education
Department. Mike took numerous ASM courses while working in Chicago and earning promotions along the way.
For the past 20 years, Mike has applied his ASM education to his work at Casey Products, a distribution company
supplying fasteners and related hardware to companies

around the world. Their materials testing lab performs quality checks on parts with extremely demanding specifications.
I still travel to the Dome every summer to help with the
Eisenman Materials Camp sponsored by the ASM Materials
Education Foundation, says Mike. Its one of the most fun
things I do! We use all the new toys and technology as we get
students thinking about careers in materials, science, and engineering. He enjoys working with other volunteer mentors
who bring various items to be examined for failure analysis
from fasteners to rocket parts and even Christmas tree lights.
Mike belongs to the Chicago regional chapter and appreciates the camaraderie in ASM. Its part of an extended family.
He was named an ASM Fellow in 2009 and earned the 2011
Alan J. Putnam Service Award. In addition to being a Materials Camp mentor for 14 years, he serves on the Failure Analysis (FA) Committee and FA Education Subcommittee. Looking
back on a career that may not have happened without ASM,
Mike reflects, Ive come full circle, reviewing the same courses
Ive taken, and trying to make them better.
For a list of upcoming ASM Training Courses, see our ad on page 32 of this issue.
57
ASMnews
HIGHLIGHTS...Members in the News
Members in the News

Asphahani as QuesTeks New CEO
Dr. Aziz I. Asphahani, FASM, joined
QuesTek Innovations LLC, Evanston, Ill.,
as the new chief executive officer on July
1. He is leading the companys efforts in
growth and business development.
QuesTek designs, develops, and commercializes new high performance materials.
Asphahani has an extensive background in
both metallurgy and business, having acted as director of
technology/R&D at Cabot Corp., vice president of sales and
marketing at Haynes International, and president at both
CABVAL and CARUS Chemical Co. He served as president
of ASM International (2001), ASM Foundation chairman
(2004), and on the board of directors of NACE and the
American Chemistry Council. Dr. Asphahani holds a
Diplome Ingenieur Physics from Ecole Centrale de Paris
and a Ph.D. in materials science from the Massachusetts Institute of Technology. He is an expert in alloy development
and metallic corrosion, has been awarded eight patents, and
has authored more than 65 papers on high alloys and corrosion control.
Lados Receives International Honor
for Seminal Contributions to Structural Integrity
Diana A. Lados, associate professor of mechanical engineering at Worcester Polytechnic Institute (WPI) and founding director of the universitys
Integrative Materials Design Center (iMdc), received the inaugural
Constance Tipper Silver Medal
from the World Academy of
Structural Integrity at the academys International Conference
on Fracture, held in Beijing, June
16-21. The medal recognizes international achievement at mid-career. Lados was honored for
her outstanding and seminal research, technical accomplishments, and pioneering contributions with worldwide impact
in the fields of metal fracture and fatigue, and her successful
efforts to transfer knowledge to industrial applications. In
2012 she received the ASM Silver Medal. Lados was the only
woman on a team of five leaders in her field selected in 2011
to participate in a Department of Energy program to identify
areas where materials science and engineering will shape research and business opportunities in the next decade. In
March 2012, she was one of 20 New England women honored
by Mass High Tech as Women to Watch.
Sandia Labs Names Cole as Fellow
Sandia National Laboratories, Albuquerque, N.M., named
Dr. Edward I. Cole a Sandia Fellow along with two research
colleagues, Jerry Simmons and John Rowe. The elite designation is reserved for those who are nationally or internation-
IN MEMORIAM
Word has been received at ASM Headquarters of the death
of Life Member John P. Fraser, of Houston (Houston Chapter).
58
ally recognized pioneers

in their fields. There have
been only six previous fellows in Sandias history,
five of whom are retired.
Cole is internationally
recognized for his widely
used work in failure
analysis and reliability
physics. His pioneering
work and leadership in
applying failure analysis
techniques to the most Newly appointed Sandia Fellows
Jerry Simmons, left, Ed Cole,
challenging national secu- middle, and John Rowe gather
rity problems has led to outside Sandias Joint
methods for finding al- Computational Engineering
most entirely hidden de- Laboratory.
fects. I am honored and excited by the Sandia Fellow
appointment and the opportunity it affords to work with
staff, leadership, and external partners in Sandias national
security mission, said Cole. Fellows are expected to bring
the very best science and engineering to Sandia and the U.S.,
shape the future of Sandias science and engineering enterprise, expand the breadth of their influence, mentor others,
and maintain extensive professional networks.
JOM Examines Diversity
in Materials Science and Engineering
United in Our Differences: Changing the
Face of MSE, is an extensive feature package in the July 2013 issue of JOM, the
monthly journal of The Minerals, Metals &
Materials Society. The feature tells the story
of progress made and challenges to a more
inclusive professional culture in the voices
of nearly 30 female materials scientists and
engineers. Among the compendium of individual profiles of
inspiring female materials science and engineering (MSE) professionals is one by Prof. Julia R. Weertman, FASM, Walter
P. Murphy Professor Emerita, who writes about how perceptions of female scientists have evolved since she started her
career more than 60 years ago. The July issue of JOM is available online through Springerlink. All articles pertaining to the
diversity topic are provided as open access.
Narayan Receives TMS Mehl Medal
Prof. Jagdish (Jay) Narayan, FASM, is
the recipient of the TMS 2014 Robert
Franklin Mehl Medal and The Institute of
Metals Lecture Award. He will deliver the
lecture on Frontiers in Thin Film Epitaxy
and Novel Nanostructured Materials in
the Symposium on Frontiers in Nanostructured Electronic and Structural Materials
and Their Applications, held in his honor at the 143rd TMS
Annual Meeting in San Diego, February 16-20, 2014. The
lecture will focus on the inherent advantages and challenges
of nanomaterials and the design of new materials leading to
novel and unique systems with improved properties. Prof.
Narayan is the John Fan Family Distinguished Chair Professor in the Department of Materials Science and Engineering, and also has an appointment as Distinguished Visiting
Scientist at Oak Ridge National Laboratory. His other honors include: Acta Materialia Gold Medal and Prize (2011),
ASM Edward DeMille Campbell Lecture and Prize (2004),
and ASM Gold Medal (1999).
NRC Committee Appoints Ballinger
The U.S. Nuclear Regulatory Commission has appointed Prof. Ronald G.
Ballinger to the Advisory Committee on
Reactor Safeguards (ACRS) for a four-year
term. Ballinger is a professor of nuclear science and engineering and materials science and engineering, and is head of the
H.H. Uhlig Corrosion Laboratory at the
Massachusetts Institute of Technology (MIT). His areas of
specialization are materials selection, nuclear engineering
systems, environmental degradation, and life assessment of
these systems. In addition to the courses he taught at MIT,
Ballinger also developed and taught several industrial
courses on environmental degradation with EPRI and the
Materials Aging Institute. He previously chaired the Materials Science and Technology Division of the American Nuclear Society.
ASTM Honors Boes
Eric R. Boes, corporate quality engineer at Delta Faucet
Co. in Indianapolis, received the Copper Club Award from
ASTM International Committee B05 on Copper and Copper Alloys. Boes was honored for his leadership of the main
committee, as well as numerous subcommittees and task
groups, and his contributions to the development of new
standards and revisions of existing standards. An ASTM fellow who received the Award of Merit in 2003, Boes has been
chairman of Committee B05 since 2010. He specializes in
supplier quality assurance and product development, auditing, metallurgical engineering, and standards development.
Prior to joining Delta Faucet Co. in 1998, Boes was a senior
metallurgical engineer at Olin Brass Corp. in Indianapolis.
First Class of NanoEngineering Graduates
This past June, nearly 20 seniors earned the first bachelors degree in nanoengineering offered at the University of
California, San Diego. Although most engineering programs
now offer courses about engineering at the nanoscale, very
April Pereia, an
Iraq war veteran,
was among the
first class of
undergraduates
to earn a bachelors degree in
nanoengineering
this past June.
ASMnews
HIGHLIGHTS...Members in the News
few provide a focused curriculum dedicated to this rapidly

growing field. UC San Diego was the first in the nation to
create a Department of NanoEngineering in 2007 and began
offering it as an undergraduate degree program in 2010. Undergraduate enrollment is expected to reach nearly 400 students this fall. The department plans to introduce a new
materials engineering degree in 2014. In the fully developed
NanoEngineering Department, we will administer the more
traditional programs of materials engineering and chemical
engineering, along with our core focus program of nanoengineering, which combines aspects of materials engineering
and chemical engineering directed at the unique properties
and enabling characteristics of nanoscale materials. This will
serve as a model for future departments of this kind, said
Prof. Kenneth S. Vecchio, chair, Department of NanoEngineering, UC San Diego.
ACerS Corporate Technical Achievement Award
Won by Surmet
The American Ceramic Societys (ACerS) Corporate
Technical Achievement Award (CTAA) for 2013 has been
awarded to Surmet Corp. (Burlington, Mass.) for development and commercialization of its ALON Transparent Optical ceramic. ACerS established the award in 1986 to honor
a single outstanding technical achievement in the field of ceramics. Surmets motto since its founding in 1982 has been
to take inventions from the lab to the production floor. This
is more easily said than done, as most inventions die in the
lab and never make it to the commercial market place, said
Dr. Suri Sastri, FASM, founder, chairman, and CEO. ALON
transparent armor provides higher than 50% weight savings
over glass-based armor. In addition to providing safety for
soldiers and military equipment, broader commercial applications are expected from the technology.
IMS Salutes
Corporate Sponsors
The International Metallographic Society (IMS) relies on

corporate financial support to maintain its excellent awards
program. IMS extends sincere appreciation to the following
companies for their support.
IMS Benefactors
Precision Surfaces
International
IMS Patrons
Allied High Tech Products Inc. Metallurgical Supply Co. Inc.
Exponent
Struers Inc.
Buehler
IMS Associates
Carl Zeiss MicroImaging, LLC
Rolls-Royce
Evans Analytical Group
Ted Pella Inc.
Hoeganaes Corp.
IMS Sponsors
Leco Corp.
PRESI Inc.
Metlab Corp.
Scot Forge Co.
Nikon Metrology Inc.
59
products &
literature
Carl Zeiss Microscopy LLC, Thornwood, N.Y., introduced

a new hardware auto focus and cleanroom kit for its Axio
Imager Vario microscope system, well suited to
surface inspections on reflective, low-contrast
samples. In transmitted and reflected light, the
focus system ensures precision to 0.3 of the
depth of field of the objective lens. The
sensor registers changes to the focus position and automatically compensates any
deviations via direct access to the Z drive
of the microscope. Axio Imager Vario is
certified for cleanroom use in accordance
with DIN EN ISO 14644-1 and, with the
cleanroom kit, fulfills the requirements of ISO 5.
www.zeiss.com/micro.
FEI, Hillsboro, Ore., released Helios NanoLab 1200AT, the
newest generation of its full-wafer dual beam analysis
systems. The addition of an optional automated FOUP
(front opening universal pod) loader allows the NanoLab
system to be located inside the semiconductor wafer fab,
where its scanning electron microscope imaging and precise focused ion beam milling are used to extract ultrathin
samples of targeted structures and defects for examination
in a high-resolution transmission electron microscope. Results are used to diagnose root causes of defects and evaluate process maturity. www.fei.com/helios.
Indium Corp., Clinton, N.Y., introduced SACM, a high-reliability solder alloy that reportedly offers drop shock
performance far superior to other SAC alloys, without
compromising on thermal cycling and at a lower cost than
that of typical SAC solder alloys. SACM offers better drop
shock performance than SAC305 and SAC105, with the
added benefit of thermal cycling reliability equivalent to
SAC305. The new alloy is especially useful for manufacturing consumer electronics that experience frequent handling, such as mobile devices. SACM is doped with
manganese for increased strength and contains less silver
than other Pb-free alloys. www.indium.com/SACM.
Olympus Corp., Newton, Mass., announced a new
benchtop analyzer that combines x-ray diffraction and
x-ray fluorescence in one unit. The BTX Profiler combines these to provide compositional materials analysis
at the structural and elemental level to save costs,
space, and time. The analyzers close-coupled transmission geometry allows for a low powered x-ray source
and a small amount of sample. A sophisticated sample handling technology incorporates a patented vibration
system that enables random crystal orientation in a fixed sample cell.
www.olympus-ims.com/en/btx-profiler.
Omega Engineering Inc., Stamford,
Conn., introduced the Dpi1701 series
1/8 DIN monochrome, high-resolution
graphic display panel meter and data
logger for temperature and process
measurement. This CE-compliant product features optional alarm relays, isolated analog output, isolated 24 Vdc
excitation voltage, and a wireless receiver. The Dpi1701 records 85,000
data points with time and date stamping. The logging starts and stops based
on time and date, alarm 1 or 2 status,
or a key press, and it monitors and displays both minimum and maximum
process values. Process input is displayed in horizontal bar graph, line
graph, or standard digital format.
www.omega.com/pptst/DPi1701.html.
Innovnano, Portugal, developed highly
pure 4YSZ (4 mol% yttria stabilized zirconia) for use in suspension. The nanostructured material is well suited for
suspension plasma spray (SPS), which
offers higher deposition efficiency to
minimize waste and also reduces capital
60
classifieds
expenditure and process costs. 4YSZ powder complements SPS as a stable ethanol-based suspension: When
applied, it produces coatings with chemical homogeneity.
This translates to improved mechanical and physical properties, including exceptional thermal insulation, high melting
points, and superior adhesion to underlying components.
www.innovnano-materials.com.
Oven Industries Inc., Mechanicsburg, Pa., offers a wide variety of temperature sensor probes, from thermistors and
thermocouples to resistance thermometers. A new Temperature Sensor Selection Guide, available free of charge on
the company website, is available to help users select the
correct probe for the application at hand. The guide shows
the tolerance level, model number, temperature range, and
key details about the companys five sensor products,
which feature a tolerance to 0.1C. www.ovenind.com.
ad index
Advertiser
Allied High Tech Products Inc.

Carpenter Technology Corp.
Clemex Technologies Inc.
DeWAL Industries Inc.
Epsilon Technology Corp.
Guyson Corp.
Hgans AB
JEC Composites
JEOL USA Inc.
LECO Corp.
Master Bond Inc.
MTS Systems Corp.
Plasma Giken Co. Ltd.
Praxair S.T. Technology Inc.
Progressive Technologies Inc.
Proto Mfg. Ltd.
Saint-Gobain Coating Solutions
Sulzer Metco Ltd.
Westmoreland Mechanical Testing & Research Inc.
Page
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61
Metallurgist
Triumph Actuation Systems in Clemmons,

NC, a subsidiary of Triumph Group Inc, designs, manufacturers and repairs complex
hydraulic and hydro mechanical aircraft
components and systems, has an opening
for an experienced metallurgist or materials scientist. This individual supports the
development, manufacture and testing of
hydraulic products by providing specialized
technical support in the area of materials
selection, heat treatment, surface engineering, NDT, manufacturing processes, and interpretation of customer requirements. The
alloy systems include ferrous, aluminum,
copper, and titanium. Typical tasks include
failure analysis, composition analysis,
determination of mechanical properties,
microstructural analysis, process development/analysis, and documentation in an
on-site Nadcap accredited Materials Laboratory. The Metallurgist also serves as the
materials technical resource person for
Quality, Manufacturing, and Engineering.
The successful candidates shall have, as a
minimum, a B.S. degree in Metallurgical
Engineering/Materials Science and 7 years
experience in a hands-on metallurgical environment. Work experience within a Materials Testing facility is a plus. To apply, visit
www.triumphgroup and select job listings
at Triumph Group.
An equal Opportunity Employer M/W/V/D
To advertise
in the classifieds,
or to order
article reprints,
please contact
Kelly Sukol at
440/338-5151,
ext. 5569;
kelly.sukol@
asminternational.org.
The ad index is published as a service. Every care is taken to make

it accurate, but Advanced Materials & Processes assumes no
responsibility for errors or omissions.
61
editorial preview
SEPTEMBER
High-Tech Materials and Processes

Highlighting:
Integrated Computational Materials
Engineering (ICME)
Overview of Superalloy Development
Advances in Spinodal Alloys
Special Supplement Inaugural Issue:
New! HTPro quarterly newsletter covering
heat treating technology, processes,
materials, and equipment, along with
Heat Treating Society news and initiatives.
Bonus Distribution:
MS&T Conference & Exposition 2013
October 27-31 Montreal, Canada
Advertising closes August 5, 2013
OCTOBER
Nondestructive Testing
Highlighting:
Modeling NDE Processes
Advanced NDE Techniques
Critical Materials and Conflict Minerals
Bonus Distribution:
International Symposium for Testing and
Failure Analysis (ISTFA) 2013
November 3-7 San Jose, Calif.
Advertising closes September 4, 2013
Contact us:
9639 Kinsman Road
Materials Park, OH 44073-0002
Tel: 440/338-5151
Fax: 440/338-4634
Web: www.asminternational.org/AMP
Subscriptions/Customer Service: 800/336-5152, ext. 0
E-mail: MemberServiceCenter@asminternational.org
Sales Staff:
Skip Wolfe, Director, Sales and Marketing
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National Sales Manager
440/338-5151 (ext. 5574)
Fax: 440/338-8542
erik.klingerman@asminternational.org
iTSSe/Affiliate Sponsorships
Kelly Thomas, CEM.CMP
National Account Manager
440/338-1733
Fax: 614/948-3090
kelly.thomas@asminternational.org
62
pastimes
Selected items from the pages of ASM Internationals monthly magazine: Metal Progress was published
from 1930 to 1986, after which Advanced Materials & Processes came into being.
Mulling over
the metric system
From an editorial by Allen Gray,
editor of Metal Progress, December 1969
For years, going metric has been the
topic of rather heated debate, and
representative viewpoints for and against
have been expressed in Metal Progress.
Now we must face up to the realities of
possible future action that is likely to affect
the operation of virtually every
manufacturing company in this country. Last
year, Congress passed the metric study bill
which was signed in to Public Law 90-472
by the President. It authorizes the Secretary
of Commerce to conduct a three-year study
to determine the advantages and
disadvantages of greater usage of a
modernized version of the metric system
and report back to Congress with
recommendations. The British took the
opposite course. The decision to adopt the
metric system came first; and they are just
now coming to grips with the practical
aspects of implementation.
The approach being taken by the U.S.
government certainly makes better sense;
and the need for cooperation at this time by
all interested parties, whether they are pro or
con, is evident. This means that every
prudent company should begin to
investigate what increased usage of SI
units would mean to its own operations,
advises William Burton of Ford Motor Co.
We would go one step further. It is time for
all engineers to become better acquainted
with the metric facts of life as they relate to
their own operations. We feel that
information developed at this working level
should be given much weight in coming to
a decision on whether or not the
United States should go metric.
Highly suitable sodium

From an advertisement for metallic sodium,
Metal Progress, August 1955
Talk about reducingand youll talk about Ethyls high
purity sodium. Ethyl Corporation, working closely with
organizations in the chemical and metallurgical fields,
offers metallic sodium ideally suited in form and purity to
the needs of those interested in reducing metal salts or in
other reactions with organic and inorganic compounds.
Available in tank cars, and cast solid in drums, Ethyl can
furnish sodium specially filtered
and handled under argon, out
of contact with nitrogen or
oxygen. Top physical
properties of the refractory
metals demand the finest
sodium. Numerous chemical
reactions may benefit greatly
from the use of this high
purity sodium. The Ethyl
Research Laboratories
have developed improved
techniques for the
analysis of sodium for
oxides and other
impurities. We would be
happy to supply high
purity sodium for your
work and to give
technical service on sodium
analysis when desired.
Little red (aluminum) Corvette
From the Materials Progress News department, Metal Progress, July 1983
The 1984 Chevrolet Corvette boasts more than 80 aluminum components
weighing a total of 375 lb (170 kg), making it the most aluminum-intensive vehicle
on Americas highways, states Aluminum Co. of America, Pittsburgh. Increased use
of aluminum helped Chevy shave 250 lb (114 kg) from the 1982 Corvette. Major
sheet applications include the rear frame extension, supports for the instrument
panel and spare tire tray, and the driveline channel beam
all made from 6000 series alloys. Of major
significance is the Corvettes use of
aluminum alloy 6061 forgings in its
suspension. These include front and
rear knuckles, upper and lower front
control arms, and rear double
trailing arms and lateral struts50
lb (23 kg) per car. The automobile
also sports a tubular aluminum drive
shaft and wheel shafts with forged
aluminum yokes welded to them; forged
aluminum pistons; cast aluminum road
wheels; and an aluminum differential cover
beam thats permanent mold cast.
63
3D big bugs reveal insect anatomy
Researchers developed 3D
structures out of liquid metal.
Courtesy of Michael Dickey.
Connecting the drops

with 3D printing
Researchers from North

Carolina State University,
Raleigh, developed 3D printing
technology and techniques to
create freestanding structures
made of liquid metal at room
temperature. Its difficult to
create structures out of liquids,
because liquids want to bead
up. But weve found that a liquid
metal alloy of gallium and
indium reacts to the oxygen in
the air at room temperature to
form a skin that allows the
liquid metal structures to retain
their shapes, says Dr. Michael
Dickey, an assistant professor of
chemical and biomolecular
engineering. www.ncsu.edu.
NovaCopy 3D
printed a new
webbed foot for
Buttercup,
based on photos
of his sister
Minnies left foot.
Courtesy of
Mike Carey.
64
Minute insects, from the Australian

National Insect Collection, were supersized up to 40 using a novel 3D
scanning system and then printed using
a sophisticated 3D printer. These tools
enable entomologists to physically
handle the insects and study their
features up close. To create the big
bugs, scientists scan the insects to
generate a CAD file, which is entered
into the 3D printing machine. The printer
adds layer upon layer of titanium to
build up each bug. Up to 12 bugs can
Scientists printed giant titanium 3D bugs, a first for
be produced at a time and after 10 hours additive manufacturing.
in the machine, immense insects emerge
from the titanium powder. www.csiro.au.
Reinventing the wheel
Shark Wheels are not circular or squarethey are

made of three strips each, which create a helical shape
when they roll, and form a sine wave pattern. When
wheels make contact with the ground, good things
happenthe user gains speed, a better grip, and a
smoother ride, according to inventor David Patrick. He
says the wheel concept began while fashioning a cube
made of different parts when he accidentally dropped
it. When it hit the ground, it rolled and kept on going no
matter what the terrain. He and his team set to work
Shark Wheel is a high/low friction
wheel designed to offer superior
modeling the design, testing wheel performance in
traction and high-speed stability.
different conditions and with focus groups of
experienced riders, and molding a final design in industry-standard urethane. The sine
wave pattern is said to support better lateral grip. The team says the wheels perform well
in rain and gravel. http://sharkwheel.com.
Lucky duck gets 3D printed foot
Buttercup the duckling was born with a bad foothis left flipper bent backwards and
faced the wrong way. When his caregivers discovered he had trouble walking, they decided
to suit him up with a replacement. The 3D-printed foot was designed by Mike Garey with
help from NovaCopy, Irving, Tex. The foot took 13 hours to print. The only way to create a
foot for Buttercup was to scan Buttercups sisters foot
and turn that into a 3D model and print it out, explains
Melissa Ragsdale, president of 3D printing services at
NovaCopy. Buttercups bad foot was surgically
removed in February. Now that his stump is fully
healed, a webbed plastic foot fits over his knee so he
can walk or swim just like any other two-footed duck,
says Ragsdale. www.novacopy.com.
We invite contributions for this page!

Please send cartoons, trivia, jokes, photomicrographs, etc.,
to stressrelief@asminternational.org.
If we use your idea, we will send you a cool mini multi-tool.

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AUGUST 2013 VOL 171, NO 8

AN ASM INTERNATIONAL PUBLICATION

Check out the

Scanning Vibrating Probe Monitors

K. Williams, R. Bayles, and D.D. Macdonald

Detailed Simulation Helps Validate Weld

Finite element analysis and other techniques verify that a

Celebrating ASMs First 100 Years in

37 International Thermal Spray

The monthly publication about ASM members, chapters, events,

ADVANCED MATERIALS & PROCESSES AUGUST 2013

Materials lifecycle issues

re you working on a materials research project that could use

ADVANCED MATERIALS & PROCESSES AUGUST 2013

Frances Richards, Senior Editor

ASM BOARD OF TRUSTEES

STUDENT BOARD MEMBERS

Jennifer Breidenich, Gregory Vetterick, Blake Whitley

ew analysis from market researcher Frost & Sullivan regarding the

ADVANCED MATERIALS & PROCESSES AUGUST 2013

Drill core of volcanic ash-hydrated lime mortar

Houses stick together with glue

WKI came up with a way of bonding

Look up, lookdown, you wont see this fish around

Researchers found the lookdown fish

ADVANCED MATERIALS & PROCESSES AUGUST 2013

METALS POLYMERS CERAMICS

Hydroformed aluminum drives down weight of Corvette

Vari-Form, Troy, Mich., began production of all-aluminum hydroformed frame rails

Collaboration on Structural Materials Data Demonstration Project

ADVANCED MATERIALS & PROCESSES AUGUST 2013

Safer circuit breakers made

Royal DSM, Heerlen, the Netherlands,

Experimental work performed at the German

Coatings database under development

ADVANCED MATERIALS & PROCESSES AUGUST 2013

terials are best suited to specific stresses. Researchers will also

Reza Shahbazian-Yassar, associate professor of mechanical

Super-strong wires made of carbon nanotubes (CNTs) were developed in a usable

NIST announces Advanced Materials Research Center

Magnetic phenomenon enables better data storage

ADVANCED MATERIALS & PROCESSES AUGUST 2013

Molecular dynamics simulation from

3D printed shoes tiptoe onto Parisian catwalks

Stratasys Ltd., Minneapolis, unveiled 12 pairs of 3D printed

Watts Water Technologies Inc.,

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A team from Stanford University, Calif., and

Advanced batteries boast 10,000 charge cycles

Investments drive next-generation efficient lighting

ADVANCED MATERIALS & PROCESSES AUGUST 2013

Filmmaking magic with polymers

A self-assembled copolymer block film

Nanocoating protects electronics from moisture

Reading, Pa., is pursuing

by the Defense Advanced Research Projects

ADVANCED MATERIALS & PROCESSES AUGUST 2013

Researchers at five Fraunhofer

Graphene enhances substrates for CNT growth

Agreement to work on graphene

ADVANCED MATERIALS & PROCESSES AUGUST 2013

Scanning Vibrating Probe