Perspectives of elementary technologies for AC power applications of high temperature superconductors

To apply high temperature superconductors (HTS) to AC power apparatuses, R&Ds for AC loss reduction and quench protection of HTS wires are as important as R&Ds for high performance HTS wires. Perspectives of elementary technologies for the AC loss reduction and quench protection are presented in the paper.     

Advancements in MEMS materials and processing technology

From achievements in display imaging to air bag deployment, microelectromechanical systems are becoming more commonplace in everyday life. With an abundance of opportunities for innovative R&D in the field, the research trends are not only directed toward novel sensor and actuator development, but also toward further miniaturization, specifically achieving micro- and nanoscaled integrated systems. R&D efforts in space, military, and commercial applications are directing specific research programs focused on the area of materials science as an enabling technology to be exploited by researchers and to further push the envelope of micrometerscaled device technology. These endeavors are making significant progress in bringing this aspect of the microelectro-mechanical field to maturation through advances in materials and processing technologies. John D. Olivas earned his Ph.D. in mechanical engineering and materials science from Rice University in 1996. He is currently a program element manager and staff engineer senior for the Advance Interconnect and Manufacturing Assurance Program at the Jet Propulsion Laboratory. Stephen R. Bolin earned his M.S. in materials science from Stanford University in 1970. He is currently staff engineer senior and supervisor of the Applications Engineering Group in the Quality Assurance Office at the Jet Propulsion Laboratory.     

A networked research program for aluminum production and transformation

In response to increasing needs and new opportunities, a provincewide network of Quebec institutions of higher learning, R&D agencies, and technology users has been set up to carry out research in aluminum production, fabrication, and transformation technologies, and to help channel the expertise and resources into large projects with more efficiency in terms of generating synergy and funding, cutting-edge research, qualified personnel training, and technology transfers. It is a unique experience in collaborative, multipartite, university-based R&D which, in addition to a comprehensive, far-reaching research program, emphasizes the various aspects of dispersed inter-institutional coordination, resource sharing, synergy creation, joint graduate training, diversification of funding, and intellectual property. For more information, contact R.T. Bui, Réseau thématique de recherche sur l’aluminium REGAL, Saguenay, Québec, Canada G7H 2B1.     

Geothermal energy—A sustainable resource of enormous potential

Geothermal energy is available at many locations on the earth’s surface. This clean and reliable energy has enormous potential and can be used to partially replace the conventional fuels that are currently used; the total magnitude of this resource is much larger than the potential contained in all of the fossil and uranium reserves worldwide. Geothermal energy will become increasingly significant during the next century; enhanced thermal energy R&D is expected to lead to commercial development some time after 2010, depending on energy costs at that time. Phillip M. Wright earned his Ph.D. in geophysics from the University of Utah in 1966. He is currently a research professor in the Department of Civil and Environmental Engineering and deputy director of the Energy and Geoscience Institute at the University of Utah.     

Virtual production platform for intelligent quench hardening of large steel moulds for plastic forming

Abstract

An innovative R&D route to improve process design, recently successfully employed by Shanghai Jiao Tong University (SJTU) in cooperation with Fushun Special Steel Co. Ltd and Yanshan University, is described.     

Talking with members of the globalization of materials R&D study

The Committee on Globalization of Materials Research and Development was appointed by the U.S. National Research Council in December 2003. Its charge: to assess the status and impacts of the globalization of materials R&D. The 12-member committee, which included representatives from both U.S. and international academia and industry, published its findings in August 2005 in the form of a report Globalization of Materials R&D —Time for a National Strategy. To gain some perspective on the report's findings, JOM spoke with representatives of the committee, retired from Alcoa; Gordon Geiger, director of the engineering management program and professor of industrial engineering at the University of Arizona; Jennie Hwang, president of H-Technologies Group in Cleveland. Ohio: and Michael Jaffe, director, Medical Device Concept Laboratory of New Jersey Institute of Technology and associate research professor at Rutgers University in Newark, New Jersey. See the sidebar for a listing of the committee's recommendations. The interviews were conducted by e-mail and telephone; respondents chose which questions to answer.     

Qualifying of metallic materials and structures for aerospace applications

The U.S. Navy’s certification and qualification process for materials and structures is undertaken to ensure the flight safety and full mission capability of naval aviation weapon systems. A building-block process is practiced in which validated engineering data and concepts provide the foundation for continued technological development and innovation. For example, prior to developing material-property standards, the manufacturing process is frozen and fully characterized. The customer’s cost, schedule, and performance requirements must be carefully considered. Technologies are selected for immediate use or further R&D based upon a risk assessment that takes into account many factors, including technological maturity, lessons learned, the sponsor budget and schedule constraints, affordability, return on investment, and life-cycle cost impact. This paper explores the process that the navy uses to qualify its airframe alloys and structures. For more information, contact W.E. Frazier, Naval Air Systems Command, Research and Engineering Group, Air Vehicle Department, Patuxent River, MD 20670; (301) 342-8003; fax (301) 342-8062; e-mail FrazierWE@navair.navy.mil.     

IFHTSE Global 21: heat treatment and surface engineering in the first decades of the twenty-first century: Part 2 – Heat treatment in China: present and future

Abstract

The large state-owned enterprises in China have achieved great progress in heat treatment production technologies over the last 10 years. In addition, the number of smaller commercial heat treatment plants has increased rapidly to more than 3000. Heat treatment plant and equipment manufacturing flourishes. However, because China covers a vast territory with uneven regional development, and consequently little uniformity across the individual enterprises, there are still obvious gaps compared with the advanced level globally. Therefore the 11th Five-Year Plan for the heat treatment industry, formulated by the China Heat Treatment Association (CHTA) and the Chinese Heat Treatment Society (CHTS) prioritises equipment renovation as the way ahead for production technology innovation. Based on a nation-wide survey, the 11th Five-Year Plan described the current status, identified the shortcomings, formulated the guiding principles and directions for development, and put defined key R&D initiatives and other measures for achieving progress. A vision up to 2020 was set out.     

Developments in the processing and properties of particulate Al-Si composites

In the past ten years, materials R&D has shifted from monolithic to composite materials, adjusting to the global need for reduced weight, low cost, quality, and high performance in structural materials. This article reviews developments in the molten processing of particulate Al-Si alloy composites and their respective properties. Existing and emerging processing innovations are discussed, and the reinforcement phases in prominent R&D activities are identified. The vortex (or mixing) method continues to be the most popular processing method in use because of its ease of operation, total production cost, and suitability, while the infiltration, compocasting (or rheocasting), in-situ, and spray atomization and codeposition techniques receive less attention. Editor’s Note: A hypertext-enhanced version of this article can be found on the TMS web site at http://www.tms.org/pubs/journals/JOM/9711/Ejiofor-9711.html. J.U. Ejiofor earned his Ph.D. in materials science from the Enugu State University of Technology, Nigeria, in 1993. He is currently a plant metallurgist for Shelco Foundries. Dr. Ejiofor is a member of TMS. R.G. Reddy earned his Ph.D. in metallurgical engineering from the University of Utah in 1980. He is the ACIPCO chair professor at the University of Alabama, Tuscaloosa. Dr. Reddy is a member of TMS.     

Passive RFID sensor systems for crack detection & characterization

A significant requirement of low-cost sensor systems for defect detection and characterization is to bridge the gap of nondestructive testing & evaluation (NDT&E) and structural health monitoring (SHM). This paper introduces an ultra-high frequency (UHF) passive RFID sensor system for crack detection and potential structural monitoring. The working principles and major research challenges are presented for the new concept of NDT&E sensor systems. One novel approach using 3D antenna and kernel principal component analysis (PCA) is investigated and validated in conjunction with two case studies for evaluation of open and closed cracks. This proposed method can partly alleviate the nonlinearity from wireless channel and demonstrate the feasibility of the in-situ motoring through amplitude and phase of tag’s backscattered signals.     

Technological and scientific landscape of laser cladding process in 2007

In the last 30 years, public and private organizations involvement in laser cladding R&D activities is increasing. These activities are mainly conducted in universities, public research institutes and technical centres of private companies worldwide. This study shows a bibliometric analysis of the patents and scientific publications in the laser cladding field for the period ranging from 1985 to 2007. This seeks to identify the activity and trends in its environment for strategic purposes. All the laser cladding processes and all the substrates (steel, aluminium and superalloys) used for coating, repairing and 3D fabrication were taken into account. At first, the world patent production was analysed in terms of volume (580 patent families found since 1985), frequency and applications. Then, the same strategy was applied to the scientific publications for a total volume of 588 targeted papers. Using bibliometric techniques, an analysis and mapping of the information was performed to highlight the temporal, geographical and institutional aspects of R&D activities. The patented applications were also classified in order to identify opportunities. This study shows the evolution of the scientific and technological environments of the laser cladding technology and can help public or private organizations to generate new ideas, gain awareness of emerging trends and validate the relevance of projects.     

Borosilicate glass and synroc R&;D for radioactive waste immobilization: An international perspective

This article provides a content analysis of publications on borosilicate glass and synroc, which are most widely used today for the immobilization of high-level radioactive wastes. Covering a period of 30 years, this study highlights the publication trends, the most productive countries, the language most frequently used, and the different categories of publications in these two subject areas. The research focuses on R&D efforts of different institutions and laboratories in these fields. For more information, contact S. Deokattey, Bhabha Atomic Research Centre, Library & Information Services Division, Trombay, Mumbai-400 085, India; e-mail clibscd6@magnum.barc.ernet.in.     

New oxidation‐resistant coatings for steam power plants at 650 °C

The increase of live steam temperature and pressure in new steam power plants is certainly the most effective measure to realize the stipulated CO₂ reduction targets for the conventional power industry. The development of new materials becomes a key challenge on the way forward to a more efficient and sustainable power generation.. There are two approaches being followed in materials technology in order to facilitate higher steam temperatures and pressures in the water steam cycle: 1.) The development of new materials. 2.) The use of oxidation resistant coatings on currently available materials with higher creep strength but inferior steam oxidation resistance. Both approaches are currently being followed in several R&D projects worldwide. The development and qualification of coatings is complementary to the development of new materials. The object of the EC funded R&D project SUPERCOAT is the development of new coatings according to the second approach. Eight partners from five European countries participate in the work. SUPERCOAT is the first R&D project of its kind in Europe. This presentation covers the project targets, the efforts carried out while exploring the suitability of coatings for steam turbine components and the actual state of the work. As far as possible, an excerpt from the main results of coating development and lab testing will be presented. Additionally the applied deposition techniques, chosen according to practical criteria will be presented and applicability to certain components will be discussed. Complementary, the author will report on the efforts, carried out in the German Ministry of Economic Affairs funded project “KOMET”. In this field test, empirical data are being gained from a real operating power plant and can be compared with data from the SUPERCOAT lab tests. Finally, the next steps in the project SUPERCOAT will be presented and applicability of the coatings will be evaluated.     

The integration of process and cost modeling—A powerful tool for business planning

Recent developments in modeling can eliminate much experimental laboratory work and can provide quick answers in a more cost-effective manner. This article presents a brief outline of technical cost modeling, a combination of physical modeling and cost modeling, which may be used to the mutual benefit of both the managerial decision makers and the R&D community within the materials processing field.     

Recycling policy in the european union

Recycling in the European Union (EU) has benefited from R&D efforts and strict environmental regulations of the EU’s members. Thanks to the adoption of sustainable development policies by the EU’s European Institutions, economic incentives are expected to further strengthen the recycling industry. Moreover, the historical accumulation of non-ferrous metals in Europe will likely enhance secondary metal production. Also contributing to EU recycling is mining in East European countries and the resulting industrial waste. The rate of growth of the recycling industry is expected to approach double digits for at least this decade. For more information, contact I. Gaballah, LEM, ENSG, INPL, BP 40, 54501 Vandoeuvre, France; +33-383-596-336; fax +33-383-569-585; e-mail lbrahim.Gaballay@ensg.inpl-nancy.fr.     

Heap bio-oxidation and gold recovery at newmont mining: First-year results

Newmont Mining Corporation began commercial gold production using whole-ore bio-oxidation from Carlin Trend ores in 2000. Commercialization of the bio-oxidation process culminates a 12-year R&D project designed to recover gold from low-grade siliceous sulfidic refractory ores and low-grade sulfidic carbonaceous refractory. This paper outlines Newmont’s biomilling process and reviews data from the first year of commercial operation.     

Refractory metal-intermetallic in-situ composites for aircraft engines

There has been substantial progress in the development of properties in high-temperature in-situ composites during the last five years. For example, fracture-toughness values in excess of 20 MPa √m have been reported in silicide-based composites toughened by niobium-based metallic solid solutions. These composites also have oxidation resistances and rupture lives comparable to those of single-crystal superalloys for temperatures up to 1,150°C. In this article, fracture toughness, oxidation characteristics, high-temperature mechanical behavior, and low-temperature fatigue properties of refractory metal-intermetallic composites (RMICs) are described and compared to air-craft-engine fundamental material property goals for the next millennium. Further avenues toward the pursuit of these goals are outlined. Author’s Note: All compositions are presented in atomic percent. B.P. Bewlay earned his Ph.D. in metallurgy and materials science at Oxford University in 1987. He is currently a metallurgist at General Electric Corporate R&D. Dr. Bewlay is also a member of TMS. J.J. Lewandowski earned his Ph.D. in metallurgical engineering and materials science at Carnegie Mellon University in 1983. He is currently director of the Mechanical Characterization Facility and professor of materials science and engineering at Case Western University. Dr. Lewandowski is also a member of TMS. M.R. Jackson earned his Ph.D. in metallurgy and materials engineering at Lehigh University in 1971. He is currently a metallurgist at General Electric Corporate R&D. Dr. Jackson is also a member of TMS.     

Functional periodicity as a concept for the (re-)design to agility of production systems

The complexity of a production system is caused by two factors: by a time-independent poor design that causes low efficiency (system design), and by a time-dependent reduction of system performance due to system deterioration or to market or technology changes (system dynamics). To optimize the efficiency and changeability of a production system, both factors must be considered. Starting from complexity theory, a procedure is presented in this paper that helps not only to design production systems with low or zero time-independent complexity (focus: flexibility and efficiency), but also to prevent the unpredictable influences of the time-dependent combinatorial complexity by transforming it into a periodic review and adaptation of the system’s volume and variant capabilities (focus: agility). With the help of a practical industrial example the validity of the approach is illustrated.     

Producing thin strips by twin-roll casting—part I: Process aspects and quality issues

This two-part paper discusses recent advances in research and development for the direct production of coilable thin strips by twin-roll casting in both the aluminum and steel industries. While the former is empowering the casters to approach the theoretical productivity limit, the latter is striving to put pilot casters into commercial operation. These intensive R&D efforts are derived from the advantages, both economic and metallurgical, offered by the process. As twin-roll casting combines solidification and hot rolling into a single operation, the process requires low capital investment and low operational cost. Also, because of the high solidification rate attained in the process, the thin strips produced have a refined metallurgical structure, characterized by columnar and equiaxed zones with fine intermetallic particles. The enthusiasm about twin-roll casting is now being spread worldwide. This paper focuses on the process aspects and quality control of twin-roll casting. Part II, which will appear in the August issue, will review process modeling and pilot-plant development activities.     

Computer Simulation of Cathodic Protection Systems for Branched Pipelines

Advantages of computably simulating cathodic protection systems for buried pipelines are discussed. Experience gained in the R&D of the object-orientated Underground model allowing to calculate the current and potential distribution over a branched pipeline system is presented. An example of applying the model to a real pipeline segment and thus improving the effectiveness of its cathodic protection, is given.