Showing papers in "JOM in 2011"

High-energy diffraction microscopy at the advanced photon source

Abstract: The status of the High Energy Diffraction Microscopy (HEDM) program at the 1-ID beam line of the Advanced Photon Source is reported HEDM applies high energy synchrotron radiation for the grain and sub-grain scale structural and mechanical characterization of polycrystalline bulk materials in situ during thermomechanical loading Case studies demonstrate the mapping of grain boundary topology, the evaluation of stress tensors of individual grains during tensile deformation and comparison to a finite element modeling simulation, and the characterization of evolving dislocation structure Complementary information is obtained by post mortem electron microscopy on the same sample volume previously investigated by HEDM

The potential of atomistic simulations and the knowledgebase of interatomic models

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Microstructure informatics using higher-order statistics and efficient data-mining protocols

Abstract: Microstructure informatics is a critical building block of the integrated computational materials engineering infrastructure. Accelerated design and development of new advanced materials and their successful insertion in engineering practice are largely hindered by the lack of a rigorous mathematical framework for the robust generation of microstructure informatics relevant to the specific application. This paper describes a set of computational protocols that are capable of accelerating significantly the process of building the needed microstructure informatics for a targeted application. These novel protocols have several advantages over the current practice in the field: they allow archival, real-time searches, and quantitative comparisons of different instantiations within large microstructure datasets; they allow for automatic identification and extraction of microstructure features or metrics of interest from very large datasets; they allow for establishment of reliable microstructure-property correlations using objective measures of microstructure; and they provide precise quantitative insights on how the local neighborhood influences the localization of macroscale loading and/or the local evolution of microstructure leading to development of robust, scale-bridging, microstructure-property-processing linkages.

The synthesis, compressive properties, and applications of metal matrix syntactic foams

Abstract: Metal matrix syntactic foams are composites that incorporate hollow particles in a matrix, where enclosing porosity inside the thin shell of the particle leads to low density without large decreases in mechanical properties Studies on Al, Mg, Pb, and Zn alloy matrix syntactic foams are available in the published literature A large stress plateau region appears in the compressive stress-strain graphs of metal matrix syntactic foams The height and length of stress plateau can be tailored by means of particle wall thickness, volume fraction, and size, and the total compressive energy absorption can be controlled Metal matrix syntactic foams seem promising in various energy absorbing applications including automobile parts since their energy absorption capability per unit weight is better than other foams and lightweight materials

Performance-driven design of Biocompatible Mg alloys

Abstract: Magnesium (Mg) and its alloys provide numerous benefits as a resorptive biomaterial and present the very real possibility of replacing current metallic implant materials in a variety of roles. The development of suitable biodegradable implant alloys is a multidisciplinary challenge, since alloy design must be confined to a range of alloying additions that are biologically nontoxic, whilst still providing the requisite mechanical properties. This leaves a small number of compatible elements that can provide benefits when alloyed with Mg, including calcium (Ca) and zinc (Zn). To date, although a range of different Mg alloys have been investigated both in vitro and in vivo, little work has been performed to characterize the relationship between the composition of Mg alloys, their corrosion and resulting mechanical properties over time. Consequently it is crucial to understand how these properties may be related if alloys are to be successfully screened for implantation in the body.

Fast fourier transform-based modeling for the determination of micromechanical fields in polycrystals

Abstract: Emerging characterization methods in experimental mechanics pose a challenge to modelers to devise efficient formulations that permit interpretation and exploitation of the massive amount of data generated by these novel methods. In this overview we report on a numerical formulation based on fast Fourier transforms, developed over the last 15 years, which can use the voxelized microstructural images of heterogeneous materials as input to predict their micromechanical and effective response. The focus of this presentation is on applications of the method to plastically-deforming polycrystalline materials.

Recent advances in modulated pulsed power magnetron sputtering for surface engineering

Abstract: Over the past 10 years, the development of high-power pulsed magnetron sputtering (HPPMS) has shown considerable potential in improving the quality of sputtered films by generating a high degree of ionization of the sputtered species to achieve high plasma density by using pulsed, high peak target power for a short period of time However, the early HPPMS technique showed a significantly decreased deposition rate as compared to traditional magnetron sputtering Recently, an alternative HPPMS deposition technique known as modulated pulsed power (MPP) magnetron sputtering has been developed This new sputtering technique is capable of producing a high ionization fraction of sputter target species and while at the same time achieving a high deposition rate This paper is aimed at giving a review of recent advances in the MPP technique in terms of the plasma properties, the improvements in the structure and properties of the thin films, and the important advances in the high rate deposition of high quality thick coatings on the order of 20–100 μm in thickness

Friction stir processing of aluminum cast alloys for high performance applications

Abstract: Friction stir processing (FSP) is a novel process developed based on the principle of friction stir welding (FSW) that locally manipulates the microstructure by imparting a high level of energy in the solid state resulting in improved mechanical properties. Additionally, FSP has emerged as an advanced tool to produce surface composites by embedding second phase particles into the matrix. Our work to date has shown that FSP can be implemented as a post-casting method to locally eliminate casting defects, such as porosity due to gas evolution during casting. Coarse second phases are broken up into fine nearly equiaxed particles and distributed uniformly in the matrix; grain refinement is also attained by dynamic recrystallization during FSP. This results in improved mechanical properties. Furthermore, our work shows that friction stir processing is a viable means of producing localized composite zones in cast Al components. Such improvements have important implications for manufactured components for diesel engines and for critical and high integrity components. The convenience of FSP as a post-processing step that can easily be carried out during machining operation makes it quite attractive for adoption.

Pressurized water reactor fuel crud and corrosion modeling

Abstract: Pressurized water reactors circulate high-temperature water that slowly corrodes Inconel and stainless steel system surfaces, and the nickel/iron based corrosion products deposit in regions of the fuel where sub-cooled nucleate boiling occurs. The deposited corrosion products, called ‘crud’, can have an adverse impact on fuel performance. Boron can concentrate within the crud in the boiling regions of the fuel leading to a phenomenon known as axial offset anomaly (AOA). In rare cases, fuel clad integrity can be compromised because of crud-induced localized corrosion (CILC) of the zirconium-based alloy. Westinghouse and the Electric Power Research Institute have committed to understanding the crud transport process and develop a risk assessment software tool called boron-induced offset anomaly (BOA) to avoid AOA and CILC. This paper reviews the history of the BOA model development and new efforts to develop a micro-scale model called MAMBA for use in the Consortium for Advanced Light Water Reactor Simulation (CASL) program.

A multi-scale statistical study of twinning in magnesium

Abstract: Hexagonal close packed (HCP) materials such as Mg, Zr, Ti, and Be are used in automotive, nuclear, aeronautic, and defense technologies. Understanding and controlling the formability of these materials is extremely relevant for these technologies. Such understanding requires an understanding of deformation twinning, an important deformation mechanism in HCP. Here we present a multi-scale modeling paradigm that passes information from the atomistic scale to the mesoscale represented by an individual grain in a polycrystalline metal. The single crystal model is, in turn, integrated into an Effective Medium model, which relates the behavior of all grains in the aggregate to the bulk response, such as stress-strain and texture evolution. This article focuses on application of the multi-scale model to HCP polycrystalline magnesium.

engineering Cell attachments to Scaffolds in Cartilage tissue engineering

Abstract: One of the challenges of tissue engineering, a promising cell-based treatment for damaged or diseased cartilage, is designing the scaffold that provides structure while the tissue regenerates. In addition to the scaffold material’s biocompatibility, mechanical properties, and ease of manufacturing, scaffold interactions with the cells must also be considered. In cartilage tissue engineering, a range of scaffolds with various degrees of cell attachment have been proposed, but the attachment density and type have yet to be optimized. Several techniques have been developed to modulate cell adhesion to the scaffold. These studies suggest that the need for cell attachment in cartilage tissue engineering may vary with cell type, stage of differentiation, culture condition, and scaffold material. Further studies will elucidate the role of cell attachment in cartilage regeneration and enhance efforts to engineer cell-based cartilage therapies.

Collagen scaffolds for orthopedic regenerative medicine

Abstract: Collagen and collagen-based scaffolds offer distinct advantages when selected as biomaterials for use across a broad spectrum of regenerative medicine applications. However, relatively poor mechanical properties are often perceived to limit their usefulness for orthopedic applications. These problems can be overcome through enhanced crosslinking mechanisms or through the addition of a second, stiffer phase such as hydroxyapatite, thus allowing tailored composite scaffolds to meet specific tissue requirements. This overview will highlight the current state of the art of these scaffolds, and consider the exciting prospects and future directions of collagen-based technologies for orthopedic regenerative medicine.

Deposition of antimicrobial coatings on microstereolithography-fabricated microneedles

Abstract: Microneedles are small-scale needle-like projections that may be used for transdermal delivery of pharmacologic agents, including protein-containing and nucleic acid-containing agents. Commercial translation of polymeric microneedles would benefit from the use of facile and cost effective fabrication methods. In this study, visible light dynamic mask microstereolithography, a rapid prototyping technique that utilizes digital light projection for selective polymerization of a liquid resin, was used for fabrication of solid microneedle array structures out of an acrylate-based polymer. Pulsed laser deposition was used to deposit silver and zinc oxide coatings on the surfaces of the visible light dynamic mask microstereolithography-fabricated microneedle array structures. Agar diffusion studies were used to demonstrate the antimicrobial activity of the coated microneedle array structures. This study indicates that light-based technologies, including visible light dynamic mask microstereolithography and pulsed laser deposition, may be used to fabricate microneedles with antimicrobial properties for treatment of local skin infections.

Tellurium, its resourcefulness and recovery

Abstract: Although it looks similar to tin, tellurium is a metalloid chemical element which is used in a variety of industries, primarily in the form of an additive to an assortment of compounds and alloys. As solar cell technology has improved the cadmium telluride (CdTe) PV modules have become among the lowest-cost producers of solar electricity. Consequently, interest has recently been focused on tellurium recovery. In this paper, tellurium’s availability and its distribution in general metallurgical processing is summarized and analyzed. Because tellurium is the scarcest of all the byproducts and mainly recovered from copper sulfides, hydrometallurgical recovery of tellurium from electrolytic copper anode slimes is described.

Calcium phosphate scaffolds for bone repair

Abstract: Calcium phosphates, with their chemical similarity to bone mineral, show biocompatibility with hard and soft tissues and offer massive potential for bone repair, both as scaffolds to be implanted directly into the defect and as structures for cell transplantation or to guide new bone growth in tissue engineering. This paper reviews the requirements and motivation for synthetic bone graft alternatives and the production routes for, particularly, hydroxyapatite porous scaffolds. It also considers the important role of substitution of ions such as silicate into calcium phosphates so as to more closely mirror the chemistry of bone mineral and to elicit specific biological responses.

High strain rate compressive characterization of aluminum alloy/fly ash cenosphere composites

Abstract: The strain rate dependence of compressive response is determined for aluminum alloy/hollow fly ash cenosphere composites. A4032 alloy is used as the matrix material. Quasi-static and high strain rate compression tests are conducted on the matrix alloy and the composite. A split-Hopkinson pressure bar is used for high strain rate testing. While the matrix alloy does not show any appreciable strain rate sensitivity, the composite shows higher strength at higher strain rates. The energy absorption capability of A4032/fly ash cenosphere composites is found to be higher at higher strain rates.

Representation and computational structure-property relations of random media

Abstract: Recent trends towards integrated computational materials engineering (ICME) demand increasing reliance on modeling and simulation to estimate microstructure-property relations of materials with random microstructures.

Pressure leaching of metals from waste printed circuit boards using sulfuric acid

Abstract: Printed circuit boards (PCBs) are essential components of electronic equipments which contain various metallic values. This paper reports a hydrometallurgical recycling process for waste PCBs, which consists of the novel pretreatment consisting of organic swelling of PCBs followed by sulfuric acid leaching of metals from waste PCBs. To recycle the waste PCBs, experiments were carried out for the recovery of copper from the crushed and organic swelled materials of waste PCBs using sulfuric acid leaching in presence of hydrogen peroxide under atmospheric and pressure condition. The leaching of PCBs at 90°C, pulp density 100 g/L under atmospheric condition, using 6M sulfuric acid resulted in the dissolution of a minor amount of copper due to the presence of plastic coating on the surface of metallic layers. On the other hand, when the liberated metal sheets from organic swelled PCBs were treated with dilute sulfuric acid of concentration 2M along with hydrogen peroxide in an autoclave under oxygen atmosphere, the percentage recovery of copper was found to increase from 59.63% to 97.01% with an increase in hydrogen peroxide concentration from 5 to 15% (v/v) keeping constant pulp density 30 g/L.

Microstructure-based description of the deformation of metals: Theory and application

Abstract: Aiming for an integrated approach to computational materials engineering in an industrial context poses big challenges in the development of suitable materials descriptions for the different steps along the processing chain. The first key component is to correctly describe the microstructural changes during the thermal and mechanical processing of the base material into a semi-finished product. Explicit representations of the microstructure are most suitable there. The final processing steps and particularly component assessment then has to describe the entire component which requires homogenized continuum mechanical representations. A key challenge is the step in between, the determination of the (macroscopic) materials descriptions from microscopic structures. This article describes methods to include microstructure into descriptions of the deformation of metal, and demonstrates the central steps of the simulation along the processing chain of an automotive component manufactured from a dual phase steel.

Waterside corrosion in zirconium alloys

Abstract: The influence of the alloy microstructure and microchemistry on uniform waterside corrosion of zirconium alloys is reviewed, with special attention to the various stages of corrosion, such as pre-transition, transition, and breakaway.

Removing arsenic from aqueous solution and long-term product storage

Abstract: The removal of arsenic from hydrometallurgical solutions, waste waters, and acid drainage mine waters has been and continues to be an important research topic. A guide to the literature is presented that is focused on the removal of arsenic from aqueous solutions using ferric and ferrous adsorption and co-precipitation processes; and, on the long-term outdoor storage of the arsenic bearing products.

X-ray line profile analysis-An ideal tool to quantify structural parameters of nanomaterials

Abstract: For a long time the shift and broadening of Bragg profiles have been used to evaluate internal stresses and coherent domain sizes, i.e. the smallest crystalline region without lattice defects. Modern technology provides both enhanced detector resolution and high brilliance x-ray sources thus allowing measurements of x-ray peaks with a high resolution in space and time. In parallel to the hardware, also diffraction theories have been substantially improved so that the shape of Bragg profiles can be quantitatively evaluated not only in terms of the crystallite size and its distribution, but also in terms of the density, type and arrangement of dislocations, twins and stacking faults. Thus state-of-the-art x-ray line profile analysis enables the thorough characterization especially of nanostructured materials which also contain lattice defects. The method can be used also to prove the existence of dislocations in crystalline materials. Examples of nanostructured metals, polymers and even molecular crystals like fullerenes are given.

Aluminum nanocomposites for elevated temperature applications

Abstract: Aluminum casting alloys conventionally used in the automotive and aerospace industries (ie, Al-Zn-Mg, and Al-Cu-Mg systems) are able to achieve excellent tensile strength at room temperature At high temperatures, such alloys lose dimensional stability and their mechanical properties rapidly degrade Aluminum-based nanocomposites show the potential for enhanced performance at high temperatures The manufacturing process, however, is difficult; a viable and effective method for large-scale applications has not been developed In the current study, an innovative and cost-effective approach has been adopted to manufacture Al/AlN composites A nitrogen-bearing gas is injected into the melt and AlN particles synthesize in-situ via chemical reaction In a preliminary stage, a model able to predict the amount of reinforcement formed has been developed AlN dispersoids have been succesfully synthesized in the matrix and the model has been experimentally validated

In-situ TEM study of dislocation-twin boundaries interaction in nanotwinned Cu films

Abstract: Epitaxial thin films of nanotwinned face-centered cubic metals such as Cu possess an unprecedented combination of high hardness and high electrical conductivity due to the unique structure of nanometer-spaced coherent twin boundaries. Recent studies of in-situ nanoindentation in a transmission electron microscope have provided new insights on the deformation behavior of nanotwins that are reviewed here. In particular, two unit processes are highlighted: first, stress-induced migration of Σ3 {112} incoherent twin boundary that leads to de-twinning of nanotwins; second, twinning dislocation can be multiplied at Σ3 {111} coherent twin boundary.

Automated serial sectioning methods for rapid collection of 3-D microstructure data

Abstract: This article presents a brief overview of current instruments for collection of microstructural data sets in three dimensions via serial sectioning.1 These instruments are dedicated or adapted to the task of collecting serial section data, which greatly accelerate the characterization process, and in selected systems offer the ability incorporate multi-modal data such as combinations of images, crystallographic and chemical maps that enable robust and automated approaches to segmentation of grains and phases.

Characterization and modeling of heterogeneous deformation in commercial purity titanium

Abstract: Heterogeneous deformation, including local dislocation shear activity and lattice rotation, was analyzed in microstructure patches of polycrystalline commercial purity titanium specimens using three different experimental methods. The measurements were compared with crystal plasticity finite element simulations for the same region that incorporate a local phenomenological hardening constitutive model. The dislocation activity was measured using techniques associated with atomic force microscopy, confocal microscopy, three-dimensional x-ray diffraction, and nano-indentation. The results indicate that a major challenge for model development is to effectively predict conditions where slip transfer occurs, and where geometrically necessary dislocations accumulate.

Beneficial and technological analysis for the recycling of solar grade silicon wastes

Abstract: In the current paper, different kinds of silicon wastes during the production of SoG-Si were summarized and the beneficial analyses, such as financial value, energy value, CO2 emissions, and efficiency and energy payback time, were briefly discussed for the recycling of SoG-Si wastes. Possible technologies to recycle and purify SoG-Si wastes were reviewed: such as filtration, sedimentation, solidification control, electromagnetic separation, plasma oxidation, centrifugation, and high temperature remelting process, et al.

Nanostructured manganese oxide thin films as electrode material for supercapacitors

Abstract: Electrochemical capacitors, also called supercapacitors, are alternative energy storage devices, particularly for applications requiring high power densities. Recently, manganese oxides have been extensively evaluated as electrode materials for supercapacitors due to their low cost, environmental benignity, and promising supercapacitive performance. In order to maximize the utilization of manganese oxides as the electrode material for the supercapacitors and improve their supercapacitive performance, the nanostructured manganese oxides have therefore been developed. This paper reviews the synthesis of the nanostructured manganese oxide thin films by different methods and the supercapacitive performance of different nanostructures.

Interface-related reliability challenges in 3-D interconnect systems with through-silicon vias

Abstract: During service, through-silicon vias (TSVs) in vertically stacked-die microelectronic packages are subjected to both thermo-mechanical cycling as well as electromigration. The disparate properties of Cu-filled TSVs and the Si chip induce substantial residual stresses in both components, as well as at the interface. These stresses may drive interfacial sliding with the interface serving as a rapid diffusion path, resulting in significant interfacial strain incompatibilities. In addition, by acting as short-circuit paths for diffusion, the interfaces may carry significant electromigration fluxes, further exacerbating interfacial sliding. The results of recent experiments and modeling are presented to illustrate these effects, and related reliability issues are discussed.