Accelerated Design and Deployment of Advanced Structural ...
Transcript of Accelerated Design and Deployment of Advanced Structural ...
October 04, 2017 / Tokyo
Accelerated Design and Deployment of Advanced Structural Materials (USA Materials Genome Initiative / QuesTek Materials by Design®)
I- Materials Informatics Overview
II- Innovative Materials Technologies in support of Industrial Sectors
- USA Materials Genome Initiative (MGI)
- Integrated Computational Materials Engineering (ICME)
III- Illustration of ICME / Materials by Design®
- Design and Deployment of Ultra High Strength Steels (Ferrium® M54)
- Additive Manufacturing of Gear Steels (Ferrium C64)
IV- Opportunities of ICME-Designed Structural Alloys in the Energy Sector
- Improving Energy Efficiency (SX-Ni) and Enhancing Oil & Gas Production (C-160)
- Innovations in Energy-Related Structural Materials (HEA Refractory Alloys)
V- ICME Technologies Contribution to Energy and Industrial Sectors
- Collaborations/Partnerships on Advanced Structural Materials
- Closing Remarks
Dr. Aziz Asphahani CEO, QuesTek International
October 04, 2017 / Tokyo
I – Materials Informatics Overview Predictive Capabilities for Advanced Materials
(Redacted from Dr. D. Shin, Oak Ridge National Laboratory; August, 2017)
Big Data High-throughput
(Experimental; Calculated DFT)
Machine Learning Multiple descriptors simulations
(no specific insight required)
Validated Data Thermodynamic/Kinetics
(Microstructure-based Models)
MGI / ICME Physics-based Simulations
(Mechanistic-based insights)
Predictive Capabilities
October 04, 2017 / Tokyo
Analogous to the US Human Genome Initiative: MGI is focused on design and deployment of novel,
advanced materials needed to enhance and sustain competitiveness (USA Materials Genome Initiative; NRC-2011)
Computational Materials Design (CMD) is being driven by a network of small businesses that have created and is maintaining the technology
(Accelerating Technology Transition; NRC-2004)
II- Innovative Materials Technologies in support of Industrial Sectors
p. 4
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Integrated Computational Materials Engineering (ICME) Technologies (National Research Council Report, 2008)
Addressing the priorities set in MGI
“…recognizing the importance of advanced materials in support of innovations …” (Office of Science and Technology, Washington DC 2011)
Using validated thermodynamic and kinetic databases, along with advanced computational modeling tools, advanced materials
precise chemical compositions and processing parameters can be accurately and quickly identified, in order to obtain the
specific microstructures needed to meet key properties, necessary to ensure the required enhanced performance
(reducing time and cost, along with minimizing risks associated with novel materials design)
October 04, 2017 / Tokyo
Integrated Computational Materials Engineering (ICME) technologies are becoming
best alternative to the traditional, empirical methods (trial & error) of materials development
III- Illustrations of ICME / Materials by Design®
Ferrium® S53® alloy First ICME-designed alloy to fly (2010)
2003 SERDP / ESTCP funded program addressing Air Force needs
Increased strength
Greater ductility
Improved corrosion resistance
Eliminated toxic cadmium-plating
Replaced “Legacy” Alloys
October 04, 2017 / Tokyo
ICME Design and Deployment of Ultra High-Strength Steel
Issues:
Stress Corrosion Cracking failures
Over $200 million spent annually on military Landing Gears
Failure Mechanism: Intergranular Stress Corrosion Cracking Caused by Hydrogen
October 04, 2017 / Tokyo
Traditional Alloy Development for Improved Toughness High-Strength Steels
Alloy UTS
(ksi)
KIC
(ksi√in)
300M
285 50
AMS 6532 (13% Co)
285 115
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Issue 2: Susceptibility to Intergranular Stress Corrosion Cracking
Issue 1: High Cost of alloying elements (AMS 6532: 13% Co)
Alloy UTS
(Ksi)
KIC
(ksi√in)
KISCC
(ksi√in)
300M
285 50 15
AMS 6532 (13% Co)
285 115 20
October 04, 2017 / Tokyo
QuesTek ICME / System-Based Approach: Design for Performance: “Olson Chart” (lines depict mechanistic-based models)
PROPERTIES (Functional Requirements)
STRUCTURE (Design Parameters)
PROCESSING (Process Variables)
STRENGTH
TOUGHNESS
HYDROGEN
RESISTANCE
P
E
R
F
O
R
M
A
N
C
E
E
R
F
O
R
M
A
N
C
E
Matrix
Lath Martensite
Ni: Cleavage Resistance
Co: SRO Recovery Resistance
Strengthening Dispersion
(Mo,Cr,W,V,Fe) 2 C
X (Nb,V)C
X
Avoid Fe 3 C, M
6 C, M
23 C
6
Grain Refining Dispersion _ d/f
Microvoid Nucleation Resistance
Austenite Dispersion
Stability (Size, Comp)
Amount
Dilatation
Grain Boundary Chemistry Cohesion Enhancement
Impurity Gettering
]
]
TEMPERING
SOLUTION
TREATMENT
HOT WORKING
SOLIDIFICATION
DEOXIDATION
REFINING
*
PERFORMANCE (USER-DRIVEN)
High Strength
Improved SCC Resistance
Lower Co-Content
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Grain Boundaries Cohesive Energy / Effects of Alloying Elements
(Rice-Wang Model: Δ2𝛾 = C𝑖𝐸𝑖𝑝𝑜𝑡
𝑖 )
Segregation Energy (driving force: ΔgGB): Does solute diffuse to grain boundary from bulk?
Embrittlement potency (Epot): Does solute make it easier to pull apart grains
To reduce intergranular brittle fracture: add alloying elements with high propensity to segregate to grain boundaries, along with the potency to improve cohesion
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Databases of Embrittling Potency
From Experiment From Theory (DFT calculation)
To reduce brittle fracture: identify the combinations of alloying elements which improve grain boundary cohesion
Solute Potency of Embrittlement [kJ/mol]
Em
bri
ttle
me
nt
Se
nsitiv
ity
[ΔD
BT
T,K
/ a
t.%
]
October 04, 2017 / Tokyo
ICME-Designed Ferrium® M54 Ultra-High Strength Steel
Alloy UTS
ksi
KIC
ksi√in
KISCC
ksi√in
Calculated Grain Boundary Cohesion
Energy
“Δ2γ”
J/m2
300M 285 50 15 ~0.2
AMS 6532 (13% Co)
285 115 20 ~0.01
Ferrium M54 (7% Co)
290 115 100 ~0.001
p. 13
October 4, 2017 / Tokyo
Ferrium M54 Hook-shanks / T-45 Trainer Jet
M54 hook shanks U.S. Navy-qualified with >2x life vs. incumbent steel
The U.S. Navy estimates $3 Million saved by implementing M54 steel
M54 approved to replace 300M on selected aircrafts for landing gear
components due to greater strength, toughness, fatigue life and
SCC resistance
(NAVAIR Public Release #2014-712)
From clean sheet design to qualification and flight in 7 years!
This innovation was
accelerated by the
application of
computational modeling
tools and extensive
materials databases
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Oil & Gas Fasteners (Off-Shore Applications)
Oil & Gas issues with unexpected breakage of connector bolts on offshore safety equipment
• Breakage linked to Stress Corrosion Cracking (SCC); H2 due to corrosion
• “recall and replace” 10,000 bolts worldwide (significant lost time and cost)
E&E News; April 2017
Properties • 290 ksi Ultimate Strength • 115 ksi√in Fracture Toughness • >85 ksi√in KISCC
Bolts for critical NAVY applications
Class 3A Fastener
F-18 Hook Point Bolt
Ferrium® M54 Steel
p. 16
October 4, 2017 / Tokyo
Additive Manufacturing of ICME-designed gear steels
Ferrium® C64 steel qualifications * Over 20 percent improved power density
* Over 2x required time to safety (oil-out conditions)
Qualified for next-generation helicopter
transmissions by Sikorsky and Bell Helicopter
C64 Additive Demonstrations • Powder successfully atomized
• AM platforms (Optomec, EOS, Arcam)
• Additive C64 met its AMS minimum
static mechanical properties,
exceeding that of incumbent wrought
alloys (e.g., Alloy X53)
Interested Industries and prototyping applications
- Sikorsky / Lockheed - Sports / Auto-racing
- Bell Helicopter - Formula 1 racing
- Rolls Royce - Wind Turbines
- Eaton Aerospace - Agricultural tooling
Other Opportunities Hybrid gear design (robots)
Addaero C64 gear blank
October 04, 2017 / Tokyo
IV- Opportunities of ICME-Designed Structural Alloys in the Energy Sector “Castable single crystal Superalloys” Blades for Industrial Gas Turbines
US Department of Energy (SBIR: DE-SC0009592, 2013 - Present)
Primary Constraints:
- Freckle formation
- Hot tearing
- Porosity
- Improved creep resistance
QuesTek SX Low Rhenium
Freckle Formation Tendency Modeling
Creep Strength Modeling
October 04, 2017 / Tokyo
“…Advanced materials are critical building blocs that can drive significant enhancements in America’s energy…” (Leverage: Advanced Materials Sector Study /US Council on Competitiveness; 2016)
. Multi-principle element alloys (HEAs) are considered the new frontier of advanced alloy design
. Government and Industry HEA research interest
(funding particularly in alloy Research & Development)
QuesTek Projects on Refractory HEA
-High strength at elevated temperatures
-High fatigue endurance limits
-Improved toughness
-Better resistance to corrosion, wear and radiation damages
Refractory HEA (hot zone compressor blades)
Innovations in Energy-related Structural Materials (High Entropy Alloys)
October 04, 2017 / Tokyo
V- ICME Technologies Contribution to Energy and Industrial Sectors
Low cost, high
performance gear
steel for light
weighting / increased
power density
Automotive Transmissions
High-temperature
aluminum for
cylinder heads for
increased fuel
efficiency
Automotive Engines
Higher strength
C-steel (C-160)
resistant to H2S
stress cracking
Oil & Gas Deep Wells
Electricity Generation
Cost-effective,
castable, high yield
single crystal
superalloy for
industrial gas
turbine blades
R & D Contract pending
MOU/License Agreement
signed
License Agreement
signed
License Agreement
pending
Energy Production Energy Efficiency
October 04, 2017 / Tokyo
QuesTek is presently interacting with Industrial Sectors (Producers, OEM’s, End-users) and
establishing “Innovation Partnerships”, as strategic alliances focused on ICME-technologies to
“…change the way industries do things…”
ICME Technologies Industry Collaborations / Partnerships (Advanced Structural Alloys)
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“… Building the bridge between the University and the Business world is critical to accelerate
investment in energy, ensuring research does not get stranded in universities and lab …” (US Council on Competitiveness /Energy Sector Dialogue ; May 2017)
Industry
Universities & Research Centers
Governmental Research institutions
Pre-Competitive IP
Proprietary IP
Pre-Competitive IP
QuesTek Europe
QuesTek USA
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Japanese Industrial Interests in QuesTek ICME Technologies
Time Topic Issue/problem QuesTek Solution
2014 C-Steel Fracture toughness Toughness modeling and compositional improvement
2015 Fe-base Creep strength Creep strength modeling and simulation
2016 UHSS Fracture toughness Compositional and processing optimization
2017 Superalloy Forging issues Recrystallization modeling for Hot-working
2017 Ni alloys Strength predictions Antiphase Boundary Energy/compositional variation
2017 CMC Oxidation / cracking Modeling of oxidation and corrosion fatigue
2017 Al alloys Tensile strength ICME-based prediction
2017 Ferritic steel Creep / weld Creep damage evaluation of welded joint
October 04, 2017 / Tokyo
Closing Remarks
- Materials Informatics (Big-data, Artificial Intelligence, Machine Learning) are being viewed as the solutions to Industry challenges (Vision: novel compounds will be discovered by computers !..)
- Within Materials Informatics, Integrated Computational Materials Engineering technologies are proven successful in designing advanced structural materials
- ICME technologies (as a transformative discipline for enhanced industrial competitiveness) are being adopted by key industries seeking to cut in half time & Cost to deploy advanced structural materials
October 04, 2017 / Tokyo
“… Materials industry in Japan, especially structural materials, has been the backbone of the whole Japanese industry…”
(Cross Ministerial Strategic Innovation Program / SIP-Japan)
Big Data / AI / ML Government Research Institutions
Academia Research Centers
Materials Genome Existing Scientific data
CALPHAD
Predicting and identifying the existence of new compounds
Deploying Advanced Structural Materials to solve industry challenges
Scientific Discovery Materials Engineering Design
October 04, 2017 / Tokyo
About Discovery and Innovations
Il ne s’agit pas de chercher, il s’agit de trouver
(Director Baron / Ecole Centrale-Paris, 1970)
ICME technologies are focused on scientific bases / knowledge required to engineer needed products that generate funds
Engineering Innovations Scientific Discovery
funds spent on Big-Data, AI, ML are needed to amass the scientific bases for the discovery of new compounds
October 04, 2017 / Tokyo
In order to effectively integrate various innovation resources such as universities and institutes in Beijing, and to establish a long-term mechanism for mutual promotion of research and applications, dynamic incorporation of science and technology innovation and talent cultivation, and the cooperative development of national and local institutions, Beijing city government decided to initiate a strategic program for establishing advanced innovation centers at universities in Beijing. At the first stage, approximately 20 centers and 50 projects were planes. In a five-year period, each center will be funded by 50 to 100 million Yuan per year. No less than 70% of the total funding should be spent on recruiting talents both international and domestically. The proposal of establishing “Beijing Advanced Innovation Center for Materials Genome Engineering” will be included in this initiative, and its application is led by the University of Science Technology Beijing.
Materials genome engineering is a research frontier, and popularization of its concept and method, emergence of novel materials therefrom and application of key resultant technologies, a revolutionary leap will be fulfilled for materials science and technology as well as the modern manufacturing industry.