AMERICAN CERAMIC SOCIETY bulletin emerging ceramics & glass technology Near net shaping of ceramic components Plant tour\' of a custom manufacturer CERAMICS EXPO Special show issue! April 28 - 30 Cleveland, Ohio USA ceramics expo APRIL 2015 Why did it break? Fractography answers Ceramics in paper manufacturing Market trends for advanced ceramics Upcoming meetings: GOMD-DGG, CMCEE • bbbb Your kiln. Like no other. Your kiln needs are unique, and Harrop responds with engineered solutions to meet your exact firing requirements. For more than 90 years, we have been supplying custom kilns across a wide range of both traditional and advanced ceramic markets. Hundreds of our clients will tell you that our three-phase application engineering process is what separates Harrop from \"cookie cutter\" kiln suppliers. Thorough technical and economic analysis to create the \"right\" kiln for your specific needs Robust, industrial design and construction • After-sale service for commissioning and operator training. Harrop\'s experienced staff is exceptionally qualified to become your partners in providing the kiln most appropriate to your application. Learn more at www.harropusa.com, or call us at 614-231-3621 See us at Ceramics Expo, Booth 117 HARROP Fire our imagination www.harropusa.com contents feature articles April 2015 Vol. 94 No. 3 Growth in advanced ceramics market fueled by new applications April Gocha 24 Advanced ceramics have attractive properties—including resistance to corrosion, heat, impact, and chemical attack—that make them competitive in a variety of markets. Near net shaping of ceramic components— \'Plant tour\' of a custom manufacturer 26 Thomas O. Henriksen Automated near net shaping of custom ceramic parts saves time, material, and energy. cover story Why did it break? 38 years of teaching fractographers how to answer the question.. George Quinn and James Varner 32 A historical perspective and closer look at Alfred University\'s fractography of glasses and ceramics short course, which has run continously for nearly four decades. Near net shaping of ceramic components―\'Plant tour\' of a custom manufacturer Credit: Ceramco paper manufacturing. 36 - page 26 Ceramic materials in pulp and Mahendra Patel Many areas of paper manufacturing use alumina, silicon carbide, silicon nitride, composites, ceramic coatings, and other advanced ceramic components. meetings Ceramics Expo 2015 42 GOMD-DGG 2015: Glass & Optical Materials Division Annual Meeting and Deutsche Glastechnische Gesellschaft Annual Meeting 44 6th Advances in Cement-based Materials. 47 11th CMCEE: International Conference on Ceramic Materials and Components for Energy and Environmental Applications 48 columns Deciphering the Discipline. . Kara Luitjohan Engineering life lessons in emerging economies resources New Products Calendar Classified Advertising Display Advertising Index American Ceramic Society Bulletin, Vol. 94, No. 3 | www.ceramics.org 56 99 feature Why did it break? 38 years of teaching fractographers how to answer the question Credit: G. Quinn and J. Varner - page 32 departments News & Trends 3 49 ACers Spotlight 8 52 Ceramics in Energy 12 53 Ceramics in Environment 13 55 Research Briefs.. 16 1 AMERICAN CERAMIC SOCIETY Obulletin Editorial and Production Eileen De Guire, Editor ph: 614-794-5828 fx: 614-794-5815 edeguire@ceramics.org April Gocha, Associate Editor Jessica McMathis, Associate Editor Russell Jordan, Contributing Editor Tess Speakman, Graphic Designer Editorial Advisory Board Finn Giuliani, Chair, Imperial College London G. Scott Glaesemann, Corning Incorporated John McCloy, Washington State University C. Scott Nordahl, Raytheon Company Fei Peng, Clemson University Rafael Salomão, University of São Paulo Eileen De Guire, Staff Liaison, The American Ceramic Society Customer Service/Circulation ph: 866-721-3322 fx: 240-396-5637 customerservice@ceramics.org Advertising Sales National Sales Mona Thiel, National Sales Director mthiel@ceramics.org ph: 614-794-5834 fx: 614-794-5822 Europe Richard Rozelaar media@alaincharles.com ph: 44-(0)-20-7834-7676 fx: 44-(0)-20-7973-0076 Executive Staff Charles Spahr, Executive Director and Publisher cspahr@ceramics.org Teresa Black, Director of Finance and Operations tblack@ceramics.org Eileen De Guire, Director of Communications & Marketing edeguire@ceramics.org Marcus Fish, Development Director Ceramic and Glass Industry Foundation mfish@ceramics.org Sue LaBute, Human Resources Manager & Exec. Assistant slabute@ceramics.org Mark Mecklenborg, Director of Membership, Meetings & Technical Publications mmecklenborg@ceramics.org Officers Kathleen Richardson, President Mrityunjay Singh, President-Elect David Green, Past President Daniel Lease, Treasurer Charles Spahr, Secretary Board of Directors Michael Alexander, Director 2014-2017 Keith Bowman, Director 2012-2015 Geoff Brennecka, Director 2014-2017 Elizabeth Dickey, Director 2012-2015 John Halloran, Director 2013-2016 Vijay Jain, Director 2011-2015 Edgar Lara-Curzio, Director 2013-2016 Hua-Tay (H.T.) Lin, Director 2014-2017 Tatsuki Ohji, Director 2013-2016 contents April 2015 • Vol. 94 No. 3 Connect with ACers online! in g+ f http://bit.ly/acersrss http://bit.ly/acerstwitter http://bit.ly/acerslink http://bit.ly/acersgplus http://bit.ly/acersfb Credit: John Karakatsanis In your hand and on the go! There are now three great ways to read all of the good stuff inside this month\'s issue of the Bulletin! On-the-go option #1: Download the app from the Google Play store (Android tablet and smartphones) or the App Store (iOS tablets only). Equally mobile option #2: Download a PDF copy of this month\'s issue at ceramics.org and save it to your smartphone, tablet, laptop, or desktop. Optimized for laptop/desktop option #3: From your laptop or desktop, flip through the pages of this month\'s electronic edition at ceramics.org. Available for iPad on the Get it on GOOGLE PLAY App Store Want more ceramics and glass news throughout the month? Subscribe to our e-newsletter, Ceramic Tech Today, and receive the latest ceramics, glass, and Society news in your inbox each Tuesday, Wednesday, and Friday. Sign up at http://bit.ly/acersctt. Top Tweets Have you connected with @acersnews on Twitter? Here are some recent top posts: Solar stores more sun Highly conductive, undoped oxide film will help solar cells harness more sunlight http://bit.ly/1CBFuv0 Simulating strength New models show how atomic placement makes concrete strong http://bit.ly/1acw0u6 Hoodie for the stars? Glass-nanosphere-coated fabric provides shelter from the paparazzi http://bit.ly/1GxQpoa David Johnson Jr., Parliamentarian American Ceramic Society Bulletin covers news and activities of the Society and its members, includes items of interest to the ceramics community, and provides the most current information concerning all aspects of ceramic technology, including R&D, manufacturing, engineering, and marketing. American Ceramic Society Bulletin (ISSN No. 0002-7812). ©2014. Printed in the United States of America. ACerS Bulletin is published monthly, except for February, July, and November, a \"dual-media\" magazine in print and electronic formats (www.ceramicbulletin.org). Editorial and Subscription Offices: 600 North Cleveland Avenue, Suite 210, Westerville, OH 43082-6920. Subscription included with The American Ceramic Society membership. Nonmember print subscription rates, including online access: United States and Canada, 1 year $135; international, 1 year $150.* Rates include shipping charges. International Remail Service is standard outside of the United States and Canada. *International nonmembers also may elect to receive an electronic-only, email delivery subscription for $100. Single issues, January-October/November: member $6 per issue; nonmember $15 per issue. December issue (ceramicSOURCE): member $20, nonmember $40. Postage/handling for single issues: United States and Canada, $3 per item; United States and Canada Expedited (UPS 2nd day air), $8 per item; International Standard, $6 per item. POSTMASTER: Please send address changes to American Ceramic Society Bulletin, 600 North Cleveland Avenue, Suite 210, Westerville, OH 43082-6920. Periodical postage paid at Westerville, Ohio, and additional mailing offices. Allow six weeks for address changes. ACSBA7, Vol. 94, No. 3, pp 1-56. All feature articles are covered in Current Contents. 2 www.ceramics.org | American Ceramic Society Bulletin, Vol. 94, No. 3 news & trends International Year of Light puts spotlight on optics, photonics, and sustainable development The 68th session of the United Nations General Assembly declared 2015 as the International Year of Light and Light-Based Technologies (IYL 2015)-a global initiative to spread awareness of the ways optical technologies promote sustainability and address growing global challenges concerning energy, health, and more. According to the IYL 2015 website, \"In proclaiming an International Year focusing on the topic of light science and its applications, the United Nations has recognized the importance of raising global awareness about how light-based technologies promote sustainable development and provide solutions to global challenges in energy, education, agriculture, and health. Light plays a vital role in our daily lives and is an imperative crosscutting discipline of science in the 21st century. It has revolutionized medicine, opened up international communication via the Internet, and continues to be central to linking cultural, economic, and political aspects of the global society.\" The website offers resources on photonics and its impact on energy, economy, and the connected world as well as a packed international schedule of events designed to promote light and light-based technologies. Many of these modern-day technologies are integral to the work being done at Clemson University\'s Advanced Materials Research Laboratory (AMRL) and Center for Optical Materials Science and Engineering Technologies (COMSET), the latter headed by ACerS member and Fellow John Ballato. Several other ACerS members, including Fei Peng and current ACerS president Kathleen Richardson, also are COMSET faculty. Optics are in the spotlight this year, thanks to the United Nations\' declaration of 2015 as the International Year of Light and Light-Based Technologies. According to the university, Clemson is \"uniquely positioned to support the research, workforce development, and outreach needs of the light-based technology industry.\" It is in that day-to-day training of tomorrow\'s technology workers that a year of celebration becomes a more immediate, moment-to-moment party for all. \"While we celebrate 2015 as the International Year of Light, in reality, \"Clemson\'s small piece of this $7.5-trillion annual global economic engine focuses on enabling materials and optical fibers-their compositions, their structures, their performance, their applications, and, most importantly, their use as tools to train the next generation of pioneers,\" he adds. every second of every day is a celebration Self-arching concrete bridge of light,\" Ballato says in an email. “From the lights that illuminate the room, to the displays on our smart phones and computer screens, to the bits of light that speed through an optical fiber enabling global communications and ecommerce, light is ubiquitous and necessary. And, like any technology, the needs of tomorrow rapidly surpass the successes of today and, so, continued innovation is always essential.\" American Ceramic Society Bulletin, Vol. 94, No. 3 | www.ceramics.org spans new lengths Engineers at Queen\'s University Belfast (Northern Ireland) have developed-and soon will install-the world\'s longest self-arching bridge. The prefab concrete bridge is a flat-pack bridge, named for its ability to be transported flat to the installation site. When lifted off a flatbed truck, flat-pack bridges use gravity to self-assemble into an arch. 3 Credit: Placbo; Flickr CC BY-NC-SA 2.0 news & trends The latest, and longest, flat-pack bridge consists of 17 one-meter-wide tapered blocks of precast concrete. Each block weighs 16 tons, for a total of 272 tons of bridge-building concrete. The technology behind this engineering feat is Macrete\'s FlexiArch system, which links the top of the concrete blocks together with a bonded flexible membrane. \"This innovative system is exceptional as it is easily transported in flat-pack form and then rapidly installed on site,\" Macrete project manager Abhey Gupta says in a Queen\'s University press release. \"It is also unique as its strength does not depend on corrodible reinforcement, thus it should have a lifetime of at least 300 years, whereas conventional bridges seldom achieve their design life of 120 years.\" In comparison with a traditional bridge, the FlexiArch system allows the structure to be built much quicker and cheaper. It also requires little maintenance, because the bridge derives its strength from compression, eliminating the need for corrod4 Business news Solar-Tectic LLC to develop new sapphire glass material in 2015 (solartecticllc.com)...Argonne partners with industry on nuclear reactor work (anl.gov)...Antimicrobial Corning Gorilla Glass to be used in mobile pay terminals (corning.com)...American Concrete Institute launches tools for concrete professionals (concrete.org)...ANH Refractories rebranded as HarbisonWalker International (anhrefractories.com)... Guardian now offers health product declaration for glass products (guardian. com)...HeidelbergCement to sell its North American and UK building products business (heidelbergcement.com)...Harper awarded contract for thermal processing of advanced ceramic powders (harperintl.com)...Arkansas startup WattGlass to develop nanoparticle coating for glass (wattglass.com)...China Ceramics announces launch of environmentally friendly tile (cceramics.com)...Avure opens isostatic pressing application cenMacrete crew members supervise installation of a FlexiArch bridge at Pleasington in Northern Ireland. ible rebar-a big concern when it comes to bridge maintenance. The United Kingdom now has more than 50 FlexiArch bridge installations. The latest and longest bridge will be installed near Portsmouth (Northern Ireland) and will span 16 meters, ter in Sweden (industry.avure.com)... Raytheon acquires Tucson drone maker (raytheon.com)...Asahi ultra-lightweight solar panel receives award (asahiglass.jp)...Corning acquires assets of NovaSol (corning.com)...Alcoa opens expanded wheels manufacturing plant in Hungary (alcoa.com)... Washington Mills debuts video on spent aluminum oxide recycling (washingtonmills. com)...Imformed provides information to industrial minerals market (imformed. com)...Morgan Advanced Materials offers ceramic-to-metal feedthroughs and connectors (morganadvancedmaterials. com)...Innovnano announces ISO 9001 certification (innovnano-materials. com)...Carbolite Gero representation in North America (carbolite.com). Materion Corporation realigns organization (materion.com)…..Samsung plans three-sided screen in new smartphone (samsung.com) the farthest yet for a flat-pack bridge. According to the release, the bridge will be installed in less than a day using a 200-300 ton crane and a specially designed lifting beam. Corning developing scratchresistant glass that rivals sapphire According to accounts from Corning Incorporated\'s annual investors meeting in New York City in February, the glass giant is developing a scratch-resistant glass that rivals the strength of sapphire. CNET reports that Corning announced work on the aptly named Project Phire, a \"developmental Gorilla Glass-like composite\" that “combines the toughness of its Gorilla Glass smartphone displays with a scratch resistance that comes close to sapphire.\" The announcement comes on the heels of the company\'s November Gorilla Glass 4 announcement, and not long after Apple\'s sapphire-screen dreams crashed and burned. In the CNET post, Corning Glass Technologies president James Clappin says, \"We told you last year that sapphire was great for scratch performance but didn\'t fare well when dropped. So, we created a product that offers the same superior damage resistance and drop performance of Gorilla Glass 4 with scratch resistance that approaches sapphire.” www.ceramics.org | American Ceramic Society Bulletin, Vol. 94, No. 3 Credit: Emma Martin at Story Contracting Ltd.; Macrete Wherever you are, it all points to Alteo for high-performance aluminas Full technical support Logistics solutions Customized innovation Our world-class P-series low soda aluminas set the standard for the most demanding requirements of technical ceramic producers: P152 and P152SB, the industry benchmarks ◆ P112, P122, P662, semi-reactive standards ◆ P162LSB and P172LSB, highly reactive aluminas All available as calcined and superground [SB] as required. We also provide: ⚫ P172HPB the new reference in high-purity and reactivity ◆P172SDP, ready-to-press powder And look forward to new developments in both these ranges. Meet Alteo\'s team at Ceramics Expo Booth 328 Alteo is close to you, now and ahead www.alteo-alumina.com 3 High-quality aluminas alteo A NEW WORLD OF ALUMINA www Design: www.arnaudtemplier.com ●news & trends Reports from Corning Incorporated\'s annual investors meeting indicate the company is working on a new scratch-resistant display that rivals sapphire. The technical details on Project Phire are slim so far. \"We are working on a composite material that has Gorilla Glass 4-like damage resistance and sapphirelike scratch resistance,\" writes Daniel F. Collins, vice president of corporate communications, in an email. \"We expect to be able to commercialize the new product later this year.\" In the meantime, the investors meeting was an opportunity for Clappin and other Corning execs to highlight the company\'s 2014 performance (optical communications and environmental technologies were up 18% and 44%, respectively) and 2015 priorities (\"positive momentum\"), which include an \"unwavering\" commitment to innovation, according to a Corning news release. That innovation has brought about developments including the Iris glass showcased at the 2015 Consumer Electronics Show. The company says that the glass can significantly reduce the size of the average LCD TV, resulting in a television with \"outstanding transmis sion\" that is \"as thin as a smartphone.\" \"2015 will be all about large-sized LCD TVs,\" Clappin says in the release. \"This segment of the display industry grew more than 50% year over year on a unit basis in 2014, and our analysis shows that the average TV screen size is growing more than 1 inch per year. Importantly, every inch in screen-size growth equates to about 150 million square feet of additional glass demand.\" Credit: Clifford Joseph Kozak; Flickr CC BY-NC-ND 2.0 Pew study finds scientific concord and discord between public and scientists Americans think that their country\'s achievements and advancements in science are tops-but when it comes to their views on top issues including climate change and nuclear power, their perceptions differ from the views of scientists, says a new report from the Pew Research Center. The study, based on a pair of surveys conducted in collaboration with the American Association The American public and scientists have some consensus, but much discord, on important scientific issues. for the Advancement of Science, represents the responses of 2,002 members of the general public and 3,748 United States-based AAAS members. According to the report, \"Science holds an esteemed place among citizens and professionals. Americans recognize the accomplishments of scientists in key fields and, despite considerable dispute about the role of government in other realms, there is broad public support for government investment in scientific research.\" . Key takeaways regarding thoughts about science and its potential to solve some of our biggest challenges include: 79% of adults believe access to better quality food, healthcare, and environment through advancements in science has made life easier; More than half of U.S. adults say the country\'s scientific achievements are the best (15%) or above average (39%) compared to the rest of the world; • 92% of AAAS respondents echo America\'s top spot among other industrial nations, with 45% declaring U.S. scientific achievements the best in the world and 47% calling them above average; and • 72% say that funding for engineering and technology and basic scientific research pays off, with an additional 61% saying that those government funds are \"essential\" for progress. The American public and scientists also believe that STEM education in the U.S. is not up to par. Just 29% of the American public consider U.S. K-12 STEM programs to be above average or the best in the world, and even fewer-a miniscule 16% of AAAS respondents agreed. Conversely, 46% of the scientists and 29% of the public said STEM learning offerings were below average. The similarities mostly end there. The disparity between the way the public views scientific issues and the way scientists view them is great, including a 51-point gap on whether it is safe to eat genetically modified foods (37% of Americans vs. 88% of scientists) and significant gaps between opinions on climate change, the world\'s growing population, nuclear power, offshore drilling, fracking, and the U.S. space program. Read the full report at pewinternet.org. Credit: Andrew Huff; Flickr CC BY-NC 2.0 6 www.ceramics.org | American Ceramic Society Bulletin, Vol. 94, No. 3 Credit: Emerging Objects 3-D printed ceramic brick combats heat through evaporative cooling Emerging Objects, an independent group that specializes in 3-D printing architecture and building components, has developed the ceramic Cool Brick that uses evaporative cooling to reduce air temperatures. The cooling system that inspires its 3-D printed ceramic brick is not new, but the technology that perfects it certainly is. Evaporative cooling has been used since at least 2500 B.C., when ancient civilizations used vessels of water to keep rooms cool. It is well suited for hot, low-humidity climates and costs far less than refrigerated air conditioning as much as 80% less. According to Emerging Objects\' website, Cool Brick designers Virginia San Fratello and Ronald Rael were inspired by the Muscatese evaporative cooling window-part wood screen, part water-filled ceramic vessel. \"Comprised of 3-D printed porous ceramic bricks set in mortar, each brick absorbs water like a sponge and is designed as a three dimensional lattice that allows air to pass through the wall. As air moves through the 3-D printed brick, the water that is held in the micropores of the ceramic evaporates, bringing cool air into an interior environment, lowering the temperature using the principle of evaporative cooling. The bricks are modular and interlocking and can be stacked together to make a screen. The 3-D lattice creates a strong bond when set in mortar. The shape of the brick also creates a shaded surface on the wall to keep a large percentage of the wall\'s surface cool and protected from the sun to improve the wall\'s performance.\" Although there is no mention of plans to offer the technology to the Emerging Objects\' 3-D printed ceramic brick, Cool Brick, uses evaporative cooling to cool structures. public just yet, Cool Brick is currently part of the San Francisco Museum of Craft and Design\'s \"Data Clay: Digital Strategies for Parsing the Earth”—“the first public exhibition to present the growing movement of architects, artists, and designers exploring the medium of ceramics coupled with digital technologies.\" ACerS Corporate Member Tethon 3D sponsored the Cool Brick project. Will your idea be the one that pops? Harper helps companies custom engineer thermal processes for the production of advanced ceramics. Let us help take your kernel of an idea from the lab to full commercialization. 000 Harper International harperintl.com American Ceramic Society Bulletin, Vol. 94, No. 3 | www.ceramics.org See us at Ceramics Expo, Booth 326 7 ●acers spotlight Society and Division news Welcome to our newest Corporate Members! ACerS recognizes organizations that have joined the Society as Corporate Members. For more information on becoming a Corporate Member, contact Megan Bricker at mbricker@ceramics. org, or visit www.ceramics.org/corporate. MEMPRO® MATERIALS MemPro Materials Corporation Broomfield, CO www.mempro.com inopor Inopor GmbH Veilsdorf, Germany www.inopor.com/en/ Varshneya to receive Michigan/NW Ohio Section Award The American Ceramic Society\'s Michigan/NW Ohio Section has honored Arun Varshneya, professor emeritus of glass science and engineering at Alfred University and president and CEO of Saxon Glass Technologies Inc. (Alfred, N.Y.), with its 2015 Toledo Glass & Ceramic Award. Varshneya Presentation of the award, which recognizes distinguished scientific, technical, or engineering achievements in glass and ceramics, will take place April 9 at the Toledo Club, Toledo, Ohio. A social hour with cash bar begins at 6 p.m., and the dinner and award presentation, which will include Varshneya\'s remarks on “Strengthened Glasses,\" will begin at 7 p.m. An ACerS Distinguished Life Member and Fellow, Varshneya served as ACerS treasurer and held offices in the Northern Ohio Section and Glass and Optical Materials Division. For more information or to make a reservation, contact Janet Bailey at jebailey@wowway.com or 248-348-6585, or Fred Stover at fstover@accesstoledo.com, by April 6. Southwest Section to hold June meeting Mark your calendars for the 2015 meeting of the Southwest Section of The American Ceramic Society, June 3-5, 2015, at the Radisson Hotel Fossil Creek in Fort Worth, Texas. The program, “Training a New Generation of Ceramic Employees,\" will include industry plant trips and technical sessions. A companions\' program for families with children also will be offered. Registration information will be available soon at ceramics.org. Credit: Vlasta2; Flickr; CC BY-NC-ND 2.0 8 What\'s new in ancient glass research? Explore glass\'s past and present during this one-day workshop hosted by ACers Art, Archaeology, and Conservation Science Division in conjunction with the American Institute for Conservation. Register at ceramics.org before April 10 to save. Members: Test drive ACerS-Wiley Download Direct program ACerS-Wiley Download Direct program puts Wiley\'s comprehensive online library of journal articles at your fingertips each month. To take the program for a spin and download your free article, visit ceramics.org. Not a member? Join now and enjoy this and the many other benefits of ACerS individual, corporate, and student membership. I May 17, 2015 | 8:30 a.m. – 5:20 p.m. Hyatt Regency Miami In memoriam Alfred J. Carsten Samuel Moore Edward E. Mueller Xiangchong Zhong Some detailed obituaries also can be found on the ACerS website, www.ceramics.org/in-memoriam. www.ceramics.org | American Ceramic Society Bulletin, Vol. 94, No. 3 Award deadlines April 1, 2015 Du-Co Ceramics Scholarship Award This $3,000 scholarship is awarded to an undergraduate student pursing a degree in ceramics or materials science. Du-Co Ceramics Young Professional Award This $1,500 honorarium is awarded to a young professional member of ACers who demonstrates exceptional leadership and service to ACerS. May 15, 2015 Glass and Optical Materials Division\'s Alfred R. Cooper Scholars Award This $500 award encourages and recognizes undergraduate students who have demonstrated excelence in research, engineering, or study in glass science or technology. May 15, 2015 (cont.) Electronics Division\'s Edward C. Henry Award This award is given annually to an author of an outstanding paper reporting original work in the Journal of the American Ceramic Society or the Bulletin during the previous calendar year on a subject related to electronic ceramics. Electronics Division\'s Lewis C. Hoffman Scholarship The purpose of this $2,000 tuition award is to encourage academic interest and excellence among undergraduate students in ceramics/materials science and engineering. The 2015 essay topic is \"Electroceramics for telecommunications.\" Additional information and nomination forms for these awards can be found at ceramics.org/awards, or by contacting Marcia Stout at mstout@ceramics.org. ACerS members save more. For members-only discounts, including savings of up to 34% on shipping, join now at ceramics.org. discover the healing power of glass BIOACTIVE GLASSES have the ability to bond to soft and/or hard tissue and are biodegradable in the body. Our staff of glass engineers and technicians can research, develop, and produce glass which is custom-made to fit your particular application. Contact us today to discuss your next project. www.mo-sci.com 573.364.2338 ISO 9001:2008 AS9100C See us at Ceramics Expo, Booth 116 American Ceramic Society Bulletin, Vol. 94, No. 3 | www.ceramics.org mo.sci CORPORATION 9 ● acers spotlight Students and outreach Micrographs highlight artistic science in University of Connecticut Keramos competition by Sapna Gupta Although the microscopist must be logical and methodical, microscopy is truly an art form. To highlight some of the beautiful research done at the University of Connecticut, the UConn chapter of Keramos, with the support of the Center for Clean Energy Engineering, recently hosted a micrograph contest open to undergraduate and graduate students within the university. Students submitted images that used techniques ranging from stroboscopy to atomic force microscopy. UConn Institute of Materials Science microscopists Roger Ristau and Lichun Zhang and professor Bryan Huey judged submissions on artistic and technical merit, and the top three entries received cash prizes. First place went to Sourav Biswas and David Kriz for their micrograph of copper-doped mesoporous manganese oxide, \"Brain in Jar.\" Yang Guo won second place for her stroboscopic image of jetting printer ink. Paiyz E. Mikael received third place for her image of a composite scaffold for load-bearing bone regeneration. UConn Keramos thanks all students for their participation, judges for their wisdom and expertise, and the Institute of Materials Science, Center for Clean Energy Engineering, and Materials Science and Engineering department for their support. First place: Sourav Biswas and David Kriz, Ph.D. candidates, Department of Chemistry \"Brain in Jar\" depicts a sample of copper-doped mesoporous manganese oxide synthesized by inverse micelle soft-templated techniques. The students captured the material\'s porous networks in the \"brain\" image with a Zeiss DSM 982 Gemini field emission scanning electron microscope with a Schottky emitter at an accelerating voltage of 2.0 kV and a beam current of 1.0 mA. The bell jar was photographed using a digital SLR camera and the composite image created using GIMP and Adobe Lightroom. Second place: Yang Guo, Ph.D. candidate, Polymer Program, Institute of Materials Science Inkjet printing is an additive manufacturing method providing high-speed versatility in 000 materials with the capability of creating complex structures. However, most functional materials are non-Newtonian fluids whose behavior is complicated at the operating frequency. Here, Guo correlated jetting behavior with liquid properties to understand the fundamentals of inkjet printing and develop empirical models for complex fluids. The image captures a liquid jet traveling at 1 m/s using stroboscopy, which allows high temporal and spatial resolution without expensive high-speed cameras. Third place: Paiyz E. Mikael, Ph.D. candidate, Materials Science and Engineering, Institute for Regenerative Engineering Mikael\'s image represents a composite scaffold designed for load-bearing bone tissue regeneration. Each microsphere is composed of poly(85% lactic-co-/15% glycolic)-acid (PLGA) and functionalized multiwall carbon nanotubes thermally sintered into 3-D matrices. Multiwall carbon nanotubes improve mechanical properties of PLGA scaffolds and contribute to calciumion nucleation and growth. UConn chapter of Keramos President: Sapna Gupta Vice president: Austin McDannald Treasurer: Nasser Khakpash Secretary: Alan Harris Herald: Chen Jiang Chapter advisor: Prabhakar Singh 10μm 10 www.ceramics.org | American Ceramic Society Bulletin, Vol. 94, No. 3 ACerS heats up Science Night with demos that showcase science\'s \'cool\' side ACerS recently participated in the Cherrington Elementary School Science Night, located near the Society\'s headquarters in Westerville, Ohio. Our volunteers got to show off the \"cool\" side of science, making ice cream with liquid nitrogen, candy fiber pull, refractory brick, and superconductivity demos-all of which are available in the Materials Science Kits and free lessons developed by the PCSA, available for purchase at ceramics.org. Thanks to David Riegner (left) and Derek Miller (right), graduate students at Ohio State University, for helping with this excellent outreach opportunity. PCSA accepting applications for 2015-2016 class The President\'s Council of Student Advisors (PCSA) seeks dedicated and motivated undergraduate and graduate students who are eager to help promote ceramics and participation in The American Ceramic Society. PCSA is ACerS student-led committee to engage students as active and long-term leaders in the ceramics community as well as to increase participation in ACerS at the local, national, and international levels. Interested students should visit ceramics.org/pcsa and click on the \"Apply for PCSA\" link to complete an application by the April 15, 2015, deadline. Nanometer Particle Size Reduction of Ceramic Powders with Wet or Dry Grinding 5-JET ale of nano NETZSCH an o second (nan\'sond. nan o tech nol o gy (n technologbuilding ele vidual at an-od molecul Test your product or application in one of our state-of-the-art test centers. Call now to learn more! 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NETZSCH Premier Technologies, LLC 125 Pickering Way - Exton, PA 19341 Tel: 800-676-6455 Fax: 610-280-1299 www.netzsch.com/gd American Ceramic Society Bulletin, Vol. 94, No. 3 | www.ceramics.org 11 ●ceramics in energy Decorative and flexible OPV panels make solar power pretty Using a method of mass production based on roll-to-roll printing, a team of scientists at VTT Technical Research Centre (Finland) is printing decorative and flexible organic photovoltaic (OPV) solar panels. According to a VTT news release, the method can produce a roughly 0.2-mm-thick decorative solar panel that includes a layer of electrodes and a layer of polymers. The panel can be included in windows, walls, machinery, equipment, and billboards. The process is fast and prints in mass-screen or gravure-printing at about 100 m/min of layered film. \"Until now, it has only been possible to pattern OPV panels into a form of stripes,\" states the release. \"The research scientists have tested the feasibility of the method by printing leaf-shaped photovoltaic cells. Active surface of one leaf is 0.0144 m² and includes connections and a decorative part. Two hundred Glass electrodes to shatter the lithium-ion battery world Researchers at ETH Zurich are among the many looking for new materials that can make better batteries for tomorrow\'s energy needs. The team has found that vanadateborate glass (made of vanadium pentoxide and lithium metaborate) coated with graphite oxide can make better cathodes that may be able to double battery capacity. Most lithium-ion batteries used today have cobalt oxide cathodes. An ETH Zurich press release explains the challenge with vanadium pentoxide in the new cathodes. \"In crystalline form, vanadium pentoxide can take three positively charged lithium ions-three times more than materials presently used in cathodes, such as lithium iron phosphate. However, crystalline vanadium pentoxide cannot release all of the inserted lithium ions and allows only a few stable charge/discharge cycles. This is because once the lithium ions penetrate the crys12 OPV leaves make 1 m² of active solar panel surface that generates 3.2 A of electricity with 10.4 W of power at Mediterranean latitudes.\" The team recog nizes that the OPV panels are not as efficient as their silicon counterparts, but the market for such offerings is \"emerging.\" Also, the organic materials used in the pan- A leaf-shaped printed solar cell, which soon may be able to els can be recycled. provide form and function. The researchers currently are exploring how their rollto-roll method might translate to the development of inorganic perovskite solar panels-which perform “roughly talline lattice during the loading process, the lattice expands. As a result, an electrode particle swells as a whole, i.e., it increases in volume only to shrink again once the charges leave the particle.\" To overcome these challenges, researchers made the material into a glass, bypassing the crystal lattice problems altogether. The scientists melted vanadium pentoxide and lithium metaborate powders at 900°C and rapidly cooled the material to form glass in thin sheets. Crushing the sheets into a fine powder provided a material with additional surface area and pore space. The team then coated the powder with graphite oxide, forming a protective layer with increased conductivity. Adding graphite oxide significantly increased the electrodes\' stability from five times better\" and cost about onetenth the price-and report that early testing has been “promising.\" 30 to 100 charge/discharge cycles. Credit: Antti Veijola; VTT Technical Research Centre The researchers continue to explore the glass and plan to patent the material with Belenos (Switzerland), their partner and collaboration company. The paper, published in Scientific Reports, is \"New high capacity cathode materials for rechargeable Li-ion batteries: Vanadate-borate glasses\" (DOI: 10.1038/srep07113). A new glass material shows promise for making better cathodes that may double battery capacity. www.ceramics.org | American Ceramic Society Bulletin, Vol. 94, No. 3 Credit: Rob Nunn; Flickr CC BY 2.0 Credit: Torsten Hofmann; Flickr CC BY-SA 2.0 ceramics in the environment Silicone-encased baking soda balls offer potential carbon capture technique ACerS Fellow, member, and awardee Jennifer A. Lewis is pioneering new technologies to combat rising greenhouse gas levels. Lewis, the Hansjörg Wyss Professor of Biologically Inspired Engineering at Harvard\'s School of Engineering and Applied Sciences, co-led a team of scientists at Harvard University and Lawrence Livermore National Laboratory that has devised microencapsulated sorbent materials for carbon capture and sequestration. The new materials absorb carbon dioxide more cheaply, safely, and energy-efficiently than current strategies. \"Microcapsules have been used in a variety of applications-for example, in pharmaceuticals, food flavoring, cosmetics, and agriculture-for controlled delivery and release, but this is one of the first demonstrations of this approach for controlled capture,\" Lewis says Harvard Gazette article. in a The team\'s new approach bypasses expensive or hazardous substances, instead finding inspiration from the kitchen-sodium carbonate (a.k.a., baking soda) is the key ingredient. Microencapsulated sorbent materials may provide a better means of carbon capture. The scientists call their new technique microencapsulated carbon sorbents (MECS), a way of packaging the sorbent materials into small round beads. Lewis\'s team produced MECS using a double-capillary microfluidic assembly. The device had the advantage of being able to precisely control each component of the material-\"a carbonate solution combined with a catalyst for enhanced CO2 absorption, a photo-curable silicone that forms the capsule shell, and an aqueous solution,\" according to the news release. \"Encapsulation allows you to combine the advantages of solid-capture media and liquid-capture media in the same platform,\" Lewis says. \"It is also quite flexible, in that both the core and shell chemistries can be independently modified and optimized.\" Scientists are now tweaking the work to bring it to scale. If successful, MECS also may be able to help other carbon-spewing industries, including cement and steel production, become more green. The paper, published in Nature Communications, is \"Encapsulated liquid sorbents for carbon dioxide capture\" (DOI: 10.1038/ncomms7124). Hexoloy® Stays Stronger. Lasts Longer.de Superior Performance ■ High strength at high temperature Superior resistance to creep Excellent shock resistance for faster thermal cycling Smaller/lightweight kiln furniture ▪ Exceptional resistance to wear, corrosion & oxidation Custom Made Components ■ ■ L Kiln support beams & tiles Thermocouple protection tubes Burner nozzles, ceramic belts, wear tiles & liners Rollers for roller hearth furnaces Custom components & special shapes SCD.sales@saint-gobain.com 716-278-6233 Visit us at Ceramics Expo Booth 435 American Ceramic Society Bulletin, Vol. 94, No. 3 | www.ceramics.org SAINT-GOBAIN 13 14 ceramics in the environment Crushing clinker at its hottest provides energy and emissions savings Efforts to curb concrete\'s carbon footprint are steps in the right direction, but an improved process that increases cement manufacturing\'s efficiency while reducing spent energy could be key in reducing emissions even further, say Rice University researchers. The work, led by ACerS member and Rice assistant professor Rouzbeh Shahsavari and former graduate student Lu Chen, began with examining clinker as it cooled after coming out of the kiln. Shahsavari and Chen looked at the crystal and atomic structures during the five phases of cooling. They then were able to hone in on the stresses and defects that make some clinker more brittle than others, and, thus, easier to grind. One of these \"unavoidable\" defects-a screw dislocation-is present in clinker pregrinding and postgrinding, This cutaway illustration shows screw dislocation, a defect present even after clinker is ground. and has a direct impact on how well the ground powders will react with water. The researchers found that the hottest clinkers were the most brittle and most reactive. \"Defects form naturally, and you cannot do anything about them,\" says Shahsavari in a Rice news release. \"But the more brittle the clinkers are, the better they are for grinding. We found that the WILEY AND THE AMERICAN CERAMIC SOCIETY Partners in Publishing Visit the Wiley Booth #416 for your discount on all ACers books. Biosurfaces Crystals Glass ACerS members receive 35% off all purchases. Come check Applied out the latest in ceramic SCIENCE THE FRACTURE OF BRITTLE MATERIALS Glass Journal Applied Ceramic TECHNOLOGY materials research. The American Ceramic Society www.ceramics.org WILEY www.ceramics.org | American Ceramic Society Bulletin, Vol. 94, No. 3 Credit: Shahsavari Group; Rice University NanoEye An new dimension in Dilatometry initial phase out of the kiln is the most brittle and that defects carry through to the powder. These are places where water molecules want to react.\" According to the release, Shahsavari and the team believe their analysis could help manufacturers “consolidate processes and cut grinding energy,\" which would mitigate the estimated 10%-12% of grind ing energy that is absorbed in cement making as well as the accompanying 50 kg of CO2 sent into the atmosphere. The paper, published in ACS Applied Materials and Interfaces, is \"Screw dislocations in complex, low symmetry oxides: Core structures, energetics, and impact on crystal growth,\" (DOI: 10.1021/ am5091808). Salmon sperm could prove key to cheaper rare earth recycling Japanese researchers say that salmon sperm might be key in recycling rare earths. According to a Chemistry World article, a team led by the University of Tokyo\'s Yoshio Takahashi found that the sperm (milt) of salmon could effectively replace the more costly and less environmentally friendly methods used to recover rare-earth elements from electronic and magnetic waste. Their work, published in PLoS ONE, is not the first to rely on fish sperm. Milt— which is plentiful, insoluble, and readily discarded by Japan\'s fishing industry-contains phosphate, particularly effective for extracting rare-earth metals. To put that rare-earth attraction to work, the team created a powder from the milt and dropped it into a waterbased solution with three metals-neodymium, dysprosium, and trivalent iron-found in magnets. According to the report, \"When the milt powder was added to the solutions, they discovered that metal ions had a high affinity for phosphate in the powder. The rare-earth elements were subsequently recovered from the milt powder using acid and centrifugation.\" But some believe that the work, although impressive, could prove problematic in scaling up. \"The idea of relying on cheap salmon milt to adsorb and separate rare-earth elements from iron in scrap magnets is quite interesting and, although the proposed protocol does not suppress dissolving the magnets in strong acid, it deserves attention,” says Jean-Claude Bünzli of the Swiss Federal Institute of Technology, Lausanne, in the report. The paper is \"Recovery and separation of rare-earth elements using salmon milt\" (DOI: 10.1371/journal. pone.0114858). See all the features live at Ceramics Expo booth #100 DIL 402 Expedis - Introducing the revolutionary NanoEye technology ■ Unique resolution up to 0.1 nm over complete measuring range ■Controlled contact force for truly linear measurements ■Maintenance-free Plus: Automatic detection of sample length ■ Software-supported sample placement \"Multi-Touching\" ■Double furnace for more flexibility Is salmon sperm the perfect material for a greener rare-earth-recycling process? American Ceramic Society Bulletin, Vol. 94, No. 3 | www.ceramics.org Credit: Scott Ableman; Flickr CC BY-NC-ND 2.0 DIL 402 Expedis Supreme NETZSCH NETZSCH Instruments North America, LLC 129 Middlesex Turnpike Burlington, MA 01803-3305, USA Tel.: (+1) 781 272 5353 nib-sales@netzsch.com www.netzsch.com Oresearch briefs Revolving STEM divulges material\'s atomic secrets Researchers at North Carolina State University have pioneered a new imaging method that allows them to peer into a material\'s atomic organization to precisely map the location of distortions, a unique perspective for probing how those tiny variations in crystallographic address affect material properties. The team of scientists led by NC State materials science and engineering professors Doug Irving and James LeBeau closely examined the placement of atoms within lanthanum strontium aluminum tantalum oxide (LSAT), a hard, optically transparent perovskite structure oxide developed as a ceramic superconductor substrate. \"We knew where the atoms were on average, but we also knew that there were variations in a material—there can be significant displacements, where atoms don\'t fit into that average pattern,\" says Irving in an NC State release. press \" \"However, detecting these distortions required indirect methods that could be difficult to interpret, so we couldn\'t fully explore how a material\'s atomic structure affects its properties,\" LeBeau says La Sr ΑΙ Ta A model of the atomic structure and electron distribution in a crystal of lanthanum strontium aluminum tantalum oxide. with in the release. \"Now we\'ve come up a way to see the distortions directly, at the atomic scale. We can create a precise map of atomic organization, including the distortions, within a material. Not only which atoms fit into the structure, Credit: J. LeBeau; NC State but how far apart they are, and how distortions in the structure are related to the chemistry of the material.\" The scientists used a method pioneered by LeBeau called revolving scanning transmission electron Research News The quest for efficiency in thermoelectric nanowires Researchers at Sandia National Laboratories say better materials and manufacturing techniques for thermoelectric nanowires could allow carmakers to harvest power from the heat wasted by exhaust systems or lead to more efficient devices to cool computer chips. The researchers used a method called \"roomtemperature electroforming,\" which allowed them to tailor key factors that contribute to better thermoelectric performance-crystal orientation, crystal size, and alloy uniformity— with a single process. Electroforming deposits the material at a constant rate, which, in turn, allows nanowires to grow at a steady rate. The method produced wires 70-75 nm in diameter and many micrometers long. The team made the nanowires from antimony-bismuth alloy, which had maximum thermoelectric performance when electroformed from an antimony chloride16 based chemistry. The next step is to make an electrical contact and study the resulting thermoelectric behavior. For more information, visit sandia.gov. Researchers build atomically thin gas and chemical sensors A team of researchers led by engineers at the University of California, Riverside has developed another potential application for molybdenum disulfide materials: sensors. The researchers built the atomically thin gas and chemical vapor sensors from molybdenum disulfide and tested them in collaboration with researchers at Rensselaer Polytechnic Institute. The devices have 2-D channels, which are suitable for sensor applications because of the high surface-tovolume ratio and widely tunable concentration of electrons. The researchers demonstrated that the sensors, which they call \"molybdenum disulfide thin-film field-effect transistors\", can selectively detect ethanol, acetonitrile, toluene, chloroform, and methanol vapors. Sensors revealed better selectivity to certain gases because of the electron energy bandgap in molybdenum disulfide. The uniqueness of the sensors is use of low-frequency current fluctuations as an additional sensing signal. Conventionally, such chemical sensors use only change in electrical current through the device or a change in resistance of the device active channel. For more information, visit ucrtoday. ucr.edu. Controlling the properties of water molecules on metal oxides Scientists at Oak Ridge National Laboratory are learning how the properties of water molecules on the surface of metal oxides can be used to better control these minerals, which are used to make products such as more efficient semiconductors for organic LEDs and solar cells, safer vehicle glass in fog and frost, and more environmentally friendly chemical sensors for industrial applications. The team of researchers studied cassiterite, www.ceramics.org | American Ceramic Society Bulletin, Vol. 94, No. 3 microscopy (STEM) to closely examine the placement of atoms within LSAT. The revolving STEM technique overcomes distortions caused by drift, or minute sample movement, during nanoscale imaging. By rotating the direction of each scan, the technique can, in the end, eliminate sample drift in STEM and provide a clearer, more accurate picture of the material\'s atomic structure. Researchers capture images of distortion from several approaches, which allows them to apply algorithms and remove the drift effect. With drift effects eliminated, the scientists were able to see complex bonds within LSAT and how outside factors, such as local variations in chemical environment, affected those bonds and led to distortions in the material lattice. According to the release, \"the researchers found that the weaker chemical bonds that hold lanthanum and strontium in place in LSAT\'s atomic structure made them more susceptible to being pushed or pulled by small variations in their chemical environment.\" The scientists hope that this unique tool will provide a vantage point that will help them understand—and predict-how atomic organization dictates a material\'s properties. \"Now that we can see these subtle distortions, and know what causes them, the next step is to begin work to understand how these structural differences affect specific properties,\" LeBeau says in the release. “Ultimately, we hope to use this knowledge to tailor a material\'s properties by manipulating these atomic distortions.\" The paper, published in Applied Physics Letters, is “Direct observation of charge mediated lattice distortions in complex oxide solid solutions\" (DOI: 10.1063/1.4908124). ENGINEERED SOLUTIONS FOR POWDER COMPACTION Gasbarre | PTX-Pentronix | Simac HIGH SPEED, MECHANICAL, AND HYDRAULIC POWDER COMPACTION PRESSES FOR UNPRECEDENTED ACCURACY, REPEATABILITY, AND PRODUCTIVITY MONOSTATIC AND DENSOMATIC ISOSTATIC PRESSES FEATURING DRY BAG PRESSING See us at Ceramics Expo, Booth 319 814.371.3015 www.gasbarre.com GASBARRE PRESS GROUP TA Instruments a representative of a large class of isostructural oxides. The team used neutron scattering to help understand the role that bound water plays in the stability of cassiterite nanoparticles and to learn more about the bound water\'s structure and dynamics. \"We show that water sorbed on the nanoparticles, which naturally happens when they are exposed to normal humid air, prolongs their lifetimes as nanomaterials, thus prolonging their potential environmental impacts,\" says coauthor David J. Wesolowski. The work captured the structural ordering of surface-bound water on cassiterite nanocrystals and provided evidence that strong hydrogen bonds drive water molecules to dissociate at the interfaces, resulting in a weak interaction of the hydrated cassiterite surface with additional water layers. For more information, visit ornl.gov. New solder for semiconductors creates possibilities A team led by researchers at the University of Chicago has demonstrated how semi-conductors can be soldered and continue to deliver adequate electronic performance. \"We worked out new chemistry for a broad class of compositions relevant to technologically important semiconductors,\" says Dmitri Talapin, a professor of chemistry. Talapin and colleagues from the University of Chicago, Argonne National Laboratory, and Illinois Institute of Technology have developed compounds of cadmium, lead, and bismuth that can be applied as a liquid or paste to join two pieces of a semiconductor by heating them to several hundred degrees Celsius. “Our paste or our American Ceramic Society Bulletin, Vol. 94, No. 3 | www.ceramics.org Discover More Advanced Ceramic and Glass Characterization ⚫ DSC/TGA • Dilatometry • ⚫ Rheology • High Temp Viscometry • Calorimetry Thermal Conductivity & Thermal Diffusivity Featuring unique new high temperature optical dilatometry and microscopy www.tainstruments.com See us at Ceramics Expo, Booth 210 17 Oresearch briefs Engineering bandgaps for next-generation complex oxides ACerS member James Rondinelli, a materials science and engineering professor at Northwestern University\'s McCormick School of Engineering, and his research group are studying how to adjust the electronic bandgap in complex oxides by simply adjusting a material\'s properties, rather than its overall composition. A material\'s bandgap dictates its properties and, thus, its potential applications. The gap is the amount of energy needed for an electron in a semiconduc tor to move from a bound state to a free state-from a valence band to a conduction band. In the conduction band, electrons can conduct energy. Bandgaps are especially important, because they dictate how a material harvests and converts light and, thus, a material\'s solar energy capabilities. \"There really aren\'t any perfect materials to collect the sun\'s light,\" Rondinelli says in a Northwestern press release. \"So, as materials scientists, we\'re trying to engineer one from the bottom up. We try to understand the structure of a material, the manner in which the atoms are arranged, and how Atomic structure of a layered oxide material designed by James Rondinelli\'s research group. that \'genome\' supports a material\'s properties and functionality.\" Rondinelli\'s team uses quantum mechanics calculations to figure out how to change a material\'s bandgap by examining how the layers within an oxide interact with one another. liquid converts cleanly into a material that will be compositionally matched to the bonded parts, and that required development of new chemistry,\" Talapin says. After application as a liquid or paste, the materials decompose to form a seamless joint. Semiconductor soldering is unlikely to have a major impact on mainstream silicon technology, but could lead to the development of less expensive, solution-processed semiconductors needed for entry into new markets, such as printable electronics, 3-D printing, flat panel display manufacturing, solar cells, and thermoelectric generators. For more information, visit newswise.com. Semiconductor works better when hitched to graphene Experiments at the Stanford Linear Accelerator Center (SLAC) National Accelerator Laboratory looked at the properties of materials that combine graphene with a common type of semiconducting polymer. They found that a thin film of the polymer transported electric charge even better when grown on a single layer of graphene than it does when placed on a thin layer of silicon. Although it was widely believed that a thinner polymer film should enable electrons to travel faster and more efficiently than a thicker film, the team discovered that a polymer film about 50-nm thick conducted charge about 50 times better when deposited on graphene than the same film about 10-nm thick. The team concluded that the thicker film\'s structure, which consists of a mosaic of crystallites oriented at various angles, likely forms a continuous pathway of interconnected crystals. This, they theorize, allows for easier charge transport than in 18 \"Today it\'s possible to create digital materials with atomic level precision,\" Rondinelli says in the release. \"The space for exploration, however, is enor mous. If we understand how the material behavior emerges from building blocks, then we make that challenge sura regular thin film, whose thin, platelike crystal structures are oriented parallel to the graphene layer. By better controlling the thickness and crystalline structure of the semiconducting film, it may be possible to design even more efficient graphene-based organic electronic devices. For more information, visit slac.stanford.edu. New paperlike material could boost electric vehicle batteries Researchers at the University of California have developed a novel paperlike material for lithium-ion batteries. It has the potential to boost by several times the specific energy, or amount of energy that can be delivered per unit weight of the battery. This paperlike material is composed of spongelike silicon nanofibers more than 100 times thinner than human hair. The nanofibers were produced using electrospinning and were exposed to magnesium vapor to produce the spongelike silicon fiber structure. Silicon normally suffers from significant volume expansion, which can quickly degrade the battery, but the silicon nanofiber structure allows hundreds of battery cycles without significant degradation. This technology also solves the problem of scalability: Free-standing materials grown using chemical vapor deposition can be produced only in microgram quantities, but the new technique allows lab-scale production of several grams of silicon nanofibers at a time. The researchers\' future work involves implementing silicon nanofibers into a pouch-cell-format lithium-ion battery, which can be used in electric vehicles and portable electronics. For more information, visit ucrtoday.ucr.edu. www.ceramics.org | American Ceramic Society Bulletin, Vol. 94, No. 3 Cormick School of Engineering mountable and meet one of the greatest challenges today-functionality by design.\" Rondinelli\'s team\'s simulations controlled interactions between layers of complex oxides, specifically between neutral and charged layers. Tuning the arrangement of cations tuned the material\'s overall bandgap without altering the material\'s composition. The team\'s computations showed that they could adjust the oxides\' bandgap by more than 2 eV. Conventional methods to tune band gaps which also require adjusting a material\'s composition-can change the bandgap by only about 1 eV, according to the press release. The next challenge is to test the computations with experiments. \"You could actually cleave the crystal and, at the nanometer scale, see well-defined layers that comprise the structure,” Rondinelli says in the release. \"The way in which you order the cations on these layers in the structure at the atomic level is what gives you a new control parameter that doesn\'t exist normally in traditional semiconductor materials.\" Adjusting the bandgap means new properties for the material, opening the possibility for engineering future materials to be more precisely fine tuned to specific applications. \"The finding could potentially lead to better electrooptical devices, such as lasers, and new energy-generation and conversion materials, including more absorbent solar cells and the improved conversion of sunlight into chemical fuels through photoelectrocatalysis,\" according to the release. The paper, published in Nature Communications, is \"Massive bandgap variation in layered oxides through cation ordering,\" (DOI: 10.1038/ncomms 7191). Perfect colors, captured with one ultrathin lens A new type of lens created at Harvard University turns conventional optics on its head-it is an ultrathin, completely flat optical component made of a glass substrate and tiny, light-concentrating silicon antennas. Light shining on it bends instantaneously, rather than gradually, while passing through. The bending effects can be designed in advance, by an algorithm, and fine-tuned to fit almost any purpose. With this new invention, the Harvard research team has overcome an inherent drawback of a wafer-thin lens: Light at various wavelengths (i.e., colors) responds to the surface very differently. Now, instead of treating all wavelengths equally, the flat lens has antennas that compensate for the wavelength variations and produce a consistent effect. Most significantly, the new design enables the creation of two flat optical devices. The first, instead of sending various colors in various directions like a conventional grating, deflects three wavelengths of light by exactly the same angle. In the second device, the three wavelengths can be focused at the same point. A flat lens, thus, can create a color image focusing, for example, red, green, and blue, the primary colors used in most digital displays. The team\'s computational simulations also suggest that a similar architecture can be used to create a lens that collimates many wavelengths, not just three. For more information, visit seas.havard.edu. TURBULA® SHAKER-MIXER For homogeneous mixing of powdered materials. Excels with oxides and other blends with varying densities. TVT A MILL FOR EVERY JOB! Specializing in lab/ pilot size jet mills, ball mills, planetary ball mills, hammer mills, mortar & pestles (electric too!), centrifugal mills, cross beater mills, dish and puck mills, etc... Call: 973-777-0777 Glen Mills INC. 220 Delawanna Ave., Clifton, NJ 07014 Fax: 973-777-0070 www.glenmills.com staff@glenmills.com Starbar and Moly-D elements are made in the U.S.A. with a focus on providing the highest quality heating elements and service to the global market. I\'R -- 50 years of service and reliability 50 1964-2014 I Squared R Element Co., Inc. Akron, NY Phone: (716) 542-5511 Fax: (716)542-2100 Email: sales@isquaredrelement.com www.isquaredrelement.com American Ceramic Society Bulletin, Vol. 94, No. 3 | www.ceramics.org 19 CALL FOR CONTRIBUTING EDITORS FOR ACERS-NIST PHASE EQUILIBRIA DIAGRAMS PROGRAM Professors, Researchers, Retirees, Post-Docs, and Graduate Students ... The General Editors of the reference series Phase Equilibria Diagrams are in need of individuals from the ceramics community to critically evaluate published articles containing phase equilibria diagrams. Additional contributing editors are needed to edit new phase diagrams and write short commentaries to accompany each phase diagram being added to the reference series. Especially needed are persons knowledgeable in foreign languages including German, French, Russian, Azerbaijani, Chinese, and Japanese. RECOGNITION: The Contributing Editor\'s initials will accompany each commentary written for the publication. In addition, your name and affiliation also will be included on the Title Pages under Contributing Editors. QUALIFICATIONS: General understanding of the Gibbs phase rule and experimental procedures for determination of phase equilibria diagrams, and/or knowledge of theoretical methods to calculate phase diagrams. COMPENSATION PER ARTICLE: $80 for commentary & first diagram, plus $20 each second & third diagrams, plus $10 for each additional diagram FOR DETAILS PLEASE CONTACT: Mrs. Kimberly Hill National Institute of Standards and Technology 100 Bureau Drive, Stop 8520 Building 223, Room A107 Gaithersburg, MD 20899-8524, USA 301-975-6009 phase2@nist.gov research briefs Silicon carbide\'s \'superiority\' makes for promising substitute in high-performance sensors Researchers at the Queensland Microand Nanotechnology Centre at Griffith University (Australia) have shown that silicon carbide\'s \"superiority\" in notso-superior conditions makes the compound a promising substitute for silicon semiconductors in devices with mechanical and electrical sensors. The work, published in Journal of Materials Chemistry C, was led by Dzung Dao, senior lecturer at Griffith\'s School of Engineering. According to a university press release, Dao and QMNC colleagues grew the silicon carbide on 6-in. silicon wafers at low temperature, generating p-type nanocrystalline SiC. They were able to demonstrate-for the first timethe effect of mechanical strain on SiC\'s electrical conductivity. The paper\'s abstract states that the researchers measured the gauge factor to be 14.5, \"one order of magnitude larger than that in most metals.\" The results suggest that SiC\'s mechanical strain strongly influences its electrical conductance, a characteristic that makes the researchers hopeful about the material\'s Materials Chemistry C DOLL future uses in specialty situations. \"Over the past 50 years, silicon has been the dominant material used as a semiconductor for sensing devices and that continues today in computers, mobile phones, automobiles, and more,\" says Dao in the release. \"However, silicon is not suitable for electronic devices at high temperatures above 200°C due to the generation of thermal carriers and junction leakage. Silicon carbide, on the other hand, possesses excellent mechanical strength, chemical inertness, thermal durability, and electrical stability due to its unique electronic structure.\" \"In areas where the temperature can reach well above 200°C, chemical corrosion and mechanical shock are extreme. That\'s where silicon carbide comes in,\" he continues. \"Silicon carbide is already used in power electronics, and these results are very encouraging for sensor technology, particularly in harsh working environments.\" The findings could prove beneficial to a host of industries, including mining, aerospace, automotive, and biomedical, the university says. The paper is \"The effect of strain on the electrical conductance of p-type nanocrystalline silicon carbide thin films,\" (DOI: 10.1039/C4TC02679A). 20 20 The American Ceramic Society www.ceramics.org NIST Dzung Dao, senior lecturer at Griffith University\'s School of Engineering. www.ceramics.org | American Ceramic Society Bulletin, Vol. 94, No. 3 Credit: Michael Jacobson; Griffith University Telescopic contact lenses and wink-controlled eyeglasses that magnify \'on demand\' could aid the visually impaired According to the World Health Organization, there are an estimated 285 million visually impaired people around the world whose vision issues cannot be corrected with contact lenses or glasses. A new telescopic contact lens and its accompanying winkcontrolled smart glasses, developed by scientists at École Polytechnique Fédérale de Lausanne (Switzerland), might be able to bring about better, stronger vision. The Defense Advanced Research Projects Agency (DARPA)funded contact lens includes a thin reflective telescope that can magnify 2.8 times. At just 1.55-mm thick, the telescopic scleral lens works by housing small mirrors that reflect light, \"expanding the perceived size of objects and magnifying the view, so it\'s like looking through low-magnification binoculars.\" The newest prototype also has 0.1-mm-wide air channels that allow oxygen to reach the cornea. \"Although large and rigid, scleral lenses are safe and comfortable for special applications and present an attractive platform for technologies such as optics, sensors, and electronics like the ones in the telescopic contact lens,\" states the release. \"We think these lenses hold a lot of promise for low-vision and age-related macular degeneration (AMD),\" says the devices\' developer Eric Tremblay, researcher at EPFL, in a university news release. \"It\'s very important and hard to strike a balance between function and the social costs of wearing any kind of bulky visual device. There is a strong need for something more integrated, and a contact lens is an attractive direction. At this point this is still research, but we are hopeful it will eventually become a real option for people with AMD.\" Tremblay says that image quality and oxygen permeability will be ongoing challenges in making the lens a real option for the NITED NEW! W Alumina ♦ Fused Quartz ♦ Zirconia ♦ Sapphire Crucibles Furnace Tubes Thermocouple Insulators Rods Plates & Disks ◆ Quartz Cuvettes Alumina & Sapphire Sample Pans for Thermal Analysis Custom Components ADVALUE TECHNOLOGY 3470 S. Dodge Blvd., Tucson, AZ 85713 Tel: 520-514-1100 Fax: 520-747-4024 sales@advaluetech.com www.advaluetech.com A AdValue Technology 24-hour Shipment of Many In-stock Standard Sizes Custom Fabrication for Special Requests A Deltech Furnaces We Build The Furnace To Fit Your Need A LIFEREN DOLLAR A telescopic contact lens prototype that may be able to restore sight. American Ceramic Society Bulletin, Vol. 94, No. 3 | www.ceramics.org Credit: Ecole Polytechnique Fédérale de Lausanne See us at Ceramics Expo, Booth 340 Standard or Custom www.deltechfurnaces.com A 21 research briefs visually impaired, but improvements to its mechanics and manufacturing have things looking up. In addition to a scleral lens, the group\'s wink-controlled glasses provide \"on demand\" magnification-transforming the glasses between unmagnified and telescopic vision-that would be useful even for those without AMD. The electronic glasses employ a light source and light detector to “recognize winks and ignore blinks.\" A right-eyed wink means magnify; a left-eye wink will bring about normal, or unmagnified, vision. \"The glasses work by electronically selecting a polarization of light to reach the contact lens. The contact lens allows one type of polarization in the 1× aperture and another in the 2.8X aperture. Thus, the user sees the view where the polarization of the glasses and contact lens aperture match.\" The glasses, along with the telescopic contact lens, \"represent a huge leap in functionality and usability in vision aid devices and a major feat for optics research,\" says the university. Atomic locales are critical for strong concrete New research from ACerS member Rouzbeh Shahsavari, a researcher at Rice University, shows how simulations can help advance the quest for better concrete. Shahsavari and colleague Saroosh Jalilvand computationally examined the interactions of atoms within a structurally complex material, using concrete as an example, to see how atomic interactions affect the material\'s mechanical properties. In addition to concrete, the team\'s work could help improve other noncrystalline materials, such as ceramics, sands, powders, grains, and colloids, according to a Rice University press release. Cement-calcium silicate hydrate (C-SH)-acts as the glue that holds concrete together. Previous research by MIT scientists revealed that cement is not quite crystalline and not quite amorphous—it is ordered somewhere in between. Computer simulation of a calcium silicate hydrate (cement) tip sliding across a smooth tobermorite surface. Although heterogeneity makes the material strong, it also makes it hard to predict how interactions within the material affect its overall properties. According to Shahsavari, the forces between the atoms are critical for the concrete\'s overall strength and fracture properties. \"Understanding interparticle interactions is of paramount importance when it comes to mechanics of particulate materials such as cementitious materials or ceramics,\" Shahsavari explains in an email. \"This work, for the first time, put an atomistic \'lens\' to decode the interplay between chemistry and mechanics for complex interfacial interactions of cementitious materials. As such, the work introduces exciting new opportunities to better understand the true origin of \'friction\' and \'contact\' in these materials and thus be better positioned to tune the mechanical properties of particulate systems. For instance, by identifying the relative importance and quantitative contribution of each atom type to the frictional properties, our works suggest that new processing routes are required to put the right elements at the interfaces of the particles, rather than putting them inside the particles or randomly distributed in the mix.\" The researchers created a computational model of concrete\'s microstructure, modeling rough C-S-H and smooth tobermorite (a calcium silicate hydrate mineral). In this virtual world, the researchers dragged a virtual tip of C-S-H across a tobermorite surface, measuring the correlation between the force of the push and the corresponding displacement of atoms. A video that shows this simulation is available at http://youtu.be/ iH9Jd3TProY. 22 22 www.ceramics.org | American Ceramic Society Bulletin, Vol. 94, No. 3 Credit: Shahsavari Group The simulations correctly predicted the fracture toughness of tobermorite, which has been previously measured-indicating to the researchers that they were on the right path-and helped provide insight into cementitious mechanics. \"What we discovered is that, besides those common mechanical roughening techniques, modulation of surface chemistry, which is less intuitive, can significantly affect the friction and, thus, the mechanical properties of the particulate system,” Shahsavari says in the press release. The release continues, \"Shahsavari said it\'s a misconception that the bulk amount of a single element—for example, calcium in C-S-H-directly controls the mechanical properties of a particulate system. \'We found that what controls properties inside particles could be completely different from what controls their surface interactions,\' he said. While more calcium content at the surface would improve friction and thus the strength of the assembly, lower calcium content would benefit the strength of individual particles.\" \"This may seem contradictory, but it suggests that to achieve optimum mechanical properties for a particle system, new synthetic and processing conditions must be devised to place the elements in the right places,\" Shahsavari adds. The researchers also found that in between molecules of C-S-H, van der Waals attractions were more significant than Coulombic (electrostatic) forces. The paper, published in ACS Applied Materials & Interfaces, is \"Molecular mechanistic origin of nanoscale contact, friction, and scratch in complex particulate systems\" (DOI: 10.1021/ am506411h). 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Order your kits today! ceramitec 2015 Technologies Innovations Materials October 20-23 Messe München ceramitec.de American Ceramic Society Bulletin, Vol. 94, No. 3 | www.ceramics.org 23 Credit: Ceramco New applications for bioceramics, including dental implants, orbital eye implants, prosthetic components, and orthopedic Growth in implants, account for growing demand in the medical market advanced ceramics market fueled by new applications Ad By April Gocha dvanced ceramics have attractive properties-including resistance to corrosion, heat, impact, and chemical attackthat make them competitive in a variety of markets, namely those comprising electronic components, transportation equipment, electrical equipment, chemicals, machinery, and medical products. Recent technological advances have allowed manufacturers to produce finer and more consistent nanoscale-sized ceramic powders. Small particles improve powder binding and allow deposition of thinner, more uniform coatings, translating into higher performance of finished ceramic components. The cover article of this issue features one such company, Ceramco, that manufactures custom parts using ceramic injection molding of high-quality powders. To embark on a \"plant tour\" of Ceramco\'s facilities and processes, turn to page 26. Processing advances have taken the advanced ceramics market to new heights, and the materials compete aggressively with nonceramic materials in a variety of markets. Market analysts from research company The Freedonia Group (Cleveland, Ohio) predict market demand for advanced ceramics in the United States alone-which already surpasses $10 billion—will increase 5.1% per year to reach $13.6 billion in 2017.1 The top eight advanced ceramics manufacturers in the U.S.—Kyocera, 3M, CoorsTek, Murata Manufacturing, Vishay Intertechnology, Corning, Vesuvius, and NGK Insulators—analyzed in a recent Freedonia report secured 24% of the market in 2012. Although the U.S. advanced ceramics market is competitive, Japan historically has led the industry and remains a key producer and exporter of advanced ceramic products, particularly electronic components, such as ceramic capacitors and piezoelectric devices. Although advances in numerous areas and industries drive the market\'s upward trend, above-average growth in the medical, transportation, and machinery markets will impact growth of the advanced ceramics market most significantly. because of the materials\' wear resistance and biocompability. Ceramics\' superior wear resistance also makes them well suited for harsh and demanding manufacturing environments, for example, in the machinery market. In the transportation sector, more stringent efficiency and emission standards will continue to drive demand for advanced ceramics, with applications in vehicle ceramic filters, catalyst supports, and engine parts. Ceramic-matrix composites also are integral to the transportation market and represent one of the fastest-growing advanced ceramic product markets. Market analysts predict ceramic-matrix composites will experience a compound annual growth rate of 13.81% through 2019, when the market will reach a value of $2.40 billion. The aerospace industry represents a significant proportion of this demand, alone accounting for $1.01 billion of the 2019 ceramic-matrix composite market.² Despite the explosive growth of ceramic-matrix composites, however, monolithic ceramics remain the most significant class of advanced ceramics and account for almost 81% of current market demand. Ceramic-matrix composites hold 6.5% of the advanced ceramics market, with ceramic coatings accounting for the final 12.5%. After experiencing a peak in 2007, the defense market for advanced ceramics is predicted to remain depressed consequent to U.S. troop withdrawal and military surpluses. Future growth of the market is expected to depend on ballistic applications, such as helmets and armor. Alumina is the material of choice for advanced ceramics and commands 38% of the total U.S. market. And, although zirconates are in much less demand-just 10% of the U.S. market-than alumina, growing use in medical applications is expected to make zirconates the fastest growing material market for advanced ceramics. Electrical and electronic parts and catalyst supports are the two highest in-demand advanced ceramics products. Together, these products carry more than a third of the total growth forecasted in the advanced ceramics market through 2017. Demand for electronic and electrical parts is predicted to grow at an annual rate of 3.3%, while catalyst supports are expected to see 4.1% annual growth. Continuously improving properties and manufacturing advanc es will push advanced ceramics markets to grow as applications for these versatile materials expand. See the opposite page for an infographic of some of the key figures and statistics from the advanced ceramics market. For more information, visit Freedonia\'s 2013 industry report, \"Advanced ceramics,\" at www.freedoniagroup. com/industry-study/3091/advanced-ceramics.htm. Sources \'The Freedonia Group, \"Advanced ceramics.\" 2013. www.freedoniagroup.com/industry-study/3091/advanced-ceramics.htm 2Markets and Markets, \"Ceramic-matrix composites market by type, by application, and by region-Trends and forecasts to 2019.\" 2014. www. marketsandmarkets.com/Market-Reports/ceramic-matrix-compositesmarket-60146548.html 24 24 www.ceramics.org | American Ceramic Society Bulletin, Vol. 94, No. 3 ADVANCED CERAMICS ☑ x 5.1% annual growth U.S. market 2007-2022 % market demand by material 2007 2012 2017 2022 TOTAL MARKET DEMAND $9,725 million $10,600 million $13,600 million $17,100 million market demand % by industry alumina titanate zirconate cordierite 7.7% ferrite 7.6% all other 7.5% SiC 7.4% 38.4% medical 3.8% 21.5% machinery 11.6% 9.9% chemical 11.8% 16.8% electrical 17.2% transportation 17.9% all other 20.9% Credit: A. Gocha Source: The Freedonia Group. \"Advanced Ceramics.\" 2013. electronic powered by Piktochart 002613 Fully automated high-pressure injection molding of complete ceramic parts. O bulletin | cover story Near net shaping of ceramic components26 \'Plant tour\' of a custom manufacturer By Thomas O. Henriksen Automated near net shaping of custom ceramic parts saves time, material, and energy. Con Contract manufacturers of customized ceramic parts face tangible challenges. In the spirit of continuous improvement, those of us in mature markets always are looking for ways to reduce delivery lead times and cost. Machining post-fired, high-hardness materials is costly and chews away at already squeezed delivery lead times. The impact of energy cost always is a consideration. For example, pressing ceramic powder into a bulk shape and then machining it down to final form consumes energy. Machined-away material that ends. up in the dust collector represents a loss of the material and the energy it took to make it-from raw material through firing. Thus, there are practical and economic drivers for shaping ceramic components as close to final form as possible and minimizing the postfired operations. www.ceramics.org | American Ceramic Society Bulletin, Vol. 94, No. 3 Credit: Ceramco Capsule summary ECONOMIC DRIVERS Manufacturing ceramic components consumes material and energy and creates an economic driver for improving efficiency. Near net shaping forms parts as close to final dimensions as possible and minimizes post-firing processes. APPROACH Ceramic injection molding allows for near net shaping of almost any ceramic formulation across a wide range of complex geometries. Automation improves manufacturing efficiency. KEY POINT Successful near net shaping of ceramic components by ceramic injection molding starts with careful formulation of ceramic powders and binders, as well as design and crafting of customized tooling. Diamond grinding achieves final dimensions in the critical areas of parts with tight dimensional tolerance specifications. Growing importance of technology Near net shaping (NNS) is an established process. Early approaches to NNS date back to iron casting in the 1620s followed by steels after 1850 and light alloys in the 1940s. Plastic injection molding was developed in the 1920s, and the first plastic parts were produced in the 1930s after the invention of polyethylene in 1933. Besides metals and polymers, engineering materials such as Portland cement, refractories, cermets, and fused silica were being formed to near net shape during the 1930s. Combining injection molding with powder metallurgy led to powder injection molding (PIM). Delco first used injection molding to form ceramic spark plug insulators in the 1940s after securing a patent on the process in 1938. The same manufacturing evolution experienced by the metals and plastics industries in the 20th century is now transforming ceramic component manufacture. Ceramic parts can be manufactured by many techniques. Pressing, casting and extruding likely always will have a place in the NNS of ceramic components, especially for simple geometries, such as plate and rod stock. These are considered to be the core, traditional ceramic manufacturing technologies. Pressing, from a NNS viewpoint, means the die or tooling allows for complete forming of the entire shape. Adding binders to starting powder gives green, pressed compacts enough structural integrity to be handled. However, press-forming NNS components that include holes, slots, interior diameters, and outside diameters-while not impossible-is extremely difficult. Therefore, as part geometry becomes more complex, molding and casting become process considerations. Although variants of earlier pressing and extrusion NNS techniques (especially isostatic pressing) will continue, complex ceramic shapes will require efficiencies achievable with casting or ceramic injection molding (CIM) methods. Slower than pressing, NNS by casting lends itself to making complex shapes, especially components that are large or have thick walls. Casting involves pouring or injecting liquid slurry into a mold. After solidification, the shape is removed and fired. Variations of this process include gelcasting, freeze casting, 3D casting, and slip casting. Low-pressure injection molding can be considered casting too, making shapes in fictile materials with virtually no pressure forces. In higher quantities, cost effectiveness diminishes when economies of scale are factored into the equation, such as labor and time it takes to make product. Similar to pressing, CIM begins with ceramic powder. The material is injected into a die or tool cavity with pressure and heat to melt the binder and fuse the material together. The starting shape has gross dimensions larger than specifications to compensate for shrinkage during firing and densification. After firing, the ceramic component is fully densified and at its final size (net dimensions). The result is a near-net-shaped component. Achieving “near-net\" dimensions requires process control and precision. As the term implies, although there is a target dimension, the objective is to be as \"near\" to target as possible after firing and within acceptable tolerances. The intended application and design parameters of the component often dictate just how closely it is possible to achieve near net shape. Living in an era of energy awareness, however, focuses bright new light on its promise for contract manufacturers of custom ceramic components. Ceramic powders require energy to mine and prepare for industrial processing, so why waste any during the forming step? NNS can provide an efficient means to produce shapes with the least amount of energy and material waste, in a shorter amount of time. Most often, economics determine which NNS process is best for manufacturing a particular ceramic component. Factors to consider include time (manufacturing speed), materials, and tolerances. At present, pressed parts own the lion\'s share of the market. A well-run press is fast and efficient, and it can press parts of high-quality ceramic powders (alumina, zirconia, silicon carbide, etc.). However, pressing is limited to manufacturing components with simpler geometries. Powder metallurgy processes are finely tuned and can achieve very near net shapes. In particular, PIM parts made with powder blends, such as tungsten carbide with cobalt binder, are very near specified net shape. Similarly, CIM under tightly controlled process conditions, dialed-in tooling, perfected binder-powder system, etc., performs just as accurately. Even with such dimensional accuracy now achievable via CIM and NNS, the ceramic component industry tends to offer a wider tolerance window, by a few standard deviations. Typically, as-fired tolerances for ceramic parts are quoted to be ±1%. As technology and experience improves, tolerances likely will become tighter. American Ceramic Society Bulletin, Vol. 94, No. 3 | www.ceramics.org 27 Near net shaping of ceramic components-\'Plant tour\' of a custom manufacturer Figure 1. Tooling for ceramic injection molding must be custom built for each part design and material combination. Onto the factory floor To demonstrate NNS of ceramics, join us on a tour of our NNS operation at Ceramco (Center Conway, N.H.; see sidebar, p. 31). Ceramco manufactures custom ceramic parts for aerospace, scientific instrumentation, energy, medical, and wire/cable industries. On this brief \"plant tour,\" we will focus on the plant\'s CIM facilities and explain the many considerations that must be appraised in a custom manufacturing business. Raw materials Ceramic powders, such as alumina, zirconia, mullite, silica, magnesia, yttria, and special blends, generally are stored in a ready-to-mix state, although some minor powder processing such as sifting and jar milling, is done before batching. The customer, as original designer (OEM) or user of the part, typically specifies material requirements, such as alumina purity level, for which there are standard formulations. Additionally, unique formulations and customersupplied powders contribute to the product mix. All raw materials are mixed in batches and standard compositions, such as high-alumina formulations, to make a wide variety of parts. Depending on the type of powder and binder (which carries the powders), we select one of four industrial mixer machines to make feedstocks. Coarsegrained powders incorporate into binder differently from fine-grained powders. Various binder types have a range of melting temperatures and shear sensitivities, and, therefore, the machine used depends on the feedstock formulation. The process is much like something done in a kitchen, with a recipe for combining critical amounts of ingredients. Powder selection and the ability to control additives provides versatility and enhances process control. Therefore, this is a major advantage over depending on outside sources to process powder and make feedstocks. Almost any ceramic powder can be made into a feedstockoxides, carbides, nitrides, and borides. Compounding of ceramic powders is integral to making ceramics. It requires an \"industrial kitchen\" of mixers and mills, a \"recipe book\" on powder technology, and years of experience to learn to do it correctly. Ceramco belongs to The Association of American Ceramic Component Manufacturers (AACCM, see sidebar, p.29), a trade association for powders-to-parts manufacturers. Processing from a powder is a requirement for membership in AACCM, which currently comprises 18 like-minded member companies, all experts in their own NNS methods and formulations. Processing parts from powders is more profitable for companies and demands disciplined adherence to ceramic science principles, which is an advantage to customers. Every successful ceramic NNS technology depends on it. CIM tooling During the quotation process for new parts, the ceramic material and the plan for tooling (which is made in-house) are determined (Figure 1). The product life, quantity needed, and quality details factor into the plan. Net-shaping molds are made of aluminum, tool steel, and/ or carbide by our expert moldmaker. In rare and very special circumstances hard rubber also is a candidate material for the molds. Customers provide, at the minimum, a 2-D drawing to design tooling for a part of simple geometry. As geometries become more complex, a 3D model file is preferred. The 3-D files can be fed directly into computer numerical control (CNC) machine centers to make the most accurate mold shape. In addition to simplifying toolmaking, 3-D files often illustrate the part in its assembly. This visual communication of the part\'s requirements is absolutely critical for production planning, espe cially the tooling design stage. Engineers review parting lines, gate locations, draft angles, and ejector pin locations that are necessary for the mold to work and compare against the design to avoid interference with fit or function. The ability to produce tooling is advantageous. New tooling, despite our experience, sometimes requires Circuit coverlid - Alumina Bobbin for aerospace Detector component for homeland security Heater core 28 Octahedron high pressure synthesis chemistry www.ceramics.org | American Ceramic Society Bulletin, Vol. 94, No. 3 adjustments. (In ceramics manufacturing, Murphy\'s Law always applies!) Whether those adjustments are minor or major, the ability to make and maintain molds in-house is more economical and timely and enables tighter control of dimensions. Tooling wears and loses accuracy as it is cycled and, because customers pay for their custom-made molds, the in-house tooling capability is a valuable asset. Molds made of aluminum last for 10,000 cycles and cost less. Therefore, new low-volume and new prototype parts often are made first from unit cavity aluminum tooling. Multiple cavities to NNS mean more parts in the same tooling set can be added later when usage volumes increase or to decrease cycle times. Value in tooling made with New Hampshire frugality of “don\'t make it any more than it needs to be\" benefits the customer and defeats the prejudice that injection-molding tooling has to be expensive. In general, CIM parts are small and should be designed with uniform wall thicknesses (although we can stretch the rules and make large parts or design combinations of thick and thin walls). In addition, process limitations exist. Part features, such as undercuts and negative draft, can be very challenging for toolmaking, because the net-shaped ceramic must be removable from the mold cavity. Special techniques, such as green or postfire machining, or employing collapsible cores in the mold, can get around these limitations, but these add expense. A mature product with such added complexities can tolerate the additional investment and the associated lead time, although adapting designs to be CIM friendly is the best policy. When the order is complete what happens to the tooling? In most cases, the customer pays for it separately and, therefore, owns it. However, tooling is engineered for use with our technology and generally is not transferrable to other manufacturers. NNS by molding What happens after preparing feedstock and building tooling depends on the product. Each injection-molding process uses equipment requiring feedstock and tooling specifically designed for it. In general, the feedstock is added to the injection-molding machine, which in turn injects it into the molding tooling where the part is near-net shaped. The geometry of the finished component and the quantity ordered by the customer most often determine the manufacturing process to achieve the NNS. Short production runs of up to 10,000 pieces, for example, generally are made by low-pressure injection molding (LPIM). Longer production runs of 50,000 pieces or more generally employ high-pressure injection molding (HPIM). Orders of very small quantities may be manufactured using hand or stack molds. Larger, complex HPIM orders often require automated tooling, having pins, slides and cores moving in an intricate sequence to produce one NNS component at a time. Less complex HPIM shapes often can be made in multiples by injecting feedstock in many cavities at once, reducing production time. Other factors that the manufacturer must consider when choosing the process to use include the material, dimensional precision and other quality specifications, including product life cycle and part design. Secrecy Manufacturers have an innate propensity to be secretive. In the case of ceramists, secrecy may trace back to the 1600s when Europeans formulated their own version of highly sought Ming Dynasty hard porcelain and processed their fine pottery under a cloak of secrecy. Like Medieval ceramic manufacturers, much of the \"trick of the trade\" in ceramic manufacturing today remains undisclosed. CIM components are chemically and thermally processed to arrive at a fully fired ceramic component. In Ceramco\'s experience, the degree of progress made in ceramic manufacturing technology is a function of how quickly we embrace new world machinery and techniques (replacing the old) to meet the demands for 21st century ceramic materials. However, we still have our secrets! Figure 2. Circle gates are used for cylindrical parts and break off when the parts eject from this six-cavity CIM tool. All runners and sprues are reclaimed and molded into parts. Firing Production staff load green parts into high-temperature kilns and fire in batches. Our facility has electric kilns, with open-air and nitrogen-purged chambers, routinely heated to 1,700°C. Some parts are prefired or bisque-fired A TE ASSOCIATION OF AMERICAN CERAMIC COMPONENT MANUFACTURERS The Association of American Ceramic Component Manufacturers (AACCM) is a trade organization for manufacturers of technical or advanced ceramic products for heat, corrosion, wear, electrical, and electronic applications. Membership is open to U.S.-based companies that form finished or semifinished ceramic parts from raw powders. Its mission is \"to advance the capabilities of the members and the quality of their products, so that they may satisfy the emerging needs of American industry. This will be accomplished by addressing concerns relative to market requirement, raw material supply, and fabrication.\" The Association of American Ceramic Component Manufacturers currently comprises 18 member companies. For more about AACCM, visit aaccm.org. American Ceramic Society Bulletin, Vol. 94, No. 3 | www.ceramics.org 29 29 Credit: Ceramco Near net shaping of ceramic components-\'Plant tour\' of a custom manufacturer Figure 3. Cooled-down kiln car loaded with fired fuse insulators formed by CIM. by ramping slowly and not reaching the sintering temperature, getting them to a “brown” stage, where they remain soft for easy removal of tooling marks, mold flash, and parting lines. Figure 3 shows a kiln car loaded with fired fuse insulators. These parts are large, about 8 inches long by 1.5 inches tall. Every material has its own firing schedule, and every part has specific firing requirements. Special setters support odd-shaped parts during firing. To keep net shapes shrinking uniformly, the kiln needs to heat uniformly from all the heating elements and dissipate heat evenly. Also, the particle size of the starting powders needs to be right. Materials with special additives need to be separated from other materials to avoid cross-contamination or unwanted chemical reactions. Thus, the firing team carefully selects appropriate furnace plates and even heating element types. Ceramco has 25 independent kilns, which enables us to process all orders at any time, regardless of product mix. Parts with complex geometries formed by NNS methods have their highest value if the as-formed dimensions are \"accurate enough.\" However, sometimes tolerance specifications are tighter than \"near-net\" dimensions. Hard-fired ceramics with tight tolerances must be diamond ground for the last step. But not too much! These machine tools are retrofitted with diamond-impregnated 30 Figure 4. Magnified visual inspection of final parts to detect flaws inside holes and other hidden areas. grinding wheels, which makes it an expensive process. Also, aggressive removal of material can inflict surface stresses and introduce microcracks that weaken the part. Therefore, only the areas of the component that are critical to function are ground. Doing so also minimizes labor investment and tool replacement costs. Quality assurance Fully fired parts are measured for dimensional accuracy and visually inspected for defects. Liquid dye penetration tests reveal hairline cracks and open porosity, making them visible to the inspector\'s eye. We use practical and ergonomic vision scopes (Figure 4) to inspect parts under magnification, especially inside holes and other hidden areas of parts. Most orders are processed in batches using qualified tooling, allowing us to rely on process control and sample checking to ensure product consistency and acceptance. Parts for use under vacuum and highpressure environments are inspected using special test jigs and gauges, depending on the critical features. Applying air pressure or vacuum and submerging the parts in fluid will expose any leaks when inspecting high-voltage, deep-water, or semiconductor chamber parts. Customers provide mating components to check fit and compatibility with the ceramic parts, as shown in Figure 5. Sometimes customers require some assembly or mating work to be done. Other quality considerations include: • Surface finish, although ultimately a function of the particle size of the startFigure 5. Finished ceramic fuse insulator formed by CIM. The foreground piece shows complex geometry achievable by NNS with slots, holes and walls of varying thickness. The background piece shows the ceramic piece with the metal fuse fitted inside. The part dimensions are 8 inches long x 2 inches wide x 1.5 inches high. www.ceramics.org | American Ceramic Society Bulletin, Vol. 94, No. 3 Credit: Ceramco Credit: Ceramco ing powder, also is a function of tooling surface character. • Precision of as-fired net-shaped dimensions (i.e., how near are to the net) in general is ±1%, although it can be as good as ±0.3%, depending on tooling, equipment, feature size, and geometry. • Quantities range from hundreds to hundreds of thousands. The production tooling is scaled to match the order quantity. Prototypes and short orders use low-cost molds, and high-volume orders use hard, multicavity tooling with appropriate degrees of automation in part handling. New, competing technologies Challenges for the future include competing technologies that are capable of fabricating complex geometries, such as 3-D printing, robocasting, and selective laser sintering. These technologies are exciting because of their ability to make geometries that cannot be injection molded, for example, undercut features. All shaping processes influence the properties of ceramic parts, and, therefore, their usefulness for applications. These new technologies are no exception. Currently, they cannot demonstrate adequate bulk density or consistent surface quality. Strength also is an issue. CIM parts have no relic structures in the ceramic body. As a result, high bulk densities are achieved. Practicality also must be considered. Thick parts would take a long time to manufacture, producing one layer at a time using 3-D printing, regardless of the technology\'s advancement. It remains to be seen whether high-volume 3-D manufacturing will be more economical than traditional forming techniques. About the author Thomas O. Henriksen is president of Ceramco, Inc., and president of AACCM. Contact Henriksen at t.henriksen@ceramcoceramics.com. Selected references M.F. Ashby, Materials Selection in Mechanical Design, 2nd ed. Butterworth, Boston, 1999. N.P. Bansal and A.R. Boccaccini, Ceramics and Composites Processing Methods. Wiley, New York, 2012. G.Y. Onoda Jr. and L.L. Hench, Ceramic Processing before Firing. Wiley, New York, 1978. R.M. German, Powder Injection MoldingDesign and Applications. Innovative Material Solutions, 2003. R. Cass and T.O. Henriksen, \"A Gateway into Ceramics,\" Ceram. Ind., June 2011. \"Tungsten Carbide-An Overview,\" International Tungsten Industry Association, 2 Baron\'s Gate, 33 Rothschild Road, London, W45HT, U.K Ceramco-A history of serving demanding niche markets In 1982, Danish scientist and Massachusetts Institute of Technology Ph.D. Anders F. Henriksen settled in Chatham, N.H., and founded a consulting firm, Chatham Technology. Less than a year later, he adapted powder metallurgy methods to ceramic part fabrication and founded Ceramco Inc. to manufacture custom ceramic components using low-pressure injection molding. The business carved a niche for making unique, complex parts of high-purity alumina, zirconia, and other refractory ceramics. Ceramco\'s niche business grew for the next 15 years, serving an increasing number of industries, to produce custom parts of increasing complexity for extreme environment applications. The ability to make functional internal and external threads for custom orders created a captive business manufacturing stock-sized ceramic nuts and bolts. To produce parts with tighter tolerances, Ceramco partnered with, and eventually acquired, a diamond-grinding shop. In 1997, Ceramco built a new 10,000 square foot facility to house the newly acquired grinding capability and the growing manufacturing enterprise. The expansion provided an opportunity to improve overall operational efficiency. Over time, Ceramco saw growing demand for high-volume, yet geometrically complex, ceramic parts. In 2008, the company acquired high-pressure injection molding (HPIM) technology to meet the challenge. This decision opened opportunities for Ceramco to pursue new industries and markets. Today, Ceramco\'s full-service manufacturing capabilities focus exclusively on near-net-shape ceramic component fabrication. American Ceramic Society Bulletin, Vol. 94, No. 3 | www.ceramics.org 31 Why did it break? 32 B rittle materials are prone to catastrophic fracture with little or no plastic deformation and often no warning. Fortunately, brittle fracture leaves clear patterns and surface markings that provide a wealth of interpretable information. In many respects, fractographic analysis of ceramics and glass is easier and can produce more quantitative information than fractographic analysis of metals or polymers. In fact, fractographic analysis of brittle materials can answer many practical problems: Why did it break? Did it break as expected or from an unexpected cause? Was there a problem with the material or was the part simply overloaded or misused? What was the stress at fracture? Was the laboratory strength test successful or was 38 years of teaching there a misalignment? fractographers how to answer the question by George Quinn and James Varner Credit: G. Quinn and J. Varner Figure 1. Van Derck Fréchette. The late Van Derck Fréchette first taught a three-day summer short course in 1977 on fractography of glasses and ceramics at the New York State College of Ceramics at Alfred University, where he was a professor (Figure 1). This course, with substantial updates, has been offered every summer since and is almost always fully subscribed—a remarkable run for a topical short course that attests to a continuing need to interpret why things break. The hands-on course explains mechanisms that produce fracture markings and emphasizes information the markings provide. The course also stresses the role of fracture analysis in failure prevention, or ensuring mechanical reliability. Alfred will offer the 2015 course, “Failure analysis and failure prevention of glasses and ceramics,\" June 15-19, with instructors George Quinn and Jim Varner. This article describes how the course has changed over time to reflect increased knowledge in the field and a growing understanding of the key role fractography plays in achieving high mechanical reliability of glass and ceramic products. The early course Fréchette had such expertise in fractography of glasses and ceramics that he was in demand as a consultant for companies and product liability cases. He had amassed a large collection of broken component pieces (glass bottles, ceramic insulators, flat plates, tubes, rods, etc.). He also had led undergraduate and graduate research projects focused on fundamental aspects of fracture in glass and ceramic materials, such as slow crack growth, effects of inclusions on crack propagation, relationships between failure stress and the number of fragments, and crack healing. These experiences allowed Fréchette to think a great www.ceramics.org | American Ceramic Society Bulletin, Vol. 94, No. 3 Figure 2. Participants in one of the Alfred fractography short courses. Note the many specimens on the front bench. deal about nomenclature in the field and to determine the steps needed to conduct objective failure analysis of broken glass and ceramic pieces-he knew that the time was right to teach others how to conduct fractographic investigations. The hallmark of Fréchette\'s first short course, and something that remains central to today\'s version, is hands-on demonstration and observation of actual specimens (Figure 2). Each student has a stereographic light microscope and light source that he or she uses to examine fracture markings and crack patterns in speci mens that have been carefully selected to highlight particular phenomena (Figure 3). The course teaches not only what to look for (the patterns and markings), but also how to look. Instructors pass around unique specimens, which are available throughout the course, for participants to examine. Students sometimes break and examine specimens, or prepare and examine replicas of fracture surfaces. Fréchette and the present instructors understand that there is no substitute for observation-newcomers to fractography need to experience firsthand the effects of lighting on fracture surfaces and the critical importance of correct illumination to see and interpret fracture markings. Capsule summary BACKGROUND Shards of fractured glass and ceramic materials contain clues that tell the story of their failure. Fractography is the art and science of assembling the clues to reveal how the service environment led to failure. Another key feature of Fréchette\'s course that is preserved today is the case study. Fréchette, a great storyteller, had fascinating tales that were both interesting and enlightening. One of his more notable tales was the broken windows in Boston\'s John Hancock building. During its construction in the 1970s, the building\'s new windows cracked and had to be replaced-and were covered with temporary plywood sheets in between-so frequently that the building became known as the \"U.S. Plywood Building\" or the \"Plywood Palace.\" The building\'s ill-fated original windows were some of the first ever produced that were both doubled-layered and used reflective glass, which had just been developed in the preceding decade. The building had another interesting design element: Its tall, thin, rhombohedral design created APPROACH high-speed wind flow around the building, or Venturi effects, that sometimes knocked pedestrians off their feet. Quinn personally observed these effects from the street below-with a wary eye towards the looming glass above-after he left engineering classes at Northeastern University at the time. The sometimes hurricane-force winds caused the building to twist and sway, so many suspected these alarming movements were the source of the glass fractures. Figure 3. Participants in one of the Alfred fractography short courses-including the late Janet Quinn, who became an expert in dental ceramics fractography, in the foreground—each with a stereographic light microscope to examine specimens. New York State College of Ceramics at Alfred University has offered a short course on fractography of glasses and ceramics continuously since 1977. SUMMARY Although Alfred\'s fractography course has evolved to reflect changes in ceramic and glass materials and their applications since it was initially offered, the course continues its tradition of teaching through hands-on observation and extensive case studies. American Ceramic Society Bulletin, Vol. 94, No. 3 | www.ceramics.org 33 Credit: Credit: G. Quinn and J. Varner; Alfred U. Credit: G. Quinn and J. Varner, Alfred U. Why did it break? 38 years of teaching fractographers how to answer the question ponent failed. Participants learn by \"looking over the shoulders\" of experienced fractographers. Fréchette\'s course notes led to publication of his book, Failure Analysis of Brittle Materials², which became a standard reference after its publication in 1990. More recently, George Quinn authored NIST Recommended Practice Guide: Fractography of Ceramics and Glasses,³ which is now a standard reference in the field, too. However, Fréchette\'s book still has relevance and includes some fascinating case studies, such as \"Tale of Two Teapots,\" \"The Fatal IV Bottle,\" and \"Engarde!,\" a case in which a broken glass meat thermometer damaged the wrist of a nationallyranked fencer. In the last case, a glass meat thermometer broke when inserted into a rolled roast of beef. It failed at a notch used to secure the temperature scale, from which a long sliver of glass broke free. Scientists reenacted the scenario on a testing machine, which confirmed the mode of failure but revealed that the thermometer broke under high force. The fencer testified that she was upset and in a hurry at the time, and that she had forcefully jabbed the thermometer into the roast. This action produced a much higher load on the glass than foreseen by the manufacturer, causing the thermometer to fail. Figure 4. The John Hancock Building in Boston, Ma. Although there were many theories as to why the fractures occurred (wind loading, nickel sulfide inclusions, etc.), Fréchette discovered that the source of the fractures were tiny \"glue chip\" cracks near the outer edges of the glass panes where they were bonded together by a lead strip soldered to bridge the panes together. With repeated thermal and mechanical loading, the glue chips grew and caused the huge windows to break. Eventually, the building\'s entire façade of 10,344 panes of double-layered reflective glass had to be replaced, at great cost, with thick, single-layered glass (Figure 4). At the time, Fréchette had to be discrete in describing the matter since there was significant litigation. Nevertheless, he shrewdly arranged to have a clause placed in his contract that, although he could not write publicly about the failures, he could use the case for teaching purposes. Today, course instructors still draw on their own extensive experience to present case studies to reinforce the steps that need to be taken to determine why a com34 Moving forward When Fréchette retired from teaching the course in 1995, Quinn and Varner agreed to take it over. The instructors expanded the amount of material on technical ceramics (fine-grained polycrystalline ceramics) and quantitative fractography (Figure 5). Over time, Quinn and Varner added more on fracture mechanics, strength and fracture-toughness testing, Weibull statistics, single crystals, and reliability. Quinn and Varner also added new demonstrations and specimens (e.g., specimen reconstruction, replicas, and slow-crack growth) and introduced new tools and techniques. With these additions, the course expanded to four andmost recently-five days. In today\'s course, instructors have evolved the curriculum to match the evolving applications and types of glasses and ceramics. For example, attendees used to be concerned with fractures in large glass cathode ray tubes used in televisions, but these are now historical relics. Attendees now are concerned with thin, flat plates used in all types of mobile electronic devices (Figure 6). Participants now discuss applications such as glass containers used in the pharmaceutical industry, ceramics used in energy-related systems, glass-ceramics, dental ceramics, and single-crystal components. The present course gives participants the tools they need to practice fractography of glasses and ceramics. Participants receive extensive and intensive exposure to the field through lectures, discussions, and ample hands-on experience, similar to Fréchette\'s original course. Specimens and demonstrations provide an experience base that participants can build upon when they return to their home organizations. Participants often bring specimens from their own work that the instructors examine with them in afterclass sessions. Following the course, participants are able to apply fractographic principles to increase mechanical reliabil ity of ceramic and glass components. Course participants range from technicians to process engineers to scientists in research and development and hail from all over the United States and the world (including Germany, Brazil, New Zealand, Poland, and France). Instructors constantly review the field and incorporate new material that reflects changes in materials, products, knowledge, and topical interests. References IV.D. Fréchette and M. Donovan, \"Some effects of the \'glue chipping\' process on strength\"; pp. 407-11 in Fractography of Glasses and Ceramics II, eds. V.D. Fréchette and J.R. Varner. The American Ceramic www.ceramics.org | American Ceramic Society Bulletin, Vol. 94, No.3 Credit: Credit: G. Quinn and J. Varner; Alfred U. Credit: Credit: G. Quinn and 1 mm Figure 5. Specimens like this silicon nitride test bar broken in flexure help familiarize course participants with fracture surfaces of fine-grained ceramics, which are more difficult to interpret than glass fracture surfaces because of the complications of microstructure. The fracture origin is on the lower edge, about halfway between the center of the bar and the left side. Society, Westerville, Ohio, 1991. 2V.D. Fréchette, Failure Analysis of Brittle Materials: Advances in Ceramics, Vol. 28. The American Ceramic Society, Westerville, Ohio, 1990. 3G.D. Quinn, NIST Recommended Practice Guide: Fractography of Ceramics and Glasses. Special Publication 960-16, National Institute of Standards and Technology, U.S. Government Printing Office, Washington, D.C., 2007. Solving a Gulfstream puzzle About the course Figure 6. The fracture surface of a glass bar shows the fracture origin and mirror, with several types of fracture markings. This specimen familiarizes course participants with the appearance of fracture surfaces of flat plates broken in flexure, and it also is used to practice measuring fracture mirrors and estimating stress at failure using the size of the fracture mirror and the fracture mirror constant. Alfred University will offer the 2015 course, \"Failure analysis and failure prevention of glasses and ceramics,\" June 15-19. For more information, visit http://engineering.alfred.edu/shortcourses/fracture.cfm. About the authors James R. Varner is professor emeritus of ceramic engineering at Kazuo Inamori School of Engineering, New York State College of Ceramics, Alfred University, and a consultant on cases involving failure of glasses and ceramics. George D. Quinn is a consultant in mechanical properties of ceramics and glass and is retired from the National Instititute for Standards and Technology, where he continues as a guest researcher. Contact Varner at (607) 324-0850 or varnerjr@alfred.edu. Course participants perform one hands-on laboratory exercise in which they analyze a broken 75-mm-diameter borosilicate crown optical glass disk. Janet Quinn broke the disks in a ring-on-ring apparatus in controlled laboratory conditions in the mid-1990s. She tested hundreds of disks to collect design data for a reliability analysis of a large (>1 m) window on a custom reconnaissance Gulfstream III aircraft that would fly at high altitudes. Each student receives a bag of broken glass pieces from a single disk and is tasked with performing a failure analysis to find the fracture origin. Usually one or two pieces are upside down, and indeed this is part of the exercise. Students must interpret fracture markings on all the pieces so they can align the tension-flexed surfaces appropriately. In fact, this is a step any fractographer must do with genuine component fractures in the field! Once reassembled, the pattern of fracture becomes apparent: Fracture radiated outwards from the central origin, not unlike the fracture patterns in actual large pressurized windows. Indeed, this pattern confirms that the disk was properly tested in the laboratory and was a valid test. Other disks that failed from rim origins have radically different fracture patterns. Students then must examine fracture surfaces at the origin site to find the origin flaw. Flaws in the disks vary from sharp contact damage sites, scratches, and even sand impact pits that simulate flaws that are found in real full-sized windows. As a final step, students measure fracture mirror size and estimate fracture strength. This latter step is a unique aspect of the fracture of brittle materials and no such analogue exists for metals or polymers. Students get a sense of accomplishment by \"solving the puzzle\" in this realistic exercise. A student reassembles a BK-7 glass disk broken in biaxial flexure. Credit: Credit: G. Quinn and J. Varner; Alfred U. The crack pattern of a reassembled BK-7 glass disk shows that the fracture origin is close to disk\'s center. Credit: Credit: G. Quinn and J. Varner; Alfred U. American Ceramic Society Bulletin, Vol. 94, No. 3 | www.ceramics.org 35 Varner; Alfred U. Paper manufacturing machine Ceramic materials in pulp and paper manufacturing by Mahendra Patel Many areas of paper manufacturing use alumina, silicon carbide, silicon nitride, composites, ceramic coatings, and other advanced ceramic components. Credit: iStock W hen touring a paper mill, the visitor sees nothing but the chimney, conveyer belts, numerous vessels-from small to gigantic-connected by pipes, and slurry pumped from one area to another. However, a paper manufacturing factory\'s myriad structures use ceramic materials, such as for the foundation, flooring, shades, tanks, and other machinery and equipment. Increasingly, ceramic materials are being used to address the inherent corrosion problems associated with papermaking, which cause enormous operations challenges, especially with regard to excessive recycling of water and fibers.2 Figure 1 shows the primary operations involved in paper manufacturing. There is tremendous emphasis now on micromaterials and nanomaterials. However, little published research details materials engineered specifically for the paper industry. Even in the journals dedicated to pulp and paper, there are few publications on material structure, properties, or composition. Figure 2 shows that many ceramic materials have potential applications in practically all areas of pulp and paper manufacturing, including raw-material preparation, pulping, bleaching, stock preparation, paper machine operation, and coatings. The ceramic products used in the pulp and paper industry include traditional and advanced products as well as composites and coatings. Characteristic properties of ceramic products-high strength, wear resistance, long service life, chemical inertness and nontoxicity, resistance to heat and fire, (usually) electrical resistance, and (sometimes) specific porosity-all can be applied to the industry. Some currently available advanced ceramic materials are as strong as metals and additionally possess inherent chemical, thermal, and abrasion resistance. These features have prompted replacement of metallic parts with ceramic materials in modern machinery, a trend that is likely to increase in the future. Composites that incorporate polymeric materials with ceramic and notably glass fibers also have been on the rise. 36 Capsule summary CAUSTIC CONDITIONS Pulp and paper manufacturing occurs under elevated temperatures and extremely low pH conditions. Abrasion, erosion, corrosion, and heat present materials selection challenges across the entire manufacturing process. ADVANCED CERAMICS OPPORTUNITY Many areas of paper manufacturing use alumina, silicon carbide, silicon nitride, composites, ceramic coatings, and other advanced ceramic components. KEY POINT Installing advanced ceramics in pulp and paper manufacturing plants can decrease wear and corrosion and increase energy efficiency. Although areas of some plants already are fitted with ceramics, many opportunites for further materials development and deployment exist. www.ceramics.org | American Ceramic Society Bulletin, Vol. 94, No. 3 Raw materials preparation (chipper) Conveyer belt with wood chips/agroresidues Recovered paper Advances in materials Engineers continuously develop new material technologies for machinery and equipment to replace metallic parts with ceramics and polymeric materials. Driving forces for substituting of metals with ceramics are energy conservation,4 high-temperature service, low bulk density, excellent erosion/corrosion resistance, long-range availability, and potential low cost. Unlike ductile metals, ceramic materials are brittle and fail under stress. Thus, ceramics require considerably more refined or totally new approaches to component design.5 The two leading candidate ceramic material systems for these high-temperature applications are densified silicon nitride (Si₂N) and silicon carbide (SiC). These materials have superior thermal shock, mechanical ware, and corrosion, and erosion properties. Si3N4 is superior in strength, fracture toughness, and thermal shock resistance, but SiC is harder, has higher thermal conductivity, and potentially has better creep resistance at high temperatures. Difficulties finding the required quality materials for pulp and paper manufacture are partly economical, but also relate to continuing alterations in manufacturing technologies. For example, the bleaching process now uses chlorine dioxide and ozone instead of the chlorine and hypochlorite used earlier. Also, water, fiber, and chemical recycling has intensified. The sizing process, which used to be acidic, is now alkaline. Environmental pressure and a need to increase overall product quality and productivity in the mill are driving forces behind these technology changes. Yet to be seen is how using nanotechnologies in mill processes and products will lead to additional changes.6 New materials developments have led to bigger and faster machinery with record-breaking results. Paper is manufactured at speeds of more than 2,000 m/min and deckle lengths of more than 11 m. (The deckle is a removable frame placed in a mold to contain paper slurry and control sheet size.) However, lack of materials innovation restrains advances in some areas. The lack of appropriate refractory materials that can withstand the high temChemical pulping Mechanical pulping Digester-kraft pulping Digestersulphite pulping Batch digester Continuous digester Black liquor Evaporator Blow tank Washing 1-1-1Pulper Deinking Bleaching Bleaching Recovery boiler sludge Stock preparation Lime Coater Lime kiln Causticizer Paper machine Slaker Green liquor Former Press Dryer Calender Reel Finishing area Figure 1. Flow chart of pulp and paper manufacturing processes.\' peratures and corrosive gases of black liquor gasification is an example. Slurry entering the paper machine contains an enormous volume of water that must be removed. Water from the slurry is removed gradually from a fabric support, on which pulp fibers form a web that dries to become board or paper. When paper machine speed increases, fabric tension also increases. Modern paper machines have long, preferably lightweight, rolls, which can lead to complex roll deflection control issues. Speed differences between roll cover and fabric often are the root cause of forming section roll cover and fabric lifetime problems. Material selection criteria Increased recycling of water, fiber, and chemicals requires American Ceramic Society Bulletin, Vol. 94, No. 3 | www.ceramics.org Ceramic materials improved materials. The elevated harshness of environments causes more corrosion and abrasion and, thus, frequent material failure.² Figure 3 shows criteria to consider in materials selection for building machinery. Criteria should be evaluated on the benefits obtainable in the long term to avoid increased maintenance costs and reduced profits. For example, without effective wear protection, expensive Alumina Silicon carbide Silicon nitride SIAION Materials for: Chipper/ Conveyer belt Pulper Washer Bleaching plant Stock preparation Paper machine: Forming Fabrics Zirconia Glass Refractory Press Tile and brick Cement Coatings Composites Drying Coater, Calender, Reel Effluent treatment Slaker, Causticizer, Lime kiln Evaporator Recovery boiler Instruments Pumps Figure 2. Ceramic materials used in various areas of pulp and paper manufacturing. The last column indicates areas in pulp and paper mills where ceramics have found application. 37 Ceramic materials in pulp and paper manufacturing Energy consumption Safety Water consumption Rebuilding possibility Corrosion Material selection criteria Durability Productivity Quality Efficiency Figure 3: Criteria for material selection. 1 production systems quickly succumb to abrasion, corrosion, and excessive heat, resulting in costly repairs and downtime. Corrosion Proper material selection is the key to avoid corrosion. When a vessel needs to be replaced because of corrosion or cracking, plant managers should consider all options before replacing the equipment in kind.² Because the previous vessel lasted for 20 years does not suggest that a new one will do the same. The level of corrosion has increased dramatically in mills, making corrosion resistance a primary factor in materials selection. Recycling has increased process temperatures and the concentrations of corrosive species, such as chlorides. Therefore, environments in modern pulp and paper mills are much more aggressive than before. Although metals are prone to corrosion, ceramic and polymeric materials are less susceptible and, therefore, where possible, are preferred over metallic parts.4 Energy The simplest route to saving energy in production is procuring energy-efficient machinery. Although pulp and paper production is an energy-intensive industry, significant progress in conservation has been made recently. Less energy is needed in the forming section by optimizing the former and forming fabric process. However, additional opportunities to optimize and conserve energy in Erosion the forming section exist. The dryer section of a paper machine consumes more energy than other sections-75% of a machine\'s thermal energy-but often is overlooked for optimization and investment compared with forming and pressing. The dryer section also has potential to improve running speed of the machine and paper quality. Water consumption Water always has been the most essential and indispensable resource in pulp and paper manufacturing. For economical and ecological reasons, an increasing proportion of \"white water\"-the filtrate that drains from the wet end of the paper machine—is recovered and reused as process water. This technological development is feasible only because of increasing closure of white-water loops. Looped systems\' materials combat harsh environments, so ceramic materials are preferred wherever possible instead of metals. Ceramic materials Four categories of ceramic materials are used in paper manufacturing: Traditional refractory ceramics, such as fire-resistant and acid-proof refractory brick, castable, tile, and cement; • Advanced ceramic products, includ ing ultrapure alumina (Al2O3), SiC, Si₂N, Si-Al-O-N (SiAION), and zirconia (ZrO2); Composites; and Nanomaterials. · • The new generation of ceramics and design methods has potential to help increase efficiency, save energy, decrease maintenance, optimize recycling, and reduce pollution.¹³ Important advances are underway in four categories: monolithic ceramics; composite ceramics; coatings; and refractories. Brick and tile-because they are costeffective and strong enough—tend not to be replaced with other materials. Brick, flooring tile, and cement are used in almost the entire mill area. Advanced ceramic materials Here, the term “monolithic\" refers to materials composed entirely of ceramic, typically having low porosity and comprising a complete component or lining. Examples include dense forms of Al2O3, Si, N₁, SiC, ZrO2, transformation-toughened zirconia (TTZ), transformation-toughened alumina (TTA), and aluminum nitride (AIN). Advances in materials development have increased the utility of monolithic ceramics for thermal, wear, corrosion, and structural applications in paper manufacturing. In particular, strength and toughness properties have been improved to a level that ceramic components can compete with metals. For example, Al2O3, Si3N4, and SiC are used for draining equipment in paper manufacturing. Ceramics solve high-wear problems associated with the paper manufacturing process. For example, at the wet end of the paper manufacturing, water is removed from the pulp slurry by moving it over ceramic dewatering foils at high speeds, often in excess of 100 km/min. The environment is very demanding, because paper pulp is abrasive and the chemical environment is severe. Si3N2 and SiC have replaced Al2O3 as dewatering foils because of their superior hardness, fracture toughness, wear resistance, and thermal shock resistance. Alumina From technical and economic perspectives, Al2O3 is the most preferred ceramic material. It has fairly high strength, and many industrial and technical ceramics are manufactured now with Al2O3 purity ranging from 80% to 99.8%. Consequently, Al₂O, is the ceramic material against which alternative ceramic materials are evaluated. Silicon carbide SiC ceramics are harder than Al2O3 and Si,N, and, thus, have superior wear resistance. The high thermal conductivity, low thermal expansion, and refractoriness of SiC make it useful for paper manufacturing. However, it is much costlier than Al2O3. Common applications of SiC include pump seals, valve components, and wear-intensive applications, such as rollers. The typical applications of SiC in pulp and paper mills include 38 www.ceramics.org | American Ceramic Society Bulletin, Vol. 94, No.3 fixed and moving turbine components, suction box covers; seals, bearings, pump vanes; and ball valve parts, hot-gas-flow liners, and heat exchangers. Silicon nitride SiN also has properties superior to Al2O3. For example, its beneficial drag coefficients are gentle to forming fabrics. It commonly is used in twin wire forming and press applications because of its excellent resistance to thermal shock. Ceramic coatings Protective ceramic coatings applied to machinery and piping extend their lifetimes, and ceramic coatings protect internal surfaces of pumps and delicate measuring equipment. Ceramic coatings are used in pulp and paper manufacturing for calender rolls, center press rolls, coater rolls, winder drums, dryer felt rolls, and paper converting rolls. Composites Advanced ceramic particulates, continuous fibers, and whiskers provide reinforcement for engineered ceramic composite materials. They represent a new generation of materials tailored for specific applications. 6-9 Ceramic composites reinforced with nanoscale materials, such as nanotubes, have mechanical properties superior to conventional composite materials. Ceramic-ceramic, metal-ceramic, and ceramic-polymer composite materials are used in pulp and paper manufacturing. These high toughness materials do not fracture easily and assure high reliability. Some oxide and non-oxide ceramic matrices contain residual metal after processing. Common oxide matrices include Al2O3, silica, mullite, barium aluminosilicate, lithium aluminosilicate, and calcium aluminosilicate. Common non-oxide ceramic-matrix materials include SiC, Si,N, boron carbide, and AIN. SiC is the most widely used, and AIN is used where high thermal conductivity is required. Si₂N is used when high strength is desired. Composite materials are used in screw conveyors, cyclones, pulverizers, hydropulpers, Y-splitters, pumps, chutes, silos, and hydrofiners. Glass-filled polymer composites (UHMWPE) are used as dewatering elements in the paper machine. Paper industry components are available in glass-filled Si3N4, SiC, and various ceramic grades. Dewatering elements include ceramic and plastic foils, ceramic and plastic covers, Uhle box covers and doctor blades, and bearings. Paper industry fast facts Paper mills worldwide Paper mills in the United States Annual global production Annual U.S. production* †Largest worldwide producer. 10,000 500 300 million metric tons 87 million metric tons Source: The Technological Association of the Pulp and Paper Association, tappi.org Other monolithic ceramic materials Other ceramic compositions have been developed based on SiAlON, AIN, mullite, and aluminosilicates for specific purposes. Applications involving many of these materials are in the development stage. Zirconia aluminum nitride, titania, borides, magnesia, and their composite materials are emerging as ceramic products for demanding areas. Monolithic ceramics, because of their strength and toughness, are especially suitable for small-to-medium-sized parts that provide improved wear resistance, corrosion resistance, low friction, and high-temperature stability. Mullite and aluminosilicate refractory materials are used in the recovery boiler area. Applications in pulp and paper industries There are many opportunities for new materials in the paper-manufacturing process. Table 1 highlights areas that well-suited for incorporating ceramic materials. Raw materials Materials with adequate abrasion resistance, such as specialty WC-Co cermet, are needed for debarking and chipping. Factory and yard storage flooring are constructed with well-burned red brick with higher Al₂O, content and cement and lower proportion of fly ash, as in case of pozzolanic cement, to reduce floor wear. Pulping Many mills continue to use digesters made of mild carbon steel, because of its economy and availablility. The sulphite mill digester is one area that could incorporate ceramic materials. Similarly, in the chemical pulping area, ceramics may serve as blow line linings, blow tank target plates, hydrocyclone cleaners, pumps, and washer vats. Washing Brown stock (unbleached pulp slurry) washer systems require proper selection of metallic and ceramic materials. Washer vats and pulp storage tanks are tile lined and constructed with chemically resistant masonry. Bleaching Unlike the alkaline pH in the pulping process, acidic pH (~2) prevails in the bleaching process with chlorine and chlorine dioxide. Stainless-steel corrosion has been a persistent problem in bleaching. Titanium metal, which is costly, is now used. Therefore, ceramic materials are preferred because of their corrosion resistance and cost effectiveness. Installing fiber-reinforced composites in bleaching areas also may prove effective. Wet end The wet end starts with the approach piping that carries treated pulp to the paper machine and continues to the dryer section. Stock tanks are made of acid- and abrasion-resistant ceramic tile. Magnesia-partially-stabilized zirconia lines the flow path and trim parts of highly abrasive rotary control applications. This area has become complicated with the introduction of synthetic surface sizing agents, which work in the alkaline range and are vulnerable to attack by microorganisms, causing corrosion. Paper machine Paper machine environments are harsh and variable. Paper machines include the typical twin wire and from stock approach piping to the reel. These areas require materials of exceptional quality for construction, and, wherever needed, appropriate surface finish requirements must be met. Energy efficiency of the paper machine is important, leading to many parts now being made up of ceramics (Figure 4). Forming Many metal parts of paper machines slowly are being replaced by ceramics. American Ceramic Society Bulletin, Vol. 94, No. 3 | www.ceramics.org 39 Ceramic materials in pulp and paper manufacturing Press section elements Gap former Twin wire former Drainage elements High- and low-vacuum suction box Dewatering elements Forming boards Gravity box Figure 4. Applications for ceramic materials in a paper machine. Credit: Patel Table 1 Critical applications of ceramics in pulp and paper manufacturing Area of application Mechanical pulping-rotating grindstones Recovery boiler Black liquor gasification system Required materials properties Abrasion resistance These components are used to remove water and control the wet paper web during paper manufacturing. Suction rolls are expensive yet necessary components of modern paper manufacturing machines. Continuous slotted ceramic suction box covers are a recent innovation. Various types of roll covers are made of rubber and other advanced polymeric materials. Corrosion, thermal shock-, and impact resistance Improved ceramic refractory and hot gas cleanup components Bleaching with hydrogen peroxide and chlorine dioxide Improved corrosion resistance Mechanical refiner rotating disks Lighter weight, wear resistance Paper machine Head box components, press rolls, pumps, chutes, and pipes Doctor blades, slitters, drums, and screen baskets in the paper machine On-line sensors to measure moisture content, thickness, stiffness, web and paper quality, and fiber properties and orientation Improved processes for gas, solid, and liquid separations Dryer rolls Example materials Carbide-reinforced metal Alumina, aluminosilicate, and mullite brick and tile; ceramic coatings Corrosion-resistant spinel refractory materials Ceramic tile and coatings; high-alumina ceramics; ceramic filter materials with 58% silica and 34% alumina, with traces of silicon carbide; acid-brick lining or solid FRP dual laminate WC-Co cermet; partially stabilized zirconia products Improved release characteristics for impulse dryer Ceramic coatings rolls in advanced paper machine Improved corrosion and wear resistance Improved abrasion resistance Erosion resistant control valves; electrical pulse measurement; gap measurement Gas separation property-diffusion and permeation; transport mechanism; pressure- and temperatureswing adsorption Higher modulus (stiffer) material Pressure shoe and roll in the paper machine Improved lubrication properties Blow plate Superheater and reheater tubes and for scrubber and gas turbine components 40 Improved wear and corrosion resistance Suphidation-resistant materials and coatings Silicon nitride and alumina; metal rolls covered with rubber or polyurethane; rolls include filled rubber and resin covers and ceramic coatings Silicon carbide and silicon nitride Ceramic ball valve (Mg-PSZ) Porous alumina membranes in double layer (a, B, y phases) Ceramic matrix composite coating; plasma-sprayed zirconia ceramic coating Composite (polymer-, rubber-, and resin-based) ceramics Platinum-alumina-cermet electrode Cast-aluminum oxide-based cements having low heat transfer capability to highly engineered silicon carbidebased cements Press Mills with less harsh manufacturing environments use painted steel frameworks. The press section now uses ceramic materials, however, lower alloyed martensitic and ferritic stainless steels are used where some corrosion resistance and higher strength are required. Dryer Dryer performance impacts energy use across the industry, and, therefore, dryer design and material selection is vital. Hard ceramic coatings have been developed to protect drying and machine glazed cylinders from wear. These coatings are applied by thermal spraying, either onsite or during maintenance work. The coatings consist of a corrosion- and wear-resistant layer, ensuring surface and geometric stability of the cylinder. Dirt-repelling versions keep the surface clean and improve sheet release. Coater Materials advancements have reduced the blade surface roughness, which results in better blade performance. Traditionally, coating blades were made of steel incorporating AO, particles. Blade technology focused on improving the existing Al2O3based material until about 2000. Ceramiccoated chromium-based alloy, metal-based materials, and elastomer-based materials that impart better quality have been developed since then. Evaporator Multiple-effect evaporators and concentrators always have been made of stainless steel. Concentrator tubings made of stainless steel succumb to general corrosion and to caustic stress corrosion cracking in liquors concentrated to higher than ~70% dry solids.5 Proper selection of metals is critical for handling higher solid content. Ceramic materials are being investigated for use in some parts of the evaporator. An evaporator includes a liquid barrier wall, a vapor barrier wall, and a wick made of ceramic, the latter positioned between the walls. Recovery boiler The recovery boiler operates at temperatures of ~1,000°C and presents one www.ceramics.org | American Ceramic Society Bulletin, Vol. 94, No.3 of the most challenging areas for materials technology. Many ceramic, metallic, and polymeric materials have been developed over the years to replace iron and steel components. The recovery boiler closed system has increased the number of nonprocess elements involved and increased likelihood of corrosion in the recovery boiler. Research to develop black liquor gasification is neither technically nor commercially feasible because of lack of proper refractory material. Lime kiln Carbon steel and low-alloy steels can be used for the first two zones of the chain if the metal temperature does not exceed 400°C. Materials selection depends on particular kiln and cost factors. Modern kiln construction consists of two-layer refractory linings-a brick lining and a layer of insulating brick underneath. 10 Effluent treatment plant Normally, the effluent treatment plant (ETP) is the most neglected area in a paper mill. Ceramics in the ETP can handle abrasive, corrosive, and, at times, hightemperature and high-pressure liquids. Instruments and pumps Materials used to make manufacturinggrade instruments and pumps must withstand the harsh environments that prevail in the manufacturing process. Efficient pulp and paper mill equipment contains sensors made of highly engineered electronic ceramics, metals, and alloys. Manufacturers of process pumps-essential to paper manufacturing are intensely interested in using ceramics and metals to combat corrosion and erosion. Other applications Commercially available ceramic components and services that recondition ceramic dewatering elements and ceramic cleaner cones for paper manufacturing exist. Applications include drainage elements, dewatering elements, forming boards, gravity box, high- and low-vacuum suction boxes, twin wire formers, gap formers, and press section elements. One manufacturer has incorporated ceramic components-96% Al₂O3, 99.7% Al2O3, ZrO2, and Al2O3 + 8% ZrO2-as dewatering elements in its production process. The most-used ceramics in pulp and Table 2: Applications of aluminium oxide and silicon nitride ceramic products in different areas of paper machine\' Ceramic type Aluminium oxide Aluminium oxide Silicon nitride Forming board: lead position Deflector Wear surface component Application Ceramic blade Former Forming board: trail position Foil Deflector Vacuum foil Wet box Unfoil Aluminium oxide Unfoil Unfoil Aluminium oxide Multi-slot covers Flatbox covers: single and multicomponent Description Solid ceramic segment for clamping dovetail holder Wire contact ceramic with fiberglass carrier on a poly base for use in any holder Full top ceramic with fiberglass for popular holders Wire contact ceramic with fiberglass carrier for wedge grip holders and unfoil Ceramic with fiberglass carrier mounted on a 316 SS frame for use on any new or existing structure Press fabric, cleaning assembly | Ceramic with heavy duty fiberglass carrier Wear strips Silicon nitride Wear strips Special applications Special applications Aluminium oxide Silicon nitride Zirconia paper manufacturing are Al₂O, and Si̟N. Table 2 presents their applications in various areas of paper manufacturing.\" The wire table contains the dewatering elements: forming board, dewatering foils, hydrofoil boxes, vacuum water boxes, and suction boxes. Ceramic hydrofoils used for dewatering have high strength, good wear resistance, and low friction coefficient, and, thus, they last longer in paper manufacturing machines. The cover materials are made of 95% and 99% Al2O3, zirconiatoughened alumina, zirconia, and highdensity polyethylene, and box materials are SS304 and SS202. Many other ceramic products, manufactured for the pulp, paper, and other industries include tubes, rods, pump shafts, impellers, washers, seal faces, nozzles, ferrules, standoffs, rings, crucibles, insulators, fixtures, element supports, thermocouple insulators and protection tubes, guides, rollers, pulleys, and custom parts. Applications drive the cost-effective use of modern ceramics. Advanced compositions, vacuum bonding, high-tensile-strength adhesives, composition fabrication, and spraying along with traditional methods all are used in pulp and paper industry applications. The products are engineered to withstand a wide range of abrasive, corrosive, and moderate impact applications. About the author Mahendra Patel owns Industrypaper, Sambalpur, Odisha, India, and serves the Indian Agro and Recycled Paper American Ceramic Society Bulletin, Vol. 94, No. 3 | www.ceramics.org Special tooling charge may apply Mills Association. Contact Patel at patel@industrypaper.net. Editor\'s note This article was adapted with permission from Ceramics in Paper Manufacturing including Advanced and Nano Materials, P. Mahendra, Industrypaper (www.industrypaper.net), New Delhi (2013). References \'M. Patel, \"Ceramics in paper manufacturing, including advanced and nano materials,\" Industrypaper (www. industrypaper.net), New Delhi, 2013. 2M. Patel, \"Operations and recycling in paper mills with micro and nano concepts,\" Industrypaper (www.industrypaper.net), New Delhi, 2012. 3M. Patel, \"Micro and nanotechnology in paper manufacturing,\". Industrypaper (www.industrypaper.net), New Delhi, 2010. 4D.W. Freitag and D.W. Richerson, “Opportunities for advanced ceramics to meet the needs of the industries of the future,\" DOE/ORO Report No. 2076, Prepared by U.S. Advanced Ceramics Association and Oak Ridge National Laboratory for the Office of Industrial Technologies Energy Efficiency and Renewable Energy, U.S. Department of Energy, Washington, D.C., 1998. 5J.A. Coppola and C.H. McMurtry, \"Substitution of ceramics for ductile materials in design,\" presented at National Symposium on Ceramics in the Service of Man, Washington, D.C., June 7, 1976. 6M. Patel and A. Karera, \"Silicon carbide from rice husk: Role of catalysts,\" J. Mater. Sci. Lett., 8, 955-56 (1989). \'M. Patel, \"SiC from rice husk: ESCA study,\" Powder Metall. Int., 22, 33-35 (1990). 8M. Patel and P. Kumari, \"Silicon carbide from sugarcane leaf and rice straw,\" J. Mater. Sci. Lett., 9, 375-78 (1990). ⁹M. Patel and B.K. Padhi, \"Production of alumina fibre through jute fibre substrate,\" J. Mater. Sci., 25, 1335-43 (1990). 10M. Patel, \"Minerals in paper manufacturing,\" Industrypaper, New Delhi, India, 2008. 41 C ceramicS April 28-30, 2015 expo Cleveland, Ohio show highlights The brand new tradeshow and conference looking at the latest innovations in technical ceramics World Exclusive of New Precision Shaping Technology Among the game-changers on display at Ceramics Expo will be the world debut of iMachining for Ceramics, which promises to revolutionize precision shaping of ceramics and other extremely hard materials. The technology enables machining fully sintered ceramics at unprecedented volumetric material removal rates. SolidCAM will be performing live demonstrations of how iMachining achieves this on the show floor at Ceramics Expo 2015! Visit SolidCAM at booth 301 Experience the Future of Laboratory Technology Attendees will have the opportunity to participate in hands-on workshops and live demonstrations conducted by Dr Gunther Crolly, Product Manager at Germany\'s FRITSCH GmbH. The company invites participants to discover first-hand the advantages of laser or image methods over other techniques such as sieving or sedimentation. On display will be the latest generation of laser particle sizer, used for wet and dry measuring, and a new dynamic image sizer that enables rapid analysis of particle size and shape. Visit FRITSCH USA Inc at booth 420 Live Demonstrations at Ceramics Expo Among the attractions at Ceramics Expo will be demonstrations and on-demand testing conducted by some of the exhibitors. Prominent among these is Setaram Inc, which has more than 60 years of experience in high-performance thermal analysis, calorimetry gas sorption, dilatometry, spectroscopy and thermal conductivity instrumentation. Among Setaram\'s demonstrations will be the company\'s Calvet technology, high-temperature solutions and superior TGA balance. In addition, it will display many of the critical parts that make Setaram an innovator in material characterization. Visit Setaram Inc at booth 401 www.ceramicsexpousa.com onference @ceramics expo Access to all conference sessions is included in your free expo pass. Conference stages are located at the far end of the exhibition hall. TRACK 1 Ceramic & Glass Manufacturing Current ceramic and glass industry opportunities and challenges approached via a series of focused presentations and interactive sessions. Sustainable Manufacturing Testing, Analytical & Quality Assurance Volume Manufacturing & Automation Additive Manufacturing High-Temperature Manufacturing Analytical Measurements in Manufacturing Processes R&D to Market Custom Manufacturing TRACK 2 Ceramic & Glass Applications Ceramic and glass applications by key ceramic characteristic, punctuated with major industry case studies and expert panels tackling key application issues. Tuesday April 28, 2015 Optical Electrical Conductivity Materials for Extreme Environments Wednesday April 29, 2015 Wear Resistance Thermal Expansion & Conductivity Additive Applications Thursday April 30, 2015 Chemical/Corrosion Resistance Energy Materials / Storage/ Hardness exhibitor list 337 3D Ceram 336 Akron Porcelain & Plastics Co 409 Alfa Full (Guangxi Tengxian) Titanium Dioxide Co Ltd 309 Alfred University 125 Almatis Inc 328 Alteo Alumina 419 AluChem Inc 108 AlzChem, LLC 240 APC International Ltd 247 Apogee Engineered Ceramics Inc 114 Applied Ceramics Inc 412 Applied Minerals Inc. 112 Associated Ceramics & Technology Inc 139 Association of American Ceramic Component Manufacturers 523 Astral Material Industrial Co. Ltd 440 AVEKA 417 Baikowski International 341 Bakony Technical Ceramics Ltd 134 Bass Tech International 506 Beijing Zhongxing Shiqiang Ceramic Bearing Co Ltd 230 Blasch Precision Ceramics Inc 414 Boca Bearing Company 413 Bullen Ultrasonics Inc 251 California Nanotechnologies 425 Centerline Technologies 226 Ceramco Inc 154 Ceramdis Advanced Ceramics 124 Ceramic Applications (CA) and Ceramic Forum International (CFI) and TASK 237 Ceramic Industry 335 Ceramics Expo 2016 346 Cleveland Vibrator Co. 342 COI Ceramics Inc 123 Corning Incorporated 141 Custom Processing Services 340 Deltech Inc 444 Diacut Inc 318 Diamond America Corp 431 DORST America 129 Du-Co Ceramics Company 311 Edward Orton Jr Ceramic Foundation 118 Eirich Machines Inc. 350 Elan Technology 324 Elkem Materials Inc. 345 ESL ElectroScience 642 Evans Analytical Group LLC 148 Exakt Technologies Inc 219 Ferro-Ceramic Grinding Inc 246 Fraunhofer-Institut für Keramische Technologien und Systeme IKTS 411 Friatec N.A LCC 420 FRITSCH USA Inc 319 Gasbarre Products Inc 325 GeoCorp Inc 618 Glass Mfg Industry Council 541 Goodfellow Corp 636 HarbisonWalker International 326 Harper International Corporation 117 Harrop Industries Inc 109 Hitachi High Technologies America Inc 638 Hysitron 244 Imerys North America Ceramics 104 Indo US MIM Tec Pvt Ltd 512 Industrial Minerals 418 Innovative Fabrication Inc 241 Innovnano - Advanced Materials SA 122 INTA Technologies 238 IPS Ceramics 614 IRD Glass 634 Keith Company 406 Kexing Special Ceramics., Ltd 147 Kläger Spritzguß GmbH & Co. KG 626 Lancaster Products 155 Lanly Company 334 Lithoz GmbH 622 M.E.SCHUPP Industriekeramik GmbH & Co. KG 347 Materion Ceramics 632 MemPro Materials Corporation 137 Metsch Refractories Inc 235 Micromeritics Instrument Corp 349 Microtrac Inc 530 MillenniTEK 510 MK Import/Export Inc 408 Momentive Performance Materials Inc 217 Morgan Advanced Materials 116 Mo-Sci Corp 229 Nabaltec AG 142 Nabertherm 446 Nanoe 100 Netzsch Instruments NA LLC 144 Ningbo Cathay Pacific Ceramics Co Ltd 511 Ningxia Haolida Industry& Trade Co Ltd 416 Noritake 110 Northern Illinois University 243 NSL Analytical 227 Nu-Star Inc 143 Nutec Bickley 543 Nyacol Nano Technologies Inc 438 Paul O. Abbe 106 Philips Ceramics Uden 423 Piezo Kinetics Inc 339 Powder Processing & Technology LLC 650 PremaTech Advanced Ceramics 441 PSC Inc 509 Qingdao Terio Corporation 407 Qingdao Western Coast Advanced Materials Co Ltd 317 Rath Inc 315 Robocasting Enterprises LLC 435 Saint Gobain NorPro 201 Saint Gobain ZirPro 136 Sauereisen 646 Sentro Tech 401 Setaram Inc 128 Shanghai Unite Technology Co. Ltd 307 Sigma Advanced Materials 442 Sinocera Technology USA Inc 301 SolidCAM Inc 111 Stahli USA Inc 529 Sumitomo Chemical & Inabata America 429 Suntech Advanced Ceramics (Shenzhen) Co Ltd 232 Superior Graphite 122 Superior Technical Ceramics Corp 513 Suzhou Jingdu Ceramics Technology Co Ltd 225 Swindell Dressler International 210 TA Instruments - Water Corporation LLC 620 TBS Abrasives 140 Team by Sacmi - Laeis GmbH 443 TevTech LLC 207 The American Ceramic Society (ACerS) 424 The City of Stoke-on-Trent 300 The Young Industries Inc 313 Thermaltek 228 Trans-Tech Inc 223 Treibacher Industrie AG 531 Tunable Materials Co Ltd 525 Union Process Inc 149 Verder Scientific Inc. 249 Verity Technical Consultants LLC 616 Vesta Si Europe Ab 126 Viridis3D LLC 517 Washington Mills Electro Minerals Corp 508 Yixing Zhong Run Ceramics Technology Co Ltd 507 Zhengzhou Zhenzhong Fused New Material Co Ltd 322 ZIRCAR Ceramics Inc 630 ZIRCAR Refractory Composites 131 Zircoa Inc Don\'t forget to put Ceramics Expo 2016 in your calendar - April 26-28, 2016 LO ACERS GOMD-DGG JOINT 2015 ANNUAL MEETING may 17-21 | Hilton Miami Downtown The American Ceramic Society www.ceramics.org Join the Glass & Optical Materials Division and the Deutsche Glastechnische Gesellschaft in Miami for the GOMD-DGG 2015 Joint Annual Meeting. The program covers physical properties and technological processes important to glasses, amorphous solids, and optical materials. Sessions headed by technical leaders from industry, labs, and academia will discuss the latest advances in glass science and technology as well as examine the amorphous state. Make your plans for GOMD-DGG 2015 today! Register now! Schedule Sunday, May 17, 2015 Welcome reception Monday, May 18, 2015 6-8 p.m. Stookey Lecture of Discovery 8-9 a.m. Hilton Miami Downtown Hotel 1601 Biscayne Boulevard Miami, FL 33132 Rates $164 Single/Double Reserve your room online at ceramics.org/gomd-dgg or by phone at 305-374-0000 by April 17, 2015 to secure the conference rate. Conference Sponsors JOURNAL OF NON-CRYSTALLINE SOLIDS Concurrent sessions Lunch provided GOMD general business meeting Poster session and student competition Tuesday, May 19, 2015 Morey Award Lecture Concurrent sessions Kreidl Award Lecture Lunch on own Conference banquet Wednesday, May 20, 2015 Varshneya Glass Science Lecture Concurrent sessions Lunch on own Thursday, May 21, 2015 Varshneya Glass Technology Lecture Concurrent sessions ceramics.org/gomd-dgg AMERICAN ELEMENTS DIAS Infrared Systems Applied Glass SCIENCE moosci CORPORATION 1804 A 9:20 a.m. 5:40 p.m. Noon 1:20 p.m. 5:45-6:30 p.m. 6:30-8:30 p.m. 8-9 a.m. 9:20 a.m. 5:40 p.m. Noon 1:20 p.m. Noon–1:20 p.m. 7-10 p.m. 8-9 a.m. 9:20 a.m. 5:40 p.m. Noon 1:20 p.m. 8-9 a.m. 9:20 a.m. Noon IRRADIANCE AdValue Technology GLASS OHIO UNIVERSITY 44 www.ceramics.org | American Ceramic Society Bulletin, Vol. 94, No. 3 Program chairs: Gang Chen Ohio University, USA cheng3@ohio.edu Steve W. Martin Iowa State University, USA swmartin@iastate.edu Reinhard Conradt RWTH Aachen University, Germany conradt@ghi.rwth-aachen.de Division chair Steven A. Feller Coe College, USA Chair-elect Randall Youngman Vice chair Edgar Zanotto Federal University of São Carlos, Brazil Secretary Corning Incorporated, USA Pierre Lucas Stookey Lecture of Discovery Monday, May 18, 2015 | 8-9 a.m. N. B. Singh, University of Maryland, Baltimore County, USA Title: Development of multifunctional chalcogenide and chalcopyrite crystals and glasses University of Arizona, USA George W. Morey Lecture Tuesday, May 19, 2015 | 8-9 a.m. *Short course: Nucleation, growth, and crystallization in glasses May 16 - 17, 2015 | 1 - 5 p.m.; 8 a.m. - Noon | Hilton Miami Downtown Instructor: Edgar Zanotto, Federal University of São Carlos, Brazil Glass and glass-ceramic researchers and manufacturers must avoid or control crystallization in glass. Zanotto—a leading expert in the field—will teach a short course on the intricate nucleation and growth processes that control crystallization in glasses and how they impact novel glass production and glass-ceramic innovations. Scheduled the weekend before the conference, the short course leads directly into the GOMD-DGG 2015 meeting. *Workshop: What\'s new in ancient glass research May 17, 2015 | 8:30 a.m. - 5:20 p.m. | Hyatt Regency Miami Organizers: Glenn Gates, The Walters Art Museum; Pamela Vandiver, University of Arizona Explore glass\'s past and present at this one-day workshop sponsored by ACerS Art, Archaeology and Conservation Science Division, in conjunction with the American Institute for Conservation. Attendees will learn about ancient glass compositions, conservation, technologies, and manufacturing techniques, including reconstructing knowledge of production events, reverse engineering ancient technologies, and the behavioral knowledge of production, consumption, and distribution that they encompass. *Separate registration fee required Jianrong Qiu, South China University of Technology, China Title: Control of the metastable state of glasses Norbert J. Kreidl Lecture Tuesday, May 19, 2015 | Noon - 1:20 p.m. Michael Guerette, Rensselaer Polytechnic Institute, USA Title: Structure of nonlinear elasticity of silica glass fiber under high strains Varshneya Frontiers of Glass Science Lecture Wednesday, May 20, 2015 | 8-9 a.m. Sabyasachi Sen, University of California, Davis, USA Title: Structural aspects of relaxational dynamics in glasses and supercooled liquids Varshneya Frontiers of Glass Technology Lecture Thursday, May 21, 2015 | 8-9 a.m. Steven B. Jung, Mo-Sci Corporation, USA Title: The present and future of glass in medicine Award Sponsors CORNING Coe College PPG SCHOTT American Ceramic Society Bulletin, Vol. 94, No. 3 | www.ceramics.org Media Sponsor: CERAMIC APPLICATIONS Official News Sources: bulletin Ceramic TechToday emerging ceramics & glass technology FROM THE AMERICAN CERAMIC SOCIETY 45 LO ACERS GOMD-DGG JOINT 2015 ANNUAL MEETING may 17-21 | Hilton Miami Downtown The American Ceramic Society www.ceramics.org Register now ceramics.org/gomd-dgg TECHNICAL PROGRAM PREVIEW Full schedule and program details at ceramics.org/gomd-dgg SYMPOSIUM S1: Energy and environmental aspects-Fundamentals and applications SESSIONS Session 1: Flat glasses, fibers, foams, and enamels Session 2: Active glassy materials Session 3: Thin film technologies S2: Glasses in healthcareFundamentals and applications DATES May 20 May 19 May 19 Session 1: Glasses in healthcare-fundamentals and applications May 18 - 19 S3: Fundamentals of the glassy state Session 1: Glass formation and structural relaxation Session 2: Nucleation, growth, and crystallization in glasses Session 3: Structural characterization of glasses Session 4: Computer simulations and modeling Session 5: Mechanical properties of glasses Session 6: Non-oxide and metallic glasses Session 7: Glass under extreme conditions S4: Optical and electronic materials and devicesFundamentals and applications S5: Glass technology and crosscutting topics 46 46 May 21 May 20 May 18-20 May 19-21 May 18-19 May 20-21 May 19-21 Session 1: Amorphous semiconductors: May 18 Materials and devices Session 2: Optical fibers May 19 - 20 Session 3: Optical materials for components and devices Session 4: Glass-ceramics and optical ceramics May 18-19 May 20-21 Session 1: Challenges in glass manufacturing Session 2: Transparent protective systems Session 3: Liquid synthesis and sol-gel-derived materials Session 4: Waste immobilization-Waste form development: Processing and performance May 18 May 21 May 20 May 19-21 www.ceramics.org | American Ceramic Society Bulletin, Vol. 94, No. 3 TH 6 abstracts due april 24! ADVANCES IN CEMENT-BASED MATERIALS July 20 - 22, 2015 Kansas State University, Manhattan, Kan., USA TECHNICAL PROGRAM - Cement chemistry and nano/ microstructure - Alternative cementitious materials - Rheology and advances in SCC - Smart materials and sensors - Advances in material characterization techniques – Durability and life cycle modeling - Advances in computational material science and chemo/mechanical modeling of cement-based materials Present your innovation or emerging research, hear cutting-edge advancements from thought leaders, and build collaborations with the cement-based materials community at Cements 2015. HOTEL INFORMATION Reserve your room at: Bluemont Hotel: $100/night, reserve by June 30, 2015 Holiday Inn at Campus: $99.95/night, reserve by June 20, 2015 The American Ceramic Society www.ceramics.org The American Exane Socity ORGANIZERS Kyle Riding program cochair Kansas State University Matthew D\'Ambrosia program cochair CTL Group Cements Division Leadership Chair: Jeff Chen, Lafarge Ceutre de Recherche Chair-elect: Tyler Ley, Oklahoma State University Secretary: Aleksandra Radlinska Trustee: Joe Biernacki, Tennessee Technological University ACBM Leadership Director Jason Weiss ceramics.org/cements2015 REGISTER NOW TO SAVE $150! 11th International Conference on Ceramic Materials and Components for Energy and Environmental Applications Ceramic technologies for sustainable development June 14-19, 2015 Hyatt Regency Vancouver, BC, Canada ceramics.org/11cmcee The 11th CMCEE identifies key challenges and opportunities for ceramic technologists to create sustainable development. A global event, 11th CMCEE promotes ceramic research for energy and environmental applications. Engage in discussions on a global scale and make lasting relationships during the networking events. Register now to take part! PLENARY SPEAKERS Dan Arvizu Director and chief executive, National Renewable Energy Laboratory; president, Alliance for Sustainable Energy LLC, USA Title: Maximizing the potential of renewable energy Arthur \"Chip\" Bottone President and CEO, FuelCell Energy Inc., USA; managing director, FuelCell Energy Solutions GmbH, Germany Title: High-temperature fuel cells delivering clean, affordable power today Sanjay M. Correa Vice president, CMC Program, GE Aviation, USA Title: CMC applications in turbine engines: Science at scale The American Ceramic Society www.ceramics.org CMCee \"Ceramic materials and technologies play a key role in solving major energy and environmental challenges facing the global community.\" SPONSORS Fraunhofer UBE UBE INDUSTRIES,LTD. A TR IKTS Wellech Furnaces Why the Pun A -Singh AdValue Technology 48 ORGANIZERS Richard Metzler Managing director, Rauschert GmbH, Germany Title: Energy-efficient manufacturing: What can be done in the technical ceramics industry and which technical ceramic products can help other industries AMERICAN ELEMENTS THE MATERIALS SCIENCE COMPANY® KFK Mrityunjay Singh Chair Ohio Aerospace Institute, USA Tatsuki Ohji Cochair AIST, Japan Alexander Michaelis Cochair Fraunhofer IKTS, Germany www.ceramics.org | American Ceramic Society Bulletin, Vol. 94, No. 3 SCHEDULE Sunday, June 14, 2015 Welcome reception Monday, June 15, 2015 Plenary session Concurrent sessions Lunch 5-7 p.m. 9:30 a.m. - Noon Noon - 1:30 p.m. 1:30 - 5 p.m. 8:30 a.m. - 5 p.m. Noon – 1:30 p.m. 5-7:30 p.m. Wednesday, June 17, 2015 Concurrent sessions Free afternoon and evening Thursday, June 18, 2015 Concurrent sessions Lunch on own Conference dinner Friday, June 19, 2015 Concurrent sessions 8:30 a.m. - Noon 8:30 a.m. – 5 p.m. Noon - 1:30 p.m. 7 – 9 p.m. 8:30 a.m. - Noon Tuesday, June 16, 2015 Concurrent sessions Lunch on own Poster session and reception TECHNICAL PROGRAM Plenary session: Technological innovations and sustainable Track 1: Ceramics for energy conversion, storage, and distribution systems High-temperature fuel cells and electrolysis Ceramics-related materials, devices, and processing for heat-toelectricity direct conversion aiming at green and sustainable human societies Photovoltaic materials, devices, and systems Materials science and technologies for advanced nuclear fission and fusion energy Functional nanomaterials for sustainable energy technologies Advanced multifunctional nanomaterials and systems for photovoltaic and photonic technologies Advanced batteries and supercapacitors for energy storage applications Materials for solar thermal energy conversion and storage High-temperature superconductors: Materials, technologies, and systems Track 2: Ceramics for energy conservation and efficiency Advanced ceramics and composites for gas-turbine engines Advanced ceramic coatings for power systems Energy-efficient advanced bearings and wear-resistant materials Materials for solid-state lighting Advanced refractory ceramic materials and technologies Advanced nitrides and related materials for energy applications Ceramics in conventional energy, oil, and gas exploration Track 3: Ceramics for environmental systems Photocatalysts for energy and environmental applications Advanced functional materials, devices, and systems for environmental conservation and pollution control Geopolymers, inorganic polymer ceramics, and sustainable composites development Porous and cellular ceramics for filter and membrane applications Advanced sensors for energy, environment, and health applications American Ceramic Society Bulletin, Vol. 94, No. 3 | www.ceramics.org Track 4: Crosscutting materials technologies Computational design and modeling Additive manufacturing technologies Novel, green, and strategic processing and manufacturing technologies Powder processing technology for advanced ceramics Advanced materials, technologies, and devices for electrooptical and biomedical applications Multifunctional coatings for energy and environmental applications Materials for extreme environments: Ultra-high-temperature ceramics (UHTC) and nanolaminated ternary carbides and nitrides (MAX phases) Ceramic integration technologies for energy and environmental applications Environment-friendly and energy-efficient manufacturing routes for production root technology Bioinspired and hybrid materials Materials diagnostics and structural health monitoring of ceramic components and systems Honorary Symposiums • Innovative processing and microstructural design of advanced ceramics-A symposium in honor of professor Dongliang Jiang • Materials processing science with lasers as energy sources-A symposium in honor of professor Juergen Heinrich HYATT REGENCY VANCOUVER 655 Burrard Street, Vancouver, BC, Canada V6C 2R7 | 604-683-1234 Single/Double: Triple: Quad: Student: CA$220 CA$255 CA$290 CA$165 If you need assistance with travel planning or have questions about the destination, contact Greg Phelps at gphelps@ceramics.org. new products Hot epoxy pump astcrete\'s D3522 attachment is the ket that can be powered by an existing hydraulic power source. 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Screens are available in meshes of 2 in.500 mesh (50 mm-25 µm) in No. 304 stainless steel, No. 316 corrosion-resistant stainless steel, magnetic 430 stainless steel, exotic alloys, and synthetics, including nylon, polyester, and polypropylene, all in single- or double-mesh designs. Kason Corp. (Millburn, N.J.) www.kason.com 973-467-8140 October 4 – 8, 2015 | Greater Columbus Convention Center | Columbus, Ohio USA | matscitech.org MS&T15 MATERIALS SCIENCE & TECHNOLOGY Technical Meeting and Exposition OVANCED CERA Reserve your booth by May 15. Save $100! Contact a representative to reserve your space! The American Ceramic Society www.ceramics.org Mona Thiel (614) 794-5834 mthiel@ceramics.org AIST ASSOCIATION FOR IRON & STEEL TECHNOLOGY Beth Kirschner (724) 814-3030 bkirschner@aist.org ASM INTERNATIONAL Kelly Thomas (440) 338-1733 Kelly.Thomas@asminternational.org TMS The Minerals, Metals & Materials Society Caron Gavrish (724) 814-3140 cgavrish@tms.org American Ceramic Society Bulletin, Vol. 94, No. 3 | www.ceramics.org Co-sponsored by: NACE INTERNATIONAL THE CORROSION SOCIETY 51 Oresources Calendar of events April 2015 12-17 UHTCIII: Ultra-HighTemperature Ceramics - Materials for Extreme Environment Applications III - Surfers Paradise, Gold Coast, Queensland, Australia; www.engconf.org 16 2015 Toledo Glass and Ceramic Award Dinner and Presentation - Toledo Club, Toledo, Ohio; www.ceramics.org 20-23 Int\'l Conference and Exhibition on Ceramic Interconnect and Ceramic Microsystems Technologies - Fraunhofer Institute Center, Dresden, Germany; http://www.ikts.fraunhofer.de/en/ Events/cicmt_2015.html 20-24 42nd Int\'l Conference on Metallurgical Coatings and Thin Films · San Diego, Calif.; www2.avs.org/conferences/icmctf 28-30 Ceramics Expo 2015 - I-X Center, Cleveland, Ohio; www. ceramicsexpousa.com May 2015 4-6 Clay 2015: Structural Clay Products Division Meeting in conjunction with National Brick Research Center Denver, Colo.; www.ceramics.org 11-14 Microstrucutral Characterization of Aerospace Materials and Coatings Long Beach Convention Center, Long Beach, Calif.; www.asminternational. org/web/ims-2015/home 17 ACerS Art, Archaeology, and Conservation Science Division Workshop, \"What\'s New in Ancient Glass Research\" - Hyatt Regency Miami, Miami, Fla.; www.ceramics.org/gomd-dgg 17-21 ACerS GOMD-DGG Joint Annual Meeting - Miami, Fla.; www. ceramics.org 23-26 ITSC 2015: Int\'l Thermal Spray Conference and Exposition - Long Beach Convention Center, Long Beach, Calif.; www.asminternational.org/web/ itsc-2015/home June 2015 14-19 CMCEE: 11th Int\'l Symposium on Ceramic Materials and Components for Energy and Environmental Applications - Hyatt Regency, Vancouver, British Columbia, Canada; www.ceramics.org 21-25 ECerS 2015: 14th Int\'l Conference of the European Ceramic Society - Toledo, Spain; www. ecers2015.org 30-July 3 5th European PEFC & H₂ Forum 2015 - Culture and Convention Centre, Lucerne, Switzerland; www. EFCF.com July 2015 7-10 ICCCI2015: 5th Int\'l HighQuality Advanced Materials Conference - Fujiyoshida City, Japan; http:// ceramics.ynu.ac.jp/iccci2015/index.html 20-22 Cements Division Annual Meeting - Kansas State University, Manhattan, Kan.; www.ceramics.org 26-31 SOFC-XIV: 14th Int\'l Symposium on Solid Oxide Fuel Cells - Glasgow, Scotland; www.electrochem.org/meetings/satellite/glasgow/ August 2015 23-26 COM 2015: 54th Annual Conference of Metallurgists - Toronto, Ontario, Canada; www.metsoc.org 30-September 4 PACRIM 11: 11th Pacific Rim Conference on Ceramic and Glass Technology - Jeju Island, Korea; www.ceramics.org September 2015 15-18 UNITECR 2015 - Hofburg Congress Center, Vienna, Austria; www.unitecr2015.org 20-23 Int\'l Commission on Glass Annual Meeting - Centara Grand at CentralWorld, Bangkok, Thailand; www.icglass.org 19-25 The XIV Int\'l Conference on the Physics of Non-Crystalline SolidsNiagara Falls, N.Y.; PNCS-XIV.com October 2015 4-8 MS&T15, combined with ACerS 117th Annual Meeting - Greater Columbus Convention Center, Columbus, Ohio; www.matscitech.org 20-23 CERAMITEC 2015 - Messe Munich, Munich, Germany; www. ceramitec.de November 2015 2-5 76th GPC: 76th Glass Problems Conference - Greater Columbus Convention Center, Columbus, Ohio; www.glassproblemsconference.org May 2016 18-22 WBC2016: 10th World Biomaterials Congress- Montreal, Canada; www.wbc2016.org ceramics expo April 28-30, 2015 Cleveland, Ohio The manufacturing tradeshow for advanced ceramic materials and technologies Dates in RED denote new entry in this issue. Entries in BLUE denote ACerS events. denotes meetings that ACerS cosponsors, endorses, or otherwise cooperates in organizing. 52 52 www.ceramics.org | American Ceramic Society Bulletin, Vol. 94, No. 3 classified advertising Career Opportunities QUALITY EXECUTIVE SEARCH, INC. Recruiting and Search Consultants Specializing in Ceramics JOE DRAPCHO 24549 Detroit Rd. Westlake, Ohio 44145 (440) 899-5070 Cell (440) 773-5937 www.qualityexec.com E-mail: qesinfo@qualityexec.com Business Services consulting/engineering services DELKIC & ASSOCIATES INTERNATIONAL CERAMIC CONSULTANTS • Worldwide Services • • Energy Saving Ceramic Coatings & Fiber Modules • FERIZ DELKIĆ Ceramic Engineer P.O. Box 1726, Ponte Vedra, FL 32004 Phone: (904) 285-0200 Fax: (904) 273-1616 custom finishing/machining Custom Machined Insulation Zircar Zirconia, Inc. 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West Penn Testing Group Zircar Zirconia Inc. www.pptechnology.com www.qualityexec.com www.rauschert.com www.sem-com.com www.sonicmill.com www.sgiglass.com www.westpenntesting.com www.zircarzirconia.com Advertising Sales Mona Thiel, National Sales Director mthiel@ceramics.org ph: 614-794-5834 fx: 614-891-8960 Europe Richard Rozelaar media@alaincharles.com ph: 44-(0)-20-7834-7676 fx: 44-(0)-20-7973-0076 Advertising Assistant Marianna Bracht mbracht@ceramics.org ph: 614-794-5826 fx: 614-794-5842 54 53 53 54 53 53 54 53 American Ceramic Society Bulletin, Vol. 94, No. 3 | www.ceramics.org 55 59 O deciphering the discipline Kara Luitjohan Guest columnist Engineering life lessons in emerging economies While looking for an interesting technical elective to round out my senior year of undergraduate studies at Purdue University, I stumbled upon a class titled \"Energy Policy and Nanotechnology in Emerging Economies.\" At the time, I never could have guessed how much of an impact the class would make throughout my graduate studies. The class collaborated with Engineering Projects in Community Service (EPICS), a Purdue program that partners undergraduate student teams with community service and education organizations to solve engineering-based problems. The class overall aimed to start an EPICS program in Colombia, with an initial project of bringing solarpowered electricity to two developing communities in Chocó, located in western Colombia. Students from various universities across Colombia—including Universidad de Antioquia, Universidad EAFIT, Universidad Technologica del Chocó, and Universidad Católica del Norte-along with students from Purdue University traveled to Medellín, Colombia, for a workshop to kick-start the collaboration. The trip offered me my first opportunity to travel outside of the United States and to work alongside students from vastly different backgrounds and cultures. Despite my excitement for the experience, I did not anticipate how many valuable lessons I would learn. Besides language barriers, a number of other issues surfaced when the team explored implementing new technologies in the community. A developing comKED UNIVERSIDAD EAFIT Purdue University students visiting Universidad EAFIT in Medellín, Colombia. munity provides a number of challenges, so the group had to hone its focus. If the project was too focused, the overall goal could be forgotten; if the project was too broad, the problem could become overwhelming. Developing the correct focus is a fine balancing act that had to be considered at all points throughout project design. The project also had to determine and align the objectives of each key player to be successful. To build a relationship with the local community, project leaders focused on building trust by getting the community directly engaged in the design process. Everyone had to keep an open mind to cultural and educational differences. As outsiders in the community, the team had to try to integrate into the community\'s culture, rather than vice versa. When it came time to educate the community about the new technology, both groups shared information—the team learned just as much from the community as the community learned from the team. These lessons align with what it takes to be successful in graduate school. When embarking on a graduate research project, the question at hand seems like a huge problem nested within a knowledge vacuum. Although the overall project is intimidating and overwhelming, it is best to start with baby steps-focusing on one small problem at a time. However, the overarching goal must stay in mind so that the small steps lead down the correct path. A good advisor-advisee relationship is an advantage, because knowing the objectives and expectations keeps the project moving smoothly and helps students reach graduation in a timely manner. My advice: If you ever get the chance to work with other cultures, abroad or at home, do it! When working with others, keep an open mind-you can learn just as much from them as they can learn from you, culturally and educationally. You never know how much you will learn or when those lessons will help you down the road. Kara Luitjohan is finishing her master\'s degree while beginning work on her doctoral degree in materials science and engineering at Purdue University. She is currently president of the graduate student association in the MSE department. Kara is passionate about exciting younger students about science and engineering and enjoys reading, cheering on the Packers, and ballet dancing. 56 www.ceramics.org | American Ceramic Society Bulletin, Vol. 94, No. 3 Where Business and Manufacturing Meet Strategy Save the date APRIL 25-26, 2016 | CLEVELAND, OHIO 5TH CERAMIC LEADERSHIP SUMMIT In conjunction with Ceramics Expo, April 26-28, 2016 • Panel discussions, moderated \"fireside\" chats, and talks •Industry leaders focused on business and technology in the glass and ceramic industries Connect, learn, and build new business opportunities ceramics.org The American Ceramic Society www.ceramics.org bismuth telluride lutetium granules metamaterials strontium doped lanthanum III-IV nitride materials organo-metallics regenerative medicine thin film dysprosium pellets atomic layer deposition nar H spersions aerospace ultra-light alloys electrochemistry solid crystal growth nanoribbons cerium polishing powder yttrium scandium-aluminum iridium crucibles van m He Li Be efrac green technology battery lithium gallium arsenide high tals surface functionalized nanoparticles ty sil B C N FL Ne tant Na Mg ite semiconductors palladium shot ΑΙ S Si P CI Ar term catho K Ca Sc Ti > Cr Mn Fe Co Ni Cu Zn Ga Ge As Se Br Kr anod nuck Rb Sr Y Zr Nb Mo Tc Ru Rh Pd Ag Cd In Sn Sb Te I Xe Con Cs Ba La Hf Ta W Re Os Ir Pt Au Hg Tl Pb Bi Po At Rn galli Fr Ra Ac Rf Db Sg Bh Hs Mt Ds Rg Cn Uut photovoltaics europium phosphors quantum dots iron iquia FI Uup Lv Uus Uuo neodymium foil ion dielectrics Ce Pr Nd Pm Sm Eu Gd Tb Dy Ho Er Tm Yb Lu ar energy spintronics Th Pa U Np Pu Am Cm Bk Cf Es Fm Md No Lr nano gels nanofabrics rare earth metals nickel foam LED lighting rod platinum ink laser crystals titanium robotic parts super alloys CIGS stable isotopes optoelectronic es tungsten carbide optoelectro carbon nanotubes gold nanoparticles Now Invent. 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