Bulletin_Vol-97_No_03_April_2018

AMERICAN CERAMIC SOCIETY bulletin emerging ceramics & glass technology APRIL 2018 Ceramics in the semiconductor-industry 0000 e.ceramics.orgrebricks offer energy solutions | Ceramic furnace coatings ceramics expo Downloaded from bulletin.antive.ceram Your Kiln... A CUSTOM FIT! New process, new product? Old kiln no longer fits? When you outgrow your current kiln, call Harrop. Like a fine suit, Harrop kilns are made-to-measure so that they fit your exact needs. Harrop kilns are built to last so that you will enjoy \"wearing” them for years to come. And like a fine tailor, Harrop can often alter your old kiln so that it fits your current needs. Harrop kilns are designed and built at our facility in Columbus, OH. We can install your kiln at your site and provide commissioning and operator training a true turnkey supplier. Contact Harrop when an \"off-therack\" kiln won\'t do. Downloaded from bulletin-archive.ceramics.org ELEECE www.harropusa.com 1.614.231.3621 HARROP Fire our imagination contents feature articles case e study cover story April 2018 • Vol. 97 No.3 32 Ceramics drive innovation and efficiencies in the semiconductor industry Ceramics serve a crucial role in enabling developments in the electronics industry through their essential role in the manufacturing, use, and application of advanced semiconductors. by Arne K. Knudsen Converting excess low-priced electricity into 40 high-temperature stored heat for industry and high-value electricity production Electricity price collapse from high wind and solar output can be limited by using low-price electricity to heat firebrick to high temperatures, store the heat in firebrick, and provide hot air as needed to industrial furnaces, kilns, power plants, and gas turbines. by Charles Forsberg, Daniel C. Stack, Daniel Curtis, Geoffrey Haratyk, and Nestor Andres Sepulveda 48 Ceramic furnace coatings can boost manufacturer\'s annual revenue by $480,000 High-temperature ceramic coatings for furnace-lining refractories can simultaneously reduce energy consumption, improve temperature uniformity, reduce furnace maintenance, and increase production. by Greg Odenthal departments News & Trends Spotlight... Ceramics in Energy Research Briefs Ceramics in Manufacturing. columns 568 18 21 30 Business and Market View... 8 Thermal management technologies for semiconductor microchips by Aneesh Kumar IMFORMED insights . . . ...... The changing sands of our time: How proppant demand has influenced ceramic mineral supply by Mike O\'Driscoll 16 Deciphering the Discipline... 64 Electrocaloric materials for heating and cooling technology by Rachel Sherbondy meetings 152 Ceramics Expo-Advancing the additive story From prototyping, small batch, and-increasingly under consideration-medium- to high-volume production, there is a keen collective eye on everything concerning ceramic additive manufacturing. GOMD 2018... Clay 2018 54 56 Cements 2018.. 57 resources New Products. Calendar Classified Advertising Display Ad Index... 61 63 8 9 6 61 60 59 Correction to the March 2018 ACers Bulletin \"Sharon Uwanyuze and Mark K. King Jr., both from the University of Alabama, won the first Student Industry Failure Trial (SIFT) competition at ICACC18,\" p. 15. The students are from the University of Alabama at Birmingham, not the University of Alabama, which is in Tuscaloosa. Downloaded from bulletin archive frame. 3 | www.ceramics.org 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, Managing Editor Faye Oney, Assistant Editor Tess Speakman, Graphic Designer Editorial Advisory Board Fei Chen, Wuhan University of Technology, China Thomas Fischer, University of Cologne, Germany Kang Lee, NASA Glenn Research Center Klaus-Markus Peters, Fireline Inc. Gurpreet Singh, Chair, Kansas State University Chunlei Wan, Tsinghua University, China 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 Eileen De Guire, Director of Communications & Marketing edeguire@ceramics.org Marcus Fish, Development Director Ceramic and Glass Industry Foundation mfish@ceramics.org Michael Johnson, Director of Finance and Operations mjohnson@ceramics.org Sue LaBute, Human Resources Manager & Exec. Assistant slabute@ceramics.org Mark Mecklenborg, Director of Membership, Meetings & Technical Publications mmecklenborg@ceramics.org Kevin Thompson, Director, Membership http://bit.ly/acerstwitter online www.ceramics.org April 2018 • Vol. 97 No.3 in g+ http://bit.ly/acerslink http://bit.ly/acersgplus http://bit.ly/acersfb http://bit.ly/acersrss Want more ceramics and glass news throughout the month? Subscribe to our e-newsletter, Ceramic Tech Today, and recieve the latest ceramics, glass, and Society news straight to your inbox every Tuesday, Wednesday, and Friday! Sign up at http://bit.ly/acersctt. eramic Bulletin BULLETIN BULLETIN archive bulletin Going Automotive Aghter, tougher bulletin ERAMIC Energy Hopesting CERAMIC BULLETIN Daniel Lease, Treasurer Charles Spahr, Secretary Board of Directors Manoj Choudhary, Director 2015-2018 Doreen Edwards, Director 2016-2019 explore the bulletin archive online! The American Ceramic Society Bulletin library—all 96 volumes, dating back to 1922—is now available online. With more than 1,100 fully searchable and downloable issue PDFs, the Bulletin Archive Online is a vast resource for all things ceramic and glass, from slip casting to sanitaryware to superconductors. archive Explore this vast resource today-access is free for ACerS members! kthompson@ceramics.org Officers Michael Alexander, President Sylvia Johnson, President-Elect William Lee, Past President Kevin Fox, Director 2017-2020 Dana Goski, Director 2016-2019 Martin Harmer, Director 2015-2018 Lynnette Madsen, Director 2016-2019 Sanjay Mathur, Director 2017-2020 Martha Mecartney, Director 2017-2020 www.ceramics.org/bulletinarchive Gregory Rohrer, Director 2015-2018 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. The American Ceramic Society is not responsible for the accuracy of information in the editorial, articles, and advertising sections of this publication. Readers should independently evaluate the accuracy of any statement in the editorial, articles, and advertising sections of this publication. American Ceramic Society Bulletin (ISSN No. 0002-7812). ©2018. Printed in the United States of America. ACerS Bulletin is published monthly, except for February, July, and November, as a \"dual-media\" magazine in print and electronic formats (www.ceramics.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. 97, No. 3, pp 1- 64. All feature articles are covered in Current Contents. Downloaded from bulletin-archive.ceramics.org www.ceramics.org | American Ceramic Society Bulletin, Vol. 97, No. 3 mo.sci A partner for your glass manufacturing needs Mo-Sci has partnered with clients across multiple industries to create custom glass solutions for their unique applications. Contact us to see how we can help with your next project. HEALTHCARE Specialty and bioactive glasses for bone and wound care applications; hemostatic devices INDUSTRIAL Precision glass microspheres; bond line spacers; sealing glasses and frit powders; silane coatings AUTOMOTIVE Ultra strong and light weight transparent glass/polymer composites for windows; precision bond line spacers ENERGY Engineered proppants for oil fracking; hydrogen storage via porous glass shells; nuclear waste vitrification DEFENSE Light sensor technology; non-toxic NVIS night vision technologies CUSTOM DEVELOPMENT PROCESS STEP 1 Bring us your custom glass requirements. Talk to us if you need a specialized glass that is custom taylored to your application. STEP 2 We find out what it will take to develop it. We will see if anything in our catalog fits your needs. If we don\'t have it, we can most likely make it. STEP 3 We provide you a proposal. We will propose a development plan for your custom glass. If you choose to move forward, we will see the product through from R&D all the way to final form manufacturing. Request a consultation at mo-sci.com/contact Downloaded from bulletin-archive.ceramics.org DRIVEN BY INNOVATION, POWERED BY COLLABORATION The National Center for Manufacturing Sciences (NCMS) is a manufacturing technology collaboration catalyst that creates professional relationships and business opportunities, drives cutting-edge research and development, and leverages industry for technical solutions. NCMS is currently seeking partners in: Advanced Materials • Smart Sensors Industrial Internet of Things (IoT) Robotics/Automation Modeling/Simulation END USERS DEVELOPERS INTEGRATORS INFRASTRUCTURE TALENT INVESTMENT NCMS COLLABORATION MODEL True collaboration happens at the intersection of innovation and technology transition We are an established non-profit dedicated to working with world-class organizations who want to innovate game-changing technologies with reduced risk and maximum efficiency. NCMS is unique as a national network and advocate for manufacturing with the primary goal of fostering innovation through collaboration and leveraging cross-industry expertise to create success. This helps bridge the \"valley-of-death” innovation gap and accelerate the pace of innovation and commercial integration. Downloaded from bulletin-archive.ceramics.org Пcms NATIONAL CENTER FOR MANUFACTURING SCIENCES COLLABORATION THAT WORKS www.ncms.org news & trends Materials science heats up athletic competition in Winter Olympics The 2018 Winter Olympics kicked up some snow and ice in PyeongChang, Republic of Korea, February 9-25. In addition to the incredible feats of human fitness and skill on display at the Olympics, however, there is a lot of research and development that happens behind the scenes to make the games the to-the-finish-line competition that they are. And there is plenty of materials science to thank for making the games so captivating. One example is how CeramTec\'s high-tech ceramics make ski jumping possible, regardless of weather. The company\'s unique ceramic material, called ALOSLIDE ICE, enables a ceramicbased inrun track system that allows ski jumpers to practice their gravity-defying soars, twists, and turns with no regard to the level of the thermometer outside. The track itself is dotted with strategically placed ceramic nubs that can be cooled, allowing track technicians to build up a 20 mm thick layer of ice for skiers to glide down. In warmer climates when it is not feasible to build up a layer of ice, the material itself acts as a standin, allowing skiers to glide down the track right on top of the ceramic nubs. CeramTec\'s innovative ceramic track is not a new debut this year, howeverthe same system was used at the 2006 and 2014 winter games. What is new for 2018 is what the athletes will be wearing-and there is plenty of interesting materials science and engineering that goes into Olympic fashions. Under Armour, for example, has devoted a considerable amount of research and development into this year\'s U.S. speed skating suit, designed to heighten the performance of already top-notch athletes. \"We\'re trying to get the body to be more aerodynamic than it is in its natural state,\" Clay Dean, chief innovation officer at Under Armour, says in a Wired article. Like several other Olympic events, 1968 speed is the key to these athlete\'s performance. Speed skaters can reach speeds of 30 mph as they race around the track, so reducing air resistance on their bodies CELEBRATING Control systems are certified by Intertek UL508A Compliant Downloaded from bulletin archieframis, 0.3 | www.ceramics.org 50 YEARS of service to the ceramic, glass, and petrology communities. 4 Deltech Furnaces We Build The Furnace To Fit Your Need™ Standard or Custom www.deltechfurnaces.com 5 news & trends CeramTec\'s ALOSLIDE ICE ceramic inrun ski track. is a legitimate strategy to shave time off the clock. The materials hugging athletes\' bodies can actually have a significant effect on how quickly they can skate across the finish line. For 2018, Under Armour has designed a speed skating suit composed of three different fabrics that are arranged to optimally reduce air resistance and drag. One of the fabrics is a slightly rough nylon spandex with an uneven surface, strategically placed in areas that have high wind resistance. Business news GrafTech International plans IPO (www. graftech.com)...Allied Mineral Products to own and supply select Graftech products (www.alliedmineral.com)... GT Refractory Solutions acquires assets of Graftech Advanced Graphite Materials (www.gtrefractories.com)...CeramTec delivers fast track to high gain transducers for medical ultrasonic applications (www. ceramtec.com)... Corning celebrates opening of fiber optic cable manufacturing facility (www.corning.com)... US Silica announces price increases on industrial and specialty products (www.ussilica. com)...Technical ceramics get injection of freedom as XJet AM solution debuts at ceramitec (www.xjet3d.com)...Input solicited for National Strategic Plan for Advanced Manufacturing (www.ncms. org)...HC Starck again receives certification for processing conflict-free tantalum raw materials (www.hcstarck.com)...National Science Board expects United States to lag in R&D investments by end of year Downloaded from bulletin-archive.ceramics.org The fabric reportedly works akin to the surface of a golf ball, where dimples on the surface disrupt air flow in an effort to reduce drag in the wake of the fastmoving object. But while this may sound like a simple job with a sewing machine, there is a fine line to make skaters as aerodymanic as possible. \"You can\'t add roughness willy nilly,\" Chris Yu, director of integrated technologies at the company that wind tunnel-tested the suit, says in the Wired article. “If you (www.nsf.gov)...DOE announces $35M for emerging research projects to address manufacturing challenges (www.energy. gov)...Kyocera and 7 other companies develop max 480-MW solar power project (https://global.kyocera.com)...Sacmi reports growing number of employees and new investment plans (www.sacmi. com)...North Glass completes world\'s largest flat glass furnace (www.northglass. global)...NIST partners with university effort for cutting-edge semiconductor technology (www.nist.gov)...AIG to open new glass fabrication location in Alabama (www.aiglass.com)... CASIS and Alpha Space announce materials science and technology research opportunity (www. iss-casis.org)...Staffordshire University secures £200,000 to support growth and innovation in ceramics sector (www.staffs. ac.uk)...DOE announces $3M for high performance computing collaborations for US manufacturers (www.energy.gov) Credit: CeramTec add too much you\'ll introduce more drag; add too little and you\'re not reenergizing the air quite enough.” And even clothes the Olympic athletes will wear when they are not competing are technologically advanced. According to another Wired article, the U.S. team\'s opening and closing ceremony uniforms are completed with outerwear equipped with a special heat conductive ink, which will help keep the athletes toasty in Korea\'s chilly weather. Designed by Ralph Lauren, the selfheating parka and jacket are printed with carbon and silver ink, fashioned into an American flag, on the inside. When a small onboard battery pack is flipped on―via smartphone control, of course-the ink heats up, warming up the wearer. US Department of Energy competition could drive energy research innovation It takes collaboration to bring new ideas to market. Many manufacturing companies have the luxury of an R&D department, but how do scientists and researchers without those resources move their ideas from concept to reality? There is some good news for U.S.based researchers focused on sustainable energy solutions. The U.S. Department of Energy recently announced a competition worth nearly $1 million for American scientists and engineers who are exploring new energy technologies. American Inventions Made Onshore (AIM Onshore) is a DOE project designed to bring together “American innovators who develop new energy technologies and domestic manufacturers who produce them,\" according to a DOE news release. The DOE will give $150,000 each to four different organizations to train engineers, scientists, and other innovators how to connect with domestic manufacturers to get their technology to market. Winners will be determined based on their experience in the number of contracts and revenue they have www.ceramics.org | American Ceramic Society Bulletin, Vol. 97, No. 3 previously generated between innovators and U.S. manufacturers. The four winning companies will conduct training through the DOE\'s Build 4Scale program. The training program, created by Lawrence Livermore National Laboratory and several organizations, is designed to help energy technology researchers navigate the process of getting their designs ready for manufacturers. \"Onshore manufacturing of American energy technologies plays an important role in promoting U.S. economic growth and competitiveness,\" U.S. Secretary of Energy Rick Perry states in the release. \"The AIM Onshore prize competition and Build4Scale training will not only help to advance energy innovation, but will also help ensure that energy technologies invented in the U.S. are manufactured in the U.S.\" The U.S. Department of Energy recently announced a competition worth nearly $1 million for American scientists and engineers to develop new energy technologies. After a year, the DOE will award $250,000 and $100,00 first and second prizes, respectively, to the top two highest performing organizations that are able to show a \"sustainable revenue stream.\" HEXOLOYⓇ SiC BEAMS Strength Under Fire Saint-Gobain leads with 30+ years\' experience in SiC beams for high-temperature kiln-firing applications. www.Hexoloy.com Downloaded from bulletin archiefs. 3 | www.ceramics.org SAINT-GOBAIN 7 Corps of Engineers; Flickr CC BY 2.0 business and market view A regular column featuring excerpts from BCC Research reports on industry sectors involving the ceramic and glass industry. bcc Research Thermal management technologies for semiconductor microchips By Aneesh Kumar Th of hermal management includes an array materials and technologies that manufacturers apply to regulate the heat generated in electronic systems. Thermal management in microchip technologies is an important part of the electronics industry\'s drive to develop high-performing applications. As a result of the widespread introduction of microelectronics, coupled with the increasing demands due to their functionality and reliability, thermal management has become an important issue in almost every branch of industry. Major end users of thermal management products are companies in the computer, telecommunications, automotive, consumer products, medical equipment/instrumentation, industrial equipment, light-emitting diode, and renewable energy industries. Thermal management materials include metals and metal alloys, ceramics, carbonaceous materials, and composite materials. Ceramics used in thermal management include alumina (Al2O3), aluminum nitride (AIN), aluminum silicon carbide (AlSiC), silicon carbide (SiC), beryllia (BeO), gallium arsenide (GAs), gallium nitride (GaN), cubic boron arsenide (c-BAs), boron nitride (BN), and hexagonal boron nitride (h-BN). Thermal management products can be classified into four parts: hardware, interface, substrate, and software. These product segments differ significantly Downloaded from bulletin-archive.ceramics.org Table 1. Global market for thermal management in microchips by product type, through 2022 ($ millions) Product type 2016 2017 2022 CAGR% 2017-2022 6.0 Hardware 4,478.7 4,676.1 6,264.2 Interface 1,303.3 1,367.8 1,840.6 6.1 Substrate 357.8 373.6 482.3 5.2 Software Total 248.9 253.4 348.5 6.6 6,388.7 6,670.9 8,935.6 6.0 in terms of revenue size and projected growth rates (Table 1). Hardware is the largest segment for thermal management products, owning 70.1% of the market in 2016. The global market for hardware is projected to grow from about $4.5 billion in 2016 to $6.3 billion by 2022-representing a compound annual growth rate (CAGR) of 6.0% from 2017 to 2022-due to increased production of small-sized microprocessor chips. Interface materials in thermal management are expected to have a CAGR of 6.1% during the same period, growing from about $1.3 billion in 2016 to nearly $1.8 billion in 2022. Growth in this segment is driven by the increasing application of interfaces in automated assembly. These interface materials are also regarded as important heat-dissipation solutions for portable and compact electronic devices. The market for substrates in thermal management of microchips is expected to grow from $357.8 million in 2016 to nearly $482.3 million in 2022. The market for software is expected to grow from $248.9 million in 2016 to $348.5 million in 2022. Major categories of hardware for thermal management consist of fans and blowers, heat sinks, heat pipes, fan sinks, cold plates, and others. Fans and blowers, heat sinks, and heat pipes accounted for 32.4%, 31.5%, and 22.2% of the hardware market, respectively, in 2016 (Table 2). Fans and blowers are expected to continue to lead the global market through 2022, reaching a value of $2.1 billion. Heat sinks are projected to closely follow. Although the market for heat pipes is projected to reach only $1.4 billion by 2022, the heat pipe segment is projected to experience the highest growth rate at a CAGR of 7.2% during 2017-2022. About the author Aneesh Kumar is a project analyst for BCC Research. Contact Kumar at analysts@bccresearch.com. Resource A. Kumar, \"Thermal Management Technologies for Semiconductor Microchips,\" BCC Research Report SMC106A, August 2017. www.bccresearch.com. Table 2. Global market for hardware for thermal management in microchips by product type, through 2022 ($ millions) Product type 2016 2017 2022 Fans and blowers Heat sinks 1,451.1 1,534.1 2,092.3 CAGR% 2017-2022 6.4 1,410.7 1,482.8 2,048.4 6.7 Heat pipes Fan sinks 994.3 1,019.7 1,440.9 7.2 331.5 340.1 357.0 1.0 Cold plates Other Total 98.4 102.9 118.9 192.7 196.5 206.7 6,388.7 6,670.9 8,935.6 2.9 1.0 6.0 www.ceramics.org | American Ceramic Society Bulletin, Vol. 97, No. 3 acers spotlight Member spotlight Corporate Partner profile: Mary Stevenson ACers Corporate Partner suggests taking advantage of member benefits If you have ever attended Ceramics Expo or MS&T, you may have met Mary Stevenson, the friendly face at the Deltech Furnaces booth. Stevenson is president of Deltech Furnaces, a company that make standard and custom electric furnaces for the materials science industry. And its motto, \"We build the furnace to fit your need,\" suggests the company does not take a cookie-cutter approach to any furnace it builds for clients. Stevenson\'s late husband Calvin started the company with a partner in 1968. They both had a background in mining engineering and experience in metallurgical research. \"We were approached by another company to build a furnace,\" Stevenson recalls of the company\'s first client. That company turned out to be Coors Porcelain Company, now known as CoorsTek. Over the years, Deltech Furnaces has earned a reputation for designing and building custom electric furnaces based on client needs. Its global customer base consists of corporate and government research labs, universities, and manufacturing plants. Stevenson began working with her husband in the business when she was in graduate school. \"I learned furnaces on my feet!\" she recalls. Deltech has been an ACerS Corporate Member for more than 10 years and transitioned to Corporate Partner when that program became available a couple years ago. \"[Joining] was a good opportunity,\" Stevenson explains. Made In Montana Sold to the World AMERICAN E CORPORATION Give Ceramists Something to Think About CUPRIC OXIDE . Blue and Red Glazes and Glass • ⚫ Ferrites CUPROUS OXIDE • Blue Glass and Glaze COPPER GRANULES Iron Spot Brick ZINC OXIDES • Brick Colorants and Ferrites • For Ferrite, Brick, Fibre Glass Credit: Mary Stevenson Copper and Zinc Oxides for Ferrites Copper, Brass, Bronze and Tin Powders Plants in Montana and Tennessee ⚫ Stock Available Worldwide O AMERICAN CHEMET CORPORATION 740 Waukegan Road, Suite 202 Deerfield, Illinois 60015 USA +1 847 948 0800 www.chemet.com Sales@chemet.com Mary Stevenson stands next to one of her company\'s furnaces. Downloaded from bulletin archief.3 | www.ceramics.org 9 acers spotlight Member spotlight (continued) Stevenson and her team at Deltech Furnaces. \"It seemed to be a good way to support the Society, of which many of our customers are members.\" Stevenson also enjoys the benefits of membership. \"We like the discounted rates on the expos, and the exposure is even better now because of the Corporate Partnership program,” she adds. \"It\'s perfect for building awareness and letting customers know that you support the Society.\" Society and Division news Consider the benefits of an ACers Lifetime Membership Designed for those dedicated to a career in the ceramic and glass profession, an Acers Lifetime Membership allows members to avoid future dues increases, maintain awards eligibility, and eliminate the need to renew every year. \"My affiliation with ACerS goes back to 1990,\" recalls one lifetime member. \"Since then I have enjoyed excellent networking, peer support, several honors, and scholarly collaborations through the decades. Lifetime membership is my lifelong commitment to ACerS and the science and engineering of ceramics and glasses.\" Join the growing list of lifetime members while securing ACerS member benefits for life. Cost is a one-time payment of $2,000. To learn more about Lifetime Membership, contact membership director Kevin Thompson at (614) 794-5894 or kthompson@ceramics.org. Downloaded from bulletin-archive.ceramics.org Stevenson is a member of the Manufacturing Division and attends Ceramics Expo and MS&T every year. She has enjoyed connecting with others in her industry. \"You develop relationships networking with other people,\" she says. \"You can see what you have in common with other businesses and share headaches and challenges.\" She also enjoys the numerous sales opportunities by talking to visitors at her booth. ACerS elects Mazurin as Honorary Member Mazurin ACerS Board of Directors unanimously approved naming Oleg Mazurin an Honorary Member of the Society at its January meeting in Daytona Beach, Fla. Mazurin, a glass scientist from Russia, made significant contributions to the glass science community during his career. He authored and coauthored several hundred technical journal articles, 15 books, and created the SciGlass database used by glass scientists worldwide. Mazurin lectured at several U.S. institutions and was an invited speaker at several ACerS meetings. Arun Varshyeya, 2014 Distinguished Life Member, nominated Mazurin for the honor. Credit: Mary Stevenson The biggest benefit she sees is being able to see all her customers in one place. \"As a small company, it\'s a way to visit with our customers and thank them for their business.\" She also likes the opportunity to take short courses. \"I thought it was a nice addition,\" she adds. Stevenson also believes in giving back, as she is a board member of the Ceramic and Glass Industry Foundation. What advice would she give to others who are considering becoming an ACerS Corporate Partner? \"Take advantage of the tangible benefits the partnership offers-like saving money on exhibiting,\" she says. \"And join a Division! They bring new energy into the Society. \"Don\'t just pay your dues and do nothing,\" Stevenson advises. \"Take advantage of your membership!\" Find corporate partners easier at Ceramics Expo with Corporate Partner Resource Guide With more than 300 exhibitors it can be difficult to know where to begin when looking for a specific product or service at Ceramics Expo. Stop by the ACerS booth to pick up your free Corporate Partner Resource Guide. Designed to help expo attendees locate specific products and services, the guide will help direct you to ACerS Corporate Partners exhibiting at Ceramics Expo. \"Quite often, people stop by the ACerS booth looking for a specific product,\" membership director Kevin Thompson explains. \"We want to help them find what they are looking for while helping our Corporate Partners by steering prospective buyers to their booths.\" To learn more about ACerS Corporate Partnership benefits, contact Kevin Thompson at (614) 794-5894 or kthompson@ceramics.org. www.ceramics.org | American Ceramic Society Bulletin, Vol. 97, No. 3 DCM Tech Rotary Surface Grinders IG 380 SD Rotary Surface Grinder DCM Tech is a direct-to-consumer manufacturer of Rotary Surface Grinders built to meet our customer\'s requirements. Est. 1975 Winona, MN EIG 380 SDE DCM IN THE SA E USA THE Ceramics Expo Booth #359 800-533-5339 | www.dcm-tech.com It\'s A Matter Of Choice EL CM Furnaces, long recognized as an industrial leader in performance-proven, high temperature fully continuous sintering furnaces for MIM, CIM and traditional press and sinter now OFFERS YOU A CHOICE, for maximum productivity and elimination of costly down time. Choose one of our exclusive BATCH hydrogen atmosphere Rapid Temp furnaces. Designed for both debinding and sintering, these new furnaces assure economical, simple and efficient operation. OR... choose our continuous high temperature sintering furnaces with complete automation and low hydrogen consumption. CONTACT US for more information on our full line of furnaces with your choice of size, automation, atmosphere capabilities and temperature ranges up to 3100°F/1700°C. E-Mail: info@cmfurnaces.com Web Site: http://www.cmfurnaces.com Downloaded from bulletin archive frame. 3 | www.ceramics.org CM FURNACES INC. 103 Dewey Street Bloomfield, NJ 07003-4237 Tel: 973-338-6500 Fax: 973-338-1625 11 acers spotlight Society and Division news (continued) Names in the news Wong-Ng Wong-Ng elected Fellow of AAAS Winnie Wong-Ng of the National Institute of Standards and Technology was honored as a fellow of the American Association for the Advancement of Science for her pioneering efforts and distinguished contributions in areas of crystal chemistry, phase equilibria, and crystallographic research of functional materials. ACerS members named Academicians of the World Academy of Ceramics Congratulations to the following ACerS members who have been named Academicians in the Science class of the World Academy of Ceramics (WCA). The WCA honors individuals who have made significant contributions to the advancement of ceramics culture, science, and technology. • Christos Aneziris, Germany • William G. Fahrenholtz, USA • • Zhengyi Fu, China Kazumi Kato, Japan • Do Kyung Kim, Korea • Young-Wook Kim, Korea • Alexandra Navrotsky, USA • Ivar Reimanis, USA • • Federico Rosei, Canada Sudipta Seal, USA • Eric D. Wachsman, USA • Jingyang Wang, China Winnie Wong-Ng, USA ACerS members elected to National Academy of Engineering The National Academy of Engineering elected ACerS members Amit Goyal and Raymond Gorte as members. Goyal is an ACerS Fellow and direcGoyal Gorte tor of the University at Buffalo\'s RENEW Institute (Buffalo, N.Y.). Gorte is Russell Pearce and Elizabeth Crimian Heuer Professor of Chemical and Biomolecular Engineering and Materials Science and Engineering at University of Pennsylvania (Philadelphia, Pa.) The Academy recognizes individuals who have made significant contributions to engineering research, practice, or education, such as pioneering new and developing fields of technology, making major advancements in traditional fields of engineering, or developing/implementing innovative approaches to engineering education. HWI adds three employees to leadership team Ch Harbison Walker International (HWI) appointed Tom Richter to senior director, strategic business technology. He will lead HWI\'s Business Technology Council that will champion new business technology platforms for the company. HWI also hired Ross Wilkin, chief financial officer and corporate treasurer, and Michael Werner, senior vice president, commercial and corporate officer. In memoriam Conrad Naber David Sheets Some detailed obituaries can also be found on the ACers website, www.ceramics.org/in-memoriam. Awards and deadlines Nominations due July 1 for ECD Mueller, Bridge Building, and Global Young Investigator awards The Engineering Ceramics Division invites nominations for the 2019 James I. Mueller, Bridge Building, and Global Young Investigator awards. Deadline for nominations for all three awards is July 1, 2018. The Mueller Award is named for James I. Mueller, who made significant contributions to the Engineering Ceramics Division and the field of engineering ceramics-and recognizes accomplishments of individuals who have made similar contributions. Nominees must have given long-term service to the ECD or work in an area of engineering ceramics that has resulted in significant industrial, national, or academic impact. The award consists of a memorial plaque, certificate, and $1,000 honorarium. Contact Jingyang Wang at jywang@ imr.ac.cn with questions. The Bridge Building Award recognizes individuals outside of the U.S. who have made outstanding contributions to engineering ceramics. The award consists of a glass piece, certificate, and $1,000 honorarium. Email Manabu Fukushima at manabu-fukushima@aist.go.jp with questions. The Global Young Investigator Award recognizes an outstanding scientist conducting research in academia, industry or at a government-funded laboratory. Nominees must be ACerS members 35 years of age or younger. The award consists of $1,000, a glass piece, and certificate. Contact Surojit Gupta at gsurojit1@gmail.com with questions. Downloaded from bulletin-archive.ceramics.org www.ceramics.org | American Ceramic Society Bulletin, Vol. 97, No. 3 MATERIALS (2) α-4πT SME Q&AA IN CH3 CH3 CH3 4 7000 SELECTION XAUKU FAILURE ANALYSIS CH₂ INNOVATION QUALITY ASSURANCE With over 100 years\' experience in ceramics and with pilot and manufacturing scale capabilities, our experts work with you to optimize your current advanced ceramics products and develop those of the future. From materials selection and characterization, quality assurance, and product and process optimization to failure analysis and disruptive technologies, we are the partner you can trust. we\'ll give you the knowledge (Z )》Q= #Ts༥/ Q&A QAA P! CH3 CH3 CH3 H3 HC oog CH3 MATERIALS CHARACTERIZATION PROCESS OPTIMIZATION TECHNOLOGY PARTNERSHIPS MATERIALS DEVELOPMENT Inn MATERIALS TECHNOLOGIES FLASH SINTERING Find out more at www.lucideon.com/ceramics LUCIDEON Materials Development and Commercialization EAS Specialty GLASS Inc. solving the science of glass since 1977 TM Leading Manufacturer of Glass Materials with Innovative Production Techniques • Standard, Custom, Proprietary Glass and GlassCeramic Compostions Melted Available in Frit, Powder (wet/dry milling), Rod or Will Develop a Process to Custom Form • Research & Development • Electric & Glass Melting up to 1650°C • Fused Silica Crucibles and Refractory Lined Tanks • Pounds to Tons www.sgiglass.com TOLL FREE: 1-800-332-5779 Downloaded from bulletin archive frame. 3 | www.ceramics.org 13 acers spotlight Awards and deadlines (continued) Nominations close May 15 for three awards Glass & Optical Materials: Alfred R. Cooper Scholars Award Recognizes undergraduate students who have demonstrated excellence in research, engineering, or study in glass science or technology. Electronics: Edward C. Henry Award Recognizes an outstanding paper reporting original work in the Journal of the American Ceramic Society or ACerS Bulletin during the previous calendar year on a subject related to electronic ceramics. Electronics: Lewis C. Hoffman Scholarship Recognizes academic interest and excellence among undergraduate students in the area of ceramics/materials science and engineering. Visit www.ceramics.org/awards for award criteria and nomination forms. Contact Erica Zimmerman at ezimmerman@ ceramics.org with any questions. CERAMICANDGLASSINDUSTRY FOUNDATION Student travel assistance for summer school in Belgium In conjunction with its 16th Electroceramics Conference and Exhibition, the European Ceramic Society (ECerS) is hosting its summer school, “Process and Properties of Electroceramics for Energy Applications,\" July 6–7, 2018, in Hasselt, Belgium. The CGIF is offering up to $1,000 in travel support to selected undergraduate and graduate students from non-European-based universities. To be eligible, applicants must be members of ACerS, Material Advantage, Keramos, or ACerS Global Graduate Researcher Network. Applicants should secure initial support from their home institutions and submit the following for consideration: - A completed application; - A brief letter of recommendation from a faculty member; and - A single-page letter of interest explaining relevance to their field of study and career ambitions, along with other sources and amount of financial support. Email all documents to Belinda Raines at braines@ceramics.org by March 30. Visit http://bit.ly/ECerSSummerSchool2018 for more information. Summer school attendees can also attend ECerS Electroceramics XVI Conference July 9-13. Visit www.electroceramicsxvi.org for details. Downloaded from bulletin-archive.ceramics.org Students and outreach Grads and undergrads-Further your career by joining the PSCA! The President\'s Council of Student Advisors (PCSA) seeks dedicated and motivated undergraduate and graduate students to help propel ACerS into the future while developing leadership skills. This student-led committee is composed of ceramicand glass-focused students. Visit ceramics.org/applypcsa to learn more. Application deadline for the 2018-19 class is April 15, 2018. ACerS GGRN helps grad students expand their professional networks Are you a current graduate student who could benefit from additional networking within the ceramic and glass community? Put yourself on the path toward post-graduate success with ACerS Global Graduate Researcher Network (GGRN)! GGRN addresses professional and career development needs of graduate-level research students who have a primary interest in ceramics and glass. ACerS GGRN helps graduate students: • Engage with other ACerS members; Build a network of contacts within the ceramic and glass community; and • Access professional development tools Visit www.ceramics.org/ggrn to learn more or contact member engagement manager Yolanda Natividad at ynatividad@ ceramics.org. Earn $250 for educating the public on ceramic science! Show off your demonstration skills and earn recognition in ACers Next Top Demo Competition, organized by ACerS PCSA. This virtual competition is a way for you to educate the public while advertising the community outreach you and your peers already perform. Get your fellow students together and submit a video conducting a ceramic and/or glass outreach demonstration. Visit www.ceramics.org/pcsademo to submit your videos. Deadline is April 28, 2017. www.ceramics.org/ceramictechtoday www.ceramics.org | American Ceramic Society Bulletin, Vol. 97, No. 3 Innovation at its Finest. We are in the solutions business. McDanel Advanced Ceramic Technologies enables you to meet the most stringent requirements of your industry, from selecting the optimum material and design for your application to comprehensive product development. Demand McDanel. See us at the 2018 CeramicsExpo Booth • #522 McDanel Advanced Ceramic Technologies mcdanelceramics.com OptiSonic TM Series World-Class Ultrasonic Machining Centers • • 500, 800, 1100, or 1200 mm of X travel OPTIPRO Trusted Technology. (larger custom machines available upon request) 3, 4, or 5 axis of motion (X, Y & Z standard, B & C optional) • Advanced IntelliSonic™ technology maintains peak ultrasonic machining performance Ideal for challenging applications in advanced hard ceramics and optical glasses: 0.27 in HEX 0.25 in base 0.09 in top 0.06 in wall thickness 2XR0.375 in 00.25 in SEE LIVE DEMOS OF THE OPTISONIC 550X AND MEET OUR TEAM AT ceramics expo BOOTH #400 K2 in -3 in0.27 in Material: 99.5 Alumina Oxide 0.25 in Learn more: www.optipro.com | 585-265-0160 | sales@optipro.com Downloaded from bulletin archivefer. 3 | www.ceramics.org 15 O IMFORMED insights A snapshot of ceramic and glass raw material markets and trends from a non-metallic minerals industry expert. Mike O\'Driscoll Guest columnist The changing sands of our time How proppant demand has influenced ceramic mineral supply Since the mid-2000s, three of the most important ceramic raw materials-silica, kaolin, and bauxite-have been in high demand as proppants from the North American oil and gas drilling industry as it develops unconventional resources, particularly shale gas and shale oil. After a recent dip in demand, we are now witnessing another Mother of a Sandstorm of proppant demand. This time it\'s slightly different in that silica is totally dominant, but there is the same question of whether there will be enough material for its other markets, including ceramic, glass, and foundry applications. And what about the future of ceramic proppants? Fracking takes off In simple terms, the extraction process of hydraulic fracturing (fracking) requires vast amounts of water entrained with additives, including spherical grains of ceramic material, to be pumped under high pressure into shale formations to recover oil and gas finely disseminated in the rock\'s pores. Drilling opens up fissures and fractures perpendicular to the main well bore, where the spherical grains function to \"prop\" open the fractures to maintain oil or gas flow (conductivity) into the main well bore for pumping to the surface. Although this treatment for well stimulation has been around since 1949, it was only perfected in the late 1980s. Combined with advances in horizontal drilling techniques and a drive for cheaper gas from flat-lying shale gas formations, fracking really came to the fore in the early- to mid-2000s. At the same time, proppant science evolved to meet demands for high crush resistance under pressure and, above all, induce high conductivity in application. Downloaded from bulletin-archive.ceramics.org Seemingly almost overnight, humble silica sand became in high demand as American and Canadian exploration and production (E&P) companies started fracking in earnest. To gain some perspective, according to U.S. Geological Survey data, just 8% (2.3 million tons) of silica sand produced in the U.S. in 2005 was used as frac sand. In 2017, this share rose to 63%, or 66 million tons! But silica sand is not the only proppant in town-deeper and higher-temperature wells require higher-strength grades that can only be manufactured mostly from sintering bauxite or kaolin, or blends of each. More recently, ultrahigh-strength grades have been introduced based on high alumina materials. Resin coating of silica sand introduced a third option in proppant selection by enhancing silica sand performance. However, silica sand still falls short in performance but is 4-6-times more expensive than ceramic proppant grades. The upshot was an explosion of U.S. frac sand mine developments (then, mainly in the so-called Northern white sands of Wisconsin, Missouri, and Illinois), diversion of existing silica sand production to frac sand, and a lesser degree but nonetheless significant investment in more sophisticated ceramic proppant plants. Chinese refractory and abrasive bauxite producers in particular lost no time in diversifying to supply the U.S. proppant market. They enjoyed high-volume penetration until around 2012, when U.S. plants started to catch up and the market was on the wane, albeit with a slight recovery in 2014. The prevailing proppant share split hovered around 70%-80% frac sand for many years, with a mix of resin-coated and ceramic proppants accounting for the remaining shares. Shifting sands From 2014, overall proppant demand started to slacken and was compounded by falling oil prices in 2015. The same time saw the beginnings of a trend that has since become a stampede-to frac ture using huge volumes of cheap silica sand, which has steadily eroded ceramic proppant\'s share of the market. During 2015, this practice caught hold to the extent that most ceramic proppant producers either closed or mothballed most of their plants-including Carbo Ceramics, Saint-Gobain, and, unfortunate latecomers to the proppant party, Imerys-affecting ~80% of U.S. capacity. There has been little if any recovery of late, as silica sand remains king. From mid-2017, proppant demand for silica sand started to pick up markedly and is now hitting stellar heights, with U.S. market demand for 2018 expected to increase by 45% to 100-110 million tons. This is a conservative estimate apparently-according to one consultant, the market \"has yet to peak.\" The proppant share split is now ~94% silica sand and 5% resin-coated, with ceramic capturing the remainder. Recently announced 2017 results indicate that Hi-Crush Partners LP sold 8.9 million tons of frac sand, more than double 2016 volumes, while U.S. Silica sold a record 3.2 million tons in Q4 2017, an increase of 52% over Q4 2016. Recovering oil prices into the $60/ barrel range has helped, but the main driver has been E&Ps drilling longer lateral lengths and the rising intensity of proppant loading levels per frac stage. For example, the Delaware basin uses 1 ton of proppant per lateral foot, up 32% from 2016 levels; Bakken uses 70 tons per stage; Permian Basin wells consume 5,000 tons per well; and reports from elsewhere indicate 6,000-7,000 tons per well. www.ceramics.org | American Ceramic Society Bulletin, Vol. 97, No. 3 IMFORMED insights (continued) A second key trend is the shift to using mostly finer 100-mesh, in addition to 40/70-mesh sizes. This raises an interesting issue of how this may affect the balance of industrial sand supply. While frac sand-only producers have tunnel vision, all-round producers (such as U.S. Silica and Unimin) need to maintain supply to industrial or speciality markets in glass and ceramics. Industrial sands can be \"converted\" to frac sand, but the reverse is not always true. The continued push for finer frac sands could impact certain industrial markets, such as fiber glass. That said, what is often specified as 100-mesh for one proppant customer does not always match that of another. Currently there is much mixing of grades-but it still works! Glass industry applications use 40/70-mesh and 100-mesh as well. But with spot prices exceeding $60/ton for frac sand (and expected to reach $75/ ton in the Permian this year; Northern white sand is already >$100/ton), which requires minimal processing and quality control-compared to <$30/ton for glass sand grade, which requires strict chemical and physical specifications and treatments-it\'s little wonder that producers, especially those that are publicly traded, are leaning toward proppant markets. Sure, 2-3-year frac contract prices are lower at around $30-$40/ton, but they remain lucrative deals-U.S. Silica recently announced it had more than 30 long-term contracts and is aiming for 70%-80% contracted output. The third main trend making waves is the rush to develop in-basin sand sources in the Permian, using cheaper and what was initially considered inferior browncolored sand in Texas. Of course, with increased Permian fracturing activity combined with the high logistical cost of moving sandwhich can account for up to 70% of delivered price-southern brown sand is suddenly in vogue, and end-users are desperate for it because supply is currently tight. Hence the latest sandstorm in the Permian is a raft of companies bringing on new mines and plants. For example, U.S. Silica alone is adding 6.6 million tons of new capacity there. The good news is that increased availability of Permian sand towards the yearend-with estimates indicating 25-30 million tons per annum in total-will ease the tight supply situation for other industrial and speciality consumers of Northern sands. About the author Mike O\'Driscoll is director of IMFORMED and has over 30 years of experience in the industrial minerals business. IMFORMED has conferences this year covering mineral recycling, magnesia, fluorspar, and China\'s abrasives and refractory minerals-see www.imformed. com for more information. Contact O\'Driscoll at mike@imformed.com. Innovative Batching Systems Custom engineering with \"off-the-shelf\" components means 20-35% lower cost than same-spec systems! From small, manual systems to very large, automated systems...we know batching. • Reduce material costs Improve consistency Minimize injury risks • Eliminate product and packaging waste Learn More. Call 513-231-7432 today. INGREDIENT MASTERS INC. 513-231-7432 ingredientmasters.com N 7529-A State Road • Cincinnati, Ohio 45255 ⚫ sales@ingredientmasters.com Downloaded from bulletin archief.3 | www.ceramics.org • 17 ceramics in energy Credit: University of Exeter Lithium ion movement inside nanoparticles could be key to faster-charging, longer-lasting batteries While observing a battery generating an electric current, scientists at the United States Department of Energy\'s Brookhaven National Laboratory noticed that the lithium concentration inside nanoparticles reversed at some point during the process. According to Wei Zhang, one of the researchers, there is a belief that lithium would continue to increase in the lattice over time. \"But now, we have seen that this may not be true when the battery\'s electrodes are made from nanosized particles,\" he states in a BNL news release. \"We observed the lithium concentration within local regions of nanoparticles go up and then down-it reversed.\" Using nanoparticles for lithium-ion battery electrodes can increase conductivity and enable higher storage density of lithium-but without the right equipment, scientists have not really been able to observe them in action. \"Similar to how a sponge soaks up water, we can see the overall level of lithium continuously increase inside the nanosized particles,\" Feng Wang, lead researcher and BNL scientist, explains in the release. \"But unlike water, lithium may preferentially move out of some areas, creating inconsistent levels of lithium across the lattice.\" According to Wang, when lithium ions move back and forth during charge/discharge cycles, the lattice stretches and shrinks each time-stressing it and contributing to its deterioration. \"Each time you charge and drain a battery, its active component will be stressed, and its quality will degrade over time,\" he says. \"Therefore, it is important to characterize and understand how lithium concentration changes both in space and time.\" Using transmission electron microscopy (TEM) and X-ray analyses, the researchers analyzed the structure of nanoparticles and created a nanoscale model battery. They also created a 2-D map illustrating lithium concentration inside a nanoparticle over time. The researchers believe that the lithium behavior they observed might also be happening in other types of highperformance batteries. \"Down the road, we plan to use the world-class facilities at CFN and NSLSII to more closely examine how battery materials work and to find solutions for building new batteries that can charge faster and last longer,\" Wang says. The paper, published in Science Advances, is \"Localized concentration reversal of lithium during intercalation into nanoparticles\" (DOI: 10.1126/ sciadv.aao2608). Brookhaven scientists-from left to right, Jianming Bai, Feng Wang, Wei Zhang, Yimei Zhu, and Lijun Wu-at the Condensed Matter Physics and Materials Science Department\'s transmission electron microscopy facility. Downloaded from bulletin-archive.ceramics.org Credit: Brookhaven National Laboratory Solar Squared glass blocks contain 13 embedded solar cells to absorb sunlight and thermally insulate a building. Solar glass blocks offer electricity and insulation A collaboration between researchers from the University of Exeter and Glass Block Technology Limited has resulted in a novel way to turn glass blocks into solar energy generators. Solar Squared is a glass block product that can generate electricity while allowing more daylight into a building, according to a University of Exeter news release. \"Buildings consume more than 40% of the electricity produced across the globe,\" Hasan Baig, research fellow and collaborator, says in the release. \"We now have the capability to build integrated, affordable, efficient, and attractive solar technologies as part of the building\'s architecture, in places where energy demand is highest, whilst having minimal impact on the landscape and on quality of life.\" Solar Squared glass blocks contain 13 embedded solar cells to absorb sunlight. They also provide additional thermal insulation to a building. And, according to Baig, the product is \"cheaper than standard glass construction blocks plus the cost of electricity.\" The solar cells can also be used in other exterior construction materials, Baig adds, by incorporating them into existing manufacturing processes. \"We can tailor it to fit any product, working with the current manufacturing process rather than demanding a change to that process. In this way, we can slot into established manufacturing chains and product markets.\" For more information, watch the video available at youtu.be/ C81tzRUhjUE. www.ceramics.org | American Ceramic Society Bulletin, Vol. 97, No. 3 Direct carbon fuel cell advancements result in cleaner, more efficient electricity A newer fuel cell technology that uses carbon as a source of power could provide electricity more cleanly and efficiently. A small research team at Idaho National Laboratory has created a direct carbon fuel cell (DCFC) that operates at low temperatures and has more power density than previous iterations of DCFCs, according to an INL news story. DCFCs use coal or biomass as their fuel source, but they tend to emit more pollutants, such as greenhouse gas CO2. Also, conventional DCFCs have limitations between active areas of the cell-the electrode, electrolyte, and carbon fuel source-which result in less effective fuel use, according to the team\'s paper. Older DCFC designs also operate at higher temperatures of 700°C-900°C (1,292°F-1,652°F), requiring more costly heatresistant materials. INL materials engineer Dong Ding and his team created a new and improved DCFC that can use a variety of carbonbased sources, such as coal, organic waste, tar, and biomassas opposed to hydrogen fuel cells, which rely on a chemical reaction between hydrogen and oxygen-making it much more efficient. 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Zırcar +1 845 651 6600 ICERAMICS sales@zircarceramics.com www.zircarceramics.com Downloaded from bulletin archive frame. 3 | www.ceramics.org 19 O ceramics in energy Materials engineer Dong Ding improves a direct carbon fuel cell. Plus, Ding\'s team\'s improvements do not require \"the energy-intensive step of producing hydrogen,” he explains in the release. Ding and his team developed the DCFC to operate at temperatures <600°C (1,112°F) by making the electrolyte out of doped cerium oxide and carbonate, which maintain performance at low temperatures. The scientists also created a cloth-like 3-D ceramic anode that connects fiber bundles together to create a larger surface area for chemical reactions. The fuel consists of carbon and carbonate, a fluidic composite that can \"easily flow into the interface, increasing the power density\" according to Ding in the release. The fuel cells can even be combined and stacked on top of each other based on energy needs. \"In this technology, the solid carbon can readily go through our 3-D ultraporous electrode and reach the interface between electrolyte and electrode, realizing the direct electrochemical oxidation, rather than gasification into carbon monoxide, which is the actual fuel for most direct carbon fuel cells,\" postdoctoral researcher Wei Wu, a coauthor of the paper, explains in a video. Adding carbonate to the carbon fuel increases carbon particle distribution within the fibers, expanding the triplephase boundaries region—the active area of the cell-which leads to better performance, according to the video. Downloaded from bulletin-archive.ceramics.org Credit: Idaho National Laboratory \"The biggest application of this fuel cell technology is for distributed electricity generation due to its high efficiency and environmentally friendly attributes,\" Ding writes in an email. He explains it could also be useful for \"fully exploiting the potential of carbon wastes and integrating low CO,-emission energy sources. \"Also, the electrode structure illuminated in this technology may have broader applications in a variety of electrochemical systems, such as lithium-ion batteries, supercapacitors, and electrolyz,\" he adds. ers, Watch the video at youtu.be/M_wOsvze2ql to learn more about the research. The paper, published in Advanced Materials is \"A high-performing direct carbon fuel cell with a 3D architectured anode operated below 600°C\" (DOI: 10.1002/adma.201704745). Recycled cathodes on spent lithium-ion batteries could save money and the environment A team of engineers at the University of California, San Diego has created a process that recycles cathode particles from spent lithium-ion batteries and can be used in new batteries. By taking used cathode particles from the spent batteries, they restored them through a heat-treating process in a hot alkaline solution of lithium salt. Even the solution can be recycled, according to a UC San Diego news release. \"Think about the millions of tons of lithium-ion battery waste in the future, especially with the rise of electric vehicles (EVs), and the depletion of precious resources like lithium and cobalt-mining more of these resources will contaminate our water and soil,\" Zheng Chen, project leader and professor of nanoengineering at the University of California, San Diego, explains in the release. According to the researchers, less than 5% of lithium batteries are recycled. And their process could likely lower initial battery costs because lithium, cobalt, and nickel have become increasingly expensive to mine and process. Their recycling method works with cathode material lithium cobalt oxide-used in electronics-and lithium nickel-manganese-cobalt, a cathode material used in EVs. Chen says the process is the same one used to make battery cathodes. Tests of the regenerated cathodes showed that charging time, energy storage capacity, and battery life was the same as a brand new battery. And lithium concentration and atomic structure returned to their original states. \"We can simply restore the degraded material by putting it through the same processing steps,\" he notes. The paper, published in Green Chemistry, is \"Effective regeneration of LiCoO2 from spent lithium-ion batteries: a direct approach towards high-performance active particles\" (DOI: 10.1039/ C7GC02831H). Used cathode particles from spent lithium-ion batteries are recycled and regenerated to work as good as new. Credit: David Baillot; UC San Diego Jacobs School of Engineering www.ceramics.org | American Ceramic Society Bulletin, Vol. 97, No. 3 research briefsMXene materials may enable more sensitive gas sensors for medical diagnostics and more Engineered materials enable gas sensors that can sniff out harmful gases, detect toxic fumes, monitor pollution, and even check up on diseases. In the case of gas sensors, the goal is low electrical noise and high sensitivity, which usually come at a trade-off within a material. However, theoretical work has predicted that a newer class of conductive materials called MXenes could offer both, which would make them excellent gas sensors-and new experimental results now confirm this is the case. MXenes are a family of 2-D materials composed of transition metal carbides and nitrides. First discovered at Drexel University (Philadelphia, Pa.) in 2011, the family of conduc tive materials have interesting and useful properties, yet can easily be manufactured, indicating they have promising commercial potential. A group of researchers from Drexel University and KAIST in South Korea has shown that titanium carbide MXene thin MIX THE IMPOSSIBLE TURBULA® SHAKER-MIXER For homogeneous mixing of powdered materials of varying densities, particle sizes & concentrations. GM Glen Mills R Call: 973-777-0777 220 Delawanna Ave, Clifton, NJ 07014 Fax: 973-777-0070 www.glenmills.com staff@glenmills.com Gas sensors allow us to engineer devices, like this smoke detector, to signal the presence of particular compounds. Research News Designing a dendrite-free lithium battery By designing a solid electrolyte that is rigid on one side and soft on the other, researchers from the Chinese Academy of Sciences and the University of Chinese Academy of Sciences have fabricated a lithium-metal battery that completely suppresses dendrite formation. This design also overcomes a typical battery tradeoff by simultaneously reducing resistance at the electrode-electrolyte interface. The electrolyte side facing the anode is a rigid ceramic material that presses against the lithium anode to discourage dendrite growth. The other side facing the cathode is made of a soft polymer, which allows for a strong interfacial connection with the cathode. Batteries with the new electrolyte showed no morphological changes even after 3,200 hours of cycling, indicating that dendrite growth was effectively eliminated. For more information, visit www.phys.org. 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To learn more, visit: materion.com/ceramics Visit us at Ceramics Expo (booth #371) A MATERION Benchtop Laboratory Hot Press MODEL FR210 Advanced Thermal Design at an affordable research briefs. films have superior gas sensing ability over existing gas sensor materials, making them particularly suitable for enabling the next generation of medical diagnostic sensor technologies. The researchers fabricated Ti₂CTx MXene thin films and tested their ability to sense various gases, including acetone, ethanol, ammonia, propanol, nitrogen dioxide, sulfur dioxide, and carbon dioxide. Their results, reported in ACS Nano, show that MXene films can accurately and acutely detect the presence of each gas. Gas sensors detect presence of a gas by measuring a change in electrical conductivity in the material when the gas is present. The MXene sensors had the best response for ethanol, and higher selectivity for gases that hydrogen bond over acidic gases. \"MXene is one of the most sensitive gas sensors ever reported. This research is significant because it expands the range for detection of common gases allowing us to detect very low concentrations that we were not able to detect before,\" Yury Gogotsi, Distinguished University and Bach Professor in Drexel\'s College of Engineering and a lead author of the study, says in a Drexel news release. \"The high sensitivity of the device may be used for detecting toxic gases or pollutants found in our environment.\" But not only can the materials sense a range of different gases, but they can do so very sensitively, indicating superior potential for medical gas sensors. \"MXene can detect gases in the 50-100 parts per billion ranges, which is below the concentration necessary for current sensors to detect diabetes and a number of other health conditions,\" Gogotsi adds in the release. With the help of density functional theory calculations, the scientists say that the MXene sensors are so efficient because of excellent conductivity of the metal core channels in the thin films and strong surface adsorption energy, likely due to the presence of hydroxyl groups. And although the scientists only report the results for titanium carbide MXene materials so far, there are many other price 25 Ton rating Accepts dies up to 3\" diameter x 4\" high • 2000°C OXYCO INDUSTRIES, INC. P.O. Box 40, Epsom, NH 03234-0040 (603) 736-8422 • Fax (603) 736-8734 e-mail: sales@oxy-gon.com⚫ website: www.oxy-gon.com Downloaded from bulletin-archive.ceramics.org Research News Ceramics to prevent wind turbine damage Researchers at the University Institute of Ceramic Technology Agustín Escardino of the Universidad Jaime I (Castellón, Spain) are working on a project to develop new materials resistant to extreme climate for the manufacture of wind turbines. Wear caused by dust particles suspended in the air, accumulation of dirt, and growth of microorganisms on the blades significantly reduces wind turbine energy production efficiency by damaging the blades\' aerodynamic shape. The AeroExtreme project studies various passive and active solutions for wind turbine blades and the nacelle with the aim of maintaining high yields of electrical power production and high durability in extreme conditions. The researchers have developed a material with superior erosion resistance than those currently used, as well as photocatalytic and antifouling coatings with increased durability. For more information, visit www.ruvid.org. www.ceramics.org | American Ceramic Society Bulletin, Vol. 97, No. 3 MXenes that may have sensor potential as well. Plus, the authors add in the paper, sensor selectivity could be further controlled via surface engineering, such as ligand functionalization or defect engineering. \"The next step to advance this research will be to develop sensor sensitivity to different types of gases and improve the detection selectivity between different gases,\" Gogotsi says in the release. \"We can also imagine personal sensors that will be in our smart phones or fitness trackers, monitoring body functions and the environment while we work, sleep or exercise, accessible with a tap of a finger. Improving the detection sensitivity with new materials is the first step toward making these devices a reality.\" The paper, published in ACS Nano, is \"Metallic Ti₂CTx MXene gas sensors with ultrahigh signal-to-noise ratio\" (DOI: 10.1021/acsnano.7b07460). Gogotsi also partnered with researchers from Missouri S&T to publish another paper recently about the potential of MXene materials as triboelectric nanogenerators (TENG) that can harvest wasted mechanical energy. Such MXene TENGS could enable self-powering devices that have the ability to harvest energy from muscle contractions, such as walking or chewing. That paper, published in Nano Energy, is \"Metallic MXenes: A new family of materials for flexible triboelectric nanogenerators\" (DOI: 10.1016/j.nanoen.2017.11.044). Materials science advances could light up new LED technologies Building on abundant research over the past several years to improve LED materials, new research continues to push the technology further forward. For instance, researchers at the Leibniz-Institut für Kristallzüchtung (Berlin, Germany) recently figured out why the indium content in blue LED material indium gallium nitride (InGaN) is limited to just 30%. Scientists have wanted to SAUEREİSEN ASSEMBLY & POTTING COMPOUNDS SINCE 1899 Our complete family of specialty adhesives, potting compounds and ceramic cements are engineered to meet specific requirements for bonding ceramic, metal and glass. If you have an unusual application, we want to hear about it. Let us engineer a solution to meet your needs. C. Fred Sauereisen circa 1900 Some features include: VOC Free Maximum continuous service temperatures of up to 3000°F ■Strong Insulating properties for sealing applications ■ High thermal conductivity ■Superior thermal shock resistance ■Non-Flammable and Non-Combustible Choice of setting mechanism and filler systems 160 Gamma Drive, Pittsburgh, PA 15238 Phone: 412.963.0303 questions@sauereisen.com www.sauereisen.com MRF Materials Research Furnaces, Inc. Enhanced emission in cubic gallium nitride Using aspect ratio nanopatterning technology, researchers at the University of Illinois (Champaign, III.) report a hexagonal-to-cubic phase transition process in gallium nitride. They measured an emission efficiency of optimized cubic gallium nitride, thanks to the polarizationfree nature of cubic gallium nitride, of approximately 29%―a sharp contrast to the general percentages of 12%, 8%, and 2% of conventional hexagonal gallium nitride on sapphire, hexagonal free-standing gallium nitride, and hexagonal gallium nitride on silicon, respectively. These photonic materials could provide viable solutions for next-generation energy conversion devices. For more information, visit www.mntl.illinois. edu/news. 2000°C 1ft Furnace with oil-free Turbo Pumping system Celebrating 27 years of serving the ceramic, R&D and production communities. Standard and customized furnaces; let our experienced team help you build a tool for your particular application. 65 Pinewood Rd., Allenstown, NH 03275 603-485-2394-Sales@mrf-furnaces.com www.mrf-furnaces.com Downloaded from bulletin archief. 3 | www.ceramics.org 23 research briefs. SWINDELL DRESSLER INTERNATIONAL Total Kiln Performance Low Cost of Ownership Firing Systems Digitally Fired Combustion Systems Dyna Pulse Digital Firing Technology World class fuel consumption NFPA compliant systems Spare Parts and Service Support We are not just a company selling a kiln. We design a firing system that will meet the precise requirement of firing your fine products with accuracy, efficiency, and ease of use. We analyze firing requirements with great care, and our custom solution to your requirements have been given the utmost care. We are certain that our custom design will provide your 412.788.7100 www.swindelldressler.com HINDALCO CHEMICALS THE QUALITY VALUE CHAIN Speciality Alumina Chemicals for CERAMIC APPLICATIONS LED lights are energy efficient, but they still have R&D challenges to address—new materials research indicates further improvements may be coming. increase the indium content because that would shift LED light emission towards green and red portions of the spectrum and manufacturers use a combination of blue, red, and green LEDs to create sought-after white LED light. No matter how the Leibniz scientists tried to increase the amount of indium by growing single atomic layers of indium nitride on gallium nitride, however, their efforts failed—they could not exceed 25%-30% indium content in the material. So they took a closer look at what was going on. Atomic res olution transmission electron microscopy and in-situ reflection high-energy electron diffraction revealed that InGaN actually undergoes an atomic rearrangement at 25% indium content. Instead of a predicted structure that bonds indium atoms with three neighboring atoms, InGaN instead favors a strucBrake Lining Ceramic Fibre Ceramic Liner & Grinding Media Ceramic Rollers Catalyst Bed Support Ceramics Tiles, Frits & Glazes Fused Grains Glass & Glass Fibre High Tension Insulators Hi tech Ceramics Industrial Ceramics Potteries & Chinaware Printed Circuit Board Refractory Spark Plugs ADSTYLE T For more details, contact: HINDALCO INDUSTRIES LIMITED The need for controlling heat and wear forced mankind to develop the art of ceramics, even before the Stone Age. Technological advances over centuries have propagated the use of Ceramic Technology for various applications now so common in our daily lives. 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Mumbai +91-22-66917000 Delhi +91-120-6692100 Kolkata +91-33-22882680 Bangaluru +91-80-40416100 www.hindalco.com/alumina-chemicals Research News Splitting crystals for 2-D conductivity Researchers at Tohoku University (Sendai, Japan) and an international team of colleagues identified the atomic structure of a group of strontium niobate compounds made of strontium, niobium, and oxygen atoms that have a layered structure derived from perovskite. The team used atom-resolved scanning transmission electron microscopy combined with theoretical calculations to learn that adding oxygen atoms to the perovskite-like crystal material split it into layers, giving it unique 2-D conductive properties. Local electrical conductivity within the material directly depended on the shapes of niobate octahedra in the layers. For more information, visit www.tohoku.ac.jp/en/press. Downloaded from bulletin-archive.ceramics.org www.ceramics.org | American Ceramic Society Bulletin, Vol. 97, No. 3 Credit: Vladimir Agafonkin; Flickr CC BY-NC 2.0 ture that bonds indium atoms with four nearby atoms. While this increased number of bonds creates a stronger structure, it also physically limits the amount of indium that can incorporate into the LED material. \"Apparently, a technological bottleneck hampers all the attempts to shift the emission from the green towards the yellow and the red regions of the spectra. Therefore, new original pathways are urgently required to overcome these fundamental limitations,\" Tobias Schulz, scientist at the Leibniz-Institut für Kristallzüchtung, says in a news release. “For example, growth of InGaN films on high quality InGaN pseudo-substrates that would reduce the strain in the growing layer.\" Although the team\'s research indicates that there is no solution to indium\'s incorporation limit, it does provide potential for overcoming InGaN\'s limited charge carrier localization due to variations of the compound\'s chemical composition, according to the release. The research, published in Physical Review Materials, is “Elastically frustrated rehybridization: Origin of chemical order and compositional limits in InGaN quantum wells” (DOI: 10.1103/ PhysRevMaterials.2.011601). Researchers from ITMO University (Saint Petersburg, Russia) are focusing on a different material to push forward the potential of LED lights-halide perovskites. The researchers recently demonstrated that subwavelength nanoparticles of the materials can act as light emitters and nanoantennas to enhance light emission—halide pervoskite nanoparticles generate, enhance, and route emission through excited resonant modes coupled with excitons, according to an ITMO news release. Excitons are bound pairs of electrons and holes that emit light when they recombine. \"The unique features of perovskite enabled us to make nanoantennas from this material,” first author Ekaterina Tiguntseva says in the release. \"We basically synthesized perovskite films, and then transferred material particles from the film surface to . • TT TevTech MATERIALS PROCESSING SOLUTIONS Custom Designed Vacuum Furnaces for: CVD SIC Etch & RTP rings ⚫ CVD/CVI systems for CMC components • Sintering, Debind, Annealing Unsurpassed thermal and deposition uniformity Each system custom designed to suit your specific requirements Laboratory to Production Exceptional automated control systems providing improved product quality, consistency and monitoring Worldwide commissioning, training and service www.tevtechllc.com Tel. (978) 667-4557 (R) 100 Billerica Ave, Billerica, MA 01862 Fax. (978) 667-4554 sales@tevtechllc.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. LED material with excellent color quality A team led by engineers at the University of California San Diego used data mining and computational tools to discover a new phosphor material for white LEDs that is inexpensive and easy to make. The new phosphor, Sr₂LIAIO or simply SLAO, is the first known material made of strontium, lithium, aluminum, and oxygen. The team discovered SLAO using a systematic, high-throughput computational approach and then generated and tested the material. The researchers then used the new phosphor to build a white LED light bulb prototype, which exhibited better color quality than many current commercial LEDs. For more information, visit www.ucsdnews.ucsd.edu. I²R -Over 50 years of service and reliability 53 1964 - 2017 I Squared R Element Co., Inc. Akron, NY Phone: (716)542-5511 Fax: (716)542-2100 Email: sales@isquaredrelement.com www.isquaredrelement.com Downloaded from bulletin-archief. 3 | www.ceramics.org 25 AMERICAN ELEMENTS THE ADVANCED MATERIALS MANUFACTURER Ⓡ cerium sputtering target euro LED lighting praseodymium r yttrium metal dielectric lanthanur yttrium granules scandium powder gadolinium acetate surface functionalized nanoparticles aluminum nanopartic terbium ingot cer H polishing powder erbium fluoride sputtering targets tar Li Be diamond micropowder quant B C N od Na Mg nium wires ultra high purity mater Al Si P cone K Ca Sc Ti ttrium Rb Sr N < CIGS Cs Ba La Hf Ta nano SSO Hemium F Netic cera CI Arepositi Cr Mn Fe Co Ni Cu Zn Ga Ge As Se Br Kr titani Rh Pd Ag Cd Os Ir Pt Au Hg Tl Pb Fr Ra Ac Rf Db Sg Bh Hs Mt Ds Rg Cn Uut FI platinum ink Pr Nd Pm Sm Eu Gd Tb Dy Ho solar energ Th Pa Pa U Np Pu Am Np Pu Am Cm Bk Cf europium phosphors alternative energy gadolinium wire iron ionic Sb Te At Rn Uup Lv Tm Yb Cf Es Fm Md No sputtering targets Now Invent. -31 Uus Uuo ectrics crystal n film Lue crystal silico No Lr metamaterials palladium shot TM tungsten carbid dysprosium meta advanced polyr super alloys 99.999% ruthenium spheres zirconium Nd:YAG erbium doped fiber optics vanadium silicon rods dysprosium pellets rhodium sponges photovoltaics nar europium www.americanelements.com nanodispersions macromolecules refractory metals ©2001-2018. American Elements is a U.S. Registered Trademark. electrochemistr Materials Characterization Analytical Services Accurate Efficient Affordable Rates (on sale) Method XRD XPS XRF FE-SEM AFM BET TG/DSC ICP-MS Instrument Model Bruker D8 Advance Thermo ESCALAB 250x PANalytical Axios FAST Hitachi 54800 Bruker ICON Micromeritics ASAP 2460 Netzsch STA449; TA Q500 Thermo ICAP-6300 From $14/sample From $60/sample From $34/sample From $50/sample From $117/sample From $60/sample From $40/sample Mercury Porosimetry AutoPore IV 9500 From $50/sample From $184/sample Explore many more services: www.msesupplies.com 4400 E Broadway Blvd, Suite 600, MSE Supplies Tucson, AZ 85711, USA Partner in Materials Research www.msesupplies.com M Single Crystals and Substrates Email: sales@msesupplies.com Phone: 520-789-6673 ITO /FTO/AZO Substrates Materials Characterization Analytical Services Lithium Battery Materials Custom-Made Sputtering Targets Ball Milling Equipment and Accessories Graphene research briefs another substrate by means of pulsed laser ablation technique. Compared to alternatives, our method is relatively simple and cost-effective.\" In addition, the emitted light color is easily tunable by simply varying anions in the material. \"The structure of the material remains the same, we simply use another component in the synthesis of perovskite films,\" Tiguntseva explains in the release. \"Therefore, it is not necessary to adjust the method each time. It remains the same, yet the emission color of our nanoparticles changes.\" That research, published in Nano Letters, is “Light-emitting halide perovskite nanoantennas” (DOI: 10.1021/acs. nanolett.7b04727). Another team of scientists at the U.S. Naval Research Laboratory (Washington, D.C.) also focuses on using halide perovskites to develop more efficient LEDs. The scientists work shows that cesium lead halide perovskite nanocrystals (CsPbX3) emit light much faster than conventional lighting materials, suggesting that the materials could enable efficiency upgrades in solid-state lasers and LEDs. \"An optically active bright exciton in this material emits light much faster than in conventional light emitting materials and enables larger power, lower energy use, and faster switching for communication and sensors,” NRL research physicist Alexander Efros says in an NRL news release. By generating nanocrystals from lead halide perovskites containing either chlorine, bromine, or iodine, the researchers found that the materials rapidly emit light through the range of visible wavelengths. \"The increased rate of light emission of these materials holds great promise for various technological applications that rely on LEDs and lasers,\" Efros adds in the release. \"In principle, the 20 times shorter lifetime could therefore lead to 20 times more intense LEDs and lasers.\" The research, published in Nature, is \"Bright triplet excitons in caesium lead halide perovskites\" (DOI: 10.1038/ nature25147). Aerobricks combine aerogel with brick to form energy-saving, super insulating building material Researchers at Empa, the Swiss Federal Laboratories for Materials Science and Technology (Dübendorf, Switzerland), have developed better insulating building materials called \"Aerobricks\"-bricks with internal cavities filled with aerogel granules. \"The material can easily be filled into the cavities and then joins with the clay of the bricks,\" Empa researcher Jannis Wernery says in an Empa news release. \"The aerogel stays in the bricks you can work with them as usual.\" Although insulating bricks themselves are not new, adding aerogel filling boosts the bricks\' insulating abilities because aerogels are one of the most effective insulating materials known. Downloaded from bulletin-archive.ceramics.org www.ceramics.org | American Ceramic Society Bulletin, Vol. 97, No. 3 165 mm 263 mm 1240 mm Credit: Empa New Optical Dilatometer Platform ODP 868 The only optical dilatometer featuring a multi-directional optical bench with patented technologies for the most accurate dilatometry, heating microscopy, and fleximetry. For the complete characterization of raw materials, semifinished products, and process optimization TA www.tainstruments.com To achieve the same insulation values as a 165 mm thick wall of Aerobricks, a wall of perlite bricks must be 263 mm thick—and a wall of noninsulating bricks 1240 mm. Compared with insulating bricks filled with perlite, an amorphous volcanic glass often used as an insulating filler material, the researchers\' laboratory tests show that same-sized aerogelfilled bricks have ~35% decreased thermal conductivity. That is a significant improvement in insulating abilities, which get even more pronounced when you compare Aerobricks with standard, noninsulating brick. Aerobricks conduct only ~12.5% of the heat of standard bricks, offering even more significant energy savings potential. \"A conventional wall would therefore have to be almost 2 m deep in order to insulate as well as an Aerobrick wall of just 20 cm in depth,\" according to the release. \"With a measured thermal conductivity of just 59 milliwatts per square meter and Kelvin temperature difference, the Aerobrick is currently the best insulating brick in the world.\" Of course, the commercial problem is predictable-because of the aerogel filling, the bricks are prohibitively expensive. According to the news release, the researchers estimate market prices for aerogels today would equate to an additional cost of more than $500 per square meter for an Aerobrick wall over the cost of a standard brick wall. If the price of aerogel can be brought down, however, the technology could offer significant energy savings to buildings by providing superior insulation and reducing the amount of building materials needed. The open-access paper, published in Energy Procedia, is \"Aerobrick-An aerogel-filled insulating brick” (DOI: 10.1016/j.egypro.2017.09.607). Downloaded from bulletin archief.3 | www.ceramics.org Thermcraft incorporated eXPRESS-LINE Laboratory Furnaces & Ovens • Horizontal & Vertical Tube Furnaces, Single and Multi-Zone • Box Furnaces & Ovens • Temperatures up to 1700°C • Made in the U.S.A. • Available within Two Weeks SmartControl Touch Screen Control System www.thermcraftinc.com • info@thermcraftinc.com +1.336.784.4800 27 27 Washington State University ARBOCELⓇ LIGNOCEL® Cellulose Pore Control Agents JRS J. RETTENMAIER USA LP 269-679-2340 www.jrsusa.com Orton Materials Testing Laboratory We provide the information you need... when its time to evaluate Materials ortonceramic.com/testing info@ortonceramic.com 1-614-818-1321 research briefs Permeable concrete prevents water runoff while solving carbon fiber waste problem Water streams through a pervious pavement laden with carbon fiber in a test at Washington State University. Researchers at Washington State University (Pullman, Wash.) have developed a type of permeable concrete that actually solves two problems: flooding from water pooling during heavy rains and recycling of an industrial waste product that previously had no reuse applications. Associate research professor in the Composite Materials & Engineering Center Karl Englund and assistant professor in the Department of Civil and Environmental Engineering Somayeh Nassiri added carbon fiber composite into a pervious concrete mix. The carbon fiber actually increased strength and durability of the concrete. “In terms of bending strength, we got really good results—as high as traditional concrete, and it still drains really quickly,\" Nassiri mentions in a WSU news release. The Pacific Northwest is prone to heavy rains and the research duo has been studying pervious concrete for the past few years. Through their research they discovered that milling, rather than heating or using chemicals, was a less expensive process and could ultimately keep manufacturing costs down at scale. While carbon fiber composite is an exceptional material to strengthen permeable concrete, it can be costly. The other problem is that there is no market for recycled carbon fiber composite. But what makes the new method interesting is that the researchers are using carbon fiber composite gleaned from the scraps of Boeing\'s manufacturing facility. Carbon fiber composite scrap that would otherwise end up in a landfill. \"You\'re already taking waste-you can\'t add a bunch of money to garbage and get a product,\" Englund says in the news release. \"The key is to minimize the energy and to keep costs down.\" So what is the difference between their research and other permeable concrete products on the market? “The innovation in our project is the addition of carbon fiber composite mateDownloaded from bulletin-archive.ceramics.org www.ceramics.org | American Ceramic Society Bulletin, Vol. 97, No. 3 AdValue Technology rials that is from the aerospace industry,” Nassiri writes in an email. \"This material needs a reuse application, and the use of them in pervious concrete adds value by enhancing durability and strength.\" Last year the duo conducted structural property tests to determine parameters for rigid pavement thickness design. Their next step is to work on scaling it for manufacturing. \"We are working now on implementation and mainstreaming,\" Nassiri adds. \"When we go through these stages we will have a better idea of cost compared to commercial fibers and other products on the market.\" The research is promising for municipalities and areas in flood plains, as well as manufacturers looking for a recycling solution for carbon fiber composite waste. \"This project is very exciting for us because we work on addressing the needs of industry in finding a reuse application for their waste,\" Nassiri adds, “and at the same time working on improving properties of pervious concrete pavements that are beneficial for stormwater management and a desired solution for municipalities.\" The paper, published in the Journal of Materials in Civil Engineering, is \"Enhancing mechanical properties of pervious concrete using carbon fiber composite reinforcement\" (DOI: 10.1061/(ASCE)MT.1943-5533.0002207). 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Downloaded from bulletin archief.3 | www.ceramics.org L&L Special FURNACE CO, INC Ilfurnace.com P:877.846.7628 E:sales@llfurnace.com 29 29 CMC laboratories Innovative Materials Solutions The Industry Leader in Laser Flash Thermal Conductivity Testing Services Discover More............. 000 -2000 D 2000 4000 6000 0000 10000 Time Ame Common Materials Analyzed - Advanced Ceramics - Metals and MMCs - Glasses and Dielectrics - TIMS - Layered Structures - Plastics and Polymers CMC can measure the TC of materials from 0.1 to 2000W/m*K from 25°C - 350°C on monolithic, composite, and layered structures. www.CMClaboratories.com info@CMClaboratories.com Matmatch The search engine for materials Find and compare ceramics, metals, polymers and more. matmatch.com Ceramics suppliers: Connect with qualified buyers globally matmatch.com/supplier Downloaded from bulletin-archive.ceramics.org ●⚫ceramics in manufacturing Rotational 3-D printing controls fiber orientation to print stronger functional composites When it comes to multifunctional materials, composites are key-because they combine several different types of materials together into one, composites can have unique combinations of properties, such as high stiffness and strength with low weight. Fiber-reinforced composite materials are particularly useful because they combine the strengthening properties of various types of fibers within a polymer matrix. But even the properties of a composite material itself sometimes are not enough to achieve all the performance goals of a particular component-the ability to control local microstructure within a component is necessary as well. For example, a component may require additional reinforcement in areas that will experience high stress during loading, lessening the likelihood of failure at those points. And now, it is possible to do just that using a newly developed additive manufacturing technique for high-performance fiber-reinforced composites. Researchers at the Harvard John A. Paulson School of Engineering and Applied Sciences (SEAS) have developed a novel 3-D printing technique that adds another dimension of control to additively manufactured composites-local microstructural control. Called rotational 3-D printing, the method uses a rotating 3-D printer nozzle to control flow of a fiber-reinforced composite ink, locally controlling orientation of fibers with the viscous polymer matrix. \"Being able to locally control fiber orientation within engineered composites has been a grand challenge,\" Jennifer A. Lewis, senior author of the study and Hansjorg Wyss Professor of Biologically Inspired Engineering at Harvard SEAS, says in a Harvard news release. \"We can now pattern materials in a hierarchical manner, akin to the way that nature builds.\" The Lewis lab is not new to innovation in 3-D printing. Last year, the lab\'s scientists whipped up 3-D-printed ceramic foams with dual-level porosity. And a couple of years before that, previous lab members developed the world\'s first 3-D electronics printer, called Voxel8. But rotational 3-D printing can put just the right spin on local microstructural control, additively manufacturing parts with tailored electrical, optical, or thermal properties. By controlling fiber orientation-whether glass fibers, ceramic whiskers, or metal platelets, for example-within a composite, rotational 3-D printing affords the ability to optimize strength, stiffness, and damage tolerance within a printed component. And, in addition to material versatility, the authors say, the technique is compatible with any extruwww.ceramics.org | American Ceramic Society Bulletin, Vol. 97, No. 3 Credit: Lewis Lab; Harvard SEAS Optimizing performance is our specialty We have experience with more than 3,000 unique compositions of specialty ceramics for a diverse group of applications, markets and industries to meet even your most exacting operational needs. Specialty Ceramics Battery Materials Environmental & Thermal Barrier Coatings Solid Oxide Fuel Cell Materials Chemically Synthesized Multi-Component Oxide Powders and Shapes 1.425.487.1769 PRAXAIR SURFACE TECHNOLOGIES www.praxairsurfacetechnologies.com A novel 3-D printing method called rotational 3-D printing yields unprecedented control of the arrangement of short fibers embedded in polymer matrices sion printing method, including fused filament fabrication and direct ink writing. \"Rotational 3-D printing can be used to achieve optimal, or near optimal, fiber arrangements at every location in the printed part, resulting in higher strength and stiffness with less material,\" Brett Compton, then-postdoctoral fellow and current mechanical engineering assistant professor at the University of Tennessee, Knoxville, says in the release. \"Rather than using magnetic or electric fields to orient fibers, we control the flow of the viscous ink itself to impart the desired fiber orientation.\" Rotational 3-D printing is thus unique in its spatial control during 3-D printing. Engineers can variably control composition within additively manufactured components, tailoring material properties in specific locations—such as flexibility in areas that need to bend or reinforcement in areas that require more rigid structural support. \"One of the exciting things about this work is that it offers a new avenue to produce complex microstructures and to controllably vary the microstructure from region to region,\" Jordan Raney, then-postdoctoral fellow and current mechanical engineering assistant and applied mechanics professor of at the University of Pennsylvania says in the release. \"More control over structure means more control over the resulting properties, which vastly expands the design space that can be exploited to optimize properties further.\" The paper will soon be published in the Proceeding of the National Academy of Sciences USA. 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Knudsen Ceramics serve a crucial role in enabling developments in the electronics industry through their essential role in the manufacturing, use, and application of advanced semiconductors. Table 1. How are ceramics used in the semiconductor industry? Attribute Mechanical strength High thermal conductivity Materials Al2O3, SiC, ZrO2, Si₂N4 Function Structural support BeO, AIN Thermal dissipation of power devices High coefficient of thermal expansion LTCC (e.g., HITCE by Kyocera) Thermal expansion matched to printed wiring board Thermal expansion matched to Si Ferroelectricity, pieozoelectricity Low loss substrates Structural support, sensor substrate Optical windows Low coefficient of thermal expansion AIN High dielectric constant PZT, BaTiO2, etc. Low dielectric constant LTCC High temperature stability Optical transparency Environmental stability Al2O3, SiC, ZrO2, Si₂N Sapphire, AION Al₂O, AIN, SiC, Si̟N Low permeability Al2O3, AIN, BEO, LTCC Chemical inertness, oxidation resistance Hermetic enclosures Downloaded from bulletin-archive.ceramics.org More p ore powerful mobile devices, larger televisions, autonomous and electric vehicles, wearables, virtual reality, and the Internet of Things (IoT)—these technologies drive innovation and efficiencies in the electronics industry and in semiconductors themselves. Ceramics serve a crucial role in enabling these developments, whether in the manufacturing, use, or application of advanced semiconductors. While ceramic technologies do not always serve glamorous roles, they provide necessary thermal, mechanical, electrical, and environmental stability to this industry. Detailing all of the ways in which ceramics contribute to modern semiconductors is beyond the scope of any article, but there are many examples where ceramics enable essential functionalities to the materials themselves, the manufacturing process, and their application in technology. Application Equipment, wafer chucks, substrates Power amplifiers (GaN, GaAs, Si) and LED submounts Large area integrated circuit packages Large image sensors Capacitors, inductors, piezoelectric sensors Filters, antennas Oxygen sensors, engine components Camera, mobile phone screens Semiconductor processing, engine components Packaging and substrates The remarkable variety of possible ceramic compositions leads to a wide spectrum of properties useful to the semiconductor industry (Table 1). Semiconductor manufacturers employ ceramics for their mechanical and environmental stability in highly corrosive environments. Ceramics have been adopted in packaging, where hermeticity, thermal conductivity, and mechanical integrity are paramount. And in communications and sensing, ceramic dielectrics support high rates of data transmission and monitoring. www.ceramics.org | American Ceramic Society Bulletin, Vol. 97, No. 3 Capsule summary INTEGRATED IN THE INDUSTRY Ceramics enable essential functionalities in semiconductor materials themselvesultimately supporting development of smaller and more powerful electronics. MATCH MADE IN CERAMICS Ceramics\' properties make the materials suitable for an array of applications, including particular roles in semiconductor manufacturing and packaging, such as transporting wafers, protecting medical devices, supporting enhanced communications, and protecting satellite electronics. ADDING FUTURE POTENTIAL Despite ceramics\' useful properties, low-cost, quick-turn manufacturing represents a market-limiting challenge. Additive manufacturing offers an attractive opportunity if it can be adopted for volume production. Semiconductor manufacturing The global semiconductor market is estimated to have exceeded $410 billion in 2017, with a projected annual growth rate of more than 7% in 2018.¹ In particular, solid-state memory [dynamic random access memory (DRAM) and 3-D NAND flash memory] and displays [liquid crystal display (LCD) and organic light-emitting diode (OLED)] are driving explosive demands for technologies and equipment to support larger, thinner, and better televisions (4K or 8K resolution) and cell phones and computers that can store more photos and videos. Other technologies expected to contribute to this growth include virtual and augmented reality, artificial intelligence, IoT, and autonomous vehicles. To support these applications and the increasing number of new wafer fabs that have been announced, manufacturers of wafer fabrication equipment (WFE) face unprecedented demand for tools and components for those tools. Wafer fabrication involves various manufacturing operations, including etching, deposition, lithography, ion implantation, inspection, and polishing. Often, these processes are conducted under high vacuum and in the presence of corrosive chemicals. In addition, high temperatures and high voltages may be involved. As such, wafer fabrication requires corrosion-resistant materials, such as stainless steel, anodized aluminum, hightemperature polymers (polyimides), and ceramics. The market for ceramics used in WFE is estimated at around $350 million, with an additional $60 million associated with LCDs. This represents a growth of approximately 50% over the past year alone-ceramic manufacturers are scrambling to meet this demand. There are a variety of ceramic components essential in wafer fabrication processes, including wafer polishing substrates, chucks and carriers, heaters, plasma-resisCeramic insulators Credit: MDC Vacuum Products Figure 1. Ceramic-metal (high voltage, high current, and electromagnet sweep) feedthroughs are evident in this image of a vacuum evaporation source, courtesy of MDC Vacuum Products. tant parts, nozzles, windows, and feedthrough insulators. Perhaps the most obvious use of ceramics in high-vacuum equipment is the occasionally decorative design of these electrical feedthrough insulators. Figure 2. Ceramic vacuum and electrostatic chucks are used to secure semiconductor wafers during processing. High-purity ceramic heaters are used in corrosive environments (e.g., ion implantation, etching) where temperature uniformity is critical. These products are commonly manufactured from SiO2, SiC, Al2O3, and AIN. As an example, Figure 1 shows a flange-mounted evaporation source. The feedthroughs shown include mechanical manipulators in addition to high-voltage (3-10 kV) and high-current insulators. These electrical feedthroughs are manufactured using pressed Al2O3 ceramic, brazed to a FeNiCo receptacle or flange. Migration from 200-mm to 300-mm semiconductor wafer fabs creates a need for correspondingly larger heaters, carriers, and chucks. Fabrication of such parts with exacting tolerances represents a manufacturing and machining challenge. Whereas Al2O3 is a standard material, some applications require other materiDownloaded from bulletin-archive ceramics, 3 | www.ceramics.org als. For example, efficient heat removal in plasma chemical vapor deposition (PCVD) processes is dependent on thermal dissipation through the wafer carrier. Whereas both Al2O3 and AIN exhibit the necessary high dielectric constant and good plasma resistance for PCVD, the inherent high thermal conductivity of 33 Credit: Kyocera Intemational Inc. Ceramics drive innovation and efficiences in the semiconductor industry Titanium enclosure Feedthrough Electronic module Cup Li-ion battery Connector block Recharge coil Titanium enclosure Figure 3. Exploded view of a hermetic neurostimulation device, courtesy of Medtronic. Figure 4. Standard 9-pin feedthrough, reflecting Pt-Ir pins brazed into an Al2O3 ceramic, which is subsequently brazed into a Ti ferrule. AIN significantly reduces the magnitude and inhomogeneity of wafer temperature during processing. Increasingly, processing requires high temperatures and aggressive chemical etchants and atmospheres. These highly corrosive gases and plasmas include reactive ions (Ar, O, and N), fluorides (CF, SF, and NF,), and chlorides (HCl, BCI, and C₁₂). Corrosion and erosion of carriers, masks, and chamber walls themselves introduce undesirable impurities into wafer chemistries. Thus, there is a need for both corrosion resistance and high purity. Some examples of wafer handling chucks are shown in Figure 2. In processing, wafers are held in place by vacuum or by electrostatic forces. Electrostatic chucks employ either Coulombic or JohnsenRahbek forces, induced by electrodes Downloaded from bulletin-archive.ceramics.org Credit: Kyocera International Inc embedded in the ceramics. Vacuum chucks are less favored as the wafer may be deformed during processing. In addition, carriers may be required to uniformly heat substrates (±1-2°C) across the full footprint of the wafer. AlN is well suited for this application, although a common requirement that the substrate be of high purity precludes the use of rare-earth oxides and other sintering aids that would increase thermal conductivity from about 70 W/mK to at least 170 W/m.°K. Semiconductor packaging Because the number of ceramics in mobile phones, televisions, Wi-Fi routers, automobiles, and beyond can be quite substantial, we focus here on a few novel applications. Critical protection in medical devices The use of ceramics in medical applications extends beyond bones and teeth. Although dental implants and artificial joints are important, especially for those in need of replacements, incorporation of electronics into implantable devices offers additional functionality in patient monitoring and therapy. Cardiac pacemakers were perhaps the first example of an implanted electronic device, with widespread introduction in humans in 1960. Early pacemakers were large and prone to leakage and failure, as they were not hermetically sealed. Eventually, welded titanium encloCredit: Medtronic sures and high reliability feedthroughs replaced plastic-encapsulated electronics. As shown in Figure 3, implantable devices include batteries, control devices, and circuit boards that, to function reliably for as long as 20 years, must be effectively isolated from body fluids or other potential sources of failure. Ceramics and glasses play an important role in assuring this reliability, serving as insulators in feedthroughs for these devices. Traditional feedthroughs, such as those shown in Figure 4, are constructed from metal pins (Pt, Pt-Ir, Nb) sealed (Au brazing) into an alumina eyelet or embedded in a glass dielectric. This assembly is, in turn, brazed into a titanium ferrule. As the functionality of devices increases, the number of feedthrough pins also increases. Eventually, it is no longer pragmatic or economical to braze a large number of pins into a device that, ideally, is becoming smaller and more compact. For instance, retinal implants may require as many as 100 feedthrough connections. To address this, manufacturers have introduced a cofired technology involving use of platinum paste rather than a metal pin and multilayer Al2O3 rather than pressed or machined ceramic monoliths. Use of multilayer technology enables concentration of many leads into a much smaller volume. Figure 5 shows a crosssection of a cofired feedthrough where filled vias function in place of metal pins. Multilayer technology offers the opportunity to include additional functionality (antennas, power dividers, etc.) within a structure. Whereas brazed (legacy) feedthroughs are among the most reliable components in an implanted cardiac device, cofired feedthroughs have demonstrated equivalent reliability in accelerated reliability testing.² Supporting enhanced communications In the era of the smartphone, there are a surprising number of ceramic components within an average mobile device, including capacitors, filters, antennas, and substrates for image sensors. With the sale of mobile phones approaching nearly two billion units annually, the number of ceramic components in phones is at least an order of magnitude higher. www.ceramics.org | American Ceramic Society Bulletin, Vol. 97, No. 3 The capabilities consumers demand would be impossible without development of wireless technologies to support enhanced data rates and extended geographic coverage. More data, more users, more phones, and more remote locations mandate more capabilities in cellular infrastructure. Cell towers that dot the global landscape are high-power broadcast terminals, housing large numbers of RF amplifiers. To satisfy the expectations of consumers, service providers have mandated increased power, efficiency, linearity, and gain in power amplifier (PA) technology-and at a lower cost. At the end of the 1990s, bipolar silicon began to be supplanted by silicon laterally diffused metal oxide semiconductor (LDMOS) PAs. Both technologies require dissipation of a substantial amount of heat. For example, high-power LDMOS PAs may transmit up to 200 W and dissipate in excess of 300 W. Bipolar devices are mounted on a ceramic insulator, typically AlN or BeO. LDMOS devices, on the other hand, are placed directly on the source electrode-an electrically conduc1 mm Al2O3 Pt Credit: Kyocera International Inc. Figure 5. Optical crosssection showing a cofired, 6-terminal feedthrough. The \"pins\" are Pt-filled vias cofired into a multilayer Al2O3 ceramic, which has been brazed into a Ti ferrule. 2.0 1.5 AIN 1.0 10 90 Normalized ejc 0.5 0.0 BeOW/Cu composites Cu/Mo/Cu laminates Cu Al/diamond 0 200 400 600 Thermal conductivity (W/m-°K) Ag/diamond 800 1000 Figure 6. Thermal performance of an LDMOS-style package, as reflected in thermal resistance (0) normalized to a copper heat sink (thermal conductivity = 400 W/m.°K). Note that an Al2O3 heat sink results in a normalized value of 7-12.2 tive heat sink. To operate reliably, packaging associated with these devices must remove heat such that the maximum operating junction temperature within the semiconductors is less than 200°C. Figure 6 displays the efficiency of various heat sink materials. BeO is a superior insulator/heat sink for PA packaging. Unfortunately, BeO suffers from its reputation as a toxic substance and, just as importantly, is a more costly solution. AIN, on the other hand, is a slightly inferior heat sink material for high-power devices. As such, the typical LMDOS package (Figure 7) employs a relatively inexpensive composite metal heat sink. An Al2O3 “window frame” is required to electrically isolate leads from the base, which is typically under high mechanical (bolt-down) and thermal stresses. Data are transmitted through various media, including free space, copper wire, and optical fiber. Packaging associated with optical data transmission is ideally suited to ceramics, as repairs of optical transmission infrastructure (underground or undersea) are expensive if not impractical. Electro-optical (E/O) packaging typically requires hermeticity, rigidity (high elastic modulus), and thermal dissipation, with well-defined optical properties of transparency or opacity. Thus, growth in mobile data in the developing world has also resulted in increased demand for E/O products. The laser diode package displayed in Figure 8 provides a good illustration of these requirements. The body of the package is metal with opaque, 90% Al2O3 feedthroughs on either side. One set of these feedthroughs includes a high-speed (5 Gbps/15 GHz) coplanar waveguide input/output (I/O). Downloaded from bulletin-archive.ceramics, 6.3 | www.ceramics.org American Ceramic Society The American Ceramic Society www.ce Accredited Nadcap Materials Testing Laboratory ANAB ACCREDITED ISO/IEC 17025 TESTING LABORATORY materials testing trusted Chemical Testing of Ceramics (Bulk and Trace Analysis) Alumina Boron Carbide Boron Nitride Chrome Oxide Magnesium Oxide Silica Silicon Carbide Titanium Dioxide Zinc Oxide Zirconia Rare Earth Oxides And more... Trust NSL, contact us at NSLanalytical.com/Ceramics or call 877.560.3875 NSL ANALYTICAL Trust Technology | Turnaround 4450 Cranwood Parkway, Cleveland, OH 44128 35 Credit: Kyocera International Inc. Ceramics drive innovation and efficiences in the semiconductor industry IC Credit: Kyocera International Inc. Figure 7. LDMOS package. The silicon die mounts directly onto a composite metal (Cu/CuMo/Cu) flange. An Al2O3 \"window frame\" insulates FeNiCo leads from the flange. In RF or high-speed digital applications, mechanical and thermal performance may take a backseat to electrical properties (e.g., dielectric constant, loss) of these materials. The two most significant loss mechanisms are conductor and dielectric loss. Conductor loss favors use of low-resistivity conductor metals (Ag, Cu, Au), such as those employed with low-temperature cofired ceramics (LTCC). In printed wiring board (PWB) applications, copper is the dominant metal, with a conductivity (6.0 × 10-7 S/m) only about 5% less than that of silver (6.3 × 10-7 S/m). High-temperature cofired ceramics (HTCC) typically use a refractory metal such as tungsten (1.8 × 10-7 S/m), which is then plated with nickel and gold (4.1 × 10-7 S/m). Figure 8. An electro-optical \"butterfly\" package including optical fiber and 15 GHz RF input/output. LTCC ceramics are often promoted as low-cost alternatives to HTCC. LTCC materials are typically sintered at temperatures of around 800-900°C, allowing use of less costly furnace materials than required with HTCC (firing temperatures of 1,600-1,900°C). This cost advantage can be very dependent on the conductor metals. At roughly $1,000/ Troy ounce (toz) and $1,300/toz, respectively, platinum and gold conductors can significantly add to the cost of a multilayer module. For example, Figure 9 compares the relative costs of an LTCC and HTCC RF module. In this case, the sample package is a multicavity module measuring approximately 4 × 2.5 × 0.5 cm, with heat sinks and an RF connector LTCC - Relative cost: 2.25 Tape. 4% block. This particular module includes a significant amount of buried conductors and ground vias for RF isolation. As such, paste costs in the LTCC module account for a whopping 56% of the total cost, dominated by the commodity price of gold powders used in the conductor paste. In contrast, the HTCC module utilizes tungsten conductors, and thus the paste represents only 5% of the cost. Overall, this LTCC module, in high volume, costs more than twice as much as a comparable HTCC module. The second source of loss in highfrequency packaging is dielectric loss, influenced by dielectric constant and loss tangent. The magnitude of these attributes, in addition to their variability within a material, can be critical. For HTCC Relative cost: 1.0 Paste Tape 3% 2% Paste 56% Labor 13% Metals 27% Metals 70% Labor 25% Figure 9. Comparative costs of the same RF module manufactured in LTCC (commercial tape with gold conductors) and HTCC (Al2O3 with tungsten conductors). Metal costs include heat sinks, seal rings, braze preforms, leads, and connectors. Downloaded from bulletin-archive.ceramics.org www.ceramics.org | American Ceramic Society Bulletin, Vol. 97, No. 3 Credit: Kyocera International Inc. Credit: Kyocera International Inc. example, embedded filters, important in communications and radar applications, are susceptible to small changes in dielectric constant. Fundamentally, dielectric properties can be subtly or significantly impacted by variability in ceramic density, phase chemistry, phase distribution, and impurities, among other factors. This vari ability can be linked to inconsistencies in chemistry, processing, and firing. Figure 10 displays dielectric constant (Dk) distribution in various commercial HTCC and LTCC systems, taken from different raw material and firing lots. The two LTCC materials with the lowest Dk (5.9 and 7.1) also exhibit the broadest distribution. In fact, each LTCC composition with noble metal conductors features resistor, solder mask, and conductor pastes that may be printed and refired. This refiring, while offering greater flexibility in design, may alter the phase Population 20 18 16 14 = 12 21 LTCC (Cu) LTCC (Au) LTCC (Au) 4 LTCC (Au) 2 ° 5.5 65 75 Dielectric constant MTCC (CuW) HTCC (W) 85 Figure 10. Distribution of dielectric constant at 10 GHz in multilayer ceramic materials: LTCC with copper or gold conductors, HTCC with tungsten conductors, and a medium-temperature cofired ceramic (MTCC) that employs a composite CuW conductor and is fired at ~ 1,300°C. distribution within the ceramic, resulting in the type of variability observed in Figure 10. Protecting satellite electronics Hermetic modules have been considered essential in satellite and other high-reliability applications. Costs associated with placing electronics in space and the impact of failures have mandated that reliability is paramount. Recent qualification of a “near hermetic” specification for space (NASA\'s Class Y microcircuit designation) has challenged that paradigm. Ceramics can also offer weight savings over metal structures, although polymeric materials are lighter still. Satellite electronics can be grouped broadly into power, sensing, analog/digital processing, and transmission/reception. The considerations associated with power handling are similar to those discussed earlier-efficient thermal dissipation with minimal electrical losses. Unlike terrestrial applications, where convective cooling is an important cooling mechanism, radiative cooling may become dominant in space. Thus, emissivity must be considered in the choice of materials. The advent of available satellite views of almost anything, on top of imagery used in the prediction of weather, assessment of drought, status of sea ice, etc., may be attributed to the sensitivity and variety of sensors placed in orbit. Ceramic substrates play a large role in silicon image sensors. Whereas the overwhelming majority of image sensor substrates are found in cameras and mobile phones, large image sensors have long been placed on satellites used by both commercial and government agencies. Once again, reliability drives the choice of ceramic substrate, which may be exposed to a large number of thermal cycles over the mission lifetime. AlN, with a coefficient of thermal expansion close to that of silicon, has been used to support large-area substrates. Credit: Kyocera International Inc. Collection of large amounts of digital images and analog data requires sophisticated image processing. Figure 11 shows a multilayer Al2O3 multichip module developed for space data processing. This particular device mandated a set of RF Associated Ceramics an Advanced Technology Company An Industry Leader in Manufacturing Advanced, Technical Ceramics Since 1966 400 North Pike Road, Sarver, PA 16055 | 724.353.1585 www.AssociatedCeramics.com Proudly Made In USA Downloaded from bulletin-archive.ceramics, 3 | www.ceramics.org American Ceramic Society 37 Ceramics drive innovation and efficiences in the semiconductor industry 30.300 30 Figure 11. Satellite digital-to-analog converter (DAC). This multichip module includes Si and SiGe chips and decoupling capacitors to enhance signal integrity. The device is shown without its hermetic lid. Credit: Kyocera International Inc. and digital performance metrics for both the semiconductor and HTCC substrate. An even more daunting challenge involved dimensional and reliability requirements—the hermetically sealed package was required to fit within a narrowly defined volume. Typically, multilayer ceramics can be fired to relatively tight x-y tolerances (e.g., ±0.5% or better). However, z (thickness) tolerances are much looser (e.g., ±10%). Hardware used by the customer using the device shown in Figure 11 could not accommodate this kind of variability. Reliability testing on such a part was extensive, including evaluation of outgassing of the die attach and thermal pastes, acceleration and vibration, particle impact noise detection (PIND), and modeling to predict failures due to thermal cycling. Understandably, nothing about packaging for satellite applications is inexpensive. Transmission between terrestrial and satellite terminals involves high-frequency signals, e.g., Ku and Ka band (10-40 GHz). Data processing, however, may use lower frequencies. Thus, there is a need for substrates and semiconductors that can efficiently process, upconvert/downconvert, and transmit/receive signals that may span 30 GHz. Figure 12 shows an example of a frequency converter package manufactured with a commercial LTCC tape system (DuPont). This multilayer part includes many RF transitions and connectors and a complex cavity structure. Integration of functionality (amplifiers, phase shifters, attenuators, etc.) into semiconductors introduces some challenges and some flexibility in the design of packaging, where passive functions (balun, couplers, dividers, and filters) may be incorporated. LTCC is particularly well-suited for these packages because resistor and capacitor structures can be fired directly into the ceramic. Embedding load resistors proximate to dividers/couplers can increase bandwidth and decrease loss. HTCC, without cofired Figure 12. A satellite frequency converter package manufacured using a commercial LTCC with cofired Au conductors, RF connectors, and a complex heat sink, seal ring, and cavity structure. resistors, must rely on discrete passive components (surface mount resistors, capacitors, and inductors) placed on exposed layers. In addition, low-loss gold, silver, and copper conductors in LTCC represent a distinct advantage, with some penalty in cost, thermal performance, and strength. High-reliability and communications antennas are increasingly migrating to a phased array architecture. Rather than utilizing a high power beam that is scanned mechanically, phased arrays provide a much more agile means of directing RF signals. A phased array can have thousands of individual radiating/receiving elements, each one individually controlled by amplifiers, phase shifters, and attenuators. Phased arrays have been adopted for automotive radar and some commercial point-to-point/5G radios.5 Severe cost constraints have steered these antennas into low-cost PWB technologies. Space and high-reliability airborne antenna continue to favor hermetic ceramic solutions, however. Like the frequency converter module shown in Figure 12, antenna modules may include cavities, connectors, and a complex array of embedded RF structures. Integration of high-performance RF connectors with low-loss interfaces is an important feature of these types of modules. Alternatively, there are applications where much of the processing is located on a PWB substrate to minimize ceramic content. In these examples, ceramic content may be limited to tuned antenna structures, such as dielectric resonators, patches, and slots. 12 Phased array antenna elements are typically placed on a grid corresponding to a spacing of one-half wavelength. At 10 GHz (2₁/2 = 15 mm), this allows a relatively comfortable placement of individual or multichannel RF modules. At Ka band (30 GHz) or V band (60 GHz), however, half wavelength spacing (5 mm or 2.5 mm, respectively) mandates significant condensation of functionality and packaging. Downloaded from bulletin-archive.ceramics.org www.ceramics.org | American Ceramic Society Bulletin, Vol. 97, No. 3 Integrated challenges In electronics, time is critical. Fabrication of ceramics is inherently slower than manufacturing plastics or easily machinable metals. Lead-times of 8-20 weeks are not at all uncommon-this limits the ability of customers to effectively iterate, and it penalizes mistakes. For example, a satellite customer may wish to iterate over several potential antenna designs before committing to a specific launch design. PWB fabrication, where short lead time is a requirement and very short lead times represent a competitive advantage, can accommodate turn-around times as short as a few weeks for a complex design. This flexibility minimizes risk for customers, enabling rapid iteration and optimization when attempting to meet a specific launch window. In the case of multilayer ceramics, green fabrication, sintering, and finishing steps typically involve expensive and timeconsuming processes. Pressed ceramics require tooling, green machining, sintering, and finishing steps that also add to cost and manufacturing time. To address these forming challenges, additive manufacturing or 3-D printing can produce complex shapes without the need for expensive or difficult tooling. However, printing of electronic devices requires printing both metallization and ceramics and, thus, also involves matching expansion and sintering rates. Whereas additive manufacturing offers tremendous flexibility for prototype or small volume applications, it has yet to be adopted in volume production. About the author Arne K. Knudsen is with Kyocera International Inc. (San Diego, Calif.). Contact Knudsen at Arne.Knudsen@kyocera.com. References: \'Gartner Inc., \"Gartner says worldwide semiconductor revenue forecast to grow 7.5 percent in 2018,\" January 15, 2018. www.gartner. com/newsroom/id/3845163 2A. Knudsen, H. Makino, K. Morioka, H. Otomaru, H. Matsumoto, S. Satou, A. Thom, G. Munns, J. Yamamoto, M. Reiterer, \"A highreliability alumina-platinum multilayer system for implantable medical devices,\" Int. J. Appl. Ceram. Tech. (submitted). 3M. Eblen, Kyocera International Inc., private communication. 4J. Schoebel, T. Buck, M. Reimann, M. Ulm, M. Schneider, A. Jourdain, G. Carchon, H.A.C. Tilmans, “Design considerations and technology assessment of phased-array antenna systems with RF MEMS for automotive radar applications. IEEE Trans. Microw. Theory Tech., 53(6), 1968-1975 (2005). 5B. Fletcher, \"Facebook, Deutsche telekom pushing mm-wave at 60 GHz,\" Wireless Week, September 13, 2017. www.wirelessweek.com/ news/2017/09/facebook-deutsche-telekom-pushing-mmwave-60-ghz ENrGite Zirconia Ribbon Ceramics Ultra-thin, flexible, dense ceramic in a R2R format Applications: Solid-State Batteries Photovoltaics Printed electronics Sensors SOFCs And more! ENRG Inc. 716-873-2939 F: 716-873-3196 kolenick@enrg-inc.com kkeefe@enrg-inc.com www.enrg-inc.com Refractory Minerals COMPANY INC. Calcined Alumina and Phosphate Bonds REF-BOND MP2 Mono Magnesium Phosphate REF-BOND BMAP Buffered Mono Aluminum Phosphate ROXAL ALUMINA Calcined Alumina 325 Mesh TOLL BLENDING Downloaded from bulletin-archive ceramics American Ceramic Bulletin, 97, etin-archive ceramics, OK. 3 | www.ceramics.org 800.753.3204 WWW.PHOSPHATEBONDS.COM 39 Converting excess low-priced electricity into high-temperature stored heat for industry and high-value electricity production** By Charles Forsberg, Daniel C. Stack, Daniel Curtis, Geoffrey Haratyk, and Nestor Andres Sepulveda The large-scale deployment of wind or solar energy results in electricity prices below the price of fossil fuels at times of high wind or solar output. Price collapse can be limited by using low-price electricity to heat firebrick to high temperatures, store the heat in firebrick, and provide hot air as needed to industrial furnaces, kilns, power plants and gas turbines. This sets a minimum price on electricity near that of fossil fuels. M ost electricity is produced by burning fossil fuels. Economic variable electricity can be produced to match demand because most fossil plants have low capital costs and high operating costs. The cost of electricity does not increase rapidly for power plants operating at part load when the operating cost is the primary cost. Concerns about climate change require going to electricity generating technologies that do not emit carbon. dioxide such as nuclear, wind and solar. These technologies have high capital costs and low operating costs (Table 1); thus, the cost of electricity increases rapidly if these capital intensive plants are operated at part load. Because total energy costs for society are typically close to 10% of the gross national product, significant increases in energy costs implies significant decreases in the standard of living. In deregulated markets the large scale use of solar and wind results in electricity price collapse at times of high wind or solar input when electricity output exceeds demand. Collapsing revenue limits the economic use of solar, wind, and ultimately nuclear. A Firebrick Resistance-Heated Energy System (FIRES) is proposed ²,³ to limit electricity price collapse at times of high wind and solar output by converting excess low-price electricity into high-temperature stored heat that can be used as a substitute for fossil fuels by industry and to generate electricity at times of high prices. *Open-access article first published in The Electricity Journal 30 (2017) 42-52 (http://dx.doi/10.1016/j.tej.2017.06.009). Excerpts republished under the terms of the Creative Commons Attribution-NonCommercial-No Derivatives License (http://creativecommons.org/licenses/BY-NC-ND/4.0) Downloaded led from bulletin-archive.ceramics.org www.ceramics.org | American Ceramic Society Bulletin, Vol. 97, No. 3 60 A minimum price of electricity is created near that of the price of fossil fuels used by industry. It is a mechanism to better utilize capital-intensive generating assets. The paper (1) defines and characterizes applications for FIRES; (2) describes FIRES technical performance characteristics; (3) analyzes implications of largescale deployment on electricity markets; and (4) estimates capital costs. The paper reports on near-term applications such as heat to industry and long-term options such as coupling FIRES to gas turbines. Electricity markets In deregulated electricity markets, electricity generators bid a day ahead on the price that they are willing to sell electricity into the market—typically for each hour of the day. The grid operator accepts electricity bids up to the expected electricity demand for each hour. The bid ($/MWh) with the highest electricity price that is accepted sets the price for that hour and everyone who bids below that price gets the same price. Historically most electricity has been generated using fossil fuels; thus, the price set for each hour was set by the fossil fuel plant operating at that hour with the highest operating costs (Table 1). The markets have a variety of other mechanisms to assure reliable electricity and remain within the technical constraints of the electricity grid. In a perfect market, wind and solar will bid zero dollars per megawatt hour (Table 1) their variable operating and 65 45 Average $/MWh BN8 & Collapsing Prices on Sunny Days: Limits Solar Use Average Market Price Average Solar Owner Price 40 35 30 25 20 O 6 12 18 24 30 36 Solar Penetration (% Peak Demand) maintenance costs. The Massachusetts Institute of Technology (MIT) Future of Solar Energy study provides an examination of the solar option and the challenge of moving from an electricity grid dominated by fossil fuel generation to a low-carbon grid. Figure 1 shows market income for solar plants with increased use of solar. The average price of electricity received for the first few solar plants that are built is above the average yearly electricity price because the electricity is produced in the middle of the day when there is high demand and the prices are high. As more solar plants are built, electricity prices at times of high solar output collapse; thus, solar revenue collapses as solar production increases. This limits unsubsidized solar capacity to a relatively small fraction of total electricity production even if there are large decreases in solar capital costs. Figure 1. Solar PV market income and average wholesale electricity prices versus solar PV penetration. At the same time there are only small changes in the average price of electricity. Other power plants are required to provide electricity at times of low solar output-but these plants operate for fewer hours per year. Investors will not build new power plants to meet this need unless the price of electricity increases at times of low solar output to cover costs of a power plant that operates only part of the time. The same effect occurs with wind. Recent studies have quantified this effect in the European market. 5,6 If wind grows from providing 0% to 30% of all electricity, the average yearly price for wind electricity in the market would drop from 73 €/MWe (first wind farm) to 18 €/MWe (30% of all electricity generated). There would be 1,000 hours per year when wind could provide the total electricity demand, the price of electricity would be near zero, and 28% of all wind energy would be sold in the market for prices near zero. To use a real example, Figure 2 shows wholesale prices for electricity in western Iowa, a state with a large installed wind capacity. One can see negative prices Table 1. US Energy Information Agency estimated levelized cost of electricity (LCOE) for new generation resources in 2020 using 2013 $/MWh(e)\' Capacity factor(%) Levelized capital cost (plant and transmission) Fixed operating and maintenance Variable O&M including fuel Total system LCOE Plant type Dispatchable technologies Conventional coal 85 61.6 4.2 29.4 95.1 Conventional CC* 87 15.6 1.7 57.8 75.2 Advanced CC with CCS* 87 31.3 4.2 64.7 100.2 Conventional combustion turbine 30 44.2 2.8 94.6 141.5 Advanced nuclear 90 71.2 11.8 12.2 95.2 Non-dispatchable technologies Wind 36 60.8 12.8 0.0 73.6 Wind offshore 38 174.4 22.5 0.0 196.9 Solar PV 25 113.9 11.4 0.0 125.3 Solar thermal 20 197.6 42.1 0.0 239.7 *CC: Combined cycle; CCS: Carbon capture and storage Downloaded from bulletin-archive.ceramics, 6.3 | www.ceramics.org American Ceramic Society 41 Converting excess low-priced electricity into high-temperature stored heat . . . Price, S/MWh 100 Day-Ahead Hourly Electricity Price at Iowa MEC.PPWIND node, 2013-2014 High-Price Electricity When Low Wind and High Demand Negative Price Electricity When Excess Wind (Subsidies) 5000 10000 Hour number 15000 Figure 2. Hourly wholesale electricity prices in Iowa over two years. Use LowPrice Electricity to Heat Firebrick Cold Air Heated Firebrick Hot Air Industrial Kiln or Furnace Using Hot Air Adjust Temperature: Add Cold Air or Natural Gas ar provides over 70% of all electricity produced. The different levels of solar, wind and nuclear penetration before significant revenue collapse reflects the relative mismatch between electricity production for each of these technologies and demand. There is a large literature on the other market effects of adding solar and wind to the grid 8,9 and limits on use of electricity storage to address this challenge. 10,11,12 The revenue collapse is a consequence of going from lowcapital-cost high-operating-cost fossil systems to high-capitalcost low-operating cost solar, wind and nuclear systems. Revenue collapse at times of high solar and wind input favors the use of low-capital-cost high-operating-cost fossil fuel electricity generation at times of low wind or solar output. This expanded the use of coal in Germany and natural gas in the United States as renewables are added to the grid. Societies can choose to subsidize particular energy systems for social reasons but because energy is such a large fraction of the global income, this has large impacts on standards of living. What is required are low-cost methods to productively use low-operating-cost excess generating capacity when available to reduce electricity price collapse under high wind or solar conditions and thus expand use of low-carbon solar, wind, and nuclear electricity generating technologies. FIRES for industrial heat Technical description FIRES (Figure 3) consists of a firebrick storage medium with a relatively high heat capacity, density, and maximum operating temperatures up to ~1,800°C. 2,3 The firebrick is \"charged\" by resistance heating with electricity at times of low or negative electricity prices. Low electricity prices are defined as electricity Figure 3. Configuration of FIRES coupled with an industrial process. prices that are less than the competing fossil fuel-that is natu(+ Capacity V1→ vo Charge Rate V1-> vo→ -W -WFigure 4. Independent performance aspects of FIRES. Discharge Rate enabled by wind subsidies on days of high wind conditions. When there are negative prices, the electricity generator pays the grid to take the electricity. Wind operators are willing to pay the grid to take electricity because their subsidies are tied to electricity produced. Without subsidies, prices would go to zero but not negative except under limited circumstances. In this specific example the price of electricity is less than the local industrial price of natural gas for over half the time. Analysis indicates that significant price reductions occur on a grid when solar provides over 10% of all electricity produced, wind provides over 20% of all electricity produced, and nucleDownloaded from bulletin-archive.ceramics.org ral gas in the United States. Resistance heating is the lowest cost method to use electricity. The firebrick, insulation, and other storage components are similar to high-temperature firebrick industrial recuperators. The ceramic firebrick is used because of its low cost and durability, while also having large sensible heat storage capabilities. If one allows a 1,000°C temperature range from cold to hot temperature, the heat storage capacity is ~0.5-1 MWh/m³. The heat is recovered by blowing air through channels in the brick. The output of FIRES is hot air, which is heated or cooled as needed for the given application by adding natural gas heat or cold air, respectively. The required discharge rate is determined by the furnace hot-air requirements that FIRES is coupled to. FIRES is designed for specific groups of industrial customers. There are three performance characteristics of interest (Figure 4), each of which is largely independent of the other: storage capacity, charge rate, and discharge rate. Storage capacity: Storage capacity of FIRES is governed by the sensible heat capable of being stored in a volume of material over a chosen temperature range (minimum and maximum temperatures). The chosen temperature range and material will be determined by the needs of the industrial process. More firebrick will store more energy. www.ceramics.org | American Ceramic Society Bulletin, Vol. 97, No.3 Charge rate: FIRES is charged by resistance heating. The charge rate will be determined by the electricity market. If the wind or solar resource combined with market demand drives prices down for only a few hours per day, high charging capacity will be preferred to capture the lowest priced electricity. If low price electricity is available for longer periods of time, lower charging capacity with its lower costs will be preferred. The type of electric resistance heating depends upon the peak temperatures. For less than 1,000°C, traditional low-cost resistance heating elements using nichrome wire or similar materials will be used-the type of heating elements in home toasters. Except for industrial applications, the wire is thicker and designed to operate at higher temperatures. Typical firebrick materials are made of aluminum, magnesium, and silicon oxides, cheap high-temperature materials that are insulators. The firebrick provides the electrical insulation for the heaters. For very high-temperature operations, conductive firebrick made of materials such as SiC may be used as the resistance heaters. Discharge rate: Within FIRES, the nominal discharge rate is determined by the heat transfer from the hot firebrick to the air, which is a function of air channel geometry, fan power and other design features discussed in Section 3.4. The heat losses in optimized systems will be below 3% per day. In addition to insulation, cold air flow into FIRES can be routed around and through the outer sections of the insulation and by electrical leads to resistance heaters to pick up heat that is leaking from the system. This type of dynamic insulation recovers most of the heat leaking though the insulation and can result in extremely low heat losses if FIRES is operating on a daily cycle. Operations The heat input rate would depend upon resistance heating capability, unused heat storage capacity, and day-ahead projections of electricity prices. 13 The price of electricity varies by the hour, thus electricity to heat the firebrick would be purchased when the prices were at their lowest given the constraint to maximize total kWh of electricity bought at less than the price of the alternative fossil fuel. This creates an incentive to oversize the electrical heaters to maximize electricity purchases when the price is low. If FIRES is fully charged and the price of electricity is less than the comparable fossil fuels, the heaters would operate at the power level of the industrial furnace-avoiding the need for a second set of electric heaters to take advantage of low-price electricity to provide heat to industrial furnaces. In locations such as western Iowa, electricity prices are below natural gas prices for over half the time, implying electric heaters are on over half the time. With large-scale deployment, the minimum electric prices will follow fossil fuel prices much of the year. Because the industrial heat demand is larger than electricity production, it has the potential to absorb all low-price electricity. This is in contrast to other storage devices (pumped storage, batteries, etc.) that have \"limited\" storage capacity. The owner of FIRES wants cheap heat-but does not care when heat is delivered. However, the electricity grid operator Downloaded from bulletin-archive.ceramics, 6.3 | www.ceramics.org American Ceramic Society has a different perspective. Electricity to FIRES resistance heaters can be cut off in a fraction of a second without impacting heat delivered to the industrial furnace from the firebrick. Shutting down or turning on the FIRES resistance heaters can be used to stabilize the grid; thus, there are incentives for the grid operator to pay the FIRES owner to control when electricity is sent to FIRES resistance heaters. Technology status Firebrick with electric heating is used for low-temperature home heating in Europe and elsewhere. Some utilities offer a discount rate for electricity at night. At such times the firebrick is heated up to 600°C with electric resistance heaters. The hot firebrick then provides warm air when needed for room heating by blowing air through channels in the firebrick. Over 100,000 MWh of such heat storage capacity¹4 has been built with heat storage capacities under 100 kWh per unit. In the last several years there have been night discount rates on electricity in parts of China. This has resulted in development of similar units to provide hot air for heating water up to 85°C to provide hotwater heat and hot water for large apartment complexes. The larger firebrick heat storage units have capacities of 8 MWh. These units have peak firebrick temperatures of 850°C. There are large incentives to maximize peak firebrick temperature to minimize physical size and weight and thus enable building the units in factories and delivery of assembled units by truck. SERVICING: Iron Foundries • Steel Plants • Aluminum Plants Electric Power Plants • Petrochemical Plants Boiler/Incinerator Facilities Lime Plants Mineral Processing Plants • Cement Plants Pre-Cast Shapes up to 40,000 lbs RRENO REFRACTORIES, INC. PO Box 201 Morris, Alabama 35116 (205) 647-0240 Toll Free: 1-800-741-7366 Fax: 877-991-0001 email: sales@renorefractories.com Conquerors of Heat 43 Converting excess low-priced electricity into high-temperature stored heat . . . Such systems could be coupled together for smaller lower-temperature industrial applications. Lower-temperature FIRES could have been developed in 1920 if there had been a market. FIRES has two major components: firebrick and electric heaters. The concept of FIRES has a great deal in common with firebrick recuperators used today in industry that were originally developed for open-hearth steel furnaces of the early-20th century. In these large systems, hot air was blown across the surface of molten pig iron (~1,600°C) to convert pig iron into steel by oxidizing the carbon in the pig iron. The hot offgas from the furnace flowed through one of two firebrick recuperators in which the hot gas flows over cold firebrick, transferring heat to the bricks before exhausting to the stacks. Later, the direction of air flow through the system was reversed, such that cold air enters and flows through the now-hot firebrick, thereby preheating the air. The hot air from the recuperator was further heated with oil before going to the furnace. The air temperatures had to be maintained above 1,600°C to avoid freezing the pig iron and freezing the liquid metal surfaces. Firebrick recuperators are used today in the steel, glass, and other high temperature industries to recover heat to lower energy costs. There is a century of experience in operating industrial recuperators up to about 1,800°C. Large-scale low-cost electric resistance heaters are an off-the-shelf technology with peak temperatures between 1,000°C and 1,200°C; but, there are tradeoffs between peak temperatures and heater lifetimes. There are multiple resistance-heater options at higher temperatures but the experience base is more limited and the costs are signifiFirebrick-A humble hero for stabilizing electricity markets By Eileen De Guire Society values renewable energy technologies for the carbon they do not contribute to the environment. They do, however, wreak havoc on electricity markets and can collapse the price of electricity, almost instantaneously, at times of high wind or solar input. Charles Forsberg, MIT principal research scientist, and his team developed the Firebrick Resistance-Heated Energy System (FIRES) to smooth the roller coaster fluctuation of electricity markets. Forsberg, a nuclear scientist, leads a multiuniversity research team on combining saltcooled reactor technology and gas turbines to generate electricity. That work led to a need to store heat. The idea is to have power plants buy their own power when it is cheap and use it to electrically heat firebrick. Later, the stored heat is used to reduce the cost of bringing gas turbines up to temperature for maximum electricity production when prices are favorable. Forsberg, with his deep knowledge of electricity market dynamics, saw a near-term market opportunity for FIRES. \"You essentially have two markets-the market for heat input into industrial boilers and the second one into higher-temperature, direct-fire industrial processes,\" he says. The system has been demonstrated in China to heat large apartments, for example. \"They\'re using electric heat to minimize burning of coal near cities. The electricity generator sells cheap electricity at night to charge the 8 MWh heat storage unit,\" says Forsberg. The promise of FIRES is the opportunity to capture and save extremely low-cost electric power in the form of high-temperature heat for industry. Downloaded from bulletin-archive.ceramics.org \"This is an economic tradeoff. I can buy cheap electricity at certain hours or I can buy natural gas and the market will determine what my preferred course of action is and how much firebrick I should buy for each storage unit,\" he says. \"This is a bottomprice driven market.\" The concept is simple. Electric heating elements heat a firebrick structure, which can be quite large on the order of hundreds to thousands of cubic meters. Clay-based firebrick is cheap. \"Firebrick is good to 1,600°C. The limiting factor is the electrical heaters,\" according to Forsberg. Cal-rod heating elements-similar to the type used in household kitchen ovens-heat only to about 850°C. Typical silicon carbide heating elements are too expensive for this system, so the team is developing conductive firebrick made of low-grade silicon carbide. Conductive firebrick would have the advantage of heating brick directly. These heating \'elements\' made of many bricks with cooling channels can be large, up to several meters thick. The channeled structure offers many pathways for electric heating, which eliminates failure if a crack occurs. Direct heating of the brick will heat brick more uniformly. The key will be cost, which is why the team is focused on low-grade silicon carbide. The team plans to evaluate mixed clay-based and conductive firebrick systems, too. \"We want cheap conductive firebrick. It\'s still early. Our goal is to find a cheap material with control over electrical conductivity in an oxidizing environment,\" Forsberg says. Because electricity markets are regional, FIRES likely will be adopted first in the Great Plains (wind), then the Southwest (solar). Ethanol producers, many of which are located near wind farms, would be prime candidates for FIRES. \"Manufacturing companies and utilities have the biggest commercial incentive to get it deployed,\" says Forsberg. The first commercial units should come online around 2020. FIRES offers another advantage-the ability to stabilize the grid. Over-supply of wind or solar energy contributes to price collapse of electricity. \"With wind and solar there are a lot of transients generated that FIRES can stabilize. Energy producers can sell large amounts of electricity very quickly, or the FIRES owner can turn it off at a moment\'s notice—for a price. The near-term market may be cogeneration facilities that currently send electricity to the grid and heat to industry,\" he says. The market for FIRES only emerged in the last four years with the diversification of the nation\'s energy portfolio. It will take time for the energy producing portfolio to settle into its optimal mix. \"Oh, there will be decades of wild changes in the electricity markets. We think maybe 20 years of chaos.\" Credit: HWI www.ceramics.org | American Ceramic Society Bulletin, Vol. 97, No.3 cantly higher. One option for low-cost very high temperature heaters is the use of conductive firebrick. Conductive firebrick is used in electric steel making processes at very high temperatures, but in a steel plant the conductive firebrick is under chemically reducing conditions and would not withstand the oxidizing environment of FIRES. There are alternative conductive firebrick options such as silicon carbide. We have initiated an experimental program to develop heaters for high temperatures using conductive firebrick as the resistance heating element, a potentially low-cost high-reliability heating system for this application. Unlike conventional resistance heaters, these heaters would literally be piles of conductive brick. Editor\'s note: See original article for section 3.4 Design Examples. Economics Table 3. Industrial applications of heat and required temperatures¹6 Heating method Steam heating Indirect heating Direct heating Two approaches²,³ were used to bound the costs of FIRES. The existing home heating variant (~ 100 kwh) of FIRES has retail prices as low as $15/kWh with a large spread in prices. Large home systems have about 100 kWh of storage capacity. For a typical industrial plant with 30 MW of heat input, FIRES would be sized to be over 100 MWh of storage capacity. Given the larger scale and avoiding markups for retail, the cost would be expected to be substantially less. The second approach was to price the components of fires from the electrical transformer to the firebrick. This yielded a price of $2.35/ kWh that depending upon other factors implies an installed cost 2 to 4 times larger. These preliminary estimates result in an industrial FIRES system between 5 to 10 dollars per kWh. Recent reviews¹² of energy storage options have broken the cost of different energy storage systems into the cost of storage ($/kWh) and the cost of power ($/kW). The low cost of FIRES relative to other energy storage technologies is a consequence of two factors. First, firebrick is clay sent through a kiln with costs of $0.5-2/kWh of storage. For comparison, pumped hydroelectricity and underground adiabatic compressed air energy storage costs can be in the $10/kWh range but battery options are $200/kWh or more. Second, FIRES\' power handling costs are low. Resistance heaters and the associated switches are cheap-a few dollars per kilowatt of power input. Resistance heaters can be designed to operate at any voltage including distribution voltages (22 kV and above) of the electricity grid and thus avoid added transformers and electrical losses. This is in contrast to other electricity storage technologies where power conversion capital costs are measured in $100s/kW. For pumped hydroelectricity and compressed air storage, those electrical systems must convert electricity from the grid into mechanical rotating energy and back requiring complex power control systems and motor-generDownloaded from bulletin-archive.ceramics, 6.3 | www.ceramics.org American Ceramic Society Industry application District heating; drying and evaporation processes Miscellaneous steam applications; pulp and paper products; food processing Petrochemical refineries Inorganic minerals production (phosphates, soda ash/sodium hydroxide, chlorine, etc.) Biofuel refineries (different processes) Chemicals manufacturing (methanol, ethylene, propylene, acetic acid, resins, etc.) Hydrogen from hydrocarbons Glass and fused silica; iron and steel making Portland cement (xCa0- yAl₂O₂- zSiO₂) Lime (Cao/CaOH) Process temperature (°C) 30-200 100-300 Distillation: 200-500 Thermal cracking: 400-650 Minerals retorting: 350 - 500 Minerals concentration: 150-250 Distillation: 150-200 Torrefaction: 250 Pyrolysis: 500 Gasification: 850-1,000 Distillation: 150-200 Softening/melting: 150-300 Reaction: 300-600 750-900 > 1,000 - 1,500 > 1,300-1,800 ators. For batteries, one must take AC electricity and convert it to low-voltage DC electricity and back. Resistance electric heating is the only low-capital-cost technology for consuming electricity and thus the only cost-effective option to use excess low-price electricity if it is available for short periods of time each day. Preliminary economic analysis² indicates that the most High Quality Manganese for the Brick, Paver & Roof Tile Industry Niokem Mn304 MnO We can supply your manganese needs, and we offer the best customer service! Call Stephen Cox for current pricing 828-774-8745 45 Converting excess low-priced electricity into high-temperature stored heat . . . Proportion of Energy Use by Source Electrical Power Steam Systems Fired Heaters Energy Use 100% 140 90% 120 80% 70% 60% 50% 40% 30% 20% 10% 0% Mining Chemicals Forest Products Iron & Steel Mills Food & Beverage Petroleum Refining Alumina & Aluminum Cement Fabricated Metals Heavy Machinery Transport Equipment Textiles Plastics & Rubber Glass & Glass Products Foundries Computers, Electronics Figure 7. Energy use by U.S. manufacturing and mining industries for 2004.15 favorable locations for near-term FIRES deployment in the U.S. is in locations such as western Iowa (wind) where the payback is estimated to be between one and two years. The areas of FIRES economic viability will grow with additions of wind or solar. Applications Most of the world\'s energy comes from burning fossil fuels in air that creates hot air-the same product as FIRES. As a consequence, FIRES couples to most existing energy production and use applications. FIRES economics are improved if it can operate year-round. The only two sectors of the U.S. economy capable of absorbing large quantities of energy at all times of year are the industrial sector and the market for electricity. Figure 715 shows energy demand and heat demand by different sectors of the U.S. economy-the industrial markets for FIRES. Table 316 describes the different markets in terms of steam production, heating of other fluids through heat exchangers, and direct heating. The largest market is indirect heating-producing steam or heating hydrocarbons (refineries and chemical plants) where heat is transferred through metallic heat exchangers with temperature limits typically between 500°C and 700°C. Current FIRES technology can meet these requirements. The glass, cement, and steel industries require very high temperatures and traditionally use direct Downloaded from bulletin-archive.ceramics.org 100 SO 60 40 40 20 heating with fossil fuels. There are incentives to operate FIRES up to 1800°C for some of these industries beyond just providing low-cost heat. For example, the production of cement and lime involves the high-temperature decomposition of CaCO3 into CaO and CO₂. However, direct heating using fossil fuels creates a hot rich in CO₂ that tends gas to drive the chemical reaction backward. If FIRES can provide some of the heat, the lower CO2 levels should reduce the energy required and increase the rate of decomposition of CaCO3. 2 FIRES can partly replace fossil fuels in various thermal electricity production systems in two different configurations. Coal, oil and natural gas plants provide variable electricity to the electricity grid. When low-price electricity is available and the fossil plant is not providing electricity, FIRES is heated. When there is high-price electricity, FIRES heat partly replaces the burning of coal, oil or natural gas to produce electricity. In this configuration FIRES acts as storage system. However, unlike batteries and pumped storage, if FIRES is depleted, fossil fuels can be used to assure electricity production capacity. The alternative configuration is designing the thermal power system to couple only to FIRES; that is, FIRES is the only heat source. In this configuration FIRES is an electricity storage system equivalent to a pumped hydroelectric or battery system. Excess energy Energy Use by Industry [GW] is stored as heat rather than gravitational potential or chemical energy. The round-trip efficiencies would be ~45% for steam cycles, ~40% for a simple gas turbine and -60% for a combined cycle gas turbine. For the thermal power cycles (steam, supercritical carbon dioxide, etc.) where the heat source is operating at atmospheric pressure, FIRES could be built in large sizes for storage system outputs of hundreds of MWe. The gas turbine options are discussed in Section 5. Siemens is beginning to develop a simple FIRES heat storage system for peak electricity production. At times of low electricity prices, air is heated to 600°C with resistance heaters and blown through a bed of crushed rock. The system is discharged by blowing cold air through the hot rock with the hot air being sent into a packaged steam boiler with the steam used to produce electricity. This storage system would be coupled to wind farms. Last, there is potential market for FIRES coupled to photovoltaics (PV) for home or small industrial applications. PV panels are inexpensive but PV electricity for the grid is expensive because of the power conditioning and grid interface requirements. For areas with low-cost land, PV output could be directly coupled to the resistance heaters of FIRES without power conditioning. Unlike other electrical devices, resistance heaters do not need power conditioning. It is an analog to the century-old Great Plains windmills used to pump water where water output was variable and uncontrolled but sent to a cheap water tank that acted as the storage system. No detailed analysis of this option has been done. The U.S. heat market includes the industrial, commercial, and residential sectors. 18 While FIRES could be deployed in each of these sectors, the industrial sector is economically preferred. First, the individual heat loads are two to five orders of magnitude larger with large economics of scale. Second, industrial facilities operate year round whereas most commercial and residential heat loads are seasonal. This is important in two different contexts: (1) the seasonal heat demands of commercial and residential heat loads www.ceramics.org | American Ceramic Society Bulletin, Vol. 97, No.3 may not match when low-price electricity is available and (2) if FIRES operates for 300 days per year versus 100 days per year, the cost per unit of energy stored is reduced by a factor of three. The number of cycles per year strongly impacts economics. Third, the industrial heat market is larger than the electricity output of the United States. 18 As a consequence the market for heat from FIRES is sufficient in size to consume all low-price electricity that may be produced. This is also true for other industrial countries such as Japan. Editor\'s note: See original article for sections: 4. Implications on Electrical Prices, and 5. FIRES Coupled to Gas Turbines. Other implications Beyond setting a minimum price for electricity that supports low-carbon generating technologies and provides heat to the industrial sector, FIRES may have other impacts on the electricity grid. Large-scale wind and solar results in large increases in grid and other electricity system costs 4,9; separate from the costs of wind and solar generating systems. One major cost is the low capacity factors for transmission lines coupled to wind and solar because of low capacity factors for wind and solar production facilities (Table 1). In locations such as China where the major electricity load centers are far from the wind resources, 33 there is a tradeoff. The capacity factors of the transmission lines can be increased by overbuilding wind capacity, but that lowers capacity factors for the wind farms. If there are local industries that can use heat, FIRES can dump some of that excess energy to the industrial sector, increasing local wind farm capacity factors while maintaining higher long-distance transmission capacity factors. Alternatively, FIRES can be coupled with a power generating system to store excess electricity to enable transport when the transmission lines have excess capacity. Conclusions The transition from a fossil-fuel based electricity system to a low-carbon electricity system is a transition from low-capitalcost high-operating-cost electricity generators to high-capitalcost low-operating-cost nuclear, wind and solar systems with low marginal generating costs. This has resulted in increasing numbers of hours in Europe and the U.S. with wholesale prices of electricity near zero-economically limiting the use of these low-carbon electricity sources. A low-cost technology is required to productively use excess electricity and raise the minimum prices for electricity at these times. FIRES converts low-price electricity into high-temperature hot air and stored heat to replace fossil fuels in industry-the only year-round market sufficient in size to absorb very large quantities of lowprice electricity. Alternatively FIRES can be used to store electricity in the form of thermal energy. The basic FIRES technology for many applications could have been developed and deployed in the 1920s. It is the change in the electricity market that creates the incentive to deploy FIRES. The estimated capital costs of FIRES to provide heat to industry is $5-10/kWh, below any other technology. Downloaded from bulletin-archive ceramics, or 3 | www.ceramics.org American Ceramic Bulletin, 97, That is because the heat storage media is pressed dirt that has gone through a kiln (firebrick) and electric resistance heating is the lowest cost device for using electricity. For some applications, FIRES can be built today. For other applications significant development is required. Acknowledgements The authors would like to thank Idaho National Laboratory and the U.S. Department of Energy for support of this work. This research is supported through the INL National Universities Consortium Program under DOE Idaho Operations Office Contract DE-AC07-05ID14517. About the authors Charles Forsberg is principal research scientist at Massachusetts Institute of Technology and executive director of the MIT Nuclear Fuel Cycle Project. Daniel C. Stack is Ph.D. candidate at MIT; Daniel Curtis is Ph.D. candidate at MIT; Geoffrey Haratyk received a Ph.D. from MIT and now works for PSEG; and Nestor Andres Sepulveda is Ph.D. candidate at MIT. Contact Forsberg at cforsber@mit.edu. References See original open-access article for references: The Electricity Journal 30 (2017) 42-52 (http://dx.doi/10.1016/j.tej.2017.06.009). CeraNova High Performance Transparent and Advanced Ceramics for Demanding Applications ISO 9001 2015 Providing Our Customers with Advanced Materials and New Product Development for Over 25 Years www.ceranova.com sales@ceranova.com. 1-508-460-0300 47 Case study Ceramic furnace coatings can boost manufacturer\'s annual revenue by $480,000 4 Credit: Intemational Technical Ceramics LLC Figure 1. Austenitizing furnace for manufacturing steel railcar coupler castings at McConway Torley LLC. By Greg Odenthal High-temperature ceramic coatings for furnace-lining refractories can simultaneously reduce energy consumption, improve temperature uniformity, reduce furnace maintenance, and increase production. Downloaded from bulletin-archive.ceramics.org For \'or every steel producer, forge shop, and heat-treating company, operating costs are a primary concern. These manufacturers constantly search for ways to reduce fuel consumption, maintenance and unscheduled downtime, and heat-up and turnaround times, while increasing product quality and revenue by adding to the bottom line. For critical part producers like forge shops, there is a continual effort to identify, contain, and minimize operating costs. For these manufacturers, heating is an essential process that must be optimized to maintain process efficiency. Ceramic coating technology High-temperature, energy-efficient ceramic coatings for refractories are used in furnace applications to reduce energy consumption, improve temperature uniformity, reduce maintenance, and increase production, all while improving product quality. By increasing the thermal reflectivity of a refractory lining in a furnace, specialized ceramic coatings can provide energy savings of up to 30% depending on the fuel type, furnace operation, furnace configuration, and production schedule. Further, ceramic-coated refractories decrease furnace heat-up and turnaround times and extend service life. The latest high-temperature, energy-efficient ceramic coatings are formulated based on water-soluble nanotechnologies, so no solvents are required for dilution or cleanup. They contain no volatile organic substances and are applicable to both refractory and metal surfaces. Once cured, they are environmentally inert and do not require special handling or disposal. www.ceramics.org | American Ceramic Society Bulletin, Vol. 97, No. 3 Invented by Feriz Delkic in 1980 to increase the efficiency of his kilns, International Technical Ceramics LLC (ITC) has been supplying high-temperature, energy-efficient ceramic coatings to worldwide manufacturers of steel and steel treaters, cement, ceramics, and brick, in addition to the waste-to-energy and petrochemical industries, for the past 40 years. Today, although Womack Industries owns ITC, the company continues to promote, advance, and supply this technology to a core customer base as well as seeks out unique new ways to help the manufacturing industry save money. The case of McConway Torley One ITC customer, McConway Torley LLC (Pittsburgh, Pa.), manufactures steel castings for the railway industry and is the leading supplier of railcar coupler castings today. In an attempt to reduce fuel consumption, high costs of refractory maintenance, and turnaround times, the foundry looked to ITC and its coating technology for help in November 2017 with a batch type, austenitizing furnace operating at 1,750°F (Figure 1). Using conventional refractories—either castable, brick, or ceramic fiber-operational losses in a furnace due to walls, opening, cooling, and stored heat can be as high as 27% (Figure 2). McConway Torley\'s furnace lining consisted of folded ceramic fiber modules with a density of 10 lbs. and thickness of 8 in. After years of service, the fiber had devitrified to a depth of approximately 0.5 in. and shrunk ~2%-3%, demanding constant maintenance and unscheduled downtime to pack and seal joints with new fiber blanket-only to have it shrink and fall out soon after start-up. Heat loss in the uncoated furnace associated only with walls and roof was 210 BTU/ ft²/hr, with a cold face temperature of 185°F (Figure 3). Applying approximately 5/16-18 i in. of ITC 100HT ceramic coating to the fiber modules reduced heat loss through the walls and roof to 195 BTU/ft²/hr, with a cold face temperature of 165°F (Figure 4). This difference equates to an average 7% decrease in heat loss through the refractory lining. Completely coating the entire hot face surface area of the refractory lining further increases furnace efficiency by providing more even temperature uniformity. Thermocouple readings showed before and after coating installation measurements of +40°F and +25°F, respectively. With additional heat available to the process due to the coating\'s ability to reradiate energy, the ceramic coating reduced McConway\'s fuel consumption by 10%, from 20.8 MCF per load down to 18.7 MCF. Total encapsulation of the refractory lining by the ceramic coating (Figure 5) protected the lining from damaging effects of devitrification and greatly reducing the amount of shrinkage that occurs in ceramic fiber. In addition to wall heat loss, energy loss associated with batch operation in itself accounts for almost 12%. Opening the door and removing treated parts to allow new parts to be charged results in loss of an enormous amount of energy and heat. Once the furnace is loaded again and the door closed, turnaround time to get back to operating temperature depends on several parameters-most important of which is the condition Downloaded from bulletin-archive ceramics, 3 | www.ceramics.org Recycled energy 10-30% Gross 100% fuel input Recovered heat input Fuel losses 20-50% Air preheater Furnace Stored heat 2-5% Wall loss 3-10% Opening loss 1-2% Useful output (heat to load) 30-60% Cooling loss 5-10% Figure 2. Sankey diagram showing operational losses in a furnace. Adapted from First ESCO India Pvt. Ltd. (www.firstescoindia.com/ glass-industry.htm). and type of refractory lining. Badly damaged and consumed linings allow greater wall losses and increase fuel consumption, thus increasing time required to reach operating temperature. Type of refractory also influences turnaround time. Denser refractories have greater heat storage values, thereby robbing the operator of valuable BTUs needed to bring the furnace back to temperature. Applied coatings can reradiate 90% of the radiant energy produced by burners (Figure 4). By reradiating the majority of BTUs instead of being absorbed by the refractory lining, NABALOX® SYMULOX® Aluminium Oxides ...multifunctional High abrasion resistance • Electrical insulation • Excellent mechanical strength • High temperature stability • Dimensional accuracy High chemical resistance NABACASTⓇ Synthetic Sintered Mullite ...refractory-grade • Excellent resistance to thermal shock Exceptional chemical resistance • High purity and homogeneity • Excellent temperature stability High toughness • ...cement-free highly refractory A new α-Al2O3-based, binder generation. Nabaltec developed an innovative cement-free binderbased on reactive alumina. NABACASTⓇ acts also as a micro-filler and a deflocculant. • Consistent product to achieve best processability ⚫ For the production of cement-free refractory castables Aluminium oxides produced by Nabaltec are essential raw materials for many applications in technical ceramics, the refractory and polishing industries. Therefore Nabaltec delivers products also as well for clientspecific requirements. Nabaltec\'s expertise in raw materials and processing guarantees consistently high quality products, optimized for customer requirements. Visit us at the Ceramics Expo at Booth 552 Nabaltec AG P.O. BOX 1860 Nabaltec 92409 Schwandorf Germany Phone: +49 9431 53-0 sales@nabaltec.de www.nabaltec.de 49 1600 1400 1200 1000 800 600 400 Temperature, °F 200 (A) Ceramic furnace coatings can boost manufacturer\'s annual revenue by $480,000 INTERNATIONAL TECHNICAL CERAMICS, ING Heat Flow Calculation (B) INTERNATIONAL TECHNICAL CERAMICS, INC ITC Heat Flow Calculation Material Premax Module, HP, 10 Thickness K-factor (in) (BTU-in/hr-ft^2-F) 8.00 1.03 Temperature (F) 1750 Material Thickness (in) Hot Face Temp. (F) ITC 100HT 0.19 Premax Module, HP, 10 8.00 K-factor (BTU-in/hr-ft^2-F) 1.53 1.01 Temperature (F) 1750 1726 Hot Face Temp. (F) 8.00 185 201 Cold Face Temp. (F) 8.19 165 Cold Face Temp. (F) Heat Loss (BTU/sq.ft/hr) 197 Heat Loss (BTU/sq.ft/hr) 1479 Heat Storage (BTU/Sq.ft) 1598 Heat Storage (BTU/Sq.ft) Ambient Temperature80 Windspeed= 0 Emissivity- 0.6 Construction Sidewall (F) (MPH) Ambient Temperature= 80 Windspeed- 0 (F) (MPH) Emissivity- 0.95 Construction Sidewall Thermal profile Thermal profile Temperature, °F 1600 1400 1200 1000 800 600 400 200 ° 0.00 1.00 2.00 3.00 4.00 5.00 6.00 7.00 0.00 0.00 1.00 2.00 3.00 4.00 5.00 6.00 7.00 8.00 Thickness, in. Thickness, in. Figure 3. Heat flow calculations for (A) the uncoated McConway Torley austenitizing furnace and (B) after installation of ITC 100HT ceramic coating. Note the additional data point on the graph after addition of the ceramic coating (red arrow). coated surfaces can reduce turnaround times by up to 20%-30%. Before coating installation, McConway Torley had minimum turnaround times of 1.33 hours. Application of ITC\'s ceramic coating decreased (A) turnaround to 0.83 hour, affording McConway one additional load per week. At roughly $10,000 per load, this equates to a potential increase in yearly revenue of $480,000. Absorbed & re-radiated energy (B) Impacts on process McConway Torley is still studying additional benefits of the coatings, including increased product quality due to elimination of cold spots and reductions in NO and CO2 emissions. The Radiation & convection ]/ Heat loss Radiation & convection Absorbed & re-radiated energy Downloaded from bulletin-archive.ceramics.org Less Heat loss Uncoated refractory substrate Figure 4. Heat diagrams showing flow with (A) uncoated and (B) coated refractory substrates. Coated refractory substrate www.ceramics.org | American Ceramic Society Bulletin, Vol. 97, No. 3 Credit: International Technical Ceramics LLC Credit: International Technical Ceramics LLC (A) (B) Figure 4. (A) Installation of ITC 100HT coating and (B) final coated sidewalls. total impact to the process and bottom line includes: • Lower shell temperatures; • Improved BTU savings; • Reduced refractory maintenance and unscheduled downtime; About the author Greg Odenthal is director of Engineering & Technical Operations at International Technical Ceramics LLC. For more information about ITC, visit www.itccoatings.com. Contact Odenthal at greg@itccoatings.com. • Increased refractory longevity; Reduced turnaround times; and • Decreased IN heat-up and cooldown times during outage. ITC\'s specialized coatings are helping McConway Torley improve the way it manufactures rail components and will continue to improve the way it manufactures products in the future. Conclusion An efficient furnace lining is essential for reducing overall maintenance costs and ensuring that facilities run smoothly without unwarranted revenue loss due to downtime. Hightemperature, energy-efficient ceramic coatings for refractoriesno longer \"theoretical\" technology—are being used successfully in furnace applications to reduce energy consumption, improve temperature uniformity, reduce maintenance, and increase production while improving product quality. The potential application of these coatings cuts across a wide spectrum of thermal process industries and types of equipment. Numerous installations have proven successful in steel manufacturing re-heat furnaces, tunnel kilns in brick plants, forge and heat-treat furnaces, and utility boilers across the globe. Trust me, you need ZYF zirconia felt. Downloaded from bulletin-archive ceramics etin-archive ceramics, OK. 3 | www.ceramics.org American Ceramic Bulletin, 97, 51 Credit: International Technical Ceramics LLC C ceramics expo Zirar Downloaded from bulletin-archive.ceramics.org Advancing the additive story IMERYS F or prototyping, small batch, and-increasingly under considerationmedium- to high-volume production, there is a keen collective eye on everything concerning ceramic additive manufacturing (AM). This PRA is certainly something that is shaping up to make an impact on the exhibit floor, innovation trails, and conference at this year\'s Ceramics Expo. A major attraction of AM is tool-free component production, added to which is the ability to handle complex geometries. Near-net-shape production also offers many advantages, not least of which is simpler and more cost competitive manufacturing. With ceramic AM, often subassemblies can be eliminated and installation is easier. It is also a great tool for rapid prototyping, enabling companies to bring products more quickly to market, and for manufacturing large/complex parts without the need for expensive tooling. Examples of significant uptake of AM in complex industrial sectors already abound, including space and aerospace manufacturers. GE Aviation\'s new Advanced Turboprop engine includes more printed components than any production engine in aviation history, with 35% of the parts built via AM. A total of 855 conventionally manufactured parts has been reduced to 12 additive parts, including sumps, bearing housings, frames, exhaust case, combustor liner, heat exchangers, and stationary flow path components. Additive components reduce engine weight by 5% while contributing a 1% improvement in specific fuel consumption. Meanwhile, Aerojet Rocketdyne and NASA completed hot-fire testing of an RS-25 rocket engine containing its largest AM component to date, which will help lower the cost of future missions of NASA\'s powerful Space Launch System heavy-lift rocket. The test demonstrated the viability of using AM to produce even the most complex components in one of the world\'s most reliable rocket engines. Increasingly, ceramics and CMCs play an important part in these ventures, as in the automotive, electronics, medical, energy, defense, and oil and gas industries. Ceramic AM, mirroring AM overall, looks set to grow exponentially in the coming years as it answers the needs of modern industry and performance demands of customers. Of course, none of these manufacturing ambitions can be realized without the input of materials and equipment innovators and suppliers-which is where Ceramics Expo comes in. Leading companies from around the world now choose this expo as a key forum at which to unveil their latest developments. We take a brief look at just some of them here. www.ceramics.org | American Ceramic Society Bulletin, Vol. 97, No. 3 Materials, components, and development Nanoe Booth 304 Nanoe is launching Zetamix, a filament for ceramic filament manufacturing (CFM). This filament comprises a polymer matrix and a zirconia toughened alumina powder, which can be used in any fused deposition modeling 3-D printer. Afterwards, the printed shape is debinded and sintered in the same processes as ceramic injection molding. CFM is very affordable with an investment of less than $2,000, customers are able to start producing some parts and learn to use this technology. Pre-orders for Zetamix will be taken at Ceramics Expo, and the first deliveries are expected in September. Johnson Matthey - Booth 546 Johnson Matthey recently opened a state-of-the-art ceramic 3-D printing facility in the U.K. Currently the company produces bespoke ceramic products with flexible geometries and feature sizes down to just 400 μm. This 3-D printing process offers a cost-effective solution for producing small, complex ceramics on a large scale. The new R&D laboratory enables Johnson Matthey to develop a greater understanding of 3-D printing, characterizing powders and inks to allow faster development and more effective solutions. Saint-Gobain High Performance Ceramics & Refractories - Booth 246 Saint-Gobain recently acquired Spin-Works International Corp., an innovative producer of highly complex ceramic burner components. Its SpyroCor Insert is placed into a radiant tube to capture and re-radiate exhaust gas energy into the furnace. The innovative AmaSiC-3D manufacturing platform enables geometries previously impossible with ceramic materials. Ceramco Inc. - Booth 242 Additive manufacturing is the most recent addition to Ceramco\'s manufacturing methods for production of ceramic parts. Unlike any of Ceramco\'s low-pressure or high-pressure injection molding methods (LPIM, HPIM, or microPIM), 3-D printing overcomes the problem of die lock often encountered in complex geometries. Systems and technology XJet Ltd. - Booth 210 XJet\'s Carmel product portfolio represents a transformation in the ceramic AM industry by printing ultrafine layers of nanoparticle \'inks.\' The technology uses dispersion at the nanolevel to simultaneously print build and support materials, achieving freedom of design for the most complex shapes. Ceramic parts produced on this system enjoy superfine details, smooth surfaces, and high accuracy due to the unique printing process. 3DCeram - Booth 257 3DCeram offers rapid custom ceramic component prototyping and volume production service; a 3-D ceramic printing system consisting of a printer, its consumables, and associated assist services; and a custom ceramics formulations service. Admatec Europe - Booth 448 Admatec was an early service provider for printing high-density ceramic components using its in-house-developed ADMAFLEX technology. In addition, it launched the Admaflex 130 3-D ceramic printer for commercial use. Zirconia, alumina, and fused silica are currently available, and additional materials will follow as a result of constant R&D. Lithoz GmbH - Booth 428 Lithoz is the system provider for AM of high-performance ceramics. The company developed LCM technology, which facilitates production of very delicate structures and fine details directly from CAD data. Lithoz covers the whole process chain, from development of the machine to materials and up to application. EnvisionTEC/Viridis3D Booth 353 Robotic AM systems from EnvisionTEC and Viridis3D are providing fast, flexible robotic 3-D printing options in the foundry and 3-D printing industries. Using a patent-pending technology, a proprietary print head attached to an ABB robot arm uses exclusive binder jetting technology to print sand molds, mold cores, and investment casting patterns for foundry applications. The proprietary systems include easy-to-use Viriprint software that uses a CAD file to print a mold and core in just a few hours. In addition to these exciting exhibits, ceramic AM promises to be one of the highlights of Conference @ Ceramics Expo. The entire conference, as with the expo, is totally free to attend. Here are some sessions you won\'t want to miss: May 1, Track 2, 3 pm Reviewing the Function of Polymeric Additives in Conventional Processing and AM of Ceramics to Optimize Structure of the Final Part This session will review the function of polymeric additives in conventional processing and AM of ceramics by looking at the following stages: evaluating binder addition levels and the role of wetting on binder behavior; reviewing resin-based binder systems for binder-jetting AM; and understanding the role of atmosphere on binder removal. May 3, Track 2, 11:30 am Developing Multi-Ceramics 3D Printing Technology for the Industrial Production of Solid Oxide Fuel Cells (SOFCS) The Cell3ditor EU project aims to develop a multimaterial 3-D printing process for mass production of monolithic SOFC stacks in a single printing step, without joints and sealing. This printer combines stereolithography and microextrusion printing in one machine for sequential application of different materials during the printing process. May 3, Track 2, 12 pm Reviewing Scale-Up of Binder Jet Ceramic AM Johnson Matthey has developed the capability to 3-D print ceramics using a binder-jet Downloaded from bulletin archieff3|www.ceramics.org technique. Follow the company\'s 10-year development journey, from initial R&D scoping exercises through prototyping, to full-scale production in Johnson Matthey\'s newly commissioned facility. From lightweighting parts used in the aerospace industry to optimization of fluid flow via design of complex catalyst supports and use of customized components in medical applications, this technology has a lot to offer. May 3, Track 2, 1 pm Industry Discussion on AM: If We Had a Crystal Ball... This session explores potential of the market and also the barriers to success, providing key insights by looking at more mature AM supply chains, such as polymer and metal AM industries. This is followed by a panel of industry experts sharing their vision on the field\'s future. If we had a crystal ball, where would we see the field going in the next 5-10 years and beyond-where will the technology be, and why will it take that amount of time to get there? Speakers at these sessions will include Kevin Keefe (ENrG Inc.), Albert Tarancón, (Catalonia Institute for Energy Research), Samantha Thomas (Johnson Matthey), Scott Dunham (SmarTech Publishing), Youping Rao (Aerojet Rocketdyne), Ingrid Kerscht (Pratt & Whitney), Tracy Albers (Rapid Prototype and Manufacturing LLC), Tobias Schaedler (HRL Laboratories), and Dror Danai (XJet). 53 REGISTER NOW! May 20-24, 2018 | Hilton Palacio del Rio | San Antonio, Texas 2018 GLASS & OPTICAL MATERIALS DIVISION ANNUAL MEETING Each year, the Glass & Optical Materials Division (GOMD) builds its annual meeting around emerging trends in glass science and technology. Technical leaders from industry, national laboratories, and academia will lead technical sessions featuring oral and poster presentations, providing an open forum for glass scientists and engineers from around the world to present and exchange findings on recent advances in glass science and technology. GLASS CORROSION SHORT COURSE May 20-8:30 a.m.-4 p.m. Instructors: Glass corrosion experts from industry and academia How do silicate glasses behave when they come into contact with water? This question is at the heart of many fields of research and is triggered by either industrial or environmental applications. This one-day short course taught by industry experts gives an up-todate overview of this topic. Course outline: - Fundamental aspects of silicate glass corrosion: Mechanisms and kinetics (theoretical background), Stéphane Gin, CEA, France - Experimental and analytical techniques to investigate glass corrosion, Joe Ryan, PNNL, USA - Atomistic modeling, Jincheng Du, University of North Texas, USA -Durability of commercial glasses, Robert Schaut and Nick Smith, Corning, USA - Nuclear waste glass corrosion and performance assessment, John Vienna, PNNL, USA - Glass alteration in volcanic and archaeological materials: Guideposts for predicting nuclear waste glass durability, Marie Jackson, University of Utah, USA SCHEDULE AT A GLANCE Sunday, May 20, 2018 Glass Corrosion short course (additional registration required) Registration Welcome reception Monday, May 21, 2018 Registration Stookey Lecture of Discovery Concurrent sessions Lunch on own New member reception (by invitation) Alfred University alumni reception (by invitation) Poster session & student poster competition Tuesday, May 22, 2018 Registration George W. Morey Award Lecture Concurrent sessions Student and Young Professionals career roundtables Lunch on own GOMD general business meeting Conference banquet Wednesday, May 23, 2018 Registration Darshana and Arun Varshneya Frontiers of Glass Science Lecture Concurrent sessions Lunch on own Publishing in American Ceramic Society journals: Writing for search engine optimization and self marketing The Norbert J. Kreidl Award for Young Scholars Lecture Thursday, May 24, 2018 Registration Darshana and Arun Varshneya Frontiers of Glass Technology Lecture Concurrent sessions Lunch on own 8:30 a.m. - 4 p.m. 4-7 p.m. 6-8 p.m. 7 a.m. 5:30 p.m. 8 - 9 a.m. 9:20 a.m.6 p.m. Noon 1:20 p.m. 5:30-6:30 p.m. 5:30-6:30 p.m. 6:30-8:30 p.m. 7:30 a.m. 5:30 p.m. 8 - 9 a.m. 9:20 a.m.-6 p.m. Noon–1:15 p.m. Noon 1:20 p.m. 5:30-6:30 p.m. 7-9 p.m. 7:30a.m. 5 p.m. 8-9 a.m. 9:20 a.m. - 6 p.m. Noon 1:20 p.m. Noon 1:15 p.m. 6-7 p.m. 7:30 a.m. 4 p.m. 8-9 a.m. 9:20 a.m. Noon–1:20 p.m. 4 p.m. Downloaded from bulletin-archive.ceramics.org www.ceramics.org | American Ceramic Society Bulletin, Vol. 97, No. 3 www.ceramics.org/gomd2018 GOMD AWARD SPEAKERS Stookey Lecture of Discovery Wolfram Höland, Ivoclar Vivadent AG, Liechtenstein Combinations of different nucleation and crystallization mechanisms to develop tailor-made glass-ceramics Morey Lecture Arun Varshneya, Saxon Glass Technologies Inc., USA Chemically strengthened glass: Science, technology and its future Norbert J. Kreidl Lectures Maxime Cavillon, Clemson University, USA Fabrication of intrinsically low nonlinearity glass optical fibers Tobias Bechgaard, Aalborg University, Denmark Temperature-modulated differential scanning calorimetry analysis of high-temperature silicate glasses Darshana and Arun Varshneya Frontiers of Glass Science Lecture Setsuhisa Tanabe, professor, Graduate School of Human and Environmental Studies, Kyoto University, Japan Glass and rare-earth elements Darshana and Arun Varshneya Frontiers of Glass Technology Lecture Xiang-Hua Zhang, research professor, University of Rennes 1, France Recent research trends of chalcogenide glasses and ceramics for infrared photonics and energy applications HOTEL INFORMATION Hilton Palacio Del Rio 200 South Alamo Street | San Antonio, TX, USA Tel: +1-210-270-0752 Group rate from $189+ tax is based on availability. Cut off is on or before April 24, 2018 Group Name: ACers Glass & Optical Materials Division Meeting (GOMD 2018) Group Code: TACS Downloaded from bulletin-archief. 3 | www.ceramics.org TECHNICAL PROGRAM S1: Fundamentals of the glassy state S1: Glass formation and structural relaxation S2: Crystallization in glass and its application S3: Structural characterization of glasses S4: Topology and rigidity S5: Computer simulation and predictive modeling of flasses S6: Mechanical properties of glasses S7: Non-oxide glasses S8: Glass under extreme conditions S2: Glasses in healthcare-fundamentals and application S3: Optical and electronic materials and devices― fundamentals and applications S1: Laser interactions with glasses S2: Charge and energy transport in disordered materials S3: Optical fibers and waveguides S4: Glass-based optical devices S5: Optical ceramics and glass-ceramics S6: Glasses and glass-ceramics in detector applications S7: Rare-earth and transition metal-doped glasses and ceramics for photonic applications S4: Glass technology and cross-cutting topics S1: Glass surfaces and functional coatings S2: Sol-gel processing of glasses and ceramic materials S3: Challenges in glass manufacturing S4: Waste immobilization-waste form development: processing and performance S5: Optical fabrication science and technology S5: Dawn of the Glass Age: New horizons in glass science, engineering, and applications Symposium to honor Professor L. David Pye― Glass scholar and ambassador For more information and to register, go to www.ceramics.org/gomd2018 55 55 REGISTER BY MAY 5 TO SAVE! 2018 ACERS STRUCTURAL CLAY PRODUCTS DIVISION AND SOUTHWEST SECTION MEETING in conjunction with the National Brick Research Center Meeting June 6-8, 2018 | Columbia, S.C. USA For the second consecutive year, ACerS Structural Clay Products Division, ACerS Southwest Section, and the National Brick Research Center have joined their meetings to serve the needs of the structural clay industry. TENTATIVE SCHEDULE Tuesday, June 5 Registration open Wednesday, June 6 National Brick Research Center meeting (members of NBRC only) Lunch on own Tech Session 1, Structural Clay Products Division and Southwest Section (SCPD-SW) Suppliers\' mixer Afternoon HILTON COLUMBIA CENTER Morning Noon 1:30 p.m. Afternoon 924 Senate Street | Columbia, SC, USA | Tel: 803-744-7800 Evening Thursday, June 7 Plant tours: Carolina Ceramics and All day Meridian Brick Group rate from $140+ tax is based on availability. Cut off is on or before May 4, 2018. DIVISION AND SECTION LEADERS Banquet Evening Friday, June 8 Tech Session 2, SCPD-SW Section ACers Structural Clay Products Division Leadership Division Chair: John Dowdle, Prince Minerals LLC Morning Chair Elect: Luke Odenthal, Acme Brick Company Vice Chair: Secretary: Mike Walker, National Brick Research Center Jed Lee, Meridian Brick TECHNICAL PROGRAM (as of 3/7/18) • Thin brick testing, George Campbell, J.C. Steele & Sons Inc. • Exploring tools to determine extrudablity—Capillary rheometry, Mike Walker, National Brick Research Center Southwest Section Leadership Chair: Japa Castro, Columbus Brick Company Chair Elect: David Ziegler, Prince Minerals LLC • Update on energy savings at the kiln, Joern Boeke, Refratechnik • Faster drying and firing considerations for brick, John Sanders, National Brick Research Center • Thin brick production, speaker tbd, Keller Grundbau GmbH www.ceramics.org/scpd18 Vice Chair: Secretary: Treasurer: The American George Campbell, J.C. Steele Fred McMann, Fives North American Combustion Harland Dixson, Acme Brick Co. Ceramic Society www.ceramics.org NATIONAL RESEARCH CENTER Downloaded from bulletin-archive.ceramics.org www.ceramics.org | American Ceramic Society Bulletin, Vol. 97, No. 3 SAVE THE DATE June 11-12, 2018 th Advances in Cement-Based 9 Materials (Cements 2018) PENNSYLVANIA STATE UNIVERSITY | STATE COLLEGE, PA. USA The Cements Division of ACerS announces its 2018 annual meeting, Advances in Cement-based Materials: Characterization, Processing, Modeling, and Sensing, June 11-12, 2018, at The Pennsylvania State University in State College, Pa. Plan to join fellow cement researchers for this annual meeting and dive deeper into the latest research on topics such as additive manufacturing of cementitious materials and cement chemistry, processing, and hydration, just to name a few. Other events include a workshop on 3-D printing of cementbased materials, a student event at the HUB Robeson Center, as well as a student video competition, a tour of the Materials Research Institute, and the latest advances in cement-based research. A A NITTANY LION INN 200 W. Park Ave., State College, PA 16803 Phone: 800-233-7505 Call 800-233-7505 and mention ACerS Cement Division (block code: ACER18B) for a rate of $118/night (to include room and taxes). Other accommodations are available at the Hyatt Place, located at 219 W. Beaver Ave., State College, PA 16803. The phone number is 814-862-9808. DELLA ROY LECTURE | Jan Olek, Professor of Civil Engineering and Director of the North Central Superpave Center, Purdue University Title: Green concrete—the past, the present and the future PRESENTATIONS AT CEMENTS 2018 WILL COVER TOPICS IN THE AREAS OF: • Cement chemistry, processing, and hydration • Material characterization techniques PROGRAM CHAIRS Aleksandra Radlinska - ara@engr.psu.edu Farshad Rajabipour - Farshad@engr.psu.edu • Supplementary and alternative cementitious materials • Rheology and advances in SCC • Additive manufacturing using cementitious materials • Durability and service-life modeling • Computational materials science • Smart materials and sensors Downloaded from bulletin-archief. 3 | www.ceramics.org NNNEN OF SELF CONSOLIDATIN MORPORATING SYNTHETIC FIB More details can be found on www.ceramics.org/cements2018 40 57 C ceramics expo May 1-3, 2018 Cleveland, OH, USA A manufacturing and engineering event for advanced ceramic materials and technologies Advanced ceramics are solving material challenges right now across a myriad of applications Why choose ceramics for your application? Automotive Strong and lightweight Energy Safe and reliable Electronic/Electrical Good electrical properties Medical Wear and corrosion resistant Aerospace/Defense Withstands high temperatures \"It\'s been a fantastic experience, I\'ve learnt a lot and looking to go home and implement some things I\'ve seen.\" Julien Mourou, Innovation, General Motors To read success stories from a range of industries or to register for a free pass today visit DownloWww.ceramicsexpousa.com Downloaded from bullem-archive.ceramies.org The American Ceramic Society www.ceramics.org Founding partner MPH 800 new products 808 Hydraulic press S acmi\'s new model CNC hydraulic press is an 800-ton press engineered for highest structural rigidity up and mechanical reliability for the powder metallurgy industry. The press features to four upper and lower levels, increas ing production performance even on the most complicated parts. An automatic die-set change system minimizes set-up times, and an automatic motorized system increases precision by regulating end stop of the press. MPH800 also features an integrated graphical interface that automatically generates the best pressing curves based on geometrical characteristics of the piece. Sacmi Imola SC (Imola, Italy) +39-0542-607111 www.sacmi.com Handheld Raman spectrometer ruker\'s BRAVO Raman spectromeby Raman spectroscopy in a handheld device. While fluorescence can prevent raw material verification by Raman spectroscopy in many instances, BRAVO uses a patented fluorescence mitigation strategy to enable measurement of a wide range of materials. Duo LASER excitation provides high sensitivity across the entire spectral range and guarantees maximum unambiguous verification. The device also features an intuitive graphical user interface supported by a large touch screen. Bruker Corp. (Billerica, Mass.) 978-439-9899 www.bruker.com Multishaft mixer ▪he Ross line of VersaMix multiThe Ross line of Versa Mix mussing medium to high-viscosity applications up to several hundred thousand centipoise, including slurries, pastes, gels, and suspensions. Model VMC-500 has a 500-gallon capacity and is equipped with a custom combination of independentlydriven agitators that work in tandem to promote efficient product turnover. Two saw-tooth, high-speed disperser blades impart shear for fast powder wet-out and thorough deagglomeration. Charles Ross & Son Co. (Hauppauge, N.Y.) 800-243-7677 www.mixers.com Field emission scanning electron microscope eiss\'s new GeminiSEM 450 field emisZeise\'s new Gemin¿SEM 450 field er combines ultrahigh resolution imaging with the capability to perform advanced analytics while maintaining flexibility and ease-of-use. High-throughput electron backscatter diffraction analysis and low voltage X-ray spectroscopy deliver excellent results due to the microscope\'s ability to precisely and independently control spot size and beam current. In addition, GeminiSEM 450 caters to a broad variety of sample types, from classical conductive metals to beam sensitive polymers. Carl Zeiss Microscopy GmbH (Jena, Germany) www.zeiss.com SPECTROLIN LED inspection lamp The New EK-3000SC EagleEye Deluxe ■is a compliant and hands free UV-A/ white light LED inspection lamp kit. The compact, lightweight kit is ideal for fluorescent magnetic particle and penetrant testing, pipeline inspections, ship hull inspections, and any environment that requires a portable, hands-free inspection. Upgraded long-lasting LED lenses virtually eliminate clouding. The lamps are powered by a rechargeable lithium-ion battery, which provides up to 90 minutes of continuous inspection between charges. Paul N. Gardner Co. Inc. (Pompano Beach, Fla.) 954-946-9454 www.gardco.com Downloaded from bulletin archieff3|www.ceramics.org Boron nitride remcolox A502-1600-99 is a hot-pressed, diffusion bonded, 99% pure boron nitride machinable ceramic. The material demonstrates a unique combination of being an excellent electrical insulator and thermal conductor, making it ideal for use in heat sink applications in high power electronics. A high thermal shock resistance and low coefficient of thermal expansion make it ideal for high-temperature applications. Aremcolox 502-1600-99 is resistant to operating temperatures to 2,000-3,000°C in an inert/ vacuum atmosphere and 850°C in an oxidizing atmosphere. Aremco (Valley Cottage, N.Y.) 845-268-0039 www.aremco.com 59 resources Calendar of events April 2018 10-13 ceramitec 2018 – Munich Germany; www.ceramitec.com 18-20 ➡ CICMT 2018: IMAPS/ ACerS 14th Int\'l Conference and Exhibition on Ceramic Interconnect and Ceramic Microsystems Technologies, University of Aveiro, Aveiro, Portugal; www.imaps.org May 2018 1-3 4th Ceramics Expo - I-X Center, Cleveland, Ohio; www.ceramicsexpousa.com 6-8 Oilfield Minerals & Markets Forum Houston 2018 - Hilton Houston Post Oak, Houston, Texas; http://bit.ly/Oilfield18 20-24 GOMD 2018: Glass and Optical Materials Division Meeting Hilton Palacio de Rio, San Antonio, Texas; www.ceramics.org/gomd18 27-June 1➡Int\'l Conference on Alkali Activated Materials and Geopolymers: Versatile Materials Offering High Performance and Low Emissions - Hotel Dos Templarios, Tomar, Portugal; http://bit.ly/Eng Conf2018 28-June 1 24th IEI Congress Drake and 80th PEI Technical Forum Hotel, Chicago, Ill.; http://porcelainenamel.com/2018_IEI_Congress June 2018 4-14 14th Int\'l Ceramics Congress and the 8th Forum on New Materials Perugia, Italy; http://2018.cimtec-congress.org 5-8 ACers Structural Clay Products Division & Southwest Section Meeting in conjunction with the National Brick Research Center Meeting - Columbia, S.C.; www.bit.ly/2018SCPDmeeting 11-12 9th Advances in CementBased Materials - Pennsylvania State University, University Park, Pa.; www.ceramics.org/cements2018 17-19 MagFORUM 2018 Magnesium Minerals & Markets Conference Grand Elysée Hotel, Hamburg, Germany; http://bit.ly/MagFORUM18 17-21 ICC7: 7th Int\'l Congress on Ceramics - Hotel Recanto Cataratas Thermas, Foz do Iguaçú, Brazil; www.icc7.com.br July 2018 9-12 6th Int\'l Conference on the Characterization and Control of Interfaces for High Quality Advanced Materials and the 54th Summer Symposium on Powder Technology Kurashiki, Japan; http://ceramics.ynu. ac.jp/iccci2018/ 9-13 15th Int\'l Conference on the Physics of Non-Crystalline Solids & 14th European Society of Glass Conference - Saint-Malo Convention Center, Saint-Malo, France; https:// pncs-esg-2018.sciencesconf.org 16-19 ➡PIRE 2018 Workshop Kansas State University, Manhattan, Kan.; http://nsf-pire-pdc.com/PDC_ Workshop.html 22-27 CMCEE-12: 12th Int\'l Conference on Ceramic Materials and Components for Energy and Environmental Applications - Suntec Convention & Exhibition Centre, Singapore; www.cmcee2018.org August 2018 11-12 Gordon Research Seminar: Solid State Studies in CeramicsDefects and Interfaces for New Functionalities in Ceramics - Mount Holyoke College, South Hadley, Mass.; www.grc.org/programs.aspx?id=17148 12-17 Gordon Research Conference: Solid State Studies in Ceramics Mount Holyoke College, South Hadley, Mass.; www.grc.org/programs.aspx?id=11085 20-23 MCARE2018: Materials Challenges in Alternative & Renewable Energy Sheraton Vancouver Wall Centre Hotel, Vancouver, BC, Canada; www.ceramics.org/mcare2018 September 2018 10-12 China Refractory & Abrasive Minerals Forum 2018 - Regal Int\'l East Asia Hotel, Shanghai, China; http://bit.ly/CRAMF2018 17-19 Advanced Ceramics and Applications VII: New Frontiers in Multifunctional Material Science and Processing - Serbian Academy of Sciences and Arts, Belgrade, Serbia; http://www.serbianceramicsociety.rs/ index.htm October 2018 1-4 MMA 2018: 10th Int\'l Conference of Microwave Materials and their Applications - Nakanoshima Center, Osaka University, Osaka, Japan; http://www.jwri.osaka-u.ac.jp/~conf/ MMA2018 8-12 ic-cmtp5: 5th Int\'l Conference on Competitive Materials and Technology Processes - Hunguest Hotel Palota, Miskolc, Hungary; http://www.ic-cmtp5.eu 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. denotes Corporate partner Downloaded from bulletin-archive.ceramics.org www.ceramics.org | American Ceramic Society Bulletin, Vol. 97, 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 custom finishing/machining 35 Years of Precision Ceramic Machining Ph: 714-538-2524 | Fx: 714-538-2589 Email: sales@advancedceramictech.com www.advancedceramictech.com • Custom forming of technical ceramics •Protype, short-run and high-volume production quantities • Multiple C.N.C. Capabilities ADVANCED CERAMIC TECHNOLOGY CUSTOM MACHINED INSULATION TO 2200°C Technical Ceramics German Quality and Innovation Rauschert Industries, Inc. 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Advertise in the Bulletin Since 1959 ITAR Registered bomas.com Downloaded from bulletin archive frame. 3 | www.ceramics.org 305 Marlborough Street Oldsmar, Florida 34677 Phone (813) 855-5779 Fax (813) 855-1584 e-mail: info@sgiglass.com Web: www.sgiglass.com 61 classified advertising TOLL FIRING SERVICES • Sintering, calcining, heat treating to 1700°C • Bulk materials and shapes • R&D, pilot production • One-time or ongoing EQUIPMENT • Atmosphere electric batch kilns to 27 cu. ft. • Gas batch kilns to 57 cu. ft. HARROP INDUSTRIES, INC. Columbus, Ohio 614-231-3621 www.harropusa.com sales@harropusa.com SEM COM COMPANY, INC. Glass & Glass Ceramic Manufacturing ISO 9001:2008 CERTIFIED • Melting to 1675°C: grams to tons • Flake, frit, rolled marble & powder forms • Redrawn & updrawn tubing or rod • Cast plates, billets & boules • Glass formula & properties development • Solid Si dopant source wafers in assoc. with Techramics, Ltd. 1040 N. Westwood Ave. Toledo, OH 43607 SEM. 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Connected and Experienced Globally Tel: +1 (810) 225-9494 sales@mohrcorp.com www.Mohrcorp.com Based in Brighton, MI USA www.ceramics.org/ ceramictechtoday BUYING & SELLING • Compacting Presses Isostatic Presses • Piston Extruders • Mixers & Blenders Jar Mills Pebble Mills Lab Equipment • Crushers & Pulverizers • Attritors • Spray Dryers Screeners • Media Mills • Kilns & Furnaces • Stokes Press Parts Huge Inventory in our Detroit Michigan warehouse Contact Tom Suhy 248-858-8380 sales@detroitprocessmachinery.com www.detroitprocessmachinery.com DPM DETROIT PROCESS MACHINERY maintenance/repair services CENTORR Vacuum Industries VII AFTERMARKET SERVICES Spare Parts and Field Service Installation Vacuum Leak Testing and Repair Preventative Maintenance Used and Rebuilt Furnaces 55 Northeastern Blvd, Nashua, NH 03062 Ph: 603-595-7233 Fax: 603-595-9220 sales@centorr.com www.centorr.com Alan Fostier afostier@centorr.com Dan Demers - ddemers@centorr.com CUSTOM HIGH-TEMPERATURE VACUUM FURNACES ADVERTISE YOUR SERVICES HERE Contact Mona Thiel 614-794-5834 mthiel@ceramics.org Downloaded from bulletin-archive.ceramics.org www.ceramics.org | American Ceramic Society Bulletin, Vol. 97, No. 3 ADINDEX *Find us in ceramicSOURCE 2018 Buyer\'s Guide DISPLAY ADVERTISER APRIL 2018 AMERICAN CERAMIC SOCIETY Obulletin AdValue Technology 29 Ingredient Masters 17 Orton Materials Testing Laboratory 28 www.advaluetech.com www.ingredientmasters.com www.ortonceramic.com/testing American Chemet* 9 I-Squared R Element* 25 Oxy-Gon 22 www.chemet.com www.isquaredrelement.com www.oxy-gon.com American Elements* Outside back cover, J. Rettenmeier 28 Praxair* 31 www.americanelements.com 26 www.jrsusa.com www.praxairsurfacetechnologies.com Associated Ceramics 37 L&L Special Furnace* 29 Refractory Minerals 39 www.AssociatedCeramics.com www.llfurnace.com http://phosphatebonds.com Centorr* 31 Lucideon 13 Reno Refractories 43 www.centorr.com www.lucideon.com/ceramics www.renorefractories.com Ceramic Expo* 58 Materials Research Furnaces* 23 Saint Gobain* 7 www.ceramicsexpousa.com www.mrf-furnaces.com www.hexoloy.com CeraNova 47 Materion Ceramics 22 Sauereisen Cements* 23 www.ceranova.com www.materion.com/ceramics www.sauereisen.com CM Furnaces 11 Matmatch 30 Specialty Glass 13 www.cmfurnaces.com https://matmat.ch/acs www.sgiglass.com CMC Labarotories 30 McDanel Advanced Ceramic 15 Superior Graphite* 21 www.CMClaboratories.com Technologies www.superiorgraphite.com www.mcdanelceramics.com DCM Tech 11 Swindell Dressler 24 www.dcm-tech.com Mo-Sci Corporation* 3 www.swindelldressler.com www.mo-sci.com Deltech Furnaces* 5 TA Instruments* 27 www.deltechfurnaces.com MSE Supplies 26 www.tainstruments.com ENRG Inc. 39 www.msesupplies.com TevTech* 25 www.enrg-inc.com Nabaltec 49 www.tevtechllc.com www.nabaltec.de Gasbarre Products* 19 The American Ceramic Society* 29, www.gasbarre.com National Center for Manufacturing 4 www.ceramics.org Inside back cover Sciences Glen Mills* 21 Thermcraft* 27 www.glenmills.com www.ncms.org www.thermcraftinc.com Harrop Industries Inc.* Niokem 45 Inside front cover Zircar Ceramics 19 www.niokem.com www.harropusa.com www.zircarceramics.com NSL Analytical* 35 Hindalco Chemicals 24 Zircar Zirconia 51 www.hindalco.com/alumina-chemicals www.NSLanalytical.com/Ceramics www.zircarzirconia.com Opti-Pro 15 www.optipro.com CLASSIFIED & BUSINESS SERVICES ADVERTISER Advanced Ceramic Technology* 61 Mohr Corp.* 62 Sem-Com Company* 62 62 www.advancedceramictech.com www.mohrcorp.com www.sem-com.com Bomas Machine Specialties Inc.* 61 PremaTech Advanced Ceramic+ 61 Specialty Glass Inc.* 61 www.bomas.com www.prematechac.com www.sgiglass.com Centorr/Vacuum Industries Inc.* 62 PPT - Powder Processing & 61 Spectrochemical Laboratories* 62 www.centorr.com Technology LLC* www.spectrochemicalme.com Detroit Process Machinery* 62 www.pptechnology.com Zircar Ceramics Inc.* 61 www.detroitprocessmachinery.com Quality Executive Search Inc.* 61 www.zircarceramics.com Geller Microanalytical Laboratory Inc.* 62 www.qualityexec.com Zircar Zirconia Inc.* 61 www.gellermicro.com Harrop Industries Inc.* Rauschert Technical Ceramics Inc.* www.rauschert.com 61 www.zircarzirconia.com 62 www.harropusa.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 Pamela J. Wilson pwilson@ceramics.org ph: 614-794-5826 fx: 614-794-5842 Downloaded from bulletin archivefer. 3 | www.ceramics.org 63 O deciphering the discipline A regular column offering the student perspective of the next generation of ceramic and glass scientists, organized by the ACerS Presidents Council of Student Advisors. Rachel Sherbondy Guest columnist Electrocaloric materials for heating and cooling technology Temperature control is a central part of the American way of life, from homes and vehicles to refrigerators and public spaces. Heating accounts for approximately 30% of residential home energy expenditure in the United States, and cooling accounts for an additional 12%.¹ However, despite its prevalence, the technology we use for heating and especially cooling is not particularly efficient-for example, standard vapor-compression refrigeration has an efficiency of just ~40%. This technology-virtually unchanged in the past 70 years³-uses chemicals that release greenhouse gases into the atmosphere (the most efficient systems use Freon gases or cholorofluorocarbons and hydrochlorofluorocarbons). Solid-state alternatives for these technologies exist, with popular designs including thermoelectric and electrocaloric materials. Peltier heaters and coolers rely on the thermoelectric effect, in which the application of an electric current forces a temperature gradient between two opposite sides of a material. One side acts as a heat source, which could be used for heating, and the other as a heat sink, which could be used for cooling. These materials provide the benefits of small size, variable shape, and absence of moving mechanical parts and liquid.* The main disadvantage of current commercial technologies for Peltier heaters and coolers include low power efficiency (10%-15%) and cost efficiency. Electrocaloric materials pose a different answer to the question of finding a solid-state material capable of heating or cooling. The electrocaloric effect relates an external electric field to a change in temperature via a change in internal entropy. Materials that exhibit this effect must contain electric dipoles. With applicaDownloaded from bulletin-archive.ceramics.org Apply electric field Allow material to cool▪ There is no applied electric field. Dipoles in the structure are randomly oriented. Entropy is high. An electric field is applied. Dipoles in the structure are constrained. Entropy is low. Temperature increases. The material is allowed to cool. The dipoles are still constrained by the electric field. Entropy is Remove electric fieldlow. The electric field is removed. The dipoles return to a random state. Entropy increases, temperature decreases. Figure 1. Stepwise depiction of the electrocaloric effect, which relates an external electric field to a change in temperature via a change in internal entropy. tion of an electric field, the dipoles orient to align with the field, decreasing entropy (Figure 1). This decrease in entropy is coupled to an increase in temperature of the material. If the material is cooled with the field on and then the field is removed, internal dipoles will return to a random state and increase the entropy. This is coupled to a decrease in energy, which is the mechanism by which electrocaloric materials can function as coolers. Challenges that researchers still hope to solve for electrocaloric materials are diverse. From Maxwell\'s equations, it follows that greater polarization induced in a polar crystal will increase entropy change and overall efficiency of the electrocaloric effect. However, materials cannot withstand infinite electric fields to obtain these polarizations-instead, actual materials exhibit a finite breakdown strength. Therefore, there is an limit to the magnitude of the posupper sible electrocaloric effect in materials. Another challenge is temperature dependence of the electrocaloric effect itself. The effect is maximized near phase transitions in the material, which occur at well defined temperatures, especially in single crystals. Temperature changes decay the effect, and the electrocaloric device loses efficiency. Ongoing work on electrocaloric heaters and coolers investigates how to diffuse phase transitions over wider temperature ranges, thereby increasing the utility of devices. Additional work is trying to identify electrocaloric materials with useful phase transitions that occur at ambient temperatures. Device patents exist, 5-7 but this technology has not yet been implemented for commercial electrocaloric heaters or coolers. Nevertheless, electrocaloric materials are an interesting candidate for replacing vapor-compression technology with a more efficient and environmentallyfriendly solution. References: ¹U.S. Energy Information Administration, Residential Energy Consumption Survey (2009). 2T. Correia, Q. Zhang, “Electrocaloric effect: An introduction;\" pp. 1-15 in Electrocaloric Mater. Next Gener. Cool., Springer Berlin Heidleberg: Berlin, Heidleberg (2014). 3T. Gottschall, D. Benke, M. Fries, A. Taubel, I.A. Radulov, K.P. Skokov, O. Gutfleisch, “A matter of size and stress: Understanding the first-order transition in materials for solidstate refrigeration,\" Adv. Funct. Mater., 27 [32], 1-6 (2017). 4H. Lee, Thermoelectrics: Design and Materials. John Wiley & Sons Ltd.: Hoboken (2017). 5A. Basiulis, R.L. Berry, Solid-state electrocaloric cooling system and method; US4757688 A (1988). 6Y.R. Kucherov, Piezo-pyroelectric energy converter and method; US5644184 A (1997). 7E. Kruglick, Electrocaloric heat transfer; US20120055174 A1 (2014). Rachel Sherbondy is a first-year graduate student at Colorado School of Mines (Golden, Colo.), researching electroceramics with Geoff Brennecka. When not in the lab, she is often running or hiking the mountains of Colorado. www.ceramics.org | American Ceramic Society Bulletin, Vol. 97, No. 3 EXPAND YOUR KNOWLEDGE ARE YOU AN ENGINEER, SCIENTIST, INDUSTRY PROFESSIONAL, OR STUDENT LOOKING TO SHARPEN YOUR SKILLS AND EXPAND YOUR KNOWLEDGE BASE? Check out our short courses in conjunction with Ceramics Expo 2018! STATISTICAL PROCESS CONTROL IN CERAMIC PROCESSING Also available to take via remote. See website for details. April 29, 2018 | 9:00 a.m. - 4:30 p.m. April 30, 2018 | 9:00 a.m. - 3:30 p.m. Instructor: Carl E. Frahme, Frahme Consulting Services, principal; University of Kansas, Materials Science adjunct professor SMART MARKETING FOR ENGINEERS April 29, 2018 | 9:00 a.m. - 4:00 p.m. April 30, 2018 | 9:00 a.m. – 1:00 p.m. Instructor: Rebecca Geier, CEO and Co-founder of TREW Marketing ADDITIVE MANUFACTURING OF HIGHPERFORMANCE CERAMICS UNDERSTANDING WHY CERAMICS FAIL AND DESIGNING FOR SAFETY May 3, 2018 | 8:00 a.m. - 4:30 p.m. Instructor: Steve Freiman, Freiman Consulting Inc. DISPERSION AND RHEOLOGY CONTROL FOR IMPROVED CERAMIC PROCESSING May 3, 2018 | 8:00 a.m. - 4:30 p.m. Instructor: William M. Carty, Alfred University Register here: www.ceramics.org/acers-courses The American April 30, 2018 | 8:30 a.m. - 4:30 p.m. Team taught with lead instructor Shawn Allen, Lithoz America LLC, and other experts *All courses held at Marriott Cleveland Airport, Cleveland, Ohio Downloaded from bulletin-archive.ceramics.org Ceramic Society www.ceramics.org AMERICAN ELEMENTS calcium carbonate nanoparticles europium ph dielectrics catalog:americanelements.com carbon nanoparticle THE ADVANCED MATERIALS MANUFACTURER Ⓡ palladium nanoparticles liquids H silicon nanopart HH He Nd: yttri medic rho 11 37 1.00794 Hydrogen Li 6.941 Lithium Na 22.98976928 Sodium K 39.0983 Potassium Rb 85.4678 Rubidium 12 20 38 56 zinc nanoparticles Be 9.012182 Beryllium Mg 24.305 Magnesium 21 optoelectronics 99.999% ruthenium spheres copper anarticles. surface functionalized nanoparticles iron nanoparticles Ca Sc 40.078 Calcium Sr 44.965912 Scandium Y 88.90585 87.62 Strontium Yttrium nadium Cs Ba 87 132.9054 Cesium tant Fr (223) Francium thin film 88 137.327 Barium 89 40 2 72 Ti V Cr Mn 47.867 Titanium Zr 91.224 Zirconium 41 73 50.9415 Vanadium 42 51.9961 Chromium Nb Mo 92.90638 Niobium La Hf Ta 138.90547 Lanthanum Ra Ac 104 178.48 Hafnium Rf 105 180.9488 Tantalum 2 74 95.96 Molybdenum 106 W 183.84 Tungsten 43 75 107 54.938045 Manganese Tc (98.0) Technetium 44 76 silver nanoparti Cu Zn Fe Co Ni Cu 55.845 Iron 45 58.933195 Cobalt 58.6934 Nickel 63.546 Copper Ru Rh 101.07 Ruthenium 102.9055 Rhodium 46 Pd 106.42 Palladium 18 47 Ag 107.8682 Silver Re Os 186.207 Rhenium Db Sg Bh 108 190.23 Osmium Hs (226) Radium (227) Actinium (267) Rutherfordium (268) Dubnium (271) Seaborgium (272) Bohrium (270) Hassium diamond m refracto sten carbide Ce 140.116 Cerium ༥ ཱཿ།སྐ ༅ ༄ 33 , ༣ 77 Ir 192.217 Iridium ༥ ༥༠ ༥ 65.38 Zinc B C 10.811 Boron 12.0107 Carbon 13 ΑΙ 26.9815386 Aluminum 14 Si 28.0855 Silicon Ga Ge 69.723 Gallium 72.64 Germanium 33 14.0067 Nitrogen 15.9994 Oxygen NP 30.973762 Phosphorus S 32.065 Sulfur As Se 74.9216 Arsenic 78.96 Selenium 48 Cd 112.411 Cadmium In 114.818 Indium Sn 118.71 Tin 51 Sb 78 Pt 195.084 Platinum 79 80 Au Hg 196.966569 Gold 112 200.59 Mercury Cn 81 113 TI 204.3833 Thallium Uut 109 Mt 110 Ds 111 ས མ བྲཱ ཀ 114 121.76 Antimony Pb 207.2 Lead 83 Bi 208.9804 Bismuth 영 115 Uup unc 84 116 17 35 F 18.9984032 Fluorine CI 35.453 Chlorine Br 79.904 Bromine 126.90447 lodine Te 127.6 Tellurium 53 85 Po At (209) Polonium (210) Astatine Lv 117 ON ཐ ༧ 10 18 36 54 86 118 4.002602 Helium Ne 20.1797 Neon Ar 39.948 Argon Kr 83.798 Krypton Xe 131.293 Xenon rod solid metals crystals cone site Rn mistry (222) Radon Uus Uuo um Rg FI (276) Meitnerium (281) Darmstadtium Roentgenium (285) Copernicium (284) Ununtrium (289) Flerovium (288) Ununpentium (293) Livermorium (294) Ununseptium (294) Ununoctium quantum dots 62 aluminum nanoparticles Pr Nd Pm Sm Eu Gd Tb Dy Ho Er Tm Yb 140.90765 Praseodymium 91 92 144.242 Neodymium 61 93 (145) Promethium 94 150.36 Samarium 63 95 151.964 Europium 96 157.25 Gadolinium 158.92535 Terbium Dysprosium 164.93032 Holmium Th Pa U Np Pu Am Cm Bk Cf 100 167.259 Erbium 101 168.93421 Thulium 102 173.064 Ytterbium Fm Md No 71 103 Lu nickel nanoparticl 174.9668 Lutetium Lr Es 232.03806 Thorium 231.03588 Protactinium 238.02891 Uranium (237) Neptunium (244) Plutonium (243) Americium (247) Curium (247) Berkelium (251) Californium (252) Einsteinium (257) Fermium (258) Mendelevium (259) Nobelium (262) Lawrencium single crystal silicon rbium doped fiber optics nano ribbons advanced polymers gadolinium wires atomic layer deposition ing powder macromolecu nano gels anti-ballistic ceramics TM nanodispersions Now Invent. ultra high purity mat dielectrics alternative energy europium phosphors Experience the Next Generation of Material Science Catalogs ttering targets LED lighting rmet anode super alloys osynthetics As one of the world\'s first and largest manufacturers and distributors of nanoparticles & nanotubes, American Elements\' re-launch of its 20 year old Catalog is worth noting. In it you will find essentially every nanoscale metal & chemical that nature and current technology allow. In fact quite a few materials have no known application and have yet to be fully explored. But that\'s the whole idea! CIGS laser platinum ink solar energy metamaterials silicon rods zirconium nanofabrics photovoltaics crystal growth American Elements opens up a world of possibilities so you can Now Invent! iron ionic spintronics rare earth dysprosium pellets palladium shot ©2001-2018. American Elements is a U.S. Registered Trademark. www.americanelements.com gadolinium wire Downloaded from bulletin-archive.ceramics.org

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