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Materials Day 2006 - Posters

Materials Processing and Manufacturing

• A02 - Particle Science and Technology
  J. H. Adair, J. M. Anderson, E. I. Altinoglu, N. Antolino, P. Chhillar, C. J. Szepesi, R. Kumar, R. Malek, J. A. Nelson, C. I. Phillips, S. M. Rouse, T. J. Yosenick, Y. Yuan
  Abstract: The Adair research group is committed to the long-term development of advanced materials derived from 10 micron to nanometer-size particulates. The physical and chemical properties of particles are tailored using materials chemistry, surface chemical modification, and innovative consolidation techniques to accelerate the development of advanced materials for structural, electronic, metallic, catalytic and bio-medical applications. Research efforts are focused towards developing formulations and processes for synthesis, deaggregation, dispersion, and consolidation of particulate materials to achieve the desired final material properties. We accomplish this in cooperation with multiple NSF research centers, industrial partners and other academic institutions.
  
  URL: http://www.mri.psu.edu/centers/pmc
  
  
• A08 - Polytetrafluoroethylene Nano/Microfibers: Applications Over Several Length Scales
  S. Borkar, M. Dirmyer, J. Badding, K. Ainslie, M. Pishko, A. Sen
  Abstract: Polytetrafluoroethylene (PTFE) nano/microfibers constitute interesting materials with wide industrial and biomedical applications. However, the current processing of PTFE is very laborious and involves multiple steps. Here with we report on jet-blowing: a novel one step solvent-free process for forming PTFE nano/microfibers. The technique allows the fabrication of nanofibers even below the conventional melting point of PTFE. The fibres are produced at a rapid rate and can adhere to a variety of surfaces. Cell adhesion study shows that the resultant fibrous mats inhibit microphage adhesion. Also these mats are superhydrophobic with water contact angle of ~150° which makes them excellent candidate for coatings. Composite materials with the metal nanoparticles can also be synthesized by in situ oxidation of metal salts.
  
  
• B04 - Novel One-Dimensional Systems: Nanotubes and Nanowires
  K. Adu, H. Gutierrez, G. Chen, U. J. Kim, Q. Xiong, X. Liu, A. Gupta, J. Wu, P. C. Eklund
  Abstract: The electronic industry has made tremendous strides since the early 1970Æs in miniaturizing silicon-based devices. This achievement has been accomplished by advancing the art of photolithography and processing techniques. This "top-down" technology is now thought to be reaching itÆs limit, and it is being asked whether smaller, faster molecular electronic devices can be built by assembling them from "bottom up" in an ordered array on a chip. A few recent studies indicate that approach may be possible using high aspect ratio nanofilaments with cross sectional dimensions on the order of a few nanometers. Not only would they lead naturally to nano-miniaturization, but the cross sectional area of the filament can also be used to tune the physical properties of the devices. The focus of our group is to explore the optical, electronic and thermal properties and elucidate on the fundamental physics of these novel nanofilaments.
  
  
• F08 - Microwave Processing of Ceramics, Composites and Metallic Materials: Developments at Microwave Processing Center
  D. Agrawal, J. Cheng, Y. Fang, R. Peelamedu, R. Roy
  Abstract: Microwave Processing and Engineering Center has emerged as a leading research laboratory in the area of microwave processing of various materials including ceramics and metallic materials. Microwave processing has several advantages over conventional sintering: reduction in cycle time, energy savings, finer microstructures and improved mechanical properties. We have synthesized and sintered many traditional and advanced ceramics including, hydroxyapatite, alumina, zirconia, non-oxides, phosphors, ceramic pigments, transparent ceramics etc. Ceramic nano powders have also been processed rapidly in microwave with relatively less grain growth than in conventional methods. Microwave sintering of cemented carbides (WC/Co) has been developed and successfully commercialized. We have pioneered the microwave sintering/melting/brazing of metal powders very effectively and efficiently. Almost all common metals alloys, steel compositions have been sintered successfully.
  
  URL: http://www.mri.psu.edu/centers/mpec
  
  
• F09 - Electrospinning of poly[bis(trifluoroethoxy)phosphazene] Nanofibers: Development of Superhydrophobic Surfaces
  A. Singh, L. Steely, H. R. Allcock
  Abstract: Poly[bis(trifluoroethoxy)phosphazene] (PTFEP), remains to date, the most extensively studied material in the field of polyphosphazenes. The wide spread interest in this polymer has been due to its versatile properties which include high hydrophobicity, fire resistance, elastomeric properties, UV stability and fiber-forming properties. In this study, submicron size fibers of PTFEP were produced by electrospinning. The average fiber diameter could be varied from 80 nm to 1.4 µm by varying the electrospinning parameters. Also, a dramatic increase in water contact angle (WCA) was observed on the electrospun mats as compared to spun cast PTFEP films. WCA on spun cast film was 92 °C which increased to 158 °C on electrospun film, making the surface of these mats superhydrophobic. Potential applications for these highly hydrophobic nanostructured fibrous mats include membranes for separation purposes, stain resistant fabrics, oxidation-resistant surfaces and possibly as biomaterials.
  
  
• F10 - Fabrication of Boron Carbide and Boron-Carbide/Silicon-Carbide Nanofibers Via the Electrostatic Spinning of Polymeric Ceramic Precursors
  D. T. Welna, X. Wei, N. R. Krogman, J. D. Bender, L. G. Sneddon, H. R. Allcock
  Abstract: Electrostatic spinning is a well-developed technique for the fabrication of fibers in the nanoscale domain. Novel boron carbide nanofibers were generated by the electrostatic spinning and ceramic conversion of poly(norbornenyldecaborane) (PND) - a polymeric ceramic precursor. The prepyrolyzed fibers were characterized by scanning electron microscopy (SEM), thermogravimetric analysis (TGA), and diffuse reflectance infrared Fourier transform (DRIFT) spectroscopy. The ceramic fibers were characterized by SEM, X-ray diffraction (XRD), 11B magic-angle spinning nuclear magnetic resonance (MAS NMR) and DRIFT spectroscopy. SEM analysis showed retention of the nanostructure in the pre- and postpyrolyzed fibers. Boron-carbide/silicon-carbide composite nanofibers were also generated via the electrostatic spinning of a blended PND/allylhydridopolycarbosilane (AHPCS) system.
  
  URL: http://research.chem.psu.edu/hragroup
  
  
• F11 - Recent Research in the Composites Manufacturing Technology Center (CMTC)
  C. E. Bakis
  Abstract: The focus of the CMTC is on the design, manufacture, and test of materials and structures composed of polymer-based composites. The laboratory portion of the Center, housed in an 8,000 sq. ft. facility on the West Campus of Penn State in University Park, PA, contains a versatile collection of equipment for manufacturing of composites, including a filament winder, pultruder, autoclave, and hot press. Recently, 13 faculty from various departments and colleges at Penn State have been involved in research mainly on manufacturing, mechanics, and testing of composites. This poster provides an overview three different research projects that are ongoing in the Center: development of carbon nanotube based composites for structural applications; ultra-high speed carbon fiber composite flywheels for energy storage; and E-glass and carbon fiber composite reinforcements for concrete structures.
  
  
• F12 - Chain-end Functionalized Polyolefins and Fluoropolymers; Synthesis and Applications in Nanocomposites and Organo-Electronics
  T. C. M. Chung, H. Hong, J. Dong, J. Langston, A. Petchsuk, Z. Wang, O. Kandil, M. Wells
  Abstract: This poster summarizes our research in synthesis and applications of chain end functionalized polyolefin (PE, PP) and fluoropolymer (PVDF), which are effective interfacial agents for forming polymer/inorganic composites for a wide range of applications, including nanocomposites, proton-conducting membranes, organo-electronics, etc. The major theme of this research is based on the idea of using a polymeric surfactant in solid mixings, resemble to the small surfactant molecules used in oil/water emulsion. Basically, the polymer contains a hydrophobic (and oleophobic in fluoropolymers) main chain, which are completely incompatible with hydrophilic inorganic substrates (particles, fibers, plates, etc.), but containing a reactive functional group at the polymer chain end to anchor the polymer chain onto the surface of inorganic substrate. The combination of attractive and repulsive forces provides the maximum power of dispersion inorganic nano-particles in polymer matrix.
  
  
• G01 - Overview of EO Materials Fabrication and Characterization Capabilities
  W. J. Everson, E. J. Oslosky, R. D. Gamble, G. M. Goda, D. W. Snyder, T. E. Bogart
  Abstract: The Penn State EO Materials Department has developed a wide range of specialized capabilities for fabrication and characterization of electronic, optical and electro-optic materials and devices. These capabilities are used to execute both internal research projects as well as to support industrial entities in the Electro-Optics Alliance. Examples of these capabilities include processing and characterization of damage free surfaces on SiC substrates using an internally developed chemi-mechanical (CMP) process. Scanning white light interferometery was used extensively as a metrology tool to provide rapid feedback. Another key thrust is the development of non-destructive electrical characterization of wide bandgap semiconductors to map substrate resistivity. Microwave loss techniques have also been developed to predict substrate electrical performance at operating frequency. This poster will review research programs for development of novel fabrication and characterization techniques.
  
  
• G03 - Synthesis, Characterization and Evaluation of Properties of Nanostructures
  R. Rajagopalan, P. J. Mankidy, K. Dronavajjala, A. Merritt, M. Holbrook, B. Yi, H. C. Foley
  Abstract: This poster summarizes the research activites in Henry FoleyÆs group. Our group is actively involved in synthesis, characterization and evaluation of properties of nanostructures. The application for these materials includes membranes for gas separation, catalysis and thin films for microelectronic applications. We are interested in synthesizing wide range of nanomaterials such as nanoporous carbon, carbon nanocomposites, polymeric thin films and polymeric nanofibers.
  
  
• G04 - Hydroceramics
  Y. Bao, M. DiCola, M. Grutzeck
  Abstract: Hydroceramics are clay based but unlike conventional ceramics are processed in an autoclave operating along the steam curve. Concentrated sodium hydroxide is used both as a solvent and reactant to form tectosilicate phases including zeolites and feldspathoids. Comparisons are made with traditional high fired ceramics. Data are also presented on the mechanical properties and solubility of hydroceramics made with sodium bearing waste now stored at the Hanford and Savannah River sites.
  
  URL: http://www.personal.psu.edu/faculty/g/u/gur/
  
  
• G05 - Multi Functional Building Materials
  M. Cazorla, M. DiCola, P. Brenner, G. Belot, A. Stone, M. Grutzeck
  Abstract: Building materials have two functions: they support load and define space. As a people we are constantly surrounded by building materials; we have become a containerized society. We no longer spend very much time outdoors. Our indoor lives are defined by economic factors that promote highly insulated and air tight environments. These are negative factors that tend to stress living things. Plants tend to suffer as do people, but in the case of people the symptoms are less obvious. Sick building syndrome (SBS) is a relatively new ailment that has no apparent cause. Individuals may sense they have a health problem caused by their environment but can do little to control it. Lighting and HVAC systems are defined by building owners and the "bottom line" more often than not is the deciding factor when designing a building. Given these constraints we are promoting the design and use of a new generation of building materials that are able to interact with the air they surround and clean it.
  
  URL: http://www.personal.psu.edu/faculty/g/u/gur/
  
  
• G06 - Molecular Beam Epitaxy of Integrated Multifunctional Oxides on Wide Bandgap Semiconductors for Advanced RF Systems - Overview of Current Activities at the Penn State Electro-Optics Center
  O. Maksimov, P. Fisher, M. Skowronski, V. D. Heydemann
  Abstract: The Penn State Electro-Optics Center uses Molecular Beam Epitaxy (MBE) for integration of multifunctional oxides on wide bandgap semiconductors. The goal of this ONR-sponsored program is the in-situ integration of X-band low loss tunable filters and phase shifters based on ferro- and paraelectric oxides on III-nitride epitaxial devices. EOCÆs MBE system consists of a nitride and an oxide growth chamber, connected through a load lock/ substrate preparation module. Each chamber contains residual gas analysis, flux monitoring, and automated RHEED to monitor the deposited epitaxial layers. A high flux ozone source, a 4-pocket electron beam evaporator and a plasma nitrogen source complement effusion cell sources. Current experiments target optimization of the growth of AlGaN/GaN HEMT epitaxial layers, and, independently, MgO, TiO2, BTO, STO, BST, followed by ex-situ characterization. Future experiments will investigate the integration of FE oxides on MBE-grown III-nitrides.
  
  
• G07 - Biomolecule-Assisted Synthesis for Inorganic Nanowires
  Q. Lu, F. Gao, S. Komarneni
  Abstract: One-dimensional (1D) nanomaterials have distinct physical and chemical properties and have been found to be building blocks for nanodevices. Usually this kind of materials can be prepared by surfactant-directed route, hard template-limited technique or high temperature-VLS (vapor-liquid-solution) growth. How to develop simple and mild methods to synthesize 1D nanomaterials is still a challenge. Biomolecules such as proteins and sugars possess special structures and contain many coordinating groups, which make them to be potential templates for the synthesis of nanowires. Based on this idea, we have developed a simple biomolecule assisted hydrothermal technique to synthesize a series of nanowires including bismuth oxide and sulfide, tellurium and selenium nanowires. These results will be presented.
  
  
• G08 - Synthesis of Ni Nanoparticles by Microwave-Assisted Polyol Process
  D. Li, S. Komarneni
  Abstract: Ni nanoparticles are useful as electrode materials in multilayer ceramic capacitors and as catalysts. Ni nanoparticles of 63 ± 2 nm were synthesized with polyvinyl pyrrolidone (PVP) and dodecylamine (DDA) as protecting agents through a microwave-assisted technique using ethylene glycol as both reducing agent and solvent. The morphology of Ni nanoparticles was controlled by the amount of DDA added in these systems. Particle size and size distribution were controlled by the concentration of metal source and the DDA to PVP ratio. The synthesized Ni nanoparticles were characterized by transmission electron microscopy for particle size and morphology, and size distribution was calculated by Image J software. Microwave-assisted polyol process was found to be faster than conventional-polyol process in Ni nanoparticle synthesis and the former technique is expected to be cost-effective compared to the latter.
  
  
• G09 - Polymer/Inorganic and Polymer/Clay Nanocomposites
  E. Manias
  Abstract: This poster presents an overview of recent and ongoing projects in our group. The focus is on projects that relate to polymer nanocomposites and well-defined polymer nanostructures. The themes, main research foci, and our research approaches are highlighted. In addition, related fundamental research efforts, such as computer modeling and Atomic Force Microscopy studies, are also mentioned in the context of how they support our more applied projects.
  
  URL: http://zeus.plmsc.psu.edu/
  
  
• G10 - Processing and Sintering of Advanced Ceramics
  G. L. Messing, S. H. Lee, K. Brosnan, A. Mohanram, S. Kochawattana, L. Kupp, M. Ugorek, B. Pavlacka, A. Stevenson, M. Ruffin, K. Appiagyei, A. Levander, M. Fujii, P. Michaux, N. Sherlock
  Abstract: The Messing group is focused on developing processes for producing optically transparent ceramics, high performance piezoelectrics, and solid state grown single crystals. We are expert in powder synthesis by spray pyrolysis and the control of phase development and transformation by solid state seeding. Recent sintering studies have explored the challenges of producing >99.999% dense transparent laser host ceramics (e.g. Nd-doped YAG), and controlling stress evolution in co-fired, integrated ceramics such as SOFCs and LTCCs. We have developed a novel templated grain growth process to obtain oriented microstructures of unprecedented control. We use a similar strategy to grow single crystals from a dense ceramic. Some of the materials we have studied include mullite, alumina, barium titanate, lead magnesium niobate, strontium barium niobate, sodium bismuth titanate, and yttrium aluminum garnet.
  
  
• G11 - Powder Mechanics Principles for Processing of Particulate Materials - An Overview
  V. M. Puri
  Abstract: Numerous industries such as agriculture, ceramic, chemical, construction, food, pharmaceutical, and powdered metal store, handle and process material in particle form. Based on the findings of a comprehensive study by Rand Corporation, systems involving particles have much lower efficiency compared with those involving solids, liquids, and gases. Toward this end, our group has championed for over two decades the use of powder mechanics principles to better understand, quantify, and model the behavior of powders and their systems. Some of the applications studied in detail have included: storage, flow, segregation, deposition, and compaction. Our emphasis has been to develop theoretical framework together with measurement devices and methodologies to accurately characterize powders and powder mixtures. To better capture the response of powder systems, we have developed and validated also computational models for select processes. This poster highlights some of our findings.
  
  
• G12 - Uniformity of Simultaneous Powder Deposition in Three Parallel - Oriented Dies
  V. M. Puri, A. S. Grader, X. Xie
  Abstract: To investigate the factors influencing the spatial uniformity of bulk density distribution of powder deposited in multiple dies by feed shoe filling method, the second generation mass deposition tester (MDT-II) with flexible design and fully automated features was developed. The computer controlled MDT-II incorporated a pressure sensor strip to measure pressure or mass increase profile at multiple locations simultaneously. Results with simultaneous filling of three dies (circular, toroid, and E-shaped cross-sections) demonstrated that MDT-II is an effective and efficient device for this research. Current results showed: 1) Quantitative information from MDT-II is useful in fill quality evaluation; 2) MDT-II data seems to agree qualitatively with CT scanner data; 3) Initial framework for a mathematical model has been formulated.
  
  
• H01 - Physics of Penetrating, Shaking, and Thermally Cycling Granular Materials
  T. Scheidemantel, K. Chen, M. B. Stone, R. Barry, M. Lohr, D. P. Bernstein, M. D. Pelc, Y. K. Tsui, B. L. Sheu, A. J. Morss, K. W. Klein, W. McConville, P. Schiffer
  Abstract: Our group studies the basic physics of granular media, materials which are composed of collections of separated solid grains (e.g., sand). Such granular media display a variety of complex properties which distinguish them from materials in bulk solid or liquid phases. For example, the motion of a solid object slowly penetrating a granular medium is resisted by a drag force which differs dramatically from viscous drag in a fluid. We have studied the drag force as a function of the velocity, the depth in the medium, the shape of the dragged object, and the grain size and morphology. We have also studied the effects of boundaries on penetration of a granular medium. Other recent studies have concerned the nature of granular flow from a shaken container with an opening on the bottom (equivalent to a salt shaker) and the effects of thermal cycling on the packing of granular materials. Recent References: Phys. Rev. E 70, 041301 (2004)and Nature 427, 503 (2004).
  
  URL: http://www.phys.psu.edu/~schiffer/
  
  
• H02 - Self-Lubricating Coatings Manufactured by High Velocity Particle Consolidation
  A. E. Segall, I. Smid, T. J. Eden, G. Aggarwal, P. Walia
  Abstract: Because of the difficulties associated with thermal-spray methods (lubricant volatilization, phase transformations, and oxidation), a new coating method known as the High Velocity Particle Consolidation (HVPC) was conceived. HVPC is a promising lower-temperature method that efficiently creates a coating through a process related to friction welding. The unique feature of HVPC is that the solid-phase particles are accelerated by a supersonic jet of gas at temperatures well below the melting temperature of most materials; the impacting particles may also effectively shot-peen the surface and improve fatigue life. Given these advantages, research funded by the Air Force and WPAFB is focusing on HVPC coatings with imbedded lubricants that would otherwise be impossible via traditional spray methods. Ni with boron nitride or molybdenum-disulphide systems are currently under study with the goal of protective coatings for Ti6AlV dovetails in turbine engines.
  
  
• H03 - Surface Modification and Fracture Control Methodologies for Ceramics using Simultaneous CO2 Lasers
  A. E. Segall, G. Cai, R. Arakrapu, S. Pullford, P. Brugan
  Abstract: While lasers are attractive for cutting ceramics, their full potential has not been realized because of premature fractures and micro-scale damage. Research has therefore been focused on dual-beam methods that can avoid/repair damage in ceramics. One strategy involves creating controlled fracture-paths using a lower-power laser to prescore ahead of the cut. Another strategy uses a simultaneously and lower-power beam to thermoelastically compress the region in front of the cutting beam to delay fracture. The use of a second beam in a Peripheral-Gaussian or "side-clip" configuration has also been shown capable of modifying surfaces and ameliorating micro-crack damage induced during laser machining. Finite-element formulations have also being developed to guide the damage reduction strategies. Results indicate the potential of the methods for surface modifications and improving cut quality.
  
  
• H04 - Composite Particles and High Performance P/M Materials
  I. Smid
  Abstract: There is a huge potential in particle encapsulation, and consolidation into fully dense products. Thermodynamically incompatible materials can be assembled into solid products, combining the advantages of e.g. hard/strong/conductive core particles with a metal encapsulation, which in the consolidation process becomes the contiguous matrix: The combination of mechanical, thermal, and electrical properties of nanotubes is unmatched, as there are no other materials with this set of properties. Nanotube/nickel-copper composites are prepared by electroless plating with Ni and Cu. Tough coated hard particles (TCHP) are a new microstructure designed to offer high performance levels in cutting tools and wear components. Hard refractory particles are coated with a hard metal and sintered. Activities in net-shaping and powder injection molding: The first metal investigated is niobium, which has excellent formability and the lowest specific weight among the refractory metal family.
  
  URL: http://www4.esm.psu.edu/people/faculty/?ID=IUS1
  
  
• H10 - Synthesis of Polypyrrole Nanofibers by a Combination of Electrospinning and Oxidative Polymerization
  S. Nair, S. Natarajan, S. H. Kim
  Abstract: Conducting polymer synthesis at the nanoscale has gained widespread attention because of their potential applications as building blocks for organic electronics. Although they offer the advantages of easy processing, good stabilities and conductivities, polymers like polypyrrole are insoluble in most solvents. This prevents them from being used in electrospinning - a cost effective method used to synthesize continuous nanofibers with control over the fiber morphology and dimensions. We have synthesized polypyrrole nanofibers via electrospinning followed by oxidative polymerization. In this approach, a solution of polyethylene oxide and ferric chloride (in a suitable ratio of ethanol and water) are electrospun, and subsequently exposed to pyrrole monomer vapors, leading to formation of polypyrrole nanofibers. The fibers are smooth and continuous, ~100 nm in diameter and have been characterized by SEM, XPS and FTIR. The kinetics of polymer formation has been attempted by using QCM.