Advanced Materials & Processes

NOV-DEC 2013

Covers developments in engineering materials selection, processing, fabrication, testing/characterization, materials engineering trends, and emerging technologies, industrial and consumer applications, as well as business and management trends

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materials witness 9639 Kinsman Road Materials Park, OH 44073 Tel: 440/338-5151 • Fax: 440/338-4634 Moving boldly into the future T he future has arrived. This is my conclusion after a whirlwind month of visits to the EWI open house in Columbus, Ohio, the Center for Electron Microscopy and Analysis (CEMAS) at Ohio State, the Zwick testXpo in Germany, and MS&T'13 in Montreal. Seeing firsthand what different people are working on is truly inspiring, and hearing what they're excited about is even more interesting. Beyond EWI's million-dollar 3D printer making intricate titanium parts, most impressive is their new SpotSight tool. It uses a handheld ultrasonic probe to evaluate the effectiveness of component joints by visualizing weld images with realtime feedback. Originally built to test spot welds on cars, the tool eliminates the need for destructive testing and is also 10 times faster. A few blocks away at Ohio State, the stunning CEMAS lab is arguably the best microscopy lab in the world, due its ability to work across multiple length scales and a pristine lab space that offers a perfect environment for its highly advanced instruments. Who knew what an old mattress factory could be turned into? In Germany, the most amazing aspect of Zwick's testXpo was the robotic technology, featured in this month's cover story. Watching beautiful KUKA robots efficiently process metal samples through a variety of testing machines was both awe-inspiring and disturbing. With China on track to install 100,000 new robots by 2015, and Zwick building a facility there to meet local testing needs, automation is clearly forging ahead. But I worry about the toll on human employment as these robots work 24/7 in cold, dark warehouses with no need for bathroom breaks or health insurance. At MS&T'13 in Montreal, attendees were treated to lectures, technical sessions, an exhibition, and most fun, a gala celebration of ASM's 100th anniversary and the annual ASM Awards Dinner. The MS&T Plenary Session kicked off the week in a spectacular way. Boeing's Kevin Bowcutt gave a riveting talk on hypersonic flight, including a May 1 video of the X-51A scramjet flying at Mach 5.1 for 210 seconds. Although test jets are lost to the ocean, Bowcutt says a retrievable scramjet is on its way. John Sarrao of Los Alamos spoke about new concepts for controlling materials in extreme environments, which he referred to as "mesoscale science—beyond atomic, molecular, and nano." He said theory and simulation need to connect models across scales and incorporate emergent phenomena to realize functionality by design. Tresa Pollock then gave a fascinating lecture on advanced materials in turbine engines and propulsion environments. Another lively event was the ASM Alpha Sigma Mu lecture by David Williams of Ohio State. He pointed out the absurdity of capturing data-rich images with multimilliondollar electron microscopes and then displaying those images on $200 monitors. He says we should be using infinitely better monitors, and also cautioned that no matter how expensive the microscope, if samples are not carefully prepared, it won't matter. On a human level, Williams emphasized the need to surround oneself with smart people and give them credit, and to always thank the people working around you. As a final note, he recognized the unpredictable nature of career opportunities and life itself and sagely advised, "When doors open, walk through them." 2 ADVANCED MATERIALS & PROCESSES • NOVEMBER-DECEMBER 2013 Frances Richards, Senior Editor Julie Kalista, Editor Barbara L. Brody, Art Director Joanne Miller, Production Manager; Editor, ASM News Press Release Editor EDITORIAL COMMITTEE Mario Epler, Chair, Carpenter Technology Corp. Yu-Ping Yang, Vice Chair, Edison Welding Institute Ellen Cerreta, Past Chair, Los Alamos National Lab William Lenling, Board Liaison Laura Addessio, PCC Structurals Inc. Arvind Agarwal, Florida International University Gerald Bruck, Siemens Westinghouse Power Corp. Steven Claves, Bechtel Marine Propulsion Corp. Adam Farrow, Los Alamos National Lab Jacob Goldsmith, University of Michigan Nia Harrison, Ford Motor Co. Alan Luo, The Ohio State University Roger Narayan, UNC-NCSU Scott Olig, Vision Point Systems Nina Pang, Boston University Somuri Prasad, Sandia National Lab Fei Ren, Oak Ridge National Lab Michael Rigsbee, North Carolina State University Kumar Sridharan, University of Wisconsin Jaimie Tiley, U.S. Air Force Research Lab Cong Wang, Saint-Gobain High Performance Materials ASM BOARD OF TRUSTEES C. Ravi Ravindran, President Sunniva R. Collins, Vice President Robert J. Fulton, Treasurer Gernant E. Maurer, Immediate Past President Jeffrey A. Hawk William J. Lenling Linda S. Schadler Iver Anderson Mitchell Dorfman James C. Foley Jacqueline M. Earle John R. Keough Zi-Kui Liu Thomas S. Passek, Secretary and Managing Director STUDENT BOARD MEMBERS Jessica Booth, Karly Chester, Raymond Hickey Individual readers of Advanced Materials & Processes may, without charge, make single copies of pages therefrom for personal or archival use, or may freely make such copies in such numbers as are deemed useful for educational or research purposes and are not for sale or resale. Permission is granted to cite or quote from articles herein, provided customary acknowledgment of the authors and source is made.

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