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High Temperature Ceramics at UMR FIRE Founders’ Meeting Leoben, Austria - February 14-16, 2005

High Temperature Ceramics at the University of Missouri-Rolla. Jeffrey D. Smith Associate Professor of Ceramic Engineering Department of Materials Science and Engineering School of Materials, Energy and Earth Resources University of Missouri-Rolla Leoben, Austria February 14, 2005.

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High Temperature Ceramics at UMR FIRE Founders’ Meeting Leoben, Austria - February 14-16, 2005

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  1. High Temperature Ceramics at the University of Missouri-Rolla Jeffrey D. Smith Associate Professor of Ceramic EngineeringDepartment of Materials Science and EngineeringSchool of Materials, Energy and Earth ResourcesUniversity of Missouri-RollaLeoben, AustriaFebruary 14, 2005 Special acknowledgement to William G. Fahrenholtz for his input High Temperature Ceramics at UMRFIRE Founders’ MeetingLeoben, Austria - February 14-16, 2005

  2. Rolla, Missouri, United States of America?!? Rolla, Missouri is both the geographic and the populous center of the United States.In the heart of the Ozarks – outdoor activities are the norm – students choose from hunting, fishing, boating, canoeing, spelunking (cave exploring), etc.Fairly close to major metropolitan areas: East (100 miles) – St. Louis, 2.1 million Northwest (200 miles) – Kansas City, 2.4 million Southwest (120 miles) – Springfield, 200 thousand North (60-90 miles) - Jefferson City and Columbia, 150 thousandSmall town of ~17,000 (~30,000 when including county)Low crime and very low cost of living High Temperature Ceramics at UMRFIRE Founders’ MeetingLeoben, Austria - February 14-16, 2005

  3. Rolla Campus in the University of Missouri System Missouri's premier technological university – other campuses have specialties (KC – law, StL – medicine) 284-acre “landgrant” campus University was founded in 1870 as the Missouri School of Mines (MSM) and became the University of Missouri - Rolla in 1964, portion that was MSM became the School of Mines and Metallurgy 320 faculty of which 99% of full-time tenured and tenure-track faculty have Ph.D.s or the highest degree awarded in their field Currently 4500 undergrads, 1000 graduate students Student to faculty ratio ~13 to 1 with average class size of 26 students High Temperature Ceramics at UMRFIRE Founders’ MeetingLeoben, Austria - February 14-16, 2005

  4. Department of Ceramic Engineering In the mid-1920s, research problems related to Missouri clays were being neglected and the local university, the Missouri School of Mines and Metallurgy, could offer no support On December 1, 1925, representatives from the Missouri Refractories Association and the Missouri Clay Association met in Rolla, Missouri and made a request to the directors of MSM to establish a chair of ceramic engineering Their bid was successful and in the fall of 1926 the Ceramic Engineering Department was established Currently, Ceramic Engineering consists of seven full time faculty members, two Curators’ Professors Emeritus and a host of research professors, specialists and technicians Enrollment in Ceramics typically ranges from 50 to 70 undergraduates and 25 to 35 graduate students Major areas of graduate research include electronic ceramics (Drs. Anderson, Dogan and Schwartz), glass, glass ceramics and bio-materials (Drs. Day, Brow and Rahaman) and advanced, structural and refractory ceramics (Drs. Hilmas, Fahrenholtz and Smith) High Temperature Ceramics at UMRFIRE Founders’ MeetingLeoben, Austria - February 14-16, 2005

  5. Ceramic Engineering at UMR Combined with Metallurgical Engineering to form the Department of Materials Science and Engineering in 2004.Programs remain independent and curriculum is largely unaffected by the change.Concurrently the School of Mines and Metallurgy was transformed into the School of Materials, Energy and Earth Resources.The new school is the first based on the principal of interdisciplinary research and education as materials has become a focal point on the campus. High Temperature Ceramics at UMRFIRE Founders’ MeetingLeoben, Austria - February 14-16, 2005

  6. Ceramic Engineering Curriculum Undergraduate Program – Properties Based Courses (ABET accredited)128 Hours Required for graduation – semester systemHeavy Laboratory Component – six semester long courses and one year long capstone senior design courseCourses Related to Refractories – Phase Equilibria, Thermodynamics, Mechanical Properties, Thermal Properties, RefractoriesGraduate Program – 9 hour core curriculum (Kinetics, Electro-optical Properties, Phase Relations)MS – 4 to 6 semesters (18hrs coursework, 12 hrs research)PhD – 6 to 10 semesters (40hrs coursework, 40hrs research) High Temperature Ceramics at UMRFIRE Founders’ MeetingLeoben, Austria - February 14-16, 2005

  7. Refractory Ceramic Group Refractory ceramics group is led by Dr. Jeffrey D. Smith, Associate Professor of Ceramic Engineering Current group is made up of four faculty, one staff, eight graduate students and five undergraduate students Emphasis of the group includes: thermal shock, strength, creep behavior, slag resistance, mix design, monolithic systems as well as structural ceramics; toughened monolithics, fiber-reinforced glass and glass-ceramic matrix composites, strength testing of composites, and fiber-matrix interactions Group is housed in 5 office/laboratory complexes totaling more than 15,000 square feet. High Temperature Ceramics at UMRFIRE Founders’ MeetingLeoben, Austria - February 14-16, 2005

  8. Refractory Ceramic Group Service Activities St. Louis Section of the American Ceramic Society American Ceramic Society Phase Equilibria Advisory Board Unified International Technical Congress on Refractories Refractories Applications and News Refractories Applications Transactions High Temperature Ceramics at UMRFIRE Founders’ MeetingLeoben, Austria - February 14-16, 2005

  9. Research Areas – Nozzle Clogging Cross-section of SEN showing typical location of clog. Clog normally consists of alumina, spinel and/or calcium aluminates derived from the steelmaking process. Investigators Jeff Smith - Cer Kent Peaslee - Met Dave Van Aken - Met Cathodoluminescence image of spinel / calcium aluminate clog. Funding: US Department of Energy and American Iron and Steel Institute High Temperature Ceramics at UMRFIRE Founders’ MeetingLeoben, Austria - February 14-16, 2005

  10. Research Areas – Dewatering of Monolithics Computer and physical modeling related to the rapid dewatering of high temperature concretes: Refinement of the models by Ahmed and Hurst and Gong and Mujumdar and Bazant Construction and operation of equipment for rapid heating of large concrete specimens, 61-cm by 61-cm by variable thickness Radar-microwave methods for location of "water wall" in the concrete Effects of polymeric fibers on the resistance of rapidly heated concretes to explode in one sided exposures Vacuum decay technique to provide a relative measure of very low permeability industrial concretes Investigators Jeff Smith - Cer Bill Headrick - Cer Funding: American Iron and Steel Instituteand National Science Foundation High Temperature Ceramics at UMRFIRE Founders’ MeetingLeoben, Austria - February 14-16, 2005

  11. Research Areas – Continuous Steelmaking Research program to design a continuous steelmaking process that begins with steel scrap and finishes with steel slabs. Investigators Kent Peaslee - Met Von Richards - Met David Robertson - Met Jeff Smith - Cer Conceptual drawing of a proposed process to continuously melt, refine, and cast high-quality steel. Funding: US Department of Energy High Temperature Ceramics at UMRFIRE Founders’ MeetingLeoben, Austria - February 14-16, 2005

  12. Research Areas – Steel Foundries Research program to identify combinations of refractory materials and foundry practices that yield reductions in production costs and energy consumption. Investigators Jeff Smith - Cer Kent Peaslee - Met Von Richards - Met Chris Ramsay - Met Funding: US Department of Energy and Steel Founders’ Society of America High Temperature Ceramics at UMRFIRE Founders’ MeetingLeoben, Austria - February 14-16, 2005

  13. Research Areas - Channel Induction Build-ups RL Investigators Jeff Smith - Cer Musa Karakus – Cer Acidic slag build-up; gray iron melting channel induction furnace CL Green - Spinel Red - Alumina Yellow - Anorthite Funding: American Foundrymans’ Society High Temperature Ceramics at UMRFIRE Founders’ MeetingLeoben, Austria - February 14-16, 2005

  14. Research Areas – Aluminum Casting Tubes Development of low permeability / aluminum resistant ceramic and castable refractory shrouds for low pressure casting of aluminum alloys. Investigators Jeff Smith - Cer Bill Fahrenholtz – Cer ORNL Funding: US Department of Energy and Pyrotek, Inc. High Temperature Ceramics at UMRFIRE Founders’ MeetingLeoben, Austria - February 14-16, 2005

  15. Research Areas – Black Liquor Gasification Refractory Determination Develop new refractory systems for black liquor containment Perform thermodynamic modeling Microstructural and phase analysis Measure bulk properties, contact angle and smelt penetration. Simulative corrosion testing Industrial trails Model Development Analysis of heat flow and thermal stress/strain. Estimation of the expected lifetime Select cost effective refractory CL image of a black liquor corrosion of alumina Investigators Bill Headrick - Cer Musa Karakus - Cer Bill Fahrenholtz - Cer Funding: US Department of Energy High Temperature Ceramics at UMRFIRE Founders’ MeetingLeoben, Austria - February 14-16, 2005

  16. OBJECTIVE To improve the surface smoothness and density of air plasma sprayed (APS) coatings to reduce manufacturing costs and improve tool durability. SOLUTION Use laser for local melting of the APS coating. RELATED PAST EFFORTS Develop APS coating technology for ceramic tooling used for superplastic forming of titanium 80 µm BENEFITS OF PROGRAM 50% to 80% reduction in fabrication costs of ceramic tool versus stainless steel Reduction in lead time (2 weeks versus 6 months) Relative ease in making engineering changes 400 µm INVESTIGATORS D.C. Van Aken, Metallurgical Engineering J.D. Smith, Ceramic Engineering Research Areas – Thermal Spray Coatings Funding: The Boeing Company High Temperature Ceramics at UMRFIRE Founders’ MeetingLeoben, Austria - February 14-16, 2005

  17. Hot gas temperature Temperature profile without TBC Temperature profile with TBC Coolant temperature Ceramic Metal wall Research Areas – Thermal Barriers Benefits: Higher engine temperature, improved efficiency, reduction in atmospheric pollution Research: Effects of composition and microstructure on properties and reliability of zirconia-based thermal barrier coatings Investigators Len Rahaman - Cer Dave Van Aken - Met Jeff Smith - Cer Funding: The Boeing Company and Wright Patterson Air Force Base High Temperature Ceramics at UMRFIRE Founders’ MeetingLeoben, Austria - February 14-16, 2005

  18. Fusion Cast Alumina Zirconia Silica Research Areas – Microstructure Library UMR provides microstructures of refractory ceramic materials to be included in a database as a “digital library” The database includes properties such as porosity, density, thermal conductivity, strength and corrosion resistance Investigators Jeff Smith - Cer Musa Karakus - Cer Bill Headrick - Cer Funding: National Science Foundation High Temperature Ceramics at UMRFIRE Founders’ MeetingLeoben, Austria - February 14-16, 2005

  19. Research Areas – Glass Industry Pilot Scale Glass Melter – 200kg/day Accessories - gas chromatograph, video camera, spectrometer, manual or automatic feed systems, NaOH/KOH monitoring, atomic absorption Evaluate effects of oxy-fuel firing, glass and vapor corrosion, batching parameters, Iining thickness, etc. Investigators Jeff Smith - Cer Bill Headrick - Cer Funding: National Science Foundation and Center for Glass Research High Temperature Ceramics at UMRFIRE Founders’ MeetingLeoben, Austria - February 14-16, 2005

  20. Research Areas – Glass Industry Characterization of key properties concerning refractory materials for improved thermal efficiency and management in industrial combustion environments. The glass industry desires thermal property data on alternative refractory materials such as magnesia-alumina spinel. Investigators Jeff Smith - Cer Bill Headrick - Cer ORNL Funding: National Science Foundation and Center for Glass Research High Temperature Ceramics at UMRFIRE Founders’ MeetingLeoben, Austria - February 14-16, 2005

  21. Research Areas – Glass Industry Glass Tank Sensors - chemistry of the combustion zone, monitoring refractory wall thickness, flame image analysis Investigators Jeff Smith - Cer and David Robertson - Met Funding: National Science Foundation and Center for Glass Research High Temperature Ceramics at UMRFIRE Founders’ MeetingLeoben, Austria - February 14-16, 2005

  22. Al2O3 Ni Al2O3-Ni Composite Prepared by Reactive Hot Pressing IndentationCrack 2 Al + 3 NiO  Al2O3 + 3 Ni BridgingLigament 6 µm Research Areas – Reactive Processing Objective - Fabricate ceramic-metal composites with improved stability and performance Approach - Use displacement reactions to form two phase materials composed of stable, refractory phases Benefits - Interpenetrating structure, improved mechanical performance, reduced processing temperatures, high strength and toughness Current Systems - Al2O3-Ni, Al2O3-MoSi2, Al2O3-Nb, Al2O3-Ni3Al Investigators Bill Fahrenholtz - Cer Jeff Smith - Cer Funding: University of Missouri, Air Force Office of Scientific Research and Caterpillar, Inc High Temperature Ceramics at UMRFIRE Founders’ MeetingLeoben, Austria - February 14-16, 2005

  23. Research Areas – Ultra High Temp. Ceramics Objective - Produce thermal protection materials with improved performance for sharp leading/trailing edge applications Solution - Use reaction-based processing for improved control of microstructure and co-extrusion to tailor meso/macrostructure Benefits - Use temperatures above 2200°C, improved aerodynamic performance, elimination of communication black-out during re-entry Materials - Borides and carbides of other early transition metals such as ZrB2, HfB2, ZrC, HfC, ZrB2-SiC, ZrB2-MoSi2 etc. Investigators Bill Fahrenholtz - Cer Greg Hilmas - Cer Funding: Air Force Office of Scientific Research High Temperature Ceramics at UMRFIRE Founders’ MeetingLeoben, Austria - February 14-16, 2005

  24. Research Areas – Others Refractory sheaths for sensor protection AccuTru International Advanced monolithic refractory formulations Missouri Refractories Company Iron and CO2 recovery from BOF slags American Iron and Steel Institute Refractories for containment of nuclear waste glasses US Department of Energy and DIAL Recycling of spent refractories Missouri Department of Natural Resources High Temperature Ceramics at UMRFIRE Founders’ MeetingLeoben, Austria - February 14-16, 2005

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