Novel Ceramic-Metallic Composites for Light
Transkript
Novel Ceramic-Metallic Composites for Light
Youngstown State University CTME -- Center for Transportation and Materials Engineering FULL PROPOSAL Submitted March 20, 2012 Proposed Project Title: Novel Ceramic-Metallic Composites for Light Weight Vehicle Braking Systems Principal Investigator (PI): Dr. Timothy R. Wagner, Professor - Inorganic / Solid State Chemistry Department of Chemistry Youngstown State University, One University Plaza, Youngstown, Ohio 44555 330-941-1960, trwagner@ysu.edu Co-Principal Investigators (Co-PIs): Dr. Matthias Zeller, Instrumentation Scientist & Adjunct Professor Department of Chemistry Youngstown State University Youngstown, Ohio 44555 330-941-7105, mzeller@ysu.edu Dr. Dingqiang Li, Instrumentation Scientist, Electron Microscopy Facility Department of Chemistry Youngstown State University Youngstown, Ohio 44555 330-941- 7102, dli01@ysu.edu Industrial Collaborators: Klaus-Markus (Mark) Peters, General Manager, TCON Division Fireline, Inc., 300 Andrews Avenue, Youngstown, Ohio 44505 330-743-1164, mpeters@fireline-inc.com Brian P. Hetzel, R&D Manager Fireline, Inc., 300 Andrews Avenue, Youngstown, Ohio 44505 330-743-1164, bhetzel@fireline-inc.com CTME: Novel Composites for Light Weight Vehicle Braking Systems YSU - Wagner 2 PROPOSAL NARRATIVE A. Intrinsic Merit Project Overview This project centers on a close interaction between the TCON Division of Fireline, Inc. and various individuals affiliated with the College of Science, Technology, Engineering, and Mathematics (STEM) at Youngstown State University (YSU). Fireline, a local company within 10 minutes walking distance from the YSU campus core, has developed a unique process that utilizes displacement reactions to transform ceramic preforms into ceramic-metallic co-continuous interpenetrating phase composites with enhanced properties while retaining the original shape and dimensions of the preform. Through initial development efforts, it was discovered that TCON composite materials have extraordinary macro-, micro-, and nanoscale features that lead to their exceptional properties ideal for applications that require cost effective, lightweight materials. The unique properties of TCON composites in general are derived from the fine interlocking of ceramic and metallic phases throughout the composite microstructure. The ceramic phase provides high stiffness, low density and high strength to the composite, while the continuous network of reinforced metal gives high thermal & electrical conductivity, and high fracture toughness to the material. Such properties make these materials excellent candidates for replacing traditional materials in a number of applications, such as high wear/corrosion resistant refractory shapes for molten metal transport and/or containment industrial processes (the major area in which Fireline currently commercializes some of its TCON products), or for new applications, including light weight, high strength components for vehicle braking systems, which is the focus of the present project. Fireline has already made significant progress using formulations based mainly on silica precursors, and is working with a number of companies towards the commercialization of these composites as brake rotors. The proposed project is focused on the synthesis of specific ceramic precursors and their subsequent transformation via reactive metal displacement to produce novel ceramic-metallic interpenetrating phase composites (IPCs) for potential use in light weight braking systems in vehicles. The proposed IPCs are closely related to TCON composites currently produced by Fireline Inc., and they are designed to yield composites displaying the high strength and strong refractory properties required for brake rotor materials in order to expand Fireline’s product line in this area even further. Specifically, the objectives for this project are to prepare novel composite materials consisting of: (1) A MgAl2O4 spinel phase combined with a light weight, high strength Ti-Al alloy and/or Al metallic phases (or other metallic phase depending on precursor), and (2) The oxynitride spinel phase, Al3O3N (related to so-called ‘transparent spinels’ discussed later) combined with Al metal. These objectives will be accomplished by preparing ceramic precursor materials such as MgTi2O4, SiAl2O2N2, and other phases, none of which have been used previously in the production of TCON composites. The spinel phases of the proposed new composites have cubic lattices, like the predominant Al metallic component of these composites, meaning even stronger binding potential between the two phases and thus a stronger composite. CTME: Novel Composites for Light Weight Vehicle Braking Systems YSU - Wagner 3 Motivation and Significance For the personal and commercial vehicle industries, gray cast iron has been the overwhelming material of choice in braking systems (such as in brake rotors and drums) because it is inexpensive and a large supply chain infrastructure is in place for engineering and manufacturing gray cast iron components. However, gray cast iron is a relatively heavy material. Utilizing lighter weight materials in braking systems would not only achieve better fuel economy by reducing the vehicle’s static weight but, since brake rotors and drums are rotating components, there would be a large multiplying effect on reducing the amount of energy required to increase their rotational speed as the vehicle accelerates. Finally, as the braking system is an unsprung weight, a lighter system would significantly improve vehicle handling performance and safety. Most lightweight materials do not have the physical, mechanical, thermal, and tribological performance characteristics required for brake applications, such as high strength and high thermal conductivity at elevated temperatures. Lightweight alternatives to gray cast iron that currently do exist are prohibitively expensive for general use in most vehicles1. Initial research on next-generation materials for brake rotors has already evaluated composites similar to TCON materials (i.e., IPC’s produced via reactive metal penetration (RMP) processes). The preliminary results were very promising, showing that these IPC’s exhibited friction and wear properties similar to cast iron, but with half the weight and better thermal conductivity2. Fireline has expanded and improved upon these earlier reported materials. They are currently producing brake rotor prototypes for testing based on promising composite formulations prepared via proprietary processes, and strongly support continued R&D efforts such as those proposed herein. Unlike precursor mixtures currently utilized in making TCON composites, the ceramic precursors proposed below are synthesized materials targeted to produce cost-effective composites with specific compositions, microstructures, and properties. A significant advantage of the proposed project is that the most promising materials discovered in the course of this work will benefit from marketing research and commercialization partnerships that will already in place from Fireline’s current significant efforts in this area. Approach and Methodology The TCON Process The TCON process utilizes displacement chemical reactions, in which sacrificial oxides are reduced by a molten metal and subsequently form a ceramic/metal composite3-8. Under certain conditions, e.g. when the ceramic material formed possesses a higher density/lower volume than the sacrificial oxide, the resulting channels which form are filled in with excess metal, directly leading to the formation of the co-continuous ceramic/metallic composite (see Figure 1). The process is essentially carried out in two steps: (1) ceramic preforms containing sacrificial precursor oxides (such as SiO2) are fabricated via conventional methods (e.g. slipcasting) routinely performed at Fireline, or for laboratory work, using standard ceramic methods; and (2) the displacement reaction (or “transformation process”) is implemented by fully immersing the ceramic performs in molten metal (such as Al) under specific processing conditions and periods of time. Subsequently, the precursors are totally transformed into unique ceramic-metallic co-continuous interpenetrating phase composites (IPCs) while 4 CTME: Novel Composites for Light Weight Vehicle Braking Systems YSU - Wagner the original shape and dimensions of the preform are retained, as indicated in Figure 2. The process offers enormous advantages such as (1) flexibility in the choice (and thus cost) of ceramic precursor material (and/or molten metal composition) used in the process, including the use of novel materials designed to enhance specific product performance; (2) ability to engineer complex components cost-effectively via net or near-net shaping for use in specific industrial applications or integration into advanced systems; and (3) manipulation of processing parameters, such as molten metal reactant composition or addition of inert phases, thereby enabling control of microstructure and thus mechanical properties of the IPC products. Al2O3 Al Figure 1. TCON Al2O3-Al matrix Figure 2 There are numerous reactions that are thermodynamically, kinetically, and mechanistically favorable4, yielding composites such as Al2O3/Al, MgO/Mg, TiO2/Ti, and NiAl2O4/Al. Of these IPC materials produced via displacement reactions, the alumina/aluminum (Al2O3/Al) composite is the one that has been most investigated4-8. This reaction can be carried out as follows: (4+x)Al + 3SiO2 → 2Al2O3 + 3Si(Al) + xAl where ‘xAl’ is the amount of excess aluminum forming a continuous network in the composite as a result of the volumetric contraction that occurs as the silica (SiO2) reacts to form alumina. Note also that the Si produced in the reaction is dissolved in the Al network, as represented by the ‘Si(Al)‘ symbol. This material is extremely strong, and contains ca. 70 weight % alumina and 30 weight % aluminum. Figure 1 (above) represents a typical microstructure of this material. Depending upon the processing conditions, the composite product materials have alumina and aluminum networks with cross-sectional thicknesses ranging from one to a few micrometers across3,5,6 and fine nanometer-sized grains8. Also, the interfaces between the alumina and aluminum phases have unique nanoscale features9-11 that are believed to directly impact the material’s macroscale properties, including stepped facets and intimate contact between the two phases4,9-11. Previous Work As discussed above, the TCON process affords great flexibility in the reaction conditions utilized to produce ceramic-metallic IPCs, and this project focuses on manipulation of sacrificial ceramic precursor materials in the production of novel TCON CTME: Novel Composites for Light Weight Vehicle Braking Systems YSU - Wagner 5 composites. In particular, to build upon previous results obtained from a Fireline-YSU Army Research Laboratory (ARL) project, novel precursors will be targeted that are likely to incorporate (1) Ti or Ti-Al alloys into the metal alloy phase and/or (2) a spinel (i.e. MgAl2O4) ceramic phase into TCON composite materials. Titanium is known to greatly increase the strength of aluminum alloys via grain refining, as well as to decrease friction and wear of aluminum alloys12. Spinel is a well-known refractory material that is less dense than Al2O3, and unlike corundum, which is the rhombohedral Al2O3 phase predominant in TCON composites, MgAl2O4 is cubic. Thus, as mentioned earlier, spinel ceramics offer improved epitaxy with the cubic Al grains, resulting in potentially stronger ceramic-metallic phase interfaces in the composite and a stronger material overall. Previous work in the PI’s research group at YSU has examined several Ti-based systems including N-doped TiO2, a TiSiO4-related composition13, and especially recent groundbreaking studies14 on the transformation of MgTiO3, an easy to prepare illmenite phase with a structure similar to α-Al2O3. Laboratory-scale transformations of MgTiO3 in an Al-5%Si bath yielded an IPC containing the desired MgAl2O4 spinel phase as well as a Ti-Al-Si alloy. Microscopy and X-ray diffraction data for a partially transformed test bar are given in Figure 3. Further detailed analyses via powder X-ray diffraction (PXRD) and EDXS in the SEM of isolated sections cut from different zones in the partially transformed sample have revealed fundamental information regarding the mechanism of the transformation. Essentially, the mechanism appears to involve the gradual reduction of MgTiO3 (with Ti4+) to a series of oxides with lower Ti oxidation states (e.g. including MgTi2O4 with Ti3+ and TiO with Ti2+) and finally to Ti metal mixed with MgO and Al2O3. The latter two compounds then undergo a secondary reaction to give spinel, MgAl2O4. The metallic phases consist of Al, and Ti alloyed with Al and Si14. Figure 3. Optical image (above left) of partially transformed MgTiO3. Several zones including completely transformed composite (outer region), the metal reaction front, and unreacted precursor are evident. The SEM image (lower left) shows the microstructure of the transformed composite with presence of spinel & Ti-alloy phases. The PXRD pattern (right) indicates the phases in the transformed region: Spinel, magenta peaks; alumina peaks, red; and aluminum metal peaks, blue. CTME: Novel Composites for Light Weight Vehicle Braking Systems YSU - Wagner 6 Proposed Research The proposed research will focus on new precursor routes derived from results of previous work on the MgTiO3 system, and will engage in studies of novel, but related, precursor systems. In our preliminary studies of composites produced from MgTiO3, we noted via powder X-ray diffraction analysis the presence of the spinel-type phase MgTi2O4 as an intermediate in the transformation. Such compositions offer the advantage of having the exact stoichiometry required to produce a spinel/metal-alloy composite: (2+x)Al + MgTi2O4 → MgAl2O4 + AlxTi2. Note that we have previously observed such direct replacement reactions in studies of SrFe12O19, in which Al displaced Fe3+ to give SrAl12O1914. Although MgTi2O4 requires synthesis in a reducing atmosphere (e.g. nitrogen or argon), it can easily be prepared on a laboratory scale and transformed for preliminary investigation. The cost effectiveness of scaled-up synthesis in reducing atmosphere depends upon property benefits of the produced composite material. Alternatively, other spinel-type phases can be studied, in particular MgFe2O4. Note that the Fe-Al alloy phase expected in composites produced from this phase, while heavier than comparable Ti systems, are still lightweight compared to brake rotors made of cast iron, for example. The mechanism derived from our previous studies of transformation of MgTiO3 suggests excess MgO as a reaction byproduct, due to insufficient Al2O3 present for further reaction to spinel. We therefore also propose to investigate the well- known and easily prepared psuedobrookite phase, MgTi2O5, which is a new precursor system for TCON processing. This material supplies sufficient oxygen to use up all MgO to produce a spinel-rich composite: (8+x)Al + 3MgTi2O5 → 3MgAl2O4 + Al2O3 + xAl-6Ti. It should be noted that it was observed during the course of our MgTiO3 work that the presence of silicon in the aluminum melt appears to facilitate Ti-alloy formation & retention in the composite, and independent work at Fireline indicates that mixing SiC with precursor material achieves the same result. However, for some precursor systems, it may be useful to find a route that does not require dependence of Si in the system for Ti alloy retention. We therefore plan to focus some effort on mixing carbon into the MgTixOy preform, which we expect will facilitate retention of Ti either through formation of TiC or C-doped Ti alloys. In addition, the presence of carbon is known to significantly increase the TiAl alloy component strength15,16. A particularly interesting system we propose to introduce to the TCON process consists of compounds known generally as sialons, one example of which is βSiAl2O2N2 . This material can be synthesized by reaction of SiO2 and AlN at 1450°C17. Of interest is whether or not this novel precursor would produce an aluminum spinel phase, ideal composition Al3O3N, known for its use as a transparent spinel for armor applications and for its excellent optical and mechanical properties18-21. For example, it is over 10% harder than spinel21. A feasible transformation reaction is: (4/3 +x) Al + SiAl2O2N2 → 2/3 Al3O3N + 4/3 AlN + AlxSi The reaction does not produce Al3O3N via direct displacement, so that AlN is actually produced as the major ceramic phase. This material is known for its high thermal conductivity and corrosion resistance, and has flexural strength similar to that of Al2O3. 7 CTME: Novel Composites for Light Weight Vehicle Braking Systems YSU - Wagner The precursor systems and respective targeted composites we propose to study in-depth during this one-year project are summarized in Table 1 below. Table 1. Summary of proposed precursor materials for synthesis and TCON transformation, and their corresponding targeted composite compositions. Targeted Novel Precursor Targeted Composite Phases MgX2O4 (X = Ti, Fe) spinel phases MgAl2O4 spinel phase with X-Al Alloy MgTi2O5 MgAl2O4 spinel and Al2O3 ceramic phases with Ti-Al alloy Sialon, i.e. β-SiAl2O2N2 Al3O3N spinel & AlN with Al(Si) Summary of the Overall Strategy Targeted precursors listed in Table 1 will first be synthesized as laboratory-scale pellets (1/2 in. diameter × 1/4 in. thick) usually via standard ceramic methods. Once prepared, the precursor samples will next be reacted in (usually) molten Al in a laboratory kiln until transformation to a composite material is complete. Resulting composites will be analyzed via optical microscopy, powder X-ray diffraction, X-ray fluorescence, and SEM/EDAX methods, and those showing promising phase compositions and microstructure will be further targeted for scale-up. The scale-up procedure is completed in conjunction with Fireline engineers, and utilizes inexpensive binary reagents which are mixed in a ball mill, processed as 1 × 1 × 7 in. test bars or 4 × 4 in. plates, and then sintered at appropriate temperatures to synthesize the desired precursor phase before being transformed in one of Fireline TCON’s furnaces. Final products are thoroughly analyzed for mechanical properties as well as micro- and nanostructural features. Any composite materials surpassing properties of existing TCON formulations for brake rotor applications will be considered for further development in conjunction with Fireline’s industrial partners for the commercial market. Figure 4 below depicts the overall project sequence. FIB/SEM JEOL 2100 S/TEM Laboratory tube furnace for precursor prep Lab (top) and TCON (bottom) furnaces for precursor transformation Mechanical properties analysis of novel composites Micro- & nanoscale composite analysis Figure 4. Sequence of steps for preparation and analysis of proposed novel composites for potential commercialization as brake rotor materials. Equipment depicted (except TCON Furnace) is available at YSU. CTME: Novel Composites for Light Weight Vehicle Braking Systems YSU - Wagner 8 Qualifications and Capacity of the Research Team All members of the project team have years of experience in the various specialties (see below) they bring to the project, and for the most part have been working together on related projects for several years. Detailed biosketches of all Project Personnel are attached in the Appendix. Roles & Responsibilities The key personnel and their primary roles for the proposed project are listed below: Dr. Tim Wagner (YSU) will serve as PI for the project. He will manage the project, and directly oversee the research related to precursor synthesis, transformation, and analysis of resulting composites, as well as supervise research students involved in the work. He will also coordinate with Fireline their activities related to scale-up of promising systems, and integrate properties elucidated by Fireline engineers (in conjunction with YSU students) into a feedback loop for precursor/composite optimization for brake rotor application. Dr. Matt Zeller (YSU) will coordinate phase (via x-ray diffraction methods) and chemical analysis of the TCON composite samples. Dr. Dingqiang Li (YSU) will coordinate the optical and electron microscopy characterization of the TCON composite samples to elucidate their micro- and nanostructural features. Mark Peters (General Manager of the TCON Division of Fireline) will serve as research consultant providing feedback on performance of the produced composites for potential brake rotor applications. He will also play a key role in deciding which formulation(s) should be moved forward into a commercialization phase, utilizing existing contacts with Fireline’s (proprietary) commercialization partner(s) related to their brake rotor marketing interests. Brian Hetzel (Fireline R&D Projects Manager) will assist with the development and characterization of the new TCON composite materials, as well as lead in the scale-up of the most promising laboratory samples. YSU research students will participate in this research primarily under the direction of the PI, and will perform syntheses and transformation of precursor materials, and conduct mechanical characterization (Young’s modulus, flexure strength, etc.) of the produced composites. They will also work with Fireline engineers on scale-up of promising composites, and their subsequent characterization. One graduate student, Alethea Mymo, is already working with the PI and is committed to the project. She plans to work as an intern at Fireline this summer. Specific Outcomes and Deliverables Outcomes for this one-year project include: • Laboratory-scale synthesis and transformation of novel precursors proposed herein • Characterization (chemical and structural) of produced composites • Scale-up of most promising produced composite(s) • Mechanical properties analysis of scaled-up composite bars or plates CTME: Novel Composites for Light Weight Vehicle Braking Systems YSU - Wagner 9 Primary Deliverable at the end of this one-year project: “Go” or “No Go” for further development of scaled-up composite(s) for use in a commercial light weight brake rotor system. B. Relevance Relevance to CTME’s Theme and Mission The CTME website (stem.ysu.edu/stem/ctme) lists as one of several Federal Transportation Research goals the need to “Protect the Environment and Promote Energy Independence”. Further listed as one of the objectives towards achieving this goal, is the “development of lighter-weight, more fuel efficient vehicles (including cars, trucks, trains, planes, and other modes of transportation)”. The project proposed herein is clearly relevant to this aspect of the CTME’s mission, as its primary goal is to produce a cost effective, light weight, high strength brake rotor material for use in vehicles. The effect of producing such a product, multiplied over many vehicles, would significantly reduce fuel consumption, thereby reducing emissions harmful to the environment. In addition, the successful project would contribute towards the economic development of the greater Youngstown region through playing a direct role in creation of high tech jobs at Fireline. Relevance to Other Work Light weight composite braking systems have already been available in the market for some time through companies such as REL – Matrix Brakes and Brembo SGL, but these are exclusively used for luxury sports vehicles or motorcycles as they are too expensive for the lower-end automobile market. The TCON Division of Fireline has been developing cost effective formulations specifically for brake rotor applications for the mass market for several years. Recently, they have produced prototype brake rotors in conjunction with their commercial partners for extensive testing. In the future, the light weight, high strength composite brake systems market will become more competitive as companies continue to develop suitable materials for commercialization. With the assistance of external R&D support in the form of projects such as this to bolster their internal efforts, Fireline will be well-poised to compete early in this potentially lucrative market. As noted above, the present project complements ongoing work at Fireline by investigating ternary or quaternary precursor systems that must be synthesized (i.e. as opposed to binary systems that can be purchased), and as a result, may produce novel but cost-effective composites (e.g. those containing Al3O3N) that can not otherwise be made using simpler precursors. Such efforts may give Fireline an edge for future growth not shared by their competitors. Relevance of Proposed Work to the State of Ohio The proposed project falls well within Ohio’s Third Frontier Project focus on Advanced Materials, as well as Ohio’s emphasis on research collaborations between universities and industry within the state. CTME: Novel Composites for Light Weight Vehicle Braking Systems YSU - Wagner C. 10 Outcomes Lasting Contributions The proposed work is part of a larger initiative involving several YSU research groups and Fireline that has benefitted from over $3M in previous NSF, Ohio Third Frontier, and Federal grants and contracts. This funding has been utilized mainly to establish state-of-the art facilities for X-ray diffraction, electron microscopy, mechanical properties analysis, and ballistics prescreen testing, and much of this infrastructure will directly benefit the current proposed project. The primary lasting contribution of this proposal then is that it would provide funds to support focused research conducted by the YSU faculty, staff, and student participants utilizing this equipment, and so serves not only to promote the research mission of the university, but also offers invaluable research opportunities to the participating students. Students would also have the opportunity to work with industrial collaborators (i.e. on-site at Fireline), giving them a competitive edge as they take their experiences to the challenging job market. Potential Economic Development or Commercialization The composites proposed herein are targeted specifically for application in vehicle brake rotor systems, and promising laboratory materials will be scaled-up to 1 × 1 × 7 in. bars or 4 × 4 in. plates for further testing. Fireline will consider for full commercialization to market any suitable composites developed from this project and will be well positioned to do so. It is noteworthy that Fireline is actively engaged at present in partnerships with other companies to assist in commercialization of their existing formulations for brake rotor applications. Examples of Fireline’s commercial partnerships include Carbotech Performance Brakes, for the high-performance automotive market, and GMP Frictions Products (in Akron) for Humvee vehicles for the U.S. military. This is beneficial to the proposed work, since by the end of the proposed project year, Fireline can utilize their already established partnerships to assist in commercialization of any optimal materials for the brake rotor market produced as an outcome of this project. Such a development could lead to significant job growth in the Youngstown area. Potential for Sustainability As mentioned above, this project is leveraged by state-of-the-art infrastructure established by previous grant awards obtained by the PI and his colleagues. Funds from these sources have been or will all be depleted by June, 2012. Fireline along with YSU and other collaborators are continually seeking funding to support fundamental research, development, and commercialization of these multifunctional TCON composite materials. For example, Fireline has applied for funding from the U.S. DoE Innovative Manufacturing Initiative, with YSU as one of the co-applicants, on a project related to the one proposed herein. That project will emphasize work on more fundamental precursor systems than the ones proposed here, thus, the two projects would complement each other. The PI plans to pursue related proposal submissions in the future to the Army Research Office for force protection applications, and/or to NSF for a related project focusing mainly on basic research (i.e. reaction mechanisms and modeling). Fundamental work such as that proposed herein will provide proof of concept results which will be very useful in strengthening the chances for funding of future proposals, ultimately towards the successful commercialization of product. CTME: Novel Composites for Light Weight Vehicle Braking Systems YSU - Wagner 11 REFERENCES 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. K. Cameron, “Using Ceramics, Brakes are Light but Cost is Heavy”, The New York Times, June 18, 2006. G.S. Daehn and M.C. Breslin, “Co-Continuous Composite Materials for Friction and Braking Applications”, J. of Materials, 89-92, November 2006. W. Liu and U. Koster, “Criteria for Formation of Interpenetrating Oxide/MetalComposites by Immersing Sacrificial Oxide Preforms in Molten Metals”, Scripta Materialia, 35, No. 1, pp 35-40 (1996). M.C. Breslin et al., “Processing, microstructure, and properties of co-continuous alumina-aluminum composites”, Materials Science and Engineering A195 (1995) 113119. W.G. Fahrenholtz et al., “Synthesis and Processing of Al2O3/Al Composites by In Situ Reaction of Aluminum and Mullite”, In-Situ Reactions for Synthesis of Composites, Ceramics, and Intermetallics, pp. 99-109, ed. by E.V. Barrera et al., The Minerals, Metals, and Materials Society, Warrendale, PA, 1995. R.E. Loehman and K. Ewsuk, “Synthesis of Al2O3-Al Composites by Reactive Metal Penetration”, J. Am. Ceram. Soc., 79[1] 27-32 (1996). E. Saiz and A.P. Tomsia, “Kinetics of Metal–Ceramic Composite Formation by Reactive Penetration of Silicates with Molten Aluminum”, J. Am. Ceram. Soc., 81[9] 2381–93 (1998). N. Yoshikawa, A. Kikuchi, and S. Taniguchi, “Anomalous Temperature Dependence of the Growth Rate of the Reaction Layer between Silica and Molten Aluminum”, J. Am. Ceram. Soc., 85 [7] 1827–34 (2002). J. Ringalda et al., "Scanning and transmission Electron Microscopy on Composite Materials prepared by SMP and In-Situ Displacive Reactions", Inst. Phys. Conf. Ser. No 147: Section 13, 1995. G.S. Daehn et al, "Elastic and Plastic Behavior of a Co-Continuous Alumina/Aluminum Composite", Acta Mater., 44[1], 249-261 (1996). X. F. Zhang, G. Harley, L. C. De Jonghe, Nano Letters, 5, 1035-1037 (2005). P. Parkhutik and M. Lubenski, “Effect of Titanium on the Structure Properties of Aluminum”, Metal Science and Heat Treatment, 9, 940-942 (1967). D. Loiacona, “Synthesis of β-Alumina-Type Compounds and Their Transformation via the TCON Process”, Master’s Thesis, Youngstown State University, OH U.S.A., (2010). K. Myers, “Investigation of Novel Precursor Routes for Incorporation of Titanium Alloys and Nano-Sized Features into Ceramic-Metallic Composites Formed via the TCON Process”, Master’s Thesis, Youngstown State University, expected graduation May, 2012. U. Christoph, F. Appel, and R. Wagner, “Dislocation Dynamics in Carbon-Doped Titanium Aluminide Alloys”, Mat. Sci. and Eng. A239-240, 39-45 (1997). F. Perdrix, M. Trichet, J. Bonnentien, M. Cornet, and J. Bigot, “Relationships Between Interstitial Content, Microstructure and Mechanical Properties in Fully Lamellar Ti-48Al Alloys, with Special Reference to Carbon”, Intermetallics, 9, 807-815 (2001). 17. P. Tessier, H.D. Alamdari, R. Dubus, and S. Boily, “Nanocrystaline β-Sialon by Reactive Sintering of a SiO2-AlN Mixture Subjected to High Energy Ball-Milling”, J. of Alloys & Compounds, 391, 225-227 (2005). 18. S. Rovner, “21st Century Armor”, Chemical and Engineering News, 48-53, July 27, 2009. CTME: Novel Composites for Light Weight Vehicle Braking Systems YSU - Wagner 12 19. F.C. Sahin, H. E. Kanbur, and B. Apk, “Preparation of AlON Ceramics via Reactive Spark Plasma Sintering”, J. Eur. Ceramic Soc., 32, 925-929 (2012). 20. N.D. Corbin, “Aluminum Oxynitride Spinel: A Review”, J. of the European Ceramic Society, 5, 143-154 (1989). 21. J.J. Swab, J.C. LaSalvia, G.A. Gilde, P.J. Patel, and M.J. Motyka, “Transparent Armor Ceramics: AlON and Spinel”, 23rd Annual Conf. on Composites, Advanced Ceramics, Materials and Structures: B: Ceramic Eng. & Science Proceedings, 20(4), 79-84 (1999). 13 CTME: Novel Composites for Light Weight Vehicle Braking Systems YSU - Wagner BUDGET The proposed budget for the one-year grant period is summarized below. CTME FUNDS COST SHARE EXPLANATORY NOTES Faculty Salaries $6,000 $10,655 Cost Share is match for 3 sh reassigned time during the academic year, and CTME Funds requested are for summer support. Faculty/Staff Fringes (38%) $2,280 $4,049 Student Salaries $5,000 $10,000 Student Fringes (5% for summer and 77% for academic year for MS students) $ 250 $7,700 $13,530 $32,404 Scholarships/Tuition $0 $0 Permanent Equipment $0 $0 Expendable Property, Supplies, and Services $18,000 $0 $8,000 for YSU (chemicals and other consumables related to microstructural analysis of TCON composites, materials property analysis, and synthesis of ceramic raw materials) and $10,000 for Fireline (to offset costs for producing scaled-up TCON composites of selected YSU samples). Domestic Travel $5,846 $0 For travel, lodging, and fees for travel to one conference for YSU participants. CATEGORIES Total Salaries and Benefits Other Direct Costs (Specify) Total Direct Costs F&A (Indirect) Costs TOTAL COSTS Cost Share is for YSU academic year graduate student (MS) stipend match, and CTME Funds requested are for graduate student summer support. The $7,700 cost share includes fringe benefits and tuition remission as part of the YSU academic year graduate student stipend match. Graduate student fringes for summer support requested from CTME do not require tuition remission. $0 $37,376 $32,404 $5,665 $10,637 $43,041 $43,041 Charged at YSU rate of 51.5% of salaries only. APPENDIX: BIOSKETCHES RESUME FOR TIMOTHY R. WAGNER, Ph.D. Department of Chemistry, Youngstown State University, Youngstown, OH, 44555-3663 330-941-1960, trwagner@ysu.edu EDUCATION AND TRAINING Institution(s) University of Wisconsin - River Falls Arizona State University Northwestern University Major/Area Degree Chemistry B.S. Solid State Chemistry Ph.D. Electron Microscopy Postdoc Year 1981 1986 1988–1990 PROFESSIONAL EXPERIENCE Director – Center of Excellence in Materials Science and Engineering, Youngstown State University (2009–present). Dr. Wagner is the principal author of the proposal to the Ohio Dept. of Development establishing Materials Science and Engineering as a Center of Excellence at YSU, as well as PI of a $2.1 M grant funded through the Ohio Third Frontier Wright Project Program which was used to establish a new electron microscopy facility at YSU, consisting of a JEOL 2010 TEM/STEM, JEM 4500 FIB/SEM, and TEM sample prep lab. The EM facility was funded largely to support our collaborative work on design & characterization of advanced composite materials produced by the TCON Division of Fireline, Inc., such as those proposed herein. Professor – Chemistry, Youngstown State University (2003–present). Synthesis and characterization (X-Ray, SEM, TEM) of mixed anion inorganic materials; synthesis of ceramic oxide precursors for preparation of ceramic-metallic composites, and analyses via X-ray diffraction, EM, & other methods to establish structure/property relationships towards rational design of advanced composite materials produced by the TCON Division of Fireline, Inc. Associate Professor – Chemistry, Youngstown State University (1998–2003). Assistant Professor – Chemistry, Youngstown State University (1992–1998). Visiting Assistant Professor – Chemistry, Illinois Institute of Technology (1990– 1992). PUPLICATIONS / PATENTS Articles & Presentations: Wagner has authored 26 peer reviewed publications and contributed to over 14 presentations (last five years) at national and international conferences A. Yurcho, A., Peters, K-M., Hetzel, B., Zeller, M., Wagner, T.R., and Solomon, V.C., “Microstructural and Compositional Investigation of Al-alloy-Al2O3 Ceramic-Metallic Composites Synthesized by Reactive Melt Penetration”, Bul. Inst. Polit. Iaşi 2011, LVII (LXI) (4), 416-426. Solomon, V.C., Peters, K.M., Hetzel, B., and Wagner, T.R., “Characterization of structure evolution in aged Al2O3/SiC composite refractories by electron microscopy” Microscopy and Microanalysis, 16(Suppl. 2) pp. 946-947 (2010). i Seibel, H., Karen, P., Wagner, T.R., and Woodward, P.M.: "Synthesis and Characterization of Color Variants of Nitrogen- and Fluorine-Substituted TiO2", J. Mater. Chem., 19, 471-477 (2009). Pugh, C.A., Lufaso, M.W., Zeller, M., Wagner, T.R., and Curtin, L.S.: “The Synthesis, Spectroscopic, Electrochemical and X-Ray Diffraction Characterization of Novel Bridged Ferrocene Precursors for use in Self-Assembled Monolayers”, J. Organometal. Chem., 691, 680-686 (2006). Jack, D.J., Zeller, M., and Wagner, T.R.: “Doubled-cubic Ca2NF,” Acta Cryst., C61, i6-8 (2005). Seibel, H. and Wagner, T.: “Preparation and Crystal Structure of Ba2NF,” J. Solid State Chemistry, 177, 2772-2776 (2004). Wagner, T.: “Preparation and Crystal Structure Analysis of Sr2NF,” J. Solid State Chemistry, 169, 13-18 (2002). Luo, J., Alexander, B., Wagner, T.R., and Maggard, P.A.: “Synthesis and Characterization of ReO4-Containing 2D and 3D Open Framework Structures,” Inorganic Chemistry, 43, 5537-5542 (2004). Seibel, H., Miner, P.L., Norris, P., and Wagner, T.R.: "Crystal Structure of 1-(2,3:5,6-DiO-isopropylidene-β-D-mannofuranosyl)-1H-[1,2,3]triazol-4,5-dicarboxylic acid diethyl ester", J. of Chem. Crystallography, 2007, 37(3), 157-163. Gadikota, R.R., Callam, C.S., Wagner, T.R., Del Fraino, B., and Lowary, T.L.: “2,3Anhydrosugars in Glycoside Bond Synthesis. Highly Stereoselective Syntheses of Oligosaccharides Containing α-and β-Arabinofuranosyl Linkages,” J. of the American Chemical Society 2003, 125(14), 4155-4165. SYNERGISTIC ACTIVITIES Dr. Wagner is a major proponent of current efforts to expand research and economic development initiatives related to the multidisciplinary Materials Science and Engineering program at YSU. He served on the advisory committee for the new Ph.D. program in Materials Science and Engineering at YSU, which has been granted final approval from the Higher Learning Commission to begin taking students in Fall, 2012. Currently, he is serving on the admissions committee for the new program. PI and Co-PI on multiple NSF grants which funded the acquisition of major instrumentation such as a CCD single diffractometer and high resolution powder X-ray diffractometer system, and an NSF DMR-IMR grant to fund the upgrade of a TEM for enhanced materials characterization. Designed and incorporated materials research modules into the general chemistry laboratory course as part of a state-wide, NSF-supported initiative. Further supported this effort through serving as PI on an NSF-CCLI grant award which funded a dedicated bench-top X-ray diffractometer and UV-Vis spectrometer for hands-on access by general chemistry students. Phi Lamda Upsilon National Chemistry Honor Society; Sigma Pi Sigma National Physics Honor Society; Phi Kappa Phi, YSU Distinguished Professor Award in Scholarship, 2004; Graduate Dean’s Award for “Superior Success in Obtaining External Funding”, 2009. ii RESUME FOR MATTHIAS ZELLER, Ph.D. College of Science, Technology, Engineering and Mathematics, Youngstown State University, Youngstown, OH, 44555-3663, 330-941-7105, mzeller@ysu.edu EDUCATION AND TRAINING Institution(s) University of Erlangen-Nuremberg University of Erlangen-Nuremberg University of Erlangen-Nuremberg Massachusetts Inst. of Technology Youngstown State University Major/Area Chemistry Chemistry Inorganic Chemistry Organometallic Chemistry Chemistry & Crystallography Degree Pre-Dipl. Diploma Ph.D. Postdoc Postdoc Year 1994 1998 2000 2001 2002–2004 PROFESSIONAL EXPERIENCE Co-Editor – Acta Crystallographica, International Union of Crystallography (2007– present). This includes handling of submissions, selection of reviewers (where the expertise of the Co-Editor is not sufficient to handle the submission independently), peer review of submissions (where the expertise of the Co-Editor is sufficient to handle the entire submission), working with the authors to try to improve submissions so that they might become acceptable for publication, and final decision on the manuscripts. The average annual workload per Co-Editor is around 100 submitted manuscripts. Adjunct Professor – Chemistry, Youngstown State University (2003–present). Has taught “NanoScience-Chem 6991”, “Polymers-Chem 5861”, and “Advanced Inorganic Chemistry-Chem 6931”, and “Special Topics - 30042 - CHEM 6991” (the advanced NMR class). He also covers the lab sections of “Solid State Structural Methods-Chem 5832”, the X-ray diffraction and X-ray fluorescence sections of “Chemical Instrumentation-Chem 5804” and offers intensive X-ray crystallography courses for individuals and small groups of students. Research Staff Scientist – College of STEM, Youngstown State University (2005–present). Zeller is responsible for operation of the X-ray Facility at the Youngstown State University housing single crystal and powder XRD instruments and an XRF spectrometer. He holds a PhD in organometallic chemistry. Zeller conducts research involving all aspects of X-ray crystallography. He routinely collaborates with others in the capacity of crystallographer and supervises the overall operation of YSU’s X-ray diffractometers; trains X-ray facility users, guests and students; gives advice and assistance with growing single crystals; assists with data collection, both on site and online via the web; provides structure solving and refinement; assists with data interpretation; deposits files for publication; and publishes collected data in scientific journals or assists others in doing so. PUPLICATIONS / PATENTS Articles & Presentations: Zeller has authored 310 peer reviewed publications and contributed to over 148 presentations at national and international conferences iii Understanding an Order-Disorder Phase Transition in Ionothermally Synthesized Gallium Phosphates, Olshansky, Jacob H.; Blau, Samuel M.; Zeller, Matthias; Schrier, Joshua; Norquist, Alexander J., Crystal Growth & Design 2011, 11(7), 3065-3071. Microstructural and Compositional Investigation of Al-alloy-Al2O3 Ceramic-Metallic Composites Synthesized by Reactive Melt Penetration, A. Yurcho, K-M. Peters, B. Hetzel, M. Zeller, T. R. Wagner, V. C. Solomon, Bul. Inst. Polit. Iaşi 2011, LVII (LXI) (4), 416-426. Synthesis and Structures of Pb3O2(CH3COO)2·0.5H2O and Pb2O(HCOO)2: Two Corrosion Products Revisited, Mauck, Catherine M.; van den Heuvel, Titus W. P.; Hull, Michaela M.; Zeller, Matthias; Oertel, Catherine M., Inorg. Chem. 2010, 49(22), 1073610743. Photoelectrochemical and Photoresponsive Properties of Bi2S3 Nanotube and Nanoparticle Thin Films, Tahir, Asif Ali; Ehsan, Muhammad Ali; Mazhar, Muhammad; Wijayantha, K. G. Upul; Zeller, Matthias; Hunter, A. D., Chemistry of Materials 2010, 22(17), 5084-5092. The Role of Stereoactive Lone Pairs in Templated Vanadium Tellurite Charge Density Matching Chang, Kelvin B.; Hubbard, Desmond J.; Zeller, Matthias; Schrier, Joshua; Norquist, Alexander J., Inorg. Chem. 2010, 49(11), 5167-5172. Copper (II) oligomeric derivatives for deposition of copper thin films, Muhammad Shahid, Asif Ali Tahir, Mazhar Hamid, Muhammad Mazhar, Matthias Zeller, Kieran C. Molloy, and Allen D. Hunter, Eur. J. Inorg. Chem. 2009, 1043-1050. Heterobimetallic Molecular Cages for the Deposition of Cu/Ti and Cu/Zn Mixed-Metal Oxides., Hamid, Mazhar; Tahir, Asif A.; Mazhar, Muhammad; Zeller, Matthias; Hunter, Allen D., Inorg. Chem. 2007, 46(10), 4120-4127. Doubled-cubic Ca2NF, Danielle R. Jack, Matthias Zeller, Timothy R. Wagner, Acta Cryst. C 2005, C61, i6-i8. SYNERGISTIC ACTIVITIES Invited Panel Member: “Cyber-Enabled Instrumentation Strategic Planning Workshop” of the National Science Foundation - Mathematical & Physical Sciences Directorate Chemistry Division - (Chemistry Research Instrumentation & Facilities: Multi-User Instrumentation Program), Arlington Virginia, 03/01/2008-02/28/2009. Peer Reviewing for Crystal Growth & Design, The Journal of the American Chemical Society, The Journal of Chemical Crystallography, The Journal of Applied Crystallography, Acta Crystallographica C and E, and others. Graduate Scholarship by the German National Academic Foundation; Zerweck Diploma Thesis Award (1998); DFG (German Scientific Society) Ph.D. Scholarship (1998 – 2000); Fellowship with the DFG sponsored Doctoral Programs Phosphorous Chemistry (1998 – 2000) and Homogeneous and Heterogeneous Electron Transfer (1998 – 2000); DAAD (German Academic Exchange Service) Postdoctoral Fellowship (2001); Staedtler Foundation Doctoral Thesis Award for the Advancement of Scientific Research (2001); 2008 Scientific and Technological Achievement Award (Level III) of the United States Environmental Protection Agency. iv RESUME FOR DINGQIANG LI, Ph.D. College of Science, Technology, Engineering and Mathematics, Youngstown State University, Youngstown, OH, 44505 Phone: (330) 941-7102, dli01@ysu.edu EDUCATION AND TRAINING Institution(s) Wuhan University of Technology Northwestern Polytechnical Univ. Shanghai Jiao Tong University Major/Area Materials Sci. and Engineering Materials Sci. and Engineering Materials Sci. and Engineering Degree B.S. M.S. Ph.D. Year 1988 1991 1994 PROFESSIONAL EXPERIENCE Electron Microscopy Scientist – College of Science, Technology, Engineering & Mathematics, Youngstown State Univ., Youngstown, OH (2011 – present): Li is responsible for the daily management of the Electron Microscopy Facility at Youngstown State University. He supervises the daily operation and maintenance of YSU’s electron microscopes; trains EM facility users, guests and students; gives advice and assistance with instrument operation; assists with image and data collection, and data interpretation • Senior Research Associate/Consultant – Department of Materials Sci. and Engineer., Case Western Reserve Univ., Cleveland, OH (2006 – 2011): Microstructure characterization of low-temperature carburized steels, bulk metallic glasses (BMGs), aluminum alloys, carbides, Cu-Ni-Nd alloys, copper alloys and iron and steels by means of SEM, HRTEM, STEM, EDS, XRD, EBSD, EELS, FIB, Auger, and XPS. TEM specimen preparations by FIB lift-out technique. Development of surface hardness enhancement on colossal supersaturated carburized stainless steels by means of post-tempering processing. • Research Scientist/Consultant –the State College of Ceramic Engineering, Alfred University, Alfred, NY (2004-2005) MPI Fellow/Guest Scientist – Max-Planck-Institute for Metals, Stuttgart, Germany (2003): (awarded and fully supported by the Max Planck Society, Germany) Conducted residual stress analysis of thin films deposited on substrates using X-ray diffraction. STA Fellow/Research Scientist – National Institute for Materials Science (NIMS), Tsukuba, Japan (2001 – 2002): (awarded and fully supported by the Japan Society for the Promotion of Science) Research on processing/mechanical properties/microstructure relations of superalloys and intermetallics. Conducted mechanical property testing and microstructure characterization via SEM, TEM and XRD. TEM conducted to study slip system and dislocation features of intermetallics foils. • Assoc. Prof. and Co-Director – Institute of Surface Modification of Metals and Materials Shanghai Jiao Tong University (1994 – 2000): Taught materials science courses and advised students. Fund raising, proposal writing. Training and technical support for users and students to operate various instruments and equipment. Served as a codirector for daily management of the Institute of Surface Modification of Metals and Materials. Conducted research in Materials Science and Electron Microscopy on metals and metallic/ceramic matrix composites. v PUPLICATIONS / PATENTS Articles & Presentations: Li has published 30+ papers in peer reviewed journals and two book chapters The carbide M7C3 in low-temperature-carburized austenitic stainless steel, Frank Ernst, Dingqiang Li, Harold Kahn, Gary M. Michal, and Arthur H. Heuer, Acta Materialia, 59(2011)2268-2276. Microstructural effects on tension behavior of Cu-15Ni-8Sn Sheet, Joshua Caris, Dingqiang Li, John J. Stephens Jr., John J. Lewandowski, Materials Science and Engineering A, 527(2010)769-781. High cycle fatigue behavior of a nanostructured composite produced via extrusion of amorphous Al89Gd7Ni3Fe1 alloy powders, Adel B. El-Shabasy, Dingqiang Li, and John J. Lewandowski, Materials Science and Engineering A, 513-514 (2009)202-207. Tensile properties and cold rolling of binary Ni-Al γ/γ' two-phase single crystals, Dingqiang Li, Kyosuke Kishida, Masahiko Demura, and Toshiyuki Hirano, Intermetallics, 16(2008)13171324. The grain boundary character distribution of O and O+BCC Ti-Al-Nb alloys, Dingqiang Li and C.J. Boehlert, Metall Mater Trans A, 36A (2005) 2569-2584. The grain boundary character distribution of a fully-orthorhombic Ti-25Al-24Nb(at.%) alloy, Dingqiang Li, S.I. Wright and C.J. Boehlert, Scripta Materialia, 51(2004), No.6: 545-550. Microstructure and mechanical properties of cold-rolled thin foils of binary Ni-Al γ/γ' twophase alloys, Dingqiang Li, Masahiko Demura, Kyosuke Kishida, Yozo Suga, and Toshiyuki Hirano, Defect Properties and Related Phenomena in Intermetallic Alloys, Mat. Res. Soc. Symp. Proc. vol.753 (2003) BB5.23. The application of computer simulation in the heat-treatment process of a large-scale bearing roller, Jiansheng Pan, Yongjun and Dingqiang Li, Journal of Material Processing Technology, 122 (2002), No2-3, 241-248. Oxidation behavior of FeAl alloys with and without titanium, Dingqiang Li, Yun Xu and Dongliang Lin, Journal of Materials Science, 36(2001)6: 979-983. Tensile behavior of SiCp/2124Al composites with various SiC particle sizes at room temperature, Dingqiang Li, Hojin Ryu and Soon Hyung Hong, Transactions of Nonferrous Metals Society of China, 10 (2000)6: 732-736. SYNERGISTIC ACTIVITIES Co-edited National Standards of China on Thermo-Chemical Heat Treatment. Trustee of the Youth Materials Research Society of China (1995-2001). Youth-Scientist Fellowship awarded by Korean Science and Engineering Foundation (1998). SAT Fellowship awarded by Japan Society for the Science Promotion (2001-2002). Max-Planck-Institute Scientist Fellowship awarded by Max-Planck-Society, Germany (2003). Secretary of the Committee of Simulation Modeling of Heat Treatment of the International Federation for Heat Treatment and Surface Engineering (1999-2000). Members of the American Microscopy Society, the American Ceramic Society, the American Iron and Steels Institute, and the Materials Information Society. vi RESUME FOR KLAUS-MARKUS PETERS General Manager of TCON Division and Director of Engineering – Fireline, Inc., 300 Andrews Avenue, Youngstown, OH 44505, 330-743-1164, mpeters@fireline-inc.com EDUCATION AND TRAINING Institution(s) Case Western Reserve University Major/Area Metallurgy and Materials Science Degree B.S. Year 1984 PROFESSIONAL EXPERIENCE Director of Engineering – Fireline, Inc. (2009 – present): Responsible for managing the Engineering staff and activities that support Fireline’s Sales and Production activities, including new product and process development, product drawings and tooling, materials approval and qualifying critical material suppliers, and manufacturing yield, costs, and throughput improvements. General Manager - TCON Division – Fireline, Inc. (2002 – present): Responsible for managing the development, implementation, commercialization, and profitability of the TCON process, a unique method of producing ceramic-metallic composites with enhanced properties. Primary focus has been on process development, establishing a new production facility, and the development of new products and markets. Responsibilities included obtaining government grants and developing partnerships with outside research and industrial organizations in order to leverage internal resources, as well as managing intellectual property, licenses, and contracts. Vice President of Technology, Technical Manager, and Development Engineer – Pyromatics, Inc. (1991 – 2001): Coordinated all technical efforts relating to the research, development, design, manufacturing, and sales of fused quartz components utilized in semiconductor processing equipment. PUPLICATIONS / PATENTS Articles & Presentations: K.M. Peters, “Evolution of an Energy Management System”, presented at the 15th Annual Ohio Energy Management Conference (2011) and the ASERTTI Industrial Energy Efficiency & Competiveness Workshop (2011) V. C. Solomon, K.M. Peters, B.P. Hetzel, and T.R. Wagner, “Characterization of Structure Evolution in Aged Al2O3/SiC Composite Refractories by Electron Microscopy”, Microscopy & Microanalysis 2010 Conference (2010) K.M. Peters, R.M. Cravens, and J.G. Hemrick, “Advanced Composites for Improved Thermal Management in Molten Aluminum Applications”, Energy Conservation in Metals Extraction and Materials Processing II Symposium Proceedings, TMS (2009) J.G. Hemrick, W.L. Headrick, and K.M. Peters, “Development and Application of Refractory Materials for Molten Aluminum Applications”, Int. J. Appl. Ceram. Technol., Vol. 5, No. 3, pp 265-277 (2008) vii J. Xu, X. Liu, E. Barbero, J.G. Hemrick, and K.M. Peters, “Wetting and Reaction Characteristics of Al2O3/SiC Composite Refractories by Molten Aluminum and Aluminum Alloy”, Int. J. Appl. Ceram. Technol., Vol. 4, No. 6, (2007). J.G. Hemrick, J. Xu, K.M. Peters, X. Liu, and E. Barbero, “Wetting and Reaction Characteristics of Al2O3/SiC Composite Refractories By Molten Aluminum and Aluminum Alloy”, Proceedings of the 31st International Conference on Advanced Ceramics and Composites, January (2007). K.M. Peters, Opaque Fused Quartz for Heat Shielding Components”, American Scientific Glassblowers Society Symposium Proceedings (1994) US Patents: 7,111,476 Ted A. Loxley, John F. Blackmer, Klaus-Markus Peters; “Electrophoretic deposition process for making quartz glass products” 6,381,986 Ted A. Loxley, John F. Blackmer, Klaus-Markus Peters; “Sintered quartz glass products and methods for making same” 6,355,587 Ted A. Loxley, John F. Blackmer, Klaus-Markus Peters; “Quartz glass products and methods for making same” 6,012,304 Ted A. Loxley, John F. Blackmer, Klaus-Markus Peters; “Sintered quartz glass products and methods for making same” 4,826,791 Pankaj K. Mehrotra, Klaus-Markus Peters, Joyce L. Swiokla; “Silicon carbidealpha prime sialon beta prime sialon” SYNERGISTIC ACTIVITIES Business community representative on the Youngstown State University 2020 Strategic Plan subcommittee (2011) 2009 Outstanding Community Partner of the Year award from Youngstown State University College of Science, Technology, Engineering, & Mathematics Adjunct Professor at Youngstown State University College of Science, Technology, Engineering, & Mathematics (Mech. Eng. 2007 – 2008, Chemistry 2009 - present) Member: Board of Advisors for JumpStart TechLift Advisors, a NE Ohio technology entrepreneurship organization, representing the Youngstown Business Incubator (2009 – 2010); of the Advisory Board for the Youngstown State University Center for Transportation and Materials Engineering (2007 to 2010) Business Representatives Committee which assisted in the search for the Founding Dean at Youngstown State University’s College of Science, Technology, Engineering, & Mathematics (2007) Innovation Committee under the Business Led Development Group for the Mahoning Valley (2006 to 2007) viii RESUME FOR BRIAN P. HETZEL R&D Projects Manager of TCON Division and R&D Technology Manager – Fireline, Inc., 300 Andrews Avenue, Youngstown, OH 44505, 330-743-1164, bhetzel@fireline-inc.com EDUCATION AND TRAINING Institution(s) University of Wisconsin-Madison Major/Area Metallurgy and Materials Science Degree B.S. Year 1989 PROFESSIONAL EXPERIENCE R&D Technology Manager for Fireline, Inc. and R&D Projects Manager for Fireline TCON Division (2004 – present): Responsible for improving current materials, developing new materials and processes, and incorporating cross functionality between R&D, Engineering, and Manufacturing. Directed and performed internal R&D and engineering projects, and worked with customers to develop and market a new product line. Market Development Manager– SSI Technologies, Inc. (1999 – 2004): Responsible for researching existing and new markets, creating awareness, and developing new business from first customer contact to final PPAP stages, providing technical assistance to customers unfamiliar with PM and MIM technology, and developing new materials/processes for customers with demanding requirements. Corporate Materials Manager – Radiac Abrasives, Inc. (1997 – 1999): Responsible for reducing materials and labor costs and incorporating cross functionality between R&D, Engineering, and Manufacturing. Senior Process Engineer – Ipsen Ceramics (1993 – 1997): Responsible for reducing material and process waste, performing process documentation, and providing research and development support for product improvement and process refinement. Materials Engineer – Woodward Governor Company (1990 – 1993): Responsible for performing materials/failure analysis in high profile accident investigations, providing materials expertise on design review boards, and certifying special processes and operators. PUPLICATIONS / PATENTS Articles & Presentations: “Metal Injection Molding Components in Automotive Applications”, Society of Automotive Engineers Symposium 2001-01-0349, co-authored with P. dePoutiloff “Nano-Scale Interpenetrating Phase Composites (IPC’S) for Industrial and Vehicle Applications”, Oak Ridge National Laboratory Technical Report TM-2010/80, Principal Investigators: Dr. J.G. Hemrick, Dr. H.Z. Hu, Oak Ridge National Lab; KM Peters, Fireline TCON; Brian Hetzel, Fireline, Inc. “Microstructural Analysis of Ceramic-Metallic Interpenetration Phase Composites”, Yurcho, A., Peters, K.M., Hetzel, B., Zeller, M., Wagner, T.R., and Solomon, V.C., Proceedings of the 2011 ASEE North Central & Illinios Indiana Section Conference, Mount Pleasant, Michigan, April 1st-2nd, 2011. ix “Microstructural and Compositional Investigation of Al-alloy-Al2O3 Ceramic-Metallic Composites Synthesized by Reactive Melt Penetration”, A. Yurcho, K-M. Peters, B. Hetzel, M. Zeller, T. R. Wagner, V. C. Solomon, Bul. Inst. Polit. Iaşi 2011, LVII (LXI) (4), 416-426. “Electron Microscopy Study of Co-Continuous Al-Fe/Al2O3 Composite Synthesized by Reactive Metal Infiltration”, Yurcho, A., Peters, K.M., Hetzel, B., Zeller, M., Wagner, T.R., and Solomon, V.C., Microscopy & Microanalysis 2011 Meeting, Aug. 9th-11th, 2011. “Structural and Compositional Investigations of Ceramic-Metal Interpenetrating Phase Composites Produced by Reactive Metal Penetration in Molten Al and Al-Fe alloy”, Yurcho, A., Peters, K.M., Hetzel, B., Zeller, M., Wagner, T.R., and Solomon, V.C., Materials Science and Technology 2011 Conference & Exhibition, October 16th-20th, Columbus, Ohio, 2011. “Microstructural Characterization of an Alumina Zirconia Silicate (AZS) Refractory Material for Molten Metal Application” Hemrick, J. G., Peters, K.M., Hetzel, B., Materials Science and Technology 2011 Conference & Exhibition, October 16th-20th, Columbus, Ohio, 2011. SYNERGISTIC ACTIVITIES Hetzel has over 20 years of experience in the field of materials science and engineering, primarily with metals and ceramics. Directly responsible for failure analysis of aerospace materials, designing and specifying new materials for aerospace, automotive, and other commercial markets, planning and carrying out R&D projects related to the processing of metallic and ceramic components and the utilization of these components in end user applications. Hetzel has over 10 years of experience in managing R&D and engineering projects for metallic and ceramics manufacturers. Researched existing and new markets for opportunities within core competencies and developed new materials/processes for synergistic opportunities outside core competencies. Member of the American Ceramic Society, ASM International, and the American Powder Metal Institute Member of the Advisory Board for the Youngstown State University Center for Transportation and Materials Engineering (2/07 to present) Member of the Advisory Board for the Youngstown State University PhD program for Materials Science and Engineering (12/08 to 3/10) x