Energy Sources

 Hi: Well the emphasis in the materials world has been on Advanced Manufacturing, and there is still much work to do in that sphere of influence. However, the world continues to be more concerned about carbon contaminating the atmosphere; than  about energy to replace carbonaceous materials.Currently the emphasis appears to be on either wind or solar power. Unfortunately, there are major problems associated with these approaches because both depend on mother nature, and she is not very predictable. In the case of wind, on calm days there is no movement to turn the enormous blades required to create electrical energy. In the case of Solar power, unless the sun shines there is no radiant energy to be captured. But.there are solutions because we can install batteries to store the energy produced during sunny or windy days and then release the energy for usage during non productive days, or  sell excessive energy to the grid. All of this costs money, Therefore there are many that suggest that these sources are not the answer.

The newest thinking is thermal energy.After all, we live on top of a molten portion of earth. There are methods developed, and more coming, to drill oil offshore, to dig deeper for fossile fuels and now for thermal energy. Until now, my thinking has been directed to the gysers in the West as the source of this energy; and of course, if you limit your thinking to this, then location becmes a problem. Now, let's expand this thinking to include the molten core that is within the earth. If we do this and assume that energy we use to drill for oil is applicable, then we have an unlimited supply of energy and it need not be expensive. However, lets step back a minute and see whether this may be a smart solution. We know that the atmosphere is infinite, but we have successfully contaminated it to the extent that we have disrupted the entire system that has supported life on earth since creatoin. Now thermal energy. Earth's population is not decreasing and slowly life standards are improving world wide. That predicts that we are going to need thermal enery considering probably a geometric progression. Maybe it isn't to good a sollution to mess with what was created long ago, by a Being more intelligent than all of us combined.

However,lets look at hydrogen and nuclear power, also as possibilities of supplying clean energy consistently.In the case of hydrogen, it too, is available in our vast world.However, it is powerful and can blow up the world, if we are not careful. This has been the main arguement that has prevented more extensive research to tame it for our consumption as a fuel. But wait a minute, aren't fossile fuels also explosive. You bet, but we haven't used them to make atomic bombs to give it a frightening past and future. If present efforts are successful then there are existing facilities for dispensing it as a fuel and it will readily clean up the atmosphere by replacing fossil fuels. Now, this becomes a renewable source to consider. 

There is one additional source of energy that can be clean, safe and abundant. This is nuclear energy. Wait a minute, we have the problem of the plant going critical and creating a major disruption to life and the atmosphere. However, there are many types of nuclear reactors. To date they depend on fusion as their production of nuclear energy. Although clean and they have been commercialized throughout the world, they too are subject of going critical and becoming violent bombs. They are also expensive and require large areas that must be safeguarded to prevent accidents from occurring.There is another form of nuclear energy though that erases the arguements of safety,  expense and large plants. Experimenttion is now at the stage where we can manufacture smaller fission  reactors that can be located in small spaces and which will not go critical. These reactors can be placed on a flat bed truck and transported to a site where the water is polluted,  salty or underground , such as in a desert and they can produce sufficient energy to supply an entire small city. Now I believe that is a solution that I can buy, whereas I have my problems with the thermodynamics of disrupting the molten core of the earth that we sit on.

A Changing World

Most recently, the happenings that are occurring in this world have left me stunned. Thirty-five years ago, I started MagnaTech P/M Labs because materials research was on the rise and there was need for innovation, especially in powder metallurgy. Driving forces then were automobiles and aerospace. They still are, but in a much advanced stage. However, with the horrors occurring in Ukraine, modern electronic devices have neutralized the value of traditional tanks, and drones have helped to neutralize the effect from aircraft superiority. All are recent electronic developments. In conjunction with the war in Ukraine, to keep supporting countries and interrupted communications in Russia and Ukraine, we now have a potential major problem in how to combat individuals that have computer savvy sufficient to shut down the grid and interrupt business that is conducted daily. All stem from computer technology.

This leads me back to the days when horses were the traditional form of transportation and Edison and others had made sufficient strides to create a mechanical and electrical world. When I was a lad in the 1930s, it still was not uncommon, in a small town, to observe horses still tied to hitching posts. However, Henry Ford put an end to this by developing a concept to mechanize the manufacturing of automotive vehicles, then referred to as “horseless carriages” Other concepts came into being through the invention of the electric motor. At that time only common materials, such as iron copper, tin, zinc, and aluminum that had unique properties were included in what was referred to as the periodic table Today the periodic table is full and even new elements are being discovered. .

That leads us to the question of whether this mechanical/electrical world is becoming obsolete, to be replaced by an electronic world. Back in the 1950’s I remember debates that were questioning whether computers would replace man in a future world where robots and electronic devices would assume most of the functions of man. Today we are approaching a time where computers will drive our cars and aircraft, and be safer than a person behind the wheel of the car. Robots have taken the place of humans in the assembly lines to weld and do other repetitive jobs that traditionally were done with manpower. Drones, as we see in the Ukraine, are now being successfully used to destroy enemy aircraft, and many companies are considering using them to make deliveries directly to your house.

How does all this affect a company that basically exists because of its ability to innovate, to improve the properties of materials and improve processing to manufacture these materials. A new concept named advanced manufacturing is commanding major consideration in the materials world. It used to be that an individual or company had an idea or concept. If considered worthy of development, at least a month of research in libraries and use of other communication tools was initiated to determine whether the concept or idea had ever been developed by anyone else, and was there need to advance the capabilities to do the job that required the development of the new idea. In addition, a cost study was made to determine whether people would buy the new product. Once the literature search was complete, a proposal was made to convince the people who could use the product or development that it would be worthy to invest a small amount of money into the project to prove the concept in the laboratory. If successful, more funds were devoted to transfer the development to the pilot production stage to find out whether the product could be made into a commercial product. Then the major funds were allocated to produce the product commercially. However all of this took too much time, taking on an average of two to five years to realize a profit. Now this tried and true technique takes much too long.

Therefore enters the computer once again. The computer has vast stored knowledge that can make the research of determining whether the concept has been considered in the past much faster. Also, most ideas or innovations derive from some basic principles Starting from here variables that affect these basic principles can be quickly changed to determine whether the innovator is traveling in the right direction or whether they are on a crash course. Then after the computer has maximized the variables that affect the concept, a few critical experiments are made to determine whether the computer has done its job. Supposedly this is quicker and cost much less than the old concept However, the computer accepts its data from what has been published, and this can be true, false or biased. The computer doesn’t think. Then the computer needs to start with basic concepts and the variables that change its properties. Most of the people are computer oriented and have little knowledge of materials engineering. Therefore, these people may not even be considering the correct variables to make the product a success. Today advanced manufacturing and modeling are the buzz-words of the industry. The concept says that you can make things as delicate as dental and medical products, using these concepts and there are inroads being made in these fields. In addition, there is no limit to the size of the product that can be made. Therefore things, such as buildings and sky scrapers, are being considered as future applications All of this new technology is going to require different thinking regarding manpower and the concepts emerging for the work being made today. Are we ready to leave the mechanical/ electrical world that we are comfortable with today for this new emerging electronic driven world? With developments such as being seen in the Ukraine and in the use of cyber technology and their capabilities for evil or good, are we ready to make them our new world?

 

 

2022 Research Activity As MagnaTech Sees It

 

Last year there was a tremendous push to develop a generic term, “Advanced Manufacturing”. Much has been accomplished in this area and more will be in this coming year. Whereas in the past research started with a literature search followed by using design of experiments to get an idea to the laboratory, This now has all been replaced by what is known as modeling. In essence, it is the same thing, except now the computer does all the grunt work.  My opinion is that computers and software program writers have little experience with metals. Therefore, I prefer to do most of my modeling using the old fashioned approach, knowing that speed is not the problem.  However, most of the materials development research is now accomplished through software designed for modeling.

Transportation remains the buzzword in most development programs. In respect to the automobile of the future, standard materials are still required, although research is still promoted to use much lighter aluminum, magnesium, composites and even plastic materials. Again, modeling is the tool generally used to develop most new alloys for automotive and off-road applications. A real push is to make the automobile electric to alleviate the pollution problem. Motor design and battery propulsion is the current big push. However, there are some interesting concepts regarding propulsion designs that do not use batteries. Electromagnetics is one interesting concept being explored.

Just starting to generate steam, however, are applications that improve or permit space applications to be improved. Again, propulsion is one area demanding attention. Most of us pay attention to the huge rockets that are launched at Cape Canaveral. However, most missiles that are launched into space are much smaller and they are not launched from earth, but from missiles launched from earth. NASA is now starting to direct their attention to development of different propulsion systems, such as electric propulsion. These concepts are not new.  The Russians developed a system in 2011. These space craft use electromagnetic fields to accelerate to high speeds, generating thrusts that modify the velocity in orbit. In fact, since 2019 there have been over 500 space craft used throughout the Solar System, using electric propulsion for station keeping. Future systems, under development, are being designed to permit exploration of the outer planets of the Solar System. If a system were developed for earth launch, payloads could be increased to 70% of initial mass to destination, whereas chemical propelled rockets deliver only  a few percent. This is a start to a future for development of additional future electric propulsion systems .

In addition to space, increased concentration is being directed toward aircraft that will fly faster in upper space, delivering increased pay loads at reduced cost in significantly less time MagnaTech would like to find a niche in this new emerging technology to improve soft magnetic materials for these emerging applications.

 

What Does Advanced Manufacturing Mean to You?

 It has been almost a year since I have found it worthwhile to publish something new. That is because a good portion of money is being concentrated on a topic known as Advanced Manufacturing. The obtuseness of this title leaves people scratching their head because it is so vague. Actually because of this many variations have developed that are designed to serve a particular market. This market started with plastic irregular objects and now advancing in many directions. In other words, something for everyone. Just change a few things to make the process work. 

So how do we understand what we need to get started? Well first of all, we need to have a purpose in mind. Reduction of weight is a good thing because our present transportation system uses a fuel that contaminates the atmosphere.Therefore, if we can reduce the weight of the vehicle; we use less  fuel and contamination is reduced.The second objective is to make either things that cannot be made by other processes or to develop the advanced manufacturing process to make parts cheaper than are made by an existing process. The automotive and the space industry are two areas that are either fast changing or developing that are being driven by these two objectives.

So, how do we develop this new process? First we need a container that houses the object or objects to be made. this is normally a box of any size , to contain and build the smallest to the largest of parts. One area where the process is growing is for small items, such as dental products or for parts  for medical purposes, that fit in small, confined spaces.On the opposite side of the spectrum, containers or  boxes are being constructed to produce components for space ships and for turbine engines. Boggles the imagination. 

The next thing required is material to construct or build the irregular shaped part.Again, the process began by using plastic in powder or liquid form to spray on a platform that can  move incrementally to permit thin layers of sprayed droplets to deposit and solidify layer by layer in a pattern that is generated from a three dimensional model, using a computer. Metallic inks for circuit boards are now being made using this technology. Plastic parts are currently being made in many differing processes. Powders now are available for making many small parts today and could be used to make parts for off road equipment soon.What is left to complete the system is a heating source. Today, lasers and electron beam guns are used for this process, although there are processes that use induction heating to repair or to make parts. 

Every day new developments are made that provides new avenues for the advancement of the technology. In addition, a process called modeling is now being more widely used in the design of complete systems made of different kinds of component parts, using basic principles of physics and chemistry. This will make possible new motor designs and artificial organs for humans and animals. The technology is mind boggling, and prepares the way for a new century becoming more and more electronically oriented.

 New Lessons Regarding Lubrication and Binding of Alloy Sub-Micron Powders

    It has been awhile since I have had the urge to write an article on metallurgy. Perhaps it was the pandemic or even though we are entering a space age era, a lack of going forward during this period of time. Actually advanced manufacturing has overwhelmed the technical realm and I am not the biggest fan of advanced manufacturing, not that I am not a believer of advancement, but I am resistant of letting computers do it for us.

    For instance, there is much publicity of advancements that are occurring to lighten materials and to introduce new lighter materials. This occurs through mostly two dimensional design, but more ideally through complex three dimensional design, with precision  possible only using a computer.

    Yes there are advantages to this, as well as disadvantages. One advantage is that it makes possible design of new alloys without conducting as much lengthy and costly experimentation. However, all of this is dependent on the experience of the individual that is operating the computer. However, if done correctly and with execution of essential experimental background work, then strength and toughness may be increased. In magnetic materials core loss and design of magnetic components can be maximized. Yes, even corrosion, the most expensive problem in modern society, can be reduced.. So yes, there are benefits, but dangers as well.

    The reason for all of this to happen is because in most advanced manufacturing processes where laser or electron beam technology is employed for fusing or melting the powder, a fine layer of sub-micron powder is distributed throughout the surface  of the area to be built.Unfortunately, fine sub-micron powders do not flow well. Therefore a binder is required to increase their size and agglomerate them into larger composite spheres to satisfy this requirement. This brings me back 40 years ago when I was in charge of a research section at Hoeganaes Corp. One of my projects was to develop a lubricant that would improve the flow of  stainless steel powders.These powders were larger, but not quite speroidal in shape. We at that time worked with a Lanza powder that permited us to reduce the quantity of lubricant admixed to 0.5 %. 

        Now MagnaTech is currently working to develop a new refractory metal powder that is manufactured as sub-micron powder and the additives are also sub-micron in size. Therefore the requirement is to find an additive that not only agglomerates these powders but also  provides sufficient lubrication to permit flow within a restricted die cavity. Therefore, MagnaTech also finds itself into development of lubricants with good binding properties.Right now there are a few other small companies that are starting to enter this field too If these new advanced manufacturing processes are to succeed,  a  free-flowing powder must be developed that will bind the sub-micron particles into a powder sufficiently large and ideally spherical to provide the uniform layers that will be fused or melted incrementally that will eventually build to form a solid shape of required dimensions MagnaTech sees a niche for itself in development of new binder /lubricants to resolve one of the problems currently causing problems in some advanced manufacturing processes.

New Nitrogen and Oxygen Testing Capability at MagnaTech

It has been a couple of months now since my last correspondence. At that time most of the activity in the materials world was concentrated on developments in new technology in advanced manufacturing to accelerate the electric powered automobile and subsequently over the road vehicles and advanced high altitude, high speed aircraft.
It is amazing how one very little molecule can put most of this development on back burner and now concentrate on a cure or a vaccine to counteract the effects of the Corona virus.All of a sudden the concern for the environment returns to the back burner  because now there is an oversupply of fuel and emissions from operating vehicles has decreased because of a large portion of the population restricted to the home, for the most part. However, the word is back burner and that is a dormant stage, ready to return as the times change and the threat of the consequences of the Corona virus disappears..
How does all of this affect the operation of MagnaTech P/M Labs? MagnaTech was conceived with the   objective  to do research and consult to improve powder metallurgy processes or materials, concentrating in development of powder metallurgy materials and processes oriented toward stainless steels, low alloy steels and their processes and soft magnetic materials and their processes. To permit development, MagnaTech equipped a laboratory that would assist in measurement of properties of new materials developed or improvement in properties resulting from improvement in processing conditions. This laboratory has now been in existence for 36 years. The equipment contained in the laboratory has been either purchased or constructed to measure properties that most other test laboratories do not measure. All equipment is operated and run with test standards and procedures established by ASTM International.
The purpose of this test equipment is to permit MagnaTech to develop material and processes for other companies that do not have the resources to do the development or the work required to advance their marketing or to improve internal processing processes to permit the company to either introduce new products or to improve the properties of the parts or powders that they manufacture.
Since one facet of MagnaTech was to advance developments in magnetic materials and performance, it is equipped to assist in the development in performance of magnetic materials. One of the requirements for the improved performance of soft magnetic materials includes reduced contamination from interstitial elements such as carbon, nitrogen, oxygen and sulfur. MagnaTech therefore purchased gas analyzers to permit the measurment of theses interstitials to improve soft magnetic materials.More recently there has been increased need to determine the nitrogen content within stainless steels and high temperature aerospace materials.The equipment within the MagnaTech Laboratory is capable of making these measurements. Test results are backed up by running standards certified by NIST and conducting measurements according to ASTM International Standards. MagnaTech normally reports results from material received for testing within three days MagnaTech has just updated these analyzers and is looking for new business. If you require these kind of data, MagnaTech assures repeatability and precision of data with fast response to your needs. Should you be interested in these MagnaTech services please contact Ken Moyer at 856-786-9061 or by e mail at moyer@snip.net. MagnaTech is a small veternan operated company.

Excitement About High Entropy Alloys

Currently materials research has slowed down, unless you are into advanced manufacturing. Today almost all technology is focused on computers and mechanical devices, such as robots. In our opinion, this is a dangerous way to proceed. Already kids are begining to have difficulty in writing and spelling, and are more confused than ever by the new math being introduced. This is the beginning; what is going to happen when most of the nation becomes hooked on this new technology that takes the human factor from the big picture?
However, materials research is still needed for improvement in light car performance, solonoids, magnetic applications, deep sea technology, space and  nuclear energy. All of these applications require either improved alloys or new alloys to permit these future applications to evolve.
One of the new systems for improvement of special alloys is entitlled high entropy alloys. Actually development began way back in the 1980s with the superaalloys. At this time alloys existed for high temperature applications, but did not quite serve the application completely. However, if a slight amount of another element was added, or even an additional element in greater quantity, then the properties for the application were satisfied and life moved on.

In reality , however, there is no real definition of what a high entropy alloy is. Actually it is an alloy that is either modified or completely invented for specific applications, such as those new technologies mentioned above as being currently in progress at some scale of development. MagnaTech has been interested in improved magnetic alloys to provide improved power for electric cars. We are also active in development of heavy alloy materials. In this case, cobalt is a problem because it is largely produced in a potentially hostile country and also, although not classified, it is being considered as a carcenogenic. The Army was so concerned that it was working on research in that area. With the advent of the new laser technology for weaponry, the need for replacement has now abated. However, MagnaTech is starting a program to develop a binder for tungsten carbide that will eliminate the use of cobalt that is traditionally used as a binder.  MagnaTech always welcomes financial support for these projects being developed to improve applications for new designs for new technology.