An advanced, patented probe sensor provides early detection of water infrastructure problems caused by corrosion and harsh atmospheric conditions. Designed to detect graphitization in active pipelines, it identifies areas at risk of major failures early on. By using indirect methods like GIS mapping, in-situ soil resistivity testing, and structure-to-soil potential measurements, high-risk zones can be pinpointed. Once these areas are identified, the probe assesses the severity and depth of graphitization, providing a comprehensive evaluation of the pipeline’s condition. This allows for the implementation of effective corrosion management strategies, including cathodic protection systems, to prevent critical failures. This article describes the sensor system and provides a case study of its use. The technology received the 2024 Engineering Materials Achievement Award from ASM International.

Residual gas analysis shows that vacuum furnaces with graphite hot zones are more economical than all-metal designs and are capable of producing contamination-free surfaces.

Active metal brazing played a key role in the development and fabrication of a modified beam target for particle-physics experiments conducted by Fermilab. The new target consists of a titanium tube filled with stacked graphite fins that were bonded in place by means of active metal brazing. This article describes the vacuum process and the methods used to evaluate the brazed titanium-graphite joints.

This article describes a procedure for optimizing the annealed microstructure of a high Al KAB steel. The main focus is directed toward characterization of microstructural development during annealing of different phases in a nanostructured bainitic steel using high resolution transmission electron microscopy (HRTEM). This entry won the prestigious 2019 Jacquet-Lucas Award for Excellence in Metallography at the International Metallographic Contest held in Portland, Oregon, October 2019.

A novel hot zone design featuring new graphite boards reduces heat loss and improves overall hot zone power requirements.

This article evaluates the sliding wear behavior of fiber-reinforced 7075 Al alloy composites. It explains how the composite samples were made and shows how different fiber materials, volume percentages, and orientations affect hardness and wear resistance. It also interprets wear test results and what they reveal about wear mechanisms in metal-matrix composites.

Metal-matrix composite (MMC) materials are being developed at the University of Wisconsin-Milwaukee for a diverse range of automotive applications from pistons and cylinder liners to exhaust manifolds and chassis sections. The ability to tailor not only the properties but also the functionality of MMCs gives automotive engineers a powerful new tool in dealing with increasingly strict fuel economy standards.

The discovery of new phases of carbon and direct conversion of carbon into diamond and diamond-like materials—at ambient conditions and without a catalyst—is a breakthrough with tremendous potential for electronics and hard-materials applications.

Advances in software algorithms and design enable automation of microstructure image analysis, leading to cost savings, reduction in measurement variability, and access to important metrics.

Understanding detrimental alpha case formation during heat treatment of titanium parts is increasingly important as titanium use in aerospace and medical applications continues to grow.

Temperature measurement, unvented cavities, loose powder, and direct contact of certain metals must be considered during process development for vacuum heat treatment of additively manufactured parts.

Raman spectroscopy is an indispensable tool in laboratories conducting research in the nascent field of carbon nanomaterials. It provides comprehensive information about the structure and layer thickness of graphene samples with high levels of sensitivity, stability, and control.

Field assisted sintering technology (FAST) enables cost-effective manufacturing of metal, ceramic, and composite components with sub-micron grain microstructures and tailored properties.

The U.S. Naval Academy is expanding awareness about corrosion-related material degradation, its effects on force readiness, and efforts to manage it. One of the goals of the Naval Academy’s corrosion education efforts and corrosion-related STEM activities is to teach students to understand materials degradation processes and prevention methods for aging defense systems.

Energy storage solutions must overcome the challenges of synthesizing and processing dissimilar materials while maintaining high lithium transport through their interfaces.

An investigation into the chemistry and type of tungsten carbide powder used for drill bits has yielded a material with improved transverse rupture strength and interesting microstructural response to thermal cycling.

Thermal-spray and solution-based synthesized coatings offer improved efficiency and durability than currently used coatings in concentrating solar power receiver applications.

Aluminum, one of the most widely used structural metals in modern industry, is produced in quantities exceeded only by steel. Its light weight, corrosion resistance, high strength after heat treatment, and global availability of bauxite ores make aluminum attractive for everything from kitchen utensils to spacecraft. This article describes early work to develop low-cost aluminum for industrial applications.

A new laser arc method is being used to apply a hard carbon coating to engine components on the production line. This article reports on work to produce hydrogen-free tetrahedral amorphous carbon coatings on an industrial scale with consistent quality.

Harnessing graphene's potential for commercial use requires attaining homogeneous dispersion and strong chemical bonding with the matrix of a target material. This can be achieved by effective surface modification. This article discusses approaches to graphene surface modification and includes a case study for using graphene as a filler to improve the mechanical properties of polymer composites.