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.

In 1845, Michael Faraday discovered that light passing through a transparent medium can be altered with an externally applied magnetic field. It is not surprising, given the science and engineering involved, that the ideal medium for observing the Faraday effect and the process by which it is made have only recently been developed. This article explains how magneto-optical sensors make use of advanced materials and processes to harness the Faraday effect, making it possible to see magnetic fields and domains with detailed resolution and instantly obtain flux density measurements over the surface of magnetic materials and magnetized parts.

Accurate and continuous dew point measurement is key to maintaining the atmosphere required to achieve high quality and consistency of sintered products in powder metallurgy processing.

Direct write technology is an innovative and economical materials deposition process that integrates conductive traces, antennas, circuits, and sensors onto components or embeds them within structures. The process has been in development since 2002 for use in aerospace, military, and energy markets. This article describes its use to print thermocouple sensors, heat flux sensors, heaters, conductors, and antenna patterns.

Flow measurement is an increasingly important part of quality control systems in the heat treating industry. This article covers selection basics, sizing, mass flowmeter overview, and frequently asked questions about about flowmeters.

Thermal spraying is being incorporated into more manufacturing processes where its primary role is to deposit a layer of material or a free-standing structure that has a functional, rather than a passive, role. Examples include thermally sprayed membranes, electrodes, antennas, thermocouples, inductors, and electrical contacts.

Researchers at the University of Akron have developed a high-resolution characterization system that incorporates six gel permeation chromatography columns, two light scattering detectors, a refractive index sensor, and a viscometer. The new system facilitates the study of separated macromolecules and is expected to play a role in the development of safer biopolymers for breast implants.

Developing a disciplined approach to standardizing special processes and introducing new technologies is key to eliminating defects in thermal spray applications.

The development of biocompatible resins and improvements in stereolithography are driving innovations in drug delivery, biosensing, diagnostic testing, and surgical devices and procedures.

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.

Stony Brook celebrates a milestone by reflecting on its Center for Thermal Spray Research from the early years of growth and expansion to the development of an industrial consortium.

Ultrasound is widely used for nondestructive evaluation, structural health monitoring, acoustic emission, sound navigation ranging, and in sensors for automobiles, medicine, and many other applications. Next-generation, small-form-factor sensors have been achieved through advances in piezoelectric micromachined ultrasonic transducers (PMUTs) that can be positioned on either a flexible polymer or a silicon substrate to form an array. This article describes a materials and design optimization study that used finite element analyses to improve designs for robust and practical PMUT sensor arrays.

Getting connected and using data for operations and maintenance decisions is a great place to start when implementing Industry 4.0 concepts. This article reviews the steps that heat treaters must take toward adopting this technology, with an emphasis on implementing or enhancing predictive maintenance capabilities.

Capable of stopping 50-caliber, armor-piercing rounds, ALON and Spinel are hard and durable transparent polycrystalline materials manufactured using powder based processes. This article describes their unique combination of mechanical, optical, and chemical properties, and reports on recent advances in manufacturing to enable their use for critical defense, industrial, and consumer applications.

This article reports on work at the Center for Thermal Spray Research over the past 25 years to develop and commercialize a new technology for digital printing of mesoscale circuits directly from a CAD file onto plates, cylinders, and complex 3D components and structures. With the evolution of cold spray technology and new powder materials, as well as advancements in control and robotics, innovative thermal spray applications are on the horizon.

A new friction stir processing method, submerged bobbin tool tunneling, creates subsurface integral pathways in components that can be used as channels for wiring, gases, fluids, powders, or as a lightweighting technique.

An integrated strategy for the development of thermally sprayed functional oxide coatings is presented in this article. Strontium-doped lanthanum manganite (LSM), a prototypical functional oxide, was selected to demonstrate the approach.

Throughout its 100-year history, the Materials and Manufacturing Directorate has conducted groundbreaking critical research programs responsible for a multitude of technological advances. This article summarizes just a few of the significant achievements of the directorate during its history.

This article provides an overview of nondestructive test methods and their application in the study of material properties and structures. It covers the most widely used NDT technologies, including optical examination, radiography, acoustic emission, and ultrasonic testing, and discusses the impact of recent advancements.

Ultrasonic additive manufacturing (UAM) originated from ultrasonic metal welding, first developed in the 1950s. Modern applications include welding of battery tabs, thin foil packaging, and electronic wire production. The article reports on a unique UAM method that excels at mixed metal applications. The technology won the 2022 ASM Engineering Materials Achievement Award.