Below are the first 10 and last 10 pages of uncorrected machine-read text (when available) of this chapter, followed by the top 30 algorithmically extracted key phrases from the chapter as a whole.
Intended to provide our own search engines and external engines with highly rich, chapter-representative searchable text on the opening pages of each chapter.
Because it is UNCORRECTED material, please consider the following text as a useful but insufficient proxy for the authoritative book pages.
Do not use for reproduction, copying, pasting, or reading; exclusively for search engines.
OCR for page 5
2
The Role of Materials tin Critical Infrastructure
The stability of the nation's critical infrastructures ant} its economic health rely in
many ways on an improved unclerstanding of the behavior of materials ant! on the
cievelopment of new processing and products. For example, some of society's most
pressing needs for new technology are in the areas of energy sv~tem.s en c! national
— — C7, — .~ ~
security, especially in the wake of September I 1, 2001. New materials also play a
continuing and important role in enabling advances in the manufacturing sector,
especially commercial vehicle production, which is a key part of the nation's economic
infrastructure.
MATERIALS IN NATIONAL SECURITY
Session Chair Julia Phillips, Sandia National Laboratories
i,,
Materials Issues in Microsystems for National Security, Duane Dimos, Sandia National
Laboratories
Advanced Sensors for Counterterrorism, Frances Ligler, Naval Research Laboratory
Transportation Infrastructure and Security, Lyle Malotky, Transportation Security
Administration
1
The national security environment is complex and full of difficult challenges for
materials scientists. In all of the key tasks involved in national security, i.e., surveillance
and assessment, protection of assets ant! infrastructure, and the use of weapons for
defending and defeating, materials science and engineering play an important role.
As an example, improved surveillance and threat assessment, a national need
certainly made more urgent by the events of September ~ I, 2001, will require
development of the key microchemical analytical systems that are at the heart of
hanclheld components with multifunctional capability. The development path for such a
system is shown in Figure 2-~. The materials that emerge when such systems are
developing will have roles in communications, chemical and biological warfare sensors,
ant! other surveillance equipment. The primary materials advances relevant to this
technology are miniaturizes! optics and fluidics. The materials must be inexpensive and
rugged, which suggests polymeric materials may be promising. However, given that very
few currently available plastics are suitable for optical crevices, improvements—
specifically in optical properties and ease of processing are key to their application for
biowarfare detection. Another possibility is the development of biological materials that
exhibit a specific response to a biochemical; this is a growing field of research.
In only the past few years, users' needs and perceptions about detection devices in
security applications have changer! considerably. Among the new requirements for these
as
OCR for page 6
MATERIALS AND SOCIETY
systems are full automation, simplicity of use in the field, minimal logistical burden,
absence of false positives, proper sensitivity for rapi(l screening, appropriate size and
weight, ant! sustainability. All of these requirements present substantial challenges for
materials engineers.
In the area of aviation security, the goal is to prevent an explosive material from
getting on board an airplane or, failing that, to minimize the damage caused by an
explosion. The latter goal calls for more impact-resistant aircraft and toughener!
containers for cargo on the aircraft and requires the development of haul, lightweight
materials. A key challenge is to recluce cost while maintaining robustness.
In the area of building security, an emerging priority is the clevelopment of
materials ant] structures with improved fire resistance as well as structural materials and
Winslow glass that are not only fracture-resistant but that shatter into clust-sizect particles
on breaking. Advances by the materials community in these areas will be an important
part of the overall protection strategy.
Finally, weapons for clefencling against and defeating an enemy will require
lightweight structural materials and miniaturizes] electronics for such applications as
unmanned vehicles and aircraft. Another neec! is for very hard materials that are also
lightweight; such materials are needed for use as earth and rock penetrators to breach
targets that may be buried or protected! with materials that are hard to penetrate.
Some issues cut across all of these applications. The ability to predict the
reliability of materials' properties is becoming a science in its own right. Surety is
important, for example, in the case of weapons in long-term storage or when
nanostructured materials are used in a builcling expected to have a lifetime of many years.
One impediment to fostering within the private sector the kind of innovation
discussed here might be the very practical issue of development costs, which can be high
for new innovative materials solutions. Another might be the low number of units
manufactured for security applications. A small manufacturing contract may not be of
sufficient interest to a large company, and small companies may not be able to produce
the quality and quantity nee(lecl for such high-precision components. One solution is
finding dual-use technologies and exploring the possibilities for contract manufacturing.
Fincling an appropriate manufacturer that can fit the product into its mix can mean spin-
off benefits for both military and commercial uses and can bring the cost of development
down. One example of this would be applying the technology used for an implantable
glucose monitor to the manufacture of a handheld device for monitoring levels of
biological agents.
Comments from the Speakers
"Materials science plays an integral role in every step of the national security scene."
Duane Dimos, Sanclia National Laboratories
"Materials advances will drive advances in biowarfare detection."
Frances Dialer, Naval Research Laboratory
"Bulk explosives detection approaches neec! better sensors and must take full advantage
of available computer technologies."
Lyle Malotky, Transportation Security Administration
6
OCR for page 7
MATERIALS IN FUTURE INDUSTRIES
| Biochemistry development, |
I FY86 (USAMRIID) l
| BURP Biosensor for |
clinical BWD 91-94 1-
Prototype fabricatio n, |
FYB7~0NR) l
Jump Start Fluidics
automation, FY94 {ONR)
Automated portable
prototype, FY96 (ONR)
...
8 lends for Desert Storm,
FY 91 (NAVSEA)
. at. __
_....
| Biosensoron unmanned air l
\ ~ I vehicle, FY96 - FY97 {DA RPA) I
Polycyclic aromatic hydrocarbon
it. dete~ion, FY97 (EPA)
| Explosive detection
I FY96-98 (ESTCP)
Portable RAPTOR,
FYO6-FY01 (OS D, USIMlC
DTM, Research
Ilite rn at i o n al)
FIGURE 2-] Steps in the research, development, and commercialization of a sensor system for biological
weapons. Research leading to the product is shown on the left; products are shown on the right. This
schematic demonstrates how many different agencies and laboratories must cooperate to implement a new
technology in the field. These organizations include the Biological Defense Research Program (BDRP) of
the Naval Medical Research Institute (NMRI); the Defense Advanced Research Projects Agency
(DARPA); the Defense Threat Reduction Agency (DTRA); the Environmental Protection Agency (ESPA);
the Environmental Security Technology Certification Program (ESTCP); the Naval Sea Systems Command
(NAVSEA); the Office of Naval Research (ONR); the Office of the Secretary of Defense (OSD); the U.S.
Army Medical Research Institute of Infectious Diseases (USAMRIID); and the U.S. Marine Corps.
SOURCE: Frances Ligler, Naval Research Laboratory.
MATERIALS IN COMMERCIAL VEHICLES
Session Chair- Harry Cook, University of Illinois
Energy/Fuel Efficiency in Commercial Vehicles, Gary Rogers, FEV Engine Technology,
Inc.
Materials in Commercial Autos and Trucks, Alan Taub, General Motors
Since 1974, General Motors has improved vehicle fuel efficiency 132 percent for
passenger vehicles and 75 percent for trucks. Better lightweight and functional materials
offer further opportunities for improvements by enabling more efficient vehicle
propulsion and reductions in vehicle weight.
Alan Taub, GM Research and Development, presentation at the workshop. Available at
. Slide 6. January2003.
7
OCR for page 8
MATERIALS AND SOCIETY
Developments in lightweight structural materials—including high-strength steels,
composite materials, aluminum ant! magnesium alloys, and tire materials have led to a
reduction in vehicle weight. These materials contribute to lightweight romnnnent~ in the
belly, chassis, an(l powertrain of toclay's vehicles. A few of them are i(lentifiecl in Figure
2-2.
O~ --rid v ·~4 ~,44_
Functional materials can be fount! throughout an entire automobile. They are
used, for example, in fuels and lubricants and catalysts and particulate traps, which lead
to increaser! efficiencies in internal combustion engines ant] in aftertreatment exhaust
systems. They are also use(1 in batteries, fuel cells, and hydrogen systems for energy
storage ant! conversion; in sensors, actuators, ant! microelectromechanical systems
(MEMS) (levices for automotive electronics: and in optical components continua once
structural materials.
~ . . ..
--rid , -~--~.=,~, A _
~~mu~auon loots can help optimize materials properties such as stiffness, strength,
ant! design thickness, thereby helping to improve the structural integrity of a vehicle.
Novel ant! hybrid material structures could be fabricates! by low-cost and robust
processes. For example, modeling has enabler! thinner castings using the lost foam
process; these thinner castings reduce the weight of an engine block cIramatically. The
fabrication process uses patterns macie from expanded polystyrene in a cavityless moIcI.
The foam pattern is replaced by molten metal to produce the casting. Another mocleling
success is hyciroformed frames that can double their torsional rigidity, resulting in a
potential 15 percent weight savings as well as improved safety and ride quality.
Hydroforming uses water pressure to efficiently and effectively force sheet metal into a
die to produce complex shapes.
Aluminum is still an important vehicle component, and magnesium is beginning
to be used. Replacing a stamped part with a casting can enable part consolidation and can
facilitate assembly. The use of reinforcer} reaction-injection-molded snap-on outer panels
has also reduced the weight of vehicles. Other advances include aluminum alloy pistons;
thin-wall, cast-iron exhaust manifolds; thinner glass wincishields and backlights; and
titanium exhaust systems.
Future improvements may include using nanocomposites to achieve much lighter
weight ant! functional benefits such as thermal insulation or integrated sensors. For
example, it is predicted that nanocomposite thermoplastic olefin parts will be more than
20 percent lighter.2
In engine technology, reductions in weight and friction have resulted! in
substantial fuel consumption savings over the last decade. Analysis shows that in the next
10 years, a further fuel consumption saving of approximately 10 to 15 percent couIcl be
achieved with these technologies.3
The further reduction of friction has the largest potential for improving today's
engines. Reduced friction in cirive trains, pistons, and bearings can be achieved, for
example, by reducing the weight of dynamic components. Engineers can also use smart
materials that change their properties in response to engine temperature or speecI.
2Alan Taub, GM Research and Development, presentation at the workshop. Available at
. Slide 26. January 2003.
3Gary Rogers, FEV Engine Technologies, presentation at the workshop. Available at
. Slide 17. January 2003.
8
OCR for page 9
MATERIALS IN FUTURE INDUSTRIES
Thin-Wall
Cast-lron
Exhaust Manifold
.~ ~ at,.
. ~ ~
l
11 -
g :Y
"e
.
Thinner Glass
Windshield &
Back Light
=_
Aluminum
Alloy
Driveshaft
FIGURE 2-2 Some advanced materials applications in the automotive
industry. SOURCE: Alan Taub, GM Research and Development.
for fuel processors and low-cost, high-temperature heat exchangers.
Comments from the Speakers
"Whenever cost can be reduced, that's important."
In the
clevelopment of both
hybrid] electric anti fuel
eel] power systems,
overcoming the
materials problems is
critical. Challenges for
fuel cell performance
include electrode
catalyst formulations
for higher reaction rates
and lower costs and
polymer electrolyte
membrane materials for
proton conduction in
fuel cells. In ad(lition,
stable clielectric
coolants are needed, as
well as low-temperature
catalyst formulations
—Gary Rogers, FEV Engine Technologies
"The automotive industry is both a mature industry and a growth industry."
· Alan Taub, General Motors Corporation
MATERIALS IN ENERGY SYSTEMS
Session Chair Jay Lee, University of Wisconsin at Milwaukee
Conventional Power Generation Technology, John Stringer, Electric Power Research
Institute
Alternative Energy Technologies, William P. Parks, Jr., Department of Energy
Portable Power, Daniel Doughty, Sanclia National Laboratories
The worIcl's civilization and economy are dependent upon the secure an(l reliable
production, distribution, ant! consumption of energy in forms practicable for both
inclustrial and private use. Throughout the world, energy consumption continues to rise,
as illustrated in Figure 2-3. Today the average annual per capita consumption of
electrical power is near 2,100 kilowatt-hours. By 2050, it is expected to exceed! 6,000
9
OCR for page 10
MATERIALS AND SOCIETY
En
o
~ 8
co
._
Q
Ct
4
2
n
~ ~ ~ ~ ~ ~ ~ . . ~ .. .~ ~ ~ ~ I. ~ ~ ~ ~ I... I. ~ ~ ~ ~ ~ ~ . ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~~ ~ ~ ~ ~~ ~ ~~ ~ ~ ~~ ~ ~
.~.~.~:~: ::: ~::~: ~ :~,.~::~:~:~: .::'::'::':.:. : ..:.~.~:~:~:~:~:~: ~ ~ ~:.~ ~ :.- ~.~ ~.~.~.~.~"'.' "~ ~.~.~---.~
1940 ~ 960 ~ 980 Pooe 2020 2040 2060
Year
FIGURE 2-3 Worldwide per capita electricity consumption, 1950-2050.
SOURCE: John Stringer, Electric Power Research Institute.
kilowatt-hours per
persona Currently,
coal-fired plants
account for 50 percent
of U.S. electrical
production.s
The scientific
and technological
response to the
forecasted needs must
include increased
efficiency in the
generation and use of
energy. It must also
embrace the
development of new,
large-scale energy
sources, including
new fuels and new
generation schemes.
The current energy
economy is largely
based on fossil fuels, but continuer] long-term reliance on these sources poses
environmental concerns ant! is increasingly sensitive to geopolitical events.
The environmental concerns include carbon dioxide generation and thermal and
material by-products or waste (such as mercury or radioactive components in coal-fired
plants). They cannot be entirely eliminated but, at some economic and political cost, can
be reduced. One barrier to developing more efficient, less polluting energy resources is
the lack of materials that enable the specific advance or technology.
Important power sources for the future are likely to include biopower, hyclrogen,
wincl, geothermal, solar, and hydropower. The technologies to efficiently and cost
effectively generate ant! distribute the energy from these sources require advances in the
properties of the relevant materials and their application. For example, superconducting
materials can virtually eliminate transmission losses but are still not sufficiently mature
for widespread application. Distributect-generation technologies such as small gas
turbines, Stirling engines, or fuel cell systems must be become easier and cheaper to
manufacture in order to outweigh the economies of scale larger generation systems enjoy.
The economically important field of portable power inclucles applications such as
batteries for internal power storage and fuel cells for external storage. While the ranges
and sizes of power needled in these systems (dictate the potential solutions, performance is
clictatec! by material composition. The properties of anocles, cathodes, ant! electrolytes,
4 John Stringer, Electric Power Research Institute, presentation to the workshop. Available at
. Slide 4. January 2003.
s John Stringer, Electric Power Research Institute, presentation to the workshop. Available at
. Slide 5. January 2003.
10
OCR for page 11
MA TERIALS IN FUTURE INDUSTRIES
for example, determine the voltage and capacity of batteries and fuel cells, and the power
produces] ciepencts on the resistance. Most materials advances in portable power today
are in the field! of electrolytes and electrocatalysts.
The need for new materials solutions is also relevant to current generation
systems. For example, the efficiency of energy generation increases as the temperature of
the process increases. However, the operational temperature limits are set by the
availability of materials and by their economic and environmental processing costs.
Lighter weight materials are needed! for windmill blades, ant} advancer! and
afforcIable semiconductor materials are needed for photovoltaic ant! thermovoltaic
generators. Progress is also being macle in developing other power-related materials with
applications in a variety of systems, including high-heat-tolerant electrical transmission
cables, energy storage systems, motors, efficient hydrogen storage systems, and improved
catalysts for efficient chemical transformations.
The ultimate source of energy for our society is the Sun. Converting the Sun's
energy that reaches our planet into electrical and chemical energy has frequently been
proposed as the only long-term solution to worIcl energy needs. It is unlikely that we can
meet the energy needs of the near future, let alone attain the ultimate goal of reliance on
solar techniques, without many of the above-mentioned materials advances.
Comments from the Speakers
"Rising energy consumption coupled with a growing world population and increased
awareness of environmental issues poses significant challenges to economic ant! political
systems both clomestically and internationally."
John Stringer, Electric Power Research Institute
"Materials dictate the performance of the power source, ant! the ranges of power dictate
potential solutions. "
Dan Doughty, San(lia National Laboratories
"Power is not only technologies, but also includes the fuels, the generation, the clelivery,
the storage, the end-use, ant] all the policies, regulations, ant! international issues that
surround them."
Bill Parks, Department of Energy
11
OCR for page 12
Representative terms from entire chapter:
fuel cells
