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MATERIALS SCIENCE
AND E
GINEER
G
FORGING STRONGER LINKS TO USERS
Committee on Materials Science and Engineering:
Forging Stronger Links to Users
National Materials Advisory Board
Commission on Engineering and Technical Systems
National Research Council
Publication NMAB-492
NATIONAL ACADEMY PRESS
Washington, D.C.
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NATIONAL ACADEMY PRESS · 2101 Constitution Avenue, NW · Washington, DC 20418
NOTICE: The project that is the subject of this report was approved by the Governing
Board of the National Research Council, whose members are drawn from the councils of
the National Academy of Sciences, the National Academy of Engineering, and the Insti-
tute of Medicine. The members of the panel responsible for the report were chosen for
their special competencies and with regard for appropriate balance.
This study by the National Materials Advisory Board was conducted under a contract
with the Department of Defense, National Aeronautics and Space Administration, Na-
tional Science Foundation, and the Department of Energy. Any opinions, findings, conclu-
sions, or recommendations expressed in this publication are those of the authorts) and do
not necessarily reflect the view of the organizations or agencies that provided support for
the project.
Available in limited supply from:
National Materials Advisory Board
2101 Constitution Avenue, N.W.
Washington, D.C. 20418
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nmab @nas.edu
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metropolitan area)
http://www.nap.edu
Cover: Scanning electron micrograph of a device with IBM's six-level copper intercon-
nect technology. Source: Courtesy of International Business Machines Corporation. Un-
authorized use not permitted.
Copyright 1999 by the National Academies. All rights reserved.
Printed in the United States of America.
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National Acaclemy of Sciences
National Acaclemy of Engineering
Institute of Meclicine
National Research Council
The National Academy of Sciences is a private, nonprofit, self-perpetuating society of
distinguished scholars engaged in scientific and engineering research, dedicated to the
furtherance of science and technology and to their use for the general welfare. Upon the
authority of the charter granted to it by the Congress in 1863, the Academy has a mandate
that requires it to advise the federal government on scientific and technical matters.
Dr. Bruce M. Alberts is president of the National Academy of Sciences.
The National Academy of Engineering was established in 1964, under the charter of the
National Academy of Sciences, as a parallel organization of outstanding engineers. It is
autonomous in its administration and in the selection of its members, sharing with the
National Academy of Sciences the responsibility for advising the federal government.
The National Academy of Engineering also sponsors engineering programs aimed at meet-
ing national needs, encourages education and research, and recognizes the superior
achievements of engineers. Dr. William A. Wulf is president of the National Academy of
Engineering.
The Institute of Medicine was established in 1970 by the National Academy of Sciences
to secure the services of eminent members of appropriate professions in the examination
of policy matters pertaining to the health of the public. The Institute acts under the respon-
sibility given to the National Academy of Sciences by its congressional charter to be an
adviser to the federal government and, upon its own initiative, to identify issues of medical
care, research, and education. Dr. Kenneth I. Shine is president of the Institute of
Medicine.
The National Research Council was organized by the National Academy of Sciences in
1916 to associate the broad community of science and technology with the Academy's
purposes of furthering knowledge and advising the federal government. Functioning in
accordance with general policies determined by the Academy, the Council has become the
principal operating agency of both the National Academy of Sciences and the National
Academy of Engineering in providing services to the government, the public, and the
scientific and engineering communities. The Council is administered jointly by both Acad-
emies and the Institute of Medicine. Dr. Bruce M. Alberts and Dr. William A. Wulf are
chairman and vice chairman, respectively, of the National Research Council.
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COMMITTEE ON MATERIALS SCIENCE AND ENGINEERING:
FORGING STRONGER LINKS TO USERS
DALE STEIN (chair), Michigan Technological University (emeritus), Tucson,
Arizona
BRADEN R. ALLENBY, AT&T, Warren, New Jersey
MALCOLM R. BEASLEY, Stanford University, Stanford, California
LOUIS L. BUCCIARELLI, Massachusetts Institute of Technology, Cambridge
JOHN V. BUSCH, IBIS Associates, Inc., Wellesley, Massachusetts
JOHN A. DECAIRE, National Center for Manufacturing Sciences, Ann Arbor,
Michigan
GEORGE E. DIETER, University of Maryland (emeritus), College Park
WILLIAM D. DOYLE, University of Alabama, Tuscaloosa
NORMAN A. GJOSTEIN, Ford Motor Company (retired), Dearborn, Michigan
HUGH R. MACKENZIE, MAC, Inc., Bourne, Massachusetts
WILLIAM D. MANLY, Oak Ridge National Laboratory, Oak Ridge, Tennessee
NEIL E. PATON, Howmet Corporation, Whitehall, Michigan
TRESA M. POLLOCK, Carnegie Mellon University, Pittsburgh, Pennsylvania
JANE M. SHAW, IBM, Yorktown Heights, New York
RONALD D. SHRIVER, Honda of America Manufacturing, Inc., Marysville,
Ohio
MALCOLM C. THOMAS, Allison Engine Company, Indianapolis, Indiana
ROBERT H. WAGONER, Ohio State University, Columbus
NMAB Staff
ROBERT M. EHRENREICH, Senior Program Officer
THOMAS E. MUNNS, Associate Director
PAT WILLIAMS, Senior Project Assistant
Technical Consultants
DONALD SHAW, Texas Instruments Incorporated (retired), Dallas, Texas
Liaison Representatives
LANCE DAVIS, U.S. Department of Defense, Washington, D.C.
ROBERT GOTTSCHALL, U.S. Department of Energy, Germantown, Maryland
DONALD U. GUBSER, Naval Research Laboratory, Washington, D.C.
JAMES KELLY, Office of Naval Research, Arlington, Virginia
ROBERT L. RAPS ON, Wright Laboratory, Wright Patterson Air Force Base,
Ohio
v
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VINCENT J. RUSSO, Wright Laboratory, Wright Patterson Air Force Base, Ohio
LEWIS SLOTER, U.S. Department of Defense, Washington, D.C.
DENNIS J. VIECHNICKI, U.S. Army Research Laboratory, Aberdeen Proving
Ground, Maryland
STEVEN G. WAX, Defense Advanced Research Projects Agency, Arlington,
Virginia
THOMAS A. WEBER, National Science Foundation, Arlington, Virginia
vim
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NATIONAL MATERIALS ADVISORY BOARD
EDGAR A. STARKE (chair), University of Virginia, Charlottesville
JESSE L. BEAUCHAMP, California Institute of Technology, Pasadena
EARL DOWELL, Duke University, Durham, North Carolina
EDWARD C. DOWLING, Cleveland Cliffs, Inc., Cleveland, Ohio
THOMAS EAGAR, Massachusetts Institute of Technology, Cambridge
ALASTAIR GLASS, Bell Laboratories, Lucent Technologies, Murray Hill,
New Jersey
MARTIN E. GLICKSMAN, Rensselaer Polytechnic Institute, Troy, New York
JOHN A.S. GREEN, The Aluminum Association, Washington, D.C.
SIEGFRIED S. HECKER, Los Alamos National Laboratory, Los Alamos,
New Mexico
JOHN H. HOPPS, Morehouse College, Atlanta, Georgia
MICHAEL JAFFE, New Jersey Center for Biomaterials and Medical Devices,
Piscataway
SYLVIA M. JOHNSON, SRI International, Menlo Park, California
SHEILA F. KIA, General Motors Research and Development, Warren, Michigan
LIAS KLEIN, Rutgers, The State University of New Jersey, Piscataway
HARRY A. LIPSITT, Wright State University, Dayton, Ohio
ALAN G. MILLER, Boeing Commercial Airplane Group, Seattle, Washington
ROBERT C. PFAHL, Motorola, Schaumberg, Illinois
JULIA PHILLIPS, Sandia National Laboratories, Albuquerque, New Mexico
KENNETH L. REIFSNIDER, Virginia Polytechnic Institute and State University,
Blacksburg
JAMES WAGNER, Case Western Reserve University, Cleveland, Ohio
JULIA WEERTMAN, Northwestern University, Evanston, Illinois
BILL G.W. YEE, Pratt and Whitney, West Palm Beach, Florida
RICHARD CHAIT, Director
. .
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Dedication
THIS REPORT Is DEDICATED TO THE MEMORY OF ROBERT LAUDISE, the chairman
of the NMAB at the time this report was commissioned and a prime mover
in developing the theme of the report. We all remember Robert as a per-
son of uncommon technical ability, with the vision and passion required of a
leader; yet so warm and human, with a happy smile and quick wit. We shall miss
him greatly.
Blessed is he who carries within himself a God, an ideal and who obeys
it ideal in art, ideal in science, ideal in gospel virtues; therein lies the
springs of great thoughts and great actions: they all reflect light from the
infinite.
Louis Pasteur (1822-1895)
. . .
vail
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Preface
MATERIAES ARE IMPORTANT. NEW MATERIAES often provide opportunities
for rapid technological advancements, but to seize those opportunities,
the materials must be adapted and integrated into economically viable
products. As history shows, this has not been easy. Studies show that it often
takes 20 or more years for a new material to make a significant penetration into
the market. Many challenges will have to be overcome for the nation to derive the
full benefit of new materials essential for a vibrant, safe, and environmentally
friendly economy. The materials community has an opportunity to play a central
role, but it will require changes in both mind-sets and methods.
Can the leisurely pace be improved? Probably. This report examines the many
links in the chain from basic research to the introduction of a new material into
the market and discusses how the links can be strengthened to accelerate the
introduction of new materials into the marketplace. Many factors influence the
effectiveness of these interactions, including maturity of the industry, frequency
of major changes in the product, openness to innovation, profitability, and com-
petitiveness. As a consequence, new materials find their way from the laboratory
to the marketplace by a multitude of pathways.
Although no single formula can ensure the rapid introduction of new materi-
als to the marketplace, practices and policies that facilitate the introduction of
new materials have been identified. The objective of this report is to broaden the
understanding of the complex factors that can impede the introduction of new
materials and to suggest changes in practices and policies to promote the intro-
duction of new materials: researchers must have a better understanding of the
constraints of the marketplace; users must be more receptive to new materials and
processes; and educators must focus more attention on team building, industrial
Six
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x
PREFACE
ecology, design, and production. Most important, a way must be found to navi-
gate the so-called "valley of death," the transfer of the materials technology from
the researcher to the end-user.
For this report, the committee conducted in-depth studies of three industry
sectors: the automotive industry, the jet-engine industry, and the computer-chip
and information-storage industries. In addition to the expertise of the committee
members, the committee conducted workshops for each case-study industry. Rep-
resentatives of the MS&E community, the industrial research community, supply
companies, and systems integrators participated in the workshops. The informa-
tion gathered in these workshops was synthesized and used as a basis for this
report and the development of findings and recommendations.
Comments and suggestions can be sent via electronic mail to nmab@nas.edu
or by FAX to NMAB (202) 334-3718.
Dale F. Stein, chair
Committee on Materials Science and Engineering:
Forging Stronger Links to Users
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Acknowledgments
THE COMMITTEE WOWD EIKE TO THANK THE PRESENTERS and participants in the
three industry workshops that served as the principal data-gathering ses-
sions for this study. Presenters at the November 1997 electronics industry
workshop were: Barry Schechtman, NSIC; Sheldon Schultz, University of Cali-
fornia at San Diego; David Thompson, IBM Almaden Research Center; Robert
Rottmayer, Read-Rite; Thomas Howell, Quantum; Paul Peercy, SEMI/
SEMATECH; Woodward Yang, Harvard University; Don Shaw, Texas Instru-
ments; Alain Harrus, Novellus; Pier Chu, Motorola; James McElroy, NEMI;
Michael Pecht, University of Maryland; William Chen, IBM; Jack Fischer, Inter-
connection Technology Research Institute; and Robert MacDonald, Intel. Pre-
senters at the January 1998 turbine-engine industry workshop were: Ambrose
Hauser, GE Aircraft Engines; Michael Goulette, Rolls-Royce PLC; Gary Roberge,
Pratt and Whitney; Anthony Giamei, United Technologies; Kathy Stevens, Wright
Laboratories; James Williams, GE Aircraft Engines; Peter Shilke, GE; Harry
grill-Edwards, consultant; Robert Noel, Ladisch Company, Inc.; Greg Olson,
QuestTek Innovations; Gernant Maurer, Special Metals Corporation; Ken Harris,
Cannon-Muskegon Corporation; William Parks, U.S. Department of Energy;
Mark Fulmer, Federal Aviation Administration; Tony Freck, consultant; and
Larry Fernbacher, Technology Assessment and Transfer. Presenters at the March
1998 automotive industry workshop were: Christopher Magee, Ford Motor Com-
pany; Roger Heimbuch, General Motors; Sam Harpest, Honda; Andrew Sherman,
Ford Motor Company; Darryl Martin, AISI International; Peter Bridenbaugh,
Alcoa; Ken Rusch, Budd Plastics; Kenneth Browell, GE; John McCracken, TWN,
Inc.; John Allison, Ford; Floyd Buch, Duralcan; Joseph Heremans, General
Motors; Sam Froes, University of Idaho; Bryan McEntire, Norton; and Jeff
x~
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xt!
ACKNOWLEDGMENTS
Dieffenbach, IBIS Associates. The committee would like to give special thanks
to Ivan Amato for developing the case study vignettes.
This report has been reviewed by individuals chosen for their diverse per-
spectives and technical expertise, in accordance with procedures approved by the
NRC' s Report Review Committee. The purpose of this independent review is to
provide candid and critical comments that will assist the authors and the NRC in
making the published report as sound as possible and to ensure that the report
meets the institutional standards for objectivity, evidence, and responsiveness to
the study charge. The content of the review comments and draft manuscript re-
main confidential to protect the integrity of the deliberative process. We wish to
thank the following individuals for their participation in the review of this report:
Kathleen Taylor, General Motors; Robert Aplan, Pennsylvania State University;
Gernant Maurer, Special Metals Corporation; Robert Eagan, Sandia National
Laboratories; Robert Pfahl, Motorola; Julia Weertman, Northwestern University;
and James Williams, Ohio State University. While the individuals listed above
have provided many constructive comments and suggestions, responsibility for
the content of this report rests solely with the authors.
Finally, the committee gratefully acknowledges the support of the staff of the
National Materials Advisory Board, including Robert Schafrik, former director
of the NMAB, who got the project off the ground; Robert Ehrenreich, who pro-
vided technical support and program management throughout the data-gathering
and report-development phases of the study; Thomas Munns, who shepherded
the report through review and publication; and Pat Williams, who provided ad-
ministrative support throughout the entire study.
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Contents
EXECUTIVE SUMMARY
1 INTRODUCTION
Taxonomy, 7
Study Mode of Operation, 10
2 MATERIALS DEVELOPMENT AND
COMMERCIALIZATION PROCESS
Duration and Drivers of Materials Transitions, 13
Conceptual Schema, 15
Phase 0: Knowledge-Base Research, 24
Phase 1: Material Concept Development, 27
Phase 2: Materials/Process Development, 29
Phase 3: Transition to Production, 38
Phase 4: Product Integration, 42
LINKAGES BETWEEN THE MS&E AND END-USER
COMMUNITIES
Industry-Industry Linkages, 44
Industry-University Linkages, 53
Industry-Government Laboratory Linkages, 62
Industry-Government Linkages, 63
Consortia, 66
4 PRIORITIES
Setting the Stage for "Product Pull," 72
Getting Down to Business, 73
x~
5
12
44
69
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xlv
REFERENCES
APPENDICES
A ELECTRONICS INDUSTRY WORKSHOP
B TURBINE-ENGINE INDUSTRY WORKSHOP
C AUTOMOTIVE INDUSTRY WORKSHOP
D BIOGRAPHICAL SKETCHES OF COMMITTEE MEMBERS
CONTENTS
76
81
91
97
102
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Tables, Figures, and Boxes
TABLES
1-1
1-2
2-1
2-2
3-1
Value of Industry Shipments of Basic Raw Materials in 1996, 6
Value of Industry Shipments of Fabricated Raw Materials, 7
Examples of Takeover Times and Substitution Midpoints, 13
Characteristics of Product Development Phase (Phase 4), 42
Characteristic Time Scales for Academia and Automotive Industry, 59
FIGURES
ES-1 Relationships in the MS&E community, 1
ES-2 Notional phases of the innovation process, 2
Graphical representation of the connections among the common
elements in the MS&E R&D discipline, 8
Graphical representation of the connections among the common
elements in the entire MS&E discipline, including the end-user, 10
2-1
2-2
2-3
Timeline for the adoption of single-crystal, first-stage, high-pressure
turbine blades for jet engines, 14
Conceptual schema of materials/processes development and
commercialization processes, 25
Revised conceptual schema of materials development and
commercialization, 26
xv
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xv!
2-4 Characteristics of knowledge-base research (Phase 0), 28
2-5 Characteristics of material concept development (Phase 1), 32
Characteristics of material process development (Phase 2), 36
Characteristics of transition to production (Phase 3), 43
2-6
2-7
TABLES, FIGURES, AND BOXES
3-1
3-2
2-1
2-2
2-3
2-4
2-5
2-6
2-7
3-1
A-1
B-1
C-1
Typical user chain for materials production cycle, from raw material to
the ultimate destiny of all materials, 45
Schematic representation of the linkages associated with industrial
ecology, 56
BOXES
Single-Crystal Turbine Blades, 16
Copper Interconnects for Semiconductor Chips, 18
Titanium Aluminides: Unrequited R&D, 20
Capitalizing on Luck: The Development of Tungsten Filament Wire, 22
Great Good Fortune: Data Storage, Magnetoresistance, and Giant
Magnetoresistance, 30
Accelerated Innovation in the Semiconductor Industry, 34
Tailor-Welded Blanks, 40
Arsenic and Silver-Laced Water, 54
Agenda for the Electronics Industry Workshop, 82
Agenda for the Turbine-Engine Industry Workshop, 92
Agenda for the Automotive Industry Workshop, 98
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Acronyms
ATP Advanced Technology Program
CMOS complementary metal oxide semiconductors
CRADA cooperative research and development agreement
DARPA Defense Advanced Research Projects Agency
DOD U.S. Department of Defense
DOE U.S. Department of Energy
ERC engineering research centers
FAA Federal Aviation Administration
GMR giant magnetoresistance
GOALI Grant Opportunities for Academic Liaison with Industry
HDD hard disk drive
I/O input/output
IOF Industries of the Future
I/UCRC industry/university cooperative research centers
ManTech Manufacturing Technology Program
MR magnetoresistance
MS&E materials science and engineering
NEMI National Electronics Manufacturing Initiative
NAICS North American Industrial Classification System
NSIC National Storage Industry Consortium
NSTC National Science and Technology Council
OEM original equipment manufacturer
PNGV Partnership for a New Generation of Vehicles
R&D research and development
SIC Standard Industrial Classification
S/IUCRC state/industry university cooperative research centers
TWO technical working group
. .
xv
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