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METALS

POLYMERS

CERAMICS

Honda Civic wins Automotive Excellence Award from AISIThe American Iron and Steel Institute has

selected the research and development teamof the 2006 Honda Civic for this years GreatDesigns in Steel Automotive ExcellenceAward, based on the vehicles evolutionaryand cost-effective applications of advancedhigh-strength steels.

Candidates were rated in several cate-gories, including implementation in produc-tion; overall contribution to the advance-ment of steel; challenges and benefits

associated with cost, weight savings, and performance; replacement of competitive materials;and structural performance and efficiency.

The extensive use of high-strength steel in the Advanced Compatibility Engineering bodystructure creates a new-generation platform that is safer and stronger, enhancing the vehiclesability to deal with crash energy during impact, says Brian Aranha, vice president of Arcelor-Mittal Dofasco and chairman of AISIs Automotive Applications Committee.

For more information: Ron Krupitzer, American Iron and Steel Institute, Southfield, MI 48075;tel: 248/945-4761; krupitzerr@autosteel.org; http://www.autosteel.org.

Molded polyurethanes replace steel in agricultural vehiclesThe two side panels and tailgate of the

Jaguar Green Eye forage harvester aremolded by Claas KGaA GmbH in Harse-

winkel, Germany. They are produced fromthe flame-retardant, microcellular poly-urethane system Baydur 110 from Bayer Ma-terialScience, Germany. The excellent flowcharacteristics and low cavity pressure aresaid to impose virtually no restrictions on thegeometric design of the molded parts, espe-cially in the edge and interior areas.

Each of the large side panels has dimen-sions of 4 x 2 meters and weighs around 40

kg (90 lb). The tailgate has external dimensions of 1.7 x 1.6 meters and weighs around 30 kg (66 lb).All three components feature complex structures such as undercuts, ribbing, and significant

changes in wall thickness, produced via inexpensive aluminum molds. Metal bushings and otherinserts are integrated into the molding process.For more information: Bayer MaterialsScience AG, Leverkusen, Germany; tel: 49 214 30 72362;

http://www.bayermaterialscience.com.

Iron-gallium magnetostrictive alloy is tough, low in costAn iron-gallium alloy system with strong magnetostrictive properties is now being commercial-

ized, report researchers at the Naval Surface Warfare Center Carderock Division, which inventedthe material in 1999. Magnetostriction is an effect in which the physical dimensions of some ma-terials are altered when a magnetic field is applied. Called Galfenol, the iron-gallium alloys havethe ability to convert electrical energy into mechanical energy.

The Galfenol alloys are mechanically tough and have saturation magnetostrictions as high as400 ppm in single-crystal form, and 300 ppm in the more easily produced highly textured poly-

INDUSTRY NEWS

ADVANCED MATERIALS & PROCESSES/JULY 2008 9

BRIEFSTheAmerican Iron andSteel Institute reportsthat steel import permitapplications for the monthof February totaled2,329,000 net tons. Thiswas an eight percent de-crease from the 2,534,000permit tons recorded inJanuary 2008, and a 12%decrease from the Januarypreliminary imports totalof 2,658,000 net tons.www.steel.org

Frost & Sullivan hasawarded the EuropeanProcess-EnhancedEngineering PlasticsExcellence in TechnologyAward for 2008 to DSMEngineering PlasticsStanyl Super FlowPolyamide 46, which wasco-developed with leadingelectronic connectormanufacturers to provide

a suitable alternative tohigh-flow versions of liquidcrystal polymer (LCP).www.dsmep.com

The InternationalMagnesiumAssociation has releasedthe latest quarterly onlineedition of its Mg Showcasenewsletter. Within eachissue, application exampleshighlight its strength,durability, low density, cost

savings, and recyclability.www.intlmag.org

Penn State Universitywill partner withHoneywell to developsolar cells for efficient,low-cost, large-areascalable solar energyconversion. The solar cellswill be based on titaniumdioxide nanotubes andorganic semiconductors.www.psu.edu

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crystalline form. These alloys can sustain approximately 400 to 500 MPa (58 to 75 ksi) of tensilestress, and can be machined and welded with conventional metalworking technology.

A target application for such an alloy is active vibration control. For example, a single layercoil wound around sections of a vibrating machine would allow active control of the vibration.

For more information: Marilyn Wun-Fogle, Naval Surface Warfare Center, Carderock Divi-sion, West Bethesda, MD 20817-5700; tel: 301/227-5968; marilyn.wun-fogle@navy.mil;www.nswccd.navy.mil.

Heat-resistant thermoplastic is stable in firemans helmetAhigh-temperature thermoplastic made by DSM En-

gineering Plastics has been selected for a new firemanshelmet by the Rosenbauer Group, Germany. The Stanylthermoplastic offers high impact and penetration resist-ance, which keeps the helmet stable even at extreme tem-peratures.

Rosenbauer, the world leader in mobile fire protec-tions and civil defense solutions, recently introducedHeros-Xtreme, a new firemans helmet, tested andapproved according to EN 443:1997 and prEN 443:2006.

Although the requirements were extreme, DSM suc-

ceeded in meeting the technological challenge of devel-oping a product that does not self-ignite, drip, or delam-inate at temperatures up to 250C (480F). Thethermoplastic passed all thermal, chemical, and mechan-ical tests. FACT (Future Advanced Composites & Technology) in Germany was responsible forcarrying out the long-fiber reinforcement process.

For more information: DSM Engineering Plastics, P.O. Box 3333, 2267 West Mill Road, Evans-ville, IN 47732-3333; tel: 800/333-4237; fax: 812/435-7702; www.dsmep.com.

Injection-molded metal properties surpass die castingsInjection-moldable metal that can reportedly be processed on standard plastic injection molding

equipment to produce three-dimensional net shape parts in high

volume has been introduced by Cool Polymers Inc., Warwick, R.I.Called Xyloy, the injection moldable metals are lightweight alloysthat are said to offer an outstanding combination of mechanical,physical, and thermal properties that surpass the performance ofplastics and die cast metals.

The company says that Xyloy is stronger than die cast metal partsand has no porosity. It can be molded in three-dimensional, netshape parts in high volume, with tooling guaranteed for the lifeof the program.

For more information: Cool Polymers Inc., 333 Strawberry FieldRoad, Warwick, RI 02886; tel: 888/811-3787; www.coolpolymers.com.

Composite reduces weight,doubles life of airfield matting

Significant progress in the design and development of a strong,lightweight-composite-based airfield matting system for forwardaircraft deployments has been reported by researchers from the AirForce Research Laboratory and Webcore Technologies Inc., Miamis-burg, Ohio. WebCore manufactures the Tycor family of fiberreinforced foam cores. Their proprietary process places fiberreinforcement through the thickness of closed cell foam sheets toform a corrugated or vertical truss-type structure, which is then in-fused with epoxy or other resin to produce a very robust anddamage-tolerant core material.

The matting system provides a 36% weight reduction over the

10 ADVANCED MATERIALS & PROCESSES/JULY 2008

B R I E F S

The Plansee Group haspurchased the GlobalTungsten and Powdersbusiness unit from OsramGmbH, Munich, Germany,a Siemens company.www.plansee.com

Seminars For EngineersUSA, a division of SensorProducts Inc. USA, an-nounces its 2008 Com-posite Materials Design,Testing and Fabrication sem-inar schedule, in associationwith BTG CompositesLLC.www.seminarsforengineers.com

Stainless steel-clad coppercoated with nickel is weldableA weldable, high-conductivity material has reportedly beendeveloped by Technical Materials Inc., a Brush Engineered

Materials company, Lincoln, R.I. Called Ni-Trueclad 36, it is astainless steel double-clad copper with a specially-processed

nickel-coated surface. It has electrical conductivity of 36% IACS,twice as high as commercially pure nickel, and overcomes

weldability issues of other high-conductivity alternatives inparallel-gap resistance welding.

The nickel coating also ensures excellent joinability via laserwelding as well as soldering. Humidity camber testing, under a

cyclic temperature-simulating profile of an automobileenvironment, demonstrated that this material has goodcorrosion resistance. It also has good formability in the

quarter-hard temper condition, and its surfaceis electroplatable.

TMI has been collaborating with industry leaders to developapplications in a wide range of power devices, including

hybrid electrical vehicles, laptop computers, and cell phones.For more information: L. Leigh Chen, Technical Materials Inc.,

5 Wellington Road, Lincoln, RI 02865;tel: 401/333-1700; fax: 401/333-2848;

lichun_chen@beminc.com; www.technicalmaterials.com.

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extruded aluminum (AM-2) panels currently in use, and has twice the operational life. Thesystems simple connection method and optimized shipping size will enable the U.S. Air Forceto deploy aircraft more rapidly via considerably faster expansion of parking aprons and connec-tion of taxiways and maintenance areas. Several years of extensive testing and analysis haveeffectively demonstrated that the new matting system meets loading and weight requirements.

For more information: Webcore Technologies, Miamisburg, OH 45342; tel: 937/435-2200;www.webcoreonline.com.

Transparent graphene layers could make better solar cellsAn easy way to make transparent graphene films that are a few centimeters wide and one to

five nanometers thick has reportedly been developed at Rutgers University, Piscataway, N.J. Thinfilms of graphene, a flat single layer of carbon atoms, could provide a cheap replacement for thetransparent, conductive indium tinoxide electrodes in organic solar cells.They could also replace the silicon thin-film transistors common in displayscreens. Graphene can transport elec-trons tens of times faster than silicon, sographene-based transistors could workfaster and consume less power.

The researchers start by making a sus-pension of graphene oxide flakes. Theyoxidize graphite flakes with sulfuric ornitric acid. This inserts oxygen atomsbetween individual graphene sheetsand forces them apart, resulting ingraphene oxide sheets, which are sus-pended in water.

The suspension is filtered through amembrane that has 25-nanometer-widepores. Water passes through the pores,but the graphene oxide flakes, each ofwhich is a few micrometers wide andabout one nanometer thick, cover thepores. When a flake covers a pore, wateris directed to its uncovered neighbors,which in turn get covered, until flakesare distributed across the entire surface.The researchers place the film-coatedside of the membrane on a substratesuch as glass or plastic, and wash awaythe membrane with acetone. Finally,they expose the film to a chemical calledhydrazine, which converts the grapheneoxide into graphene.

For more information: ManishChhowalla, Rutgers University, 607Taylor Road, Piscataway, NJ 08854; tel:732/445-5619; manish1@rci.rutgers.edu;www.nanotubes.rutgers.edu.

Oxide-oxide ceramiccomposite shields aircraftparts from heat

An oxide-oxide ceramic matrix com-posite for aft fairing heat shields on mil-itary and commercial aircraft is said to

ADVANCED MATERIALS & PROCESSES/JULY 2008 11

2008ThermoFisherScientificInc.AlltrademarksarethepropertyofThermoFisherScientific

Inc.anditssubsidiaries.Allrightsreserved.

Thermo Scientific NITON XRF analyzers continue to lead the

handheld alloy analysis field with technology that responds

directly to the industrys need for material analysis. The

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rugged, dependable tools with improved ergonomics, speed, and

performance.

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be under development at the Air Force Research Laboratorys Materials and Manufacturing Di-rectorate, under a Dual Use Science and Technology program with the Boeing Company.

High-temperature turbine engine exhaust washes over the aluminum struts that hold the en-gines in place on commercial aircraft such as the Boeing 777 or military aircraft such as the C-17.Eventually, this thermal exposure could cause the aluminum struts to fail. For this reason, thestruts are protected from the exhaust with a structure called an aft fairing heat shield (AFHS).

Thermal stress and acoustic loading of various AFHS designs with the CMC material have

been extensively modeled. The modeling eventually converged on a design with adequate mechan-ical properties and which also met the weight and cost objectives. An AFHS sub-element hasbeen fabricated of the chosen CMC, and T-joints and panels of the material have been mechanicallytested.

For more information: Materials and Manufacturing Directorate, Wright-Patterson Air ForceBase, Dayton, OH 45433; tel: 937/255-6469; techinfo@afrl.af.mil. Refer to item 06-142.

Lightweight composites shield from heat, improve fuel efficiencyLightweight composite panels that cover almost the entire underside of the new BMW, which

provide optimized aerodynamics for improved vehicle handling and fuel efficiency, have beenmade of SymaLite from Quadrant Plastic Composites, Lenzburg, Switzerland, by Takeo GmbHAutomotive Systems, Dietfurt, Germany. The new BMW application for which SymaLite is spec-ified includes engine shield, gear box shield, and under body shields.

SymaLite is a composite material based on polypropylene and specially oriented glass fibers.The pre-oriented fibers allow good loft behavior during the heating and molding process, en-abling expansion of up to six times its original thickness and achieving densities of only 0.3g/cm3,while increasing bending stiffness in the Z-direction. Physical and mechanical properties can betailored to match the demands of the part by varying the mix of PP and glass fibers.

For more information: Quadrant Plastic Composites, Lenzburg, Switzerland; tel: +41 62 88581 50; qpc@qplas.com; www.quadrantcomposites.com.

12 ADVANCED MATERIALS & PROCESSES/JULY 2008