Materials Australia Magazine | June 2022 | Volume 55 | No.2 by materialsaustralia

CONFERENCE

CAMS2022 REPORT PAGE 8

CONFERENCE

APICAM2023 & LMT2023 PAGE 17

UNIVERSITY SPOTLIGHT

The University of Tasmania PAGE 40

Online Short Courses

PAGE 57

Technology-First Approach For Light Metals Innovation VOLUME 55 | NO 2 ISSN 1037-7107

JUNE 2022

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From the President Welcome to the June 2022 edition of Materials Australia magazine. Since the last magazine was prepared, we can certainly say that things continue to change and evolve around us at an ever-increasing rate. For example, no one would ever have though only three months ago that we would be paying the high prices for fruit and vegetables that we are now! Inflation is unusually high and the cost of doing business is as challenging as ever. We do of course have a new federal government, and as a professional community, I believe we can look forward to the implementation of the government’s “A Future Made in Australia” plan for boosting our Manufacturing sector. The opportunities to generate some excellent new technologies and capabilities are as good now as there has ever been. For me personally, I am very pleased that the AWBell titanium metal casting project has been officially announced, and a media release from the Defence Innovation Hub is included this edition of Materials Australia magazine. This is a great opportunity for a new Australian advanced manufacturing capability and it is exciting to be a part of it. Recently, I have had the opportunity to be the keynote speaker at the Australian

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Foundry Society (AFS) Conference, held in Brisbane in May. It was a great opportunity to see friends and colleagues from across the foundry industry, and share our common challenges from the past two years. I’m also very pleased that was able to meet with some members of the Queensland branch of Materials Australia and catch up with them in person. Recently, I attended the CAMS conference here in Melbourne, which was very high calibre. The organising committee and especially the conference chairs did a fantastic job of coordinating this event after it was delayed multiple times. Special thanks go to Andrew Ang for his commitment to running the event so well. I also have to mention the outstanding effort from the Materials Australia excutive Officer, Tanya Smith, who worked tirelessly on ensuring success. The next CAMS conference is due for 2024 and will be held in Adelaide. Looking to our future activities, we have an outstanding set of conferences planned for 2023 including APICAM and Light Metals Technology, which are expected to run on schedule. With respect to further events through 2022, we are certainly looking to increase opportunities through the second half of the year. We are particularly looking at promoting the branch level events, so please talk to your state representatives, get involved and let’s see what can be done. One of the interesting things I was asked at the recent AFS conference is to whether I would consider presenting a future seminar on how to design a

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cost effective program of research work for a production manufacturing facility and then how to implement any resulting innovation. I have been thinking about this, and although it may seem straight forward, it can be far more complicated than what it first seems. In an industry setting, an innovation cycle may be six months or less, and work must be scheduled to fit in with production. Making sure that the required outcome is properly understood by everyone involved can also be a challenge. However, there is the innovation you plan, and then there is that which happens fortuitously or simply by accident. A lot of it comes about through recognising ways of overcoming challenges where something goes wrong. The discovery of penicillin is a case in point and I would encourage anyone to read the story for themselves. We often don’t tell the whole story of these fortuitous events, and I would really like to hear some of the readers stories about their own. I have had a few of these myself and they make great tales. I believe these good mistakes are something we really should learn to celebrate, as these are probably among the greatest learning experiences we can have and such a great way to understand innovation. The year is flying by again and I would like to wish you, your family and colleagues the best of health and to stay safe through 2022. Best Regards Roger Lumley National President Materials Australia

JUNE 2022 | 3

CONTENTS

Reports From the President

Contents

Corporate Sponsors

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Materials Australia News CAMS2022

WA Branch Technical Meeting - 11 April 2022

Materials Innovations in Process Engineering

WA Branch Technical Meeting - 9 May 2022

WA Branch Meeting Report - 9 June 2022

New Conference Dates | APICAM 2023 | LMT 2023

NSW Branch Report

CMatP Mini Conference

CMatP Profile: Professor Nikki Stanford

Fundamentals of Metallurgy and Additive Manufacturing

Our Certified Materials Professionals (CMatPs)

Why You Should Become a CMatP

MANAGING EDITOR Gloss Creative Media Pty Ltd EDITORIAL COMMITTEE Prof. Ma Qian RMIT University Tanya Smith MATERIALS AUSTRALIA

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PUBLISHER Materials Australia Technical articles are reviewed on the Editor’s behalf PUBLISHED BY Institute of Materials Engineering Australasia Ltd. Trading as Materials Australia ACN: 004 249 183 ABN: 40 004 249 183

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CONTENTS

Industry News Assessing the Quality of Raw and Processed Battery Materials Using the Phenom XL Desktop SEM

Australia Leading the Way in Construction and Building Materials

Making Muscles, Building Brains: Inside the Mind-Blowing World of Biofabrication

Deakin Supports Local Industry to Advance Battery Technology

Hitachi High-Tech Sets a New Pace for Plating and Coatings Analysis with the New FT230

Better Battery Design by Analysis

Boston Micro Fabrication’s Ultra-High Resolution 3D Printers Now Available in Australia through AXT

Materials Science Contribution to Advanced Manufacturing at IMCRC

Super Duplex Can Corrode

University Spotlight - University of Tasmania

Breaking News

Feature Technology-First Approach For Light Metals Innovation

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Materials Australia National Office PO Box 19 Parkville Victoria 3052 Australia T: +61 3 9326 7266 E: imea@materialsaustralia.com.au W: www.materialsaustralia.com.au

NATIONAL PRESIDENT Roger Lumley

55 This magazine is the official journal of Materials Australia and is distributed to members and interested parties throughout Australia and internationally. Materials Australia welcomes editorial contributions from interested parties, however it does not accept responsibility for the content of those contributions, and the views contained therein are not necessarily those of Materials Australia. Materials Australia does not accept responsibility for any claims made by advertisers. All communication should be directed to Materials Australia.

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Advancing Materials and Manufacturing The 7th conference of the Combined Australian Materials Societies; incorporating Materials Australia and the Australian Ceramic Society.

Report | 1st - 3rd June 2022 | The University of Melbourne Australia’s leading materials scientists, engineers, technology trailblazers, and thought leaders recently gathered for the Combined Australian Materials Societies (CAMS) 2022 Conference. The event is Australia’s largest interdisciplinary technical meeting of the year, and featured a wide range of speakers and delegates from around the world. Held at The University of Melbourne from 1 to 3 June, the seventh annual conference brought CAMS, Materials Australia, and the Australian Ceramic Society’s delegates under the same roof to exchange ideas, technology and advances in research. The conference covered a broad range of themes, including additive, advanced and future manufacturing; materials characterisation; surface coatings; biomaterials and nanomaterials for medicine; ceramics, glass and refractories; energy generation, conversion and storage materials; corrosion and wear resistant materials; nanostructured and nanoscale

8 | JUNE 2022

materials; and polymers and composites. CAMS2022 is one of the first major scheduled face-to-face Materials Australia events in 2022 and continued its strong tradition of promoting materials research. The CAMS2022 organising committee maintained a concerted effort to work towards a gender balance with an all-female line up of plenary speakers. The three-day conference started with a plenary session from Professor Amanda Barnard, who is one of Australia’s most experienced computational scientists. Professor Barnard addressed delegates about the inverse design of multi-functional materials. She drew on her experiences from the Centre for Nanoscale Materials at Argonne National Laboratory in the United States, and the University of Oxford. Dr Alex Shekhter also delivered a plenary session address, where she discussed air and space platform technologies, and shared an overview of the future challenges for Australia’s

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defence industry. Dr Shekhter has worked on the certification of modern technologies for military aircraft, and delivered technical risk assessments for advanced materials and technologies. Professor Caroline McMillen drew on her experiences as South Australia’s Chief Scientist, and as the ViceChancellor at the University of Newcastle during her plenary session. Delegates heard Professor McMillen reflect on South Australia’s 10-year plan to grow the economy through a suite of research and development projects, and the advancement of future industries. The keynote speakers at CAMS2022 included: Professor Nikki Stanford (University of South Australia); Dr Andrew Breen (University of Sydney); Professor Baohua Jia (Swinburne University of Technology); Professor Craig Brice (Colorado School of Mines); Professor Cuie Wen (RMIT University); Professor Dong Ruan (Swinburne University of Technology); Dr Judy Hart (UNSW Sydney); Professor George Franks (University of Melbourne); Professor Martin Leary (RMIT);

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10 | JUNE 2022

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Professor Huijun Li (University of Wollongong); Professor Zhenguo Huang (University of Technology Sydney); A/ Professor Bernd Gludovatz (UNSW Sydney); Professor Michael Preuss (Monash University); Professor Rui Yang (Chinese Academy of Science); Professor Yun Liu (Australian National University); Associate Professor Sophie Primig (UNSW Sydney); Dr Vladimir Luzin (ANSTO); and Ms Alex Kingsbury (RMIT University). In addition, a range of local and international speakers were invited to share their industry knowledge about a variety of topics including advanced duplex stainless steels; laser additive manufacturing; and pore-scale modelling in heterogeneous porous materials.

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Together, the CAMS2022 organising committee selected speakers who delivered a series of interactive keynotes, where they drew on their experiences to inspire, motivate and share knowledge with the broader sector. The four-parallel symposia event was rescheduled to ensure a face-to-face meeting was possible. This allowed delegates to attend networking events and awards ceremonies, where they were encouraged to connect with likeminded peers. There were also conference posters, where PhD students and industry academics put their research on full display, answered questions and discussed the future scope of research.

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Special thanks to all the session chairs and student volunteers for helping in organising the breakout sessions. CAMS2022 is a proud supporter of WREN Research Engineers Network (WREN). CAMS2022 would like to acknowledge the organising committee for this event: Dr Andrew Ang; Professor Aijun Huang; Professor Xinhua Wu; Professor George Franks; Dr Michelle DeSilva; Ms Tanya Smith; Professor Gwenaelle Proust; Professor Nikki Stanford; Professor Nick Birbilis; Dr Roger Lumley; Mr Richard Bowman; Dr Robert Acres; and Ms Vesna Stefanovski. CAMS2022 was supported by The University of Melbourne, CSIRO, JEOL and Thermo Fisher.

JUNE 2022 | 11

MATERIALS AUSTRALIA

WA Branch Technical Meeting - 11 April 2022 Western Australian Specialty Alloys Source: Michael Lison-Pick, Operations Manager The Western Australian Branch held a technical meeting in early April. Michael Lison-Pick, Operations Manager at Western Australian Specialty Alloys (WASA) was the guest speaker. WASA produces superalloy ingot, billet and bar for forging and ring rolling applications for a range of aerospace, power generation and oil and gas applications. Established in 1993 and now part of the Precision CastParts Corporation group, WASA is undoubtedly one of the most unusual local manufacturing operations—its material input is almost entirely imported, and its products are almost entirely exported. WASA’s success has been established on its hard-earned capacity to produce more than 100 highly specialised nickelbased alloys, notably for the most demanding aerospace applications. This capacity is confirmed by client accreditation, often based on ‘fixed process’ agreements. In this rarefied part of the world of metals, alloy grades are only the starting point, as individual clients have extremely tight and differing specifications within grade ranges. These limits can be as low as 0.1 ppm maximum limits on certain elements, such as antimony and selenium. Where a specified element content is demanded, the composition limits may be as tight as 10-20 ppm. The fixed process specification, goes beyond composition to ensure that other variables, notably segregation, are also tightly controlled. Michael Lison-Pick and Seach Hwee Goh led visitors on the tour of WASA’s operation, starting with charge formulation for the vacuum induction furnace. Approximately half the charge is ‘revert’ alloy, mostly returned in-process scrap from customers, with remainder being virgin material, mainly nickel. With such tight limits on impurities, segregation of stored raw materials is critical. Michael explained that the slowest part of the operation is charging the furnace, which must be done under vacuum. Up to ten charging pans are prepared, and the rate-controlling step in the melting process – introducing each charge pan under vacuum – means that a typical batch time is around eight hours. The analytical facility is critically important in meeting the composition specification. After each pan is loaded and melted, a sample is analysed using a combination of rapid combustion and x-ray techniques, and the make-up of the next charging pan adjusted accordingly. Wet chemical analysis (ICP-MS) for certification of composition. The vacuum induction melting (VIM) has two product types. ‘Little sticks’ (~6 t, 150-200mm diameter ingots) are sawn into small (less than 10kg) billets for melting by customers, in which case the segregation typical of VIM ingots is irrelevant. ‘Big sticks’ (400-600mm diameter, ~15 t ingots) are used internally as feed to the next processes in line: vacuum arc remelting (VAR) and electro-slag refining (ESR). 12 | JUNE 2022

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(L to R): Seach Hwee Goh, Michael Lison-Pick.

The purpose of vacuum arc remelting (VAR) is to control solidification to the avoid micro-segregation and the formation of laves, sigma and mu phases that cause problems in the forging of nickel superalloys. The VAR process can follow the primary step of vacuum induction melting (VIM) used to produce the alloy (double melting). Vacuum arc remelting can be likened to 'a big DC arc welder in a vacuum', but under highly sophisticated control. A VIM ingot is used as an electrode with an arc struck in the gap between its bottom and a second ingot underneath, which continues to grow as the upper ingot is melted drip-wise through the 10mm vacuum space above it. The remelted ingot typically has a diameter around 50mm larger than that of the original ingot. Ingots destined for forging into rotating machinery parts, such as turbine shafts, require the extra step of ‘triple melting’ in which the VAR ingot is re-processed with ESR. The ESR process can be likened to submerged arc welding, in which droplets of molten alloy fall through a specifically formulated calcium fluoride-based flux pool on top of the growing remelted ingot underneath. This alloys even greater control over impurities. It was interesting to see the changes since the WA branch’s last visit to the WASA operation some years ago. The OPTIMAT system is used for management raw materials and charge control, greater use is made of nickel-based master alloys for additional of minor elements, the VAR and ESR processes are subject to more sophisticated control, and laser surface cleaning is now applied to ingots. One of the most dramatic recent impacts has been the rise in the nickel price, with full VIM charge currently worth around $0.25 million. These changes show that while there are advantages in incumbency, constant innovation is essential to ‘stay in the game’. WWW.MATERIALSAUSTRALIA.COM.AU

21 JULY 2022

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MATERIALS AUSTRALIA

WA Branch Technical Meeting - 9 May 2022 Insulated Panels – Build a Better Way Source: Alex Dennis, National Business Development Manager, Kingspan Alex Dennis (National Business Development Manager, Kingspan) presented at the May Western Australia Branch meeting. Alex has had 15 years’ experience in the building supplies sector. Most recently, he has spent ten years with Kingspan, first in the UK, with the last six in Australia. Alex is responsible for running national business development from his Perth office. The focus of his talk was the use of Kingspan’s steel and foamed polymer composite panels as construction materials, together with its façade systems that can be used to meet varied architectural appearance requirements. Kingspan is headquartered in Ireland, where it was established in 1963. It now operates in more than 70 countries with nearly 200 manufacturing facilities, including one in Sydney. The company describes itself as the global leader in high-performance insulation and building envelope solutions. Its mission is driven by a vision of a netzero emission future through greater thermal efficiency. Nearly two-thirds of Kingspan’s business is in the supply of composite insulated panel. These panels are most widely used in construction of cold stores and industrial buildings, and not only because of their insulating qualities. The panels have a structural function, allowing reduction underlying building structure. Their availability in lengths up to 17m, with up to 1m width, together with fixing from the inside, allows rapid construction, often without the need for cranes. They offer a particular benefit in that a building can be made watertight at an early stage of construction. Alex illustrated this with pictures of a selection of extremely large industrial buildings, including time-lapse photographs of construction. The panels, manufactured in Sydney, consist of two steel skins, typically 0.4 and 0.5mm thick, sandwiching polyisocyanurate (PIR) foam, with

14 | JUNE 2022

(L to R): Alex Dennis, Dr Steve Algie.

thicknesses in the range 50 to 140mm. In the continuous panel production process, coiled steel sheet is roll-formed to the specified profile (such as ribbed) and the PIR is applied in liquid form. The PIR expands as a solidifying and highly adhesive foam as a second rollprofiled sheet is laid on top. Panels are cut to specified length as the composite structure emerges from the line. Alex summarised the thermal performance of the panels, with a focus on how fire rating is specified and measured. While PIR composite panels do not support combustion, they cannot be described as noncombustible, because they do undergo mass loss when held at the specified 750°C. This means that while they can be used in many applications, there are some for which mineral insulation is needed in place of the PIR to meet code requirements. Kingspan also supplies the mineral-insulated alternative, but its needs to be around twice as thick, and more than twice the mass, to provide the same thermal insulation. Alex stressed that the use structural insulated panels should be decided early in the design process as it the greatest benefits come when it is

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integrated with the HVAC and structural design. Its structural properties also allow economies in façade design, as the façade can be fixed to the panel rather than being designed as an independent structure. He summarised the design considerations of using Kingspan’s ‘Rainscreen’ façade system with its structural panels. Wind loading is a key consideration and the system, which has a number of variants is designed using FEA and proved using an air-bag loading test. One of the examples that Alex gave of such integrated design is the recently completed NextDC data centre that most of the audience had driven past on the way to meeting. Alex concluded his talk with the use of Kingspan panels and façades in the high-profile Western Australia Museum Boola Bardip redevelopment. In this case, the huge cantilevered upper floors, which are an outstanding architectural feature, dictated a very light façade design, as well as one that met the challenging demand for the aesthetic aspect. His extensive photographic record of construction was much appreciated, as were his responses to countless questions.

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palladium catalysts

janus particles

glassy carbon

nickel foam

thin film 1

surface functionalized nanoparticles

organometallics

1.00794

Hydrogen

zeolites 11

anode

2 1

99.999% ruthenium spheres

6.941

2 8 8 1

2 8 18 8 1

22.98976928

24.305

Sodium

osmium

Mg Magnesium

MOFs ZnS

Rb Cs

2 8 18 18 8 1

(223)

2 8 18 9 2

44.955912

2 8 18 18 8 2

Francium

(226)

Ac (227)

Radium

50.9415

Vanadium

91.224

2 8 18 18 9 2

138.90547

2 8 18 10 2

104

Rf (267)

2 8 18 32 10 2

140.116

Th 232.03806

2 8 18 32 32 10 2

2 8 18 21 8 2

Praseodymium 2 8 18 32 18 10 2

Thorium

Pa 231.03588

2 8 18 32 20 9 2

Protactinium

transparent ceramics EuFOD

spintronics

105

Db (268)

optical glass

2 8 18 32 11 2

2 8 14 2

2 8 18 15 1

2 8 15 2

2 8 18 16 1

2 8 18 32 12 2

106

2 8 16 2

2 8 18 18

Sg (271)

Ru 101.07

2 8 18 32 13 2

186.207

107

Bh (272)

Seaborgium

2 8 18 1

2 8 18 18 1

102.9055

2 8 18 32 14 2

190.23

108

Hs (270)

Bohrium

106.42

2 8 18 32 15 2

Mt (276)

Hassium

2 8 18 23 8 2

(145)

Np (237)

Neptunium

150.36

Promethium 2 8 18 32 21 9 2

2 8 18 24 8 2

195.084

2 8 18 32 32 15 2

110

Ds (281)

151.964

Samarium

2 8 18 32 22 9 2

2 8 18 27 8 2

158.92535

Gadolinium 2 8 18 32 25 8 2

2 8 18 32 32 17 1

Rg (280)

Roentgenium

112

(244)

(243)

(247)

Americium

Curium

(247)

Berkelium

rhodium sponge

2 8 18 18 3

2 8 18 32 18 2

(285)

Nh (284)

2 8 18 4

2 8 18 18 4

Sn Pb

Fl (289)

Nihonium

2 8 18 32 18 4

Mc (288)

Flerovium

2 8 18 28 8 2

2 8 18 29 8 2

164.93032

Er 167.259

Holmium 2 8 18 32 28 8 2

(251)

Californium

(252)

100

(257)

Fermium

2 8 18 31 8 2

2 8 18 32 30 8 2

101

Md (258)

laser crystals

2 8 18 32 32 18 5

116

102

No (259)

Mendelevium

Lv (293)

2 8 18 32 32 8 2

103

pharmacoanalysis

(262)

Br I

2 8 18 32 18 6

117

2 8 18 32 32 18 7

118

calcium wires

(294)

(222)

Lawrencium

process synthesis

(294)

Oganesson

2 8 18 32 32 18 8

InGaAs AuNPs

superconductors

chalcogenides excipients CVD precursors deposition slugs YBCO

refractory metals metamaterials Fe3O4

shift reagents

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platinum ink

cisplatin

2 8 18 32 18 8

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fluorescent microparticles

cermet

2 8 18 18 8

Xenon

Tennessine

2 8 18 32 9 2

2 8 18 32 32 8 3

2 8 18 8

131.293

(210)

2 8 18 32 32 18 6

Nd:YAG

83.798

cryo-electron microscopy

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2 8 18 32 18 7

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Krypton

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ferrofluid dielectrics

Iodine

174.9668

2 8 18 18 7

39.948

Argon

126.90447

Lutetium

Nobelium

79.904

Livermorium

2 8 18 32 8 2

2 8 18 7

Bromine

(209)

Ytterbium 2 8 18 32 31 8 2

Polonium

173.054

Thulium

2 8 18 18 6

Neon

35.453

ITO

20.1797

2 8 7

Chlorine

127.6

Moscovium

168.93421

Erbium 2 8 18 32 29 8 2

Einsteinium

2 8 18 30 8 2

Tellurium

silver nanoparticles

2 8 18 6

78.96

208.9804

115

32.065

Bismuth 2 8 18 32 32 18 4

2 8 6

Selenium

2 8 18 32 18 5

2 8

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graphene oxide

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2 8 18 18 5

Fluorine

Sulfur

121.76

207.2

114

2 7

18.9984032

Antimony

Lead 2 8 18 32 32 18 3

2 8 18 5

74.9216

Tin

Arsenic

118.71

2 8 18 32 18 3

2 8 5

30.973762

72.64

15.9994

Phosphorus

Oxygen

Germanium

204.3833

113

28.0855

Thallium 2 8 18 32 32 18 2

2 8 4

2 6

14.0067

Silicon

114.818

Pu Am Cm Bk Cf Es Fm enantioselective catalysts Plutonium

Nitrogen

Indium

Copernicium

Dysprosium 2 8 18 32 27 8 2

200.59

2 8 18 32 32 18 1

2 8 18 3

69.723

Mercury

162.5

Terbium

2 8 18 32 25 9 2

111

112.411

2 8 18 32 18 1

Gallium

Gold

Darmstadtium

157.25

Europium 2 8 18 32 24 8 2

2 8 18 25 9 2

2 8 18 18 2

Cadmium

196.966569

Platinum

Meitnerium

2 8 18 25 8 2

Zinc

Silver

2 8 3

26.9815386

2 8 18 2

65.38

107.8682

2 8 18 32 17 1

192.217

109

Palladium

macromolecules 61

12.0107

Carbon

Aluminum

Copper

Iridium 2 8 18 32 32 14 2

63.546

Nickel

Rhodium

Osmium 2 8 18 32 32 13 2

58.6934

Cobalt

Ruthenium

Rhenium 2 8 18 32 32 12 2

58.933195

Iron

(98.0)

183.84

2 8 18 32 32 11 2

55.845

Technetium

Tungsten

144.242

2 5

Now Invent.

indicator dyes

tungsten carbide

Nd Pm Sm

Uranium

2 8 18 13 2

54.938045

95.96

2 8 18 22 8 2

238.02891

Manganese

Molybdenum

Neodymium 92

51.9961

Chromium

Dubnium

2 8 18 13 1

2 8 13 2

Helium

2 4

sputtering targets

MOCVD

rare earth metals

mesoporous silica MBE

2 8 13 1

ultralight aerospace alloys

180.9488

140.90765

Cerium 90

quantum dots

2 8 18 12 1

Tantalum

Rutherfordium

2 8 18 19 9 2

92.90638

178.48

2 8 18 32 18 9 2

2 8 11 2

Niobium

epitaxial crystal growth drug discovery

Hafnium

Actinium

Zirconium

Lanthanum 2 8 18 32 18 8 2

47.867

Yttrium

137.327

2 8 10 2

Titanium

88.90585

Barium 2 8 18 32 18 8 1

2 8 9 2

Scandium

87.62

Cesium

Strontium

132.9054

2 8 18 8 2

40.078

85.4678

Calcium

Rubidium

3D graphene foam

nanodispersions

2 8 8 2

metal carbenes

Boron

2 8 2

isotopes

39.0983

Potassium

nanogels

4.002602

2 3

10.811

Beryllium 2 8 1

gold nanoparticles

bioactive compounds

9.012182

Lithium

2 2

buckyballs

III-IV semiconductors

screening chemicals

alternative energy

diamond micropowder

Now Invent!

metallocenes BINAP

conjugated nanostructures

MATERIALS AUSTRALIA

WA Branch Meeting Report - 9 June 2022 Solar Glass – A Renewable Energy Resource Source: Victor Rosenberg, Executive Chairman, and Dr Mikail Vasliev, Lead Scientist, ClearVue PV Ltd even quadruple glazed configurations without affecting their PV performance. Not surprisingly, the company sees its future in these overseas markets rather than in Australia.

L to R: Dr Steve Algie, Dr Mikail Vasiliev, Victor Rosenberg.

ClearVue PV has vision of a world where nearly all building surfaces become solar photovoltaic (PV) collection sources, and a key part of the response to the climate crisis. The company has developed a range of high-transparency window and glazed façade products that operate as solar PV generators, producing 30-40 watts per square metre. The feature that differentiates the product from those of competitors is that this performance is achieved while maintaining 70% transparency to visible light, with high clarity – the clear glass does not have any visible energy-collecting elements. This is an important aesthetic and practical advantage. The economic selling point for the technology is the combination of green energy production and energy saving. In Europe and North America, there are already strong motivations to reduce the greenhouse gas footprint of buildings, in the form of both incentives and very substantial financial penalties for failing to do so. These penalties are already in place and are legislated to increase progressively over the next decade. Already, there are many major potential markets where the combination of incentives and penalties are more than sufficient to offset the higher cost of ClearVue glass. In these markets it is effectively a lower cost option than ordinary glass. In many climates, the cost-benefit case can be further increased since the panels can be combined in double or 16 | JUNE 2022

The way the product works is easiest understood by describing how it is made. Microscopically small particles of photoluminescent compounds are embedded in a plastic film, which is used to laminate two sheets of clear glass (as in a laminated windscreen). When infrared and ultraviolet radiation strike the particles, they luminesce to produce light of wavelengths that can be absorbed by solar silicon PV collectors to generate PV electricity. The particles only absorb around 30 percent of visible light, so the panel appears to be clear glass. The luminescence generated by the particles in the film is channelled by total internal reflection towards the edge of the glass panel; Mikail Vasiliev characterised the composite pane as a leaky photonic waveguide. Small silicon collectors are arranged in a complex array around the edges of the glass, concealed within the frame, and connected so as to allow the panel to, in effect, plug-in, as a PV module. The multiple small silicon collectors provide the collecting area sufficient to absorb the energy collected over the exposed glass surface. The addition of clear glass panels either side of the luminescent composite panel allows it to be encapsulated in a multiple-glazed configuration, reducing heat transfer through the glass panel module while not affecting its generating capacity. Compared to ordinary rooftop solar PV, the ClearVue PV glass has around 10 percent generation capacity per unit area. However, its efficiency does not depend on exposure to direct sunlight. It generates in shade and retains 30 percent of peak efficiency on a wet cloudy day. Moreover, multistorey buildings have a far higher proportion of window area than rooftop area. Victor Rosenberg summarised events that had led to the invention BACK TO CONTENTS

of ClearVue PV glass. His career had taken him from pharmacy, through pharmaceutical manufacturing, to having led multiple start-up businesses in the pharmaceutical and packaging industries. This had given him a keen understanding of both the importance of sustainability and of the potential that can be realised from doing things differently. He explained that while ClearVue glass is certainly a new invention, it does not depend on new science. Instead, it combines a number of established technologies into a new form. Victor came up with the idea for the product, and started working with Mikail at Edith Cowan University in 2011. Mikail’s role centres on applying his expertise in photonics to optimise performance. Technical challenges dealt with in a decade of development include transparency, colouration of the glass, haze caused by the dispersion of luminescent particles, and conversion efficiency. The company now has a staff of 13. Its first building-scale installations are in in Perth, a glasshouse at Murdoch University and the atrium at Warwick Shopping Centre. A major office installation. Window-scale installations have already been made in China, where the windows are currently manufactured, and adoption of the technology for a new office building in Japan is projected. As these installations indicate, the windows are already manufactured in floor-to ceiling size, with panels up to 3.2m × 2m. Victor showed a number of economic and engineering studies that have guided the development of a suite of products based on the concept and have served to identify the target markets. He acknowledged that there are competing systems, but also provided figures for the vast areas of glass that are constantly being installed in buildings, and the rate of growth in demand, which few in the audience would have known. WWW.MATERIALSAUSTRALIA.COM.AU

CONFERENCE DATES

APICAM2023 Asia-Pacific International Conference on Additive Manufacturing

21 - 23 June 2023 University of Sydney, Australia The 3rd Asia-Pacific International Conference on Additive Manufacturing (APICAM) is the not-to-be-missed industry conference of 2023. APICAM was created to provide an opportunity for industry professionals and thinkers to come together, share knowledge and engage in the type of networking that is vital to the furthering of the additive manufacturing industry. The purpose of this conference is to provide a focused forum for the presentation of advanced research and improved understanding of various aspects of additive manufacturing. This conference will include lectures from invited internationally distinguished researchers, contributed presentations and posters. Contributions will be encouraged in the following areas of interest: Additive Manufacturing of Metals Additive Manufacturing of Polymers Additive Manufacturing of Concretes Advanced Characterisation Techniques and Feedstocks Computational Modelling of Thermal Processes for Metallic Parts Part Design for Additive Manufacturing Failure Mechanisms and Analysis Mechanical Properties of Additively Manufactured Materials New Frontiers in Additive Manufacturing

The Light Metals Technology (LMT) Conference is a biennial event that focuses on recent advances in science and technologies associated with the development and manufacture of aluminium, magnesium and titanium alloys and their translation into commercial products. The conference presents an opportunity for academic researchers, students and industry to discuss cutting edge developments and to facilitate new collaborations.

CALL FOR ABSTRACTS

You are invited to submit abstracts on topics within the themes of Net Shape Manufacturing, Solid State Transformations and Mechanical Performance, and Translation to Applications. For example, but not limited to: > Alloy development > Solidification and casting > Thermomechanical processing and forming > Machining and subtractive processes > Mechanical behaviour of light metal alloys > Corrosion and surface modification > Advanced characterisation techniques > Joining > Applications in bio-medical, automotive, aerospace, and energy industries > Simulation and modelling > Integrated computational materials engineering

Process Parameter and Defect Control Process-Microstructure-Property Relationships Testing and Qualification in Additive Manufacturing

www.apicam2022.com.au

www.lmt2023.com

Opportunities for sponsorships and exhibitions are available for both APICAM2022 and LMT2023. Enquiries: Tanya Smith | Materials Australia +61 3 9326 7266 | imea@materialsaustralia.com.au

MATERIALS AUSTRALIA

NSW Branch Report

Two New Members Join Our Committee Source: Rachel White

The New South Wales Branch would like to introduce two new members to our committee: Dr Yi-Sheng (Eason) Chen and Alan Todhunter. Dr Yi-Sheng (Eason) Chen CMatP is a Research Fellow in the Australian Centre for Microscopy and Microanalysis at the University of Sydney. Dr Chen’s research focuses on hydrogen energy materials and related materials characterisations via advanced microscopy techniques, particularly atom probe tomography and in-situ micromechanics. He completed his PhD in Materials in 2018 at the University of Oxford, in the United Kingdom, before moving to Australia. He served in a consulting business for three years before starting his research career. He received Masters (2009)

Dr Yi-Sheng (Eason) Chen

and Bachelors (2007) in Materials Science both from National Tsing Hua University, Taiwan. Dr Chen has received funding support valued at over $5 million from the Australian Research Council, the University of Sydney, the Ministry of Education of Taiwan, and industry. He is a proud Taiwanese immigrant and a father of two lovely girls. Alan Todhunter CMatP is an academic in the School of Engineering, Built Environment and Design at Western Sydney University. He teaches in Sustainable Construction Materials, Building Science and Construction Practice and supervises honours and masters students. Alan has an honours degree in Materials Science and Masters in Science from the University of Technology, Sydney. Alan’s areas of research include the durability and sustainability of construction materials, research for industry into flammability of cladding materials, circular economy and recycling of construction and demolition waste, and applications of biomimicry in energy efficiency of the built environment. Alan has a strong connection with industry. He is a recognised construction materials expert, having completed over 200 consultancy projects including as a materials consultant with BCRC Pty Ltd and Aurecon in relation to material performance and durability. Alan is a member of

CMatP

the Australian Institute of Building, a Certified Materials Professional and a Fellow of the Higher Education Academy. Our first event of the year is coming up in August, a metallurgy course run by committee members. Information for people interested in registering will be made available soon. With a number of new CMatPs in New South Wales, our branch CMatP miniconference will be held in September. In October, the UNSW MATSOC will be hosting a careers event supported by Materials Australia New South Wales Branch and the Australian Ceramic Society. Our final event of the year is in November when we will host our ever-popular student presentations event. Keep an eye out for our upcoming New South Wales branch newsletter.

Alan Todhunter

Our NSW Branch is holding its popular CMatP Mini-Conference again in September 2022. More information and booking details coming your way soon!

MINI-CONFERENCE R E G I S T E R YO U R I N T E R E S T

18 | JUNE 2022

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WWW.MATERIALSAUSTRALIA.COM.AU

w w w .sydney. edu.a u/m edicine -he alth/sc hools/school -of- me dical-sc ienc es/wom e n-in-stem m w o r kshop.html

A workshop designed for ECR women aimed at strengthening the scientific writing and critical thinking skills of Australia’s next generation of scientists and academics in STEM M. This workshop will provide an opportunity for ECRs to build on their scientific writing skills and gain inspiration from mentors and like-minded researchers, forming a valuable component of their academic career development.

APPLICATIONS CLOSE 11:55 PM 31st August NOTIFIED by 5th September ~ FREE REGISTRATION ~

Supported by

With an excellent faculty of mentors • • • • • • •

Professor Chennupati Jagadish ANU Professor Lan Fu ANU Professor Julie Cairney USYD Professor Joanne Tipper UTS Professor Elizabeth New USYD Professor Igor Aharonovich UTS And more!

MATERIALS AUSTRALIA

CMatP Profile: Professor Nikki Stanford external influence on my professional career has been the environmental challenges that face us. I find it hard to justify the expense and effort of large research programs if they aren’t focussed on meeting our environmental targets, or something equally as important. I think this pragmatic view, that real-world outcomes should trump less applied research endeavours, has had an enduring effect on the research projects that I get excited about, and also those that I don’t.

Which has been the most challenging job/ project you’ve worked on to date and why? Where do you work and describe your job. I work at the University of South Australia. I’m an academic, and do both teaching and research. I teach the first year materials engineering course— that’s the best part of my job. I love it. I have several PhD students that I supervise, an aspect of my job that is both challenging and rewarding. I also manage all of our Institute’s advanced characterisation equipment, which includes all things materials scientists love: electron microscopes, x-ray machines, that kind of thing.

What inspired you to choose a career in materials science and engineering? I was looking for a job in research or science, but didn’t really have a passion for the traditional disciplines of chemistry or physics. I like the applied nature of materials, the real life applications, so that’s why I ended up where I am. As time transpired, I realised that what I really like about it is the multi-disciplinary nature of materials research—there’s always something new and different to look into.

Who or what has influenced you most professionally? I think the whole field of advance characterisation, particularly microscopy, was the most influential factor for my early career. In more recent years, I’ve moved away from an interest in academic research, and prefer to work on applied projects with tangible outcomes. I think the biggest 20 | JUNE 2022

Scientifically the most difficult thing I’ve worked on is steel strip casting. The rapid solidification excludes equilibrium phases, so weird precipitates form that have never been reported before. It keeps things interesting, but also makes it hard yakka to get anywhere fast. That work was a good prelude to the strange things we find in additively manufactured steel alloys.

What does being a CMatP mean to you? I enjoy being part of a recognised group, and the people I’ve met through Materials Australia are really nice human beings. The CMatP (hopefully) shows I’m not just an academic—I have useful skills as well.

What gives you the most satisfaction at work? The thing that gives me most satisfaction is helping people. Although, often I’m telling people things they don’t want to hear. Maybe that’s why I like the teaching and mentoring aspects of my job.

What is the best piece of advice you have ever received? Many years ago I worked with a rather inspirational man, Professor Pete Bate at the University of Manchester. Most people were scared of him. He was the kind of guy who would start fights in the pub, and he continued to smoke in his office for decades after the ‘No Smoking’ policy was in place,. Having said all of that, Pete was easily the smartest person I ever worked with. He published finite element crystal BACK TO CONTENTS

plasticity using his own code eight or 10 years before it became recognised. He also wrote software that could simulate the texture from phase transformations. Now that he’s retired, I don’t think that capability exists anywhere in the world. One day at the pub he said to me,“If it ain’t been published, it ain’t been done”. It’s a very Mancunian way of telling someone that if you do something in the lab, and don’t tell everyone what you found by analysing the data and publishing it, you’ve wasted your time and resources. It also points to the adage, finish what you started.

What are you optimistic about? My next holiday

What have been your greatest professional and personal achievements? Professionally, I’m proud to have received an international award—that was nice recognition. Having a few well cited papers is nice too. I guess they’re like my research ‘street cred’. I think the work I did with the South Australian Health department during the pandemic will probably be a highlight. It was a time of such stress for everyone, and we were getting phone calls and requests almost daily for the first few months for a whole range of tests, advice, options … it was a wild ride! Now we’ve turned that opportunity into a NATA certified surgical mask testing lab, so that’s a nice outcome. From a personal perspective, I volunteered with the SES for about five years, and went to about 100 emergency events. I don’t think I’m strong enough to hold the jaws-of-life anymore—those things are heavy! Incidentally, they also suffer low cycle fatigue and I’m itching to get the chance to work on it. I think the problem is eminently solvable! Apart from that, my other personal achievement is being able to make a mean cocktail.

What are the top three things on your “bucket list”? Get out of academia before I die. Take a year-long road trip around Australia. Get a salt water aquarium with live coral. WWW.MATERIALSAUSTRALIA.COM.AU

FUNDAMENTALS OF METALLURGY AND ADDITIVE MANUFACTURING NSW BRANCH TRAINING WORKSHOP - ONLINE- 17-19 AUGUST 2022 | DAY 1 2:00PM-6:00PM | DAY 2 2:00PM-6:00PM | DAY 3 9:00AM-6:30PM AEST | Metals and alloys are used in the greatest variety of applications of all engineering materials. As such it is essential for those involved in manufacturing, engineering, and construction to have an understanding of what metals (ferrous and nonferrous) are, how they behave, and why they behave differently than ceramics, glass, and plastics. It is also important to understand how they can be made stronger, how they can be shaped by casting, forging, forming, and how these processes along with heat treatment can alter properties. This course provides important basic knowledge to those who are not metallurgists.

TOPICS Topics may include: • Introduction to Metals and Alloys • Solidification of Metals • Metal Forming • Mechanical Properties • Strengthening Mechanisms • Failure Analysis • Heat Treatment • Strengthening Steels & Cast Iron • Materials Characterization

LEARNING OBJECTIVES

WHO SHOULD ATTEND?

Upon completion of this course, you should be able to: • Describe how metals and alloys are formed and why • Recognise how metals can be strengthened by alloying, cold-working, and heat treatment • Determine why metals and alloys are not behaving as expected and can be made to behave as needed • Choose what metal or alloy to use for its specific combinations of properties • Comprehend the most common metal additive manufacturing methods

• Metal Processing Personnel • Engineers who need to gain a better understanding of metals and alloys. • QA Managers • Heat Treating Operators & Managers • Component Designers • Technicians • Marketing, Technical Writers, Purchasers and individuals without a materials background who wish to better understand the role of materials science

PROGRAM DAY 1 2:00pm

Introduction, Solidification

4:00pm

Tea break

4:30pm

Crystal Defects

DAY 2 2:00pm

Mechanical Properties, Strengthening

3:30pm

Tea break

4:00pm

Steel, Cast Iron

5:00pm

Wire arc additive manufacturing

PRESENTERS

REGISTRATION

DAY 3

Prof. Madeleine du Toit, CMatP Professor – Welding Engineering Research Group Discipline Advisor – Materials Engineering University of Wollongong

MEMBER $660 INCL GST

9:00am

Joining, Corrosion, Failure

11:00am

Morning tea

11:30am

Forming

1:00pm

Lunch break

2:00pm

Heat Treatment, Materials Selection

4:00pm

Afternoon tea

4:30pm

Laser/electron beam additive manufacturing

5:30pm

Q & A, Feedback, Certificates

Prof. Huijun Li, CMatP School of Mechanical, Materials & Mechatronic Engineering University of Wollongong Dr. Nima Haghdadi School of Materials Science & Engineering UNSW Sydney

NON MEMBER $880 INCL GST STUDENT $550 INCL GST

FOR MORE INFORMATION www.materialsaustralia.com.au BOOKING PAGE

www.materialsaustralia.com.au/event/ fundamentals-of-metallurgy-and-additive-manufacturing

CLICK HERE TO REGISTER

e: imea@materialsaustralia.com.au w: www.materialsaustralia.com.au t: +61 3 9326 7266 The Institute of Materials Engineering Australasia Ltd ABN 40 004 249 183

MATERIALS AUSTRALIA

Our Certified Materials Professionals (CMatPs) The following members of Materials Australia have been certified by the Certification Panel of Materials Australia as Certified Materials Professionals.

A/Prof Alexey Glushenkov ACT Dr Syed Islam ACT Prof Yun Liu ACT Dr Karthika Prasad ACT Dr Takuya Tsuzuki ACT Dr Olga Zinovieva ACT Prof Klaus-Dieter Liss CHINA Mr Debdutta Mallik MALAYSIA Prof Valerie Linton NEW ZEALAND Ms Maree Anast NSW Ms Megan Blamires NSW Dr Phillip Carter NSW Dr Anna Ceguerra NSW Mr Ken Chau NSW Dr. Igor Chaves NSW Dr Yi-Sheng (Eason) Chen NSW Dr Zhenxiang Cheng NSW Dr Evan Copland NSW Mr Peter Crick NSW Prof Madeleine Du Toit NSW Dr Azdiar Gazder NSW Prof Michael Ferry NSW Dr Yixiang Gan NSW Mr Michele Gimona NSW Dr Bernd Gludovatz NSW Mr Buluc Guner NSW Dr Ali Hadigheh NSW Dr Alan Hellier NSW Prof Mark Hoffman NSW Mr Simon Krismer NSW Prof Jamie Kruzic NSW Prof Huijun Li NSW Dr Yanan Li NSW Mr Rodney Mackay-Sim NSW Dr Matthew Mansell NSW Dr Warren McKenzie NSW Mr Arya Mirsepasi NSW

Dr David Mitchell NSW Mr Sam Moricca NSW Dr Anna Paradowska NSW Prof Elena Pereloma NSW A/Prof Sophie Primig NSW Dr Gwenaelle Proust NSW Prof. Jamie Quinton NSW Mr Waldemar Radomski NSW Mr Ehsan Rahafrouz NSW Dr Mark Reid NSW Prof Simon Ringer NSW Dr Richard Roest NSW Mr Sameer Sameen NSW Dr Luming Shen NSW Mr Sasanka Sinha NSW Mr Frank Soto NSW Mr Michael Stefulj NSW Mr Carl Strautins NSW Mr Alan Todhunter NSW Ms Judy Turnbull NSW Mr Jeremy Unsworth NSW Dr Philip Walls NSW Dr Rachel White NSW Dr Alan Whittle NSW Dr Richard Wuhrer NSW Mr Deniz Yalniz NSW Mr Michael Chan QLD Prof Richard Clegg QLD Mr Andrew Dark QLD Dr Ian Dover QLD Mr Oscar Duyvestyn QLD Mr John Edgley QLD Dr Jayantha Epaarachchi QLD Dr Jeff Gates QLD Mr Payam Ghafoori QLD Dr David Harrison QLD Miss Mozhgan Kermajani QLD Dr Andrii Kostryzhev QLD Mr Jeezreel Malacad QLD Dr Jason Nairn QLD Mr Sadiq Nawaz QLD Mr Bhavin Panchal QLD Mr Bob Samuels QLD Dr Mathias Aakyiir SA Mr Ashley Bell SA Ms Ingrid Brundin SA Mr Neville Cornish SA A/Prof Colin Hall SA Mr Nikolas Hildebrand SA Mr Mikael Johansson SA Mr Rahim Kurji SA Mr Greg Moore SA Mr Andrew Sales SA Dr Thomas Schläfer SA Dr Christiane Schulz SA Prof Nikki Stanford SA Prof Youhong Tang SA Mr Kok Toong Leong SINGAPORE Mr Madhusudhanan Jambunathan UK Mr Devadoss Suresh Kumar UAE Dr Shahabuddin Ahmmad VIC Dr Ivan Cole VIC Dr John Cookson VIC Miss Ana Celine Del Rosario VIC Dr Yvonne Durandet VIC Dr Mark Easton VIC

22 | JUNE 2022

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They can now use the post nominal ‘CMatP‘ after their name. These individuals have demonstrated the required level of qualification and experience to obtain this status. They are also required to regularly maintain their professional standing through ongoing education and commitment to the materials community. We now have over one hundred Certified Materials Professionals, who are being called upon to lead activities within Materials Australia. These activities include heading special interest group networks, representation on Standards Australia Committees, and representing Materials Australia at international conferences and society meetings. To become a CMatP visit our website:

www.materialsaustralia.com.au

Dr Rajiv Edavan Dr Peter Ford Mrs Liz Goodall Mr Bruce Ham Ms Edith Hamilton Dr Shu Huang Mr Long Huynh Mr. Daniel Lim Dr Amita Iyer Mr Robert Le Hunt Dr Michael Lo Dr Thomas Ludwig Dr Roger Lumley Mr Michael Mansfield Dr Gary Martin Dr Siao Ming (Andrew) Ang Dr Eustathios Petinakis Dr Leon Prentice Dr Dong Qiu Mr John Rea Mr Steve Rockey Miss Reyhaneh Sahraeian Dr Christine Scala Mr Khan Sharp Dr Vadim Shterner Dr Antonella Sola Mr Mark Stephens Dr Graham Sussex Dr Jenna Tong Dr Kishore Venkatesan Mr Pranay Wadyalkar Mr John Watson Dr Wei Xu Dr Ramdayal Yadav Dr Sam Yang Dr. Matthew Young Mr. Mohsen Sabbagh Alvani Mr Graeme Brown Mr Graham Carlisle Mr John Carroll Mr Sridharan Chandran Mr Conrad Classen Mr Chris Cobain Ms Jessica Down Mr Jeff Dunning Dr Olubayode Ero-Phillips Mr Stuart Folkard Prof Vladimir Golovanevskiy Mr Chris Grant Dr Cathy Hewett Mr Paul Howard Dr Paul Huggett Mr Ehsan Karaji Mr Biju Kurian Pottayil Mr Mathieu Lancien Mr Michael Lison-Pick Mr Ben Miller Dr Evelyn Ng Mr Deny Nugraha Mr Stephen Oswald Mrs Mary Louise Petrick Mr Johann Petrick Mr Stephen Rennie

Mr James Travers

VIC VIC VIC VIC VIC VIC VIC VIC VIC VIC VIC VIC VIC VIC VIC VIC VIC VIC VIC VIC VIC VIC VIC VIC VIC VIC VIC VIC VIC VIC VIC VIC VIC VIC VIC VIC WA WA WA WA WA WA WA WA WA WA WA WA WA WA WA WA WA WA WA WA WA WA WA WA WA WA WA

WWW.MATERIALSAUSTRALIA.COM.AU

MATERIALS AUSTRALIA

Why You Should Become a Certified Materials Professional Source: Materials Australia Accreditation as a Certified Materials Professional (CMatP) gives you recognition, not only amongst your peers, but within the materials engineering industry at large. You will be recognised as a materials scientist who maintains professional integrity, keeps up to date with developments in technology, and strives for continued personal development. The CMatP, like a Certified Practicing Accountant or CPA, is promoted globally as the recognised standard for professionals working in the field of materials science. There are now well over one hundred CMatPs who lead activities within Materials Australia. These activities include heading special interest group networks, representation on Standards Australia Committees, and representing Materials Australia at international conferences and society meetings.

Benefits of Becoming a CMatP • A Certificate of Membership, often presented by the State Chapter, together with a unique Materials Australia badge. • Access to exclusive CMatP resources and website content. • The opportunity to attend CMatP only

networking meetings. • Promotion through Materials Australia magazine, website, social media and other public channels. • A Certified Materials Professional can use the post nominal CMatP. • Materials Australia will actively promote the CMatP status to the community and employers and internationally, through our partner organisations. • A CMatP may be requested to represent Materials Australia throughout Australia and overseas, with Government, media and other important activities.

standards. They are recognised as demonstrating excellence, and possessing special knowledge in the practice of materials science and engineering, through their profession or workplace. A CMatP is prepared to share their knowledge and skills in the interest of others, and promote excellence and innovation in all their professional endeavours.

The Criteria

• Networking directly with other CMatPs who have recognised levels of qualifications and experience.

The criteria for recognition as a CMatP are structured around the applicant demonstrating substantial and sustained practice in a field of materials science and engineering. The criteria are measured by qualifications, years of employment and relevant experience, as evidenced by the applicant’s CV or submitted documentation.

• The opportunity to assume leadership roles in Special Interest Networks, to assist in the facilitation of new knowledge amongst peers and members.

Certification will be retained as long as there is evidence of continuing professional development and adherence to the Code of Ethics and Professional behaviour.

What is a Certified Materials Professional?

Further Information

• A CMatP may be offered an opportunity as a mentor for student members.

A Certified Materials Professional is a person to whom Materials Australia has issued a certificate declaring they have attained all required professional

Contact Materials Australia today: on +61 3 9326 7266 or

imea@materialsaustralia.com.au or visit our website:

www.materialsaustralia.com.au

GLOBAL STEEL HEAT TREATMENT

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JUNE 2022 | 23

INDUSTRY NEWS

Assessing the Quality of Raw and Processed Battery Materials Using the Phenom XL Desktop SEM Source: ATA Scientific Pty Ltd With the need to improve the performance, capacity and stability of lithium batteries, the quality of the raw and processed materials used to manufacture electrodes is pivotal. Consisting mainly of lithium metal oxide, graphite, silicon, and sulfurbased particles, material quality is critical to the performance of the final battery. The ability to quickly analyse components to obtain high-resolution size and morphology data of submicron particles allows performance to be optimised while also preventing any quality control issues that may jeopardise the final battery during manufacture.

The Thermo Scientific Phenom XL Desktop SEM can generate images at 10 nanometer resolution and enables researchers to perform their own analyses in-house with very little training. When combined with the SmartScan tool, users can automatically obtain images from multiple samples to analyse size and morphology, while ParticleMetric Software can provide fully automated particle measurements to confirm the quality of raw and processed materials. With Auto-Scan script, the Phenom XL can automatically test up to 36 samples at the same time, generating more than 200 images in under 30 minutes. The script is easy to use: simply define the number of positions that require analysis, and

Using the Phenom XL Desktop SEM, lithium battery manufacturers can easily detect abnormal regions of cathode electrodes (left) where the area appears more porous and the cathode particles flattened and fractured.

the desired magnification levels at all the positions. Image acquisition can be done unattended overnight, dramatically reducing turnaround times while eliminating repetitive testing work and variation, common with different operators. With the ability to quickly and accurately characterise these samples in-house, users can accelerate the R&D process as they work to design safer, more powerful, and longer lasting lithium-ion batteries.

Discovering Defects During the Manufacturing Process The quality of the cathode electrode surface is also important. Any defects or contamination can cause the final lithium battery to rapidly degrade,

shortening its overall lifespan. By using the Phenom XL Desktop SEM together with 3D reconstruction software, manufacturers can detect the presence of defects and contaminants as well as determine their source. The fully integrated energy dispersive X-ray spectroscopy (EDS) capabilities of the Phenom Desktop SEM, enables elements such as nickel, cobalt, and manganese to be quickly identified, quantified and their location mapped to assess homogeneity, which is critical for the battery’s performance. Together, this information helps manufacturers to detect defects and contamination that may otherwise lead to future performance and safety issues.

Manufacturing the High-Quality Lithium Batteries of the Future Using the Phenom XL Desktop SEM, users can ensure the quality of lithium batteries at every step of the manufacturing process—from the raw materials used to the final components produced – to accelerate innovation and power our future.

Using a Phenom XL Desktop SEM in combination with SmartScan and ParticleMetric Software, lithium battery manufacturers can capture size and morphology data on thousands of submicron particles in minutes.

24 | JUNE 2022

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Reference: van Zyl, W. (2022, May 25). Improving the Quality of Lithium Batteries Using a Desktop SEM. Advancing Materials. https://www. thermofisher.com/blog/materials/lithiumbattery-manufacturing-improved-withdesktop-sem/

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Australia Leading the Way in Construction and Building Materials Source: Sally Wood Australian researchers are at the forefront of materials science innovation.

Together, with their industry counterparts, scientists have been bringing research to life to transform Australia’s renewables and technologyfirst future. Two research projects, from Monash University and UNSW Sydney have been recently published. Together, these breakthroughs will improve a material’s damage tolerance by reducing the use of cement used in construction materials; and offer a design solution to moderate temperatures year-round

Animal Exoskeletons Lead to Advances in Designing Construction Materials Researchers from Monash University recently discovered a design motif derived from the rigid external covering of invertebrates. This research may help to create more damage-tolerant materials for future building and construction projects. The cement industry is one of the largest producers of carbon dioxide. It creates up to 8% of worldwide humanmade emissions of this gas. But this research from Monash University will assist in reducing the use of cement by improving the material’s damage tolerance. Professor Wenhui Duan from the Department of Civil Engineering said the pattern can add a high strength motif to commonly used building materials like composites and cement, and may help in reducing carbon emissions. “We demonstrated the application of this design motif in producing a high strength, damage tolerant lightweight cement material,” he said. In addition, this design motif can also be applied to various materials like ceramic, glass, polymeric and metallic materials for advanced materials design, energy storage, conversion, 26 | JUNE 2022

and architectural structures. The research team replicated the design motif in cement material, which is one of the most consumed construction materials in the world. Together, they used a 3D printing technique combined with nanotechnology and artificial intelligence to fabricate a lightweight cement composite, which adopted a segmental design motif. This demonstrated a superior loadbearing capacity and a unique progressive failure pattern. Since the 1972 discovery of the helical structure—one of the most common structural patterns in biology—there has been a drive to extract design motifs from more than 7 million living species in the world. After 50 years of research undertaking, remarkable repetitions have been confirmed in most classes of species but only eight categories of design motifs have ever been extracted and adopted in materials design, until now. This design structure has been identified in various species such as the exoskeletons of arthropods, the legs of mammals, amphibians and reptiles. They are valuable sources of inspiration for modern materials design and aid the fabrication of structural material. “Compared to the current design motif, our segmental design motif dissipates the energy by segment rotation,” Professor Duan said. “The beauty of our discovered design motif is that the material can exhibit a unique periodic progressive failure behaviour.” “It means we can contain the damage within a particular region of material, while the rest of the structure can still maintain the integrity and most (around 80%) of load-bearing capacity,” he added. The research is widely available in Nature Communications, and forms part of the ARC Nanocomm Hub. This provides a centralised platform BACK TO CONTENTS

to transform the construction materials industry into an advanced manufacturing sector in sustainable and resilient infrastructure assets. Professor Wenhui Duan works at the interface of materials science and civil engineering. He is a Fellow of the Australian Academy of Technology and Engineering, and has been an early pioneer in the development of nanoscience and nanocomposites for civil engineering applications.

Innovative Building Materials Helping to Moderate Temperature A team from UNSW Sydney has developed intelligent building materials that can help keep the temperature in check throughout the seasons. This innovative design solution adjusts the optical properties used in conventional heat mitigation materials to change the amount of heat they reflect and emit. The changes occur depending on the temperature in the air. The materials were designed by a team of researchers, who believe they can be used in buildings worldwide to better protect them from the elements. “This is a smart, intelligent building material that understands the urban temperature, and it is modulated according to the weather conditions. So it is ideal for cities that have issues with overheating in summer, but also have heating requirements during winter,” Professor Mat Santamouris said. Extreme urban heat is the most documented climate change phenomenon. It affects more than 450 cities worldwide. Higher urban temperatures significantly increase energy consumption needs and adverse impacts on health, including heatrelated morbidity and mortality. Professor Santamouris specialises in developing heat mitigation technologies and strategies that decrease urban temperatures. His team recently tested the new generation of materials in Kolkata, India. WWW.MATERIALSAUSTRALIA.COM.AU

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The new materials used to coat buildings could help moderate temperatures in summer and winter. Photo: Shutterstock.

Many conventional cooling materials help mitigate urban overheating during warmer periods, but are not necessarily suitable for cities that have winter heating requirements. Because the materials reflect light, they can generate glare, and can only be used in specific locations. “Traditional supercool materials work by having very high reflectivity and emissivity, making them ideal for cities that only require heat mitigation.” “However, they can cause overcooling in cities that also need heating during cooler periods,” Professor Santamouris said. The research team worked with an international collaboration of

colleagues from the University of Calcutta, India; Public University of Navarra, Spain; and the University of Tsukuba in Japan. The study is the latest in an ARC Discovery Project, which seeks to develop cooling technologies to mitigate urban overheating and reduce cooling energy demands in buildings. Researchers employed new layers to the conventional supercooling materials to help modify their solar reflectance and emissivity during colder periods without compromising the cooling efficiency. “They also can’t be used in low-level streets or vertical façades because of the glare, so they can only really be used on roofs of high-rise buildings—

not in walls or pavements,” Professor Santamouris said. The first layer is composed of a ‘phase change’ material that uses transitional metal oxides to modulate the reflectivity and emissivity during the seasons. Then, a second fluorescent layer increases the cooling capacity of the material. “We have integrated a new layer into the materials which changes the reflectivity and emissivity as a function of the ambient temperature,” Professor Santamouris said. “We have also decreased the reflectivity of the materials to decrease glare by integrating [another] new layer that increases heat losses through fluorescence,” he added.

Sky's the Limit for Victorian Company with $5.9 Million Innovation Investment The Australian Government signed a $5.9 million contract with Victorian based company A.W. Bell Machinery to develop a world-leading titanium high grade casting system for in-service aircraft.

The contract, signed in late 2021, is the company’s first with the Defence Innovation Hub. If successful, the WWW.MATERIALSAUSTRALIA.COM.AU

technology would be the first of its type in the southern hemisphere. The Chief Executive Officer of A.W. Bell Machinery, Sam Bell, said, “The investment allows us to develop advanced manufacturing and innovation in Australia, delivering a key sovereign capability that directly supports Defence’s strategic priorities.” BACK TO CONTENTS

The Defence Innovation Hub invests in innovative technologies that can enhance Defence capability and grow the Australian defence industry and innovation sector. Industry and research organisations can submit innovation proposals through the Defence Innovation Portal at: www.innovationhub.defence.gov.au. JUNE 2022 | 27

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Making Muscles, Building Brains: Inside the Mind-Blowing World of Biofabrication Source: Sally Wood Researchers have begun work to turn biomedical science fiction into reality.

From biosynthetic brains for predicting epilepsy to tiny 3D printed implants for regrowing muscle and bones, this research is at the very edge of what is medically possible. Engineers, robotics experts and biologists have linked with top surgeons and clinicians to bridge the gap between dreaming and delivering. Professor Rob Kapsa is a lead RMIT researcher at the Aikenhead Centre for Medical Discovery, where he heads a research group using ACMD’s purpose-built biofabrication lab. ACMD is based at St Vincent’s Hospital in Melbourne, and brings researchers and clinicians together to find solutions for some of the world’s biggest biomedical challenges. “This is fundamentally about making things that fully integrate into our bodies, to heal, repair and restore function. Unlike traditional implants, biofabricated structures and devices can actually come close to mimicking the phenomenal complexity of living human tissue.” “Biofabrication combines materials engineering, biological sciences, additive manufacturing, nanotechnology and biomedical health technologies,” Professor Kapsa said. The research opens fresh opportunities for making structures to restore, replace and regenerate bones and muscles, joints and connective tissues. For example, researchers are working on new biofabricated technologies to repair deteriorating bones in older people. The process also involves developing a customised, self-regulating artificial pancreas for people with diabetes and build replacement muscles for trauma patients. Professor Kapsa said 3D technology is the key to success when the researchers are conducting their modelling. “When you’re trying to understand 28 | JUNE 2022

how the brain works, and how to fix it when it goes wrong, looking at cells on two-dimensional slides only takes you so far. So we build in three dimensions, using 3D bioprinting,” he said. The centre’s ‘brains’ are around 3mm by 3mm but there is still enough functioning brain to be studied and analysed. The brain blocks are made from skin cells, which are reprogramed into stem cells that can make neurons. The block of ‘brain’ is suspended in a 3D collagen matrix and put on array of electrodes. The ‘brains’ are paving the way for research into epilepsy, which affects one in 100 people. “We know that about half of those develop the condition later in life, after experiencing some injury to the brain when they were younger.” “We take skin cells from people who have that genetic mutation, remove the mutation and grow biosynthetic ‘brain’ from those genetically-edited cells. For comparison, we also make brain out of their ‘epilepsy-positive’, unedited cells,” Professor Kapsa said. The ‘brains’ are then tested against a certain level of injury to see if, and when, they display epileptic-like activity. Researchers are working with neurologists at the Murdoch Children’s Research Institute who discovered a genetic mutation that causes epilepsy, as well as neurologists at St Vincent’s Hospital. “What we’re ultimately aiming for is a simple genetic test that could determine if you are likely to develop epilepsy from minor head trauma, such as through playing AFL football or other sports,” Professor Kapsa said. The ‘brains’ can also be used for the personalised modelling of neurological disorders. This is where a ‘brain’ grown from a patient’s own cells could enable a clinician to better understand their BACK TO CONTENTS

condition, optimise treatment and ultimately, even their prognosis. “This work opens exciting new avenues for the design, development, fabrication and translation of biomechatronic hybrid devices and systems,” Professor Kapsa said. The Victorian Government recently award $206 million for a purposebuilt facility to support the centre’s continued growth. Images from top: Biofabrication focuses on making structures to restore, replace and regenerate anything from bones and muscles to brain. This bioprinted block of ‘brain’ – neural cells suspended in a 3D collagen matrix – helps scientists understand and treat neurological conditions. State-of-the-art technologies at the ACMD are helping power the research.

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Deakin Supports Local Industry to Advance Battery Technology Source: Sally Wood to an increased demand for lighter and environmentallyfriendly batteries, which boast a longer life-cycle. "Our work with Deakin enables us to test and develop our current technology to deliver an even better battery," he said. These batteries have a wide range of applications in electric transport, including electric buses and unmanned aircraft, and for use in large-scale energy storage. They are energy dense, which means they can store more energy per kilogram of battery. Deakin's work with Li-S Energy also forms part of an important battery research and development program within the university's rapidly expanding BatTRI-Hub, which sits under the Institute for Frontier Materials. Deakin University is delivering cleaner and greener batteries through a growing partnership with Li-S Energy.

BatTRI-Hub Director Professor Patrick Howlett said the partnership has highlighted the important work needed to provide world-leading research expertise.

The initiative will see the company significantly expand its production capabilities in Geelong and strengthen industryled research development. The Executive Director of Deakin Research Innovations, Ross Mahon said Deakin had entered into the arrangement to enable Li-S Energy to increase production capacity for lithium sulphur and lithium metal batteries. "This is a cornerstone agreement in the realisation of Deakin's Recycling and Renewable Energy Commercialisation Hub, which aims to drive a sustainable manufacturing revolution," he said. These materials will be produced on-site at Deakin's Geelong Waurn Ponds campus, in a new ManuFutures 3 building. Deakin has played a significant role in the genesis of Li-S Energy, which began as a joint venture between Ppk Group Limited and BNNT Technology Limited in 2019. It then launched on the Australian Stock Exchange to become a multi-million dollar company last year. The Chief Executive Officer of Li-S Energy, Dr Lee Finniear said the company was excited to establish its new facility as part of Deakin's advanced manufacturing precinct in Geelong.

"Li-S Energy will benefit from our team’s extensive expertise in battery development and, in particular, our experience with lithium metal batteries.” "Our goal is to use our expertise to work with partners to translate Australian battery technology from proof-ofconcept, to prototype, to production-level energy-storage products,” he said. Professor Howlett added that the project also supports local industry with the testing and manufacture of battery technology. Li-S Energy is one of many specialised companies that BatTRIHub will partner with as it establishes a new $9.5 million facility at Deakin's Melbourne campus. Together, it involves upgrading the current BatTRI-Hub facility to include a testing lab and pilot production line to research and manufacture advanced lithium and sodium batteries. The expansion project includes a $5.2 million contribution from the Victorian Government through the Victorian Higher Education State Investment Fund.

"It continues to give us access to world class researchers, cements our long-term partnership with Deakin, and will bring additional skilled jobs to regional Victoria," Dr Finniear said. The new space will expand production capacity for lithium sulphur batteries to over 1,000 cells per week, which translates to in excess of two megawatt hours of production capacity per annum. In addition, it has several adjoining research labs to ensure close and ongoing cooperation between research and production teams. Dr Finniear said the focus on renewable energy is leading WWW.MATERIALSAUSTRALIA.COM.AU

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Hitachi High-Tech Sets a New Pace for Plating and Coatings Analysis with the New FT230 Source: Hitachi High-Tech Analytical Science Hitachi High-Tech Analytical Science, a global company within Hitachi High Tech Group, has expanded its plating and coatings analysis range with the launch of the breakaway FT230.

The new FT230 is designed to enable quality control to keep pace with production by significantly simplifying and accelerating testing of components and assemblies. Removing the traditional hurdles of XRF analysis, the FT230 speeds up analysis and reduces costly errors to help electronics and component-level manufacturers, general metal finishers and plating-on-plastic facilities achieve 100% inspection and meet tightening specifications.

Let the XRF Make Decisionsfor You Every aspect of the FT230 was designed to reduce the amount of time it takes to complete an XRF measurement. With traditional XRF instruments, around 72% of testing time is lost on set up, meaning that operators spend significantly more time preparing a measurement and manipulating the results than the instrument spends analysing the part. The user experience of the FT230 is significantly improved by an intelligent part recognition feature called Find My Part™ that automatically selects the features that need to be measured, the analytical routines and reporting rules so the operator spends less time using the XRF and more time working the results. The on-board, user-built library is easily expanded to handle new parts and new routines as your work changes.

Simply Smarter The FT230 is the first product running Hitachi’s all new FT Connect software, carrying the best aspects of its established SmartLink and X-ray Station software and adding new functionality ready to improve usability. FT Connect completely inverts the traditional interface. 30 | JUNE 2022

Whereas with traditional software, most of the screen is occupied by controls – many of which are used infrequently, if at all, FT Connect focuses the interface on the most important aspects of the XRF. The real estate is dominated by the largest sample view in the industry and clear results presentation, making it easier to position parts for analysis and see the results.

Data Handling for Industry 4.0 You can instantly get results to where you need them with FT Connect’s flexible data handling features. Results are prominently displayed in the main measurement screen so operators can take action quickly, and stored on-board for later reviews. The results can be exported in spreadsheet or comprehensive JSON format for integration with SCADA, QMS, MES or ERP systems. Customised reports can similarly be created for internal or external customers.

Easier Instrument Maintenance In addition to a series of functions to confirm instrument stability BACK TO CONTENTS

(including routine instrument checks and calibration validation tools), the on-board diagnostics give users further information about the health of the instrument. This data can be shared directly with Hitachi’s technical support team over ExTOPE Connect (Hitachi’s cloud-based advanced data management and storage service that allows you to share data instantly and securely).

Measure Beyond Plating and Coatings The FT230 adds value beyond measuring plating and coating thickness and composition. The powerful software and high-resolution SDD makes it possible to screen parts for conformity to restricted materials legislations such as RoHS and analyse the composition of materials. This includes plating bath solutions and metal alloys, useful for validating incoming substrates and confirming chemistry, which is crucial for hallmarking centers handling precious metals.

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Get it Right the First Time Matt Kreiner, Hitachi’s Coatings Analysis Product Manager, said, “The FT230 fundamentally changes the way operators interact with an XRF. For decades, the user had to remember or look up the recipe for measuring a production part, making decisions about the application (is the plating Ni/Au or Ni/Pd/Au), measurement locations, spot size, measurement time and reporting rules. Even with systems that could provide some of this information with a barcode or QR code scan, the user would still need to make decisions. And decisions leave room for mistakes that manufacturers cannot afford to make.” “With the FT230, the user loads a part into the chamber, runs the Find My Part™ routine and the instrument takes care of the rest. Everything we’ve built into the FT230 was designed to shorten and simplify the most time-consuming and complex part of an XRF measurement – the setup. This reduces mistakes, frees up operators to perform value-added tasks and increases testing volumes so XRF owners can do more with less,” said Kreiner. From simple plating and coatings to sophisticated applications on the smallest features, Hitachi High-Tech’s extensive range of analysers – now including the FT230 – is designed to confidently measure coated parts throughout production, from incoming inspection, process control through final quality control.

About Hitachi High-Tech Analytical Science The Hitachi High-Tech range of X-ray, laser and optical emission spectrometer analysers provide superior analysis for incoming inspection, factory floor process control and NDT for final inspection to provide you with cutting-edge solutions. Their range includes: XRF (X-ray Fluorescence) is available in both benchtop and handheld formats, is ideal for measuring a wide range of elements and concentrations in many different materials, including metal alloys. XRF technology utilises an X-ray tube to induce a response from the atoms in the tested sample. This technique is ideal when you need low limits of detection for accurate grade separation. OES (Optical Emission Spectroscopy) is available in mobile and stationary formats. OES can analyse all the key elements at low limits of detection, like phosphorous, sulphur, boron – and carbon, starting with a detection limit of 30ppm. Compared to handheld XRF, the OES technique requires more sample preparation and a small but visible burn spot is left on the surface. LIBS (Laser Induced Breakdown Spectroscopy) is a fast, handheld format, ideal for the identification of different types of alloys. With a LIBS analyser, there are no X-rays as it uses a focused laser pulse to hit the sample surface, removing a very small amount of material for analysis. This means the LIBS burn mark is so small that it can often be used for finished goods.

100% Positive Material Identification The Hitachi High-Tech range of metals analysers and technologies ensures: • Rapid, reliable material verification, even in the most demanding quality assurance and control applications • Meeting of standards, avoiding potentially devastating results for your customers, your company and even your reputation • Avoidance of costly reworks through incoming inspection of alloy material before the production phase • Avoidance of costly recalls by confirming chemical composition and material verification prior to shipment • Production lines kept running at optimum efficiency • Access to powerful data management and reporting

Read the metal. Reveal the quality. Hitachi’s range of materials analyzers support the end-to-end metals production process from incoming inspection to final product assembly and finished goods testing to ensure product reliability, safety and regulatory compliance. See the full range at: hhtas.net/read-the-metal X-MET8000 - XRF

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Better Battery Design by Analysis By Dr Cameron Chai, Peter Airey and Dr Kamran Khajehpour, AXT PTY LTD

The race is well and truly on to make the next battery breakthrough that will help electric vehicles (EVs) travel further or simply extend the time between charges for your iPhone. Key to any developments are the materials, and of course, developing an understanding of their chemistry and structure.

In Situ X-Ray Diffraction XRD is a staple materials characterisation technique, commonly used to analyse powders, including battery raw materials. Using a battery testing cell, XRD’s, including small benchtop units like the Rigaku MiniFlex or larger systems like the SmartLab can be used to test batteries in situ so you can measure phase changes at any point during the charge/discharge cycle.

Nuclear Magnetic Resonance Spectroscopy Benchtop NMR instruments like the X-Pulse from Oxford Instruments allow you to directly measure diffusion of electrolyte components. This provides critical information for electrolyte design, such as identification and quantification of breakdown products. As well as monitoring degradation reaction.

In Situ Transmission Electron Microscopy TEM allows imaging materials at the atomic scale. Using specially design platforms like the Lightning (biasing and heating) or Stream (biasing or heating in a liquid environment) from DENSsolutions, dynamic experiments can be performed that mimic real-life operating conditions. Observing them in this way opens a window to clearly understand how your specific battery chemistry behaves.

Computed Tomography CT systems like the TESCAN UniTOM XL are valuable tools for non-destructive 3D imaging of batteries. Useful for refining the fabrication process or quality control

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in production environments, CT can be used to identify minute structural imperfections that can impact the quality and performance of batteries.

Summary Battery research is a highly competitive landscape both in industry and academia. Understanding how specific battery chemistries behave can be key to their success. There are many analytical techniques used in materials science such as XRD, NMR, TEM and CT that can be used to accelerate the R&D process as well as later in production.

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Boston Micro Fabrication’s Ultra-High Resolution 3D Printers Now Available in Australia through AXT By Dr Cameron Chai, AXT PTY LTD

AXT is proud to bring the range of ultra-high resolution 3D printers from Boston Micro Fabrication (BMF) to Australia and New Zealand. Using Projection Micro Stereolithography (PµSL) technology, these printers can achieve resolutions down to 2µm, micro fabricating at high speeds making them ideal for economical rapid prototyping and industrial scale production of parts too complex for more traditional production technologies. BMF are the world leaders in microprecision 3D printing. Their range of printers have been designed with industrial and academic applications with the capability of printing true microstructures with ultra-high printing resolution (2µm~25µm) and

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printing tolerance (±10µm ~ ± 25µm). Their PµSL technology enables printing of ultra-high resolution, accuracy and precision allowing for more intricate, exact and replicable parts going beyond the limits more conventional techniques like highresolution injection moulding and CNC machining. Furthermore, their easy to program open system is compatible with a broad range of specially formulated liquid resins or your own blend so you can create any 3D structure that your desire. Chris Jianlin Zhou, General Manager of the Asian Pacific Business Unit of Boston Micro Fabrication said, "Our 3D printers have gained excellent acceptance around the world in areas such as medical devices, electronics,

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microfluidics and MEMS to name but a few. Expanding into Australia where technology is rapidly accepted was a natural progression for us and we are pleased to partner with AXT for this next stage in our growth." Richard Trett, Managing Director at AXT commented, "Additive manufacturing is a rapidly growing field with broad applicability. We are proud to partner with BMF to bring their instruments to Australia, where they will complement our existing range of 3D printers and bioprinters." For more information on BMF’s range of 3D printers, please visit www. axt.com.au/products/microarchindustrial-micro-precision-3dprinters/

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Materials Science Contribution to Advanced Manufacturing at IMCRC Source: Dr Matthew Young, Manufacturing Innovation Manager, IMCRC 2022 marks the final year of the Innovative Manufacturing Cooperative Research Centre (IMCRC) and my sixth year as Manufacturing Innovation Manager. When I joined IMCRC, only four projects had been approved for funding, with no projects started. This year, IMCRC will see the completion of a portfolio now made up of 71 individual collaborative projects representing a total investment of more than $230 million in cash and in-kind value catalysed from an original pool of $30 million in funding granted in CRC Round 17 by the Department of Industry, Science, Energy and Resources. Although IMCRC is a manufacturing focused research organisation, advanced materials and processes have been key in the foundation of the organisation and a key strength within our partner universities from Australia that researchers have focused to develop and advance Australian manufacturing Industry.

Uncovering Growth Opportunities for Industry IMCRC was founded on three core research programs themed as 'Additive Manufacturing', 'Automation and Assistive Technologies' and 'High Value Product Development' as well 34 | JUNE 2022

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as an 'Industry Transformation' education program. Guided by a set of milestones and goals outlined in an agreement with the Commonwealth, all programs were to be achieved within major industry-led projects conducted with our essential and project participants. Beyond these programs, IMCRC saw the opportunity and capacity to do more. We went to market for new projects aligned to CSIRO’s Advanced Manufacturing: A roadmap for unlocking future growth opportunities for Australia. The roadmap identifies five enabling technologies for strategic growth in manufacturing: • Sensors and data analytics • Advanced materials • Smart robotics and automation • Additive manufacturing (3D printing) • Augmented and virtual reality Providing significant overlap with the original IMCRC core research programs, these enabling technology priorities helped enhance IMCRC’s objectives. Because these priorities were independent of the six national priority areas WWW.MATERIALSAUSTRALIA.COM.AU

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announced in late 2020 as part of the Government’s Modern Manufacturing initiative, all projects were assessed based on technology and commercial benefit alone. By considering industry partners’ existing and future manufacturing intentions, IMCRC operated without prejudice to the product manufactured or Australian manufacturing industry type.

A Focus on Proof of Concept and Prototype Development Central to IMCRC’s selection of projects was targeting technologies that started at a Manufacturing Readiness Level (MRL) of 'proof-of-concept' (MRL-4) and progressed to 'prototype development' level (MRL-7). The MRL definitions are equivalent to NASA’s Technology Readiness Levels but focus more on outlining manufacturing outcomes at each stage. In the context of IMCRC, this means most technologies already exist at the proof-of-concept stage. As a result, our projects are more development than research orientated.

Further, many of our research and industry partners had already established relationships to reach this proof-of-concept stage. Consequently, IMCRC’s collaborations have benefitted from mutual trust, and partners have had the confidence to invest in larger projects that run over multiple years. In 2020 the IMCRC activate initiative was launched to help Australian manufactures act and gain a competitive edge in the post-COVID world. Driving shorter - term research engagements (three-18 months) and offering matched project funding between $50,000 to $150,000, the initiative have been very successful with industry. Today, 37 of the 71 IMCRC projects are activate projects. Key to this program’s success has been the rapid pace to build, assess, grant, and contract projects which was all accomplished within a four to eight week period.

Supporting Life-Changing Advancements in Medical Technology One of IMCRC’s longest projects involves leading medical technology company Stryker, RMIT University, The University of Technology Sydney (UTS), University of Melbourne and St Vincent’s Hospital. The five-year project is combining 3D printing, robotic surgery and advanced manufacturing to create tailored implants that improve outcomes for patients with bone cancer. Of particular interest is Stryker’s work in additive manufacturing with RMIT. Under the project leadership of Prof. Milan Brandt, RMIT has developed lattice-structured titanium implants designed to match the behaviour of bone and allow long term integration. This work involved significant modelling and testing of lattice designs and configuring lattice generation tools to allow the automation of patient-specific implants. Corin Australia has engaged in an IMCRC project to produce antimicrobial nano surfaces or 'smart surfaces' on implants to dramatically reduce implant infection. This technology can be applied to a number of medical devices irrespective of the material. Key to this project has been the development of protocols and recipes to create the smart surfaces on Corin’s titanium implants. Researchers have used these protocols to ensure the smart surface fits with all other processes to deliver an approved medical device. This project has seen close collaboration between the University of South Australia’s materials and surface specialists and its biological science researchers to ensure surfaces are correctly prepared and characterised pre and post antibacterial efficacy evaluation. Another IMCRC project that garners attention is the use of kangaroo tendons as a xenograft material in ligament reconstruction and repair. Industry partners Bone Ligament Tendon (BLT) and Allegra Orthopaedics joined forces to develop an alternative to synthetic ligament replacements, which have a significant failure rate. As a material, kangaroo tendons are uniquely strong and long. However, to be used as a medical device, the material properties must be maintained through sterilisation and decellularisation. Beyond the ligament material, the project has also developed a 3D-printed ligament bone fixture screw made from bioresorbable Sr-HT-Gahnite. This novel material will allow for full bone integration with the ligaments and ensure the patient’s body will eventually be free of any synthetic material.

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INDUSTRY NEWS

Optimising Alloys and Post-Treatments for Additive Manufacturing Many IMCRC projects involving metals technologies are driven by the need to optimise alloys and post-treatments to suit 3D printing processes. Because these additive manufacturing processes often significantly differ from traditional cast or wrought processing, novel materials are needed. Material scientists and metallurgists working on these problems are now designing unique materials and process parameters that are less sensitive to 3D printing processes. In some cases, researchers can utilise the unique thermal or mechanical cycles associated with additive manufacturing to provide properties that match or exceed those of traditional metal processing. One project of interest in this respect has been conducted between RUAG Australia and RMIT University. The project developed an additive manufacturing process to address metal damage of aircraft components by leveraging geometry restoration, primarily Laser Additive Deposition (LAD). Researchers investigated problems associated with metal structural components without the need for traditional major structural repair or component replacement. This involved tuning the LAD processing to achieve desired microstructure, temper and residual stress and created significant insight to be applied to RUAG Australia’s repair operations for different metal types. Deakin University is working with industry partner AML3D to develop high-strength aluminium-scandium welding wire for its Wire Additive Manufacturing (WAM®) structures. By incorporating scandium, researchers hope to develop an alloy that requires minimal post-heat treatment. Once commercialised, the alloys will provide a competitive advantage for AML3D and stands to create new opportunities for Australia’s resource and welding wire sector with aluminium and scandium being converted into a value-add product. Leading additive manufacturing company Conflux Technology has used the Laser Powder Bed Fusion (LPBF) process to manufacture its compact heat exchange devices more efficiently. The devices have highly complex geometries and are more efficient than traditionally manufactured heat exchangers. Yet, the alloy compositions that are currently commercially available to additively manufacture heat exchangers lack the same thermal conductivity properties as their traditional casting counterparts. In a project with Deakin University, the partners are seeking to develop novel aluminium alloy compositions that improve the thermal conductivity performance of additively manufactured heat exchangers. These alloys will allow further optimisation of heat exchanger design and geometries for manufacture by LPBF.

Solving Global Challenges with Novel Composite Materials IMCRC has a diverse range of projects that fall into composites materials technology, each reflecting the depth and breadth of expertise within Australian universities and industries. IMCRC’s largest project in composites has been under a partnership between global technology company Carbon Revolution and Deakin University. The project has delivered 36 | JUNE 2022

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a series of step changes in the manufacturing efficiency and economics of Carbon Revolution’s unique carbon fibre composite wheel technology. The three-year research project focused on the development and the optimisation of key enabling technologies including binders, filler material and release agents. Close collaboration of researchers based at Carbon Revolution’s production facility delivered innovations that have reduced cycle times, lowered costs and developed higher performance products to support high volume production. In 2018, leading mineral processing company Mineral Technologies partnered with UTS to research solutions that will revolutionise how composite polymers are used to manufacture precision-engineered mineral separation and mining equipment. During this project, researchers have WWW.MATERIALSAUSTRALIA.COM.AU

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looked to 3D printing to replace conventional open mould composites in the design and manufacture of the helically shaped gravity concentrator. Materials innovations have been combined with a product-specific 3D printing machine that has prototyped the gravity concentrator. Further, innovations in materials and 3D-printed Internet of Things sensors have been created to give insight into equivalent wear and structural characteristics for specific minerals and ore concentrations. A recent IMCRC project sees defence contractor Thales Australia collaborate with Deakin University to develop new intermediate modulus carbon fibres. The fibres will be used to overwrap metal gun barrels, resulting in a lighter product with increased precision. In addition to defence, the overwrap will also be used in prototypes for civil applications. Working collaboratively, the project team will design all aspects of fibre, sizing and resin combination to create the desired compositemetal interface. In building and construction, IMCRC is supporting a collaboration with Boral, UTS and Southern Highland Concrete Construction to develop advanced technology for manufacturing, placing and curing novel ultra-sustainable concrete. The aim of the two-year research project is to produce and test concrete with an increased binder content of 70% supplementary cementitious materials. The new cement must meet industry requirements without disrupting current construction and manufacturing practices. If successful, this project stands to make a significant contribution to reductions in CO2 emissions within the cement industry.

able to adjust the coating composition to the component and the dominant wear mechanism. Based on their findings, they can now take the proof-of-concept laser clad wear-resistant materials and manufacturing technologies to a prototype stage for mineral processing applications. As a metallurgist and materials scientist, it has been rewarding to help build and guide IMCRC’s projects as they run to completion. For those who currently work in industry or within research fields and collaborate extensively, it will come as no surprise that Australia punches well above its weight in materials sciences and the development of technology. Materials science is a discipline where Australia has successfully bridged the valley of death to commercialisation in a great number of technologies and applications, from raw materials processing through to high-value production. IMCRC’s partners’ R&D has contributed further to this and will put industry partners in good stead to commercialise project outcomes.

Taking Innovative Surface Coating From Proof to Prototype IMCRC has several projects focused on surface modification and functionalisation of metals, fabrics and fibres. In this field, it has been rewarding to see several projects grow from discovery and proof of concept through work conducted at the Surface Engineering for Advanced Manufacturing (SEAM) ARC Training Centre. This includes a collaboration between Swinburne University of Technology and Lightning Protection International (LPI) to further develop a range of novel materials that can be additively deposited onto lightning protection devices known as “air terminals”. Air terminals intercept lightning strikes and safely pass their extremely high currents to ground through connected ’downconductors’, thus protecting structures. With enhanced properties, the new materials will enable LPI to optimise the performance of its flagship corona (air-ionization) minimising technologies. The IMCRC project is supporting LPI to develop, integrate, and test these novel materials from industrial-level scale-up to manufacture. Under the guidance of LPI, the project also seeks to build and field test the performance of full-scale prototypes. With the support of the University of South Australia’s specialist Coatings Research Group at the Future Industries Institute (SEAM-ARC Member), surface engineering company LaserBond aims to refine its laser cladding technology and develop the world’s most resilient mineral processing equipment. By assessing the wear and tear of critical mineral processing components in different settings – erosion, corrosion, and abrasive impact – the research team has been WWW.MATERIALSAUSTRALIA.COM.AU

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JUNE 2022 | 37

INDUSTRY NEWS

Super Duplex Can Corrode Source: LMATS (Laboratories for Materials Advanced Testing Services) This short investigation demonstrates how poor heattreatment during initial manufacture can still have detrimental effects years later.

at various positions around the circumference. The intensity of the metal loss was evident, with very deep pitting and severe loss of material.

Introduction

Macrosections were cut through some of the areas of corrosion, which revealed that extensive corrosion had propagated the whole depth of the sections.

Leaking was found to be occurring from the ends of super duplex (UNS S32750) pipes. It was reported that the pipes had been in operation for 10 years and the pipework was connected together using mechanical pressure joints. The affected material was similar to material that had been in operation for two years longer under the same conditions, which showed none of these failures. Two rings, which had been cut from the ends of two 425mm diameter pipes, were supplied for examination. The reported operating conditions for both rings were: • Pressure of 60Ba • Temperature of 13-180oC • Approximate pH of 8.1 Ring 1 carried brine with a salinity of 51,200ppm. Ring 2 carried seawater with a salinity of 32,640 to 34,560ppm. Ring 1 – Brine Severe corrosion was found on the end face of the supplied ring in three positions around the circumference. The rest of the end face was relatively unaffected, but red rust staining was prevalent. The intensity of the metal loss showed that the metal of the ring had practically disintegrated.

Macrosections though the Rings showing the extensive internal corrosion.

Hardness, Chemical and % Ferrite The chemical analysis for both samples met the requirements of UNS S32750, a superduplex stainless steel except for the slightly lower Nitrogen values. Both meet the requirements of NORSOK M-630 (MDS D51/D52(5)) for a PREN > 40. PREN = CR% + (3.3 x Mo%) + (16 x N%) 2251/01 = 24.4 + (3.3 x 4.1) + (16 x 0.15) = 40.33

The as received Ring 1 showing extensive corrosion on the end face.

Close up of Ring 1 showing extensive corrosion on the end face. The yellow paint marks the position of the microsection.

Ring 2 - Seawater Severe corrosion was also found on the end face of the Ring 2

2251/02 = 24.7 + (3.3 x 4.2) + (16 x 0.21) = 41.93 The percentage ferrite was measured using a Ficher Ferritscope. The percentage ferrite met the requirements of DNV-OS-F101 with ferrite content of 35 – 55%. The hardness values of 255Hv (Ring 1) and 258Hv (Ring 2) met the requirements for UNS 32750 of < 326Hv in the solution annealed condition. ASTM G48 Corrosion Test The corrosion test, ASTM G48 Method A, was conducted at 500oC for 24 hours. An acceptance criteria of a maximum weight loss of 4g/m2 is specified in DNV-OS -F101 for superduplex stainless steels. Pitting was observed in both samples after testing with weight losses of 867g/m2 for Ring 1, and 670g/m2 for Ring 2.

The as received Ring 2 showing corrosion on the end face.

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Close up of Ring 2 showing corrosion on the end face.

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Sigma phase precipitation and the precipitation of other intermetallic phases increases the susceptibility to corrosion(7). Sigma phase is a chromium-molybdenum rich phase that can render stainless steels susceptible to intergranular corrosion, pitting and crevice corrosion. Third phases and precipitates can lower the alloy content locally in adjacent areas, consequently the PREN is effectively reduced in these areas making them very susceptible to pitting corrosion. Sample from Ring 1 after testing showing pitting.

Sample from Ring 2 after testing showing pitting.

Microstructural Examination Examination of the metallographic structures followed the procedure given in ASTM A923 and was etched using electrolytic 40% sodium hydroxide. Structures from both Ring 1 and Ring 2 showed evidence of intermetallic precipitation at the grain-boundaries.

Sigma phase forms when an alloy is cooled slowly through the range from around 1,000oC to 5,500oC. The formation of sigma phase can be avoided during initial production by solution annealing at a temperature above the formation range, followed by a rapid quench with minimal delay. Careful control of heat treatment and quenching conditions should be an important part of purchasing specifications, and also forms the basis for industry approvals such as Norsok M-650. Achieving a fast enough cooling rate can become more challenging at larger diameters, and for thicker section castings. The corrosion seen in the rings was concentrated on the end faces. This is where a crevice would have been formed due to the joining of the rings by the mechanical connectors. Crevice corrosion can be considered a severe form of pitting. Any crevice, whether the result of a metal-to-metal, a gasket, fouling or deposits, tends to restrict oxygen access, concentrate the chloride ion and reduce the pH resulting in attack.

High magnification of Ring 1 showing the intermetallic precipitation at the grain boundaries.

High magnification Ring 2 showing the intermetallic precipitation at the grain boundaries.

Discussion The chemical analysis for both samples met the requirements of UNS S32750, a superduplex stainless steel except for the slightly lower nitrogen values but both samples had a PREN > 40. The ferrite / austenite phase balance was measured to be 48.4% which met the requirements of DNV-OS-F101 and Norsok M-603 D51. PREN >40 is typically specified for seawater service[1][2][3]. Both stub rings had a PREN greater than 40. Although, Ring 2 was slightly higher that Ring 1. This lower PREN of Ring 1, and hence lower corrosion resistance, could also be seen in the G48 test where it suffered more corrosion than Ring 2. However, both samples failed the G48 test with pitting and weight losses far greater than the industry standard of 4g/ m2(4,5). The critical pitting temperature of UNS 32750 should be >70 C for a fully solution annealed structure (6). The metallographic structure of the stub rings was found to consist of austenite and ferrite. However, precipitation of intermetallic phases at the grain boundaries was observed. The precipitation in Ring 1 was higher than in Ring 2, which could also account for the greater attack. Also, the higher salinity of the brine that Ring 1 was exposed to would also increase the corrosivity. WWW.MATERIALSAUSTRALIA.COM.AU

It is considered at under normal circumstances, with the material not having reduced corrosion resistance due the precipitation of intermetallic phases, that the material would not have suffered from crevice corrosion. Conclusion The corrosion is considered to have been caused due to the formation of crevices, which then propagated by an autocatalytic mechanism into the material which had reduced corrosion resistance due to the precipitation of intermetallic phases. The precipitation of the intermetallic phases would have been due to ineffective heat treatment during the manufacture of the pipes 10 years previously. References 1. Gerhard Schiroky, Anibal Dam, Akinyemi Okeremi, Charlie Speed (2013). "Pitting and crevice corrosion of offshore stainless-steel tubing". Offshore Magazine. 2. Kathy Riggs Larsen (2016). "Selecting Stainless Steels for Seawater Pumps". Materials Performance. 3. Dirk Aberle and Dinesh C. Agarwal (2008). 08085 High Performance Corrosion Resistant Stainless Steels and Nickel Alloys for Oil & Gas Applications. NACE. Product Number: 5130008085-SG, 4. DNV-OS-F101 – Submarine Pipeline Systems 5. NORSOK M-630 D51 6. Practical guidelines for the fabrication of Duplex Stainless Steel, 2nd ed, IMOA 2009 7. ASM Metals handbook Vol 13B, 2005. BACK TO CONTENTS

JUNE 2022 | 39

UNIVERSITY SPOTLIGHT

A Quiet Pursuit Of The Extraordinary: The University of Tasmania Source: Sally Wood Over 130 years ago, a sandstone building in Hobart was the home of three lecturers who began imparting their wisdom to 11 students.

Today, the University of Tasmania is Australia’s fourth oldest university. It boasts a wide range of courses for Tasmania’s 541,000 residents, and supports mainlanders who come to thrive on the island From science, technology and engineering; to earth, sea, Antarctic and environmental studies; the university offers an impressive feat of specialised courses. At the height of the pandemic, the university made the decision to reduce its subject offerings, and present students with a set of clear, compelling, and specialised choices. In its 2020 Annual Report, the university said some undergraduate courses were “duplicated, disconnected and confusing”. As such, the university shifted from

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209 courses to 60 nests containing 93 courses, with a focus that is “clear, aligned, and presents a compelling array of choices, offering students a better experience from enrolment onwards”.

Investing in Nature Students are encouraged to invest in nature and work outside the classroom. For example, pupils who are learning about environmental economics have travelled to Tasmania’s Derwent Valley to learn about bushfire assessment impacts. Similarly, geology students have mapped the tessellated pavement at Eaglehawk Neck, where coastal erosion has created striking patterns. By next year, the university will also have 25% of first-year undergraduate students completing an assessment item on Indigenous knowledge and culture. These progressive decisions are paying off on the global stage. The university was recently ranked first

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in the world for its action on climate change. Vice-Chancellor Professor Rufus Black said he was proud of the result. “We face an urgent climate crisis, a fact that drives our efforts to do all we can to effect real change and support the development of a zero-carbon economy. Our approach is concerted and comprehensive. We strive to have a positive impact through our research, our teaching, our work with the community and our operations, including how we invest and how we build,” Professor Black said. The University of Tasmania has also been certified carbon neutral since 2016 and moved away from carbonintensive investments last year.

Island Research With Mainland Impacts The University of Tasmania’s College of Sciences and Engineering is at the forefront of Antarctic, marine, maritime, terrestrial and built

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UNIVERSITY SPOTLIGHT

nation-building ambitions in modern technology, infrastructure, and renewable energy.

environment research. Researchers and students alike use science and mathematics, to solve complex realworld problems. Similarly, the School of Engineering is the lead solution for applied and exploratory engineering research and development across Tasmania. The facility draws on its industry connections to deliver sustainable and dynamic local research with international impacts. Some of the focus areas include renewable energy systems, highspeed catamarans, and biomedical implants. In one case, researchers are working with governments and mining operators to create a sustainable critical metal industry. The ‘Environmentally Sustainable Production of Critical Metals’ initiative will also focus on renewed education and training opportunities in Tasmania. “Australia is seeking to grow its capacity in critical metal resource extraction and production to help meet these needs domestically,” said Professor David Cooke, who is the Director of the Centre for Ore Deposit and Earth Science (CODES). The project was recently awarded $3.5 million through the Federal Government’s Regional Research Collaboration program. “This project aims to provide new methods and approaches to critical metal processing from existing mines, and from legacy mine wastes, leading to improved environmental outcomes,” Professor Cooke said. Critical metals are vital to Australia’s WWW.MATERIALSAUSTRALIA.COM.AU

“Tasmania can contribute significantly to this growth due to its unique geology, and the University is particularly well-positioned to facilitate environmentally sustainable development of critical metals production through our research expertise,” Professor Cooke said. CODES boasts a worldwide collaborative network of 28 countries, who work across 59 major research initiatives. The centre also offers a range of postgraduate research opportunities.

Seaweed Solution Nets Student Prize In a show of the University of Tasmania’s strength and commitment to materials science and research, students recently won a prestigious international competition to help solve the climate crisis. The XPRIZE Carbon Removal Student Competition was launched to fund initiatives for carbon removal technologies by student-led teams. A team of students from the University of Tasmania won US$250,000 as part of the scheme, which is sponsored by Elon Musk’s Foundation. The ‘Blue Symbiosis’ team was named as one of 23 international winners for its concept, which seeks to repurpose offshore oil and gas platforms to grow seaweed for carbon extraction from the ocean. Joshua Castle is a Bachelor of Marine and Antarctic Science (Honours) student, who led the research team on this project. He said the concept was inspired by the topic of his thesis. “I researched the potential of repurposing oil and gas infrastructure to regenerative seaweed sites, which led to the conclusion that this holds BACK TO CONTENTS

real promise for both environmental and commercial reasons,” he said. Governments are faced with a $60 billion challenge for the decommissioning of oil and gas infrastructure. But seaweed can potentially fill this gap and deliver a range of environmental benefits for ocean health. “Our concept aims to increase seaweed production to a scale large enough for it to have a significant impact on ocean health, and to harvest a proportion of the seaweed in 100-year construction materials, such as fire resilient bricks. This way, we can quantify the exact amount of carbon we store,” Mr Castle said. Blue Symbiosis is also focussed on commercial applications that address one crucial climate question: how can we reduce the amount of carbon stored in our oceans? The project draws on clear targets with measurable goals. Together, the team seeks to capture the imaginations of people from around the world. Professor Marcus Haward is an academic supervisor and the team’s mentor, who commended the students on their work. “We are all incredibly proud of their efforts being recognised on the global stage and look forward to supporting them as they progress through to the next level of competition.” The team’s submission was assessed by a panel of judges who considered the overall design, research utilisation and team capabilities. The project team has also begun work on a prototype to enter in the major US$100 million XPRIZE Carbon Removal competition, where innovators connect with international thought-leaders. Teams must demonstrate a working solution at a scale of at least 1,000 tonnes of carbon removed per year; and model their costs at a scale of 1 million tonnes per year. JUNE 2022 | 41

BREAKING NEWS Sustainable Solutions for Ghost Net Waste A recent report has found solutions in the fight against discarded ‘ghost’ nets and other fishing marine debris in northern Australia.

Cheaper, Cleaner, Faster — New Technology for Better Lithium Batteries

The research was conducted by the environmental not-forprofit organisation TierraMar and the UNSW SMaRT Centre, who uncovered sustainable methods to detect, collect, transport and responsibly dispose of ghost nets. “Ghost nets are fishing nets that have been lost at sea, abandoned or discarded when they have become damaged,” said Professor Veena Sahajwalla from the UNSW SMaRT Centre. “Discarded fishing equipment can cause pollution such as microplastics and entangle marine wildlife and damage reefs, silently killing,” she added. Marine debris accumulates in the Gulf of Carpentaria off northern Australia, which is recognised as a global marine debris ‘hot spot.’ “Four of the six marine turtle species found in Australian waters are listed as threatened under Australian environmental legislation and they are regularly found entangled in derelict fishing nets,” Professor Sahajwalla said. Self-sustaining solutions are critical for ghost nets and marine debris in northern Australia. Meanwhile, reducing the reliance on government support to clean-up and dispose of the debris depends on the ability to create high quality products made from waste. “There is an opportunity to develop a range of high-quality homeware and building products made directly from ghost nets and marine debris coming out of northern Australia,” Professor Sahajwalla said. “The products, such as ceramic tiles, could creatively reflect the unique cultures, artistic values and connections to country by local communities,” she concluded.

Researchers from Monash University recently took another step towards the holy grail of renewable energy: the ability to store it cheaply. Image courtesy of Monash University.

Researchers from Monash University recently took another step towards the holy grail of renewable energy: the ability to store it cheaply. The research team created a lithium-sulfur battery interlayer that promotes exceptionally fast lithium transfer and improves the performance and lifetime of the batteries. It is also cheaper, greener and faster, which enables the charge and discharge of batteries, and discharge of energy at a much faster rate than previously offered. “A lithium battery interlayer sits in the middle of the battery and keeps the electrodes apart, it helps lithium get from one side of the battery to the other faster,” said Professor Matthew Hill, who led the research project. “The new interlayer overcomes the slower charge and discharge rates of previous generation lithium-sulfur batteries,” he added. This latest breakthrough continues the world-leading work into lithium battery development by a team from Monash University’s Faculty of Engineering. Lithium-sulfur batteries offer higher energy density and reduced costs compared to the previous generation of lithium-ion batteries. They can store two-to-five times as much energy by weight than the current generation of lithium-ion batteries, which means a car may only need to be charged once a week. In previous cases, the electrodes in lithium-sulfur batteries deteriorated rapidly and the batteries broke down.

Ghost nets can entangle marine wildlife, such as marine turtles.

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“These batteries are not dependent on minerals that are going to lack supply as the electrification revolution proceeds, so this is another step towards cheaper, cleaner and higher performing batteries that could be made within Australia,” Professor Hill said. WWW.MATERIALSAUSTRALIA.COM.AU

BREAKING NEWS SPEE3D Demonstrates World's Fastest Metal 3D Printer at Melbourne Grand Prix

Liquid Metals, Surface Patterns, And the Romance of The Three Kingdoms

Australian additive manufacturing company, SPEE3D recently showcased its world-leading metal 3D printing technology at the Melbourne Formula One Grand Prix.

Researchers recently found that a single silver–gallium system can produce distinct patterns such as particles or bundle-like structures of an Ag2Ga compound.

The company's flagship product, the WarpSPEE3D, is the world's fastest metal 3D printer. It can produce parts up to 1,000 times faster than traditional methods.

The individual Ag2Ga structures that build the patterns are small, with micrometre or nanometre thicknesses, which are tens or hundreds of times smaller than a human hair.

SPEE3D teamed up with Gary Rogers Motorsport to bring the high-speed production of aluminium parts for the s5000 open-wheelers to life.

The researchers observed that the patterns divide and unite in a repeated manner. Dr Jianbo Tang from University of New South is the first author of the study who said this came as a surprise. “The first time I saw such cyclic divergent-convergent patterns, it immediately reminded me of the famous opening lines of the Romance of the Three Kingdoms.”

The company is based in Melbourne, and provides global racing teams with the opportunity to witness the worldleading technology in action. In recent years, the company has claimed many awards for their technology, and hold the record for the world’s fastest print of a 1kg part. In Melbourne, it was the first time crowds of motor racing enthusiasts were able to see dozens of metal parts printed on demand. Byron Kennedy (CEO of SPEE3D) said it was a pleasure to highlight the technology to racing fans. “It was exciting to showcase our technology at this fantastic event in Melbourne. SPEE3D’s technology is the world’s fastest way to make metal parts, and what better place to show this off than at the Grand Prix which is all about speed and innovation.” One of the many metal automotive parts featured at the event included an s5000 Support Arm. This 2.4kg aluminium part was printed in only two hours on a WarpSPEE3D metal 3D printer for $180 dollars.

Pattern formation is a fundamental yet ubiquitous phenomenon, which has interested and inspired scientists for a long time. In fact, some pattern types are more common than others. Divergent pattern formation, or bifurcation, is frequently seen in nature because the arrangement tends to favour energy conversion or distribution. Bifurcation is evident in river networks, tree branches, lightning pathways, and vascular systems. In comparison, convergent pattern growth, or inverse bifurcation, is encountered less frequently. The cyclic divergent and convergent growth is rare and has not been observed in solidification structures before this piece of work.

SPEE3D focuses on the development, assembly, and distribution of machines and integrated system solutions.

The researchers observed oscillatory bifurcation patterns on the surface of several liquid alloys after solidification. This suggests this counter-intuitive behaviour is quite general for solidification patterns forming on the surface of liquid metals.

Top left: SPEE3D metal 3D Printed Support Arms on Garry Rogers MotorSport s5000 open-wheeler. Top right: SPEE3D Printed Support Arm installed on s5000 Garry Rogers Motorsport. Above: SPEE3D printed Crest CNC machined Intake Runner Manifold on s5000 open-wheeler Garry Rogers Motorsport.

Above left: Divergent surface patterning spreading out from a ‘seed’ (left to right), meeting convergent patterning (right to left). Bottom: oscillatory bifurcation patterns on surface of solidified Ag-Ga alloy (scanning electron microscopy image). Above right: Examples of oscillatory bifurcation patterns observed in (a-c) Ag-Bi alloys and (d,e) Bi-Ga alloys. Scanning electron microscopy (a,b,d) and energy dispersive spectroscopy (c,e) Below left: Left: Time-lapse of the seeded surface solidification process, with arrows indicating the propagating direction of the surface solidification front. Centre: scanning electron microscopy reveals multiple surface subdomains with different patterns. Right: atomic force microscopy of the surface patterns. Below right: Initial and final (50 picoseconds) atomic configurations of the Ag atoms (pink) and Ga atoms (grey) seen in one of the molecular dynamics simulations

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APRIL 2022 | 43

BREAKING NEWS

Monash University Opens World-Class Robotics Research Facility

New Hub to Make Diamond-Based Quantum Computers A joint research and development hub will use the strength of synthetic diamonds to build a new generation of quantum computers. The recently established Research Hub for Diamond Quantum Materials uses the impurities within diamonds— where a carbon atom is swapped out for a nitrogen atom within the crystal—to generate qubits, which are the standard bits within a quantum computer. The German-Australian quantum computing provider, Quantum Brilliance leads the hub, alongside RMIT and La Trobe universities as major research partners. The process results in a microprocessor, which is protected by its diamond casing. Once inside, fragile quantum states that typically survive in a vacuum or at ultra-cold temperatures can interact at room temperature and enable quantum computing.

Monash University recently launched a world-class robotics research facility. Image courtesy of Monash University.

The Monash University Faculty of Engineering recently launched a world-class robotics research facility to train the next generation of engineers and global innovators.

Dr Marcus Doherty is the Chief Scientific Officer of Quantum Brilliance, who said the team's fabrication techniques would enhance the performance of diamond-based quantum computers.

The $6.5 million investment into Monash Robotics drives the emerging artificial intelligence economy.

“The hub is another example of our collaborative research efforts to advance diamond-based quantum technology and deliver economic benefit to Australia in the years to come,” he said.

Monash University President Professor Margaret Gardner AC said the launch of the facility is a major step in advancing knowledge and innovation.

The hub is designed to make great strides in developing synthetic diamond accelerators, and create a network of experts in diamond material science.

“Robots are changing and improving the lives of people across the globe every day.”

RMIT Deputy Vice-Chancellor for Research and Innovation Professor Calum Drummond said collaborations like these are vital in supporting future industries.

“This investment shows our ongoing commitment to world-leading research and education in this important and dynamic field, and aligns with our goals and ambitions within Monash’s Strategic Plan, Impact 2030, to address the great challenges of our time through innovative and excellent education and research,” she said. The Monash Robotics facility will give researchers the opportunity to support and enhance impactful robotics research. It will bring top researchers together to develop robots that can improve the nation’s economy and wellbeing.

“We value this opportunity to support development of new technology, which will in turn grow new businesses here in Victoria,” he said. All three organisations have world-leading expertise and resources in diamond materials sciences.

“Robotics and artificial intelligence will deliver the next generation of breakthrough technologies and will rapidly change the way we live and work, and help shape our future,” said Professor Elizabeth Croft, who is Monash University’s Dean of the Faculty of Engineering. Robotics deployment across the world is rising rapidly. The International Federation of Robotics reports that three million industrial robots were operating in factories around the world in 2021.

A joint research and development hub will harness the strength of synthetic diamonds to build a new generation of quantum computers. Image courtesy of RMIT University.

As such, Monash University is taking advantage of the immense research and industry collaboration opportunities. “This is a very exciting step for Monash University,” Professor Croft concluded.

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BREAKING NEWS Self-Healing 3D Printed Plastic Can Repair Itself... Using Only Light

Dr Xiaoqing Li: Taking the Guess Work Out of Sustainable Textiles

New research from UNSW demonstrates that special treatment of liquid resin used in 3D printing can cause the material to mend itself if it becomes damaged. Engineers recently demonstrated a way to help 3D printed plastic heal itself at room temperature using only lights. Professor Cyrille Boyer and his team have shown that the addition of a ’special powder’ to the liquid resin, which is used in the printing process, can assist with making quick and easy repairs if the material breaks. The process can be conducted by shining standard LED lights on the printed plastic for one hour. This causes a chemical reaction and fusion of the two broken pieces. The entire process makes the repaired plastic stronger than it was before it was damaged. Researchers hope that further development and commercialisation of the technique will help to reduce chemical waste in the future. “In many places where you use a polymer material, you can use this technology. So, if a component fails, you can repair the material without having to throw it away,” said Dr Nathaniel Corrigan, who also worked on the research project. Researchers used trithiocarbonate, which is known as a reversible addition fragmentation chain transfer agent that was originally developed by CSIRO. The agent enables rearrangement of the nanoscopic network of elements that make up the material and allows the broken pieces to be fused. “There is an obvious environmental benefit because you're not having to re-synthesise a brand-new material every time it gets broken. We are increasing the lifespan of these materials, which is going to reduce plastic waste,” Dr Corrigan said.

Dr Xiaoqing Li is using benth plants as a transient expression tool to make novel fibres for the cotton industry.

Researchers continue to uncover fresh ways to trace the origins of fibres to ensure people can buy sustainable textiles and trust their origins. Dr Xiaoqing Li from CSIRO is a leader in novel fibres for the cotton industry. She is investigating methods to be more sustainable in a growing consumerist society. “Customers are seeking more sustainable products, particularly in the textile industry. Unfortunately, without being able to verify the history of the fibres it’s hard to tell where the material comes from,” she said. “So, traceability is a very good tool to make this happen and to improve the sustainability of the whole supply chain.” Dr Xiaoqing recently developed an engineered cotton germplasm, which produces a protein that is not naturally found in cotton fibres. She believes it could be used to trace cotton back its original source. A 2021 report by the Economist Intelligence Unit found the popularity of Google searches relating to sustainable goods has increased by 71% globally since 2016. Dr Xiaoqing said her research can make a significant impact for the industry. As such, she is exploring a plant-based way of tracing Australian cotton fibres that will make it easier to choose sustainable textiles. “We hope this work can lead a new direction in developing plant-based tracing technology. If this can happen, we really can make a leap forward.”

3D printed materials treated with a reversible addition fragmentation chain transfer (RAFT) agent have been shown to selfheal under UV lights.

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“If this added protein is stable and we can detect it, we can possibly trace it from the beginning to the end of the life of the fibre,” she concluded.

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JUNE 2022 | 45

BREAKING NEWS Surfing At the Atomic Scale: ANSTO Scientists Confirm Experimentally New Fundamental Law for Liquids

Silicon-Carbide Modulator Overcomes Decades Long 'Missing Block'

The first experimental evidence to validate a universal law that provides insights into the complex energy states for liquids has been discovered. ANSTO researchers used an advanced nuclear technique that has solved the problem of obtaining the distribution of complex energy states for liquids. “One of the most important quantities in the physics of matter is the distribution of the frequencies or vibrational energies of the waves that propagate in the material,” said Professor Alessio Zaccone from the University of Milan. “It is particularly important as it is the starting point for calculating and understanding some fundamental properties of matter, such as specific heat and thermal conductivity, and the light-matter interaction,” he added. The problem with liquids involves other types of vibrational excitations related to low energies of the disordered motion in atoms and molecules— excitations that are almost absent in solids. “These excitations are typically short-lived and are linked to the dynamic chaos of molecular motions but are nevertheless very numerous and important, especially at low energies,” Professor Zaccone said. The time-of-flight neutron spectrometer Pelican at ANSTO’s Centre for Neutron Scattering was used to measure the vibrational densities of states for several liquid systems including water, liquid metal, and polymer liquids. The instrument has the sensitivity to measure rotational and translational vibrations over short time intervals and at low energies. Researchers confirmed the linear relationship of the vibrational density of states with frequency at low energies. This work was published in the Journal of Physical Chemistry Letters as the editor’s choice and featured on the front cover of the journal.

Silicon carbide is known for being difficult to work with, but researchers are now harnessing its unique properties.

A Harvard University collaboration recently led to the development of a new-generation electro-optic modulator that could stamp out its bulky predecessor. The new modulator was made possible by harnessing a ‘difficult’ compound—silicon carbide. This was first recognised as a photonics wonder material more than three decades ago when it was found to display the ‘pockels effect.’ Despite silicon carbide's durability in demanding electrical, mechanical and radiation environments, its use in photonics has been limited. However, researchers believe their technique, which was described in Nature Communications, will advance quantum communications and microwave photonics. Lead researcher from the University of Sydney’s School of Electrical and Information Engineering Professor Xiaoke Yi said this breakthrough had wide implications for industry professionals. “The use of silicon carbide will potentially open up a new chapter of opportunities in photonics for various applications including quantum computing.” Electro-optic modulators encode electrical signals onto an optical carrier. They are essential for the operation of global communication systems and data centres. “Modulators that use the Pockels effect enable low loss, ultrafast and wide-bandwidth data transmission.” “Overcoming the previous unworkability of silicon carbide may allow for unique photonic-integrated circuits to transmit and process wideband and fast-speed signals – as well as for emerging quantum technologies,” Professor Yi said.

Dr Dehong Yu (left) and PhD candidate Caleb Stamper of the University of Wollongong at the time-of-flight neutron spectrometer Pelican. Not shown: Dr David Cortie. Image courtesy of ANSTO.

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The University of Sydney and Harvard modulator had no signal degradation, and demonstrated stable operations at high optical intensities. This paves the way for high optical signal-to-noise ratios for modern communications in datacentres, 6G and satellites, and future quantum internet. WWW.MATERIALSAUSTRALIA.COM.AU

BREAKING NEWS

A Flash Future of X-Ray Technology Could Come from A Digital Camera

Cutting Edge Steel to Be Made at Port Kembla Port Kembla recently became the home of specialist steel manufacturing for armoured vehicles, navy vessels and renewable energy installations. The University of Wollongong (UOW) will lead the Federal Government’s $217 million Advanced Steel Manufacturing Precinct, in partnership with BlueScope Steel. The precinct will include a new facility that will produce plate steel for armoured vehicles and ocean vessels, and the type of steel used to create wind turbine towers and large-scale solar installations. Together, it will reduce the need for overseas imports and secure our sovereign capability in steel fabrication. Dr Phil Commins is the Acting Director at the Facility for Intelligent Fabrication at UOW, who said the involvement of a research partner was vital for the success of the bid by BlueScope Steel.

A Curtin University researcher is embarking on an international project to develop a technology that will aim to take x-rays using a standard digital camera. The project is one of eight that successfully secured funding from the Hebrew University of Jerusalem out of 69 applications. Associate Professor Guohua Jia, from Curtin’s School of Molecular and Life Sciences will focus on developing x-ray detectors from metal halide perovskite materials. This is a type of cheaper semiconductor compound that serves as a visualisation tool for x-ray radiography. Together, this enables a very low detection limit, which means they could lower medical expenses and reduce the risk of radiation to patients. “X-ray detection is widely used in medical diagnoses and the non-destructive inspection of luggage and industrial products at airports and other custom entry points.” “This modern x-ray imaging uses scintillator materials such as caesium iodide and gadolinium oxysulfide as photodetectors to convert the high-energy X-rays into visible light.”

“This is a fabulous example of industry collaborating with the university sector delivering real translational research outcomes.” “The project is about investing in new capital equipment and processes. BlueScope wants to ensure that it takes full advantage of the modern Industry 4.0 manufacturing principles, which is where our expertise comes in,” he said. UOW will provide support to the project in areas such as manufacturing design, simulation, modelling and pilot scale demonstrations. “The investments proposed by BlueScope will foster deeper business-to-research collaborations and will likely develop and propagate new skills and industry best practices,” Dr Commins said. More than 200 people will be employed directly in steel manufacturing, with an additional 1,000 workers in adjacent industries. The Facility for Intelligent Fabrication at UOW is part of the School of Mechanical, Materials, Mechatronic and Biomedical Engineering.

“The problem with this is that these materials are made of very expensive crystals grown at high temperatures, and they usually show low radioluminescence conversion efficiency,” Dr Jia said. The team is investigating the use of a cheaper metal halide perovskite material made in solution at low temperatures to fabricate X-ray detectors. “Based on these materials, we believe we should be able to detect small doses of X-ray photons, converting them into visible light,” Dr Jia said. The project has been funded for two years with the support of $150,000 for both participating parties per annum. WWW.MATERIALSAUSTRALIA.COM.AU

Dr Phil Commins, Acting Director, Facility for Intelligent Fabrication (FIF) at UOW.

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FEATURE – Technology-First Approach For Light Metals Innovation

TechnologyFirst Approach For Light Metals Innovation Source: Sally Wood Light metals are a gamechanger in Australia’s renewables future.

These low density and cost-effective alternatives boast a strength-toweight ratio that is not matched by other materials. They are crucial for a range of engineering solutions in land, sea, air, and space transportation. In fact, researchers have discovered that a 10% weight reduction in today’s vehicles delivers a 6% fuel economy improvement. The average vehicle in North America is estimated to contain around 208kg of aluminium,and approximately 10kg of magnesium. These materials have a long usage history in the automotive sector. However, the next generation of thinkers believe there are a suite of lighter materials for improved performance and reduced costs in the sector. Similarly, light alloys are critical for the aerospace industry, where approximately 70% of commercial aircraft airframes are made from aluminium alloys. In fact, the Wright brothers used aluminium for the engine parts on their first flight in 1903. This was also the first time that an aluminium alloy had been heat-strengthened. But the jumbo jets of today are flying further and carrying a greater payload, which means they demand more consideration about the materials being used. Even when one kilogram of metal is saved in the design of an aircraft, it can lead to crucial economic savings in terms of weight, construction spending and fuel use. Specifically, aluminium, magnesium, and titanium are light metals with commercial importance for local 48 | JUNE 2022

manufacturers. These metals, and their alloys, are the three most common metals used in industrial systems. They also have a wide range of commercial benefits. For example, aluminium is one of the most versatile materials, while titanium is resistant against corrosion.

Aluminium Alloys In the world of materials science and manufacturing, aluminium is a proven winner. The metal boasts wide fabrication abilities by forming, machining, or welding. These lightweight, non-ferrous metals also offer corrosion resistance and strength.

Magnesium Alloys When combined with another alloying metal, like copper, zinc, or aluminium, magnesium alloys offer lightweight possibilities that are crucial in the manufacturing sector. Their decent ductility, fair corrosion resistance, and moderate strength means they have been used in several industries and applications like aerospace and marine. Crucially, pure magnesium is highly flammable. Although it is challenging to ignite, this remains a key concern for some sectors. Flame temperatures of magnesium and some magnesium alloys can reach up to 3,100°C.

Titanium Alloys

Aluminium also offers electrical and thermal conductibility, which is a key consideration for researchers and commercial partners alike.

Titanium alloys are known for their lightweight, resistance to corrosion and their strong capacity to withstand extreme temperatures.

Its durability is also met with versatility, as aluminium is present in almost every industrial and commercial device.

Titanium is typically alloyed with tiny amounts (6% and 4%) of aluminium and vanadium—a concoction that has a solid solubility, depending on the temperature.

However, like many metals, aluminium has a downfall. The metal has a low melting temperature (660°C), which limits the maximum temperature in certain applications.

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Australia has 51% of the world's known titanium ore deposits, which positions researchers to take advantage of the nation’s vast manufacturing capabilities. WWW.MATERIALSAUSTRALIA.COM.AU

FEATURE – Technology-First Approach For Light Metals Innovation

Research and Development Latrobe Magnesium is an Australian company who are drawing on industryfocussed research to transform brown coal waste into a valuable mineral. This objective is securing the company as a global manufacturing powerhouse, and positions Australia as an international source of magnesium. China is a dominant player in the global magnesium market. It produces over 85% of the world’s magnesium supply. While the process of making magnesium is energy intensive, the automotive sector relies on this material. Magnesium is an essential part of aluminium alloys and has become an increasingly popular mineral because aluminium cars are lighter than older vehicles made from steel. Latrobe Magnesium seeks to draw magnesium metal from fly ash, which is a common waste product when brown coal power is generated. The company is drawing on its research and development initiatives to position Australia as an alternative magnesium supplier. It has patented the ground-breaking technology in every country that has brown coal deposits and has plans to licence the intellectual property to global markets. A $40 million pilot plant will also enhance the company’s standing on the world stage.

There are also legal and environmental frameworks to meet, like the European Union’s greenhouse reduction targets. Professor Xinhua Wu from Monash University said the research team is working at the atomic level. “In metallurgy, just a few atoms in a million added to an alloy can influence engineering at the macro-scale; how we control the homogeneity of metal sheeting when it is rolled, or the integrity of the metal when it is fabricated into a component." One of the Professor Wu’s projects is an aluminium alloy that will reduce the weight of an average aircraft by 30% to 40%, make it twice as fuel-efficient and still meet structural requirements. "From just a materials research perspective, without worrying about costs, we can make the most wonderful metal and alloy materials.” “But the goal is not just to develop stronger, lighter, more durable and more stable metals. They must also be produced through more efficient and cheaper manufacturing with lower energy consumption, both during construction and during the aircraft's operational life over 25 or more years.” "This is what makes industrial science exciting. Yes, the fundamental science must be good, but it is the industrial science that has to deliver this material, functionally and cost-

effectively, to industry. And it doesn't stop with developing the material; new manufacturing processes have to be designed for each new material developed,” Professor Wu said. This research was inspired by Professor Wu’s 20 years with RollsRoyce’s aerospace division. She described the experience as learning experience at "a technology-driven company and world leader in materials technology and manufacturing". Professor Wu is also involved in the development of titanium and titanium aluminide alloys. Some of her work has sharpened the approach of manufacturing technologies to produce complex 3D parts from a computer design. This process is expected to reduce material waste by 90%. It will also lower manufacturing costs by 30% to 50%, and the lead time will drop to three months for certain components. It is a win for manufacturers who have pivoted during the COVID-19 pandemic, but do not want to compromise on environmentally conscious choices for their business. Australia’s research hubs and institutions are the backbone of ensuring tailored research meets enduser requirements.

Specifically, the company is seeking to penetrate the United States and European markets, where there are growing restrictions on vehicle emissions. This is creating a demand for fuel-efficient and environmentally sustainable cars. Similarly, light materials are also taking to new heights in the aviation sector. Monash University is at the forefront of metallurgical research, which is attracting the attention of some of the world’s biggest companies. Aviation manufactures are on the hunt for materials that are lighter, yet stronger, safer, cheaper, and environmentally sustainable. It is a major challenge for a sector that is experiencing vast competition from new manufacturers in Canada, China, India, Brazil, and Russia. WWW.MATERIALSAUSTRALIA.COM.AU

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FEATURE – Technology-First Approach For Light Metals Innovation

Deakin University Deakin University’s Institute for Frontier Materials (IFM) is a pioneer in the development of smarter solutions for the future. IFM’s research areas seek to address material challenges in the energy, mining, environment, health, transport and manufacturing sectors. For example, Dr Thomas Dorin’s research is focussed on renewable solutions for the transport sector, which accounts for around 20% of global greenhouse gas emissions. Dr Dorin believes aluminium could reduce the weight of vehicles and lower emissions. To make this dream a reality, Dr Dorin has used scandium, a metallic d-block element that can improve the performance of aluminium. His research will determine the interactions between scandium and other alloying elements. He has also pioneered RAPDID—a software that can reduce the production and costs associated with alloy manufacturing. “Traditional alloys are complex systems of up to 15 different elements and the processing route can include up to ten different thermo-mechanical stages.” “This results in an extremely complex system and the best solution is unlikely to be found with traditional trial and error (iterative) methods,” Dr Dorin said. The software uses adaptive experimental design to ensure the best results under strict time constraints. Dr Dorin said a nickel super alloy derived from traditional trial and error methods would take around twoand-a-half years. But RAPID produces an alloy with a 13% improvement in properties within six weeks. The researcher was recently the recipient of the prestigious Discovery Early Career Researcher Award from the Australian Research Council. This award granted Dr Dorin with $407,000 to pursue academic research on new classes of aluminiummagnesium-silicon alloys through the inclusion of scandium.

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IFM prides itself on end-user driven research. As such, the research hub has partnered with also Callidus Welding Solutions to improve the life of metal components used in mineral processing. Researchers are working together on a $3.9 million Cooperative Research Centre project to create engineering solutions that avoid severe erosion and corrosion in metal reactor components. “The partnership we have developed with Deakin is a true win, I hope for both teams. Innovation although a bit overused today is at the core of our DNA as a company said Gary Lantzke, who is the Chief Executive Officer at Callidus. The project focusses on the novel component design to double a component’s life, which is poised to save millions of dollars across the industry. IFM believes in a strong pipeline of future research trailblazers. The facility is responsible for graduating more than 30 PhD students each year, and training 80 post-doctoral researchers at any given time.

Australian National University The Department of Electronic Materials Engineering at the Australian National University is a launchpad into a suite of world-class research underpinned by state-of-the-art facilities The scope of research is endless: • Light-matter interaction at the nanoscale • Physics and engineering of photonic, electronic and quantum materials • Integrated and meta-optics • Physics of nanoscale devices • Advanced materials for the energy sector • Bio and chemical sensing The Research School of Physics undertakes an ambitious research program. Researchers use state-of-the-art facilities like an ultra-high speed laser ablation to modify and create nanoscale ablation products. Some of

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the outputs include ultra-light carbon foams. In addition, the school undertakes mechanochemistry research, which generates powders with a unique physical property. Researchers are actively engaged in creating a range of selective nanostructures that are commercially viable.

International Players Across the ditch, the University of Auckland boasts the Light Metals Research Centre (LMRC). This facility leans into the world of smelter-grade alumina, where researchers have expertise in aluminium smelting. LMRC hosts the world’s first purposebuilt centralised control system that can alter aluminium smelter potline operations. The Gen3 device includes a specific software that creates a controlled and managed research environment. Likewise, the University of Cape Town develops competitive research in light metal alloy products. For example, powder metallurgy processing routes are analysed to form a cheaper supply of titanium metals for local manufacturers. The team of researchers collaborate with representatives from the transport, medical and chemical industries by drawing on South Africa’s rich energy and mineral resources.

Commercial Partners Institutions rely on solid end-user arrangements, where research comes to life. One company, data M, is specialising in sheet metal processing, alongside a range of consulting and engineering services. Many companies turn to data M for support to assist with insufficient design capacity; resource allocation; time to market solutions; and knowledge of crucial processes. For example, data M tune into the demands of clients who are seeking lightweight construction improvements for their services. The company has pioneered the COPRA software package, which is a roll-forming design tool that plays a

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FEATURE – Technology-First Approach For Light Metals Innovation

crucial role in the development and validation of high-strength and ultrahigh-strength steels. For over 30 years, data M has developed roll-formed parts for the automotive industry, including cars, commercial vehicles and bespoke trailer components. COPRA offers customised and predefined lightweight outputs, which save time and costs for end-users. The tailor-made approach is essential for meeting respective customer requirements.

sector should see a strong rebound from the pandemic during 2022.”

Technology conference, which is calling for abstracts.

“Our Tullamarine facility is well placed to offer highly competitive aftermarket solutions both domestically and across the Asia-Pacific region,” said Mark Burgess, who is Quickstep’s Chief Executive Officer

The biennial event gives industry professionals and researchers an opportunity to share knowledge and engage in networking across light materials and their applications.

The deal marks the first contract to be awarded to an Australian independent maintenance, repair and overhaul provider.

Similarly, Quickstep is Australia’s largest aerospace and composites organisation. The company was recently awarded a $30 million maintenance contract by Jetstar for its V2500 Engine Nacelle. The airline has 53 Airbus A320 aircraft, which will be serviced by Quickstep Aerospace Services. “In our opinion, the Australian aviation

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The event is curated by Materials Australia and will share success stories and developments from across science and technology linked to aluminium, magnesium and titanium alloys. It will also focus on their translation into commercial products. Delegates will have a front-row seat for interactive presentations that address challenges and opportunities in the light metals industry.

LMT2023 Light Materials Technology Conference

LMT2023 is scheduled for 9–12 July 2023 in Melbourne.

Light materials will be on full display at the LMT2023 Light Materials

For more information, please visit: lmt2022.com

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FEATURE – Technology-First Approach For Light Metals Innovation

Opening ATLAS To A World Of Opportunity Source: Sally Wood From the days of Henry Ford’s Tin Lizzie, commercial vehicles have been primarily made of steel.

Despite its cost-effectiveness and durability, steel is a very heavy material. As such, Australia’s next generation of automotive movers and shakers are at the forefront of ATLAS, where they draw on fresh research initiatives to design and manufacture lightweight structures. ATLAS, or the ARC Training Centre in Lightweight Automotive Structures, is administered through RMIT University. It brings together expertise from Deakin University, the Australian National University, and lead industry partners under the same roof. In all, there are 12 local and international partner organisations including the CSIRO, who are tasked with addressing Australia’s challenges in light weighting. The centre seeks to develop and design new technologies, manufacturing processes and energy storage designs to reduce Australia’s carbon dioxide emissions in transportation. John Davis is an American Emmy Award winner, and the host of the MotorWeek automotive program. He believes lightweight materials are crucial for the longevity of the automotive sector but there are some challenges. “If we all could afford Bugattis, then carbon fibre would be an easy answer. It’s half the weight of steel and four times stronger. But at $15 per pound, it’s more than three times the cost.” ATLAS seeks to bridge this gap by developing high-performance materials that can be used by Australian manufacturers in the automotive sector. For example, the centre works with highly formable metal alloys and carbon-fibre composites that are helping the next generation of manufacturers. ATLAS boasts four key research themes, which drive its innovation: 52 | JUNE 2022

1. L ightweight materials 2. I ntegrated multi-material structures

within the lightweight materials research theme:

3. D esign and advanced structures

1. Surface sizing of carbon fibres

4. W hole of life assessment

2. R apid cure on-demand resins for automotive composites

The program is run by Professor Stuart Bateman, who also serves as the Director of the ARC Training Centre in Lightweight Automotive Structures. Professor Bateman has vast expertise in polymeric materials for advanced manufacturing across disciplines like additive manufacturing, and biomimetic surfaces and interfaces. He also believes in the commercialisation of research outcomes.

Lightweight Materials Lightweight materials are the backbone for modern automobiles. They offer an enhanced fuel economy and environmentally sustainable travel opportunities. They also maintain crucial safety and performance features. The United States’ Department of Energy believes a 10% reduction in the weight of a vehicle, can lead to a fuel improvement of between 6 and 8%. When lightweight materials are used, like carbon-fibre and polymer composites, it can also reduce a vehicle’s framework by up to 50%. ATLAS undertakes three projects BACK TO CONTENTS

3. I nfluence of heat treatment and chemical composition on the bendability and toughness of 6,000 series aluminium These projects analyse the structural performance of vehicles by optimising their sizing for thermoplastic composites. They also seek to uncover the relationship between cure chemistry, trigger mechanisms, and material properties, and develop timetemperature transformation curves. In the United States context, lightweight components, alongside high-efficiency engines in around 25% of vehicles is estimated to save over 5 billion gallons of fuel per annum by 2030.

Integrated Multi-Material Structures ATLAS researchers are focussed on the design and usability of multi-materials structures to power the automotive sector’s next generation of smart vehicles. The centre undertakes four projects within the lightweight materials research theme: WWW.MATERIALSAUSTRALIA.COM.AU

FEATURE – Technology-First Approach For Light Metals Innovation

“Whether you’re seeking maximum performance or maximum fuel economy of a vehicle, reducing weight is a sure-fire way of achieving meaningful results.” “But striking the ideal balance between light, strong, safe, efficient, and costeffectiveness is a complicated feat of engineering,” said John Davis from MotorWeek.

Paving The Way For Industry Adoption The ATLAS research training centre relies on its worldwide network to bring knowledge to life. 1. Hot stamping light alloys 2. Novel carbon fibre pre-form 3. A dditive manufacturing of gradient lattice structure 4. P roduction of longitudinal components by combining flexible roll forming and free-forming Together, these projects seek to reduce the time and production costs for ATLAS’ industry partners.

Design and Advanced Structures This research theme considers additive manufacturing, flexible roll forming technologies and multi-material joining techniques to grant a suite of new opportunities for manufacturers. Australia’s manufacturing sector is the backbone of the nation’s economy and requires research to unlock high value products for local and international markets. Within this research theme, there are four key projects: 1. M ulti-materials joining using 3D printed micro-pins 2. Integrated energy storage structure 3. N on-destructive evaluation of laser beam welded and brazed joints 4. M ulti-material design solutions In one project, PhD student Simon Inverarity from RMIT University recently developed novel methods WWW.MATERIALSAUSTRALIA.COM.AU

for joining composite to aluminium components. His work trialled a series of fresh techniques in composite development, computer simulations and failure analysis. “We will create micro-pins with unique geometric design to minimise the manufacturing time and increase the structural performance of light alloycomposite joints for vehicle assembly,” he said. This ATLAS research project is a gamechanger for the current methods of composite-to-metal joining. It will also pave the way for a renewed approach for methods like pinned joints, self-piercing rivets and thermoplastic welding. “An adhesive layer can be added and cured as the component goes through the paint oven to further improve the fatigue and crash performance of joints,” Inverarity said.

There are also several industry organisations like the Ford Motor Company; Australian Rollforming Manufacturers; Composite Materials Engineering; Quickstep Automotive; Capral Aluminium Centres; M.T.M Pty Ltd; Data M Sheet Metal Solutions; and Shape Corporation. Ford is a trailblazer for putting research into practice. The company is incorporating Dura-Touch—a new sustainable material—into its luxury brand. The material is expected to be rolled out on its Lincoln Corsair models, as a lighter and more cost-effective alternative. The Ford Authority, is a hub for enthusiasts of the Ford Motor Company, who said “this material is also more durable, easier to clean, and more stain resistant than real leather.”

This research theme considers the environmental, economic and societal benefits that the next generation of lightweight materials can offer.

World-leading scientists and industrial engineers from 16 organisations across Australia, the United States, United Kingdom and Germany make up the industry-focussed environment at ATLAS.

Researchers focus on how certain design decisions can impact the overall outcome of a vehicle. These decisions include energy consumption, material selection, and recyclability, which is crucial for a material’s end-of-life plans.

Project teams work in collaboration with the Imperial College London; University of Bristol; Michigan Technological University; and Friedrich Alexander University Erlangen in Nuremberg.

Whole of Life Assessment

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FEATURE – Technology-First Approach For Light Metals Innovation

CSIRO’s Pivot Towards A Future Of 3D Printing Source: Sally Wood Australia’s national science agency, CSIRO, has been transforming people’s lives for over a century.

Lab22 Creates Value For Australia’s Manufacturing Industry

The facility has a patented novel titanium powder production process, which has had commercial success.

Throughout history, the organisation has shifted its operations to better align itself with Australia’s science objectives and focus on emerging opportunities across industry.

Additive manufacturing is the next frontier in Australia’s manufacturing capabilities.

For example, ‘Flying Machine’ is a bicycle company based in Perth, who are using Lab22’s innovation in their bespoke products.

In its early years, the organisation was tasked with exploring control measures for the prickly pear pest, which was impacting the agricultural sector on Australia’s east coast. By the 1950s, CSIRO’s research focussed on animal pests and diseases; fuel problems; and the preservation of food. In 2014, CSIRO simplified its research practices to better connect with industry and shift its attention towards ‘impact science’, which address the nation’s biggest challenges. As such, researchers and scientists began their ‘ore to more’ project, which sought to expand the national value chain. This approach builds on Australia’s ore reserves and wide-ranging knowledge on additive manufacturing, or 3D printing, and material science, to deliver a more resilient future for industry. Additive manufacturing has a range of benefits: • Waste material reduction • Lower labour costs • Increased speed • Product customisation • Scope to produce complex parts The CSIRO approach works around the pillars of economic viability; environmental; and cost-effectiveness. The metal industries branch seeks to position Australia as a world leader in novel metal production by making additive manufacturing a more costeffective and robust process.

It offers a suite of advantages over traditional manufacturing methods and leads to a significant increase in productivity and efficiency. CSIRO understands the importance of connecting research with industry. As such, CSIRO is an active partner and end-user driven organisation, where fresh process in metallic additive manufacturing is passed onto local manufacturing hubs. For example, the Lab22 Innovation Centre works to increase metallic additive manufacturing across Australia. Since it opened in 2015, the centre has become one of the nation’s frontrunners for metallic additive manufacturing. The metal 3D printing sector is expected to reach a market value of $10 billion by 2030. As such, Lab22 is well-positioned to take advantage of this by linking itself with key players in the aerospace, biomedical, defence, and sports manufacturing sectors. Lab22 offers advanced machining; surface engineering; metallic 3D printing and laser heat treatments to create a range of endless possibilities for industry. Some of the facilities available to researchers include: • Arcam A1 • Concept Laser M2 • Optomec LENS MR-7 • Voxelject VX1000 • Cold Spray Plasma Giken Researchers and industry are able to connect and use the facilities to print materials from sand, titanium and other metals. The machines can also handle several other ferrous metals and non-ferrous metals.

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“CSIRO are the only titanium printer in the southern hemisphere, so for us it not only was cheaper getting it here in Australia than from overseas, but it was also quicker in its turnaround time,” said Sam Froud, who recently designed a bicycle for the company. The bicycles capitalise on the 3D printed titanium frame with a carbon belt drive. “I’ve just been so stoked to be able to get on it finally and go for a ride.” “I actually went to ride around the block, and then ended up riding right down into the city and back. It’s like the titanium’s just completely blown my mind about how it was going to be,” Froud said. This Lab22 innovation unlocks the capacity for anyone to own a 3D printed bicycle that is made to fit.

Low-Cost Titanium Wire For Additive Manufacturing CSIRO has developed an innovative process to transform inexpensive alloy waste into a high value wire product, which is a winner for the additive manufacturing market. This method of producing titanium wire is an Australian first. “The result is a product that is significantly cheaper than titanium wire made by conventional processes,“ Dr Robert Wilson said. Researchers used low-cost titanium alloy particulates to produce a wire, which can be used to make a series of 3D printed parts. The global market for titanium wire is estimated to be worth over $200 million. In this instance, the 2.5mm to 3mm titanium wire can also be used to produce metal powders for 3D printing. WWW.MATERIALSAUSTRALIA.COM.AU

FEATURE – Technology-First Materials Engineering Approach in Manufacturing For Light Metals Innovation

The Chief Executive Officer of Amaero International, Barrie Finnin, said the titanium alloy wire and powders offer a valuable capability for Australia’s growing additive manufacturing sector.

The challenge for Australia’s additive manufacturing market is onshore processing. However, the Director of the Australasian Wire Industry Association, Richard Newbigin, said this research will bridge that gap.

“This technology has the potential to put Australia on the map as a competitive supplier of aerospace grade titanium alloy wire for additive manufacturing and will greatly impact on our global competitiveness,” Mr Finnin said.

“Currently, Australian additive manufacturers have to source their titanium wire offshore, but this new capability will change that,” he said.

Amaero is an additive manufacturing company, which provides an integrated metal 3D printing research, design, and construction program. “Even better, the end product will be comparable to what is currently available overseas, but much cheaper because it is using waste product,” Mr Finnin added. The patented wire extrusion process is also working to produce 50kg of titanium wire at pilot scale. WWW.MATERIALSAUSTRALIA.COM.AU

Australia is also well represented in other types of wire manufacturing, which grants researchers and industry professionals with a suite of fresh opportunities.

Improving Horse Racing Performance In a horse racing-first, CSIRO recently produced a 3D printed set of titanium shoes for one Melbourne horse. A 3D modelling software was used to design and fit a lightweight racing shoe, which is a gamechanger for horse racing. BACK TO CONTENTS

Horse shoes are typically made from aluminium and can weigh upwards of 1kg. But CSIRO’s lightweight solution was able to print four customised shoes within a short timeframe. John Moloney is a horse trainer, who said the ultimate race shoe should weigh as little as possible. “Any extra weight in the horseshoe will slow the horse down. These titanium shoes could take up to half of the weight off a traditional aluminium shoe, which means a horse could travel at new speeds.” Moloney’s horse has been dubbed ‘Titanium Prints’. The process involved a research team scanning the horse’s hooves with a handheld 3D scanner. The precision scanning process takes several minutes but its possibilities are endless. “Naturally, we’re very excited at the prospect of improved performance from these shoes,” he concluded. JUNE 2022 | 55

FEATURE – Technology-First Approach For Light Metals Innovation

Pelvic Organ Prolapse Source: Zahrina Mardina, Jeffrey Venezuela, Christopher Maher, Zhiming Shi, Matthew S. Dargusch, Andrej Atrens Pelvic organ prolapse, or POP, is the herniation of pelvic organs such as the bladder, uterus, and rectum due to loss of muscle support. POP affects more than 50% of women in the ageing population—physically demanding activities such as heavy lifting or vaginal labour increase the prevalence of POP. The protruding organs compress the surrounding vaginal nerves, intensify the pain, and reduce women’s life quality.

The early treatments of POP are pelvic floor exercises or the insertion of doughnut-shaped polymers, known as pessaries. Pessaries are intended to suspend the prolapsed organs. However, pessaries are hard to fit, prone to bacteria, and inadequate to treat higher grade prolapse. The gold standard for POP treatment is the surgical implantation of pelvic mesh. Pelvic mesh is intended to replace the weakened muscle’s function. The most commonly used material was polypropylene. However, in 2016 the Food and Drug Administration (FDA) reclassified pelvic mesh as high-risk (class III). The reclassification was based on the reported complications as follows: • E xposure: the visibility of the mesh through the vagina epithelium. • Perforation: the tendency of the mesh to come through the entrance of some hollow organs, which could rupture these organs. • E xtrusion: the tendency to protrude through an opening such as the vagina. The more generic term erosion is

often used rather than the other three terms. The pelvic mesh complications urge the search for alternative materials that could perform better in biocompatibility, mechanical, and degradation behaviour. Our study [2, 3] utilises lightweight, biodegradable metals, namely magnesium alloy, zinc alloy, and iron alloy. The biodegradable metals could be alternative materials for pelvic mesh. The issues with polymer-based mesh are: •P rolonged inflammation response due to its non-degradable nature • uniaxial loading causes pore loosening and hinders tissue integration • Low yield point induces plastic deformation • Strain hardening of polymeric yarns Biodegradable metals offer advantages over polymer-based meshes. The advantages are: • Completely degrade after the tissue healing is achieved. The degradation obviates the possibility of prolonged inflammation • A bigger pore size provides better resistance to pore loosening, hence promoting integration • A higher yield point ensures elastic deformation during physiological loading

Figure 1. Vaginal inspection indicates (a) pelvic mesh erosion and (b) pelvic mesh exposure. Reproduced from Ref [1] American Journal of Obstetrics and Gynecology, with permission from Elsevier, copyright 2008.

56 | JUNE 2022

Some remaining challenges in the use of biodegradable metals are hydrogen production and rapid degradation of magnesium alloys, zinc alloys’ ageing which alters the mechanical properties during storage, and bulky corrosion products and MRI artefacts for ironbased alloy. References

• Susceptibility to creep

• A higher melting point results in better creep resistance

Figure 2 provides a schematic of biodegradable metal mesh. One of the most common suspended organs is the uterus. The expected healing time of the supporting tissue is two and a half years. Therefore, given this timeframe, the pelvic mesh should completely degrade into safe ion intakes such as Mg2+, Zn2+, and Fe2+.

[1] R.U. Margulies, C. Lewicky-Gaupp, D.E. Fenner, E.J. McGuire, J.Q. Clemens, J.O. Delancey, Complications requiring reoperation following vaginal mesh kit procedures for prolapse, Am J Obstet Gynecol, 199 (2008) 678 e671-674. doi:10.1016/j.ajog.2008.07.049 [2] Z. Mardina, J. Venezuela, C. Maher, Z. Shi, M. Dargusch, A. Atrens, Design, mechanical and degradation requirements of biodegradable metal mesh for pelvic floor reconstruction, Biomaterials Science, (2022). doi:10.1039/d2bm00179a [3] Z. Mardina, J. Venezuela, M.S. Dargusch, Z. Shi, A. Atrens, The influence of the protein bovine serum albumin (BSA) on the corrosion of Mg, Zn, and Fe in Zahrina’s simulated interstitial fluid, Corrosion Science, 199 (2022).doi:10.1016/j.corsci.2022.110160

Figure 2. Work schematic of the biodegradable metal-based mesh created with BioRender.com

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Steel is the most common and the most important structural material. In order to properly select and apply this basic engineering material, it is necessary to have a fundamental understanding of the structure of steel and how it can be modified to suit its application. The course is designed as a basic introduction to the fundamentals of steel heat treatment and metallurgical processing. Read More

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Taking a fundamentals approach, this course is presented as an introduction to the world of induction heat treating. The course will cover the role of induction heating in producing reliable products, as well as the considerable savings in energy, labor, space, and time. You will gain in-depth knowledge on topics such as selecting equipment, designs of multiple systems, current application, and sources and solutions of induction heat treating problems. Read More

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Titanium occupies an important position in the family of metals because of its light weight and corrosion resistance. Its unique combination of physical, chemical and mechanical properties, make titanium alloys attractive for aerospace and industrial applications. Read More

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Technology-First Approach For Light Metals Innovation

MA - Short Courses

Breaking News

University Spotlight - University of Tasmania

Super Duplex Can Corrode

Advanced Manufacturing at IMCRC

Hitachi High-Tech Sets a New Pace for Plating and Coatings Analysis with the New FT230

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Boston Micro Fabrication’s Ultra-High Resolution 3D Printers Now Available in Australia through AXT

Better Battery Design by Analysis

Australia Leading the Way in Construction and Building Materials

Making Muscles, Building Brains: Inside the Mind-Blowing World of Biofabrication

Assessing the Quality of Raw and Processed Battery Materials Using the Phenom XL Desktop SEM

Why You Should Become a CMatP

CAMS2022

CMatP Profile: Professor Nikki Stanford

WA Branch Meeting Report - 9 June 2022

Fundamentals of Metallurgy and Additive Manufacturing

Our Certified Materials Professionals (CMatPs

WA Branch Technical Meeting - 11 April 2022

From the President

Materials Innovations in Process Engineering