Materials Australia Magazine December 2020 | Volume 53 | No. 4 by materialsaustralia

CAMS2021 PAGE 9

Materials Australia has planned the Materials Australia has planned the following features for 2014, designed to following features for 2014, designed to highlight different disciplines and sectors highlight different disciplines and sectors of the Materials Community. of the Materials Community. Our aim is to publish a relevant, interesting and current Our aim is to publish a relevant, interesting and current magazine for those involved in all aspects of Materials. magazine for those involved in all aspects of Materials. These features attract attention from the right audience These features attract attention from the right audience and if your business is active in one of these areas, and if your business is active in one of these areas, then you you will will want want to to be be involved. involved. then We offer offer your your company company the the opportunity opportunityto topromote promote We your business directly to decision makers in the your business directly to decision makers in the Materials Community. Materials Community.

September 2014 NEW CONFERENCE DATES September 2014 Focus on Education and Training. Targeting: universities,

APICAM2022 & LMT2022

Focus on Education and Training. Targeting: universities, high school students and vocational training. high school students and vocational training. Content Deadline: Friday 29th August PAGE 13 Content Deadline: Friday 29th August Advertising Deadline: Friday 5th September Advertising Deadline: Friday 5th September

MAMAS 2020

December2014 2014 December

Power Generation. Materials for Energy: Power Generation. Materials for Energy: Solar, Wind & Wave Energy. Solar, Wind & Wave Energy. Content Deadline: Friday 21st November Content Deadline: Friday 21st November Advertising Deadline: Friday 28th November Advertising Deadline: Friday 28th November

Materials Australia Australia also also encourages encouragesmembers memberstoto Materials contribute to our magazine and we will consider contribute to our magazine and we will consider all editorial contributions. all editorial contributions.

PAGE 14

Women In The Industry PAGE 22

University Spotlight PAGE 40

Online Short Courses PAGE 59

Technical Innovations in Steels New technologies and enhanced processes VOLUME 53 | NO 4 please For further details, further details, pleasecontact: contact: Gloss GlossCreative CreativeMedia MediaPty PtyLtd Ltd

DECEMBER 2020

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From the President The same philosophy is true for the increase in flexibility for working from home, and the decentralisation of our workplaces. Although, this does of course bring about a whole new set of challenges for Workplace Health and Safety and cyber security. Of course, the opportunity for working from home is typically limited to white collar workers. Decentralisation of blue collar workplaces is a far bigger logistical challenge.

Welcome to the December 2020 edition of Materials Australia magazine. The year is quickly drawing to a close and things are progressing well for Materials Australia. As we reach the end of what has been an extraordinary year, it is really quite important to look back over what we have learned, what we have done differently, what has worked, and what has not. If we were to each take the top six things weâ&#x20AC;&#x2122;ve learnt from the year, and share them with our colleagues, it really does highlight what the new normal will look like in 2021. Here are a few lessons that I think are worth mentioning. Meeting via online platforms will become an important means through which we do business and communicate. For the foreseeable future, most professional conferences will, at the very least, take a hybrid format with a greater number of attendees present through an online setting. Online presentations, conferences and seminars will undoubtedly continue. These types of events have been run quite successfully this year, and attendee numbers suggest they are reaching greater audiences. I personally have given two online presentations this year from home. I attended an awards ceremony, and registered for a virtual conference, both of which I had originally planned to attend in-person. WWW.MATERIALSAUSTRALIA.COM.AU

As we emerge from isolation as a country, I believe the resilience we have displayed has been exceptional in trying times. Although our economy has suffered considerably from the financial stresses placed on it, we have done significantly better in 2020 than many other countries where economic contractions are worse. Where supply chain deficiencies in the manufacturing and materials sectors have been present, new market opportunities have arisen, and as a country we have a new appreciation of the fundamental importance of sovereign capability. The concept of â&#x20AC;&#x2DC;second sourceâ&#x20AC;&#x2122; becomes more significant, as we ensure continuity of robust supply chains. Additionally, it is becoming clear that a long-term strategic plan for sovereign capability will be required that goes beyond the three years of a term of government. Those from the manufacturing and materials sectors around the country I have recently spoken with on the topic all have similar stories: Businesses are very busy and are doing well. This is especially encouraging for parts of the Victorian manufacturing sector of course, who had to significantly restrict activities under CovidSafe plans over an extended period this year, including the most recent lockdown of 112 days. Some important parts of the manufacturing sector, such as caravan building for example, are having one of their best ever quarters as more people choose to holiday locally. Another especially important observation of working in a manufacturing business through the extended Victorian lockdown is how much closer teams are and how much better integrated they have become due to the stronger reliance on workplace friendships. Skills training or reskilling is emerging as a BACK TO CONTENTS

particularly hot topic for the recovery of the economy. It has been acknowledged widely that many people who have lost their jobs in the last nine months will not return to the same career they held before. Careers that previously were stable are now viewed through a different lens. Training in the manufacturing and materials sectors remains a major priority and is achieving support from high levels of government. Advanced manufacturing is being promoted widely, and the materials community has a large role to play in our opportunities for growth. The Australian higher education sector will never be the same as it was before 2020 as it undergoes widescale restructuring. Australians have a huge appetite for technology in the advanced manufacturing sector. One example that comes to mind is that of the additive manufacturing company, Amaero, spun off out of Monash University, who listed on the ASX in December 2019 with a bid to raise $8 million. Approximately 11 months later, the market capitalisation of Amaero (at the time of writing) is $130 million. There are plenty of other examples. However, what is apparent is that the Australian advanced manufacturing sector is set for a great future. Finally, 2020 has also been a remarkable year with respect to climate change. At the beginning of the year, Australia suffered devastating bushfires that have been linked to climate change. Later, as lockdowns occurred around the world we were able to see the rapid turnaround in air and water quality across the globe. New initiatives have been put in place to prioritise recycling, including in Australia with the introduction of the Recycling and Waste Reduction Bill 2020. Most recently, in November 2020, we have seen the initiative from the United Kingdom to end the sales of gasoline and diesel vehicles by as soon as 2030. Looking towards 2021. I would like to wish you, your family and colleagues the best of health and to stay safe during the holiday period. Materials Australia looks forward to seeing you all at our online events, and then in person once it is safe to do so. Best Regards Roger Lumley, National President DECEMBER 2020 | 3

CONTENTS

Reports From the President

Contents

Materials Australia - Corporate Sponsors | Advertisers

6 Advancing Materials and Manufacturing

Materials Australia News VIC & TAS Branch Report

CAMS2021 9 WA Branch Technical Meeting - 14 September 2020 10 WA Branch Technical Meeting - 12 October 2020

Award Citation â&#x20AC;&#x201C; Distinguished Service Award Cathy Hewett (Western Australia)

New Conference Dates

WA Branch Report - MAMAS 2020

NSW Branch Report - Certified Materials Professional Mini-Conference

Short Online Course: Metallurgy for Non-Metallurgists

NSW Branch Report 2020 Undergraduate Student Awards Presentation

CMatP Profile: Payam Ghafoori

Our Certified Materials Professionals (CMatPs)

Why You Should Become a CMatP 21 Women in the Industry Associate Professor Laure Bourgeois

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

4 | DECEMBER 2020

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ADVERTISING & DESIGN MANAGER Gloss Creative Media Pty Ltd Rod Kelloway (02) 8539 7893 PUBLISHER Materials Australia Technical articles are reviewed on the Editorâ&#x20AC;&#x2122;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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From feature article on page 48. CAMS2021 PAGE 9

Materials Australia has planned the Materials Australia has planned the following features for 2014, designed to following features for 2014, designed to highlight different disciplines and sectors highlight different disciplines and sectors of the Materials Community. of the Materials Community. Our aim is to publish a relevant, interesting and current Our aim is to publish a relevant, interesting and current magazine for those involved in all aspects of Materials. magazine for those involved in all aspects of Materials. These features attract attention from the right audience These features attract attention from the right audience and if your business is active in one of these areas, and if your business is active in one of these areas, then you you will will want want to to be be involved. involved. then We offer offer your your company company the the opportunity opportunityto topromote promote We your business business directly directly to to decision decisionmakers makersininthe the your Materials Community. Community. Materials

September 2014 September 2014

NEW CONFERENCE DATES

Focus on Education and Training. Targeting: universities, Focus on Education and Training. Targeting: universities, high school students and vocational training. high school students and vocational training. Content Deadline: Friday 29th August PAGE 13 Content Deadline: Friday 29th August Advertising Deadline: Friday 5th September Advertising Deadline: Friday 5th September

APICAM2022 & LMT2022

MAMAS 2020

December2014 2014 December

Materials Australia Australia also also encourages encouragesmembers memberstoto Materials contribute to to our our magazine magazine and andwe wewill willconsider consider contribute all editorial editorial contributions. contributions. all

PAGE 14

Women In The Industry PAGE 22

University Spotlight PAGE 40

Online Short Courses PAGE 59

Technical Innovations in Steels

Letters to the editor;

New technologies and enhanced processes VOLUME 53 | NO 4 please For further details, further details, pleasecontact: contact: Gloss GlossCreative CreativeMedia MediaPty PtyLtd Ltd

DECEMBER 2020

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CONTENTS

Industry News High Performance Titanium Filtration Membranes Produced in Australia

Using Protons to Tune Interlayer Forces: in Van-Der-Waals Materials

ANISOP and UniSA Partner to Deliver Infection Resistant Dental Implants

Is a Rotary Tube Furnace Right for your Process?

Global 3D Printing Partnership to Boost Local Manufacturing

Modernising Asbestos testing with a desktop Scanning Electron Microscope

New Facility to Put Swinburne and CSIRO at Forefront of Manufacturing Digitalisation

Deakinâ&#x20AC;&#x2122;s Boron Nitride Nanotubes (BNNT) Are Pure and Industry-Ready

Silicosis the Silent Killer

Sigray Launch Revolutionary X-Ray Microscope with Unique Imaging Modes

LIBS â&#x20AC;&#x201C; Ideal for PMI, CE and Pipeline Maintenance

University Spotlight: University of Southern Queensland

Breaking News

30 40

Feature Technical Innovations in Steels

Materials Australia - Short Courses 59 www.materialsaustralia.com.au/training/online-training

Materials Australia National Office PO Box 19 Parkville Victoria 3052 Australia

This magazine is the official journal of Materials Australia and is distributed to members and interested parties throughout Australia and internationally.

T: +61 3 9326 7266 E: imea@materialsaustralia.com.au W: www.materialsaustralia.com.au

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.

NATIONAL PRESIDENT Roger Lumley

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

M A M A S|2020

DECEMBER 2020 | 7

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Victoria and Tasmania Branch Report Source: Ivan Cole, Paul Plater and Robert Acres

Throughout the extended COVID-19 lockdown, the Victorian and Tasmanian Branch has kept is members involved, educated and—hopefully—entertained through a series of Zoom meetings. These meetings followed our regular calendar of events, and included partners across and outside Victoria. An overview of the recent branch events is provided below. Emerging Topics in Materials Science: Hydrogen Market Opportunities Panel Discussion On Wednesday 11 November, ANSTO hosted our panel on Emerging Topics in Materials Science. The panel discussion focused on opportunities for research and industry collaboration arising from the National Hydrogen Strategy. Panellists Professor Craig Buckley (Future Energy Export CTC and Curtin University), Dr Patrick Hartley (CSIRO), Dr Andrew Dicks (Griffith University) and moderator Luigi Bonadio (Jacobs) led the 40+ participants through the national context, materials challenges for hydrogen generation, storage and use, and ways to get involved in the national hydrogen effort. The session was recorded and will be available shortly on the Materials Australia website.

8 | DECEMBER 2020

2020 Borland Forum On Wednesday 28 October 2020 , Monash University hosted our annual Borland Forum, in honour of the wonderful contribution Doug Borland made to developing generations of materials scientists. Excellent presentations where given by: • Nigar Rashida (Deakin University): Cotton Textile Waste to Microfibrillated Cellulose: Towards a Thriving Circular Economy • Jayshri Dumbre (Monash University): Precipitation of Sc-containing Phases in the model AlSi-Sc alloys • Ashok Meghwal (Swinburne University of Technology): Thermal Spray High-Entropy Alloy Coatings for Extreme Engineering Environments • Mohammad Nur E Alam Al Nasim (RMIT University): Ultra-strong and Ductile Nanolaminates with Superb Wear Resistance However, the judges awarded this year’s Borland Prize to Daniel McCloskey (University of Melbourne) for his paper on Examining the Diamond Surface: Models, Experiments and Applications. It was a wonderful example of combining modelling and computation to solve a critical problem.

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Robert C Gifkins 2020 Annual Lecture On Thursday 22 October, Professor Nick Birbilis gave a lecture that, in the tradition of the Gifkins lecture, was stimulating, educational and entertaining. Nick presented on Recent Trends In Materials Design in which he highlighted the rapid evolution of materials in the last decade. Professor Birbilis outlined how environmental concerns and new manufacturing technologies, such as additive technologies, are driving new ways to design materials. We are moving away from monolithic materials to materials designed to exploit length scales and structural hierarchy like nature does. The talk was illustrated by great and entertaining examples including a glass ball that can fall from a high building without fracture. ----------------------------------------------------The Victorian Branch is looking forward to an exciting year ahead in 2021. We’re particularly excited to host CAMS 2021 Advancing Materials & Manufacturing in Melbourne in December next year. We’d like to wish all our members a happy festive season. Ivan Cole Victoria / Tasmania President

WWW.MATERIALSAUSTRALIA.COM.AU

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

1-3 December 2021 | The University of Melbourne

Call For Papers Closing Date: 30 July 2021

Join Australia’s largest interdisciplinary technical meeting on the latest advances in materials science, engineering and technology. Our technical program will cover a range of themes, identified by researchers and industry, as issues of topical interest. CONFERENCE CO-CHAIRS

Prof Xinhua Wu Monash University

Dr Andrew Ang Swinburne University

xinhua.wu@monash.edu

aang@swin.edu.au

Opportunities for sponsorships and exhibitions are available. CAMS2021 1-3 December 2021 The University of Melbourne VICTORIA, AUSTRALIA www.cams2021.com.au

Conference Secretariat: Tanya Smith tanya@materialsaustralia.com.au dvances in materials characterisation dvances in steel technology T +61 3 9326 7266

hemes

dvanced manufacturing Photos courtesy of George Vander Voort iomaterials ements & geopolymers omposites in roadmaking & bridge uilding erroelectrics ight metals design

Symposia Themes • Additive, advanced & future manufacturing, processes and products • Advances in materials characterisation • Advances in steel technology • Biomaterials & nanomaterials for medicine • Ceramics, glass & refractories • Corrosion & degradation of materials • Durable & wear resistant materials for demanding environments • Light metals design • Materials for energy generation, conversion & storage • Materials for nuclear waste forms & fuels • Materials simulation & modelling • Metal casting & thermomechanical processing • Nanostructured & nanoscale materials & interfaces • Innovative building materials in civil infrastructures • Photonics, sensors & optoelectronics & ferro electrics • Progress in cements & geopolymers • Surfaces, thin films & coatings • Translational research in polymers and composites • Use of waste materials & environmental remediation

www.cams2021.com.

MATERIALS AUSTRALIA

WA Branch Technical Meeting - 14 September 2020 Annual Ron Cecil Lecture - Pressform – Staying the Course Source: John Worner, Managing Director, Pressform Group

In mid-September, the Western Australia Branch facilitated a technical meeting at Pressform Group, which was addressed by John Worner (Managing Director, Pressform Group). Before starting his address on the successes and challenges of running a manufacturing business in Western Australia, John Worner, who is himself a regular at Branch meetings, acknowledged the presence of Ron Cecil and long-standing member, Dick Taylor. John Worner graduated in metallurgy from Curtin University, and shortly after, in 1976, established Pressform Engineering in a bid to break into the stainless steel fabrication market. Fast-forward more than 40 years, and today Pressform operates from a 2,200m2 facility in Bassendean, in northeastern Perth, with a workforce of around 35 people. From its beginnings in pressing, the company has expanded its capabilities substantially, to include CNC punching and perforating, profiling, rolling, bending and stamping, as well as all forms of welding, CNC machining, hot forming, and laser and high-definition plasma cutting. For this Ron Cecil lecture, John took the opportunity to tell the story behind the beginnings of the company. The Pressform operation began when John realised that, while custom fabrication of one-off items of specialised stainless steel equipment was good for developing skills, it was not a sustainable business model – the pricing of individual items was difficult, and there was no guarantee of winning work. Consequently, John decided that it would be better to become a manufacturing business that sold products. The questions were: what products would sell and what manufacturing methods would be useful and versatile? Building on his fabrication experience, John acquired a set of mechanical presses and started to manufacture a range of fasteners and threaded components used in maintenance activities in the local processing industry. Capitalising on his Skilled long-term workforce, flexibility and metallurgical know-how, Pressform expanded its range and prospered, until the emergence of China and Malaysia as low-cost competitors 10 | DECEMBER 2020

L to R: Jonathon Worner, John Worner, Paul Huggett, Ron Cecil

eroded profit from this sort of work. John’s practical response involved several approaches, one of which was through patents. He found the difficulty and expense of patenting, and then defending a patent, meant that this was not a solid long-term approach for a small business. His eventual answer was, and remains, to be flexible, innovative, diverse, and difficult to copy. Being innovative includes recognising opportunities; being flexible is one way to create such opportunities. Thus, Pressform undertook some specialised fabrication for a Malaysian high-pressure valve maintenance business – this was a return to fabrication, but as John remarked, “once you’ve done something, you remember forever”. This became the basis for a new business—Pressurelube—the major customer of which is Saudi Aramco. Entry into the world of valves eventually led to a third business—Valve Sales Australia— which distributes valves manufactured in Malaysia. The fourth company in the Pressform Group is ALLOY Design, the brainchild of John’s son Jonathon. The mainstay of ALLOY’s business has been the manufacture of metal mosaic tiles (stainless steel, copper, brass and titanium) aimed at high-end architectural applications. Supplying this industry opened the door to larger architectural screens and panels, and fabricated BACK TO CONTENTS

sculptural works. Diversity has worked well for the Pressform Group, spreading the ups and downs experienced with individual target industry segments. Following John’s address, both John and Jonathon answered a barrage of questions from the highly engaged audience. They acknowledged that there had been many lost opportunities, both for Pressform and Australian industry in general – staying the course means recognising that you cannot expect anything to go on forever. As such, constant innovation is the key to survival and growth. Innovation generally means building from your skill base – John singled out the critical role of tradespeople and their understanding of the materials with which they work. Confidence in the whole team, nd the internal supply chain has been a vital factor in Pressform’s success in pursuing new markets with new products. One increasing challenge is the result of the greater control that steelmakers have developed in making alloying additions. Steels are now produced with compositions that fall within grade specifications, but which lead to unexpected difficulties in mechanical process forming. A consequence, for Pressform, is that spring-back, and ductile to brittle transitions, are not what they once were, and cannot be relied upon.

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MATERIALS AUSTRALIA

WA Branch Technical Meeting - 12 October 2020 Galvanising AS/NZS 11663:2016 – the Actual Requirements Source: Louise Petrick CMatP, Senior Welding Engineer, Weld Australia

The Western Australia Branch hosted a technical meeting in October on the requirements of AS/NZS 11663, with Louise Petrick (a Past President of the Western Australia Branch) delivering a highly engaging presentation. Louise introduced her presentation with the observation that recent structural projects have brought to light significant misunderstanding in industry, as to the steel chemistry requirements for circular hollow sections that require hot dip galvanising after construction, specified to AS/NZS 1163:2016. She went on to look at how the requirements are specified, compared to the 2009 version, and what the actual requirements should be for projects and project specifications. The major misunderstanding can be summarised as the belief that the 2016 version of the Standard has no silicon requirements, so anything can be used! The convenience of this misunderstanding is that it is put forward as an excuse to avoid potentially significant delays in obtaining steel suited to galvanising. The price is paid later, when the results prove to be unsatisfactory. The origin of the misunderstanding is that whereas the 2009 version has its Section 7.4 ‘Suitability for zinc coating’, the 2016 version moves the information to an appendix – ‘Purchasing Guidelines’. The essentials of the galvanising process are that when a suitable steel is immersed (after cleaning, pickling and fluxing) in a bath of molten zinc, the iron and zinc react to form intermetallic compounds, which grow outward as crystals chemically bond to the steel surface. As growth proceeds, the composition of the intermetallic compound changes progressively until the outer surface of the galvanised layer is almost pure zinc. This zinc surface gives sacrificial protection against corrosion. Louise referred to AS/NZS 2312.2:2014 Guide to the Protection of Structural Steel, for graphs of recommended thicknesses of zinc for various environments and lifetimes. The point is that galvanising is not like painting; it is a process of crystal growth, WWW.MATERIALSAUSTRALIA.COM.AU

depending on time, temperature, and composition. As Louise explained, the silicon content of the steel turns out to be critically important in determining the thickness and crystal structure of the galvanised layer. The effect of silicon content on the galvanised layer is conveniently shown by the Sandelin diagram, which plots coating thickness after galvanising against the silicon content of the steel. A silicon content between 0.14 and 0.25% is ideal for galvanising, with thickness becoming relatively insensitive to additional galvanising time. As the silicon content exceeds 0.25%, the zinc-rich coating layer is thicker and continues to increase in thickness, but is less adherent and has an unattractive grey appearance. If the silicon content is less than 0.04%, the zinc layer is thin but has an aesthetically pleasing shiny appearance. The region of silicon content to avoid is between 0.04% and 0.15%. In this region the thickness and appearance of the zinc-rich layer is extremely sensitive to composition. Around 0.10% silicon, the growth rate is very rapid. Moreover, there is an added complication: the level of silicon, which is added as a deoxidiser in the steelmaking process, can vary considerably between different heats of steel of the same grade. Silicon is not the only deoxidiser (aluminium is an alternative), and the amount added depends on steelmaking variables. Furthermore, silicon content can vary throughout the casting of a single heat of steel. The consequence is that if the mill test certificate of a steel is in the range 0.05% to 0.14% Si, which would be negative for galvanising in any case, it is highly likely that individual sections

made from this heat will behave quite differently, and unsatisfactorily, when placed into the galvanising bath. There are ways of compensating, to some extent, for silicon content. Adding nickel to the galvanising bath inhibits the growth of the intermetallic phases. Lowering the bath temperature reduces growth rate. Sweep blasting, to roughen the surface, and controlling dip time, are also possibilities. All of these options involve additional cost, and test work. Louise’s first piece of advice was to pay heed to the Purchasing Guidelines in the 2016 version of the Standard – they are included for good reasons. However, as steelmaking is becoming increasingly precise, and as silicon is used as a controlling element, the silicon content of steel stocks held by merchants is tending to become more variable. As such, Louise’s second piece of advice was that steel composition needs to be managed, which could mean independent testing for silicon content rather than relying on mill certificates. If there are potential problems, the galvaniser and the asset owner need to know in advance. these are.

L to R: Louise Petrick, Paul Huggett

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MATERIALS AUSTRALIA

Award Citation â&#x20AC;&#x201C; Distinguished Service Award Cathy Hewett (Western Australia) Source: Steve Algie

L to R: Branch President Paul Huggett, National Honorary Treasurer Paul Howard, Past National Presidents Cathy Hewett, Stuart Folkard

Cathy Hewett recently received the Materials Australia Distinguished Service Award. Cathy grew up in Melbourne and after starting her studies in Physics she began her involvement in the manufacturing of materials, working on a project with CSIRO on the fabrication of SiC powders using Victorian brown coals as part of her honours thesis. She then took on her PhD studies, during which she was focused on ceramic materials (Ca-SiAlON), again with an emphasis on manufacturing (and characterisation). In her last year of these studies Cathey joined CSIRO as a Research Fellow, continuing her work on ceramic materials, particularly the design and fabrication of Si-SiC ceramics. In 1998, Cathy moved to Western Australia to join Concord Engineering where she was able to expand her skill base and took on the commercialisation of Si-SiC ceramics for use in industry. As these ceramics have excellent wear properties, the components manufactured by Concord Engineering soon found a use in the mining industry. This new venture was highly successful and Cathy remained there for some 11 years. Cathy went on to complete an MBA, 12 | DECEMBER 2020

breaking the mould for traditional technical specialists that have completed a PhD. During this time, Cathy joined Bradken in their Resources (Mining) Division, where she initially led product development in wear plate, before taking over the management of the Wundowie Foundry facility where they were mass producing white iron wear plate. Cathy then moved with Bradken to their Newcastle head office, where she took on a Global Product Development Manager role in their Mineral Processing Group. Here, she was involved in the optimisation of various products to suit major client installations. Cathy was with Bradken for more than five years and formed extensive networks into the broader Australian mining and materials industries. She has been a major contributor to the use and application of wear materials in this sector.

2005. Cathy was then elected to the role of Branch President in 2007. During her time in this role, Cathy led the Western Australia Branch through some very successful years, as well as the challenges introduced by the GFC. She held this position for three years. Cathy was subsequently appointed National President of Materials Australia in 2013. During this time, the institute was in a poor financial position and Cathy set strategies in place to reduce overheads and operating costs which enabled a turnaround in the Institute finances. Cathyâ&#x20AC;&#x2122;s stewardship during this time and strong relationships with the National Executive and our Executive Officer were instrumental in turning this situation around.

After a couple of years as a Technical Consultant, Cathy joined Davies Wear Part Systems in Western Australia as a Manufacturing and Product Development Engineer, again servicing the mining sector.

During her tenure, Cathy oversaw the move of Materials Australia away from the Coresoft accounting system (used as the platform for managing membership and accounts), to be replaced by a new website and the creation of the bespoke membership portal created by Gloss Media (still in place).

Cathy has also been a long-term member of the Institute of Materials Engineering Australasia (IMEA). Cathy joined the Western Australia Branch in 1998 and then the Western Australia Branch Council in

With her infectious laugh and commendable passion for this industry, Materials Australia has no hesitation in recommending Cathy for the Distinguished Service Award.

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NEWCONFERENCE DATES

Due to the uncertainty of COVOD-19, we have had to postpone both the APICAM and LMT conferences.

APICAM2022 Asia-Pacific International Conference on Additive Manufacturing

6 - 8 July 2022 RMIT University, Melbourne The 3rd Asia-Pacific International Conference on Additive Manufacturing (APICAM) is the not-to-be-missed industry conference of 2022. 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 MetallicÂ Parts

Part Design for Additive Manufacturing

Failure Mechanisms and Analysis

Mechanical Properties of Additively Manufactured Materials

New Frontiers in Additive Manufacturing

Process Parameter and Defect Control

Process-Microstructure-Property Relationships

Testing and Qualification in Additive Manufacturing

www.apicam2022.com.au Opportunities for sponsorships WWW.MATERIALSAUSTRALIA.COM.AU

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

www.lmt2022.com

and exhibitionsBACK areTOavailable and 2020 LMT2022. CONTENTS for both APICAM2022 SEPTEMBER | 13 Enquiries: Tanya Smith | Materials Australia +61 3 9326 7266 | imea@materialsaustralia.com.au

MATERIALS AUSTRALIA

Materials & Maintenance Advancements in the South West Bunbury, October 2020 Source: Paul Howard

In late October, the Western Australia Branch of Materials Australia, with the support of AINDT and Engineers Australia, held a one-day seminar on Materials and Maintenance Advancements in the South West. The seminar was held in Bunbury at the relatively new Dolphin Discovery Centre Function rooms, overlooking the picturesque Bunbury Port. This event was conducted following the succes of a similar seminar held in Bunbury by the Western Australia Branch in 2018. The organising committee was comprised of the Branch President Paul Huggett, Colin Lorrimar, Paul Howard (Seminar Convenor), Irene Pettigrew and Stephen Woodhouse who helped facilitate the local components and served as the local Engineers Australia representative on the committee. The committee was able to bring together an excellent technical program, which included presentations on concrete and pressure equipment inspection and maintenance, welding and weld procedure qualifications, surface engineering and wear monitoring, non-destructive testing, corrosion, pump and valve life extension and dangerous goods testing of materials.

Commerce and Industry. He provided an excellent overview of the wide range of industries in the south west region of Western Australia, including how they are all contributing to the economy. These industries span mining, timber, agriculture, tourism, electricity and power, transport, arts and an emerging technology sector. Surprisingly, the largest sector by revenue is manufacturing. Peter Farinha from Extrin Corrosion Consultants delivered a very entertaining keynote presentation on stainless steel corrosion. He focused on how many designers neglect to design properly when using stainless steel and are constantly surprised when it fails by corroding. This presentation was also populated with excellent examples from the south west and from the Pilbara.

Peter Farinha from Extrin Corrosion Consultants.

The committee was very pleased to have Paul Huggett (Applus), Peter Farinha (Extrin Consultants) and Louise Petrick (Weld Australia) return to the program, after making valuable contributions to the 2018 seminar in Bunbury. The event started with a breakfast and keynote address. After a short welcome from Paul Howard, the opening speaker was Rob Skipsey who is the President of the Bunbury Geographe Chamber of

Rob Skipsey who is the President of the Bunbury Geographe Chamber of Commerce & Industry.

14 | DECEMBER 2020

Katerina Lepkova from the Curtin Corrosion Centre.

Centre provided an excellent overview of some of the work they are doing, including the testing of corrosion inhibitors and how they react differently around welded joints. Katerina also spoke about their investigations into corrosion under mineral deposits, which has had application in the bulk transport of minerals in large ships. Reuben Barnes from PCTE provided an excellent overview of the range of nondestructive testing techniques that are now available for use on concrete structures including ground-penetrating radar, eddy currents and ultrasonics, which have traditionally been used in other fields. This was followed by a presentation by Paul Huggett, from Applus (one of the Gold Sponsors), on more advanced surface measurement techniques now being employed to enhance in-situ inspection processes for wear and or corrosion or other materials defects. These included the application of digital microscopy and laser scanning to create 3D frameworks for the reporting of inspection program and failure analysis projects within any plant environment.

Trevor Overton presented for Austral Technologies.

The presentations after breakfast had a strong focus on materials and spanned the areas of surface engineering, concrete, corrosion inhibitors and materials failure analysis. Trevor Overton presented for Austral Technologies. His talk provided a great update on the development work they are undertaking to produce overlay coatings that combine excellent impact and abrasion resistance using fine grained carbides in micro-composites and also amorphous alloy compositions. Katerina Lepkova from the Curtin Corrosion BACK TO CONTENTS

Reuben Barnes from PCTE

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MATERIALS AUSTRALIA After morning tea, the seminar delegates returned to the lecture room where they heard another series of presentations focused on product developments for life extension. Stephen Hooper from Hofmann Engineering presented a number of case studies that demonstrated how they have extended the life of common products such as boxed piping manifold that needed a longer life cast insert and lining system (from 18 months to 60 months), as well as ball valve retaining pins that had their life extended using specialised hardfacing. Cathy Hewett, a previous National President of Materials Australia, provided an excellent paper on the latest developments from Davies Wear Part Systems (recently acquired by Metso Outotec). Cathy focused on how their unique wear liner attachment systems are now supplemented with an in-situ wireless wear monitoring system called WearSense. The fixing systems have matched hardness materials to ensure the wear data is representative of the larger wear plates. Prior to lunch, Alex Cesan from the Platinum Sponsor, Sonomatic and Vertech, provided an overview of the innovative approach they are taking to inspection and testing of oil and gas and industrial assets around the world. He also introduced a new ROV joint venture, Blue Oceans. After an excellent lunch, spent overlooking the aquamarine waters of Bunbury Harbour, the seminar kicked off again with a very interesting discussion by Louise Petrick (West Australian Technology Manager with Weld Australia). Louise presented on the current challenges being created by the recent update of AS 3992:2000 to create more harmonisation with ISO 15614-1 and ASME IX Standards. Tyron Kimble, also from Sonomatic, provided an overview of the various adaptations for ultrasonic inspection tools being used for non-intrusive inspection of complex process pressure equipment and how the scope of the inspection can be determined by the combination of corrosion rate predictability and the risk of failure. The last formal presentation was from Rick Hughes who provided an overview of the recent changes to chemical and dangerous goods classifications and testing to ensure compliance to these new standards. Many of the tests began resulting in failures so Rick and his team have been working to resolve these issues to support Australiaâ&#x20AC;&#x2122;s mineral export industries. Materials Australia then hosted a bus

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tour to the expanded Geographe facilities in Bunbury, which was enjoyed by all delegates. On show was a range of robotic and automated machining centres that produce a wide range of gears and bushes for the mining industry. There was also a multi-metal foundry, an impressive bank of fluidised bed heat treatment furnaces and a newly commissioned continuous seal quench carburising furnace brought in from Victoria. This commitment to manufacturing in the south west of Western Australian was a very fitting end to the formal proceedings for the day. Thanks to the team at Geographe for hosting such a large crowd. Following the bus tour, the seminar delegates were able to come together again at the Dolphin Discovery Centre and enjoy drinks and canapes while watching the sun set over the serene Bunbury harbour. Materials Australia and the seminar organisers would like to thank our sponsors: Vertech Group Applus, Integroty

Dolphin Discovery Centre and enjoy drinks and canapes.

Engineering Solution, Extrin, Eddyfi Technology, MicroAnalysis Australia, Asset Reliability Inspections and ME Elecmetal, as well as our event supporters, the Bunbury Geographe CCI, AINDT and Engineers Australia. As a change to our previous format, we also held a Golf Day the day before the seminar in Bunbury, at the beautiful Capel Golf Course. This was held jointly by the AINDT and was well endorsed with eight teams of four making the rounds. Apart from a swarm of mosquitos, the players all had a very good afternoon and a fine BBQ to finish off proceedings.

Tyron Kimble also from Sonomatic.

Colm Kinsella (Olympus) and Neil Young (ARI) presenting Awards at the end of the Golf Day.

Rick Hughes from MicroAnalysis Australia.

The sun sets on a very productive and satisfying day in Bunbury.

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MATERIALS AUSTRALIA

NSW Branch Report

Certified Materials Professional Mini-Conference – 29 July 2020 Source: Dr Nima Haghdadi

The Materials Australia New South Wales branch hosted an online mini-conference at the end of July. In the wake of the COVID-19 pandemic, the mini-conference was hosted online this year, which allowed people to sign in from interstate and around the world. As a result, more than 100 people attended from four different continents. With such a great degree of interest, the event was limited to only New South Wales presenters and attendees of Materials Australia events in previous years.

then presented on the capabilities at ANSTO, with regard to sample environments. Professor Jay Kruzic from the School of Mechanical and Manufacturing Engineering at UNSW Sydney spoke next. Professor Kruzic’s talk was on a fracture mechanics view of materials reliability, including the report of an extraordinary fracture behaviour exhibited by emu eggs, which attracted

significant interest from the audience. The final presenter was Professor Huijun Li from the School of Mechanical, Materials, Mechatronic and Biomedical Engineering at the University of Wollongong. Professor Li’s talk was on the wire arc additive manufacturing capabilities at the University of Wollongong. The mini-conference closed with an interactive open discussion.

The mini-conference was cochaired by New South Wales Branch councillors Dr Nima Haghdadi from UNSW Sydney and Dr Anna Ceguerra from the University of Sydney. The mini-conference kicked off with a keynote talk by Professor Matthew Barnett, Director of the Institute for Frontier Materials at Deakin University. Professor Barnett took attendees through some of the latest discoveries at Deakin University, focused on mining alloys and the circular economy. Dr Rachel White, Sample Environment Group Leader at ANSTO,

Zoom composite photo of some CMatP mini-conference participants.

Short Online Course: Metallurgy for Non-Metallurgists – November 2020 Source: Professor Huijun Li

The New South Wales Branch of Materials Australia organised an online two-day short course Metallurgy for Non-Metallurgists in November 2020. The course focused on metallic materials and their common processing and manufacturing technologies. With metals and alloys used in the greatest variety of applications of all engineering materials, it is essential that people involved in manufacturing, engineering and construction have an understanding of what metals (ferrous and nonferrous) are, how they behave in various environments and under different loading conditions, and why they behave differently 16 | DECEMBER 2020

than ceramics, glass, and plastics. It is also important to understand how metals and alloys can be made stronger, how they can be shaped by casting, forging, forming, and how these processes along with heat treatment can alter their properties. This course provided important basic knowledge of all these principles, and an integrated practical overview of metals and alloys, for people who are not metallurgists. The course delved into the mechanical and physical characteristics of metals, starting from materials testing and physical and mechanical properties, through corrosion properties and strength and deformation principles. BACK TO CONTENTS

For both ferrous and non-ferrous alloys, the nature of hot and cold working of metals and heat treatment, including annealing, normalising, tempering and case hardening was explained. The course also covered the introduction of materials welding and joining. In this year’s online course, the current status and future direction of 3D printing and additive manufacturing were also added as frontier materials processing and manufacturing techniques. The course was organised by Associate Professor Sophie Primig, and delivered by Professor Madeleine du Toit, Prof Huijun Li and Dr Nima Haghdadi. There were 16 people who attended the course. WWW.MATERIALSAUSTRALIA.COM.AU

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NSW Branch Report

2020 Undergraduate Student Awards Presentation - 16 November 2020 Source: Peter Richardson On 16 November, the NSW Branch of Materials Australia held their annual Undergraduate Student Awards Presentation event, taking place online for the first time as a Zoom video conference. Students from The University of New South Wales (UNSW), University of Wollongong (UOW), University of Sydney (USYD) and University of Newcastle (UON) presented their recent work on a wide range of fascinating topics comprising corrosionresistant coatings on Al-Zn coated steel, nuclear waste storage, wire-arc additively manufactured nickel alloys, SLM titanium components, MAB phase synthesis, white/ brown etching layer formation in head hardened and carbon steel rails, bismuth ferrite thin films, and platinum electrode dissolution. The students were each allocated 10 minutes to speak about their Honours research projects, which are critical in advancing our fundamental and industrial knowledge of materials science. Their presentation skills and research understanding were judged by a panel consisting of a past winner Sophie Armstrong (UNSW), Dr Mark Reid (ANSTO), Associate Professor Gwenaelle Proust (USYD), Professor Huijun Li (UOW) and

Dr Hong Lu (National Ceramic Industries Australia). After careful deliberation, the following award winners were announced: Bernadette Pudadera – UNSW (1st place), Coco Kennedy – UNSW (2nd place), Aurpa Bhuiyan – UNSW (3rd place) and Lisa Morgan – UOW (4th place). Additionally, all participants received a 1-year student membership of Materials Australia and a certificate for taking part in the event. The students’ prizes were provided by the event sponsors (SOTO Group, Gravitas

Technologies, United Steel and ANSTO), and their representatives each gave a brief presentation, providing an interesting glimpse into their respective organisations. The Materials Australia NSW Branch would like to extend their sincere gratitude to all event sponsors, judges, student presenters and those involved with organising the event. Fulsome congratulations to all presenters and prize winners. We very much look forward to seeing a new generation of students take part in the 2021 event next year.

Zoom composite photo of the student presenters and some of the audience members.

Thank You to Our Sponsors

Event winner (Bernadette Pudadera) and her presentation on platinum electrode dissolution.

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DECEMBER 2020 | 17

MATERIALS AUSTRALIA

CMatP Profile: Payam Ghafoori MEng, PE, IEng, IWE, EWE, AWeldI, CMatP professional for pressure vessel, piping systems and a materials damage and deterioration specialist by the American Petroleum Institute (API); and an Integrated Management Systems (IMS) Lead Auditor (EG AU TL QM EM OH), as certified by the Exemplar Global. A keen supporter of industry associations, Payam is a voting member of ASTM Steel and Stainless (A01) and Mechanical Testing (E28) committees, as well as a member of the Welding Institute UK (TWI), the American Welding Society (AWS), the American Society of Mechanical Engineers (ASME), the American Society for Testing and Materials (ASTM), the American Society for Metals (ASM International) and the Society of Tool and Carbide Engineers (STCE).

With over 17 years industry experience as a professional materials and welding engineer, Payam Ghafoori has worked across a diverse range of sectors, from infrastructure and construction, through to hydrocarbon and oil and gas. He has worked for some of the world’s largest EPCM engineering and construction contractors, across several largescale projects, including those in the North Dome, Pluto, Xena and the Ichthys gas fields. Payam holds a Bachelor degree (2001) in the field of materials engineering (industrial metallurgy), as well as a Masters (2004) in materials engineering, majoring in materials characterisation and selection. Payam’s industry certifications are certainly impressive. He is an International Institute of Welding (IIW) certified International Welding Engineer (IWE); a European Welding Federation (EWF) certified European Welding Engineer (EWE); a recognised professional engineer (PE) by the Engineers Australia; an Incorporated Engineer (IEng) and a member of the Engineering Council UK; a certified welding inspection professional by TWI; an authorised in-service inspection 18 | DECEMBER 2020

Where do you work? Describe your job. I am currently a freelance consultant and expert in the field of materials engineering and welding technology. This is mostly in the fields of materials defects and deterioration, service failures, creep and fatigue damages, welding related defects and failures and, finally, quality management and audits, particularly in the related fields to materials manufacturing and welding.

What inspired you to choose a career in materials science and engineering? Whilst at school I was always fascinated by engineering designs and how things work. Our high school had a program through which academics and industry professionals were invited to the school to give short talks to the students about their majors and field of research or work. These talks provided insights into different career paths and helped us decide on which path we want to pursue. This led me to choose materials engineering; it had a promising potential to provide me with a real world, tangible understanding of how materials are constructed, behave and are put in service. BACK TO CONTENTS

Who or what has influenced you most professionally? I have worked in a number of major organisations and been involved in many different large-scale international capital budget projects. As such, I have been privileged to meet many decent and very capable professionals. But the one person who inspired me the most was the late Jon Lambert. Jon was an expert engineer and advisor in the field of welding but, on top of his expertise, he had a very big personality and a positive aura around him. His positive attitude was a blessing in the high paced and stressful environment of construction projects. I learned a lot about those essential qualities and how to appreciate life through simple everyday experiences just by being in touch with Jon and will always remember him.

In the midst of the project challenges, always pause, take a step back and look at the whole picture Which has been the most challenging job or project you’ve worked on to date and why? I have worked in a number of high profile and strategic mega construction projects ranging from massive marine infrastructure and machinery, to offshore and onshore gas plants and petrochemical facilities. Each and every one of them by nature presented numerous challenges and problems to solve. One of the most demanding recent challenges I encountered was a wide spread welding related defect. This defect was found in high temperature chromium WWW.MATERIALSAUSTRALIA.COM.AU

MATERIALS AUSTRALIA

steel piping spools for a power plant, which had been fabricated overseas. As the key EPCM subject matter expert, it was my responsibility to deal with, and mange, the defect.

being recognised as a CMatP is a valuable privilege. It gives me a sense of belonging to the greater network of the materials professionals across the country.

The issue was particularly challenging because all spools and parts had already been delivered to the construction site and each day of delay hindered the entire construction and commissioning schedule, causing millions of dollars of losses.

What gives you the most satisfaction at work?

It is worth noting that dealing with technical challenges on a busy and highly congested construction site, with critically high hazard levels and dozens of multidisciplinary subcontractors working nearby and with many intertwined work areas and interfaces is fundamentally different to a research project in a controlled academic environment. The former not only requires high technical knowledge and hands-on expertise for rapid decision making, but a high level of people skills, communication, interface management and team work.

What does being a CMatP mean to you? The CMatP is recognition of a high level of academic and professional expertise in the field of materials engineering and, to my knowledge, it is very unique for this field of engineering. Hence, to me,

What are you optimistic about? I am optimistic that the disturbed construction industry, especially the oil and gas sector, will revive and improve after the easing of the recent pandemic.

What have been your greatest professional and personal achievements?

My main source of satisfaction at work comes from its investigative and problem solving aspects. The whole process of initial finding, defects and damages all the way through to the inspection, sampling, experiments, literature review and final repair, rectification or replacement only become interesting and satisfying when I look at the whole picture and see the progress towards solving my team or clients’ problems, thereby adding value to the whole project or business.

My greatest personal achievement is being able to meet great people throughout my life especially as a working professional and having many of those people become valuable and long lasting friends. Professionally, I am proud of being able to help my employers and clients in solving their materials and welding issues. I am also proud of maintaining my interest in learning, and completing several courses through top ranked universities, on subjects in which I have always been interested, including project management, business management, leadership, finance, quality management and corporate analysis.

What is the best piece of advice you have ever received? The best piece of work related advice I have ever received was from one of the senior managers I was working with on my first major construction project. The advice was that, in the midst of the project challenges, always pause, take a step back and look at the whole picture. Re-observe the main concept, the main goal and what the whole team is trying to achieve and this will serve as a good compass to better help your team.

What are the top three things on your “bucket list”? I want to improve my guitar skills. I am learning French and want to get to an advanced level. Finally, I want to refresh my drawing skills and get back to the habit of everyday sketching.

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DECEMBER 2020 | 19

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. 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 Syed Islam Prof Yun Liu Dr Takuya Tsuzuki Prof Klaus-Dieter Liss Mr Debdutta Mallik Mr Dashty Akrawi Ms Maree Anast Ms Megan Blamires Dr Todd Byrnes Dr Phillip Carter Dr Anna Ceguerra Mr Ken Chau Dr Zhenxiang Cheng Mr Peter Crick Prof Madeleine Du Toit Dr Azdiar MCGazder Prof Michael Ferry Dr Bernd Gludovatz Mr Buluc Guner Dr Alan Hellier Prof Mark Hoffman Mr Simon Krismer Prof Jamie Kruzic Prof Huijun Li Prof Valerie Linton Mr Rodney Mackay-Sim Dr Matthew Mansell Dr Warren McKenzie 20 | DECEMBER 2020

ACT ACT ACT CHINA MALAYSIA NSW NSW NSW NSW NSW NSW NSW NSW NSW NSW NSW NSW NSW NSW NSW NSW NSW NSW NSW NSW NSW NSW 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 Simon Ringer NSW Dr Richard Roest NSW Mr Sameer Sameen NSW Dr Luming Shen NSW Mr Sasanka Sinha NSW Dr Frank Soto 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 Payam Ghafoori NT 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 Miss Mozhgan Kermajani QLD Dr Andrii Kostryzhev QLD Mr Jeezreel Malacad QLD Mr Arya Mirsepasi QLD Dr Jason Nairn QLD Mr Bhavin Panchal QLD Mr Bob Samuels QLD Mr David Schonfeld QLD Ms Ingrid Brundin SA Mr Neville Cornish SA A/Prof Colin Hall 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 Ms Deborah Ward SA Mr Ashley Bell SCOTLAND Mr Kok Toong Leong SINGAPORE Mr Devadoss Suresh Kumar UAE Dr Ivan Cole VIC Dr John Cookson VIC Dr Evan Copland VIC Dr Malcolm Couper VIC Miss Ana Celine Del Rosario VIC Dr Yvonne Durandet VIC Dr Mark Easton VIC Dr Rajiv Edavan VIC BACK TO CONTENTS

Dr Peter Ford Mrs Liz Goodall Mr Bruce Ham Ms Edith Hamilton Mr Nikolas Hildebrand Mr Hugo Howse Mr Long Huynh Dr Amita Iyer Mr Robert Le Hunt Dr Thomas Ludwig Dr Roger Lumley Mr Michael Mansfield Dr Gary Martin Dr Siao Ming (Andrew) Ang Dr Eustathios Petinakis Mr Paul Plater Dr Dong Qiu Mr John Rea Dr M Akbar Rhamdhani Dr Christine Scala Mr Khan Sharp Dr Vadim Shterner Dr Antonella Sola Mr Mark Stephens Dr Graham Sussex Dr Jenna Tong Mr Pranay Wadyalkar Mr John Watson Dr Wei Xu Dr Sam Yang Mr Graeme Brown Mr Graham Carlisle Mr John Carroll Mr Sridharan Chandran Mr Conrad Classen Mr Chris Cobain Ms Jessica Down Mr Jeff Dunning 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 Dr Yanan Li Mr Michael Lison-Pick Mr Ben Miller Mr Sadiq Nawaz 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 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 WA

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MATERIALS AUSTRALIA

CMatP

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. • A CMatP may be offered an opportunity as a mentor for student members. • Networking directly with other CMatPs who have recognised levels of qualifications and experience. • The opportunity to assume leadership roles in Special Interest Networks, to assist in the facilitation of new knowledge amongst peers and members.

What is a Certified Materials Professional? A Certified Materials Professional is a person to whom Materials Australia has issued a certificate declaring they have attained all required professional 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 promotes excellence and innovation in all their professional endeavours.

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

Further Information For further information on becoming a CMatP, contact Materials Australia today: on +61 3 9326 7266 or imea@ materialsaustralia.com.au, or visit our website: www. materialsaustralia.com.au.

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WOMEN IN THE INDUSTRY

Associate Professor Laure Bourgeois Source: Sally Wood Fellow at the Department of Materials Engineering. Two years later she was awarded the prestigious Monash University Logan Research Fellowship to study crystalline phase transformations in lightweight aluminium alloys. In 2006 she joined the newly-created Monash Centre for Electron Microscopy (MCEM) as a Senior Lecturer and Microscope Manager. Since then she has been closely involved in the installation and running of microscopy instrumentation in the specially-built ultra-stable MCEM building. She also runs her own research group and teaches both undergraduate and postgraduate students.

Associate Professor Laure Bourgeois, from Monash University, has over two decades of knowledge in the materials engineering space, with no signs of slowing down. In 1990 she completed a Bachelor of Science at the University of Western Australia, where she first developed an interest in physics, and then crystallography. The crystallography branch of science focuses on the arrangements, and atomic bonding, in crystalline solids.

Today, she works as an Associate Professor at MCEM, and as an Adjunct Research Fellow in the Department of Materials Science and Engineering. This combination of roles allows her to undertake and support research into materials science, it also balances her artistic impulses to explore the natural world. “I have also always loved the idea of looking at marvellous little worlds in mundane things. “Everyday materials can be considered mundane, but there is often a hidden beauty to them, such as aluminium alloy structures viewed in a powerful transmission electron Microscope,”

Associate Professor Bourgeois said. Her role at MCEM involves collaborating with many different researchers to help characterise a wide variety of materials. These materials can be used for renewable energy, bio-sensing or opto-electronics. “I love discovering through ‘seeing’ new structures in the microscope.“ “It’s amazing to be shooting an electron beam thinner than an atom and seeing atoms in the flesh,” Associate Professor Bourgeois said. The MCEM, which was founded in 2005 by Professor Joanne Etheridge and set up as a central university research platform, is a hub for world-class research in electron microscopy. It allows researchers to innovate and share research in the electron microscopy field, and address scientific challenges for the future. Through MCEM, Associate Professor Bourgeois provides expertise and training to researchers from Monash, and other partners in government and industry. She has a strong passion for learning and inspiring the next generation of researchers, which is a large part of her work’s focus. “I love learning about new things all the

Three years later, Associate Professor Bourgeois moved to Paris, France, where she undertook a Diploma of Advanced Studies at the University of Paris-Sud. A short time after, in 1997, she completed her PhD on the topic of carbon nanostructures, which are structures related to nanotubes and fullerenes, at the University of Melbourne. The Associate Professor said her early academic experiences motivated her to undertake further study. “As a physics student, I was introduced to transmission electron microscopy, which seemed the perfect technique to probe the world of atomic structures,” she said. In 2000, Associate Professor Bourgeois joined Monash University as a Research 22 | DECEMBER 2020

The Monash Centre for Electron Microscopy. Image Courtesy of Monash University.

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WOMEN IN THE INDUSTRY

time, whether directly in my field or more broadly.“ “I also enjoy teaching students, whether undergraduates or postdoctoral; it’s great to work with the enthusiastic youth of today,” she said. In addition to her busy schedule, she also supervises PhD students on a range of topics centred on atomic-scale structure, and transformations in light alloys for high-strength applications.

An International Researcher Associate Professor Bourgeois has studied and worked on three different continents, which have prepared her for the international nature of scientific research. After submitting her PhD, she worked as a Research Fellow in Professor Yoshio Bando’s research laboratory at the National Institute for Materials Science (NIMS) – formerly the National Institute for Research in Inorganic Materials – in Japan. “This was a very exciting time: NIMS was not only well funded and the home of many world experts in the field of materials science and microscopy, it also granted many young international scientists with great research freedom.“ “I was very lucky – Professor Bando was particularly supportive and internationallyfocused. His lab also housed topperformance transmission electron microscopes,” she said. During her two and a half years in

Japan, Associate Professor Bourgeois determined the structure of several novel nanomaterials and collaborated with chemists on new crystals for X-ray instrumentation.

“It’s amazing to be shooting an electron beam thinner than an atom and seeing atoms in the flesh.” Upon returning to Australia and joining Professor Barry Muddle’s group at Monash University, Associate Professor Bourgeois’ primary research focus shifted to aluminium and magnesium alloys as highstrength structural materials. This is now her main research interest, where she uses atomic-resolution electron microscopy to elucidate the mechanisms associated with alloy properties. “I was lucky, as I joined a leading international research group from which I learnt a lot,” she said. Through this work, Associate Professor Bourgeois has been collaborating with different research groups in Europe, Asia and Australia. She also regularly collaborates on

many other topics, such as energy nano materials, with colleagues in China, the CSIRO and Monash; and opto-electronics materials, with the CSIRO and interstate colleagues. “Working with other researchers on new materials’ properties to address current energy challenges or to discover new capabilities is really rewarding.“ “Many materials properties are controlled by regions containing very few atoms, and seeing those tiny features in a microscope can generate new insights for materials’ design,” she said.

Leading Research Associate Professor Bourgeois works on projects with a real world impact. Her focus on holistic and meaningful research means that she takes the time to find out not only what the research means, but also why. Her recent Australian Research Council Discovery Projects include the Complex Interfaces and Solid-State Precipitation in Advanced Materials project, which ran for four years. Under this project, Associate Professor Bourgeois led a team of researchers to understand the practical control of solidstate precipitation in materials that have some technological importance. This leading research analysed the microstructures of model aluminium alloys, which many aerospace alloys are based upon. Optimising the properties of these materials remains a formidable challenge. The project utilised the latest microscopy technology and computational techniques to develop atomic-scale mechanisms for the formation of strengthening precipitates. More recently, she led work showing that vacancies, or the absence of atoms, play an even greater role than previously thought in the development of materials’ properties. This work was recently published in the journal, Nature Communications. “I have had the great chance to enjoy a career doing interesting research in exciting laboratories around the world.” “But more than just conducting research on advanced instrumentation, it has been working with many different researchers that has been most rewarding for me,” Associate Professor Bourgeois said.

Image Courtesy of Monash University.

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DECEMBER 2020 | 23

INDUSTRY NEWS

High Performance Titanium Filtration Membranes Produced in Australia Source: Craig Erskine, Advanced Material Solutions (AMS)

Developed in South Australia by Advanced Material Solutions (AMS), the super-strong titanium membrane is unaffected by salt or chemicals such as chlorine and can be adjusted to screen out specific materials down to 0.05 microns. A commercial system has already been installed at a meatworks in Victoria where the filters removed fats, oils, grease, blood cells and reduced e coli levels from 240,000 down to less than 20 parts per 100ml.

“They bring the wool in then they wash out all the dirt and then they remove the lanolin oil to end up with nice clean wool but it creates a lot of waste and it uses a lot of water,” Erskine said.

Porous titanium membrane, showing the diameter and thin wall section, comparison against a $1 Australian coin.

Raw

Filtrate

Concentrate

As a membrane material, titanium is highly suited. It is non-corrosive, light, biocompatible, highly hydrophilic. It can tolerate the full pH scale and chlorides and has high pressure and temperature resistance.

Advanced Material Solutions (AMS) in Adelaide has recently released titanium as a membrane filtration medium that has some real advantages, Craig Erskine explains. The titanium membrane is a technological breakthrough in the world of filtration and separation. It will drastically upgrade liquid/solid separation in an everexpanding industrial sector. The product is the only one of its kind in the world, 100% titanium metal with filtration capabilities from microfiltration 0.8μm (800nm) all the way down to ultrafiltration of 0.05μm (50nm). AMS Managing Director, Gilbert Erskine said

“We’ve got a membrane that removes the particulate to clean the water while leaving the detergents in there but in that there’s also the oil. Then we put it through another membrane that splits and removes oil from water. We’ve proved that we can reuse that water. And on the lanolin itself we end up with this beautiful, sparkling lanolin oil.”

Dairy Caustic (NaOH) recovery the ability to efficiently separate oil and water had led to the development of the first of a possible five wool scouring plants in Australia and the potential for a further three in New Zealand.

The titanium membrane has an asymmetric structure. It is a continuous length of porous titanium tube. It has no joins, with lengths up to 1360mm long, wall thickness of 0.35mm and internal bore dimensions of 2.5mm ID, 5.5mm ID and 12mm ID, making this the only one of its kind in the world.

He said the dual filtration system led to a huge reduction in water, chemical and energy use because the cleaning water could be reused and did not to require as much energy to reheat.

The single length titanium membranes get bundled together, where depending on diameter of the filter casing, there can be 50 to 2000 titanium tubes per filter casing, and up to 80 casings in a 40 foot container.

CBD Cannabidiol (cannabis oil)

Scanning Electron Microscope (SEM) picture of a cross section of the AMS asymmetric titani-um membrane.

24 | DECEMBER 2020

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Algae lagoon water Raw, Concentrate and Filtrate

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About AMS Advanced Material Solutions (AMS) is a wholly Australian-owned and operated company specializing in quality products made from high value alloys using advanced manufacturing technologies. Advanced manufacturing allows AMS to produce complex parts with high consistency, high strength, tight tolerances and almost no waste. AMS make the smallest diameter, longest single length metallic microfiltration membrane in the world and are the only producers of Metal Injection Moulded (MIM) components in Australia. All AMS products are produced and controlled using our Quality Management System, developed Industrial Automated Crossflow according to ISO 9001:2008.

2 stage titanium crossflow filter

Being titanium metal gives a lot of advantages over other polymeric or ceramic membranes, which have limiting factors such as temperature, thermal shock, chemicals, pH limits, chlorides and cleaning times. Unlike some metallic membranes on the market that have a ceramic coating (be it either TiO2 or ZrO2 inside the metallic tube), the AMS titanium metallic membrane is all titanium. A wide variety of industry sectors have conducted tests and have all reported great success, these range from municipal, textile industry, meat rendering, algae, plant protein, cannabidiol (CBD) oil, yeast, pre-filtration to desalination, dairy milk solids concentration, potato starch recovery, kerosene water separation, oil and water separation and aquaculture. The titanium membrane is not just limited to these feed streams, new opportunities and industries are opening all the time. The market for recovering fats, oils and grease (FOG) is ever growing and a global concern, as the population of the planet expands, titanium membranes provide opportunities for the FOG to be reprocessed. AMS can provide potable quality water on the permeate side of the membrane and a highly concentrated FOG liquor on the retentate side. Oils and Fats - AMS can separate oil and fat from water. Algae for municipal applications is an increasing market, titanium, is a well suited material for the filtration recovering lake waters or wastewater treatment ponds of with a 99.9% recovery. WWW.MATERIALSAUSTRALIA.COM.AU

Plant Protein Raw

Filtrate

Concentrate

The global filtration market is worth around 49 billion dollars annually, which mostly uses disposable membranes (polymeric or ceramic), which then become wastes. Titanium membranes outlast both types of filtration materials and can be reused and recycled. All existing filtration systems have issues with variable feed streams. For instance, filtration systems may be unable to handle variable solids (SDI), temperature, pH, fats, oils, grease and algae, COD, BOD, TDS, SS, Fe, Mn, the list goes on. For titanium membranes, it is not worth getting upset over variable changes. Yes— flux may change and indeed we may need to offer different cleaning—but you will always receive our membrane clean. It is for this reason that we pride ourselves on being able to handle variables. AMS is always committed to a safer, cleaner, greener Australia.

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Facilities AMS is located in Lonsdale, South Australia. It has a 2,500m2 manufacturing area incorporating metallic feedstock production, Metal Injection Moulding, sintering and testing facilities. AMS also boasts a 1,200m2 machine shop, fabrication and electrical workshop, as well as an offsite workshop for mild steel support the manufacturing facilities complete custom filtration systems according to clients’ needs and specifications.

Capabilities AMS has the in-house capability to take a variety of projects from concept to completion. Their capabilities include: • Development, engineering, design, drafting, 3D modelling, fabrication, commissioning, FAT, SAT and documentation in the process, mechanical, electrical, instrumentation and automation disciplines • In-house and on-site training • In-house and on-site filtration trials • New membrane development and component prototyping in conjunction with Australian Universities For further information, visit: http://www.ams100.com

DECEMBER 2020 | 25

INDUSTRY NEWS

Using Protons to Tune Interlayer Forces in Van-Der-Waals Materials Source: Sally Wood

A joint collaboration between Australia and China recently demonstrated for the first time that interlayer coupling in a van der Waals (vdW) material can be largely modulated by a protonic gate. This protonic gate can inject protons to devices from an ionic solid and opens the way to exciting new uses of vdW materials, through the insertion of protons as an important new technique. It also has several real world applications, which are readily available for the wider 2D materials research community. The Australian component part of the study was led by the Australian Research Council Centre of Excellence in Future Low-Energy Electronics Technologies (FLEET), which is developing developing a new generation of ultra-low energy devices. FLEET researchers at RMIT University were assisted by partner organisation – High Magnetic Field Laboratory, Chinese Academy of Sciences, led by the vicedirector Professor Mingliang Tian. This lab was well positioned to offer support to its RMIT counterparts, as the premium centre for frontier research on material science, condensed matter physics and chemistry. Graphite is the most famous vdW material, which are made of many 2D layers held together by weak, electrostatic forces.

Single layers of vdW materials can be isolated individually, such as the famous Scotch tape method of producing graphene, or stacked with other materials to form new structures. The study’s first author and FLEET research fellow, Dr Guolin Zheng described this process. “But the same weak interlayer forces that make vdW materials so easy to separate also limit these materials’ applications in future technology,” Dr Zheng said. Stronger interlayer coupling in vdW materials would significantly increase potential use in high temperature devices utilising quantum anomalous Hall effect, and in 2D multiferroics. The new RMIT-led study demonstrated that coupling in a vdW material, Fe3GeTe2 (FGT) nanoflakes, can be largely modulated by a protonic gate. With the increase of the protons among layers, interlayer magnetic coupling increases. “Most strikingly, with more protons inserted in FGT nanoflakes at a higher gate voltage, we observed a rarely seen zero-field cooled exchange bias with very large values,” said co-author of the paper, Associate Professor Lan Wang. Through the successful realisation of both field-cooled and zero-field cooled exchange bias in FGT, it implies the interlayer coupling can be largely modulated by gate-induced proton insertion. This technique opens the road to many applications of vdW materials requiring strong interface coupling.

FLEET Chief Investigator, Associate Prof Lan Wang (RMIT).

26 | DECEMBER 2020

vdW materials and heterostructures are keenly studied at FLEET, which brings together over a hundred Australian and international experts, with the shared mission to develop BACK TO CONTENTS

Hall-bar device on solid proton conductor used for measurements

a new generation of ultra-low energy electronics. The impetus behind such work is the increasing challenge of energy used in computation, which uses five to eight per cent of global electricity and is doubling every decade. At the nano scale, nanofabrication of functioning devices will be key to the Centre’s future success. Specialised techniques needed to integrate novel atomically-thin, 2D materials into high-quality, high-performance nanodevices are coordinated within the Centre’s enabling technology B. The partnership studies 2D magnetic materials, vdW ferromagnetic heterostructures and topological condensed matter systems. Theoretical calculations were also performed by Professor Yujun Zhao’s group at the South China University of Technology. As well as funding from the Australian Research Council, the researchers acknowledged the support of the RMIT Micro Nano Research Facility in the Victorian Node of the Australian National Fabrication Facility, and the RMIT Microscopy and Microanalysis Facility. FLEET’S research is centralised on the challenge of reducing the energy used in information technology, which now accounts for eight per cent of all the electricity used on Earth. It is also doubling every ten years. Its research sits at the very boundary of what is possible in condensed-matter physics. WWW.MATERIALSAUSTRALIA.COM.AU

INDUSTRY NEWS

ANISOP and UniSA Partner to Deliver Infection Resistant Dental Implants Source: Sally Wood

Advanced research into the amazing antimicrobial properties found in creatures and plants has laid the groundwork for a new partnership between medical technology company, ANISOP Holdings and the University of South Australia (UniSA), to develop advanced dental implants resistant to microbial infection. Lead UniSA researcher, Professor Krasi Vasilev said the partnership seeks to translate the nanoengineering concepts into new and improved implants that protect patients from implant-related infections. “This is the beginning of an exciting collaboration with the potential for growth to include a wider range of medical devices,” Professor Vasilev said. UniSA researchers have looked to nature to find examples of bacterial and microbial resistance. “Research has shown that the surfaces of certain species of plants and animals are highly resistant to microbial attack because of their unique structure at the nanoscale,” Professor Vasilev said.

European Union – providing a clear slate for the research to progress. “The impressive breakthrough with this research is that it relies on a nanomechanics to defend from bacteria rather than drawing on a diminishing pool of antibiotics to fight infection,” Professor Vasilev said.

rights to commercialise a novel surface treatment for titanium implants that is transformational, safe, and effective,” Dr Barker said. “Our partnership with UniSA, and access to world experts such as Professor Vasilev, is a key strategic ingredient to help take this technology to market,” he added.

The UniSA-ANISOP collaboration will position products for market and commercial success in what is a $5 billion global dental implant market. It will also provide licensing opportunities for orthopaedic and trauma applications.

UniSA Deputy Vice Chancellor Research and Enterprise, Professor Marnie HughesWarrington also said the collaboration is a cogent example of how universities play a significant role in creating new knowledge and supporting its commercialisation.

“This kind of nanotechnology opens up important new ways of preventing infections before they become a serious or potentially life-threatening problem.“

“This research started with a clear industry problem and researchers brought their considerable creativity and knowledge to finding a solution that could be applied in an industry context – considering all the elements, from the actual nanoengineering, to how that technology could be brought to a commercial manufacturing environment,” Professor Hughes-Warrington said.

“It will also help save millions globally from the costs of having to repeat implant procedures for, in the case of some devices, the five to 10 per cent that fail,” Professor Vasilev said. ANISOP Chief Medical and Technology Officer, Dr Dan Barker said infection prevention is the most important unmet need for medical devices such as dental and orthopaedic implants. “We have acquired the intellectual property

“It’s exciting stuff and it highlights the significant contribution UniSA is making to South Australia and to developing technologies that will play a role in rebuilding our economy post the pandemic,” she added.

“Our work has focussed on mimicking structures found on the wings of insects which contain billions of nanopillars that operate as a nano mechanical barrier to bacterial colonisation,” he added. Professor Vasilev is a Fellow at the Royal Society of Chemistry and has been actively engaged in postdoctoral research since the completion of his PhD in 2004. “The structure mechanically kills the same broad range of bacteria known to cause orthopaedic and dental implant infections, which can lead to the failure of the procedure,” he said. The UniSA-ANISOP collaboration will take the research from ‘the bench to the bedside, by demonstrating the safety and efficacy of new nano engineered surfaces for implants. Proof of concept research has already been undertaken, and patents have been awarded in both Australia and the WWW.MATERIALSAUSTRALIA.COM.AU

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DECEMBER 2020 | 27

INDUSTRY NEWS

Is a Rotary Tube Furnace Right for your Process? Source: Deltech

Not only do rotary tube furnaces provide efficient heat and mass transfer, they minimise material handling in applications such as powder processing. Deltech rotary tube furnaces are custom designed and built for your application requirements. You can specify a range of factors, including: • Maximum operating temperatures up to 1,700°C • Workspace size • Residence time • Tube rotation rate • Tube inclination angle • Temperature profile • Atmosphere flow rate

You May Not Know That…

• Powder bed depth

Rotary tube furnaces are unsuitable if you need long residence times, with a small angle of inclination and a slow tube rotation rate. In this instance, it is difficult to control residence time for more than two hours. Look to a lab scale or production size bottom load, front load, or top hat furnace if your product requires longer processing times. These furnaces are available with optional controlled atmosphere capability.

• Feed rate

Factors to Consider when Choosing a Tube for Your Furnace Tube stresses include rotational speed, amount of material, diameter of the tube, suspended length, and tube thickness. For tube diameters larger than 9”, alloy tubes are your best option. However, keep in mind that alloy tubes are limited to temperatures under 1,200°C. It is also important to use ceramic tubes when metals in the alloy could react with a high purity product or off gas. Ceramic tubes are also required for high temperature processing. Lower grade silicon carbide tubes are porous, as are alumina oxide tubes. This porosity also makes lower grade silicon carbide tubes undesirable for most applications that require processing in a controlled atmosphere. Quartz tubes are not permeable, which means they are only suitable for processing under 1,300°C.

About Deltech Furnaces Deltech manufactures standard and custom electric resistance labscale and production furnaces and control systems for operating temperatures from 1,400°C to 2,000°C in air, inert atmospheres (with and without vacuum assisted evacuation), and under positive pressures. Deltech also offers a special ‘RS’ line for glass melting applications. With a presence in over 30 countries all around the world, Deltech maintains stock and supplies related spare parts including reline kits, heating elements, thermocouples, and ceramics including hearth plates. They also sell, install, and service all their products. From their 1,800m2 production facility in Denver, Colorado, Deltech can design and build even the largest scale furnaces. Deltech supplies furnaces to materials science researchers and manufacturers around the world. In the US, just some of their customers include universities, national labs, and industrial ceramics manufacturers such as include M.I.T., the Carnegie Institute, Pacific Northwest Labs, the Jet Propulsion Laboratory, ATK, 3M Specialty Glass Division, Kyocera, and Coors Tek. Over the course of its 50 years in business, Deltech has established a reputation for delivering high-quality custom projects that others will not—all without the usual charges required for the engineering time required for custom designs.

Further Information Not sure what you need for your application? We can help.

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DECEMBER 2020 | 29

INDUSTRY NEWS

Global 3D Printing Partnership to Boost Local Manufacturing Source: Sally Wood

RMIT University will partner with Europe’s leading 3D printing institute to support the transformation of Australian manufacturing. The memorandum of understanding, or MoU, with the Fraunhofer Institute for Material and Beam Technology IWS, covers staff and student exchanges and joint research projects with Australian companies. The applied projects will focus on using advanced 3D printing technologies to manufacture and repair high value-added products. RMIT’s Deputy Vice-Chancellor of Science, Engineering and Health, and Vice President for Digital Innovation, Professor Aleksandar Subic, said the deal will grant Australian companies access to some of the world’s best experts and technologies, critical for Industry 4.0 (i4.0) transformation. “Germany is a key global driver of i4.0 technology and Fraunhofer IWS is the leading applied 3D printing institute in Europe,” Professor Subic said. “It’s exciting to have the best in Australia partnering with the best in Europe, working together on high impact, globally relevant projects with industry.” The i4.0 transformation describes the

trend towards cyber-physical systems with high levels of automation, data driven processes and digital manufacturing technologies like 3D printing. Professor Subic said the partnership was also a significant step towards establishing a world-leading 3D printing technology centre within the RMIT Advanced Manufacturing Precinct. Director of Fraunhofer IWS, Professor Christoph Leyens, said the agreement was the first of its kind they had signed in Australia. “The decision was an easy one, considering RMIT’s Centre for Additive Manufacturing is one of the top addresses for additive manufacturing worldwide,” Professor Leyens said.

The announcement follows other recent MoUs with Siemens and Festo, which are designed to drive workforce transformation for i4.0 in the Australasian region, including the establishment of an Industrial Digital Innovation Hub at RMIT.

“Our primary goal through this partnership is closer contact with the Australian market where there is so much latent potential for additive manufacturing, while at the same time fostering student exchange and joint PhD supervision that we know will be of high quality,” he added.

Director of RMIT’s Advanced Manufacturing Precinct and Centre for Additive Manufacturing, Distinguished Professor Milan Brandt, said after years of decline across much of Australia’s manufacturing sector, there were now clear opportunities for Australia to carve out a new niche.

Once safe to travel internationally, researchers from Fraunhofer IWS who are specialising in metal additive manufacturing, will arrive in Melbourne to work alongside RMIT researchers.

“We cannot compete with labour costs on low value, high volume manufacturing, but Industry 4.0 presents us with a real opportunity in high value-add technology, such as rapid repairs of metal parts in mining, defence, transport and renewables, so that’s where we need to head,” Professor Brandt said.

They will also be joined by local postgraduate students to discuss industryengaged projects. The partnership will also allow RMIT postgraduate students to travel to Germany for research at Fraunhofer IWS.

Professor Aleksandar Subic says the deal gives Australian companies access to some of the world’s best experts and technologies, critical for Industry 4.0 transformation.

30 | DECEMBER 2020

RMIT’s Paul Spithill with a batch of the 3D printed plastic face shield frames.

“This partnership will serve as a conduit between Australia and Germany to tap into that rich vein, which will support Australia’s manufacturing transformation at a critical time, while also training the next generation of local additive manufacturing experts,” Professor Subic said.

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“Our future will be in collaborating nationally and globally, co-designing and co-creating advanced manufacturing solutions, and being agile in providing those solutions as they’re needed by industry,” he added. Professor Brandt also said 3D printing technology was perfectly suited for a tailored, agile response to all industry needs, as highlighted through recent work by AMP staff in printing face shields for frontline healthcare workers. “Faced with potential PPE shortages earlier this year when coronavirus first hit our shores, we optimised open source designs for face shields and printed hundreds of them for trials in local hospitals within days,” he explained. WWW.MATERIALSAUSTRALIA.COM.AU

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Modernising Asbestos testing with a desktop Scanning Electron Microscope Source: ATA Scientific

Safe Environments provides numerous services for clients Australia-wide, including slip testing, asbestos plus hazardous material testing, expert risk assessment and advice across a range of occupational health and safety services. The team has recently upgraded their laboratory by purchasing a Malvern Panalytical Epsilon x-ray fluorescence (XRF) and Aeris x-ray diffraction (XRD) systems, along with a Thermo Scientific Phenom XL G2 desktop Scanning Electron Microscope with energy-dispersive X-ray spectroscopy capabilities (SED-EDS). With this new equipment and their existing expertise in occupational hygiene, characterising hazardous dust and chemicals, Safe Environments has positioned itself to offer the most advanced testing available for health and safety issues. Characterisation of asbestos-containing materials is of great importance, whether it be a small home renovation or large-scale construction. Accurate identification and classification of commercial bulk materials, naturally occurring asbestos and airborne asbestos fibres is a critical part of managing the risk of exposure to workers and the community. Construction is often halted when the presence of asbestos is suspected, costing time and money. Rapid and accurate classification of the unknown fibres is essential to maintain a healthy work environment while ensuring the project continues. Traditional asbestos testing uses a combination of Phase Contrast Microscopy (PCM) and Polarised Light Microscopy (PLM), in addition to dispersion staining with oils of different refractive indices to the fibres being studied. Fibres interact with the polarised light due to their crystalline structure and the observed morphology of the fibres are used to classify potential asbestos types. This longstanding method is an industry standard that is a critical part of any asbestos testing laboratory. However, this technique which is part of the Australian Standard (AS4964) requires a method such as SEM with elemental analysis to be able to identify and confirm all six regulated types of asbestos. 32 | DECEMBER 2020

Traditional Polarised Light Microscopy (PLM) imaging, like that shown above, is a critical tool in identifying asbestos types but lacks the certainty that chemical analysis from Scanning Electron Microscope with energy-dispersive X-ray spectroscopy capabilities (SED-EDS) provides.

Traditional Polarised Light Microscopy (PLM) imaging, like that shown above, is a critical tool in identifying asbestos types but lacks the certainty that chemical analysis from Scanning Electron Microscope with energydispersive X-ray spectroscopy capabilities (SED-EDS) provides. When there is uncertainty in the results of the traditional techniques, the team at

Safe Environment turn to their Phenom SEM with EDS, particularly for cases of unknown mineral fibres. PCM which is used for counting fibres on an air filter does not differentiate between asbestos and nonasbestos fibres. The method simply counts the number of airborne fibres collected which have asbestos-like morphology. As a result, construction sites often shut down for days due to interfering respirable

Scanning Electron Microscope (SEM) images, like this one of Amosite from the Phenom XL G2, provide high-resolution shape and morphological information.

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Techniques available at an asbestos testing laboratory provide different information such as determining the crystalline structure and morphological characterisation. However, only SEM-EDS can provide critical morphological and elemental identification.

Crocidolite Asbestos fibres. The chemical analysis using Energy-Dispersive X-ray Spectroscopy (EDS) can be targeted from the SEM images to chemically characterise specific fibres.

fibres from carpet or fibreglass insulation bats, while an investigation takes place. This inaccurate characterisation can be prevented when an SEM-EDS is used in concert with PCM. Determining the chemical composition of fibres using EDS, whilst also providing high resolution-images of the fibre morphology is what sets the Phenom SEM apart from traditional techniques. EDS works by exciting atoms in the structure of the sample with the Phenom’s electron beam, which can be targeted at specific fibres or areas. As the atoms within the targeted interaction volume are excited, some of the absorbed energy forces a core-shell electron to be ejected. A higher energy outer-shell electron then fills its place, releasing the difference in energy as an x-ray that has a characteristic spectrum based on the excited atom. These x-rays are then collected by the sensitive x-ray

A typical EDS spectra of Chrysotile asbestos fibres. The position of the peaks identifies the elements present, while the signal corresponds to the concentration. The Phenom XL G2 has a maximum Acceleration Voltage of 20kV.

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detector which is integrated within the Phenom and this allows for the elemental composition and concentration of the sample to be determined. Specific asbestos types can then be identified by comparing the measured spectra to that of reference material and by comparing the atomic ratios of elements present to known asbestos chemical structures. While there are many techniques available for asbestos testing, most rely on morphological and crystalline structure information for identification which lacks the certainty of direct chemical identification. While a Transmission Electron Microscope (TEM) with EDS can provide all three pieces of characterisation information, TEMs can be complicated systems and cost-prohibitive for a commercial testing laboratory. This was also the case for floor-model SEM-EDS before affordable yet powerful desktop SEMs like the Phenom XL become available. The Phenom XL provides the option for sample automation. With its extra-large sample stage, the Phenom XL can fit 36 standard 12.7 mm SEM pin stubs with bulk samples mounted, or with a filter holder inserted nine 25 mm standard airborne fibre collection filters can be mounted. The Phenom XL has several different automated imaging and fibre characterisation options available to process these numerous samples. Combined with the fact that sample preparation for SEM is less involved than for traditional methods like PLM, the BACK TO CONTENTS

use of a Phenom SEM with EDS not only provides more information than alternative methods but does so significantly faster as well. The outcome of the new Phenom SEMEDS system for the customers of Safe Environments is that there will be significantly less uncertainty in testing. This new method compliments their existing techniques by giving unique information and providing confidence in results when critical decisions need to be made. The SEM provides lower detection limits and greater accuracy than the traditional methods, which equates to a safer work environment. By combining morphological data with chemical identification, asbestos samples can now be quickly and accurately identified, removing the need for expensive and timely work site shutdowns and material removal. Safe Environments is in the process of adding the Phenom XL G2 SEM to their existing NATA accreditation for asbestos analysis and will be offering its capabilities along with their other techniques to all commercial and industrial customers. For more information contact: Safe Environments Pty Limited +61 2 9621 3706 info@SafeEnvironments.com.au www.SafeEnvironments.com.au

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New Facility to Put Swinburne and CSIRO at Forefront of Manufacturing Digitalisation Source: Sally Wood

Swinburne University of Technology and Australia’s national science agency, CSIRO have collaborated to launch a joint research and development facility in Victoria. The National Industry 4.0 Testlab in Composite Additive Manufacturing will be the first national facility in a network of six state-based Industry 4.0 Testlabs established across Australia. It will include a pilot plant for a world-first process for the additive manufacturing of carbon fibre composite materials. Dr Marcus Zipper is the Executive Director of CSIRO’s future industries sector, who said the partnership is a major project for the wider industry. “The joint CSIRO/Swinburne Testlab is focused on a world-first process for additive manufacturing of carbon fibrereinforced composites at an industrial scale. “This makes its location, at the heart of Clayton’s additive manufacturing precinct, a great fit. At CSIRO we’re all about creating opportunities for SMEs and the broader innovation ecosystem, and this Testlab is another example of that,” Dr Zipper said.“ The facility will seek to work with a variety of collaborators, forging a path for new Australian manufacturing with high-tech products based on sustainable, advanced manufacturing processes. It also intends to enable flexible manufacturing that can rapidly adapt to changing industry demands and future environmental challenges. The Industry 4.0 initiative allows manufacturers to innovate the ways in which they create and capture value. It will be used to prototype commercial parts from carbon fibre at a lower cost than traditional manufacturing, with minimal waste and improved production capability. The goal of the new facility is to enable small and medium enterprises to test new technologies and business models created by Industry 4.0. It will also explore aspects 34 | DECEMBER 2020

Artist’s impression of the Industry 4.0 Testlab in Composite Additive Manufacturing, located at CSIRO’s Clayton site. Construction began earlier this year and is due to be completed in October.

from design to economic feasibility in a pre-competitive environment with minimal technical and financial risk. Swinburne’s Deputy Vice-Chancellor for Research and Enterprise, Professor Bronwyn Fox added that the facility builds on the strong collaborative partnership with CSIRO. “The facility will build on the strong track record of collaboration between Swinburne and CSIRO. Strengthening that partnership will catalyse the development of new digital manufacturing technologies,” she said. “I have worked for or with CSIRO for my entire career and have seen the incredible impact that university partnerships with CSIRO can have in developing new technology that stimulates economic growth for Australia. I’m personally committed to, and very passionate about, this strategic collaboration,” Professor Fox added. The Testlab will also help explore opportunities for manufacturing processes that might help in developing new products for the automotive industry at competitive prices. The automotive industry has undergone significant changes in recent years, particularly in Australia with the closure of many local plants. BACK TO CONTENTS

The joint Testlab will also fill potential gaps in the intermediate product market. The Advanced Manufacturing Growth Centre, which was established in 2015, reported that 41 per cent of the global economy is reliant on this area. But Australia only participates in less than one per cent of this at the present time. Many Australian companies do not have a digital strategy in place, but through this Testlab, and with other crosscollaborations, businesses will begin to understand its benefits. Swinburne and CSIRO have a strong association and links to Industry 4.0. The program is fundamentally focused to changing a business to capitalise on new and emerging trends, and capture value. A broad network of suppliers and end users has contributed to the codesign and creation of the Testlab. The network includes global aerospace and automotive companies and their supply chains with other partners such as ARENA2036, Fill, Quickstep, Langzauner, Plataine, and Cikoni. Construction of the partnership’s facility, at CSIRO’s Clayton site in Victoria, began earlier this year and and is expected to reach completion in late 2020.

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INDUSTRY NEWS

Deakin’s Boron Nitride Nanotubes (BNNT) Are Pure and Industry-Ready Source: Sally Wood

A recent study has revealed that Boron Nitride Nanotubes (BNNT) have the highest purity among commercial products in the world. The work was led by co-inventors at BNNT Technology Limited who used patented technology from Deakin University to produce the nanotubes. Professor Ian Chen, Deakin’s nanotechnology group leader; and Dr Luhua Li, Senior Research Fellow at Deakin’s Institute for Frontier Materials (IFM), welcomed the outstanding results. “The commercialisation of BNNTs is the culmination of two decades of research and it is exciting to see the rapid progress that is being made,” Professor Chen said. The diameters of the BNNTs are around 30 to 120nm. They are also hollow inside, and researchers even have the capacity to see the thin wall of the nanotubes through high functioning magnification images. BNNT technology is crucial to the creation of new and improved materials that shield radiation for safer aviation, space travel, defence, hospital equipment, and in some high-risk industries.

“BNNT Technology has the potential to be one of the standout success stories of University commercialisation in Australia, and has already led to three further spin out businesses,” Mr Spincer said. ManuFutures is a purpose-built hub with a specific focus on advanced manufacturing innovation. It was developed in strong partnership with the Victorian State Government to support emerging Australian enterprises to scale and commercials their products. “As part of a broader partnership between Deakin University and the PPK Group, joint venture companies have already been established to use advanced BNNT composite materials in Li-S battery (Li-S Energy Ltd) and 3D dental ceramics (3D Dental Technology Pty Ltd) with more expected to follow,” Mr Spincer added. The facilities also provide tenants with access to a vast array of research, knowledge and business support options to bring research, like the BNNT breakthrough to life. “We look forward to continuing our support of BNNT Technology at ManuFutures both as a shareholder and research partner as it seeks to fulfil the exponential growth in global demand for BNNTs.”

The defensive barrier created by the technology provides protection against all risks of radiation-emitting environments or products. Professor Chen’s counterpart, Dr Li added that he was always confident about the ground breaking project.

An independent analysis of BNNT purity was also produced by BNNT Technology Limited in July.

“We have always been confident in the scalability and quality of our technology, but it is still pleasing to see such a stunning independent validation,” Dr Li said.

The review analysed seven BNNT products from five different suppliers. The analysis provided researchers with important information about their morphology and purity, by using scanning electron microscopy. A sample of Boron Nitride Nanotubes.

BNNTs are super flexible fibres that are 100 times stronger than steel but as light as carbon fibre, with potential applications in industries ranging from aviation to mining, medicine, and space travel. They are notoriously expensive to produce, with one kilogram valued at $900,000, and also difficult to manufacture at scale. The IFM has led global research into BNNTs for a number of years, becoming the first in the world to develop and patent the technology that allows them to be manufactured in bulk for the first time. In 2018, IFM licensed its BNNT manufacturing technology, becoming BNNT Technology Limited, a start-up based at the Deakin’s ManuFutures facility in Victoria’s regional city, Geelong. The company’s new $3 million plant, at ManuFutures began production in 2019 and is now in the advanced stages of scaling up to meet worldwide demand for BNNT products in a variety of new material applications. Deakin’s Executive Director of Research Innovations, Ben Spincer, believes BNNT Technology could become a major new business, boosting Geelong’s reputation as the home of advanced manufacturing in Australia. WWW.MATERIALSAUSTRALIA.COM.AU

Boron Nitride Nanotubes under the microscope.

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DECEMBER 2020 | 35

INDUSTRY NEWS

Silicosis the Silent Killer Source: Dr. Cameron Chai

While the COVID19 pandemic is publicly sweeping its way across the globe, there is another materials-based crisis that is killing skilled tradesmen that is also on its way to becoming a national pandemic. Our penchant for polished stone and concrete surfaces and the desire to move transport systems underground have lead to rising incidences of silicosis. In a report titled “Occupational Lung Diseases in Australia 2006–2019” carried out by Safe Work Australia and Monash University, it was reported that there is an “increasing number of cases of an accelerated and rapidly progressive form of silicosis and associated Progressive Massive Fibrosis (PMF) have been identified among engineered stone workers in Australia”. In 2018 the Office of Industrial Relations, Queensland Government screened 1017 workers who had been exposed to respirable crystalline silica (RCS) with 302

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exhibiting abnormalities requiring further testing from respiratory physicians. Of these, 199 were diagnosed with a workrelated respiratory condition including 26 with PMF and 163 with work-related silicosis and 10 with another respiratory condition. This resulted in 186 claims submitted to WorkCover Queensland including 100 silicosis claims lodged in Queensland between August and November 2018. Cabrini Respiratory and Sleep Disorders Physician Dr Ryan Hoy said, “The first case of this recent wave of silicosis in Australia was reported in 2015. Since then, we have seen a rapid increase in presentations of the disease.” What’s more, he describes it as “unfathomable” that silicosis had re-emerged given that it was a totally preventable disease.

What is Silicosis Silicosis is a preventable but irreversible disease that affects the lungs. People can develop silicosis when they work in environments where they are exposed to RCS dust particles. Continued inhalation

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of silica dust leads to the formation of nodules and scarring of the lung tissue, otherwise known as pulmonary fibrosis. While it may take many years to develop, sufferers will be afflicted with reduced lung capacity, sometimes requiring oxygen and other devices to help them breath. In the worst cases, severe scarring can result in PMF. The extensive scarring and stiffening of the lung make it difficult to breath. While early stage symptoms may be very difficult to detect, down the track those suffering from silicosis typically endure coughing, breathlessness and tiredness Three forms of silicosis have been identified: • Acute silicosis develops after only a few weeks to five years of high exposure to RCS and rapidly progresses to respiratory failure. It has occurred in sand blasters and silica flour workers. • Accelerated silicosis develops within 5 to 10 years after the initial exposure to RCS and is also associated with high exposure, for example in those

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INDUSTRY NEWS

working with engineered stone. In accelerated silicosis, the progression to PMF can occur within a few years. • Chronic silicosis has historically been the most common form of silicosis and develops more slowly. With lower exposure levels, people may not show symptoms for more than 10 to 20 years after first exposure.

it can lead to silicosis, which can be fatal in as little as five years and can affect anyone, regardless of age. In fact, any operation that disturbs or breaks crystalline silica containing materials e.g. mining operations, quarrying and building demolition, can be a sources of silica dust or RCS. The following table outlines some sources of crystalline silica

Typical crystalline silica levels in different materials are: Material

Silica Content (approx.)

Sand & sandstone

70-100%

Manufactured stone Granite

>93%

20-45% (typically 30%)

Concrete & mortar

25-70%

Calcium silicate bricks

50-55%

Slate

20-40%

Brick

up to 30%

Fibre cement sheet

10-30%

Demolition dust

Silicosis is also a gateway to other respiratory problems such as lung cancer, tuberculosis and chronic bronchitis. Furthermore, it has no cure with perhaps the exception of a lung transplant and can only be treated with supportive care. In an article authored by Dr. Susan Miles from the School of Medicine and Public Health at the University of Newcastle, people, diagnosed with silicosis lose an average of 11.6 years of their lives.

Sources of Crystalline Silica Dust Silica is the most abundant mineral on earth. Crystalline silica or quartz is found all around us, from sand and sandstone, through to soil, natural stone products such as granite, engineered stone products as well as concrete and brick. Its popularity in engineering and building applications continues to grow due to its durability, good looks and the high-end finishes that can be achieved. When silica containing materials are machined using processes such as cutting, drilling, sanding or grinding, silica dust is generated. When this dust is inhaled, WWW.MATERIALSAUSTRALIA.COM.AU

3-4%

Marble

Limestone

Exposure standards Following a review by Safe Work Australia, they reduced the recommended exposure level from 0.1mg.m3 in any weighted 8hr period down to 0.05mg.m3. This guideline has been implemented by all states and territories by July 1, 2020.

How to Avoid Exposure to Crystalline Silica Dust There are a number of ways to reduce the risk of silicosis: 1. Elimination or substitution – Change designs such that silica-free materials are being used, or substitute for lower silica content materials 2. Isolation – Any areas where silica dust is generated should be isolated to safely exclude other workers 3. Engineering controls – Use of suitable ventilation and dust capture systems, in conjunction with good housekeeping practices e.g. use of H or M class vacuums 4. Administration – Use of safe work procedures, minimising workers BACK TO CONTENTS

exposure, alerting other workers and visitors of dangers and suitable education and supervision 5. Personal Protective Equipment – Use, maintenance and training in the proper use of personal Respiratory Equipment (PRE) Most importantly, the generation of crystalline silica dust can be eliminated using wet machining processes while the use of half face piece reusable or disposable respirators as a minimum, that comply with the Australian Standard 1716:2012 Respiratory Protective Devices is also necessary.

Health Monitoring Under model WHS Regulations, it is mandatory for a PCBU or Person Conducting Business or Undertaking which involves workers who are in contact with crystalline silica dust that could pose risks to their health to provide health monitoring. This involves engaging a medical practitioner to examine and monitor workers to check if exposure to crystalline silica is affecting their health.

Summary The following two statements from Safe Work Australia CEO, Michelle Baxter best sum up the silicosis situation: “Businesses that work with silica containing products, such as engineered stone, have a duty to ensure the health and safety of their workers is protected and must do all that is reasonably practicable to control exposure of their workers to respirable crystalline silica (silica dust). This includes compliance with the recently revised workplace exposure standard for respirable crystalline silica which has been implemented in most states and territories from 1 July 2020.” “Previously in Australia, silicosis was a disease found in workers that mined or worked with natural stones. Silicosis is now being diagnosed in workers that create silica dust through mechanical processing of engineered stones such as, cutting, grinding, trimming, sanding or polishing.” On a final note, if you are having renovations done that involve machining or polishing stone, tile or concrete products, please ask the tradesmen to wet process. You could save their lives!

DECEMBER 2020 | 37

INDUSTRY NEWS

Sigray Launch Revolutionary X-Ray Microscope with Unique Imaging Modes Source: Dr Cameron Chai, AXT Pty Ltd

With a long history in X-ray microscopy (XRM), Sigray, have recently launched the next generation PrismaXRM submicron 3D X-ray microscope that brings synchrotronlike performance to your laboratory. With industry-leading spatial resolution of 0.5µm for 3D tomography, voxel size below 60nm and the most advanced contrast imaging modes, you will be able to see things never before possible. The PrismaXRM has already won the 2020 Microscopy Today Innovation award thanks to its flexible customisable platform. It incorporates the latest developments in x-ray technology, including a diamond backed transmission x-ray source, diffractive x-ray gratings and novel photon counting detector technology that take performance to the next level. Sigray has revolutionised XRM with tri-contrast imaging. While X-ray absorption contrast microscopy has come a long way in recent times, there are still features and details that it can’t detect. Sigray now offer two addition imaging modalities that are simultaneously acquired. • Quantitative Phase™ - a completely new phase contrast mode that provides quantitative access to refractive index and compositional information • Subresolution Darkfield™ - reveals microstructural changes, including cracks and voids, that are otherwise invisible in absorption contrast These new contrast imaging modes now allow you to see hidden defects (cracks and voids) and quantitative information on density to improve segmentation. With these new imaging modes and resolution, the PrimsXRM is ideal for applications including: • Materials – Carbon Fibre Reinforced Plastics (CFRP composites) • Biomaterials – Unstained biological tissues (plants and animals) • Energy - Batteries and fuel cells - in operando and in situ • Failure Analysis - Cracks, voids, and delamination previously invisible for x-ray microscopy are now visible using the PrismaXRM’s unique Quantitative Phase and Subresolution Darkfield contrasts • In situ Experiments - Three-phase flow, crack propagation, tensile and loading. Tri-contrast is particularly powerful for imaging in situ experiments. If you have applications that you think would benefit from imaging using the new Sigray PrismaXRM, please visit www.axt.com.au or contact us at info@axt.com.au.

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Shown above is a tri-contrast image of a frog’s toe joint using the Sigray PrismaXRM; different features are clearly visible in each mode of contrast, such as the spongey tissue using the darkfield and musculature in phase contrast.

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INDUSTRY NEWS

LIBS â&#x20AC;&#x201C; Ideal for PMI, CE and Pipeline Maintenance Source: Dr Cameron Chai, AXT Pty Ltd

LIBS or Laser Induced Breakdown Spectroscopy is rapidly becoming more accepted in PMI (Positive Materials Identification) applications with its ability to rapidly determine the chemical composition of metals and alloys. Accepted as a technique for measuring carbon and other alloying elements in steels and stainless by the American Petroleum Institute (API, Recommended Practice 578 (3rd Edition)), it continues to grow in popularity. With the ability to measure every element in the periodic table, including carbon, alloys can be identified within seconds. CE (Carbon Equivalents) can also be determined in parallel making it ideal for pipeline repairs and other applications

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requiring an assessment of weldability. PMI in recent times has been dominated by handheld XRF. While LIBS and XRF are available in similar handheld formats that are ideal for field use, LIBS has the advantage of being able to detect light elements and carbon with sufficient sensitivity to be able to differentiate 316 from 316L stainless steel. The other competitor in this space is spark OES (Optical Emission Spectroscopy). Traditionally a benchtop analytical device, portable systems are available, but are so bulky they require a cart and some also require a large gas bottle, making them even more unwieldy. Handheld LIBS, specifically the SciAps Z200C+ has been shown to produce similar results to even larger benchtop spark OES systems with obvious portability advantages. First Gas in New Zealand have embraced the SciAps handheld LIBS and integrated it

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into their pipeline maintenance workflow where accurate PMI and CE are essential. The field portable device has replaced the need to take samples back to the lab to be analysed by spark OES. This has brought about further efficiency and economic gains with repairs able to be carried out immediately, enhancing their ability to maintain the nations all-important natural gas infrastructure that spans over 2500km.

DECEMBER 2020 | 39

UNIVERSITY SPOTLIGHT

University of Southern Queensland Source: Sally Wood

The University of Southern Queensland (USQ) leads the state’s academic charge with over 700 specialised, professional courses on offer. The University is based in Toowoomba, but has an additional two campuses in Ipswich and Springfield. Together, the institution grants students access to a range of disciplines such as sciences and engineering, agriculture and the environment, and surveying and the built environment. The University is ranked number one in Australia for engineering graduates in full-time employment, and it leads Australia for graduate starting salaries. In all, over 27,000 students study at USQ, where over 126 languages are spoken.

The University of Southern Queensland’s Contribution to Materials Science and the Centre for Future Materials The University’s commitment to end-user driven research is vastly evident through their premium research institutes, faculties and centres. Three research institutes underpin USQ’s research capabilities, including: • Institute for Resilient Regions • Institute for Advanced Engineering and Space Sciences • Institute for Life Sciences and the Environment These research institutes address national and global challenges for the materials industry, and work with several industry partners to bring the academic research to fruition. In particular, the Centre for Future Materials (CFM) sits within the Institute for Advanced Engineering and Space Studies. It is led by Professor Peter Schubel. CFM strives to be a world leader for providing innovative industrial partnerships through research in advanced composite materials.

The USQ Toowoomba campus is home to the Centre for Future Materials (CFM). Image courtesy of USQ.

The composites group has been in existence at USQ for over 25 years. But in 2016, the group received an upgraded status, which resulted in the formation of the Centre in 2016, with an increased industrial engagement focus. Today, it works with 27 active industrial partners including: Austrak, Forest and Wood Products Australia, Neilsens, Queensland Rail, and other government bodies and departments. CFM has contributed over $15 million worth of support to industry. To achieve premium outcomes for industry, CFM operates a dedicated testing service for over 1,000 industrial clients in multiple sectors on both a national and international scale. It conducts testing on mechanics and structural components, the characteristics of certain materials and polymer analysis. On the international stage, CFM hosts major international conferences, where it leads research proceedings. It is also the founder of a joint research institute in China, which specialises in the area of advanced materials and manufacturing. This institution is a partnership with four universities in the Zhejiang Province, China and The University of Queensland as an associate member.

New Research to Unlock Renewable Hydrogen Researchers at USQ recently discovered new materials that could lead to a cost effective conversion of carbon dioxide into hydrogen fuels, chemicals and fertilisers.

would avoid the need for fossil fuels altogether.

PhD student Yangli Pan led the paper, which was featured in Nature Communications, with support from lead researcher Dr Lei Ge.

Hydrogen could also play a greater role in Australia’s future energy and manufacturing sectors, through the removal of fossil fuels, which are widely used in the current environment. This research opens up the possibilities of a sustainable future with renewable energy at the centre.

The breakthrough research identified alternatives to the expensive and precious metals that have been traditionally utilised in the hydrogen production process. The new alternative

40 | DECEMBER 2020

The processes could benefit both industry and society through the reduced costs of chemical feedstocks, hydrogen production and fertilisers.

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Lead researcher Dr Lei Ge (Centre for Future Materials). Image courtesy of USQ.

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UNIVERSITY SPOTLIGHT

The Centre has also been recognised internationally for its leading research. In 2018, together with Joinlox, CFM received the JEC Asia Innovation Award in the Civil and Infrastructure Engineering category. The award recognised CFM’s technology on easy fit and self-locking composite jacket for structures repair.

Advanced Composites Manufacturing

Australia. This area of research involves large scale structural testing, analysing innovative composite structures for civil applications, and computational modelling. CFM intends to future proof Queensland’s infrastructure with advanced technologies for enhanced climate and environment outcomes. There are five core research areas focused in this branch:

Professor Schubel leads a new research capability at CFM, which focuses on automated manufacturing, process development and modelling for the defence, civil engineering and aerospace sectors.

• • • • •

This branch of CFM takes existing thinking, and launches it into the future, drawing on current knowledge and research gaps. Within this research area, there are seven core projects:

Geopolymers and Concrete

• • • • • • •

Pultrusion Filament winding Composites repair AM metal and composite scarf bonding Smart composites Applied artificial intelligence Resin infusion

These research areas address safety criteria, value-add production, and seek to reduce existing costs for industry materials.

Functional Materials CFM does a broad range of work on developing functional composites and other similar composites for special future applications. The breadth of research undertaken in this stream investigates in-situ structural health monitoring systems, shape memory composites, and the scope of nano-material for high-efficiency energy conversion. This research area focuses on six core research areas: • • • • • •

Thermoelectrics Flame retardant building material Shape memory Bio-based flame retardants Nanocomposites Sensing

Civil Composites For over 20 years, CFM research and development has been leading engineered fibre composites for use in civil infrastructure projects across WWW.MATERIALSAUSTRALIA.COM.AU

Composite rebar Strata control Structure repair Railway Climate resilient infrastructure

Around the world, concrete is the most commonly used construction material, by mass. However, the heating process generated in the production of concrete, also known as calcination, is not sustainable. The production of one tonne of cement generates an equivalent tonne of carbon dioxide into the atmosphere. As such, CFM research is focused on the development of environmentally sustainable ‘green cement’ and concrete. This includes geopolymer concrete – which uses waste materials for production – and other permeable concrete. This stream of research has four core areas: • • • •

Green concrete Geopolymer concrete Phase engineering Shrinkage control

Leading Research Facilities The structural and polymer testing facilities at the CFM facilities are well positioned to undertake this vast research. The facilities offer a suite of expert advice and consultancy, comprehensive materials analysis and testing services for industry partners. CFM’s range of equipment and accessories extends from mechanical testing machines to ovens and furnaces. CFM also recently received a dual-ring 24/60 carrier braider from South Korea. The new equipment enables highly advanced composite structures, like carbon, glass and thermoplastic to be produced at USQ. The dual-ring braider was the first to be introduced, at an industrial scale, in Australia. BACK TO CONTENTS

Carbon Fibre Cryotank Research Receives $3 million Funding Boost A project aimed at developing carbon fibre rocket fuel tanks has recently been awarded a $3 million grant by the Australian government. The $12.5 million research is a collaborative project between Gilmour Space Technologies (Helensvale, Australia), the University of Southern Queensland (USQ, Toowoomba, Australia) and Teakle Composites (Acacia Ridge, Australia), with support from the federal government. Included in the last round of the Australian government’s Cooperative Research Centres Projects (CRC-P) grants, the project is targeting the design, development and manufacture of flight-ready carbon fibre cryotanks. It brings industry and academia together to use advanced robotic filament winding with advanced materials, suited to the extreme operating conditions of space. According to the researchers, the new carbon fibre cryotanks have the potential for up to 30% weight savings and 25% cost savings compared to previous tank designs. According to Gilmour Space CEO and founder Adam Gilmour, the goal is to launch the first commercial rocket to orbit by 2022. “We are grateful to receive this funding, which will allow us to develop world-class composite materials and components for our orbital launch vehicles, making our rockets more efficient and reducing the cost of access to space,” Gilmour said. Gilmour Space signed a strategic agreement with USQ in 2019 to collaborate on advanced rocket technology research.

L to R: James Gilmour (Co-Founder and Chief Operating Officer) and Adam Gilmour (Co-Founder and Chief Executive Officer) of Gilmour Space.

DECEMBER 2020 | 41

INDUSTRY NEWS

BREAKING NEWS Discovery of Molecular Structure Wins Prestigious Chemistry Award Researchers at London’s Imperial College who developed a transition metal complex predicted by a chemist in 1893, recently earned the 2020 Chemistry of Transition Metals Award by the Royal Society of Chemistry. The research, published in Nature journal, reported a transition metal complex with a geometric arrangement of atoms, which was predicted in 1893 by the 1913 Nobel Prize recipient for Chemistry – Alfred Werner. It has vast significance for catalysis, synthesis, materials science and bioinorganic chemistry. The research was assisted by the Koala Laue diffractometer measurements undertaken at ANSTO, which verified the hexagonal planar structure. The spectroscopy, x-ray crystallography and theoretical calculations used to characterise the structures were completed at Imperial College. This important development in inorganic chemistry demonstrates the existence of hexagonal planar geometry in a transition metal complex. Dr Alison Edwards from ANSTO, co-authored the research paper.

Renewable Energy Heat System to Reduce Industrial Gas Use By Up To 80 Per Cent

“The neutron diffraction experiments allow verification that the hydrogen nuclei lie where the electron density from x-ray diffraction suggests.

Australia is considering a range of post-COVID economic options, including the value of increased investment in gas infrastructure and the benefits of other renewable energy projects.

“The experiments were quite challenging as the crystals were air and moisture sensitive so we used an inert nitrogen gas atmosphere at low temperature to prevent sample degradation,” Dr Edwards said.“

While fossil fuels will likely retain some role in industry, researchers at the University of South Australia’s Future Industry Institute (FII) are prototyping a commercial scale system that stores renewable electricity as heat, and releases it on demand.

The neutron diffraction experiment confirmed that the addition of one more ligand pushes the six coordinating ligands away from the metal plane, but also retains the hexagonal array.

Dr Rhys Jacob is part of a team developing technologies to deliver renewable alternatives for industrial gas applications.

The University of Oxford also collaborated with Imperial College London and ANSTO on the research.

“This research is looking at how we use low-cost variable renewables to offset what is traditionally fossil fuel fired heat, and the recent progress has been excellent,” said Dr Jacob.

“With six high profile chemistry papers in the last year, the aspiration for Koala to be a major resource for chemical crystallographic studies of novel structures is now a reality,” said Dr Edwards.

The thermal storage system, which is set to begin testing in early 2021, will initially be designed to deliver heat in the range of 200 to 700 degrees Celsius. Dr Jacob says the most cost-effective system could reduce gas use by between 60 and 80 per cent depending on the application. “You will still need to have the option of fuel as a backup for when renewable output is low, because from the data we have run, if you want to use purely renewables and storage, you would require a huge amount of storage just to cover the extreme situations.“ “So, we’ve developed a hybrid approach, where our system can deliver 60, 70, and 80 per cent of heat needs using renewables and storage, then the small shortfall will be covered by a fuel, which could be an existing gas system, or renewable fuels like hydrogen or biogas,” said Dr Jacob.

A neutron diffraction image from the Koala experiment, reported in Nature. Image courtesy of ANSTO.

42 | DECEMBER 2020

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The project is supported by ARENA and the new Reliable Affordable Clean Energy for 2030 Cooperative Research Centre. WWW.MATERIALSAUSTRALIA.COM.AU

INDUSTRY NEWS

BREAKING NEWS Now You See It, Now You Don’t: Adding Chameleon-Like Capabilities to Defence Drones Alongside the Department of Defence, University of South Australia (UniSA) material scientists have developed a range of lightweight panels that can change colour on demand. Drones, are a huge asset for intelligence, surveillance and reconnaissance operations, and this innovation allows them to match their appearance to the colours of the sky. The Australian Army has drones ranging from the Black Hornet – which is about the size of a whiteboard marker – to larger models with unique surveillance capabilities. Despite their utility, all military drones currently face the same simple problem – the sky changes colour, but they don’t. But researchers from UniSA’s Future Industries Institute (FII) have developed a range of lightweight polymer panels that can change colour on demand. Led by Dr Kamil Zuber, the polymers change colour in response to an electric field, and the exact colours can be tuned to specific voltages. “Similar technology has been used in luxury cars, for diming mirrors, and on the windows of the Boeing 787 Dreamliner,” Dr Zuber said. “But those applications are slow, require high power consumption to switch, and the electric flow must be maintained to sustain the change state.“ The panels are inexpensive, lightweight and durable, and can be either rigid or flexible, making them ideal for of all sizes and specifications. “We have five or six different materials, and each of the materials can produce two to three distinct different colours,” said Dr Zuber. The technology is currently being refined to integrate selfawareness and autonomous adjustment into the system, to allow drones to automatically change colour in response to the surrounding environment.

Monash University engineers have created world-first technology to help industry identify high quality graphene cheaper, faster and more accurately than current methods.

New Tech Extracts Potential to Identify Quality Graphene Cheaper and Faster Engineers at Monash University have developed world-first technology to help industry identify and export high quality graphene cheaper, faster and more accurately than current methods. Researchers used the data set of an optical microscope to develop a machine-learning algorithm that can characterise graphene properties and quality, without bias, within 14 minutes. The research, which was published in the international journal Advanced Science, is a game changer for hundreds of graphene or graphene oxide manufacturers globally. It will help them boost the quality and reliability of their graphene supply in quick time. Professor Mainak Majumder from Monash’s Department of Mechanical and Aerospace Engineering and the Australian Research Council’s Hub on Graphene Enabled Industry Transformation led this breakthrough study. “Graphene possesses extraordinary capacity for electric and thermal conductivity. It is widely used in the production of membranes for water purification, energy storage and in smart technology, such as weight loading sensors on traffic bridges,” Professor Majumder said. Currently, manufacturers can only detect the quality and properties of graphene used in a product after it has been manufactured. But this innovation has the potential to be rolled out globally with commercial support, as graphene producers can be assured of quality product and remove the time-intensive and costly processes. “At the same time, graphene is rather expensive when it comes to usage in bulk quantities. One gram of high quality graphene could cost as much as $1,000 a large percentage of it is due to the costly quality control process,” Professor Majumder said.

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DECEMBER 2020 | 43

INDUSTRY NEWS

BREAKING NEWS Breakthrough Technology Purifies Water Using the Power of Sunlight A global research team has transformed brackish water and seawater into safe, clean drinking water in less than 30 minutes using metal-organic frameworks (MOFs) and sunlight. The World Health Organisation suggests good quality drinking water should have a total dissolved solid (TDS) of <600 parts per million (ppm). But researchers at Monash University were able to achieve a TDS of <500 ppm in just 30 minutes and regenerate the MOF for reuse in four minutes under sunlight. The discovery could provide potable water for millions of people across the world, and was recently published in Nature Sustainability. Lead author Professor Huanting Wang at Monash University, said this work opened up a new direction for designing stimuliresponsive materials for energy-efficient and sustainable desalination and water purification. “Desalination has been used to address escalating water shortages globally. Due to the availability of brackish water and seawater, and because desalination processes are reliable, treated water can be integrated within existing aquatic systems with minimal health risks,” Professor Wang said.

Insect Wings Inspire New Ways to Fight Superbugs

“But, thermal desalination processes by evaporation are energyintensive, and other technologies, such as reverse osmosis, has a number of drawbacks, including high energy consumption and chemical usage in membrane cleaning and dechlorination,” he added.

The wings of cicadas and dragonflies are natural bacteria killers, a phenomenon that has prompted researchers to search for ways to defeat drug-resistant superbugs.

The research team created a dedicated MOF called PSP-MIL-53, which was synthesised by introducing poly (spiropyran acrylate) (PSP) into the pores of MIL-53 – a specialised MOF. The PSP-MIL-53 was able to yield 139.5L of fresh water per kilogram of MOF per day. “This study has successfully demonstrated that the photoresponsive MOFs are a promising, energy-efficient, and sustainable adsorbent for desalination,” Professor Wang said.

Scientists have revealed how nanomaterials inspired by insect wings are able to destroy bacteria on contact.

The new anti-bacterial surfaces feature different nanopatterns that mimic the deadly action of insect wings. Researchers have detailed exactly how these patterns destroy bacteria – stretching, slicing or tearing them apart in new research published in Nature Reviews Microbiology. Lead author, RMIT University’s Distinguished Professor Elena Ivanova, said finding non-chemical ways of killing bacteria is critical. Particularly with more than 700,000 people dying each year due to drug-resistant bacterial infection. “Bacterial resistance to antibiotics is one of the greatest threats to global health and routine treatment of infection is becoming increasingly difficult,” Professor Ivanova said. “Our ultimate goal is to develop low-cost and scaleable anti-bacterial surfaces for use in implants and in hospitals, to deliver powerful new weapons in the fight against deadly superbugs,” she explained. Bacteria that land on these nanostructures find themselves pulled, stretched or sliced apart, rupturing the bacterial cell membrane and eventually killing them. “While the synthetic surfaces we’ve been developing take nature to the next level, even looking at dragonflies, for example, we see that different species have wings that are better at killing some bacteria than others.“

An international research team, led by Professor Huanting Wang, has used a metal-organic framework to desalinate water with sunlight. Image courtesy of Monash University.

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“When we examine the wings at the nanoscale, we see differences in the density, height and diameter of the nanopillars that cover the surfaces of these wings, so we know that getting the nanostructures right is key,” Professor Ivanova said. WWW.MATERIALSAUSTRALIA.COM.AU

World-first plasma-coated bandage

INDUSTRY NEWS

BREAKING NEWS Microrecycling Science Delivers New ‘Material Microsurgery’ Technique A new technology that promises to enhance the advanced manufacturing sector in Australia has been developed by the pioneers at the University of New South Wales’ (UNSW) Centre for Sustainable Materials Research and Technology (SMaRT). The novel ‘material microsurgery’ technique – published in the esteemed American Chemical Society Omega journal – was developed by Professor Veena Sahajwalla and her team. The technique can can extract valuable materials and elements from complex waste items – like glass, textiles and plastics – and reform them into strengthening layers for steel and other applications. Professor Sahajwalla sought to develop new ways to address society’s growing waste and recycling challenges with innovations that can boost manufacturing capability. SMaRT can also create jobs and economic prosperity, while enhancing environmental and social outcomes. “Australia’s governments have agreed to ban the exporting of glass, plastic, paper and rubber tyres from January 2021, therefore we need to start treating these waste items as the ‘renewable resources’ they really area,” Professor Sahajwalla said. The ‘material microsurgery’ technique pioneered the concept of microfactories to reform different waste streams that mostly end up in landfill or stockpiles. This is completed by turning them into value-added ‘green’ materials and products. “We use the term ‘material microsurgery’ because we were inspired by the processes medical surgeons use in microsurgery where they apply targeted and selective solutions to problems,” Professor Sahajwalla explained. “Existing waste and recycling technology doesn’t do this for our traditional waste treatments. We need to step up to do the things that were thought unimaginable for waste management so it can be cutting edge,” she added.

UNSW Engineering researchers have invented a soft haptic device which recreates the sense of touch - something many people take for granted.

New Glove-Like Device Mimics Sense of Touch Engineers have invented a soft wearable device that simulates the sense of touch and has wide potential for medical, industrial and entertainment applications. The engineering researchers, from the University of New South Wale (UNSW) invented the soft haptic device, which recreates the sense of touch – a big step in the current climate of social distancing. Haptic technology mimics the experience of touch by stimulating localised areas of the skin in ways that are similar to what is felt in the real world, through force, vibration or motion. The development is pending user tests and funding to commercialise the new technology, but it could become a reality in a matter of years. Dr Thanh Nho Do is the UNSW Medical Robotics Lab director, and senior author of the study surrounding the device. “When we do things with our hands, such as holding a mobile phone or typing on a keyboard, all of these actions are impossible without haptics,” Dr Do said. The development could be crucial for the medical industry, particularly in a telehealth consultation where a doctor is unable to physically examine a patient. It may also have applications for phone conversations between friends on different sides of the world, through the soft skin sketch design (SSD), which can be integrated into fabric, like a finger glove.

“Recyclers traditionally haven’t seen themselves as manufacturers, and manufacturers haven’t seen themselves as recyclers, but we need them to,” Professor Veena Sahajwalla. Photo: Anna Kucera

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es, with the power to attack infection

“If your friend picks up an object, it will physically press against your friend’s fingers and their glove with 3D force sensors will measure these interactions. BACK TO CONTENTS

DECEMBER 2020 | 45

INDUSTRY NEWS

BREAKING NEWS Researchers Discover Monster Black Holes 150 Times Heavier Than the Sun A global team of astronomers including researchers from The University of Western Australia (UWA) have detected two gravitational wave black holes colliding into a big black hole, more than 150 times the weight of the sun. UWA researchers were among the fastest to detect the black holes, within seconds, making a discovery that changed scientists’ understanding of the Universe. A black hole is one of the most mysterious objects in the Universe. Scientists do not know what is inside black holes – the region where gravity becomes so strong that not even light can escape its pull. The origin of the two colliding black holes, found in this discovery, is not currently understood. The larger black hole in this binary system requires a complementary or a new theory for its formation. Professor Linqing Wen from UWA’s School of Physics, Mathematics and Computing, who led the team, said the waves were detected on 21 May 2019 through the LIGO-Virgo mission. These early detections led to public alerts generated through the LIGO scientific collaboration. “It is excellent that our team contributed directly to the detection of this unusual system,” she said. “To be among the first to detect gravitational wave signals, we rely heavily on innovative high-performance computing technologies,” Professor Wen said.

Curtin Team Steps Closer To Developing Tiny ‘SelfPowered’ Electronics A team of Curtin University researchers recently took an important step towards developing miniature ‘self-powered’ electronics, which may be used in devices such as medical implants or pacemakers, where batteries may be difficult to recharge.

UWA PhD student and co-author, Manoj Kovalam, was directly involved in the search for gravitational waves. He said it was exciting to make such a significant scientific discovery.

The research team was able to create the biocompatible, continuous source of direct-current electricity, by making small sliding movements with a piece of metal on a concave silicon surface.

“It was thrilling to see our program detect this rare event in realtime. Discoveries like these are very essential to understand the formation channels of such unusual black holes.” he said.

Lead researcher and PhD candidate, Stuart Ferrie, said small, wireless devices require direct-current supply and re-charging them with a battery is the only practical solution. “Our research team was able to show that the mechanical vibrations and friction created from sliding a piece of metal on the silicon surface could be converted into continuous direct electrical current,” Mr Ferrie said. “This is a significant step towards developing miniature devices that are able to ‘self-power’, without needing to be plugged into an electrical socket or recharged by solar panels,” he added. Dr Simone Ciampi, who co-authored the piece, said the research findings have important implications for the electronics, medical and environmental industries. “Creating autonomous power supplies is the way of the future and will have significant benefits for a range of different industries that currently rely on batteries or solar panels for recharging,” Dr Ciampi said. “The full spectrum of creating these types of ‘self-powered’ electronics is still relatively unclear and further research and testing is needed, but this work provides explicit evidence that it is possible to create a continuous source of direct-current electricity.,” said Dr Ciampi.

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INDUSTRY NEWS

BREAKING NEWS New Tech and Policy Lab to Tackle Biggest Challenges in the Tech Ecosystem

Research Hub to Make Australia a World Leader in Battery Technology

The University of Western Australia (UWA) will launch a worldfirst tech and policy lab.

Researchers from the University of Wollongong will deliver new energy storage outcomes to eliminate the serious fire risk in current technologies through a new Australian Research Council (ARC) Research Hub.

The new investment will provide intellectual leadership and bold reform proposals to develop best-practice tech governance for tech-importing nations like Australia and its close neighbours. It will interrogate and correct the ways digital technology has evaded law, governance and associated responsibilities designed to protect individuals and communities from harm. Directed by Associate Professor Julia Powles, the Minderoo Tech and Policy Lab will coordinate and lead a global project with companion programs at the University of Cambridge, New York University, the University of California Los Angeles and the University of Oxford. Professor Powles said that when compared to other sectors, industries, and utilities, the tech ecosystem exists in a legal vacuum. “The lab aims to dramatically change this status quo, with a relentless focus on defending rights and protecting against harms to people and the environment.” “From our vantage point in Western Australia, in neighbourhood with many of the world’s net tech importers, we have a significant agenda for reining in the unchecked power of the tech monopolies and designing the pro-public technologies we deserve in their place,” she said. The lab’s first three externally-led projects will involve innovative private law remedies at the University of Sydney; public law protections at the Australian National University; and data governance and professional sport at the Australian Academy of Science. All three projects further the aim of making Australia a bestpractice jurisdiction for technology regulation. It also plans to recruit research fellows and PhD students to Western Australia.

Reviewing Multiferroics For Future, Low-Energy Data Storage A new UNSW study comprehensively reviews the magnetic structure of the multiferroic material bismuth ferrite (BiFeO3 – BFO).

The New Safe and Reliable Energy Storage and Conversion Technologies Hub is one of five new ARC Industrial Transformation Research Hubs, which was announced by the Federal Minister for Education Dan Tehan in July. It will bring together Australian and international research organisations with a broad range of industry partners, to develop innovative solutions to challenges facing current energy storage and conversion technologies. Distinguished Professor Zaiping Guo from the University will serve as a Chief Investigator. “The research will deliver a new generation of technologies for storage, from small-scale portable devices to large-scale industrial applications, using recycled and natural materials, and eliminating the serious fire risk in current technologies,” she said. It will strategically position Australia as a leader in the emerging energy storage and conversion space. This will ensure Australian industry can maintain a competitive advantage and world-leading technology development position in this critically important sector. It will also enable efficient utilisation of renewable energies, address global environmental concerns, and accelerate the development and commercialisation of renewable energy technologies. It will enshrine the creation of start-up companies and commercialisation opportunities for existing partners, benefiting both the Australian economy and potentially transforming the energy industry landscape. Several other universities are also contributing to the hub, including: the University of Sydney, University of Adelaide, University of Queensland, and University of Southern Queensland.

The study reviews the magnetic structure of bismuth ferrite; in particular, when it is grown as a thin single crystal layer on a substrate.

The review advances FLEET’s search for low-energy electronics, bringing together current knowledge on the magnetic order in BFO films, and giving researchers a solid platform to further develop this material in low-energy magnetoelectric memories.

The paper also examines BFO’s complicated magnetic order, and the many different experimental tools used to probe and help understand it. Multiferroics is a challenging topic. For example, for researchers trying to enter the field, it is very difficult to get a full picture on the magnetism of BFO from any one reference.

BFO is unique in that it displays both magnetic and electronic ordering—it is ‘multiferroic’—at room temperature, allowing for low-energy switching in data storage devices.

“So, we decided to write it,” says Dr Daniel Sando. “We were in the perfect position to do so, as we had all the information in our heads, Stuart wrote a literature review chapter, and we had the combined

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necessary physics background to explain the important concepts in a tutorial-style manner.” The result is a comprehensive, complete, and detailed review article that will attract significant attention from researchers and will serve as a useful reference for many.

Co-author Dr Daniel Sando preparing materials for study at the University of New South Wales.

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FEATURE â&#x20AC;&#x201C; Technical Innovations in Steels

Technical Innovations in Steels New technologies and enhanced processes

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FEATURE – Technical Innovations in Steels

Steel is a vital material for Australia’s ongoing development of infrastructure. From the iconic Sydney Harbour Bridge to Melbourne’s expansive rail network, steel is an important material that helps Australians move around with flexibility and ease every day. As steel plays a prominent role in beams, buildings and bridges, local steel production ensures that Australia can continue with large scale developments for many years to come. Australia is the world’s largest exporter of coal, iron ore, aluminium ores and lead – which have traditionally been integral to the steel manufacturing process. As a whole, the industry generates $29 billion in revenue each year. In addition, over 110,000 Australians work in the steel industry, according to data from the Australian Steel Institute. The industry is supported by two major producers, BlueScope and InfraBuild – formerly Liberty OneSteel – and over 300 distribution outlets. While it’s clear that steel’s unique capabilities are an essential part of the world’s development, Australia’s abundance of resources also means that it is vital for economic prosperity. While the durability aspects and economic security of steel is evident, steel production does come at a heavy cost to the environment. However, the environmental costs of ongoing steel production are almost intangible to measure for future generations, which means that companies and governments are mainly driven by the current economic benefits of steel. The Australian Senate Economics References Committee recently explored the future of Australia’s steel industry in a report, which outlined the structure, economics, international obligations and the environmental impacts of the sector. The report also discussed government procurement and the role of industry in future-proofing Australia’s steel industry. The environmental shift is also on the agenda for industry. In a new era of environmental challenges, steel manufacturers and producers are seeking to capitalise on these growing trends for more sustainable approaches and an environmentally safer future.

Traditional Processes and Outcomes Technical innovations to bolster and augment existing processes are already a large focus for the steel industry. These processes start with metallurgy. Metallurgy is the name given to the branch of materials science that deals with the process of producing and purifying metals. Traditional forms of metallurgy include production of medieval piping and ancient steel sheets with high strength. The process is driven by the discovery of new and advanced materials, which are safer, more sustainable and secure. As materials continue to evolve, the process does too. Anatolian people, known as The Hittites, innovated the process was driven of placing ore and wood in a furnace. When carbon combined with the oxygen in the ore, a new iron metal was created. Later, in the second half of the 19th Century, the Bessemer process took over. This was an inexpensive alternative to mass produce steel, as an iron oxide reacted with carbon in the pig iron. Following this process, the open-hearth process took over after its invention in 1864. This method relied heavily on pre-heated air to produce steel in a furnace. In a push for more efficient and sustainable processes, electrical generators began operating in 1902. This innovation at the time produced a high quality level of steel with fewer impurities. While the process was not particularly cost effective, it allowed for a more controlled environment. It also helped to produce steel with enhanced longevity through a large-scale production process. As history shows, there is always new technology and innovation to drive growth and change for a better future. Now, in 2020, this discourse of discovering new materials and new production processes is still evolving. Metallurgy builds on this narrative, as it considers a suite of new knowledge and processes to create the building blocks of tomorrow.

Today, the Australian steel industry is focusing on a suite of new technical innovations to leverage Australia’s efficient production processes. Industry is leading an approach towards a circular economy, through major partnerships with researchers to support a healthy transition.

Australia is in the prime position to adapt the steel supply chain, and make technical innovations in the steel industry. An overhaul of the current processes, through alteration and careful changes, will position Australia as a global thought leader when it comes to new steel innovation.

This new approach is based on all elements of the supply chain – from sourcing steel, to its production, and waste management. There is an abundance of scope to reduce carbon emissions, and increase the recycling and reusability of steel.

However, for technical innovations in steel to occur, it requires cross-collaboration and a whole-of-industry approach. Research from PwC Australia shows that 47 per cent of senior executives, across a range of sectors, including metals, describe ‘innovation’ as ‘a competitive necessity’.

Technical innovations in steel have historically taken place through the invention of new technologies and

enhanced processes. But scientific evidence shows that time is running out to make a safe transition for a greener planet, which means that there has never been a more important time to innovate for the future.

Most of these companies spend a small percentage of

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FEATURE – Technical Innovations in Steels

their total revenues on innovation. From the same survey, four in ten of the same executives do not describe innovation as a key priority. To maximise technical innovations in steel, and grow Australia’s circular economy, innovation and associated spending must be a priority. At a broad level, change is required, whether it is culturally, technically or environmentally. The World Steel Association (worldsteel) is already showing that steel companies from North America, Japan and Europe – who account for a high portion of the global steel production – have reduced their energy consumption per tonne of steel produced, by 50 per cent over a 30 year period. Sustainability is the core rationale behind this reduction. As previous examples have shown, manufacturing is very energy intensive, and creates waste and emissions.

3D Printing In light of new manufacturing projects, and the technologies available to bring those projects to life, industry is capitalising on the growing role of 3D printing. The leading-edge approach that 3D printing offers, allows industry to innovate and construct steel frameworks in a controlled, safe and a sustainable environment. The technology is cleaner, greener and cost effective when compared with traditional practices. Augmented reality (AR) and virtual reality (VR) are integral to the steel fabrication and design process. Together, they consider the real world, and simulated environment of a project, respectively. When these processes are combined with state-of-the-art 3D laser scanning, the options for safer outcomes and retrofitting existing structures, are endless. The AR process has already been used to assist steel fabricators during the manual fabrication process. Fabricators have used advanced headsets to superimpose imagery of many planned products onto the current work piece. Several prototypes have already been constructed, including the world’s first 3D printed bridge in Madrid, Spain. This application of 3D printing can help to create future structural components that mirror structural steel. While the technology is still relatively new, and its intended use for larger steel structures is 50 | DECEMBER 2020

largely unknown, it is expected to disrupt the traditional narrative of steel production.

Movers and Shakers in the Australian Environment Australian research bodies and universities are at the forefront of metallurgical and technical steel innovation to build a greener and more circular Australian economy. The building blocks for enhanced steel production are already in place to a large degree. Steel is the most recycled material on the planet, with a global recovery rate of more than 70 per cent. Research from worldsteel also shows that approximately 630 million tonnes of scrap steel is recycled annually. This equates to around 950 million tonnes of CO2 that would have been emitted through the creation of new steel products. While over 97 per cent of materials that are used on a construction site are transformed into products that can be reused or recycled, there is still scope for improvement in the manufacturing and construction space. Australia is sparking a new era of steel metallurgy, with exciting initiatives and utilisation objectives placed at the centre of research.

ANSTO The Australian Nuclear Science and Technology Organisation, or ANSTO, is the home of leading facilities and research with a sharp innovation focus. Thousands of scientists collaborate with industry and other academics each year to bring state-of-the-art research to life. As a public research organisation, ANSTO works in health, nuclear and the environment to boost Australia’s future manufacturing outputs through a safe and sustainable approach. A key part of ANSTO’s business is their cross-sector and multinational research efforts to take the heat out of traditional manufacturing processes and innovate towards the future. Research recently conducted at ANSTO was recognised in Metallurgical and Materials Transactions A, and received the ASM International Henry Marion Howe Medal. The research analysed the repair treatments of two nickel based superalloys – Inconel 718 and Udimet 720LI – which are BACK TO CONTENTS

typically used in aeronautical engines or the broader energy and environment sector. ANSTO’s Industrial Engagement Manager, and Professor in Advanced Structural Materials at the University of Sydney, Professor Anna Paradowska worked in strong collaboration with the University of Manchester in the United Kingdom, and Institut Laue-Langevin in France to conduct the research. The researchers found that through a detailed picture of the stress during the heating of, and holding at, the annealing temperature, tailored ageing treatments can be better understood. “The in situ data that we acquired can be used to validate models that predict the residual stresses on full-scale components,” said Professor Paradowska. Nickel based superalloys are corrosion resistant and high-temperature alloys that are typically able to withstand service temperatures of above 500 degrees Celsius. Similarly, researchers at ANSTO have conducted an analysis of welded structures, which may help extend the service life of steels – hence providing durable and sustainable options for the future. This technical innovation is focused on identifying the core material requirements to predict solid-state phase transformation kinetics during the welding of ferritic steels. Ferritic steels are rich in chromium and are nickel-free. However, the extreme heating and cooling process that these steels encounter during welding causes a transition phase in the metal. Modellers used the ABAQUS software to analyse these welds. The researchers found that through successfully predicting the phase composition in ferritic steel welds, further tests can be carried out to understand the residual stress profiles predicted in a coupled thermo-mechanical weld model. Once this next phase of innovation has been validated, further work can be undertaken to predict the risk that welds face with regards to cracking and damage. This knowledge will boost the steel industry’s capacity to provide long-term solutions, with a reduction in greenhouse gas emissions. It will also save on company costs and scheduling requirements. WWW.MATERIALSAUSTRALIA.COM.AU

FEATURE – Technical Innovations in Steels

CSIRO Australia’s national science agency, CSIRO, solve challenges through science and technology innovation. With an environmental focus, the community and planet are at the core of CSIRO’s business. CSIRO has worked with counterparts at the Beijing MCC Equipment Research & Design Corporation (MCCE) to convert blast furnace waste from steel production into new products for cement. This Australian innovation is already being trialed in China, where 60 per cent of the world’s blast furnace waste matter is produced. The new innovation is technically known as dry slag granulation (DSG), which reduces greenhouse gas emissions in the steel manufacturing process. The technology is retrofitted into blast furnaces, and includes a spinning disc and chamber for granulation. This separates the waste matter into tiny droplets. It then uses air to solidify the droplets before extracting a cleaner granulated slag product. The DSG technology also saves water consumption and heavily reduces underground water pollution, which is an issue in China. Estimates have already shown that if the technology is adopted in full, the savings are similar to 14 per cent of Australia’s overall energy, or 10 per cent of overall greenhouse gas emissions.

than it is in the mining process,” Mr Vining added. In the Australian context, CSIRO is understanding more about water and gangue removal, which has the capacity to lower the carbon intensity linked with Australia’s iron ore exports. CSIRO has found that designed biochar – a cleaner version of charcoal made from pyrolysis of plant matter – can replace coal and coke, which are currently used for smelting in steelmaking. These traditional processes are used in up to 50 per cent of all production but are not environmentally sustainable. Mr Vining noted that this process may increase Australia’s carbon emissions in the short-term, but overall it will reduce carbon output from the iron and steel making process in the long-term. “One of the biggest emitters of carbon in the iron making value chain is the use of metallurgical coke in the blast furnace, and the simplest way we can influence how that is reduced is by upgrading the material prior to shipping it overseas,” Mr Vining said.

The Research Group Leader at CSIRO, Keith Vining, has worked in the research sector for two decades. “The majority of the work and the carbon-intensity is in the steel making process at the other end of the chain in Asia, for example in China, Japan and South Korea,” he said. “It’s difficult for us to influence what goes on there, and the energy used is significantly higher in the smelting process WWW.MATERIALSAUSTRALIA.COM.AU

• • • • • •

Advanced alloys Electromaterials Carbon fibres and composites Infrastructure materials Fibres and textiles Micro/nano materials

Specifically the advanced alloys stream focuses on alloy production from the fundamental phase, through to the industrial scale. Researchers work through a lens based on profitability, energy efficiency, competitiveness and extended product life. This stream of research includes the Australian Research Council’s (ARC) Training Centre in Alloy Innovation for Mining Efficiency (mineAlloy). Researchers within the mineAlloy business unit are working in conjunction with innovators to design highly customised, wear-resistant components for long-term premium use. There are a wide variety of applications for this research in the fabrication and construction areas of steel production. Other ongoing projects include the scope for increased steel 3D printing, severe mining conditions and novel characterisation. Furthermore, to revolutionise minerals processing, IFM partnered with Callidus Welding Solutions to develop new surface engineering outcomes in response to severe erosion in metal reactor components. These components, which also suffer from corrosion, are typically used to process cobalt, nickel and even gold.

To achieve this technical innovation, CSIRO was guided by end-user driven objectives. Researchers worked in partnership with industry bodies such as BlueScope and InfraBuild. CSIRO’s work on similar projects has involved all levels of the supply chain, to take the heat off traditional metallurgical approaches, and to modernise the industry’s innovation. Scientists understand the carbon-intensive nature of steel production, but through vast industry collaboration, they have identified scope for change.

The centre has six branches of research:

Dry slag granulation technology will result in a cleaner, greener and more productive steel industry.

Deakin University Deakin University’s Melbourne-based campus is another leader in innovative steel practices. The University’s Institute for Frontier Materials (IFM) cuts through academic red tape to rapidly develop materials and infrastructure for real world applications. The role of IFM is to address materials challenges across a range of sectors, including but not limited to: mining, environment, health, transport and energy. Each year, over 30 PhD students graduate from IFM, and over 80 post-doctoral researchers gain practical knowledge and experiences at any given time. The Institute also generates $16.5 million in research outcomes annually. BACK TO CONTENTS

The $3.9 million project has the potential to double each component’s life, which will save on cost and gas emissions. The CSIRO researchers, IFM and Callidus also partnered with several mining companies on this project. Associate Professor Daniel Fabijanic is the lead researcher from IFM, who said the partnership was a natural choice.“ “First, we assisted Callidus with insight into a process they had been independently developing over a few years. “Callidus is very open to new ideas, and so far these new concepts are working well. The benefits and learning have been two-way, which is how partnerships should be,” he said. IFM has also patented another innovation that is the first scientifically-based and designed forming system, where DECEMBER 2020 | 51

FEATURE – Technical Innovations in Steels

corrugated steel sheets can fold. Similar to origami, the FormFlow bend, can stretch existing steel on a broad scale.

important expertise across many components required in the mine rehabilitation process.

Unlike other industries that use a high degree of automation, the building sector is still quite labour intensive. As such, this innovation will help builders construct durable products at a fraction of the time and cost.

Monash uses the latest technology, such as artificial intelligence and drones to conduct geological assessments, extract environmental information and map surfaces in 3D. This provides Australian mining practitioners with the information they need to safely and efficiently draw materials, and lessen the likelihood of increased greenhouse gas emissions in the process.

It also opens up the door to endless possibilities for cleaner and greener buildings by using scrap steel components.

Monash University Monash University is a global pioneer in materials research. Metallurgy research undertaken at Monash ranks as number one in Australia, and features in the top ten across the world. It is the only Australian university in the top 20 for metallurgical research worldwide.

The University generates $5.90 for every dollar worth of government funding spent. In 2016, Monash secured the top spot across all Australian universities for the highest international competitive research income, which totalled $79.7 million.

To achieve these high standards, Monash University’s Department of Materials Science and Engineering is committed to discovering new innovations in the space. The Department undertakes a large breadth of research on all metals and alloys, including advanced steels.

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Similarly, the nickel laterite ore project will examine ferronickel production to provide enhanced measures for better optimisation and output. Both projects are funded by Baoshan Iron and Steel Co, which is evident of the University’s strong linkages which is proof of multinational industry partners.

Together, PYROSEARCH’s customer-focused intentions allow viable research to come to fruition.

Professor Hutchinson’s team has invented new, ultra-high strength steels, which can be used for a suite of localised or international purposes. These include applications in the global automotive industry, wear-resistant steels for the mining industry, corrosion resistance improvements of light alloys, and the emerging area of 3D steel manufacturing.

Additionally, Monash is also working collaboratively with the mining industry to bring real world solutions to fruition and meet existing environmental concerns. By examining soil physics, erosion, geochemistry, artificial soils and soil carbon sequestration, researchers are providing

For example, there are currently two projects underway that focus on innovative steel research for the future. The iron sintering project is exploring novel approaches to optimise iron sinter through microstructural design processes. The project will develop new FactSage thermodynamic databases that will guide a selection of raw input materials, and help with the identification of the conditions required to achieve optimum results.

The research undertaken at PYROSEARCH links to the University’s worldwide network and leaders in the minerals industry. Some of these close links include BHP Billiton, Umicore, Kazzinc and Baosteel.

The Department is led by Professor Christopher Hutchinson. He is an expert in many areas of materials science, including physical metallurgy, mechanical metallurgy and 3D metal printing.

The research undertaken at Monash is relevant to the entire supply chain, with tangible applications to the product and materials design phases, and prototyping and production. There are also vast opportunities for professional development in the evolving sphere of steel innovation, as early career researchers gather to learn more about resources in research and training.

Within the University’s research branch sits the Pyrometallurgy Innovation Centre, or PYROSEARCH. This capability provides vast research services, including testing and ongoing analysis of non-ferrous and ferrous metal smelting and refining; recycling; and coal.

The Hydrometallurgy Research Group is also actively engaged in industry-related research, including base metals and Bayer alumina processing. This process can be complex – essentially it involves the extraction of metals from their respective ores by utilising water.

University of Queensland The University of Queensland is the home of many mineral processing engineers and scientists who work on the grand challenges for the 21st Century and on end-user driven research. Metallurgy and minerals processing is a key part of the University’s research arm, which hones in on five core areas: • Coal and minerals processing • Colloid, or surface chemistry and electrochemistry • Froth flotation • Pyrometallurgy • Hydrometallurgy BACK TO CONTENTS

This group, based within the University is led by Professor Peter Hayes. Professor Hayes has an impressive resume, with extensive knowledge and experience in the metallurgy sphere ever since he obtained his PhD from the University of Strathclyde in Glasgow, Scotland, in 1974. Hydrometallurgy has been understood to be a more environmentally friendly alternative to other metal extraction techniques like pyrometallurgy. Similar to other works like the DSG technology pioneered at CSIRO, hydrometallurgy preserves water quality by effective disposal of waste techniques. In addition, the University also boasts the WWW.MATERIALSAUSTRALIA.COM.AU

FEATURE – Technical Innovations in Steels

HBIS-UQ Innovation Centre for Sustainable Steel (ICSS). This brings new capabilities for researchers to apply their knowledge and expertise to one of the world’s most advanced and leading steel plants in China. The ICSS research groups focus on three core areas of business – capability, training and research – to change the global narrative for metallurgy, environmental engineering and technologies associated with the production of steel. It also addresses a central issue of Australia exporting materials offshore for steel production, and the lack of visibility that comes with that process.

University of NSW The University of New South Wales (UNSW) has a range of worldleading research centres, which are primarily funded by the Australian Research Council. Sitting within the School of Materials Science and Engineering, these research capabilities position UNSW as a thought leader for excellence in research, with high research utilisation outcomes. Firstly, the Baosteel-Australia Joint Research and Development Centre is a consortium between UNSW, The University of Queensland, Monash University and University of Wollongong. These researchintensive universities have partnered with one of the world’s largest steel companies – Baosteel – to overcome the environmental and technological challenges of contemporary steel manufacturing. The partnership places technical innovation in steel at the forefront, as it conducts research with a strategic focus that is rich in value and low in carbon abatement. Additionally, UNSW is part of the AustraliaChina Joint Research Centre for Minerals, Metallurgy and Materials. The role of this Centre is to provide support and tangible outcomes for raw materials and metallurgical processing, materials manufacturing and safe applications.

Oxy-hydrogen hand torch to seal silica crucibles. Image courtesy of University of Queensland.

China is the world’s largest steel producer, but Australia has a strategic interest in this by exporting vital minerals and materials offshore. This Centre has short, medium and long-term goals to share infrastructure between Australia and China for research outcomes with mutual benefits. This collaboration also prompts Australia and China to cooperatively innovate processes or products, and develop the next generation of scientists and engineers for commercial purposes.

Electric furnaces with controlled gas atmosphere. Image courtesy of University of Queensland

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Similarly, the ARC Centre of Excellence for Design in Light Materials was an inclusive, research-focused centre that ran until 2014. While the Centre is currently not operating in its original form, its outcomes are still drawn upon today. The Centre paved the way for addressing major gaps in research regarding fabrication techniques and novel processing for greater performance of light alloys and light metal hybrids. BACK TO CONTENTS

The Centre specifically examined the role of titanium, hybrid materials and surface engineering of light alloys, to position Australian industry towards a greener future. UNSW was one of six major Australian universities which were part of the Centre, including: The University of Queensland, Monash University, The University of Sydney, Deakin University and The University of Melbourne. Finally, the Centre for Sustainable Materials Research and Technology, better known as SMaRT is leading the materials science space. SMaRT takes UNSW’s unique research capabilities, and links them to a proven track record of delivering high quality and engaging research. SMaRT’s focus is on the rapid implementation of research, and cutting through red tape and other processes to accelerate technical innovation. As an internationally recognised Centre, it intends to bring enhanced technology to traditional processes for materials manufacturing, such as steel. It also seeks to reduce the environmental impact of waste and other by-products, and enhance the sustainable development of all industries. The Centre was founded in 2008 by ARC Laureate Fellow Scientia Professor Veena Sahajwalla, and has since developed a strong network of stakeholders. These partners include not-for-profits, representatives from all tiers of government, commercial operators in the private sector and local communities. DECEMBER 2020 | 53

FEATURE – Technical Additive Manufacturing Innovations in Steels

The ASI Steel Innovation Portal: Showcasing the Best of Steel Innovation in Australia Source: Sally Wood

The Australian steel supply chain has a long and proud tradition of producing high quality products and services backed by a commitment to investing in technology, innovation and skills development. According to the Department of Industry, Innovation and Science, approximately 75% of modern steels have been designed, developed and brought to market over the last 20 years. Not surprisingly, Australia has some of the world’s leading researchers undertaking cutting-edge projects and developments. For instance, BlueScope boasts an innovation and product development team of over 70, based at its Port Kembla steelworks. Similarly, InfraBuild has invested in a major energy efficiency program that will see the use of renewable energy at its Whyalla steelworks, as well as the installation of solar panels, pumped hydro and battery storage. Innovation is not confined solely to industry. Several Australian universities and research organisations are also leading the charge, including the Australian Research Council Research Hub for Australian Steel Manufacturing at the University of Wollongong, who helped fund the initial Steel Innovation portal development. Amid this exciting research and innovation in areas as diverse as ‘green steel’ and renewables, new product development, and advancements in digitisation, robotics, automation and virtual augmented reality, it comes as no surprise that Australia is experiencing a steel renaissance. There is an unprecedented pipeline of opportunities in infrastructure, defence, building and construction. To this end, the Australian Steel Institute (ASI) has created the ASI Steel Innovation Portal. The ASI Steel Innovation Portal is a central web-based repository designed to house innovative steel-related research and developments, which will be accessible to the entire community. 54 | DECEMBER 2020

According to Mark Cain (Chief Executive, ASI), “The ASI must help foster a vibrant Australian steel industry. As such, we are putting in place the mechanism by which to create linkages between industry and academia. Through the Steel Innovation Portal, we are striving to create a robust future for the steel industry, founded on identifying and developing innovative concepts.” “It is important that steel manufacturers, distributors and fabricators learn from, and share ideas with, their peers both locally and internationally. We must be able to capture and share the cuttingedge ideas and emerging innovative concepts among all participants in the steel industry, including Australia’s leading universities and research hubs.” “The ASI Steel Innovation Portal has been designed to promote innovation, collaboration and communication. The use of this web-based tool by the industry should support greater flexibility, productivity, and efficiency in the local steel supply chain,” said Cain.

The ASI Steel Innovation Portal: • Allows universities, research organisations and manufacturers to post structured details of the research projects being undertaking in a format that is standardised and egalitarian across the range of projects and institutions involved • Allows posting of researcher biodata in a structured format, with linkages to the relevant research projects • Allows searching and data mining by the local and international community on the range of projects and researchers in the portal • Facilitates connectivity and communication between industry and the organisations and researchers involved, both locally and internationally • Allows easy updating and editing of details to ensure information currency • Supports matching of innovation ideas to research capability • Facilitates international communication and collaboration between stakeholders on steel related innovation

The Concept There is a significant body of world-class steel related research being undertaken in Australia, through entities as diverse as universities, manufacturers, private research institutes and industry bodies. The ASI currently interacts with a select group of these entities. However, it is not currently possible for any one organisation to be aware of, or to help coordinate, all the research being undertaken. Without an overarching view of our ‘innovation capital’, industry cannot hope to action the key initiatives articulated in the current Government National Innovation and Science Agenda – ‘Welcome to the Ideas Boom’ (http:// www.innovation.gov.au/), which recognises the need for Australia to embrace innovation if the economy is to prosper and grow. The ASI Steel Innovation Portal is a central web-based library of ‘innovation capital’ principally associated with innovative steel-related research and development. BACK TO CONTENTS

The ASI Steel Innovation Portal (SIP) development demonstrably actions support for several the focus areas in the Government’s ‘Ideas Boom’ and identified issues of: • Developing capability of the local steel supply chain by harnessing awareness of our local innovation capital, particularly in areas related to design, fabrication and manufacturing • Dovetailing with the current Government funded University of Wollongong Steel Research Hub initiative (http://steelresearchhub. uow.edu.au/). The SIP is a practical implementation of ideas generated in this ongoing research effort • Supporting outcomes from the Government funded ‘Digital Steel’ Report (http://apo.org.au/node/34768) which in part addressed overcoming barriers to innovation and the path towards advanced manufacturing, with a strong focus on our existing and required research capabilities WWW.MATERIALSAUSTRALIA.COM.AU

FEATURE – Technical Innovations in Steels

• A need for ASI to better connect with our research community to provide the Australian steel community with the tools necessary to better integrate the supply chain.

Industry Support Whilst ASI was responsible for the establishment and initial operation of the portal, it has garnered support from the entire steel supply chain, including the following key organisations:

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• Steel Manufacturers; InfraBuild, BlueScope, Stramit and Bisalloy • Weld Australia (formerly the Welding Technology Institute of Australia (WTIA)) • Australian Stainless Steel Development Association (ASSDA) • Steel Reinforcing Institute of Australia (SRIA) • National Association of Steel Framed Houses (NASH)

The ASI Steel Innovation Portal.

• Galvanizers Association of Australia (GAA)

Up-Front Benefits

Current Status

The ASI Steel Innovation Portal will provide a range of tangible benefits, including:

Based on a small funding grant from the University of Wollongong Steel Research Hub (http://steelresearchhub.uow.edu. au/) and significant funding in kind from ASI, the inaugural ASI Steel Innovation Portal is available at: https://innovate. steel.org.au. The ASI Steel Innovation Portal provides an entry point from which to search for current steel related research projects at major universities and research institutions. It enables users to search the significant ‘innovation capital’ being undertaken by hundreds of talented researchers across Australia. Keyword searches on specific requirements can also be undertaken, if looking for capability to undertake innovative research. Through ongoing engagement with universities in each state, the ASI now has a commitment from over 25 leading Australian universities to be part of the portal. These universities are currently being logged onto the portal and provided the credentials that will enable them to submit approved project and researcher details to the portal.

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• Transparent and egalitarian connectivity between research and industry, helping to overcome the ‘disconnect’ often felt and cited by both researchers and industry

• Promoting innovation through publishing and sharing public data • Connecting industry to the world-class innovation infrastructure that exists in Australia • Boosting the effectiveness of the excellent Australian R&D currently being undertaken by building the linkages with industry

• Magnification of Government research funding initiatives, through greater awareness of research outcomes;

• Driving better collaboration across the university sector in steel related research

• Integration of researcher ‘innovation capital’ into industry through the direct connection between researchers and industry

• Aligning the Australian steel industry’s world-class national research infrastructure

• Support of small and medium enterprises, who often have the innovative ideas but rarely the understanding of how to research, commercialise and take them to market

Value-Add Benefits The value is not only in the initial existing portal implementation, but in the ability for this to nucleate a range of value added services, which funding and support can help expedite:

• Removing barriers and facilitating collaboration, promoting an openmarket approach to industry research • Providing a vehicle through which individuals and business from regional areas can connect with the innovation and leading edge ideas being developed • Potential for adding functionality to support innovation migration from research institutes to industry, such as promotion of employment opportunities, requests for targeted research by industry, and so on

• Establishing a centralised ‘Steel virtual space’ to promote collaboration and facilitate innovation across the Australian steel industry BACK TO CONTENTS

DECEMBER 2020 | 55

FEATURE – Technical Additive Manufacturing Innovations in Steels

Steel Research Hub: Ensuring Sustainable Industry Growth Source: Sally Wood

In December 2013, the Federal Government, through the Australian Research Council (ARC), awarded a grant of $5 million over five years to fund research in support of the Australian steel industry. The grant, awarded under the Industrial Transformation Research Hubs scheme, was in addition to over $7 million in cash already pledged by the industry and university partners of the ARC Research Hub for Australian Steel Manufacturing, or Steel Research Hub (http:// steelresearchhub.uow.edu.au). Since launching in September 2014, the groundbreaking initiative has been testament to the critical importance of the steel industry in Australia, and has demonstrated the value that both industry and government place in collaborative, cross-disciplinary research. Based at the University of Wollongong, the Steel Research Hub has brought together key partner, BlueScope, with Arrium, Bisalloy, Cox Architects, the Australian Steel Institute (ASI), Lysaght, Stockland, University of Queensland, University of Newcastle, Swinburne University of Technology, RMIT and Monash University, to drive its research program. In later years, new industry partners have joined, including GFG Liberty OneSteel and ArcelorMittal. The Hub’s vision was to bring together teams of internationally recognised research and industry talent to help deliver innovative solutions and some breakthrough technologies in manufacturing and product development areas, helping to ensure sustainable growth in the Australian steel industry. Research programs were undertaken in order to achieve this vision, including: developing highly differentiated, marketfocused product innovations; developing and commercialising world-class innovative technologies in steel coating technologies; and transforming the economic and environmental sustainability of iron and steelmaking in Australia. The 56 | DECEMBER 2020

idea was to focus on strategic outcomes to challenging industry issues and train a future workforce including PhD candidates and research fellows who were exposed to difficult industry problems and worked alongside experienced steel technologists and researchers. According to Paul Zulli (Director, ARC Research Hub for Australian Steel Manufacturing), “One of the Hub’s major achievements was harnessing the skills and expertise of Australia’s best researchers to deal with specific issues facing the Australian steel industry. We were able to foster a strong collaboration and commitment from both academia and industry to help deliver a range of strategic outcomes that were not independently realisable. The Hub has also helped train members of the future workforce. We’ve seen some of our PhD candidates move into industry, which is advantageous for them, for the industry, and for the universities involved.”

and Tempered plate steels. “The largest project in the Hub was concerned with steel intensity in Australian mid-rise apartment buildings. This cross-disciplinary project brought together architects, engineers (structural, materials, chemical, mechanical, civil) and supply chain expertise to design an apartment building structure made almost entirely from cold-formed steel. This was a significant initiative, encompassing architectural design, structural systems, energy systems, internal environmental quality and supply chain aspects,” said Zulli. The surface engineering innovations focused on antimicrobial properties of painted steel surfaces and utilised a fundamental, multi-disciplinary approach drawing on expertise in microbiology, surface engineering and chemistry, and computational molecular dynamics. “The innovative research undertaken investigated the design of nanoparticlebased platforms which would enable

Market Focused Product Innovations This program’s aim was to optimise the market interface to clearly define end-user needs; the product developments would be marketdriven. This was achieved through enhanced customer engagement in both the development of ideas and product development. In the Steel Research Hub, product development Images courtesy of: Craig Holbrook. initiatives involved painted surfaces to be more resistant to transformative research on hot-rolled strip microbial attack so that the aesthetics and wear-resistant plate products, coldand appearance of the product could formed steel use in Australian mid-rise be retained for a longer time,” Zulli apartment buildings, and paint coated explained. products. The hot-rolled product projects focused on the development of very high strength steel for structural, transport and mobile equipment applications, as well as improved abrasion resistant Quenched BACK TO CONTENTS

Innovative Coating Technologies The fundamental research undertaken in this program significantly increased existing capability and new knowledge WWW.MATERIALSAUSTRALIA.COM.AU

FEATURE – Technical Innovations in Steels

on the microstructure development next generation metallic coated steel of products. These projects aimed to understand the mechanisms responsible for the development of stable, high quality coatings of optimal thickness during continuous coatings processes. Through thermodynamic and high temperature modelling research, an indepth understanding of how operational factors affect the generation and growth of intermetallic compound particles in the coating bath was developed. This knowledge will now be used to deliver improvements in the manufacture and quality of next-generation metallic coated steel products in Australia. New knowledge concerning the physical properties of liquid metallic alloys was also generated, particularly with reference to the interfaces between the liquid alloy and surrounding atmosphere, and the liquid and steel substrate. These play a crucial role in coating formation. This new understanding helps clarify how the properties vary with processing conditions, alloy composition and atmospheric exposure. Finally, sophisticated computational fluid dynamic models and experimental techniques were used to investigate the complex phenomena affecting the liquid alloy coating surface in the jet stripping section of the continuous coating line. In this project, key contributing mechanisms that led to surface instabilities were identified and optimal process line set-ups suggested.

Sustainable Steel Manufacturing The objective of this wide-ranging and broad research program was to help maintain Australia’s competitiveness in iron and steelmaking, with attention to both economic and environmental WWW.MATERIALSAUSTRALIA.COM.AU

sustainability. There were two key areas: economic sustainability through enhanced productivity and flexibility of raw material usage in steelmaking; and environmental sustainability through lower greenhouse gas emissions and greater recycling of plant waste. An example of the relevant research undertaken related to increased utilisation of Australian raw materials. The investigation of the sintering and assimilation behaviour of complex raw material blends that incorporated conventional Australian iron ores, fluxes and recycled plant byproduct streams, identified the optimal operational conditions for sintering with respect to blast furnace conditions. The knowledge generated will give ironmakers more flexibility in reducing costs and help deliver confidence in greater use of Australian raw materials.

Innovation and Collaboration are Imperative Paul Zulli believes that it is important that the Australian steel industry continue to engage in cross-collaborative, crossdisciplinary research and development. “The Hub was a model for collaboration between academia and industry. If it were to be improved, it would be to continue to bring the large companies together, but also to bring in the small to medium enterprises. “Collaboration is important to the future of the Australian steel industry. It would be tremendous if the Hub researchers were employed directly by our industry partners, or industry partners continued to support them in an academic capacity. It is also important to maintain the key capabilities that were augmented by the Hub, in areas like core product research. In closing out the Hub, we’re compiling a significant body of research outcomes, which industry partners will find extremely useful in their businesses,” said Zulli. There is a significant body of world-class steel related research being undertaken in Australia through entities as diverse as the Steel Research Hub, universities, manufacturers, private research institutes and industry bodies. Without an overarching view of our ‘innovation capital’, industry cannot hope to action the key initiatives articulated in the current Government National Innovation and Science Agenda: Welcome to the Ideas Boom; this recognises the need for Australia to embrace innovation if we are to prosper and grow. BACK TO CONTENTS

Research Collaboration Improves Consistency of Thin Coatings for BlueScope Products Researchers from the Steel Research Hub, who are engaged with industrial counterparts to solve complex problems, have delivered a computational fluid dynamic models to help steel manufacturers produce consistent and high-quality coated steel products. Coated steel products such as corrosion resistant metallic alloy coated steels are important for BlueScope and other Australian steel manufacturers, particularly in building applications that must withstand the demands of the harsh Australian climate for extended periods. The metallic alloy coating is applied to the steel strip by first passing the strip through a molten alloy bath, such as in hot dip galvanising; then, as the strip passes out of the bath, a series of tiny air jets blow or ‘wipe’ away the excess coating material to achieve the desired coating thickness and uniformity. While the process sounds simple, getting the system tuned correctly involves understanding and predicting the effects of several process variables, such as the speed of the steel strip, the pressure of the air jets and the metallic alloy coating itself. This poses a constant challenge for steelmakers in delivering high-quality coated products that meet product specifications and requirements. Associate Professor Buyung Kosasih, a Chief Investigator within the Steel Research Hub, from the University of Wollongong’s Faculty of Engineering and Information Sciences, said the joint University of WollongongBlueScope – University of Queensland research team had developed a mathematical model that enables the prediction of the coating response under different operating conditions. “This represents a key modelling tool for BlueScope operational personnel to produce quality coatings,” he said. “The mathematical model is the first that links the jet instability to potential coating surface defects.” This article first appeared in steel Australia, the quarterly magazine of the Australian Steel Institute (ASI): https://steel.org.au/

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FEATURE – Technical Additive Manufacturing Innovations in Steels

Steel Research Hub wins $28 million Funding Boost Source: Sally Wood

The Federal Government has announced an additional $5 million in new funding for the University of Wollongong-led, ARC Research Hub for Australian Steel Innovation (Steel Research Hub). The Steel Research Hub will be funded for another five years (2021-2025) and led by Dr Paul Zulli. The Minister for Education, The Hon Dan Tehan, announced the funding as part of the ARC’s Industrial Transformation Research Program, which brings together the best and brightest researchers, scientists and engineers from higher education and industry to drive innovation and improve global competitiveness in key industries. In addition to the ARC funding, the Steel Research Hub’s eight industry partners, BlueScope Steel, Liberty Primary Steel, Infrabuild, ArcelorMittal, Bisalloy, Australian Steel Institute, Weld Australia and Australian Industry Group will contribute another $13.9 million in cash and in-kind support. The University of Wollongong, together with RMIT University, Australian National University, Swinburne University of Technology, University of Newcastle, Deakin University, University of Sydney, University of New South Wales and Monash University, will contribute a further $9.5 million cash and in-kind.

The total funding for the Steel Research Hub is $28.4 million. The overarching goal of the new Hub is to support the transition of Australia’s steel manufacturing industry to a more sustainable, competitive and resilient position, based on the creation of new, higher value-added products and more advanced manufacturing processes. The Hub Director, Dr Zulli welcomed the funding announcement, and said he looked forward to the Steel Research Hub strengthening its collaboration with the Australian steel industry, through delivering both new innovative research outcomes and training of a new generation of capable and influential researchers and technologists. “A globally competitive domestic steel 58 | DECEMBER 2020

manufacturing industry is a strategic asset for Australia’s nation-building, economic growth and employment,” Dr Zulli said. “The domestic industry must continue to provide a secure, flexible and highquality local source of steel and products for infrastructure and construction, manufacturing, mining and agriculture. “The research outcomes delivered over the coming five years will benefit the competitiveness and future growth of large and small steel-related businesses in Australia.

• Novel approaches to next-generation products incorporating improved functionality such as higher strength, ductility, durability and resilience; • Step-change performance in anticorrosion treatments for products, new processing capability and more productive manufacturing facilities, and • New applications of enabling and other advanced manufacturing technologies (Industry 4.0) to achieve a generational shift in capability across the supply chain. Daksesh Patel, GFG Alliance Regional President (Australia and USA) & CEO InfraBuild said, “InfraBuild and Liberty Primary Steel, part of the GFG Alliance, are excited to be industry partners for the new Steel Research Hub and welcome the additional funding provided by the Australian Government.”

Hub director Dr Paul Zulli, research program leader Professor Lip Teh, research fellow Dr Aziz Ahmed, PhD student Refat Ahmed, and lab manager Cameron Neilson. Picture: Paul Jones.

“In turn, these should positively affect key societal challenges, such as providing affordable housing and quality infrastructure, developing longer-lasting materials, recycling of resources, and training a more capable and diverse workforce.” Sean Wong, BlueScope’s Manager Product Innovation & Technology, said: “BlueScope are delighted to be a partner in the second ARC Steel Research Hub. BlueScope invests significantly in both product and process innovation to sustain product leadership in our target segments. “This second Steel Research Hub facilitates collaboration between BlueScope, UOW and eight other Australian Universities to develop and enable the next wave of technology innovation that will improve the competitiveness of BlueScope.” These research activities are focussed in four main areas: • New methodologies that significantly improve resource intensity and utilisation while maintaining productivity, quality and life of steel manufacturing facilities; BACK TO CONTENTS

“With a huge pipeline of infrastructure projects expected over the next 10 years, innovation in steel has never been more important and we are proud to be part of it.” “The new technologies and products that will be developed through the hub will help keep the industry competitive and ensure Australian made steel is used in infrastructure projects across the country.” UOW Deputy Vice-Chancellor (Research and Innovation) Professor Jennifer L. Martin AC said the University’s strong historic links with Australia’s steel industry put it in an ideal position to drive innovation in the industry. “Our researchers are recognised as worldleaders in many aspects of steel innovation and development. In its first five years, the Steel Research Hub has worked closely with industry to research and develop innovative products and processes that have enhanced the global competitiveness of Australian steel.” “With the announcement of a new Steel Research Hub, the University of Wollongong and its industry and research partners will continue to deliver world-class research, enhancing economic and environmental outcomes for the steel industry, and ultimately benefiting all Australians.”

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MATERIALS AUSTRALIA – Short Courses

Short Courses - Study at Home

These short courses provide you with an engaging learning experience. Courses may include flash animations, video of instructors teaching the course in a classroom, video segments from ASM’s DVD series relevant to the learning material, and PDFs of instructor Power Points used in the instructor led training. All online courses require internet access for reading and viewing course content. Both HTML pages and PDF files for each lesson are downloadable and printable for easy offline access.

www.materialsaustralia.com.au/training/online-training BASICS OF HEAT TREATING

HEAT TREATING FURNACES AND EQUIPMENT

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

This course is designed as an extension of the Introduction to Heat Treatment course. It discusses advanced concepts in thermal and thermo-chemical surface treatments, such as case hardening, as well as the principles of thermal engineering (furnace design). Read More

NEW - INTRODUCTION TO COMPOSITES HOW TO ORGANIZE AND RUN A FAILURE INVESTIGATION Have you ever been handed a failure investigation and have not been quite sure of all the steps required to complete the investigation? Or perhaps you had to review a failure investigation and wondered if all the aspects had been properly covered? Or perhaps you read a failure investigation and wondered what to do next? Here is a chance to learn the steps to organize a failure investigation. Read More

MEDICAL DEVICE DESIGN VALIDATION AND FAILURE ANALYSIS This course provides students with a fundamental understanding of the design process necessary to make robust medical devices. Fracture, fatigue, stress analysis, and corrosion design validation approaches are examined, and real-world medical device design validations are reviewed. Further, since failures often provide us with important information about any design, mechanical and materials failure analysis techniques are covered. Several medical device failure analysis case studies are provided. Read More

Composites are a specialty material, used at increasing levels throughout our engineered environment, from high-performance aircraft and ground vehicles, to relatively low-tech applications in our daily lives. This course, designed for technical and non-technical professionals alike, provides an overarching introduction to composite materials. The course content is organized in a manner that guides the student from design to raw materials to manufacturing, assembly, quality assurance, testing, use, and life-cycle support. Read More

METALLURGY FOR THE NON-METALLURGIST™ An ideal first course for anyone who needs a working understanding of metals and their applications. It has been designed for those with no previous training in metallurgy, such as technical, laboratory, and sales personnel; engineers from other disciplines; management and administrative staff; and non-technical support staff, such as purchasing and receiving agents who order and inspect incoming material. Read More

PRACTICAL INDUCTION HEAT TREATING

This course provides essential knowledge to those who do not have a technical background in metallurgical engineering, but have a need to understand more about the technical aspects of steel manufacturing, properties and applications. Read More

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

PRINCIPLES OF FAILURE ANALYSIS

TITANIUM AND ITS ALLOYS

Profit from failure analysis techniques, understand general failure analysis procedures, learn fundamental sources of failures. This course is designed to bridge the gap between theory and practice of failure analysis. Read More

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

METALLURGY OF STEEL FOR THE NON-METALLURGIST

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