Materials Australia Magazine | September 2021 | Volume 54

NEW CONFERENCE DATES

CAMS2021

PAGE 9

NEW CONFERENCE DATES

APICAM2022 & LMT2022 PAGE 13

UNIVERSITY SPOTLIGHT

Curtin University

PAGE 32

Online Short Courses

PAGE 51

How Materials Science is Helping Australian Manufacturing

Materials science delivers a suite of endless opportunities—it has the power to revolutionise virtually any product across Australia's manufacturing industry. VOLUME 54 | NO 3 ISSN 1037-7107

SEPTEMBER 2021

Official Publication of the Institute of Materials Engineering Australasia Limited Trading as Materials Australia | A Technical Society of Engineers Australia www.materialsaustralia.com.au

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From the President vaccines for rabies and anthrax in the late 1870s and 1880s) are as important today as ever. Additionally, when you are next able to raise a glass of wine or beer with colleagues and friends, remember the fact that Louis Pasteur first published the scientific understanding of alcoholic fermentation in 1858, and then in 1865, patented the means of how pasteurisation could be applied to beer, wine and milk. I would therefore like to focus on one of the most important quotes attributed to Louis Pasteur who many consider the founder of modern innovation. This quotation of course is that “fortune favours the prepared mind”. Welcome to the September 2021 edition of Materials Australia. It feels as though I only just wrote one of these messages, and yet so much has changed in the past three months—again. In my last President’s Message, I discussed the topic of resilience and what that might mean to our businesses, the institutions for which many of our members work, and also to Materials Australia. Now, more than ever, it is clear that our resilience gives us the capacity to recover quickly from difficulties. Resilience embeds an ability to help us navigate volatility, respond to uncertainty and mitigate risk, recover from adversity, and reimagine the unexpected. I was recently reading some of Louis Pasteur's career history, which included quotes attributed to the great scientist during his times of adversity. Notably, early in his career, Pasteur submitted two theses as a graduate student (Chemistry and Physics), following on from his research in crystallography. His contributions to crystallography and the discoveries made were, at the time and in the years that followed, considered to be his most significant and original contributions to science. Pasteur was admitted to the French Academy of Sciences in 1862 for contributions to mineralogy. Beyond that time, he made incredible advances in scientific knowledge, and his discoveries related to microbiology, immunology and vaccination (including WWW.MATERIALSAUSTRALIA.COM.AU

Understanding what constitutes invention and innovation is so much of what we strive to achieve, and the philosophy that we hope to instil in those we work with, and who we inspire. Perceptions of what constitutes invention or an innovative approach to materials and manufacturing are especially subjective and not always well understood by many professionals, particularly as they relate to established industries. In reality, a failure to recognise innovation, and properly capture it may lead to loss of business and intellectual property. This is true, not only of inventors of new technology, but also of the potential customers who can benefit from it. We often hear press releases or media discussing the latest digital advances, but these are not always a great fit for many manufacturing businesses, including those associated with advanced materials, where core activities are somewhat different and where there is an overwhelming priority to produce positive revenue streams and business growth. However, it is also clear that without innovation, businesses cannot increase profits, decrease overheads, or develop new products in the marketplace. Innovation doesn’t necessarily have to involve a new discovery, a new material or a new manufacturing technique. But, it may involve a new philosophy, and it does have to produce an outcome that can be commercialised and marketed successfully.

major opportunity for our materials and manufacturing industries and research initiatives. I make particular note of this because we are heading into grant writing season for ARC Discovery Projects, Linkage Projects, Linkage Industrial Transformation Training Centres, Industrial Transformation Research Hubs, and Centres of Excellence. I believe the opportunities for what we do in the materials industries and research communities is especially promising right now. I look forward to hearing about the successful outcomes for those of our community, which will be announced over the next three to six months. Next, as you likely have already seen, Materials Australia has a new logo. This will help us develop and build a strong brand, and maintain a forward facing outlook in our role as the trusted voice of the materials science and engineering community. Finally, I would like to make a note about conferences that were planned for 2021. These conferences have been postponed until 2022, with more details to follow. We are planning to run CAMS in February 2022, which has so far received a very good set of abstracts. I would encourage anyone who has not yet submitted an abstract to do so as soon as possible, to ensure inclusion in the conference. Looking to the future, we have an outstanding set of conferences planned for 2022. This includes APICAM and LMT 2022, which are expected to run in the middle of next year, notwithstanding restrictions on movement. At this time, I would also like to wish everyone the best of health as we head towards the end of the year. I hope that I will be able to talk to many of you soon at one of the planned Materials Australia events. Best Regards Roger Lumley National President Materials Australia

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CONTENTS

Reports From the President

Contents

Materials Australia - Corporate Sponsors | Advertisers

6 Advancing Materials and Manufacturing

Materials Australia News WA Branch Technical Meeting - 12 July 2021

CAMS2021 9 WA Branch Technical Meeting - 9 August 2021

Oil & Gas Integrity Symposium 2021 11 WA Branch Technical Meeting - 13 September 2021

New Conference Dates | APICAM 2022 | LMT 2022

Phase Transformations and Microstructural Evolution in Additive Manufacturing Symposium - 9/10 August 2021

NSW Branch Technical Meeting - 17 June 2021

NSW Branch Technical Meeting - 8 September 2021

CMatP Profile: Dr Leon Prentice

Our Certified Materials Professionals (CMatPs)

Why You Should Become a CMatP

Women in the Industry - Alex Kingsbury

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

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ADVERTISING & DESIGN MANAGER Gloss Creative Media Pty Ltd Rod Kelloway (02) 8539 7893

From feature article on page 40. NEW CONFERENCE DATES

CAMS2021

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

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APICAM2022 & LMT2022

PAGE 13

UNIVERSITY SPOTLIGHT

Curtin University

PAGE 32

Online Short Courses

PAGE 51

How Materials Science is Helping Australian Manufacturing

Materials science delivers a suite of endless opportunities—it has the power to revolutionise virtually any product across Australia's manufacturing industry. VOLUME 54 | NO 3 ISSN 1037-7107

SEPTEMBER 2021

Official Publication of the Institute of Materials Engineering Australasia Limited Trading as Materials Australia | A Technical Society of Engineers Australia www.materialsaustralia.com.au

Letters to the editor; info@ glosscreativemedia.com.au

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CONTENTS

Industry News Reviewing Pressure Effects On Iron-Based High-Temperature Superconductors

Advanced Care: Smart Wound Dressings With Built-In Healing Sensors

Smarter Electronics A Step Closer With Nanotech Advance

Plasma Tech Could Replace One Of World's Rarest Materials

A Leading Supplier Of Non Destructive Testing Equipment

Computed Tomography Buyers Guide

Rigaku and JEOL Launch a Revolutionary Electron Diffraction Platform XtaLAB Synergy-ED 29 Generate Stunning Ultra-High Resolution Images Of Structures As Small As Two Nanometres Using The Tabletop Phenom Pharos G2 Feg-Sem

University Spotlight - Curtin University

Breaking News 34 Feature

MA - Short Courses

How Materials Science is Helping Australian Manufacturing

https://www.materialsaustralia.com.au/training-courses-and-workshops/online-training

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

NATIONAL PRESIDENT Roger Lumley

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

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WA Branch Technical Meeting - 12 July 2021 Asset integrity in Subsea Oil and Gas Source: Dr Alex Ham, Team Lead, Subsea Integrity Management, Wood Dr Alex Ham, holds a PhD in Materials Engineering and has extensive experience in asset management in the water supply industry, mining and in subsea oil and gas. He summarised the principle of asset management as “the coordinated activity of an organisation to realise value from assets". The guiding standard for risk-based asset management is ISO 55000, with the subsea industry also using DNV and API standards. Ultimately, a balance is needed between risk, consequences, and mitigating actions. Dr Ham summarised his role as helping ensure that “nothing exciting happens”, though this raises a challenge in demonstrating value when the outcome is the absence of failures. He remarked that, if anything exciting (or even catastrophic) were to happen, ideally applied risk-based asset management should be able to justify the response that “we wouldn’t have done anything differently”. There are, however, many potential pitfalls, as he went on to explain. Asset management considers both capital expenditure (CAPEX) and total lifecycle expenditure (TOTEX). It therefore requires the integration of asset data and financial data, covering the full asset life cycle: acquisition, operation, maintenance, and ultimately, disposal. In the oil & gas industry, the major opportunities to reduce total life cycle cost are often ‘up-front’ in the design stage.

L to R: Schree Chandran (Branch President) and Dr Alex Ham.

The continuing cycle of asset management comprises four steps:

In general, the goal of maintenance is to ensure a specified level of availability. For surface installations, this might be achieved by ensuring easy maintainability, with only fair reliability. However, in subsea operations, high reliability is essential because maintenance is very expensive.

1. Risk assessment – leading to inspection and monitoring planning 2. Inspection, monitoring and testing – incorporated in maintenance planning 3. Integrity assessment – leading to corrective action 4. Mitigation of risk, intervention and repair – leading management of change and then to revised risk assessment Understanding failure mechanisms is a key part of risk assessment, incorporated in Failure Mode, Effects and Criticality Analysis (FMECA). This involves understanding the equipment in the scope, and understanding the failure scenarios, and describing the failure mechanisms. This is followed by determination of valid inspection, measuring and monitoring responses, and then determining the intervals for these responses. Dr Ham pointed out that the management of subsea assets into different groups raised a particular risk issue: managing the interfaces between the groups to ensure that nothing is missed. Dr Ham referred to shared information on 108 ‘significant issues’ in five subsea fields, reported by three operators. More than 50 per cent involved subsea controls (typically carrying electric currents to operate valves), and only 1 per cent involved risers. However, those few involving risers had potentially much more sever consequences for safety, the environment and production. Dr Ham then spoke about some pitfalls in asset management, starting with the consequence of not effectively managing the people who participate in risk management meetings! The next pitfall is failure to document decisions effectively. 8 | SEPTEMBER 2021

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If the response to a risk is inspection, then an identifiable precursor to failure must be identified, along with an allowable timescale for inspection, and pass-fail criteria. He illustrated the principles involved by giving an example of dealing with the risk of scouring under a seabed pipeline.

The highly engaged audience had many questions. In response to to one question regarding the issue of the people in the risk management workshop, Dr Ham noted that some people tend to derail the methodology: some do not cope with the lack of precision, and the need for balance in ‘suspending disbelief’ when considering options. He also pointed out the need to understand the industry’s (or company’s) appetite for risk, and remarked on the differences between the oil and gas, mining and the water industries, and in the latter, between different jurisdictions. Asked about innovation, he remarked that for subsea oil and gas, saving vessel-days is the big driver. This is leading to a shift from inspection to monitoring, although it has proved difficult to ‘marinise’ monitoring equipment for subsea use. One issue with inspection, is that because it is difficult to mobilise for inspection there is a tendency to over-inspect, just to be sure. Dr Ham highlighted the application of very high resolution underwater cameras. These allow a specified inspection resolution from a greater distance, leading to much more rapid surveillance. He forsees this application being combined with artificial intelligence techniques. As a final comment, Dr Ham likened the inspection task to understanding the complete jigsaw picture, while looking at as few of the pieces as possible. WWW.MATERIALSAUSTRALIA.COM.AU

Advancing Materials and Manufacturing

NEW CONFERENCE DATE ANNOUNCED

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

2nd - 4th February 2022 | The University of Melbourne

BOOK NOW

www.cams2021.com.au 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 xinhua.wu@monash.edu

Dr Andrew Ang Swinburne University aang@swin.edu.au

Opportunities for sponsorships and exhibitions are available. CAMS2021 2nd - 4th February 2022 The University of Melbourne VICTORIA, AUSTRALIA www.cams2021.com.au

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

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.au

MATERIALS AUSTRALIA

WA Branch Technical Meeting - 9 August 2021 Curtin Corrosion Centre Source: Prof Mariano Iannuzzi, Director, with staff and students The Curtin Corrosion Centre has been conducting industry-directed research and education for 35 years. Professor Mariano Iannuzzi, who has been Director of the Centre since 2019, explained how its well-earned reputation as a trustworthy research partner for oil and gas businesses has enabled a rapid expansion over the past five years, to the point where the Centre now has 22 staff and 23 research students, as well as 14 research associates and three collaborators. Professor Iannuzzi went on to outline some of the clusters of world-class expertise for which the Centre is particularly noted, including microbially induced corrosion, corrosion under insulation, hydrogen sulfide and carbon dioxide corrosion, tribo-corrosion, stress corrosion and environmentally assisted cracking. The Centre has already established facilities to deal with research challenges from the emerging hydrogen economy and is diversifying into computational modelling, concrete corrosion, polymers, and additive manufacturing. Through its links to other Curtin University Centres, it has exceptional capability in failure analysis. The Centre operates like a not-for profit business. One stream is market-priced demand-driven research, with projects typically running less than 18 months.

The other stream comprises longer term (e.g. five-year) partnerships between Curtin University and business groups. The partnerships fund longer-term PhD research and professorial appointments. Professor Iannuzzi then handed over to staff and students to provide some examples of current work. Sofia Hazarabedian described how her PhD research arose from an oil and gas industry problem with cracking of precipitation hardened Alloy 725 nickel-based alloy components, made from batches that had passed standard qualification tests of mechanical properties and microstructure. Using a suite of sophisticated analytical techniques, she identified the cause as grain boundary precipitation of an unusual intermetallic phase (F-phase), which depleted the adjacent alloy of cobalt and molybdenum. She also devised a simple objective cyclic polarisation test procedure, which can quantify the extent of F-phase precipitation. At the same time, this electrochemical test can serve as a preparatory step for metallographic evaluation, as it makes the precipitates more easily visible. These tests make it possible to screen batches of alloy and will help producers develop thermomechanical treatments to minimise the embrittlement.

Dr Sheila Omar, one of the Centre’s Research Fellows, gave an example of shorter-term demand-driven research. She described a one-month project to determine whether corrosion treatments proposed for a mineral transport slurry pipeline were likely to be cost effective. Dr Omar described the four-step approach of: evaluating the literature; conducting a suite of corrosion tests that simulated operating conditions (water quality, bacterial populations); evaluating and communicating the results to a non-expert audience; making recommendations for action. The ten tests conducted simultaneously, without the proposed corrosion mitigations, showed that concerns about differences between the welds and the original steel were not justified, and that only one set of conditions involved the risk of pitting corrosion. Otherwise, without expensive treatments, the uniform corrosion could be managed for the designed life of the pipeline. Time restraints limited the inspection of the Centre to a small section of the extensive laboratory and testing facilities, along with a video presentation of the autoclave testing for hydrogen sulfide and mercury corrosion. One of the projects on view involved additive manufacture and subsequent mechanical testing of 316 stainless steel components. A technique under investigation is weight reduction by making components with internal lattice-like structures, which could not be produced by conventional forming methods. As several of the visitors were personally familiar with the problems being studied, the opportunity to meet the researchers generated insightful questions and answers, which were greatly appreciated.

L to R: Caption

10 | SEPTEMBER 2021

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I N T E G R I T Y

S Y M P O S I U M

2 0 2 1

HOSTED BY WOODSIDE ENERGY LTD

Digital Future of Integrity Management

The Biennial Oil and Gas Integrity Symposium (OGIS) was hosted by Woodside Energy Limited from 8 to 10 September at the Melbourne Hotel in Perth. OGIS is a not for-profit, fully independent event that encourages the open sharing of experiences and knowledge by integrity specialists within the oil and gas Industry. The symposium has been held every two years since 1983, and is unique in that it is organised by industry integrity professionals, and is free from commercial interests. Attendees are required to be permanent staff from petrochemical or pipeline operating companies and all information discussed or presented is of a technical nature. No proceedings are published. Even with the limitations of travel due to COVID-19, over 30 specialists were able to come together to discuss issues and challenges associated with this year’s theme: The Digital Future of Integrity Management. Delegates representing Chevron, Inpex, Santos, BHP Petroleum, ConocoPhillips, Alcoa and Woodside Energy were in attendance. The Symposium keynote address was given by Lauchlan Wallace who demonstrated the Woodside Fuse platform. Wallace spoke

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about the process and technical hurdles associated with developing digital platforms. He also touched on integrating ‘digital twins’ with engineering and process data to support operations, maintenance and inspection. The technical sessions covered a range of key areas, including asset integrity management systems, digital transformation and data management, integrity operating window management, robotics, drone and UAV inspection, pipelines, pressure safety valves and learnings from incidents.

and quality of the work. The OGIS organising committee would like to thank Woodside Energy for hosting this year’s symposium, all the individual contributors for their time and effort, Materials Australia for their support, and the wonderful staff of the Melbourne Hotel. The next OGIS is planned to be held in South Australia in 2023. Dwayne Doherty – OGIS Organising Committee Chair

At the end of each day, an open forum was held to allow attendees to further discuss issues arising out of the day’s technical presentations. In keeping with tradition, Thursday’s session concluded with a networking evening, including a fine dining experience at the Grand Orient Restaurant within the Melbourne hotel. At the end of the conference the organising committee faced the difficult task of deciding the symposium’s best technical presentation and selected Benjamin Ho from Inpex who presented on Piping Inspection using Unmanned Aerial Vehicles (UAVs). This presentation was a standout due to the impressive scale

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WA Branch Technical Meeting - 13 September 2021 On-demand Additive Manufacturing Source: Richard Elving, APAC Director, Markforged The Western Australia branch recently hosted a technical evening, presented by Richard Elving (APAC Director, Markforged). Elving spoke on the topic of On-demand Additive Manufacturing. Based in Boston, Markforged was founded in 2013 on the belief that additive manufacturing can transform how entire industries operate. It describes its operating platform as ‘The Digital Forge’, based on the combination of proprietary software, materials and printers. Of these three components, it is the software that makes the company’s offering quite distinctive, networking a fleet of more than 12,000 printers in 73 countries. Elving’s career has seen him apply his background in finance to manufacturing, starting with Volvo in Sweden. He drew on this experience in outlining the strengths and limitations of traditional manufacturing and of additive manufacturing. Elving spoke about the challenges of supply chains and the volatility of skilled labour availability, and how this has led to the vision of ‘digital inventory’, with (additive) manufacture at the point of need. Elving gave an example of this approach already being applied in the case of a critical part for an industrial jack-hammer. The original part is additively manufactured, but in addition, spare parts are made (using Markforged technology) on-demand in the country where they are needed, saving inventory and shipping delays. While maybe only one per cent of parts could be made this way at present, Richard challenged the audience

to consider how this might change in the next ten years. Markforged’s origins lie in the development of an innovative 3D printer that simultaneously lays a skeleton of continuous carbon fibre filament while printing a nylon matrix reinforced with chopped carbon fibre or Kevlar. The next innovation was to combine the printing technology with a software design and production platform so that parts can be designed, optimised and produced with great reliability and minimal human input. Markforged’s second technical printing innovation is a composite filament of metal powder, wax and polymer material that can be spooled, allowing safe and convenient 3D printing of metal powders. Metal components are first printed, then the wax is washed out, while a final sintering operation burns-out the polymer and consolidates the metal. Markforged sells the metallic printing material and manufactures the production system comprising the proprietary printer, automated wax wash-out unit and automated sintering unit. A significant part of the value proposition is that the printable metals (currently 17-4 stainless, Inconel, copper and tool steel) have all been developed, tested and optimised for consistent production and performance. The integrated software handles the design, including internal lattice structures and allowance for shrinkage during sintering. Elving reminded the audience that these machines are a world away from consumer-grade 3D plastic filament printers. Carbon-reinforced nylon components are equal to aluminium alloys in many applications, while additively manufactured sintered metal are commonly lighter than conventionally manufactured parts. At present, the working volume for Markforged printers is approximately a 350mm cube. The Markforged business model has parallels with other software businesses with cloud-based computing networked machines and digital transmission of design and manufacturing instructions. Feedback on machine performance and utilisation allows improvements to be made through software updates to machines and to design and production management software; increasing uptake leads to an improved knowledgebase, and in turn, to improved user productivity. The company claims “the Digital Forge lives in the cloud, powered by AI. It collaborates, scales, and gets smarter with every print.” Elving concluded his talk with a glimpse into the near future as Markforged continues the development of its blacksmith adaptive additive manufacturing software. This is based on the use of artificial intelligence techniques to monitor and analyse operating data from its printer fleet. Richard pointed out that printers are fitted with currently unused in-built laser metrology in anticipation of future software upgrades. Questions included weldability (yes, if so-designed), potential for printing precipitation-hardening metals (not yet clear) and the ratio of metal printers to sintering furnaces (printers are typically the bottleneck). To sum up, Elving emphasised the point that the key to take-up of additive manufacturing is reliability: “press the button and it just works”.

L to R: Schree Chandran, Richard Elving

12 | SEPTEMBER 2021

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CONFERENCE DATES

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 Metallic 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

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

Opportunities for sponsorships and exhibitions are available for both APICAM2022 and LMT2022. WWW.MATERIALSAUSTRALIA.COM.AU BACK TO CONTENTS SEPTEMBER 2020 | 13 Enquiries: Tanya Smith | Materials Australia +61 3 9326 7266 | imea@materialsaustralia.com.au

Phase Transformations and Microstructural Evolution in Additive Manufacturing Phase Transformations and Microstructural Evolution in Additive Manufacturing - Symposium 9 & 10 August 2021 Symposium Organisers: Professor Simon Ringer (Chair), Associate Professor Gwénaëlle Proust (Co-Chair), Symposium Secretariat: Tanya Smith (Materials Australia), Renee Barber (Univ of Sydney). Symposium Supporters: Sydney Manufacturing Hub, 3DAdditive (AUSMURI), GE Additive

Materials Australia and The University of Sydney recently held a special symposium on Phase Transformations and Microstructural Evolution in Additive Manufacturing to mark the launch of the Sydney Manufacturing Hub – the University of Sydney's newest core research facility. The symposium featured invited lectures by leading researchers from Australia, Europe, the United States, Asia and the Pacific. The symposium was held online (live only) over two days between the 9th and 10th of August 2021. Local and international experts in the field presented their latest results and/or provided insights into the future of Additive Manufacturing in industrial applications. These experts came from a wide range of backgrounds including industry, national laboratories and universities across the world. Participant data from the symposium showed that there was great attendance with 209 participants attending on Day 1 and 114 participants attending on Day 2. Participants logged into the event from both Australia and abroad with 40 international participants from 15 countries attending. The excellent depth and breadth of Australian Additive Manufacturing R&D from coast to coast was evident from the symposium. The Symposium was very well received by the attendees with positive feedback received regarding the excellent quality of the speakers, the content of the talks and the organisation of the event. There was a strong interest from participants in this symposium being run on a regular basis. As a result, we are looking to organise a yearly symposium and other such events in the future. 14 | SEPTEMBER 2021

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Photos from the Sydney Manufacturing Hub and some of the speakers (Ms A. Andreaco from GE additive, USA; A/Prof M. Seita from Nanyang Technological University, Singapore; Dr S. Lathabai from CSIRO, Australia).

For more information on the Sydney Manufacturing Hub & the Core Research Facilities please visit: https://www.sydney.edu.au/research/facilities/sydneymanufacturing-hub.html WWW.MATERIALSAUSTRALIA.COM.AU

MATERIALS AUSTRALIA

NSW Branch Technical Meeting - 17 June 2021 Career Paths Seminar Source: Dr Rachel White and Dr Peter Richardson Over the past two years, the New South Wales (NSW) Branch of Materials Australia has greatly expanded its national and international reach by hosting a series of exciting online (Zoom) events. Two of the events that were run in 2021 include the Career Paths Seminar and the Certified Materials Professional (CMatP) Mini-Conference. Both of these events were attended by over 35 people from various institutes around Australia.

Career Paths Seminar On 17 June, the NSW Branch of Materials Australia and the Australian Ceramic Society hosted the second edition of the very well-received Career Paths Seminar. This event was first held in 2020. The event was targeted at PhD students, students considering PhDs, and those who have recently completed PhDs or are considering their next career move. The seminar was chaired by Associate Professor Sophie Primig, Dr Judy Hart and Dr Rachel White. The panel for the event comprised a diverse group of speakers who each discussed their career path since receiving their materials science PhD. Speakers highlighted how they got to their career stage and their thoughts on their current roles.

Screenshot of the audience for the 2021 Career Paths Seminar.

The seminar commenced with introductions from Associate Professor Sophie Primig on behalf of Materials Australia and Dr Samuel Pinches on behalf of the Australian Ceramic Society. Dr Vivian Liu then spoke about her change of field after her PhD into finance. Dr Alan Xu told us about his path from Australia to Oxford and back. Dr Alice Antony described her decision-making process in moving into Research and Development and the rewarding work she’s found there. Dr Sagar Cholake stepped us through his path to Laboratory Supervisor at Austral Bricks and the differences he sees in a commercial environment as opposed to a research environment.

NSW Branch Technical Meeting - 8 September 2021 CMatP Mini-Conference Source: Dr Rachel White and Dr Peter Richardson Held on 8 September, the CMatP Mini-Conference showcased some of the most interesting and relevant scientific research, development and analysis that is currently being performed across both the academic and industrial sectors. After a brief introduction to Materials Australia, the session chair, Dr Rachel White, introduced the four speakers for the evening. The audience was captivated by a diverse selection of CMatP presenters who spoke with passion about their experiences. Professor Michael Ferry (University of New South Wales) spoke about his experience in high-strength light-weight magnesiumlithium-aluminium alloys. Associate Professor Berndt Gludovatz (University of New South Wales) detailed fracture and fatigue properties of high entropy alloys. Sam Moricca (Gravitas Technologies) discussed design, processing and performance testing of advanced material components for extreme environment applications. Judy Turnbull (Bureau Veritas) spoke about root-cause failure analysis of fire damaged mechanical and electrical components in heavy industry. For both of these events, attendees asked insightful questions, particularly about how the panellists made choices in their WWW.MATERIALSAUSTRALIA.COM.AU

Screenshot of the audience for the 2021 CMatP Mini-Conference.

career paths, what they liked about choosing to work outside of academia, and some interesting technical questions for the CMatP presenters. We found these events to be highly enjoyable and hope to repeat them next year with a new line-up of presenters. If you would like to share your career paths with students next year or enquire about becoming a CMatP, please get in contact. The Materials Australia NSW Branch is grateful to each of the presenters for their time and enthusiasm in participating in these events, and we look forward to hosting them again in 2022. BACK TO CONTENTS

SEPTEMBER 2021 | 15

MATERIALS AUSTRALIA

CMatP Profile: Dr Leon Prentice for SDI, and undertook a PhD in biomaterials at the same time.

Who or what has influenced you most professionally? It’s difficult to give credit to any one person. Different people have influenced me in many ways. At CESL, an older engineer would walk by with a casual gait and his hands in his pockets but calculate in his head the heat load in a titanium pressure oxidation autoclave by the volume of steam condensate we collected. (“Thirteen BTUs…”) He taught me that understanding how things work can be readily coupled with basic heat balances to get quick meaningful answers.

Where do you work? Describe your job. I recently moved from CSIRO Manufacturing to take up the role of Chief Research and Development Officer at SDI—a biomedical manufacturing company in Bayswater, Melbourne. SDI employs close to 400 people around the world (including a significant sales network), exports 90 per cent of its production, and is one of the global leaders in dental restorative materials and related products. My role oversees research and development, builds the overall Innovation strategy of the company, and manages some of its key external research collaborations.

What inspired you to choose a career in materials science and engineering? I’ve always loved materials. They’re the perfect interface between physics, chemistry, and engineering! I considered the pure option – Materials Engineering at Monash – after high school. In fact, my brother’s friend gave me a Materials Engineering Student Society t-shirt while I was in Year 11, but Melbourne University called more loudly. I started in Mechanical Engineering, moved to Chemical, did a double degree with Physics, and headed mostly into research. After undergraduate study I started working in research and development (R&D) 16 | SEPTEMBER 2021

At CSIRO, Mark taught me that keeping the collaborators and clients front of mind meant thinking about what the work would mean for them, and how it could make life easier. Kathie taught me that people are different, and that consideration and mindfulness go a very long way in building teamwork.

Which has been the most challenging job/ project you’ve worked on to date and why? Probably one I can’t say much about, but it involved critical deadlines, novel chemistry and process equipment, and complex professional relationships! I’ll have to cite another. Soon after taking on the Metal Industries Research Program at CSIRO, we faced challenges that in some ways were existential queries about the Program. I worked with my leadership team (and beyond) to sharpen our strategy and focus, pursue some major opportunities, build connections, make the case for new staff (including post-docs), and successfully push for a Science Leader. For a while there, I didn’t think metals had a long-term future in CSIRO, but we made some profound changes and advances.

What does being a CMatP mean to you? A badge of professionalism. It means someone else has had a look at what I can do, measured it against established criteria (that are beyond a pass mark at university), and said I measure up. BACK TO CONTENTS

More than that, though, are two other factors – a commitment to furthering the profession, and the professional network. On the first of those, it means encouraging others to get into the field, by setting an example of what a career pathway can be, exemplifying excellence in professional ethics and technical capability, and mentoring and encouraging students and early career engineers. On the network side, it’s good to see others at events or in newsletters, and a real pleasure to connect at conferences or on projects that bring our capabilities and interests together.

“I like seeing the results of research scaled up, implemented, and achieving a benefit beyond the commercial.” What gives you the most satisfaction at work? Seeing processes and products become a commercial reality, making a real difference to the world. Sometimes research can focus on a problem that’s fundamental or esoteric – the results may be great, but in the end the impact may be incidental or very far in the future. I like seeing the results of research scaled up, implemented, and achieving a benefit beyond the commercial. The ‘beyond commercial’ is really important to me – a large part of what I’ve worked on professionally has a real environmental or healthcare benefit. For example, my first ever ‘real’ engineering project, at BHP, was in lead (Pb) recycling; the CSIRO MagSonic™ process could reduce CO2 emissions WWW.MATERIALSAUSTRALIA.COM.AU

MATERIALS AUSTRALIA

by up to 85 per cent; and SDI’s dental restorative and preventative products, that we develop, can help treat the 2.3 billion people who suffer from dental caries (decay).

What is the best piece of advice you have ever received? Always be upfront – never try to hide technical or interpersonal issues. There have been times when things have gone wrong – either technically or interpersonally – and I’ve seen firsthand what happens when those issues are ignored, or the topic or person simply avoided. I once led a project, where I was the key researcher, that was meant to be a quick (few weeks) exploration for a client. After three weeks of anomalous results, I realised I had a different thermocouple than what I had thought, and I’d been out by 150°C, wasting time and materials. I had to just own it. Interpersonally, people often don’t get along, and sometimes conflict is inevitable. Perhaps in addition to the ‘be upfront’ message is the ‘appropriate forum’ message: choose when, where, and with whom to have the difficult conversations. Sometimes that might mean acting immediately, one to one; sometimes it’s scheduling the discussion and having others involved. Be sensitive to the dynamics, focus on the outcome you seek, and remember they’re people.

What are you optimistic about? This is a difficult one. I think we’re in a climate emergency, and doing far too little too slowly; global inequality is shocking (I grew up in Tanzania and Kenya) and rich countries could do much more; geopolitics are fraught, and respect is hard to find. On the positive side, I do see significant effort by people who care, and it’s making a (slow) difference. And those people are increasingly working together. I’m passionate about new energy sources – concentrated solar thermal is one of my favourites – and new processes like carbon-neutral cement and steel. I see the materials agenda as fundamentally underpinning these opportunities. As we develop better materials, we’re also working at developing the whole lifecycle for them, and I’m optimistic that a real circular economy is coming soon.

What have been your greatest professional and personal achievements? I’ve been thankful for awards over the years. Highlights included Victorian Professional Engineer of the Year, IChemE’s Sustainable Technology Award, and the TMS Vittorio de Nora Prize. The de Nora prize is probably the biggest – administered by TMS between 2010 and 2014, it was awarded for Environmental Improvements in Metallurgical Processes (in my case, for MagSonic™).

Sometimes the achievements aren’t awards, however, getting a Science Leader in Active Materials into my research program at CSIRO was a big one. Have a look at a past issue of this very magazine for Dr Antonella Sola CMatP – I’m really pleased she’s moved to Australia to take on this great role! In terms of personal achievements, I’m just thankful for the blessing of a wife and two daughters, and I’m thankful for the opportunity to mentor and encourage students and early career researchers and engineers. Sometimes it’s close to home: my wife completed a PhD in bioethics while working full time as a neonatologist, and I hope I helped a little!

What are the top three things on your “bucket list”? Get a multi-combination driver’s licence. Reversing a B-Double! Living on Mars. Books like Kim Stanley Robinson’s Mars Trilogy, or Andy Wier’s The Martian, bring together physics, engineering, and sociology into an awesome frontier. Just travelling again. One of the real joys before COVID was combining both mine and my wife's overseas conferences, and taking our two daughters away for a couple of weeks. Doing more of that is high on the priority list, when we’re allowed to go again – or even have conferences again!

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SEPTEMBER 2021 | 17

MATERIALS AUSTRALIA

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

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

Mr Arya Mirsepasi NSW Dr David Mitchell NSW Mr Sam Moricca NSW Dr Anna Paradowska NSW Prof Elena Pereloma NSW A/Prof Sophie Primig NSW Dr Gwenaelle Proust NSW Prof. Jamie Quinton NSW Dr Mark Reid NSW Prof Simon Ringer NSW Dr Richard Roest NSW Mr Sameer Sameen NSW Dr Luming Shen NSW Mr Sasanka Sinha NSW Mr Frank Soto NSW Mr Carl Strautins NSW Mr Alan Todhunter NSW Ms Judy Turnbull NSW Mr Jeremy Unsworth NSW Dr Philip Walls NSW Dr Rachel White NSW Dr Alan Whittle NSW Dr Richard Wuhrer NSW Mr Deniz Yalniz NSW Mr Michael Chan QLD Prof Richard Clegg QLD Mr Andrew Dark QLD Dr Ian Dover QLD Mr Oscar Duyvestyn QLD Mr John Edgley QLD Dr Jayantha Epaarachchi QLD Dr Jeff Gates QLD Mr Payam Ghafoori QLD Miss Mozhgan Kermajani QLD Dr Andrii Kostryzhev QLD Mr Jeezreel Malacad QLD Dr Jason Nairn QLD Mr Sadiq Nawaz QLD Mr Bhavin Panchal QLD Mr Bob Samuels QLD Mr David Schonfeld QLD Mr Ashley Bell SA 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 Prof Nikki Stanford SA Prof Youhong Tang SA Ms Deborah Ward SA Mr Kok Toong Leong SINGAPORE Mr Devadoss Suresh Kumar UAE Dr Ivan Cole VIC Dr John Cookson VIC Miss Ana Celine Del Rosario VIC Dr Yvonne Durandet VIC Dr Mark Easton VIC Dr Rajiv Edavan VIC Dr Peter Ford VIC

18 | SEPTEMBER 2021

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

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

VIC VIC VIC VIC VIC VIC VIC VIC VIC VIC VIC VIC VIC VIC VIC VIC VIC VIC VIC VIC VIC VIC VIC VIC VIC VIC VIC VIC VIC VIC VIC VIC VIC VIC VIC 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

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 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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SEPTEMBER 2021 | 19

WOMEN IN THE INDUSTRY

Alex Kingsbury She understands what it means to meaningfully connect industry to research and development activity. Alex’s volunteer roles include sitting as the independent expert on the Standards Australia Additive Manufacturing Technical Committee, Chair of Oceania for Women in 3D Printing, and TCT Expert Advisory board member. Alex holds a Bachelor of Engineering (1st Class Honours) with a major in metals processing from RMIT University in Melbourne and is also a Graduate of the Australian Institute of Company Directors. She is currently a PhD candidate at RMIT University.

Alex Kingsbury is an Additive Manufacturing Industry Fellow at RMIT University, where she works to enhance links between industry and the university. These links extend across research, and teaching and learning functions at the university. Previously, Alex was the Research Group Leader for Additive Manufacturing and the Director of CSIRO’s Additive Manufacturing Innovation Centre ‘Lab22’—a metal additive manufacturing centre for industry access and research and development. In these roles, she oversaw CSIRO’s additive manufacturing research projects, both strategic and industry funded.

A known authority on additive manufacturing technologies, Alex is frequently called upon for expert opinion on additive technologies, the global marketplace for additive manufacturing, and forecasts for the additive manufacturing market. She has spoken at international conferences, contributed to highly respected industry publications, and worked across the media formats of television, print and radio. Alex provided Materials Australia with some thoughts on what it’s like to be a materials engineer.

From Alex Kingsbury I never set out to be a materials researcher, but here we are! I didn’t come from an engineering, or even a scientific family. But, an aptitude and keen interest in maths and chemistry, plus a fascination with how things worked led me to choose to study chemical engineering. After having spent some time consulting to the mining and oil and gas industries, I joined CSIRO to work as an engineer on their commercialisation projects. I was immediately thrown into the deep end of titanium metal powder research and development projects, both making it and consolidating it via a number of different processes. It was 2011, just as a process called metal additive manufacturing, also known as rapid prototyping or 3D printing, was just taking off. Little did I know, my career was just about to take off too! Additive manufacturing, as I am sure most of you are aware, is a process where you add material layer by layer. This is as opposed to subtractive manufacturing, where an item is machined out of billet, rod or plate.

Together with AMTIL, a manufacturing association, Alex established a national industry network called the Additive Manufacturing Hub, a body representing the interests and concerns of additive manufacturing businesses in Australia. This program of local industry engagement was the first of its kind in Australia for the additive manufacturing industry. Alex has experience in electron beam, laser, binder jetting and kinetic deposition additive technologies. She has worked more broadly in metal technologies including additive manufacturing since 2011, with a focus on powder and wire-based additive manufacturing technologies. 20 | SEPTEMBER 2021

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WOMEN IN THE INDUSTRY

The early days of additive manufacturing started out with polymers, but advances in laser technology meant we could use lasers as a heat source to melt metal powders, layer by layer. Then it was found that different heat sources could be used, such as electron beams, and different ways of handling the powder were found, such as spraying metal powder into the path of a laser. But why use just powder? What about wire, using an electron beam or an electric arc? Do we even need a heat source? Why not spray metal powders at a substrate at supersonic speeds to consolidate them? Very quickly the additive manufacturing field found many different ways that material could be deposited in this ‘layer by layer’ fashion.

Industry 4.0 Enabling Technology The world of additive manufacturing exposed me to the world of manufacturing, and my role at CSIRO changed rapidly as the appetite for this new Industry 4.0 enabling technology came to prominence. No longer a commercialisation engineer, I was now a research group leader and then—as my 3D printing lab grew—I

became an Additive Manufacturing Innovation Centre Director. Through those roles I spent a lot of my time engaging with the manufacturing industry, committed to understanding their needs, and assisting them to leverage the vast research capability that exists in Australia. I did factory tours, I met founders, I presented to Boards. I came to see clearly just how important manufacturing was for our nation. We needed manufacturing, not only because to lose the ability to make things for ourselves would put us in an unacceptably vulnerable position, but also because manufacturing was a jobs multiplier in our economy. Recent pandemic related disruptions to our supply chains have brought this point into sharp relief.

The knowledge of alloys and how they melt and solidify was the basis upon which we could catapult the field of metal additive manufacturing. However, there were also some differences; building a part from a 3D model, using a layer by layer process, leads to a very different thermal history. Having the most similarities with welding, suddenly the joining process was the process. And while welding alloys are largely very suitable for additive manufacturing, particularities in the process mean that alloy chemistries, designed around this new thermal history and solidification regime, simply perform better.

Wire Arc Additive Manufacturing

It is this that I am now dedicating my time and energy to, both as a PhD student and an Industry Fellow at RMIT University – designing new alloys for the wire arc additive manufacturing (WAAM) process.

But back to materials. While additive manufacturing was ‘new’, it also wasn’t. Decades of experience in metal casting, forming, welding and joining gave us the foundations upon which we could develop metal additive manufacturing technologies.

Maintaining a job at a university whilst also being a student is quite the balancing act; and going back to study mid-career has it’s challenges, but I have always believed that you are never too old to learn, and likewise, never too young to teach!

Photos courtesy of AML3D.

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SEPTEMBER 2021 | 21

INDUSTRY NEWS

CSIRO and Partners Scope NT Hub to Lower Emissions and Boost Investment Source: Sally Wood CSIRO, the Northern Territory Government, industry and engineering companies have joined forces to develop a path towards rapid emissions reduction across the energy sector in Northern Australia. CSIRO will lead the new consortium in the development of a business case to assess the viability of a large-scale low emissions Carbon Capture Utilisation and Storage (CCUS) Hub outside of Darwin. The Hub would significantly reduce emissions, and catalyse the growth of new sustainable industries that could continue throughout the energy transition. If realised, the Hub would enable the development of an interconnected hydro-gen industry and the utilisation of the carbon dioxide captured in other industrial processes, such as production

of other non-fossil fuel alternatives for transporta-tion. It could also create a blueprint for future low emissions hubs around Australia. The business case will assess the Hub’s viability and outline options to significantly reduce the emissions of the Territory’s gas in-dustry, providing a tangible pathway towards the region’s net zero emissions targets. CSIRO Chief Executive Dr Larry Marshall, said CSIRO’s expertise across the ener-gy domain, along with its deep connection with industry, meant it was well placed to lead the work. “As Australia’s national science agency, CSIRO is always looking for ways to bring business and government together to envision and deliver a more sustainable future for some of our largest industries,” Dr Marshall said. “The NT Hub could create new jobs

The Low Emissions CCUS Hub would be based on Darwin's Middle Arm Peninsular in the NT. Image: Wayne Zerbe.

and export pathways, and give Australia a global advantage by pushing the boundaries of science and technology to put home-grown innovation into real world demonstration projects, including through our Hydrogen Industry mission.”

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INDUSTRY NEWS

Advanced Care: Smart Wound Dressings With Built-In Healing Sensors Source: Sally Wood Researchers have developed smart wound dressings with built-in nanosensors that glow to alert patients when a wound is not healing properly. The multifunctional, antimicrobial dressings feature fluorescent sensors that glow brightly under ultra violet (UV) light if an infection starts to set in. It can also be used to monitor healing progress.

numbers of surgical procedures, and the rising prevalence of chronic wounds and chronic diseases such as diabetes and cancer. While magnesium is known to be antimicrobial, anti-inflammatory and highly biocompatible; there has been little research on how it could be used on medically-relevant surfaces like dressings and bandages.

The smart dressings were developed by a team of scientists and engineers from RMIT University, who harnessed the powerful antibacterial and antifungal properties of magnesium hydroxide.

The fluorescent nanosensors respond to changes in pH, making them ideal for use as sensors to track healing. Image courtesy of RMIT University.

“The smart dressings we’ve developed not only fight bacteria and reduce inflammation to help promote healing, they also have glowing sensors to track and monitor for infection.”

Next Generation Wound Dressings The global advanced wound dressing market is currently valued at an estimated $US6.9 billion and is expected to grow to $US9.9 billion by 2028. Demand is typically fuelled by technological innovations, increasing WWW.MATERIALSAUSTRALIA.COM.AU

Dr Truong said the process to make the fluorescent nanosheets was simple to scale for potential mass production. “Normally, antimicrobial wound dressings start to lose their performance after a few days but our studies show these new dressings could last up to seven days.” “Because magnesium is so abundant compared to silver, our advanced dressings could be up to 20 times cheaper,” he said.

“Being able to easily see if something is going wrong would reduce the need for frequent dressing changes and help to keep wounds better protected,” Dr Truong, who is also a Vice-Chancellor's Postdoctoral Fellow at RMIT, explained. The research team hopes that with further studies, multifunctional dressings could become part of a new generation of low-cost, magnesiumbased technologies for advanced wound care.

The nanosheets are easily integrated onto any biocompatible nanofibre, which means they can then be deposited onto standard cotton bandages. Laboratory tests developed through the research showed the magnesium hydroxide nanosheets were nontoxic to human cells. In addition, they also destroyed emerging pathogens like drug-resistant golden staph and Candida auris.

Project leader Dr Vi Khanh Truong said the development of cost-effective antimicrobial dressings with builtin healing sensors is a significant advancement in wound care. “Currently the only way to check the progress of wounds is by removing bandage dressings, which is both painful and risky, giving pathogens the chance to attack,” said Dr Truong.

Healthy skin is naturally slightly acidic, while infected wounds are moderately alkaline. However, under UV light, the nanosheets glow brightly in alkaline environments and fade in acidic conditions. This indicates the different pH levels that mark the stages of wound healing.

The research team is keen to collaborate with other clinicians to further progress the technology, through pre-clinical and clinical trials.

The process to make the new magnesium hydroxide-based material, pictured before embedding onto nanofibres, is simple to scale for potential mass production. Image courtesy of RMIT University.

But this latest RMIT study is the first to develop fluorescent magnesium hydroxide nanosheets that could contour to the curves of bandage fibres.

The multi-disciplinary study was led by Dr Adam Truskewycz, who is currently at the University of Bergen in Norway. It was co-authored by RMIT researchers Dr Nazim Nassar, Dr Shadi Houshyar and Dr Hong Yin, Dr Billy Murdoch, Professor Ivan Cole, and Professor Andy Ball. The research was supported by the Australian-American Fulbright Program. It was published in ACS Applied Materials and Interfaces.

The research team synthesised the nanosheets—around 10,000 to 100,000 times thinner than a human hair—and embedded them onto nanofibres. BACK TO CONTENTS

SEPTEMBER 2021 | 23

INDUSTRY NEWS

Smarter Electronics A Step Closer With Nanotech Advance Source: Sally Wood As silicon-based technology reaches its absolute limits, a new material, recently engineered by University of Queensland researchers, could start the next generation of electronics with more memory, faster speeds and advanced features. The carbon-based material could contribute to a growing nanoelectronics market predicted to be worth $162 billion by 2027. Professor Debra Bernhardt from the University of Queensland’s Australian Institute for Bioengineering and Nanotechnology (AIBN) and School of Chemistry and Molecular Biosciences said potential applications include telecommunications, automatic access systems and medical equipment.

The new structures enabled the production of various electronic components, which can be combined to produce electronics that boast requirements and capabilities as diverse as refrigerators and smartwatches. ‘’This is exciting because it combines theoretical predictions and experimental research to develop new devices that could be used in many applications such as computer memory and flexible electronics,” Professor Bernhardt said. Professor Bernhardt is a Fellow of the Royal Australian Chemical Institute and a Fellow of the Australian Academy of Science.

‘’Changes in the alignment of the layers can result in the ability to tailor the flow of electricity for various devices, which is not possible with just graphene.’’ 24 | SEPTEMBER 2021

• advanced materials • agriculture nanotechnology • advanced biomanufacturing. There are also two developing areas of expertise and skills: • energy nanotechnology in materials, processes, conversion, devices, storage and delivery • theoretical and computational molecular science.

Above all, the University conducts research across several key areas, including clean energy, healthcare, food science, and the environment.

She said her latest research will open new opportunities in the materials science space.

Professor Bernhardt explained how the changes in the alignment of layers provide a suite of benefits.

• precision nanomedicine

Researchers are engaged with developing new materials, and utilising and controlling existing materials in a safe and efficient manner.

The researcher has a strong background in theoretical and computational approaches to the behaviour of matter, and the applications of certain materials for energy storage and conversion.

‘’This material—C3N bilayers—has the potential to expand the capabilities of nanoscale electronics, which enables more functionality in a smaller area.”

• stem cell ageing and regenerative engineering

The University of Queensland is committed to innovative research in materials science. The University plays a key role in discovering current and emerging technologies that will assist a new generation of engineers, scientists and trailblazers.

‘’Graphene has long been considered a promising material for use in electronics, with its high mechanical strength and electrical and thermal conductivity, but it has limitations,’’ Professor Bernhardt said.

‘’The research team engineered a material with nitrogen atoms included in two layers of honeycombpatterned graphene, then experimented with shifting and twisting the layers.”

The AIBN boasts five key areas of research:

A new material recently engineered by University of Queensland researchers could start the next generation of electronics with more memory, faster speeds and advanced features. Image courtesy of University of Queensland.

She is also a strong international researcher with appointments at universities and research institutes overseas. The University of Queensland’s AIBN solves the challenges in society by integrating sustainable materials, translational success, and healthy living into everyday life. BACK TO CONTENTS

Professor Bernhardt said this recent research was a significant step, but more work is needed to produce the material more readily at a reduced cost. Professor Bernhardt was awarded an Australian Laureate Fellowship in 2020. In addition, she has an ARC Discovery Project Grant. She has collectively received more than $15 million in ARC grants since 1998. The concept for this latest material was conceived by AIBN’s Dr Qinghong Yuan, and was developed by a team of researchers at the AIBN; SCMB and international collaborators, alongside theoretical calculations by visiting PhD student Wenya Wei. WWW.MATERIALSAUSTRALIA.COM.AU

palladium catalysts

janus particles

glassy carbon

nickel foam

thin film 1

surface functionalized nanoparticles

organometallics

1.00794

Hydrogen

zeolites 11

anode

2 1

99.999% ruthenium spheres

6.941

2 8 8 1

22.98976928

24.305

Sodium

osmium

Mg Magnesium

MOFs ZnS

40.078

2 8 18 8 1

85.4678

(223)

Francium

(226)

2 8 18 18 8 2

2 8 18 9 2

Ac (227)

Radium

2 8 18 10 2

91.224

2 8 18 18 9 2

138.90547

2 8 18 32 10 2

104

Rf (267)

2 8 18 19 9 2

140.116

Th 232.03806

2 8 18 32 32 10 2

105

Db (268)

2 8 18 21 8 2

140.90765

Thorium

Pa 231.03588

2 8 18 32 20 9 2

Protactinium

transparent ceramics EuFOD

spintronics

optical glass

2 8 18 13 1

2 8 15 2

2 8 16 2

183.84

106

Sg (271)

(98.0)

2 8 18 32 12 2

186.207

107

Bh (272)

Seaborgium

2 8 18 15 1

101.07

2 8 18 32 13 2

2 8 18 1

190.23

108

Hs (270)

Bohrium

2 8 18 16 1

102.9055

2 8 18 32 14 2

Mt (276)

Hassium

2 8 18 23 8 2

(145)

Np (237)

Neptunium

150.36

Promethium 2 8 18 32 21 9 2

2 8 18 24 8 2

2 8 18 32 15 2

151.964

Samarium

2 8 18 32 22 9 2

2 8 18 32 24 8 2

2 8 18 32 32 15 2

110

Ds (281)

2 8 18 25 9 2

2 8 18 32 32 17 1

2 8 18 27 8 2

111

Rg (280)

Roentgenium

(244)

(243)

(247)

Americium

Curium

(247)

Berkelium

rhodium sponge

2 8 18 32 18 2

112

Cn (285)

Nh (284)

Copernicium

2 8 18 4

2 8 18 18 3

Sn Pb

2 8 18 18 4

2 8 18 32 18 4

Fl (289)

Nihonium

Mc (288)

Flerovium

2 8 18 28 8 2

2 8 18 29 8 2

164.93032

Er 167.259

Holmium 2 8 18 32 28 8 2

(251)

Californium

(252)

100

(257)

Fermium

2 8 18 31 8 2

101

Md (258)

laser crystals

116

102

No (259)

Mendelevium

Lv (293)

2 8 18 32 8 2

2 8 18 32 32 8 2

103

2 8 18 32 18 6

pharmacoanalysis

(262)

2 8 18 32 32 18 6

117

2 8 18 32 32 18 7

118

calcium wires

(294)

Xenon

(222)

Lawrencium

process synthesis

(294)

Oganesson

2 8 18 32 32 18 8

InGaAs AuNPs

superconductors

chalcogenides excipients CVD precursors deposition slugs YBCO

refractory metals metamaterials Fe3O4

shift reagents

American Elements opens a world of possibilities so you can

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h-BN

spectroscopy

platinum ink

cisplatin

2 8 18 32 18 8

Radon

NMR

new products. And much more. All on a secure multi-language "Mobile Responsive” platform.

fluorescent microparticles

cermet

2 8 18 18 8

131.293

Tennessine

2 8 18 32 9 2

2 8 18 32 32 8 3

Nd:YAG 2 8 18 8

83.798

cryo-electron microscopy

The Next Generation of Material Science Catalogs

dysprosium pellets

2 8 18 32 18 7

2 8 8

Krypton

(210)

state-of-the-art Research Center. Printable GHS-compliant Safety Data Sheets. Thousands of

ferrofluid dielectrics

Astatine

174.9668

2 8 18 18 7

39.948

Argon

Iodine

Lutetium

Nobelium

126.90447

Livermorium

Ytterbium 2 8 18 32 31 8 2

(209)

2 8 18 32 32 18 5

2 8 18 7

79.904

Polonium

173.054

Thulium

2 8 18 32 30 8 2

Over 30,000 certified high purity laboratory chemicals, metals, & advanced materials and a

graphene oxide

biosynthetics

2 8 18 32 18 5

Neon

Bromine 2 8 18 18 6

ITO

20.1797

2 8 7

35.453

2 8

nano ribbons

Chlorine

127.6

Moscovium

168.93421

Erbium 2 8 18 32 29 8 2

Einsteinium

2 8 18 30 8 2

Tellurium

silver nanoparticles

2 8 18 6

78.96

208.9804

115

32.065

Bismuth 2 8 18 32 32 18 4

2 8 6

Selenium 2 8 18 18 5

Fluorine

Sulfur

121.76

207.2

114

2 7

18.9984032

Antimony

Lead 2 8 18 32 32 18 3

2 8 18 5

74.9216

Tin

Arsenic

118.71

2 8 18 32 18 3

2 8 5

30.973762

15.9994

Phosphorus

72.64

Oxygen

Germanium

204.3833

113

28.0855

Thallium 2 8 18 32 32 18 2

2 8 4

2 6

14.0067

Silicon

114.818

Pu Am Cm Bk Cf Es Fm enantioselective catalysts Plutonium

Nitrogen

Indium

200.59

Dysprosium 2 8 18 32 27 8 2

2 8 18 18 2

Mercury 2 8 18 32 32 18 1

2 8 18 3

69.723

112.411

162.5

Terbium

Cadmium 2 8 18 32 18 1

Gallium

Gold

158.92535

2 8 18 32 25 9 2

196.966569

Darmstadtium

Gadolinium 2 8 18 32 25 8 2

2 8 18 32 17 1

Zinc

Silver

195.084

157.25

Europium

2 8 18 18 1

2 8 3

26.9815386

2 8 18 2

65.38

107.8682

Platinum

Meitnerium

2 8 18 25 8 2

106.42

192.217

109

2 8 18 18

Palladium

macromolecules 61

12.0107

Carbon

Aluminum

Copper

Iridium 2 8 18 32 32 14 2

63.546

Nickel

Rhodium

Osmium 2 8 18 32 32 13 2

58.6934

Cobalt

Ruthenium

Rhenium 2 8 18 32 32 12 2

58.933195

Iron

Technetium

Tungsten 2 8 18 32 32 11 2

55.845

2 8 18 13 2

2 5

Now Invent.

indicator dyes

MOCVD

2 8 18 32 11 2

144.242

2 8 14 2

Helium

2 4

sputtering targets tungsten carbide

Nd Pm Sm

Uranium

54.938045

95.96

2 8 18 22 8 2

238.02891

Manganese

Molybdenum

Neodymium 92

2 8 13 2

rare earth metals

mesoporous silica MBE

2 8 18 12 1

Dubnium

51.9961

180.9488

Praseodymium 2 8 18 32 18 10 2

2 8 13 1

Chromium

Tantalum

Rutherfordium

Cerium 90

quantum dots

ultralight aerospace alloys

92.90638

178.48

2 8 18 32 18 9 2

2 8 11 2

Niobium

epitaxial crystal growth drug discovery

Hafnium

Actinium

50.9415

Vanadium

Zirconium

Lanthanum 2 8 18 32 18 8 2

47.867

Yttrium

Barium 2 8 18 32 18 8 1

2 8 10 2

Titanium

88.90585

137.327

Cesium

2 8 18 8 2

87.62

132.9054

Scandium

Strontium 2 8 18 18 8 1

2 8 9 2

44.955912

Calcium

Rubidium 55

isotopes

39.0983

Potassium

3D graphene foam

nanodispersions

metal carbenes

Boron

2 8 2

2 8 8 2

nanogels

4.002602

2 3

10.811

Beryllium 2 8 1

gold nanoparticles

bioactive compounds

9.012182

Lithium

2 2

buckyballs

III-IV semiconductors

screening chemicals

alternative energy

diamond micropowder

Now Invent!

metallocenes BINAP

conjugated nanostructures

INDUSTRY NEWS

Plasma Tech Could Replace One Of World's Rarest Materials Source: Sally Wood New plasma coating technology could see the phase-out of rare earth metal indium that is used in smartphone glass and dimmable windows. This breakthrough research is a gamechanger for modern technology that relies on earth materials, which are expected to run out in ten years. A team led by a researcher from the University of Sydney has developed a low-cost, sustainable, and readily available technology. Together, the technology can dim the screens of electronic devices, anti-reflection automobile mirrors, and smart architectural windows at a fraction of the cost of current technology. It could also replace one of the world’s scarcest—yet highly ubiquitous in use— modern materials, indium. This is a rare chemical element, which is widely used in devices such as smartphones and computers, windscreen glass and self-dimming windows. Indium is expensive as it is hard to source. It naturally occurs only in small deposits. Industrial indium is often made as a byproduct of zinc mining, which means a shortage could occur if demand for optoelectronic devices, like LCDs and touch panels ramps up. Dr Behnam Akhavan, is an ARC Fellow from the School of Biomedical Engineering, and the School of Physics and Sydney Nano. He has developed a plasma-generated, hybrid nanocomposite material which is free of indium. The material also offers a low-cost, accessible and environmentally friendly electrochromic technology that allows glass to be dimmed at the push of a button or touch of a screen. The plasma-generated material is composed of tungsten oxide and silver, and can be applied to coat almost any solid surface, including flexible plastics. Plasma is created by adding energy to gas, and is commonly used in 26 | SEPTEMBER 2021

fluorescent light bulbs, neon signs and some television and computer screens. It is also known as the fourth state of matter. “When you change the transparency of a wearable electronic or a smart window, an electrochromic device is doing the work,” Dr Akhavan said. “Until now, these devices have typically relied on materials like rare indium to do the job.” “What we have created is a manufacturer’s dream: a technology that removes the need for indium and instead uses a plasma-engineered, three-layered structure that is much cheaper to produce,” Dr Akhavan said.

The layered nanotechnology. Credit: Dr Behnam Akhavan. Image courtesy of the University of Sydney.

Early iterations of the technology were produced, for the first time, in 2019. Researchers used a new method of tungsten oxide deposition known as ‘HiPIMS’, which is the plasma technology used to create these materials. However, instead of a bare tungsten oxide layer, the recent research developed a nanocomposite of tungsten oxide and silver. This nanotechnologyenabled approach allowed electrochromic devices to efficiently and rapidly change colour upon a user’s request.

Dr Behnam Akhavan in the plasma lab. Credit: Dr Behnam Akhavan. I mage courtesy of the University of Sydney.

These breakthrough plasma coatings are transparent and also electrically conductive. They are made up of a layer of silver that is approximately 10,000 times thinner than the width of human hair, and placed in between two nanothin layers of tungsten oxide decorated with silver nanoparticles. “These plasma-fabricated coatings can then be applied to electronic papers, smart phones and glass windows and can be dimmed with the application of a small electrical current,” Dr Akhavan said. Dr Akhavan has worked as a Postdoctoral Researcher at the Max Planck Institute for Polymer Research and Fraunhofer Institute of Microtechnology in Germany. He is a materials scientist and researcher who has also represented the University of South Australia’s Enterprising Faces. BACK TO CONTENTS

Dr Behnam Akhavan's plasma. Credit: Dr Behnam Akhavan. Image courtesy of the University of Sydney.

The University of Sydney boasts a wide-ranging materials science and engineering department. Researchers and post-doctoral students specialise in mechanical properties; fatigue mechanics; materials engineering, and fracture and fatigue mechanics. This recent research was published in Solar Energy Materials and Solar Cells. WWW.MATERIALSAUSTRALIA.COM.AU

INDUSTRY NEWS

A Leading Supplier Of Non Destructive Testing Equipment

With over 26 years in business, the company has built strong and lasting relationships with their clients and suppliers, leading to the introduction of new and innovative products into the NDT and security markets. NDT Equipment Sales continues to remain at the forefront of the industry due to their extensive NDT equipment product range, coupled with their approach to customer service. Based in Sydney, NDT Equipment Sales is the exclusive Australian sales and servicing agent for QSA Global, and has grown to become Australia’s largest supplier of gamma radiography equipment, accessories,

and industrial isotopes. They also supply a comprehensive range of magnetic particle, ultrasonic, x-ray, and vacuum testing equipment.

Digital Technology Enhances Gamma Radiography in NDT Gamma radiography is used in NDT to inspect the inside of closed structures for flaws and defects. Gamma rays are produced by isotopes and are beamed through an object onto radiographic film. As gamma rays pass through an object, the object absorbs some of the radiation. The radiation that entirely passes through the object, produces an image of the internal structure of the object, which can be used to identify cracks, porosity, voids in weld interiors, inclusions and more. NDT Equipment Sales’ Portable Digital

Tritex Multigauge 6000 A Drone Ultrasonic Thickness Gauge

Radiography Systems operate wirelessly, and allow engineers to generate immediate and high-quality images of the internal structures of objects. The images are then displayed on a tablet. Images can be enhanced in real time to give clear indications regarding the location and severity of flaws and defects in any object. Processing, storing and sharing images of objects that have undergone NDT is easy, when engineers use a Portable Digital Radiography System. -----------------------------------------------UNIT 21/3 BOX ROAD, TAREN POINT, NSW 2229 AUSTRALIA Tel: +61 2 9524 0558 1800 24 61 16 (In Australia only) Email: ndt@ndt.com.au www.ndt.com.au

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NDT Equipment Sales is a leading supplier of non-destructive testing and inspection equipment and consumables in Australia.

Specifically designed to mount onto drones and transmits live measurements up to 500 meters. Features include: • Measures through coatings up to 6 mm thick using Multiple Echo. • Remote-controlled gel dispenser. • Lightweight. • No zeroing required. • Single crystal soft-faced probe for curved surfaces. • Intelligent Probe Recognition (IPR). Available with or without a drone.

For further information please contact: NDT EQUIPMENT SALES: UNIT 21, 3 BOX ROAD TAREN POINT NSW 2229 TEL: (61-2) 9524-0558 • FAX: (61-2) 9524-0560 • Email: ndt@ndt.com.au • Web: www.ndt.com.au

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SEPTEMBER 2021 | 27

INDUSTRY NEWS

Computed Tomography Buyers Guide Source: By Dr Cameron Chai, Peter Airey and Dr Kamran Khajehpour from AXT PTY LTD In Australia, the advanced manufacturing sector is booming. With the increasing implementation of additive manufacturing techniques, the need for nondestructive testing of complex components has become even more important. Not surprisingly then, computed tomography (CT) is now the go-to solution for nondestructive testing. Similar trends for CT are being seen in research, where there is a growing need to examine components non-destructively in 3D to optimise designs, as well as the fabrication processes. There are currently a large number of CT solutions available, depending on your requirements. With so many options, choosing the right solution for your needs can be confusing. We look at the various factors you should consider in your decision making process.

Sample and System Size Benchtop systems are perfect for smaller samples, while larger systems cater to samples in the meter plus range. It is also important to consider the availability of space in your laboratory or workspace.

Materials to be Examined CT uses x-rays that are attenuated as a function of density and thickness. The penetrating power of a CT is dictated by its power. For example, kV systems are available up to 600kV for the largest, densest components.

Imaging Modes

• The ability to perform multiple scans, ideally on a continuous, uninterrupted basis, generating real-time, 4D or dynamic imaging, ensuring no instantaneous event (such as fracture) is missed

System Flexibility For the ultimate in flexibility, systems are available with different x-ray sources and detectors (sometimes with multiple detectors installed side-by-side) that can be easily swapped over depending on specific requirements.

Often, the component being examined is comprised of different phases. Depending on what these phases are (such as differences in density), you may need to rely on different imaging modes to reveal any flaws or defects. These modes might include quantitative phase contrast, bright field, dark field or phase retrieval.

Investing for the Future

Spatial Resolution

Like any instrument, preventative maintenance should be performed periodically to ensure optimal performance. Make sure your supplier has a support network to facilitate both preventative maintenance and emergency servicing if required. Your supplier should also stock a ready supply of spare parts and consumable items (such as filaments) that are essential to the operation of your CT.

Depending on the size of the features and defects you are looking for, systems are available with sub-micron resolution using nano-focus x-ray sources and high resolution detectors.

Speed and Temporal Resolution CT scans generate large datasets, with higher spatial resolutions, generating even larger datasets. Faster detectors and computers now allow for 360° scans in less than 10 seconds, opening the door for higher throughputs and true dynamic (4D) scanning.

2D, 3D and 4D CT is—by definition—3D imaging. The ability to perform simpler 2D scans can also be a useful capability, acting as a rapid quality control checking technique akin to radiography. There is also a growing trend towards performing in-situ studies within a CT. To do this successfully requires two things: • The ability to incorporate a testing rig into the instrument (such as 28 | SEPTEMBER 2021

mechanical, thermal, environmental) that does not interfere with the imaging hardware

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A CT system is a significant capital expense. As such, it is important to factor in future demands. This provides added flexibility and extends or increases the useful service life of your instrument.

After Sales Support

Summary AXT has Australia’s widest range of CT solutions from manufacturers such as Yxlon, TESCAN, Rigaku and Sigray. AXT also has access to the components and software needed to design and build custom solutions where the need arises. If CT technology is on your roadmap, please contact AXT to discuss your requirements. AXT Australia Units 1-2 / 3 Vuko Place, Warriewood NSW 2102 Australia Phone + 61 (0)2 9450 1359 www.axt.com.au WWW.MATERIALSAUSTRALIA.COM.AU

INDUSTRY NEWS

Rigaku and JEOL Launch a Revolutionary Electron Diffraction Platform XtaLAB Synergy-ED Source: By Dr Cameron Chai from AXT PTY LTD Rigaku Corporation (leading x-ray analysis instruments company) and JEOL Ltd (leading electron microscopes and analytical instruments company) have announced the launch of the XtaLAB Synergy-ED. A joint project in development since May 2020, the XtaLAB Synergy-ED is an integrated electron diffraction platform for the determination of molecular structures from nanocrystals. XXtaLAB Synergy-ED is a new, fully integrated electron diffractometer that creates a seamless workflow from data collection to structure determination of three-dimensional molecular structures. The XtaLAB Synergy-ED is the result of an innovative collaboration to synergistically combine our core technologies: Rigaku’s high-speed, high-sensitivity photoncounting detector (HyPix-ED) and state-of-the-art instrument control and single crystal analysis software platform (CrysAlisPro for ED), and JEOL’s longterm expertise and market leadership in designing and producing transmission electron microscopes. The key feature of the XtaLAB SynergyED is that it provides researchers an integrated platform that enables easy access to electron crystallography. The XtaLAB Synergy-ED is a system any x-ray crystallographer will find intuitive to operate without having to become an expert in electron microscopy. The determination of 3D molecular structures at the atomic level is a key technique for driving innovation in the drug discovery, synthetic chemistry and material science fields. Single crystal x-ray structure analysis has long been the primary technique used to determine WWW.MATERIALSAUSTRALIA.COM.AU

accurate 3D molecular structures for inorganic, organic and protein molecules. By providing highly accurate and reliable molecular structures, x-ray crystallography has contributed to the discovery of new substances, elucidation of biological activity and chemical reactivity, prediction of interactions with other substances, and confirmation of expected efficacy of medicines.

nanocrystals utilising key technologies from both companies. The result of this collaboration is the XtaLAB Synergy-ED, a dedicated electron diffractometer that is operated by the same control software that is used to run Rigaku’s x-ray diffractometers and includes a complete integrated pipeline from sample selection and diffraction measurement to data processing and structure solution.

However, in recent years, there has been an increasing need for the structure analysis of substances that only form microcrystals—crystals that are only a few hundred nanometers or less in size. Analysis of crystals of this size is not possible with x-ray crystallography, where the smallest possible crystal dimension is 1 micron, and only then when utilizing the brightest x-ray sources.

This instrument can easily be installed in an existing x-ray crystallography facility, where researchers and students will be able to easily master the MicroED technique since the software workflow is the same as for an x-ray diffractometer. Having such an instrument installed in an x-ray facility immediately provides structure determination for materials that only form nanocrystals.

In recent years, a new analytical method, MicroED, has been developed that uses electron diffraction on a TEM electron microscope to measure 3D molecular structures from nanocrystalline materials. Researchers developing this technique have relied on customised electron microscopes and a combination of microscopy software for measuring diffraction data, and public domain x-ray crystallography software for data processing and structure determination. Switching a microscope configuration between imaging and diffraction can be timeconsuming, making the sharing of an instrument sometimes difficult. To address these issues, Rigaku and JEOL started a collaboration to develop a dedicated single crystal structure analysis platform for BACK TO CONTENTS

According to Hikaru Shimura (Chairman and CEO, Rigaku Corporation), “Today, on the first anniversary of signing the joint development agreement with JEOL, we are very pleased to see the collaboration between the two companies has come to fruition and we are launching the XtaLAB Synergy-ED. Rigaku will steadily follow our corporate philosophy of ‘contributing to the development of human society through advances in science and technology’, and will continue to provide solutions satisfying our customers.” Izumi Oi (President and COO, JEOL Ltd), said, “We are proud that the collaboration between Rigaku and JEOL has created a synergistic effect among the core technologies of both companies and reached the point to announce the new platform XtaLAB Synergy-ED. Since its foundation, JEOL’s main goal has continued to be ‘“contributing to the progress in both Science and Human Society’ on the basis of ‘Creativity’ and ‘Research and Development’. As progress in science and technology has been remarkable and the roles expected from a company are diversifying, we will continue to provide solutions matching the needs enabling customer innovation.” SEPTEMBER 2021 | 29

INDUSTRY NEWS

Generate Stunning Ultra-High Resolution Images Of Structures As Small As Two Nanometres Using The Tabletop Phenom Pharos G2 Feg-Sem Source: By Dr Cameron Chai, Peter Airey and Dr Kamran Khajehpour from AXT PTY LTD

While optical and conventional (tungsten) Scanning Electron Microscopes (SEM) provide highresolution imaging of surfaces for many types of samples, only a field emission SEM (FEG-SEM) can reveal the finest details. The morphology of nanoparticles, small defects in thin films, insulating materials, or materials sensitive to high energy electron beams can all be adequately studied using a FEGSEM. However, FEG-SEM systems are large—they often require a dedicated room as well as special infrastructure and connections. Additionally, FEG-SEM can be difficult to use and master. As a result, many institutions that own a FEGSEM will restrict its use to highly trained personnel. Many research groups, departments and companies outsource their FEGSEM needs to service labs or central facilities to avoid these inconveniences. The Phenom Pharos G2 Desktop FEGSEM helps overcome these challenges with ease. The Phenom Pharos G2 Desktop FEGSEM combines all the capabilities of a floor-standing FEG-SEM in a tabletop system with the simplicity, speed and ease-of-use for which Phenom desktop SEMs are known. The desktop Phenom Pharos enables research groups or companies to own their own FEG-SEM and no longer rely on external services.

A (solid) table and a regular power outlet are all that you need to install the Phenom Pharos. In under 30 seconds after sample loading, full screen high quality images are presented on a wide 24 inch monitor at 2.0 nanometer resolution and with acceleration voltage up to 20 kilovolts. With a range of high, medium and low vacuum capabilities, users can image soft, beam-sensitive, or insulating samples at energy levels as low as 1 kilovolt without needing to apply a coating (Figure 1). The Phenom Pharos G2 Desktop FEGSEM also offers multiple fully integrated detectors. The elemental contrast of the backscatter detector can be used to better understand material differences within the sample. A secondary electron detector is optimal for applications where topography and morphology are important, while the energy dispersive spectroscopy detector provides comprehensive elemental analysis. Phenom Pharos G2 Feg-Sem Delivers • High-resolution imaging: 2.0 nm resolution • A wide acceleration voltage range of 1-20 kV to image a wide range of samples • Integrated low, medium and high vacuum modes • Images can be obtained in under 30 seconds for high sample throughput.

Figure 2: Particles of Halloysite-Kaolinite mixture, a clay material, show a distinct, highly organised layered structure. While this challenging and uncoated sample was imaged well using the Phenom XL G2 (left), the superior performance of the Field Emission source of Phenom Pharos G2 is clear (right).

• Ease-of-use with an intuitive user interface on a widescreen, 24 inch monitor •Q uick installation (40% faster than the previous version) speeding time to results • I ntegrated power supply and robust parts designed to ensure reproducible data Still Not Excited About The Pharos? Check Out These Images. Figure 2 Will Surprise You! Send us your samples or book a remote demonstration with one of our specialist staff today.

Figure 1: Sensitive materials require gentle conditions. With an acceleration voltage down to 1 kV, the Phenom Pharos G2 Desktop FEG-SEM images beam-sensitive samples without sample coating or other sample preparation. Left: pharmaceutical powder, imaged without damage at 1 kV. Right: the same sample imaged at 5 kV, with damage, illustrating the need for low-kV imaging.

30 | SEPTEMBER 2021

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ATA Scientific Pty Ltd +61 2 9541 3500 enquiries@atascientific.com.au www.atascientific.com.au WWW.MATERIALSAUSTRALIA.COM.AU

Easy-to-use Field Emission Phenom Pharos SEM

FASTEST, ALL-IN-ONE DESKTOP FEG-SEM FOR SUPERIOR IMAGING OF SENSITIVE SAMPLES Phenom Pharos G2 Desktop FEG-SEM offers floor model performance on a desktop microscope with loads of added benefits that make it fast and easy to operate. Full screen high quality images are presented in <30 seconds, at 2.0 nanometer (nm) resolution and up to 20 kilovolts (kV). Users can also image soft, beam-sensitive or insulating samples at energy levels as low as 1 kV.

•

High-resolution imaging at 2.0nm

•

Wide acceleration voltage range of 1-20 kV for a greater range of samples.

•

Fastest time-to-image of just 30sec for high throughput.

•

Integrated low / medium / high vacuum modes.

•

Easy-to-use interface on a widescreen, 24-inch monitor.

5kV: damage

Phenom Pharos G2 Desktop FEG-SEM allows beam-sensitive materials to be imaged using gentle conditions without sample coating. Left: pharmaceutical powder, imaged without damage at 1 kV. Right: the same sample imaged at 5 kV, with damage, illustrating the need for low-kV imaging.

ATA Scientific Pty Ltd | enquiries@atascientific.com.au | www.atascientific.com.au | +61 2 9541 3500

UNIVERSITY SPOTLIGHT

Curtin University Source: Sally Wood Curtin is a world-ranked university with a mission to deliver outstanding education and high-impact research. Ranked in the top one per cent of universities worldwide in the highly regarded Academic Ranking of World Universities (ARWU) 2020, Curtin is a proud institution taking an innovative approach to learning and teaching.

education and research, and providing a personalised and enriching experience. With strong ties to the local community, a reputation as one of the most diverse universities in Australia, and close relationships with companies and industry, Curtin University is making a difference in the lives of Australians.

The $116 million Resources and Chemistry Precinct offers an ideal environment for students and researchers to work and explore. The precinct attracts world-class academics and industry professionals, creating a vibrant research community and a range of career paths to students.

Research Projects

Curtin University is named after John Curtin, Australia’s fourteenth prime minister. It was established in the early 1900s as the Perth Technical School. Since then, the university has developed into a wide-reaching institution of academic excellence. In 1987, it began operating as Curtin University of Technology – Australia’s first university of technology.

Materials and Engineering Robot bricklayers, automated mine sites, and meteorite recovery. Curtin University Engineering and Materials students are working in fields as diverse as biomedical engineering and space technology.

A global leader in research and student engagement, Curtin is committed to enriching the lives of its students and wider community through positive action. It considers the students of today to be the change-makers of tomorrow, valuing them as partners in

Curtin’s Engineering Pavilion is a pillar of innovation. With a 5 star Green Star Rating, the building inspires the next generation of engineers with its environmentally-friendly design and hands-on learning tools. The building is one of only a few in Australia to be submitted to the Green Building Council of Australia for assessment using the Green Star – Education v1 Rating Tool.

Some of the research areas offered to students and researchers at Curtin University, within the Materials and Engineering faculty, include: • Electric fields as catalysts in chemical manufacture, using electrical fields, instead of chemical materials or metallic particles, as the catalyst for chemical reactions. • Zinc oxide light emitting diodes, taking existing nuclear technology, used for treating silicon, and applying it to ZnO to produce low-cost, environmentally friendly LED lights • Rapid flux oxygen separation membrane

Curtin University Engineering Pavilion. Image courtesy of Curtin University.

32 | SEPTEMBER 2021

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WWW.MATERIALSAUSTRALIA.COM.AU

UNIVERSITY SPOTLIGHT

• A ‘smart’ molecule that changes colour in a matter of milliseconds when exposed to UV light • Easily synthesised optically-active nanoparticles, which are free of cadmium and other toxic heavy metals • An algorithm that continually monitors power transformers for internal mechanical and electrical faults

The Legacy Living Lab The university has been the home of numerous break throughs in technology over the past decades, leading the world in environmentally-conscious research and innovation. The Legacy Living Lab (L3) project is an example of this commitment; a modular building, designed using principles of the circular economy, and aiming to design out waste by including as much recycling and re-use of materials as possible.

Project Spotlight: Gold Extraction Process Researchers at Curtin University have developed glycine leaching technology to enhance the leaching rates for gold ore. This is achieved by using a low concentration of a strong oxidising agent known as potassium permanganate. The lead researchers have published a paper on their findings, titled Gold leaching from oxide ores in alkaline glycine solutions in the presence of permanganate. The project was led by Professor Jacques Eksteen and Dr Elsayed Oraby from the WA School of Mines: Minerals, Energy and Chemical Engineering. Curtin has been working in this space for eight years, including with minerals industry partner, Mining and Process Solutions Pty Ltd (MPS), to commercialise the new process. “Traditionally, leaching or separating gold and other precious metals from an ore deposit or e-waste materials requires the use of cyanide – a highly toxic chemical compound that is known to have detrimental effects to the environment and to the human body,” Professor Eksteen said. “Industrially, it is very expensive to detoxify cyanide, but it still does not eliminate the risks associated with transporting, handling and processing the chemical.” Glycine is naturally produced by the human body and is essential for life. On the other hand, cyanide destroys life and is dangerous for humans. “Permanganate and glycine partially decompose to form insoluble manganese dioxide, insoluble calcium oxalate, and nitrogen all of which are naturally occurring, low-toxicity chemical compounds. Whereas cyanide retains its toxicity, even in the waste solution of the extraction process,” Professor Eksteen said.

Curtin researchers Timothy O'Grady, Professor Greg Morrison and Roberto Minunno outside the Legacy Living Lab (L3). Image courtesy of Curtin University.

Constructed as part of their thesis, Curtin University Sustainability Policy Institute PhD candidates Timothy O’Grady and Roberto Minunno, together with Curtin Professor Greg Morrison, worked alongside many industry partners to create L3 as a resource to support and inform the building industry on different construction methodologies, test new products, and review the performance of materials, including their energy consumption, automation, and effects on building wellness. “In Australia, the construction industry is responsible for about 30 per cent or 20.4 million tonnes of annual waste. Although it’s a significant and largely ignored issue, this is also an opportunity,” O’Grady said. “The circular economy concept sits at the heart of the L3’s design and construction and reduces waste by incorporating many fortuitous finds and generous donations, giving real meaning to the phrase ‘one person’s trash is another’s treasure’.” WWW.MATERIALSAUSTRALIA.COM.AU

“With low concentrations of potassium permanganate being added to the alkaline glycine system, we were able to leach 85.1 per cent of gold from the ore deposit (similar to the extraction by cyanidation) at ambient temperature and using a substance known as a benign reagent, which in industry standards is quite an achievement.” “Researchers at Curtin University have spent years developing a new leaching process and our work broadens the use of this patented technology, making it more suitable for extracting gold deposits,” Dr Oraby said. “We believe this new process will bring many benefits to gold extraction industries, which from an environmental point of view, is a much friendlier extraction method.”

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SEPTEMBER 2021 | 33

BREAKING NEWS Electrons On The Edge: Atomically-Thin Quantum Spin Hall Materials Quantum spin Hall insulators are a class of 2D topological states of matter that are electrically insulating in their interior. But a research team from ANSTO has recently analysed materials engineering alongside their theoretical description to understand classical and quantum electronic device applications. Unlike semiconductors, they carry a pair of one-dimensional (1D) metallic states, which are strictly confined to their edges. Particular to these ‘edgy’ 1D electrons are helical structures, where the spins of conduction electrons are aligned and tied to the direction that electrons move along the 1D edge. These helical properties offer potential solutions for problems in electronics and spintronics, as well as quantum electronic devices. This exotic and topological state of matter was first realised in carefully designed, and layered semiconductor heterostructures. These classes of atomically-thin crystals are emerging, similar to the famous graphene, which hosts this electronic state of matter as an intrinsic property. For example, the temperature range in which the exotic edge states can be harnessed scales with the properties of these crystals, such as the coupling strength of the electron’s spin to its orbital momentum. Quantum spin Hall insulators may be used for new kinds of electronics that consume less power, but this would require room-temperature operations to avoid costly cooling. This study was led by Associate Professor Weber, who specialises in the design, fabrication and measurement of molecular to atomic-scale electronic devices. The study was supported by the National Research Foundation Singapore and the Singapore Ministry of Education.

Prof Weber’s laboratory is equipped with a growth facility for quantum spin Hall materials, combined with a sensitive scanning tunnelling microscope (shown), operating at extremely low temperature. Photo credit: SPMS Communications, College of Science, NTU Singapore

UNSW Tops ARC Research Hub Grants More than $9 million in ARC grants was recently awarded to two UNSW projects—topping the nation for the largest share of funding. The two projects will provide research into sensors for the health sector and new technologies for Australia’s infrastructure needs. Together, they will ensure innovative research and stronger connections with the health, urban, energy and resources sectors. Professor Nicholas Fisk, who is UNSW’s Deputy ViceChancellor (Research and Enterprise), said the two projects will transform UNSW’s research capabilities. “To secure a quarter of the national awards to transform research for the new industrial economies is outstanding.” “These two hubs are exemplars of scale and collaboration, involving a total of nine universities, nearly 50 partner organisations, over 60 chief investigators with two-thirds at UNSW, and a total cash and in kind spend of around $25 million,” he explained. Professor Chun Wang will lead the hub to position Australia at the forefront of connected health by integrating sensor science with data analytics, regulatory approval and certified manufacturing capabilities. “The health sensors will be able to monitor biophysical and biochemical markers to aid rehabilitation and chronic disease management, and support frail, ageing and at-risk populations,” Professor Wang said. Meanwhile, Professor Nasser Khalili will lead a hub awarded $4.98 million. The hub will deliver technologies to address Australia’s infrastructure needs in the urban, energy and resources sectors.

Nanyang Assistant Professor Bent Weber (left) and Dr Michael S. Lodge in the Quantum Spin Hall lab. Photo credit: SPMS Communications, College of Science, NTU Singapore.

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“The hub will solve industry challenges and translate research and development into commercial opportunities and outcomes,” Professor Khalili said. WWW.MATERIALSAUSTRALIA.COM.AU

BREAKING NEWS Inducing And Tuning Spin Interactions In Layered Material By Inserting Iron Atoms, Protons Researchers have discovered that magnetic-spin interactions, which allow spin-manipulation by electrical control, can have potential applications in energy-efficient spintronic devices. An antisymmetric exchange known as Dzyaloshinskii-Moriya interactions (DMI) is vital to form various chiral spin textures, such as skyrmions, and permits their potential application in energy-efficient spintronic devices. But a recent China-Australia collaboration has illustrated that DMI can be induced in a layered material tantalum-sulfide (TaS2) by intercalating iron atoms, and can be further tuned by gate-induced proton intercalation. Generally, chiral spin textures are stabilised by DMI. As such, introducing and controlling DMI in materials is the key to searching and manipulating the chiral spin textures.

It's All About The Interface With Multi-Use Polymer Brushes The University of Newcastle and UNSW Sydney are using advanced neutron scattering techniques at ANSTO to carry out research on the structure of polymers in complex salt environments. This research will provide a way to predict the behaviour of polymers for real-world applications. Researchers have analysed polymer brushes—densely packed arrays of polymer chains that are tethered to flat surfaces—for use in environmentally-friendly cleaning products and other applications. The behaviour of many of these applications is determined by the interface between the polymer, the surface substrate and the nanostructure of the brush. Professors Grant Webber and Erica Wanless at the University of Newcastle, Associate Professor Stuart Prescott at UNSW, and Dr Andrew Nelson from ANSTO, examined and fully characterised the convoluted behaviour and properties of polymer brushes in complex environments.

“Tantalum-sulfide is one of the large family of transition metal dichalcogenide investigated by FLEET for low-energy applications,” said Dr Guolin Zheng from RMIT University. The team successfully realised a sizable DMI in the TaS2 by intercalating Fe atoms. But the researchers found that electrically controlling the DMI can be a challenging process. “Both conventional electric-field gating, and the widelyused alternative technique of ion-liquid (Li+) gating have hit stumbling blocks in the electrical control of DMI in itinerant ferromagnets, because the electric-field and Li+ can only modulate the carriers close to the surface,” Dr Zheng explained. The RMIT research team developed a new protonic gate technique, and successfully illustrated that DMI can be dramatically controlled by gate-induced proton intercalations. In addition, the team was able to significantly change the carrier density and further tune the DMI through the Ruderman-Kittel-Kasuya-Yosida mechanism. This refers to the coupling of nuclear magnetic moments.

Past and present investigations have relied on neutron reflectometry, because of its unique ability to characterise the interface at a nanoscale.

Crystal structure, showing iron atoms (red) in tantalum-sulfide structure.

“Experiments using the neutron reflectometer Platypus and Spatz provided in situ information about structural changes to the polymer molecules in real time,” said Dr Nelson. “The development of dedicated sample environments for the polymer brushes by Associate Professor Prescott and data analysis software by his recent PhD graduate Isaac Gresham, means we are really well set up for these experiments,” he explained. The team is also working with industry partners to use this knowledge to develop environmentally-friendly cleaning agents for household and personal care products, and more water-efficient mineral processing additives for the mining sector. WWW.MATERIALSAUSTRALIA.COM.AU

Hall-bar device on solid proton conductor, used to measure Hall resistivity under different conditions.

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SEPTEMBER 2021 | 35

BREAKING NEWS Australian-First Tech: Next Step In Waste Transformation Innovation

Transforming The Layered Ferromagnet Fe5gete2 For Future Spintronics A RMIT University-led international collaboration has achieved record-high electron doping in a layered ferromagnet, which causes a magnetic phase transition with significant promises for future electronics The study demonstrates that ultra-high electron doping concentration can be induced in the layered van der Waals (vdW) metallic material Fe5GeTe2 by proton intercalation. In addition, researchers found that it can cause a transition of the magnetic ground state from ferromagnetism to antiferromagnetism (AFM). Compared to itinerant ferromagnets, AFMs have unique advantages as the building blocks future spintronic devices.

Left to right: Maree Lang (Managing Director, Greater Western Water), Steve McGhie (Member for Melton), Lara Olsen (Managing Director, South East Water), Dean Barnett (Program Director, Intelligent Water Networks), Associate Professor Kalpit Shah (RMIT). Photo: Shawn Smits Photography. Photo courtesy of RMIT University.

The next iteration of waste transformation innovation is underway through research developed at RMIT University. The breakthrough research involves the water industry transforming biosolids headed for landfill into reusable products for farmers. The technology is the first of its kind in Australia, and uses high temperatures to destroy pathogens and micro plastics in biosolids, creating high-value biochar. It allows farmers and the wider agricultural industry to reuse 100 per cent of the product safely. “This collaboration will enable the water industry to find alternative markets for biosolids, reducing waste going to landfill and allowing 100 per cent of products to be reused or recycled,” said Steve McGhie, who is the Member for Melton. Mr McGhie recently inspected the technology, while it was on trial at the Melton Recycled Water Plant in Victoria. The technology will make biosolids management more environmentally sustainable and cost effective, and help to reduce carbon emissions for both the water and agriculture industries.

Their robustness to stray magnetic fields makes them suitable for memory devices. “We chose to work with newly synthesised vdW itinerant ferromagnet Fe5GeTe2,” said FLEET Research Fellow Dr Cheng Tan from RMIT. “Our previous experience on Fe3GeTe2 enabled us to quickly identify and evaluate the material’s magnetic properties, and some studies indicate Fe5GeTe2 is sensitive to local atomic arrangements and interlayer stacking configurations, meaning it would be possible to induce a phase transition in it by doping,” Dr Cheng explained. The team investigated the magnetic properties in Fe5GeTe2 nanosheets of various thicknesses by electron transport measurements. Initial transport results showed the electron density in Fe5GeTe2 is high as expected. This indicates that the magnetism is hard to be modulated by traditional gate-voltage. Co-author Guolin Zheng explained it was worth the time, despite the high charge density in Fe5GeTe2. “We knew it was worth trying to tune the material via protonic gating, as we have previously achieved in Fe5GeTe2, because protons can easily penetrate into the interlayer and induce large charge doping, without damaging the lattice structure.” said Zheng.

Farmers and the wider agriculture industry commonly use biosolids as fertiliser and soil amendment. Around 30 per cent of the world’s biosolids resource is stockpiled or sent to landfill, which creates an environmental challenge. “By creating a safe product with a steady supply stream, we’re also providing our farmers and the wider agriculture industry a product which is completely natural and can improve soil health and fertility,” Mr McGhie said. The next stage of the trial will scale up the technology and have a unit in place at a water recycling plant over a longer period of time. The technology was supported through funding from RMIT’s Enabling Capability Platforms.

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Crystal structure and initial characterisation of F5GT.

A SP-FET transistor, with F5GT flake on a solid proton conductor (SPC) – scale = 10µm.

Team leader FLEET Chief Investigator Associate Professor Lan Wang in Class 100 clean room, RMIT.

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BREAKING NEWS New Technique Breaks The Mould For 3D Printing Medical Implants. A tiny and intricate biomedical structure created with the new technique. Image courtesy of RMIT University.

'Miracle Protein' Biosensor Set To Transform Early Cancer Detection A commercialisation agreement for a high-tech biosensor is paving the way to improved diagnosis, monitoring and treatment for cancer patients around the globe. Science from Deakin University has discovered a world-first, point-of-care cancer sensor, which could be on the market within five years. Dr Wren Greene and his colleagues at Deakin have unlocked the potential of lubricin, a non-sticking ‘miracle protein’ found in human joints, to reliably detect cancer. The protein has an outstanding potential for earlier treatment, better monitoring and improved long-term outcomes for cancer patients.

Researchers have flipped traditional 3D printing techniques to create some of the most intricate biomedical structures.

Universal Biosensors, an industry partner of Deakin, formalised an exclusive licence and supply agreement with US company Lubris BioPharma LLC to develop the technology for market. Universal Biosensors expects to invest up to $10 million to achieve commercialisation over the next five years. RMIT researchers Stephanie Doyle and Dr Cathal O’Connell. Image courtesy of RMIT University.

The breakthrough advances the development of new technologies for regrowing bones and tissue.

"To be able to identify and measure, then monitor the rate of a healthy human cell becoming a cancer cell from a handheld, point-of-care biosensor device is an exciting prospect for UBI," said John Sharman, who is the Chief Executive Officer at Universal Biosensors.

The emerging field of tissue engineering aims to harness the human body’s natural ability to heal itself, to rebuild bone and muscle lost to tumours or injuries.

"Putting aside the possibility for early screening and then staging of cancer from a handheld device, the blood testing market for the monitoring of cancer remission patients annually is estimated at $17 billion.”

Biomedical engineers have designed and developed 3D printed scaffolds that can be implanted in the body to support cell regrowth.

“It would be wonderful if the initiative could improve the lives of many of the 131 million cancer remission patients around the world," Mr Sharman said.

An RMIT University-led research team, collaborated with clinicians at St Vincent’s Hospital in Melbourne to overturn the conventional 3D printing approach.

The Deakin research team is also exploring other potential lubricin sensor applications, including the testing of water quality, fire retardant detection and use in the food and beverage industry.

Instead of making the bioscaffolds directly, the team 3D printed moulds with intricately-patterned cavities then filled them with biocompatible materials, before dissolving the moulds. Using the indirect approach, the team created fingernailsized bioscaffolds full of elaborate structures that were considered impossible with standard 3D printers. “The shapes you can make with a standard 3D printer are constrained by the size of the printing nozzle—the opening needs to be big enough to let material through and ultimately that influences how small you can print,” said lead researcher Dr Cathal O’Connell. “By flipping our thinking, we essentially draw the structure we want in the empty space inside our 3D printed mould. This allows us to create the tiny, complex microstructures where cells will flourish,” Dr O’Connell explained. Other approaches are able to create impressive structures, but only with precisely tailored materials, tuned with particular additives or modified with special chemistry. “Importantly, our technique is versatile enough to use medical grade materials off-the-shelf,” Dr O’Connell said.

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SEPTEMBER 2021 | 37

BREAKING NEWS CSIRO Appoints New Chief Scientist CSIRO has appointed Professor Bronwyn Fox as Chief Scientist, close to 30 years after she began her career as a research assistant at the organisation.

Novel Nanotech Improves Cystic Fibrosis Antibiotic By 100,000-Fold

Professor Fox is CSIRO’s fourth female Chief Scientist, and joins the agency from Swinburne University of Technology. “It is wonderful to return to CSIRO as Chief Scientist after starting as a 22-year-old research assistant, and to be able to champion science research and capability, working with industry and fostering STEM careers,” Professor Fox said. Professor Fox was the founding Director of Swinburne’s Manufacturing Futures Research Institute, with a mission to support the transition of Australia’s manufacturing sector to Industry 4.0. She also has a background as a materials and engineering scientist. “The depth of scientific research at CSIRO and its committed people are a unique and special national treasure and I look forward to taking up the role,” she said. CSIRO Chief Executive Dr Larry Marshall said Professor Fox brings great depth of scientific experience to the role. “Bronwyn exemplifies the CSIRO way—driven to deliver, brilliant but humble, leading by listening, and a generous collaborator.” “She has a long history of bringing together researchers from across multiple scientific domains and institutions, leveraging digital science, and helping industry to translate brilliant ideas into real world solutions,” Dr Marshall concluded. In addition to this role, Professor Fox is the Chair of the Australian Academy of Technology and Engineering (Victorian Division); a Fellow of the Academy of Technological Sciences and Engineering; and a Graduate of the Australian Institute of Company Directors.

The nano-enhanced antibiotic effectively erradicates bacteria from lung cells (bottom line). Image courtesy of the University of South Australia.

World-first nanotechnology developed by the University of South Australia could change the lives of thousands of people living with cystic fibrosis. Groundbreaking research can improve the effectiveness of the cystic fibrosis antibiotic Tobramycin, by increasing its efficacy by up to 100,000-fold. The new technology uses a biomimetic nanostructured material to augment Tobramycin, which is the antibiotic prescribed to treat chronic Pseudomonas aeruginosa lung infections in severe cases of cystic fibrosis. Cystic fibrosis affects one in 2,500 babies and causes severe impairments to a person’s lungs, airways and digestive system, traps bacteria and leads to recurrent infections. The research team believes the discovery could transform the lives of people living with cystic fibrosis. “Cystic fibrosis is a progressive, genetic disease that causes persistent, chronic lung infections and limits a person’s ability to breathe,” said PhD candidate, Chelsea Thorn, who worked on the research. “The disease causes thick, sticky mucus to clog a person’s airways, attracting germs and bacteria, such as Pseudomonas aeruginosa, which leads to recurring infections and blockages.” “Tobramycin is commonly used to treat these infections but increasingly antibiotics are failing to make any significant difference to lung infections, leaving sufferers requiring life-long antibiotic therapy administered every month,” she explained. Researchers enhanced the Tobramycin with a biometric, nanostructured, lipid liquid crystal nanoparticle-based material. Then, they tested it on a new lung infection model to showcase its unique ability to penetrate the dense surface of the bacteria and kill the infection.

Professor Bronwyn Fox will be CSIRO's next Chief Scientist. Image courtesy of the CSIRO.

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The technology is currently entering pre-clinical trials and hopes to be on the market in the next five years.

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BREAKING NEWS CMRP To Play Key Role In Space Technology Testing Network

Australian Researchers Create Quantum Microscope That Can See The Impossible In a major scientific leap, researchers from the University of Queensland have created a quantum microscope that can reveal biological structures that would otherwise be impossible to see. This paves the way for applications in biotechnology, and could extend far beyond into areas ranging from navigation to medical imaging. Professor Warwick Bowen, from the University’s Quantum Optics Lab and the ARC Centre of Excellence for Engineered Quantum Systems explained that the microscope is powered by the science of quantum entanglement. “This breakthrough will spark all sorts of new technologies— from better navigation systems to better MRI machines, you name it,” Professor Bowen said.

L to R: Associate Professor Marco Petasecca, CMRP Director Distinguished Professor Anatoly Rozenfeld, and Professor Michael Lerch, head of the School of Physics. Image courtesy of the University of Wollongong.

The University of Wollongong will contribute to a national network of facilities to test technology for use in space.

“We’ve finally demonstrated that sensors that use it can supersede existing, non-quantum technology.” “This is exciting—it’s the first proof of the paradigm-changing potential of entanglement for sensing,” he explained. Australia has a quantum technologies roadmap, where quantum sensors are spurring a new wave of technological innovation in healthcare, engineering, transport and resources.

The facilities, which are currently unavailable in Australia, will ensure electronics used in space can withstand the harsh conditions, undergo a qualification process, and a rigorous series of tests.

“The best light microscopes use bright lasers that are billions of times brighter than the sun,” Professor Bowen said.

The National Space Qualification Network (NSQN) will ensure local space industry organisations—and those across the Indo-Pacific region—undergo testing in Australia.

Professor Bowen said there were potentially boundless opportunities for quantum entanglement in technology.

The NSQN recently received $2.5 million in Federal Government funding. The NSQN features a six-partner consortium led by the Australian National University, Steritech, Nova Systems and Saber Astronautics. Associate Professor Marco Petasecca will lead the construction and operational aspects of the NSQN facility. “The environment in space is so harsh. The gradient of temperature, for example, is extreme: it's minus 270 degrees one moment and then suddenly, in close proximity to Earth, it may reach 250 degrees if exposed to sunlight,” he explained.

The benefits are far-reaching, including a better understanding of living systems, to improved diagnostic technologies.

“Entanglement is set to revolutionise computing, communication and sensing.” “Absolutely secure communication was demonstrated some decades ago as the first demonstration of absolute quantum advantage over conventional technologies,” he concluded. This development opens the door for further wide-ranging technological revolutions.

UQ team researchers (counterclockwise from bottom-left) Catxere Casacio, Warwick Bowen, Lars Madsen and Waleed Muhammad aligning the quantum microscope. Image courtesy of the University of Queensland.

But the NSQN will provide a point of difference, and motivate a new generation of space-enthusiasts. “Our NSQN industry partners will also play a critical role in building the stakeholder base that will need to utilise the University of Wollongong Node Facility.” “[It will] also [be] engaging in physics student training through work integrated learning, and student placements for those with an interest in current and emerging Australian space supply chain industries that will service this global market.” said Associate Professor Petasecca. The University of Wollongong’s contribution will be led by scientists from the Centre for Medical Radiation Physics.

Artist's impression of UQ's new quantum microscope in action. Image courtesy of the University of Queensland.

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SEPTEMBER 2021 | 39

FEATURE – Materials Engineering in Manufacturing

How Materials Science is Helping Australian Manufacturing Materials science delivers a suite of endless opportunities—it has the power to revolutionise virtually any product across Australia's manufacturing industry.

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FEATURE – Materials Engineering in Manufacturing

Materials science and engineering is a big job. The practice of sourcing existing materials, and scientifically engineering them for future use, has transformed existing societies and contemporary cities. From selecting and processing existing materials, to the development of new materials through rigorous research and design, materials science engineering brings complex technological ideas to life. For centuries, scientists have been perplexed by understanding processproperty relationships, which involve the structures and properties of materials. In addition, scientists have analysed the formability of new materials; and integrated this knowledge into process modelling for enhanced manufacturing. Today, every human-made product— from roads and bridges to schools; semi-conductor chips and medical equipment—relies on research into microstructures, modelling, and technological innovations. But without advanced science and materials engineering, the world as we know it would not exist. The practice of materials science engineering allows the quality of life to be improved through greener, costeffective, and advanced developments. In advanced economies, like Australia, manufacturing is an essential part of nation building for the future. Advanced manufacturing allows nations to remain competitive, smarter, flexible, and cleaner. As such, materials science is transforming a new generation of space exploration; new materials for the medical sector; energy storage materials; and other environmentally friendly ventures for a greener planet. Traditional thinkers may feel challenged by advances in materials science, which disrupt global supply chains and challenge existing thinking. But materials science provides a suite of endless opportunities. Together, materials science and engineering can revolutionise existing supply chains for virtually any product or service across a range of industries. Crucially, materials science requires cross-sector collaboration between researchers and local manufacturers for the future. WWW.MATERIALSAUSTRALIA.COM.AU

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How Does Materials Engineering Help Manufacturers? Materials science and engineering improves Australia’s manufacturing industry. New and improved materials require manufacturing to turn them into engineered products. The practice of materials science analyses material components, like the existing composition and microstructures. Together, scientists and engineers examine how a material’s composition and microstructure are altered when its properties are changed to create new, and more efficient materials. In fact, up to 70 per cent of the cost of new products is a result of its materials. As such, it is crucial that scientists understand the composition of materials to determine a new product’s long-term success. Materials engineering helps Australian manufacturers to get the balance right and meet specific targets and quality control measures. Together, this process ensures that all recreated or new materials are: • Durable, and do not degrade or prematurely fail • Cost-effective • Safe • Easily fabricated to create new components and joints In all, materials science is a collection of existing materials that are welded, fabricated and joined. They are designed to meet strict product performance, cost requirements and reliability targets. As such, it is pivotal to: • Select materials that satisfy a range of component and joint performance, reliability, and cost requirements • Use control measures that guarantee the properties of materials that make up components and joints to consistently meet tight specification requirements Materials science does not leave any stone unturned. It considers the shape, dimensions, weight, texture, and features of materials for enhanced mechanical construction for optimum component and joint performance. As such, materials engineers work collaboratively with Australian SEPTEMBER 2021 | 41

FEATURE – Materials Engineering in Manufacturing

manufacturers to select materials that satisfy their needs and meet the requirements of the future. Together, quality control measures ensure the properties of materials meet certain specifications for industry-wide utilisation.

value chain, from extraction to processing, separating, refining and manufacturing high value materials and products,” Law said.

Controlling the variation of properties in materials requires:

Australia is at the forefront of linking materials science to industry, through strong research partnerships that boast high utilisation outputs.

• A thorough analysis thorough design and process specifications with all material requirements and details— like composition, microstructure, and properties—listed. • A strict process for selecting suppliers that are capable of providing materials that meet material properties requirements. • Using advanced manufacturing and assembly protocols that minimise error and budget blowouts.

A Collaborative Approach for A Greener Future Many countries are taking advantage of advanced materials to develop cleaner energy technologies for a more sustainable future. In fact, the Chief Executive of CSIRO, Dr Larry Marshall believes material science will be a gamechanger as Australia pivots towards a net-zero emissions future. “Australia’s future economic prosperity will depend on how well we can use our vast energy and mineral resources to play to our strengths and create new opportunities through the global transition to net zero emissions,” Dr Marshall said. “There is a wealth of opportunity in front of us that will only be fully realised by developing a Team Australia response.” CSIRO’s Critical Energy Minerals Roadmap has unlocked increased potential for Australia’s mining sector to capitalise on the opportunities posed by materials science. The roadmap turns mineral resources into high purity materials. CSIRO’s Director for Mineral Resources, Jonathan Law added that Australia could increase the value of local mineral exports, enhance local manufacturing, and strengthen global supply chains by linking materials science with manufacturers. “Australia has a real opportunity to operate all the way along the energy 42 | SEPTEMBER 2021

Closing The Loop: From Research To Project Utilisation

In one project, the Advanced Manufacturing Growth Centre (AMGC) is developing a world-first geopolymer and carbon fibre solution, which offers durability like concrete. Together, AMGC is working with Austeng, a Victorianbased engineering firm to research, to design and develop a solution that offers superior thermal stability and a higher corrosion resistance. A shortfall with existing concrete is that is uses steel rebar, which rusts and breaks the concrete over time. But Austeng’s Managing Director, Ross George, said the project delivers “a cure for concrete cancer”. Materials scientists at AMGC and Austeng have discovered that carbon fibre and geopolymer will not rust. It is also acid and salt-resistant, and can accommodate higher temperatures. George said the new material provides a suite of benefits for manufacturers. “It’s actually got better flexural strength than concrete.” “Basically, you can dump it in a tub full of acid, you can light a fire underneath it, you can put it next to salt water and it won’t degrade, it won’t rust, and it’ll still be there in 100 years or more,” he explained. George added that the new bridges will require “zero maintenance” if the new material is used. The project also meets strict budgetary requirements. It is estimated to cost $120,000. But the project is expected to provide $20 million in export revenue, as part of its early earnings forecast. In addition, it will create a domestic manufacturing capability for carbon fibre and create several jobs as part of its commercialisation venture. This project was supported by an industry contribution of $85,000; government funds of $50,000; and inkind contributions of $35,000. BACK TO CONTENTS

The project will also provide a range of qualitative benefits to the Australian manufacturing market, including: • Increased spending on research and development to validate new and complex products, specifically for the construction industry • Advanced industry expertise and knowledge by providing greater collaboration with end-user partners • Increased energy efficiency and performance, as compared to traditional products such as concrete The project has several potential research utilisation outputs for Australian manufactures and suppliers, including interest from The City of Greater Geelong, which has published a procurement for innovation tender. If this project is successful, the product will be used in three local pedestrian bridges across Geelong. The City of Greater Geelong currently owns and maintains around 160 bridges. It spends up to $200,000 in annual maintenance costs, which would be significantly reduced if the AMGC and Austeng project is successful. AMGC forms a crucial part of the Federal Government’s Industry Growth Centre Initiative, which drives industry-focussed innovation, competitiveness and productivity, across the nation’s local manufacturing industry.

Tec.Fit’s Manufacturing Expertise Provides A Point of Difference Similarly, Tec.Fit is a manufacturing company that operates in the textile, apparel, machinery and equipment space. Tec.Fit aims to disrupt the global clothing industry by providing retailers with customised garments online. The company has developed a humanbody scanning smartphone application that converts 2D images into precise 3D digital layouts of the purchaser’s body and their measurements. In addition, a second-generation prototype 3D printer complements the Tec.Fit team by using digital layouts to produce the customised clothing. The new technology provides many benefits for Australian clothing manufacturers, who typically throw away over 25 per cent of their returns. WWW.MATERIALSAUSTRALIA.COM.AU

FEATURE – Materials Engineering in Manufacturing

Omni Tanker is developing two types of carbon fibre reinforced polymer tanks for storing and transporting cryogenic liquid propellants.

Clothing manufacturers can use this technology to produce tailored garments like wedding dresses, wetsuits, and uniforms. Together, this innovative materials science is helping Australian manufacturing: • It reduces the return rate of online clothing purchases by 95 per cent • It reduces fabric wastage that ends up in landfill • It lowers CO2 emissions across the entire supply chain, including raw fabric production, garment manufacturing, warehousing, freight and returns logistics • It reduces working capital that is typically invested in stocks • It reduces warehouse operational demands

where he has gained innovative skills and expertise on carbon fibre-based materials. “I guess carbon fibre is very engineered, it is very considered, but at the same time it is really a young technology, so there is lots of opportunity for innovation and new ideas and development,” he said. But Partington, who is also undertaking a PhD in advanced composites, has combined his expertise with his passion for cycling. “I have been a keen competitive amateur cyclist on the road, and recognised there was an opportunity within the composites space to bring these two together, particularly around lightweight wheels for pushbikes.”

• It reduces the overall amount of raw materials used in production

“Polymer composites have very different qualities to metals and they process very differently; they have different strengths and weaknesses,” he said.

In all, Tec.Fit’s technology enables retailers and clothing manufacturers to connect and provide fresh, and valuable services through a unique global platform.

At Partington Advanced Engineering, a multi-material approach is using digital modelling to combine composites, metals and plastics to develop new materials and structures.

The company is also expecting to provide a boost to the Australian economy. In the 2023 financial year, the company has estimated revenue to be between $53 million and $139 million.

The design process has produced wheels, which have been trialled by elite cyclists. The company is also seeking to commercialise high-end wheels, which boast the smart and economical use.

Tec.Fit also estimates this project will generate more than 15 skilled labour jobs within the first two years of its completion.

The project team has worked with industry experts and manufacturers to turn Partington’s dreams into a commercial reality.

Living Life in The Fast Lane with Advanced Composites Jon Partington has spent over two decades in the automotive industry, WWW.MATERIALSAUSTRALIA.COM.AU

In 2018, Partington Advanced Engineering moved into Deakin University’s ManuFutures Hub, which brings a host of new collaboration opportunities between the company and BACK TO CONTENTS

industry partners. “It has put me in touch with people within engineering enterprises which are pioneering or developing technologies or starting up,” Partington said. “It puts you in a small community of people that are having similar experiences, and that can be really useful from the very basic point of just having someone to dialogue with over similar problems, or that can extend to creating new contacts and professional relationships, which might support other business activities in the future,” he concluded.

Bolstered Tanker Capabilities In a partnership with the University of NSW and Lockheed Martin, Omni Tanker is developing two types of carbon fibre reinforced polymer tanks for storing and transporting cryogenic liquid propellants. These tanks will offer chemical resistance; improved thermal insulation; low gas permeation; and light tank weight; with enhanced thermal insulation properties. They will provide significant benefits to space and hydrogen transport operations. In developing the tanks, the project team has characterised commercially available materials; conducted multiple tests; and analysed structural design processes. This project will ensure a higher trade intensity, and increased geographical reach for Omni Tanker. By 2026, the company is expected to reach $7 million in revenue as a result of strong research partnerships, and capitalising on the latest in the materials science space. SEPTEMBER 2021 | 43

FEATURE – Materials Engineering in Manufacturing

How FormFlow’s C90 Bend Became a World First Source: Sally Wood An innovative manufacturing plant in regional Victoria is using Industry 4.0-enabled manufacturing technology to transform materials science in Australia. FormFlow brings great ideas to life. Since it was established in 2016, the company has commercialised a world first metal forming technology and created a range of unique building products. The company draws on cutting edge technology and expertise to upscale its production outputs and capabilities, which has opened new pathways for commercial and residential modular buildings across Australia. FormFlow is based in Geelong, Victoria, and employs 15 staff who operate across a 1,300m2 workshop. Several students and apprentices also undertake internships at FormFlow, which builds on the company’s commitment to a stronger manufacturing sector into the future. In addition, the company works with a range of partners, including Deakin University researchers and the Innovative Manufacturing Cooperative Research Centre (IMCRC). Together, these partners have developed a new manufacturing cell to control and optimise the company’s corrugated steel-bending process for greater use. Dr Matthew Dingle is the Managing Director at FormFlow, who said the steel-bending project represents a vital step in FormFlow’s technology development and commercialisation journey. “FormFlow’s bending technology is unique. It is a secondary forming operation that relies on the theory of ‘folded developables’ to limit material

An aesthetically pleasing product that inspires.

44 | SEPTEMBER 2021

deformation in incoming roll-formed strip to simple bending, while forming a complex shape, such as a 90-degree angle,” he said. FormFlow’s operations are backed by Industry 4.0 principles— focussing on the automation of traditional manufacturing with new technology—and will allow high volume manufacturing of building products to be consistent in quality and shape. The project will transform FormFlow’s processes and outputs to become a trailblazer in the materials science and engineering space. BlueScope, who markets Australia`s iconic COLORBOND® building products and technologies, has recognised the value of FormFlow products and has signed an exclusive licence to commercialise the FormFlow C90 (90-degree bend in corrugated strip) as LYSAGHT CUSTOMFLOW™ in Australia. For the process to work, the incoming corrugated strips need to conform to the surface contours of the bending tool profile. “Unfortunately, this is often not the case as different steel manufacturers use different profile shapes and material parameters.” “Thus, being able to trace the incoming profile shapes and material properties in real time and adjust the technology accordingly will enhance our bending process significantly, allowing us to respond to different customer requirements and deliver products of greater quality,” Dr Dingle explained. The company’s Industry 4.0 transformation is led by Associate Professor Matthias Weiss, who forms part of Deakin’s Institute for Frontier Materials (IFM). He said that his team was looking forward to taking FormFlow’s bending technology to the next level. “We are taking a new approach towards process monitoring and control of secondary forming operations. By linking load signatures measured throughout the bending process to changes in incoming profile shape and material parameters, we hope BACK TO CONTENTS

From this

To this

to develop a proactive routine for FormFlow’s shape control,” Associate Professor Weiss said. The C90 FormFlow Bend, which is a world first invention, was unanimously voted the winner of ‘Over 40 Great Innovations’ in season four of Channel 10’s ‘Australia by Design: Innovations’. This innovation enables sharp bends to be created in corrugated iron. The technology changes traditional design and construction industry practices as it ensures a smooth transition between corrugated sheet sections across a range of different angles. “It is a structural joint and it has all sorts of benefits and it looks great. Before this, if you wanted to connect bits of the roof or bits of the wall, you needed to put two flat sheets and a cover over the top. Now you can do it in one piece,” Dr Dingle explained. The C90 bend offers smoother transitions between corrugated sheet sections across a wide range of angles. It leaves clients with a distinct interlocking system that is strong, safe and reliable. Likewise, David Chuter, Managing Director and Chief Executive Officer at IMCRC, said the outcomes of this research partnership will have farreaching benefits. “By applying smart technologies, the project removes the main barrier for a much wider application of the technology.” “It opens the door for FormFlow to upscale their manufacturing capabilities and expand their business model—not just in Australia, but globally,” Mr Chuter said. FormFlow’s ‘no gaps’ solution is a winner for all clients: WWW.MATERIALSAUSTRALIA.COM.AU

FEATURE – Materials Engineering in Manufacturing

• Provides better insulation • Lowers risk of ember attack and improves bushfire safety • Stronger than conventional corners • Clean and attractive solution • Eliminates ingress of dirt • Provides watertight and airtight finishes "The process has received praise from developers and architects, who now can produce sharp bends and ideas that are not matched by other similar technology,” Dr Dingle said. Associate Professor Weiss has been involved with sheet metal forming research at Deakin for nearly a decade. He said the “Eureka moment” occurred when the FormFlow Bend was proven. At the time, ten engineers were present, with “all of them standing there saying it couldn’t be done”. But Weiss said the innovation “came out perfect”. “We were very proud and very excited about the future,” he explained. The company has global markets in its sights, that draw on the cutting-edge technology and expertise that will upscale its production capability. FormFlow’s strong commercial interest has been sparked by

the production of ‘tiny homes’ and eco-friendly construction. “It’s all about reuse and recycling, and also being able to use recycled content in our base materials.” Dr Dingle said. FormFlow has transformed the FormFlow C90 technology into a prefabricated building system, and commercialised it as FormFlow Living. FormFlow Living provides modular building systems that enable flexible, cost-effective construction of small units through to full-size family homes, at a significantly reduced cost, fostering a new approach to prefabricated modular building. “The FormFlow Bend is a world first; there’s nobody else in the world doing that. The building system may not be as revolutionary as our C90 technology, but I think we’re taking a unique approach to it,” Dr Dingle said. In collaboration with Professor James Doerfler from Deakin`s School of Architecture, FormFlow has also developed emergency shelters and isolation facilities that can be rapidly deployed for people impacted by natural hazards. These services will also be crucial for quarantine arrangements in future health crises or pandemics like COVID-19.

FormFlow's Work In Action FormFlow is committed to real-world differences. For example, people who visited Melbourne’s Federation Square may have recently noticed the Future Food System—a three-storey building developed by sustainability advocates. The Future Food System demonstrated a fully self-sufficient, zero-waste dwelling. “The science behind FormFlow`s C90 core technology was developed by John Duncan, a Deakin Emeritus Professor who now lives in New Zealand,” Dr Dingle said. "He was a mentor for Matthias and I when we were doing our PhDs. It’s based on the mathematics of origami, a clever but deceptively simple process.” With the commercialisation of FormFlow`s new C60 (60-degree bend in corrugated sheet) on the way, the company is looking to expand its building technology to interconnected wall and roof cladding (gable roof) solutions and structural panel joints solutions for architectural sheds and buildings. These complex structures provide a suite of environmental benefits and have an airtight seal to deliver increased insulation. “It’s particularly good in bushfire-prone areas. It can prevent things like ember attacks, where embers make their way into the building envelope through gaps in the structure. In traditional building methods, there’s nearly always gaps in the structure. With our system you don’t get anything,” Dr Dingle explained. In collaboration with renowned bushfire architect, Ian Weir, FormFlow has extended the modular prefabrication approach to allow for BAL-FZ, full flame zone, Ratings, allowing the platform to help address the severe challenges in Australia around bushfire rebuilding and affordability.. “FormFlow`s vision is a world where everyone has a bright future and a home they love. To achieve this we innovate, refine and scale smart building solutions that benefit the environment, society and future generations” Dr Dingle said. The future of Building in Australia is here now, and it is powered by FormFlow.

The FormFlow C60 at Earthship in Jurien Bay, Western Australia. FormFlow Living – Beautiful, sustainable, modular, and relocatable homes.

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FEATURE – Materials Engineering in Manufacturing

Quickstep’s Composite Components Lead Australia’s Defence And Aerospace Sector Source: Sally Wood Quickstep is Australia’s largest independent manufacturer of composite aerospace components.

aerospace sector, where the company proudly welcomes new clients and projects.

The company services a range of clients in the aerospace and defence industries—from small operators to the big players like Northrop Grumman, Lockheed Martin and Boeing.

Quickstep supplies Vertical Tail Assembly components to BAE Systems for the F–35 stealth fighter aircraft. In December 2020, the company announced the production of its 10,000th component for the F–35 joint strike fighter program, representing around $250m in revenue over the last seven years.

Quickstep seeks to bring materials science and local manufacturing to life in their state-of-the-art 16,000m2 aerospace composite manufacturing plant in Sydney, and their Research and Development centre in Geelong, which is also their Advanced Air Mobility (AAM) manufacturing Center of Excellence. Nearly 300 employees work for Quickstep, including staff based in the United States, who work closely with US-based defence and commercial aerospace clients. All employees are specialists in defence products, commercial aviation and aerospace, and advanced applications. Above all, the company is dedicated to innovation through research and development of new and exciting materials.

Quickstep’s Chief Executive Officer, Mark Burgess, said the company’s manufacturing abilities are a milestone. “We are extremely proud of the trust and confidence placed in us by leading global aerospace OEM, the US DoD and the Australian DoD.” “We have built a reputation for excellent delivery, quality and cost performance and look forward to securing more production opportunities on F–35 and other advanced aerospace platforms,” he said.

Taking To New Heights With Advanced Technology

Each F–35 Lightning II aircraft incorporates approximately $440,000 of content built at Quickstep’s manufacturing facility at the Bankstown Aerodrome in Sydney.

Quickstep is a consistent player in the

These aircraft are poised to change

the face of the Australian Defence Force. In fact, Australia has 72 F–35s on order as part of the $17 billion AIR 6000 defence program. Quickstep also supplies the global fleet of C–130 J Super Hercules military transport aircraft with flaps. Composites are a combination of two or more materials that boast unique chemical or physical properties. The defence and aerospace sector has been a trailblazer in the composite components field, as the components are lightweight, and also enhance the performance of aircraft. Damien Quinnell, Project Manager at Quickstep, said 'no two projects are alike.' “Quickstep dedicates substantial time and effort towards driving technological change in the composites industry via our research and development team.” “We all want to do the interesting stuff and at Quickstep, we get to work on innovative composite solutions that aim to solve real world problems. And what could be better than that,” said Quinnell. The company’s ‘AeroQure’ method of production has paved the way for premium quality, lighter materials, and cost-effective production. AeroQure is a patented technology that moulds and cures large volumes of carbon fibre composite parts at high rates. AeroQure process for materials manufacturing follows a rigid process: • Low viscosity processing: which involves rapid heating of the mould and material to reduce process viscosity, improve air release and fibre wetting. • Exotherm control: a heating and cooling process to improve thermal control and heat transfer rates. • Low pressure, low void: which assists with the removal of air and other volatiles before the gelation of the resin. This achieves void levels of less than one per cent.

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FEATURE – Materials Engineering in Manufacturing

“The AeroQure manufacturing process has demonstrated reduced cycle times, substantially increased automation and step-change cost performance,” Quinnell said. The AeroQure process also achieves increased performance that exceeds industry requirements in the aerospace sector. Unlike traditional autoclave practices, AeroQure offers significant advantages, including: • Reduced production time • Reduced capital investment • Reduced energy consumption • Reduced costs • Increased flexibility with design • Increased control over the cure cycle • Increased surface finishes “The project team has already worked to validate AeroQure as a viable commercial aerospace production solution, capable of meeting aerospace quality and performance requirements, as well as reduced product cost and high production rates,” Quinnell said. In addition, the AeroQure technology offers a fully automated manufacturing system for the AAM industry, helping companies productionise their prototype drones.

Research And Development In Sharp Focus At Quickstep’s research and development facilities at Deakin University’s Geelong campus, skilled researchers, and industry experts jointly pursue a range of innovative projects in advanced laboratories. The partnerships forms a crucial part of Deakin’s ‘carbon cluster’, which bridges the gaps between research and industry. The research and development centre manages the development and innovation of Quickstep’s intellectual property and technologies. It is a enhances Quickstep’s disruptive technologies that are used in the manufacturing of carbon-fibre components. In addition, the company has harnessed the opportunities presented by Industry 4.0 to manage materials in a sustainable way. For example, Jetcam’s Crosstrack software optimises precise cutting WWW.MATERIALSAUSTRALIA.COM.AU

measures and nesting that reduces the amount of material wastage across the entire company. Quickstep has also developed 3D printing capabilities that use templates and automated production to minimise wastage and error. The research and technology developed at Quickstep has secured interest from CSIRO—Australia’s leading scientific research organisation. CSIRO has analysed Quickstep’s polymer composites technology to add value and find potential users across the Australian scientific industry. The company’s advanced polymer components are strong and lightweight. The components boast ten times the strength to weight ratio, as compared to other similar materials.

Advanced Manufacturing Front And Centre During Pandemic Like many manufacturing organisations, the COVID-19 pandemic has altered operations. But Quickstep has leveraged its supply chain, and maintained a steady pipeline of projects during the height of the pandemic.

At the same time, the company’s net profit increased by 44 per cent—a promising sign that Quickstep’s strategy to grow into other aerospace sectors such as MRO and AAM is bringing success. Quickstep also has a steady stream of new orders with a range of new and emerging clients, like the rail and medical industry.

In fact, Quickstep’s sales revenue increased by 12 per cent to $82.3 million in the last financial year.

The company’s Chief Executive Officer said there are vast opportunities to take advantage of during the pandemic.

Quickstep’s defence contracts have ensured the company remains globally competitive.

“In our view, there is never a more important time to invest in your business than during periods of instability.”

“There are very few companies in our industry who can, like us, point to strong sales growth and even stronger profit improvement at the moment,” Burgess said. BACK TO CONTENTS

“New technology is always exciting, but improved efficiency and enhanced margins are more exciting still,” Burgess said. SEPTEMBER 2021 | 47

FEATURE – Materials Engineering in Manufacturing

Company Profile: AML3D Source: Sally Wood AML3D is a globally accredited Wire Additive Manufacturing facility, manufacturing high-strength parts from a wide range of feedstock materials grades. Their innovative manufacturing technology is disrupting traditional metal manufacturing processes, providing a green, lower energy and lower waste solution. AML3D’s patented Wire Additive Manufacturing (WAM®) process includes the use of welding science, robotics automation, materials engineering and proprietary software to support smarter, leaner and greener manufacturing. The company works closely with a range of universities and scientific bodies, such as CSIRO, to find new ways of manufacturing. AML3D combines welding science with robotics, metallurgy and proprietary software. The company's process produces automated wire-fed 3D printing in a freeform environment, which can be set up anywhere and manufacture parts of any size. AML3D is the only metals diversified large-scale WAM® production facility in the Southern Hemisphere and is capable of producing finished parts and components to a certified standard under an accredited Quality Management System. The award of the Australian patent for its WAM® process has allowed AML3D to expand further. In July 2021, they launched their multi-million dollar headquarters in Adelaide. AML3D’s Managing Director, Andrew Sales, founded the company after a lifelong interest in welding and joining. Sales is a mechanical engineer and welding engineer who was inspired when studying 3D metal printing using arc welding technologies at Cranfield University in the UK. “The opening of this incredible facility has been a long-time dream of AML3D and marks yet another significant milestone for our company and our journey alongside the recent granting of our patent. Our new premises will enable AML3D to keep up with accelerating demand in 3D printing, while continuing to push boundaries in technological research and development,” Sales said. 48 | SEPTEMBER 2021

Robot Welders Transform Metal 3D Printing AML3D is disrupting the welding process with innovative technology. The traditional joining process of arc welding, or melting a wire with an electric circuit to form molten beads, has been revolutionised by the manufacturing of complex and high value parts with the assistance of robots. AML3D uses ABB robotics to provide a faster and more efficient metals manufacturing process. Since introducing the ABB robot system in 2018, the industrial robots have been coordinated to act as welders within the AML3D system. “The welding head and torch are mounted on the robot, and the robot points and moves the welder, and so the robot is making the shape,” explains Sales. The use of robotics improves sustainability, using far less energy and saving the metal waste of the traditional BACK TO CONTENTS

methods of casting, forging and machining metals. Because the process melts metal wire rather than smelting large blocks of metals, it consumes “less energy by order of magnitudes,” says Sales.

Steel Products That Are Stronger Than Forged AML3D has revolutionised steel products, providing ‘Additive Metal Layering’ 3D printing services at a commercial scale. This technology is utilised by a wide range of industry sectors, taking advantage of AML3D’s WAM® printed high strength steel. The steel products have Ultimate Tensile Strength (‘UTS’) 30 per cent higher than applicable global standards. Intertek, a group accredited by the National Association of Testing Laboratories, conducted the strength testing on behalf of AML3D. This testing involved printing of a series of geometrically shaped specimens WWW.MATERIALSAUSTRALIA.COM.AU

FEATURE – Materials Engineering in Manufacturing

AML3D’s Managing Director, Andrew Sales. All images courtesy of AML3D.

of standardised dimensions, allowing for direct comparisons with metals produced by conventional methods. These tests have confirmed the superior strength of the WAM® printed product, demonstrating that AML3D is capable of making high strength steel components that perform better than conventionally manufactured parts. Industries including Defence, Resources and Automotive are particularly interested in the results of the Intertek testing. The WAM® process allows steel products to be produced in a way that is more cost-effective and environmentally friendly. Additionally, it highlights AML3D’s ability to disrupt conventional manufacturing within these sectors, both within Australia and globally. The results of this testing will be provided to existing and potential customers of AML3D. In a media release regarding the steel products, Sales said, “These results, which clearly demonstrate the superiority of our WAM® process compared to normal forging techniques, demonstrate what a ‘game changer’ we have to offer. The independent, third party validation testing confirmed our own data regarding how WAM® metal printing of high strength steel offers significant advantages in strength and weight reduction opportunities compared to other conventional manufacturing techniques. We look forward to near term discussions on these results with our current customers.”

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Research And Development AML3D has been working closely with industry and academia for some time, including a collaboration with Flinders University and BAE Systems Maritime Australia in large-scale metal additive manufacturing. Recently, the company announced that they are joining BAE’s and Flinders University’s ‘Factory of the Future’ to further enhance large scale additive manufacturing. This Research and Development (R&D) facility will be located at the Tonsley Innovative District in Adelaide. Sharon Wilson, Continuous Naval Shipbuilding Strategy Director at BAE Systems Maritime Australia, welcomed the addition of AML3D and their work in additive manufacturing. “The establishment of a permanent Line Zero facility will support the development of new manufacturing techniques and technologies within a factory-like environment that will ultimately be adapted to the state-of-the-art digital shipyard at Osborne, and beyond. This supports the growth of an enduring and uniquely Australian sovereign industrial capability that supports the nation’s continuous naval shipbuilding strategy for generations to come,” she said. Testing and trials of metal additive manufacturing systems will soon be underway for the potential application in naval shipbuilding. The collaboration will grant students at Flinders University the opportunity to participate in the design and delivery of BACK TO CONTENTS

metal additive manufacturing research projects. Metal additive manufacturing curriculum and training modules are being introduced, as well as work on digital shipbuilding. Flinders University will also provide access to testing and validation equipment during the project. It is expected that the partnership will attract more students and researchers to the ‘Factory of the Future’. “The additive manufacturing R&D facility is a shining example of the capacity for collaboration in advanced manufacturing at ‘The Factory of the Future’ pilot site, which will enable joint research into and enhanced uptake of technologies and processes, so we can leverage the potential benefits for shipbuilding and advanced manufacturing in Australia,” Professor John Spoehr, Flinders University’s Pro-Vice Chancellor Research Impact, said. “The opportunities for additive manufacturing are endless and our researchers and students look forward to collaborating with AML3D to explore all the potential applications.” Andrew Sales also commented on the advantages of the R&D facility. “The trials and research projects to be undertaken at the facility in conjunction with BAE Systems Maritime Australia and Flinders University will enable AML3D to further develop its large-scale metal additive manufacturing capability through added features such as in process measurement, monitoring and adjustment that will improve quality,” he said. SEPTEMBER 2021 | 49

FEATURE – Materials Engineering in Manufacturing

Research To Examine Whether 'Strong as Steel' Spider Silk Can Be Replicated for Manufacturing Source: Sally Wood University of New South Wales (UNSW) Sydney has been awarded a grant to assess whether mimicking spider silk can be used in clothing, medical devices and prosthetics. Researchers will examine whether spider silk can be replicated for use in military and sports clothing, and medical devices and prosthetics as part of an international study funded by the PLuS Alliance. Dr Sean Blamires is from the Evolution and Ecology Research Centre at UNSW Science, he also leads the PLuS Alliance project. “Spider silk is stronger than steel and Kevlar. Tapping into its secrets could herald a revolution in manufacturing.” “Several high-performance materials could be produced such as ultra-tough ropes and cables, light-weight safety uniforms, prosthetics, binding sutures and other medicinal materials,” said Dr Blamires. Dr Blamires was selected after a call for submissions from researchers at King's College London, UNSW Sydney, and Arizona State University, which all form part of the PLuS Alliance. The PLuS Alliance seed grant will provide a much-needed opportunity to develop and assess recombinant spider inspired silk proteins, in the hope of mimicking the strong, non-toxic and antibacterial silk. Spider silk is the world’s toughest natural fibre. But unlike silkworms, harvesting silk directly from spiders is not a commercially viable option. Spiders require vast amounts of space for their webs. However, individual spiders do not produce high quantities of silk, and they tend to eat each other. Research is underway at the Spider Silk Research Laboratory, which was founded by Dr Blamires, to better understand how to produce spider silk biomimetics for a range of applications. “In this age of massive amounts of plastics pollution, the creation of spider silk materials using cutting edge genetic 50 | SEPTEMBER 2021

and spinning technologies would be of great interest to industry.” “Biotech is one of the fastest growing industries right now and this project will contribute significantly to that. There’s also the potential for new green manufacturing industries to arise in the future,” Dr Blamires said. The lab has received praise from international counterparts. It has also been visited by constituents from Australia, Germany, Taiwan, and Japan. In addition, the lab has trained PhD, honours and graduate diploma students, and produced multiple research papers. Dr Blamires said that advancing the development of high performing products using pollution-free manufacturing is a “great win for society”. The PLuS Alliance seeks to provide global solutions with impact. Together, the project boasts researchers and academic experts from three continents to address global challenges and provide world-leading education to people in need.

Above: Researchers say tapping into spider silk could herald a revolution in manufacturing. Image: Shutterstock.

Dr Blamires’ team includes Associate Professor Christopher Marquis, who is the Director of UNSW’s Recombinants Products Facility and Dr Aditya Rawal from UNSW’s Mark Wainwright Analytical Centre. Dr Blamires has participated in a range of publications, collaborations, writing and speaking appointments where he has shared his game-changing research to a panel of experts and likeminded peers. The researchers work across biotechnological, biochemical, biophysical and bioengineering disciplines to produce and evaluate recombinant spider silk proteins for spinning into fibres using microfluidic based techniques. PLuS Alliance seed funding is available to assist in the development of research projects that address one or more of the alliance themes: • Sustainability BACK TO CONTENTS

Right: Dr Sean Blamires says the creation of spider silk materials would be of great interest to the biotech industry. Photo: UNSW.

• global health • social justice • technology • innovation. The funds that are allocated through the project enable teams to conduct preliminary work and facilitate collaboration across the three universities. The seed-funded projects are part of an ongoing drive by the PLuS Alliance to achieve international impact through collaborative research. WWW.MATERIALSAUSTRALIA.COM.AU

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

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

NEW - INTRODUCTION TO COMPOSITES 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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Materials Australia Magazine | September 2021 | Volume 54 | No.3

Articles inside

Feature

Breaking News

Generate Stunning Ultra-High Resolution Images Of Structures As Small As Two Nanometres Using The Tabletop Phenom Pharos G2 Feg-Sem

Rigaku and JEOL Launch a Revolutionary Electron Diffraction Platform XtaLAB Synergy-ED

University Spotlight - Curtin University

Computed Tomography Buyers Guide

A Leading Supplier Of Non Destructive Testing Equipment

Plasma Tech Could Replace One Of World's Rarest Materials

Advanced Care: Smart Wound Dressings With Built-In Healing Sensors

Women in the Industry - Alex Kingsbury

WA Branch Technical Meeting - 13 September 2021

Why You Should Become a CMatP

WA Branch Technical Meeting - 9 August 2021

CMatP Profile: Dr Leon Prentice

Phase Transformations and Microstructural Evolution in Additive Manufacturing - Symposium - 9/10 August 2021

WA Branch Technical Meeting - 12 July 2021

From the President