Ohio State Materials and Manufacturing Conference Program

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Spacecraft materials in low Earth orbit (LEO) are challenged by atomic oxygen, charged-particle radiation, micrometeoroid and orbital debris impacts, thermal cycling, and UV radiation, all of which contribute to material degradation. The OSU-led SPACE-Mat Center of Excellence addresses these challenges by developing predictive physical and data-driven models that reliably forecast material lifetimes under realistic LEO conditions with quantified uncertainties. SPACE-Mat is developing computational lifetime prediction capabilities for widegap semiconductors and structural polymers through physics-based and data driven models, based on a multidisciplinary approach integrating previous data from NASA’s Materials International Space Station Experiments (MISSE), new data from in-lab experiments in facilities simulating the LEO environment, detailed simulation down to the atomic level, and rigorous multiscale characterization. In this talk, we will first describe the general framework developed to understand degradation of materials in the LEO environment, predict their lifetime within space systems, and design strategies for identifying longer-lived materials. Following this, we present detailed findings on the impacts of the space environment on wide-gap semiconductors – specifically GaN and Ga₂O₃ – and on polyimide films used in thermal blankets, which protect electronics and components from the extreme temperature fluctuations and radiation in space.

In-Space Manufacturing (ISM) encompasses a broad scope of technologies necessary to enable Earth-independent exploration and the colonization of space. These advancements in ISM technologies are focused on bringing terrestrial manufacturing capabilities to space while addressing the harsh environmental conditions present in Low-Earth Orbit (LEO) and on the Lunar and Martian surfaces. The NASA ISM portfolio includes projects that develop, test, and implement the materials, technologies, and capabilities needed for critical spares and repairs and infrastructure manufacturing in space. The need for critical on-demand repairs, reduced resupply, and the construction of massive structures that would be impractical to launch are the challenges that the NASA ISM portfolio is focused on solving. The drive to address NASA’s near-term mission needs while considering long-term economic sustainability of NASA missions leads to a mix between developing near-term capabilities for unforeseeable repair scenarios and long-term capabilities to build the infrastructure required for a permanent human presence beyond LEO. The NASA ISM portfolio prioritizes technologies that can create high value missions while creating a foundation of knowledge and technology advancement that enables a long-term spacefaring presence. Technologies of particular interest to the ISM portfolio include: 1) manufacturing of electronics, sensors, and semiconductors, 2) welding, cutting, forming, and additive manufacturing, 3) recycling, and 4) nondestructive evaluation, high-throughput testing, and electrical performance validation. 
 
Zach Courtright has been serving as the In-Space Manufacturing Portfolio Manager at NASA since May 2023. Previously, he worked for eight years as a Welding Engineer at NASA’s Marshall Space Flight Center. During his time at NASA, he has performed technical and project management responsibilities by proposing, supporting, and leading an array of research and development projects involving welding, additive manufacturing, electronics, nondestructive evaluation, and recycling. Recently, he has participated in and led projects pertaining to the development of in-space laser welding and on-demand manufacturing of electronics. Other research efforts that he is focused on are solid-state additive manufacturing and high-throughput mechanical testing, both of which have terrestrial and in-space manufacturing applications (one patent awarded and one patent pending). He holds a bachelor's and master's degree in Welding Engineering from The Ohio State University and a PhD in Materials Science and Engineering from Georgia Institute of Technology.

For decades, it has been known that oxide dispersion strengthening (ODS) is one of the most effective means of producing creep-resistant alloys.  However, the widespread deployment of ODS has been limited by the complex, conventional processing route to create these alloys involving mechanical alloying and subsequent thermomechanical processing.  A new additive ODS process using laser powder bed fusion has recently been developed by collaborators at NASA Glenn Research Center and enables the synthesis of ODS alloys in a single step [1].  This route has been utilized to design an ODS solid solution alloy (GRX-810) which has exceptional high temperature properties when compared with other solid solution Ni-base superalloys [2].  Detailed electron microscopy analysis has been performed to characterize the structure and composition of the oxide dispersoids, and other minor grain boundary phases.  These microstructure insights are being used to understand the significantly improved creep resistance of GRX-810 in comparison to a model NiCoCr ODS alloy.  The present status of this work, understanding of strengthening mechanisms, and prospects for developing a wider range of ODS strengthened alloys will be discussed.

Optical Cavities for Quantum Information Science and Precision Gravity Measurements

Matt Jaffe, Assistant Professor of Physics at Montana State University

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Van der Waals (vdW) heterostructures offer an unprecedented platform for engineering the physical properties of two-dimensional (2D) materials through control of twist angle, strain, and environmental interactions. The advent of state-of-the-art angle-resolved photoemission spectroscopy with nanoscale spatial resolution (nanoARPES), combined with its ability to probe fully functional devices, has opened new avenues for directly visualizing exotic electronic phenomena in these systems. In this talk, I will present our work leveraging cutting-edge in-operando nanoARPES to directly map the electronic properties of vdW heterostructures and their functional devices. I will highlight experiments that demonstrate on-demand tuning of the electronic structure by varying the substrate, twist angle, alkali metal doping, and applying an electric field. First, I will discuss the formation of quasiparticle-like trions and polarons arising from strong many-body interactions in transition metal dichalcogenide (TMD)-based heterostructures. Next, I will present our recent findings on the electronic structure of bilayer graphene on two distinct insulating substrates—hBN and RuCl₃—revealing intriguing new features. Time permitting, I will show our work on the thickness dependent electronic band structure of topological semimetals and their devices.

Scaling up new battery technologies from the lab to mass production remains a significant challenge. AI-driven digital twins are being explored as powerful tools which enabling predictive modeling, process optimization, and real-time decision-making – while also enabling exciting new possibilities, such as AI-driven co-learning and co-optimization opportunities in battery manufacturing. As the leading foundational partner of the new Battery Cell R&D Center (BRDC), Honda is actively engaged in developing these technologies to accelerate advancements of in-house battery production. This talk will present insights from a joint Honda-OSU investigation into process modeling, identifying key barriers to scale-up and demonstrating how digital twins may overcome them. We will explore current progress, ongoing challenges, and the future outlook for these tools towards the next-generation of battery manufacturing.

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The fabrication of lithium-ion electrodes typically involves four key steps: mixing, coating, drying, and calendering. Despite extensive research in recent years, the influence of each step and their associated process parameters on the final electrode microstructure and performance has not been thoroughly investigated. In this study, a novel multi-scale, multi-physics computational framework is developed to predict process-to-property relationships in lithium-ion cathode manufacturing. First, using discrete element method (DEM), slurry containing active materials, a carbon-binder domain, and solvent was created. Second, a macro scale computational fluid dynamics (CFD) model was constructed to mimic the coater and drying step. Third, the CFD model was coupled with thermo-mechanical finite element model and DEM to simulate the calendering step and predict how variations in manufacturing process parameters affect the microstructure, performance, and aging characteristics of lithium-ion cells. To validate the numerical simulation results, experimental test was conducted for NMC 111 cathode electrode. Materials characterization including scanning electron microscopy (SEM), energy-dispersive X-ray spectroscopy (EDS), and micro-CT were performed at various cross-sections to analyze the formation of microstructure. The numerical simulation results also predict the onset of crack formation and delamination phenomena which are considered the main failure mechanisms in cathode electrode fabrication process.

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Advancing novel materials requires precise analysis of atomic structure and defects to understand their impact on electronic, functional, thermal, and mechanical properties. This presentation will provide a broad overview of the pioneering research led by my group, utilizing and advancing CEMAS capabilities including high resolution quantitative STEM, 4D-STEM, EELS, and EBSD to drive scientific innovation. Through strategic collaborations with multiple research centers at OSU and external institutions, we have led transformative discoveries across diverse materials systems. Key topics will include ultrawide bandgap semiconductors and atomic scale defect engineering, novel magnetic interfaces that enable emergent properties, next generation energy storage materials, disordered materials for structural and functional applications, remote epitaxy, and the development of cutting edge electron microscopy techniques for probing thermal properties. By showcasing these advancements, this talk will highlight CEMAS’s leadership in materials research and its role in driving creative solutions to critical scientific challenges.

Metastable beta titanium alloys have attracted significant attentions in the aerospace industry due to their high strength, low density, and excellent toughness. Various nanostructures can form in metastable beta titanium alloys, affecting their microstructure evolution under different service environment. Understanding the nature of these nanostructures from atomic scale using advanced transmission electron microscopy is essential to design the next generation of titanium alloys with tailored properties. In this presentation, we will introduce our recent studies of various nanostructures in metastable titanium alloys using aberration-corrected scanning transmission electron microscopy (ACSTEM). Our first study identifies a novel ordered orthorhombic O” phase in a Ti-5Al-5Mo-5V-3Cr alloy. By combining ACSTEM and 3D atom probe tomography, we demonstrate that the nanoscale Al-rich O” phase can promote finescale alpha precipitation in titanium alloys. In the second case, we characterize the nanostructures in a coldrolled Ti-24Nb-4Zr-8Sn alloy. Using diffraction contrast transmission electron microscopy and ACSTEM, we reveal the formation of nanoscale omega phase and alpha” phase at the deformation twin boundaries and identify the role of these nanostructures during deformation. Our studies provide new insights into the nanostructure-mediated microstructure evolution in metastable beta titanium alloys, contributing to the design of next-generation titanium alloys through microstructure engineering.

Superalloys exhibit exceptional high-temperature capabilities owing to their characteristic two-phase γ/γ’ microstructure. Here, we present an optimized pre-deformation strategy to further refine this microstructure by introducing an extremely high density of two-dimensional defects (about 25 defects per precipitate) into the alloy prior to creep deformation. High-resolution structural and chemical investigations using advanced electron microscopy reveal that these planar defects have locally transformed into ordered hexagonal phases. The introduction of such high defect density significantly enhances both yield and creep strengths up to 750 °C compared to the undeformed reference state. Additionally, we propose a complementary approach utilizing additive manufacturing as an alternative to plastic deformation for introducing high densities of locally transformed defect phases.