Advanced Materials Manufacturing.pptx

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U.S. DEPARTMENT OF ENERGY OFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGY
Advanced BULK Materials Manufacturing
Steve Sikirica
Advanced Manufacturing Office
AMO Peer Review
June 2020 | Washington, DC manufacturing.energy.gov

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U.S. DEPARTMENT OF ENERGY OFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGY
Advanced Bulk Materials Manufacturing Objectives and
Targets
OBJECTIVE
Advance technologies that accelerate the development of new processes
to make next generation materials, on a path towards integration of these
materials into applications for cost effective, advanced energy
technologies.
TARGETS
1. Develop manufacturing processes for lightweight metals for light duty
vehicles at a strength/weight ratio of at least 200 megapascals
(MPa)/grams per cubic centimeter (g/cm3) at an added cost of no
more than $7/kg of weight saved.
2. Use existing modeling and simulation tools to accelerate capability of
predicting material behavior (e.g., tensile strength, hardness, fatigue
strength, corrosion, and toughness) as microstructure evolves during
materials processing.
3. Develop new process technologies that can provide production
quantities of commercial-scale atomically precise products.

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U.S. DEPARTMENT OF ENERGY OFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGY
Advanced Bulk Materials Manufacturing Key Thrusts
 Contributing to broader materials community technology advancement
 Responding to specified direction in Congressional appropriations:
 FY20: $5,000,000 to develop and industrialize a low-cost polymer
infiltration process for the fabrication of silicon carbide components;
leveraging best practices from large-scale, high-rate commercial composite
aerostructure manufacturing
 FY19: $5,000,000 for research into the materials and manufacturing
process development of high-strength, light-weight nano-crystalline metal
alloys

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U.S. DEPARTMENT OF ENERGY OFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGY
Advanced Bulk Materials Manufacturing Portfolio
 AMO FY19 Multi-topic-FOA: Subtopic 1.3: Materials and Manufacturing Process
Development of Nanocrystalline Metal Alloys:
 3 awards in total with DOE funding of $5.0 million
 FY18 Lab Call: One topic on materials for harsh conditions
 2 of 4 awards (one each from 4 sub-topic areas) with DOE funding of $2.8 million
 Emerging Research Explorations FOA: One topic on advanced materials with multiple
subtopics
 2 of 10 awards announced in February 2018 with DOE funding of $3.23 million
 One SBIR Phase II project with funding of $1.93 million (does not include all SBIR
funding):
 1 award for FlashSteel Works die wear project with DOE funding of $1.93 million
 Other ongoing and recent activities:
 High Performance Computing for Manufacturing (HPC4Mfg) led by Lawrence
Livermore National Laboratory with separate topic presentation
 Planned FY20 funding of $5 million for bulk advanced materials manufacturing:
 No specific budget request in FY21 for advanced materials manufacturing

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U.S. DEPARTMENT OF ENERGY OFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGY
Advanced Bulk Materials Manufacturing Activities
Project Title Organization
Accelerating Manufacturing of Powder-Processed Strong, Lightweight,
and Thermally Stable Bulk Nanocrystalline Al Alloys via Engineered
Interface States (Lightweighting and Modeling and Simulation))
University of California, Santa
Barbara
Affordable, Stronger, Lighter, Next-generation Nanocrystalline Metal Alloy
Technology with Scalable Manufacturing (Lightweighting)
Veloxint Corporation
The Grain Boundary Relaxation (GBR) Approach for Manufacturing of
High Strength Nanocrystalline Lightweight Metals (Modeling and
Simulation)
University of Nevada, Reno
3 Awards from the FY19 AMO Multi-Topic FOA (New Starts)
(excluding energy conversion and storage materials)
Project Title Organization
Flash® Processed Steel for Automotive Applications (Lightweighting) Flash Steelworks, Inc. (SBIR)
Material Mechanisms for Robust Flash Processing (Lightweighting) Oak Ridge National
Laboratory
Accelerated Discovery of Compositionally Complex Alloys for Direct
Thermal Energy Conversion (Modeling and Simulation AI/ML)
SLAC (completed 2019)
Solid Phase Processing: A Manufacturing Platform for the Production of
Extraordinary Materials with Reduced Energy Input (Lightweighting)
Pacific Northwest Laboratory
4 Awards from the FY18 AMO Lab Call

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U.S. DEPARTMENT OF ENERGY OFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGY
Advanced Materials Manufacturing Activities
Project Title Organization
Lifetime Energy Savings Via Advanced Manufacturing of Low Density Steels For
Transportation Applications (Lightweighting)
AK Steel
Carbon-Free Iron for a Sustainable Future (Decarbonization) Boston Metal
Bulk Materials Awards (ERE)

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U.S. DEPARTMENT OF ENERGY OFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGY
Advanced Materials Manufacturing Collaborations
 Steel Industry Roundtable
 The American Ceramic Society
 Congressional direction supporting the steel industry
 VTO coordination on solid phase processing

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U.S. DEPARTMENT OF ENERGY OFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGY
Advanced Materials Manufacturing Accomplishments/Successes
 Full-scale prototype Flash Steel heat treating line completed

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U.S. DEPARTMENT OF ENERGY OFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGY
Advanced Materials Manufacturing Accomplishments/Successes
 ShAPE has one granted patent and several pending applications
 ShAPE is available for licensing and collaboration opportunities, and one option
agreement has been executed to date
 SLAC demonstrated how data driven materials discovery which utilizes artificial
intelligence can be utilized by both the industrial and academic sectors. In total 35,000
unique alloys were explored resulting in the identification of 7,000 new ternary metallic
glass compositions.