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OppOrtunity AnAlysis fOr MAteriAls science And engineeringOppOrtunity AnAlysis fOr MAteriAls science And engineering

linking trAnsFormAtionAl mAteriAls and Processing for an energy-eFFicient and low-cArbon economy:

Creating the Vision and Accelerating Realization

opportunity Analysis for materials science and engineering In support of DOE EERE Industrial Technologies Program In cooperation with ASM International and The Energy Materials Initiative energy.tms.org OppOrtunity AnAlysis fOr MAteriAls science And engineering 1 3 3 7 ....................................9 Smart Coating/Lubricant Systems for Lightweight Alloys ....................................10

Coatings to Inhibit Galvanic Corrosion

New Solar Photovoltaic Materials that Utilize a Broader Spectrum of Ligh t .......12

New Surface T

reatment Processes to Rebuild or Enhance Surfaces ....................13

High-Flux Membranes for Selective Separation of A

tmospheric Gases ................14 15

High-T

emperature, Phase-Stable Alloys ................................18

Lightweight, High-Strength Ductile Materials

Irradiation-Resistant Structural Alloys F

or Nuclear Applications ........................20

High-Pressure Hydrogen-Resistant Materials

Collaborative, Comprehensive Materials Database

P redictive Materials Performance Code 24
Low -Cost Carbon Fibers and Composites Manufacturing Processes ...................27

Joining P

rocess for Assembling Multi-Material Structures ..................................28

High Energy Density

, Low-Cost Battery Cathodes L ow-Cost Fuel Cell Catalyst .....30 Integrated Computational Materials Engineering Modeling P ackage ...................31 32

Net-Shape Processing of Structural Metals

A dditive Manufacturing of Components and Systems L ow-Cost Processing and Energy Reduction Technology for Metals ....................37

Separation of Materials for Recycling

Real- Time Sensor Technology for Gases and Molten Metals ...............................39

OppOrtunity AnAlysis fOr MAteriAls science And engineeringOppOrtunity AnAlysis fOr MAteriAls science And engineering

executive summAry T entitled Linking Transformational Materials and Processing the Vision and Accelerating Realization next-generAtion bAttery And Fuel cell m

AteriAls And c

once Pt s

Radical Cost

Reduction

metallic and non-metallic materials and their

Performance

Breakthroughs

OppOrtunity AnAlysis fOr MAteriAls science And engineering breAkthrough thermoelectric m

AteriAls

next-generAtion structurAl metAls

For extreme environments

cAtAly sts For Fuels And energy- intensive

Proces

ses new PArAdigm mAnuFActuring

Proces

ses

For metAllic And non-

met

Allic mAteriAls And their

com Po sites surFAce treAtment Processes For

Product PerFormAnce And liFe

extension

Integrated Computational Materials Engineering

(ICME)

OppOrtunity AnAlysis fOr MAteriAls science And engineeringOppOrtunity AnAlysis fOr MAteriAls science And engineering

OppOrtunity AnAlysis fOr MAteriAls science And engineering energy, cArbon, And ec onomic devel o Pment oPPor tunities

For the

united stAtes In this report, materials science and engineering (MSE) is used to represent the science and engineering of the full spectrum of materials, and includes both primary and secondary materials, manufacturing and synthesis processes, system integration, and performance. i. introduction Figure 1. Estimated U.S. Energy Use, 2008 (99.2 quadrillion Btu) 0.01 2.43 0.51 0.31 0.42 0.46

0.670.831.79

2.03 0.02

Trans-

portation27.86Electricity

Generation39.97

Net Electricity

Imports

12.680.11

Industrial

23.94Commercial

8.58Residential

11.48

RejectedEnergy57.07

Energy

Services42.15

26.330.10

0.06

0.013.204.99

0.02

0.010.494.70

1.17 4.61 0.57 3.35 8.14

8.5827.39

9.18

6.868.45

6.82 20.54
19.15

6.962.29

1.71 4.78

20.900.08

Geothermal0.35Geothermal0.35Wind

0.51

Natural

Gas23.84

Coal 22.42

Biomass

3.88

Petroleum

37.13Petroleum37.13Hydro

2.45Hydro2.45Nuclear

8.45Nuclear8.45Solar

0.09

OppOrtunity AnAlysis fOr MAteriAls science And engineeringOppOrtunity AnAlysis fOr MAteriAls science And engineering

Figure 5. Energy Consumption in the

Transportation Sector, 2008

Primary Energy Consumption

(28.8 quadrillion Btu)Figure 4. Energy Consumption in the Industrial Sector, 2006 Primary Energy Consumption (32.5 quadrillion Btu)Figure 2. Total Energy Consumption by Sector (1949-2009)

2

Figure 3. Total Energy-Related Carbon

Dioxide Emissions by Sector (1949-2009)

chemicals7.323%

Petroleum

refining6.921%

ForestProducts3.511%

Food and

bever age1.96%steel 1.96% transportation equip.0.93%Plastics0.72%Fabricated metals0.72%Aluminum0.62%computer & electronics0.52%textiles0.51% cement0.51%machinery 0. 41%
glass 0.51%

Foundries0.31%

other mfg.1.65% non-mfg.

3.511%

Li gh t vehicles16.4 5 8% M edium /heavy trucks5.017%Air2.48%Off-highway

2.07%Water1.24%Pipeline0.93%

Ra il

0.62%Buses0.21%

010203040

Quadrillion Btu

Industrial

Transportation

1950 1960 1970 1980 1990 2000 2009Residential

Commercial

0.00.61.21.82.4

Billion Metric Tons Carbon Dioxide

IndustrialTransportation

20091950 1960 1970 1980 1990 2000Residential

Commercial

OppOrtunity AnAlysis fOr MAteriAls science And engineering the PotentiAl imPAct oF mAteriAls science And engineering overview And Process oF the current study

Linking

Transformational Materials and Processing for an Energy

Accelerating Realization

OppOrtunity AnAlysis fOr MAteriAls science And engineeringOppOrtunity AnAlysis fOr MAteriAls science And engineering

to commercial readiness areas

Vision of the Energy Materials Blue Ribbon Panel

Materials science and engineering (MSE) breakthroughs will enable the United States to greatly reduce the energy and carbon intensity of its economy. Near-term improvements in the materials employed in today"s massive energy infrastructure will deliver the United States to meet its national energy needs. Meanwhile, transformational innovations in MSE hold promise to revolutionize the way the nation produces, transports, and consumes energy in the long term. By pursuing a balanced approach to material and manufacturing science R&D, the United States can deliver near-term improvements while also laying the foundation for radical advances in the longer term.

2030 near-term energy and carbon

intensity reductions

2050 long-term energy and carbon

intensity reductions energy storage (batteries)energy storage (batteries) nuclear Fusion nuclear Fusion hydrogen and Fuel cells hydrogen and Fuel cells solar energysolar energy industrial energy efficiency industrial energy efficiency

Carbon Management

Vehicle Energy Efficiency

Biomass Energy

2010
highest highest high high

Moderate Priority

near-term Prioritiesnear-term Priorities industrial energy efficiencyindustrial energy efficiency vehicle energy efficiency vehicle energy efficiency nuclear Fissionnuclear Fission energy storage (batteries) energy storage (batteries)

Materials Recycle and Reuse

Solar Energy

Carbon Management

Biomass Energy

long-term Prioritieslong-term Priorities Figure 6. Energy Application Areas with Greatest Promise for Transformational Near- Term and Long-Term Impact Through MSE Technologies OppOrtunity AnAlysis fOr MAteriAls science And engineering

Figure 7. MSE Themes and Foundational Areas

Foundational Areas

crosscutting mse themes

Foundational Areas

crosscutting mse themes

Functional

surface technology computational modeling

Advanced characterization methods

integrated Process control and sensorsFunctional surface technologyhigher- performance materials for extreme environmentshigher- performance materials for extreme environmentsmulti-materials integration in energy systemsmulti-materials integration in energy systemssustainable manufacturing of materials

Foundational Areas

crosscutting mse themes

Functional

surface technology computational modeling

Advanced characterization methods

integrated Process control and sensorsFunctional surface technologyhigher- performance materials for extreme environmentshigher- performance materials for extreme environmentsmulti-materials integration in energy systemsmulti-materials integration in energy systemssustainable manufacturing of materials

Foundational Areas

crosscutting mse themes

Functional

surface technology computational modeling

Advanced characterization methods

integrated Process control and sensorsFunctional surface technologyhigher- performance materials for extreme environmentshigher- performance materials for extreme environmentsmulti-materials integration in energy systemsmulti-materials integration in energy systemssustainable manufacturing of materialsFunctional surface technology computational modeling

Advanced characterization methods

integrated Process control and sensorsFunctional surface technologyhigher- performance materials for extreme environmentshigher- performance materials for extreme environmentsmulti-materials integration in energy systemsmulti-materials integration in energy systemssustainable manufacturing of materials

OppOrtunity AnAlysis fOr MAteriAls science And engineeringOppOrtunity AnAlysis fOr MAteriAls science And engineering

FOUR TECHNICAL WORKING GROUPS' FOCUS

Energy Materials

Blue Ribbon Panel Focus

technologygapstechnologygapsnewProducts/ProcessesnewProducts/Processesbenefits,timelines,r&d needsbenefits,timelines,r&d needs

Figure 8. Logic Flow of Blue Ribbon Panel and Technical Working Groups' Outputs key application areas limitations and gaps in materials technologies prioritized set of new products and manufacturing processes preliminary time line

Preliminary lists of R&D

OppOrtunity AnAlysis fOr MAteriAls science And engineering ii. mse theme 1: FunctionAl surFAce technol ogy

Product And Process

inno v

Ations

OppOrtunity AnAlysis fOr MAteriAls science And engineeringOppOrtunity AnAlysis fOr MAteriAls science And engineering

Table 1. Potential Product and Process Innovations - Functional Surface Technology

Industrial Energy

Improved catalysts for industrial processes

High thermal conductivity materials and improved thermal barrier conditions aggressive environment resistance

Vehicle Energy

Reduction of friction and wear

Smart coating/lubricant systems for lightweight alloys tailored interfaces Novel, robust, lightweight materials with adequate properties for vehicl e applications

Coatings to inhibit galvanic corrosion

Hydrogen and Fuel

Cells

Better solid state H

2 storage materials 2 storage materials Solar EnergyNew materials that utilize a broader spectrum of light New solar photovoltaic materials that utilize a broader spectrum of ligh t

Materials Recycle

and ReuseLife extension of components to reduce replacement New surface treatment process to rebuild or enhance surfaces

Carbon ManagementNew CO

2 capture materials 2 2 release it

LightingCommercial lighting with reduced CO

2 emissions OppOrtunity AnAlysis fOr MAteriAls science And engineering

catalysts with high selectivity and conversion efficiencycatalysts with high selectivity and conversion efficiency

The production of ammonia, ethylene, and almost all industrially important chemicals involves catalysis. Catalysts with high selectivity and conversion efficiency improve industrial process energy efficiency by optimizing chemistry and structure to result in more efficient surface catalysis reactions and enable more cost-effective manufacturing.quotesdbs_dbs8.pdfusesText_14