Robotic touch sensors are not just skin deep

Researchers at Northwestern University and Tel Aviv University have addressed a key challenge in developing affordable robotic touch by identifying a flaw in the materials used for robotic skin. They discovered that inexpensive silicone rubber composites form insulating layers on their surfaces, which block electrical contact between the sensing polymer and electrodes, leading to inaccurate readings. By eliminating this issue, the team has paved the way for low-cost robotic skins capable of mimicking human touch—enabling robots to detect curves and edges for more precise object handling.

“A lot of scientists misunderstand their sensor response because they lump together the behavior of the contacts with the behavior of the sensor material, resulting in inconsistent data,” Grayson said. “It turns out, if you are not aware of this problem, you can publish papers which no one can reproduce. Our work identifies the exact problem, quantifies its extent both microscopically and electrically, and gives a clear step-by-step trouble-shooting manual to fix the problem.”

The rubber that can be used for typical robotic skin, called an elastomer, is flexible, lightweight and inexpensive, and when electrically conducting fillers like carbon nanotubes are added to the mix, the resulting composite becomes an ideal candidate for a touch sensor, whose resistance changes locally when pressed. But to receive electrical signals, the sensors need to be electrically contacted, and the researchers detected a thin insulating layer ever-present in such composites which could drastically change the behavior of the contacts. Just by sanding down the ultrathin insulation layer, the team was able to achieve a much stronger electrical contact and calibrate the thickness of the insulating layer both electrically and microscopically.

“All interesting things happen at the interface,” said co-author and professor at Tel Aviv University Noa Lachman. “This publication not only shows the importance of sensor interfaces, but also the importance of working at the nexus between two different disciplines: materials science and electrical engineering. Materials experts suspected the presence of this insulating external layer in conductive polymer composites for years but couldn’t understand its electrical effects. Each of us has one piece of the puzzle, but only together can we get the whole picture.”

Robotics in particular can be tricky in part because it requires so many types of expertise. The polymer materials scientist designing the functional electronic material for a robot, for example, does not have the same training and skills as the electrical engineer whose electronics will process the sensor signals. Grayson said the “contact preparation” challenge was precisely where the conversation about this research began.

“That’s why our collaboration with Tel Aviv is essential – they know the materials science that we don’t know,” Grayson said. “We rely on them to prepare the materials we are studying, then we take and study the material before turning around to help the Tel Aviv materials scientists characterize their materials better.”

Producing new materials — and then reproducing them — requires consistency across many different variables that are often difficult or even impossible to control. In exposing the question of reproducibility in much of the literature on touch sensing, Grayson challenges the research community to hold itself to a higher standard with the quality check described in the paper. As awareness of this problem spreads among researchers, new publications can be more rigorously relied upon to advance the field with new capabilities.

For more information: Journal of Advanced Electronic Materials

Machine learning powers new approach to detecting soil contaminants

Researchers at Rice University and Baylor College of Medicine have developed a novel method to detect hazardous soil pollutants, including previously unstudied compounds, using a combination of light-based imaging, theoretical predictions of molecular light signatures, and machine learning algorithms. This technique enables the identification of toxic substances like polycyclic aromatic hydrocarbons (PAHs) and their derivatives (PACs)—common combustion by-products linked to cancer and developmental issues—without the need for physical reference samples or advanced lab facilities, overcoming a major limitation in traditional soil contamination analysis.

“This method makes it possible to identify chemicals that have not yet been isolated experimentally,” said Naomi Halas, University Professor and the Stanley C. Moore Professor of Electrical and Computer Engineering at Rice.

The new method uses a light-based imaging technique known as surface-enhanced Raman spectroscopy, which analyzes how light interacts with molecules, tracking the unique patterns, or spectra, they emit. Spectra serve as “chemical fingerprints” for each compound. The technique is refined through the use of signature nanoshells designed to enhance relevant traits in the spectra.

Using density functional theory ⎯ a computational modeling technique that can predict how atoms and electrons behave in a molecule ⎯ the researchers calculated what the spectra of a whole range of PAHs and PACs look like based on the compounds’ molecular structure. This allowed them to generate a virtual library of “fingerprints” for PAHs and PACs.

Two complementary ML algorithms ⎯ characteristic peak extraction and characteristic peak similarity ⎯ were used to parse relevant spectral traits in real-world soil samples and match them to compounds mapped out in the virtual library of spectra.

“We are using PAHs in soil to illustrate this very important new strategy,” Halas said. “There are tens of thousands of PAH-derived chemicals and this approach ⎯ calculating their spectra and using machine learning to connect the theoretically calculated spectra to those observed in a sample ⎯ allows us to identify chemicals that we may not, or do not, have any experimental data for.”

The method addresses a critical gap in environmental monitoring, opening the door to identifying a much broader range of hazardous compounds ⎯ including those that have changed over time. This is especially important given that soil is a dynamic environment where chemicals are subject to transformations that can render them harder to detect.

Thomas Senftle, Rice’s William Marsh Rice Trustee Associate Professor of Chemical and Biomolecular Engineering, compared the process to using facial recognition in order to find an individual in a crowd.

“You can imagine we have a picture of a person when they’re a teenager, but now they’re in their 30s,” Senftle said. “In my group what we do is, on the theory side, we can predict what the picture will look like.”

The researchers tested the method on soil from a restored watershed and natural area using both artificially contaminated samples and a control sample. Results showed the new approach reliably picked out even minute traces of PAHs using a simpler and faster process than conventional techniques.

“This method can identify lesser-known and largely unstudied PAH and PAC pollutant molecules,” said Oara Neumann, a Rice research scientist who is a co-author on the study.

In the future, the method could enable on-site field testing by integrating the ML algorithms and theoretical spectral library with portable Raman devices into a mobile system, making it easier for farmers, communities and environmental agencies to test soil for hazardous compounds without needing to send samples to specialized labs and wait days for results.

Ankit Patel, assistant professor of electrical and computer engineering at Rice and assistant professor of neuroscience at BCM, is a corresponding author on the study alongside Halas.

Other Rice co-authors include computer science doctoral alum Yilong Ju; doctoral students Sarah Denison, Peixuan Jin and Andres Sanchez-Alvarado; Peter Nordlander, the Wiess Chair in Physics and Astronomy and professor of electrical and computer engineering and materials science and nanoengineering; and Pedro Alvarez, the George R. Brown Professor of Civil and Environmental Engineering.

For more information: Proceedings of the National Academy of Sciences

Image: Naomi Halas and Ankit Patel

Tapping a new toolbox, engineers buck tradition in high-performing heat exchanger

Engineers at the University of Wisconsin–Madison have developed a high-performance, twisty high-temperature heat exchanger using a combination of topology optimization and advanced 3D metal printing. This innovative design significantly outperforms traditional straight-channel heat exchangers in terms of heat transfer, power density, and overall effectiveness. These heat exchangers are critical in industries such as aerospace, power generation, and aviation, where efficient heat dissipation is essential.

“Traditionally, heat exchangers flow hot fluid and cold fluid through straight pipes, mainly because straight pipes are easy to manufacture,” says Xiaoping Qian, a professor of mechanical engineering at UW–Madison. “But straight pipes are not necessarily the best geometry for transferring heat between hot and cold fluids.”

Additive manufacturing enables researchers to create structures with complex geometries that can yield more efficient heat exchangers. Given this design freedom, Qian set out to discover a design for the hot and cold fluid channels inside a heat exchanger that would maximize heat transfer.

He harnessed his expertise in topology optimization, a computational design approach used to study the distribution of materials in a structure to achieve certain design goals. He also incorporated a patented technique, called projected undercut perimeter, that considers manufacturability constraints for the overall design.

With an optimized design in hand, Qian worked with colleague Dan Thoma, a professor of materials science and engineering at UW–Madison, who led the 3D printing of the heat exchanger using a metal additive manufacturing technique called laser powder bed fusion.

From the outside, the optimized heat exchanger looks identical to a traditional version with a straight channel design—but their internal core designs are strikingly different. The optimized design has intertwining hot and cold fluid channels with intricate geometries and complex surface features. These complex geometric features guide fluid flow in a twisting path that enhances the heat transfer.

Collaborator Mark Anderson, a professor of mechanical engineering at UW–Madison, conducted thermal-hydraulic tests on the optimized heat exchanger and a traditional heat exchanger to compare their performance.

The optimized design was not only more effective in transferring heat but also achieved a 27% higher power density than the traditional heat exchanger. That higher power density enables a heat exchanger to be lighter and more compact—useful attributes for aerospace and aviation applications.

While previous research has used topology optimization to study two-fluid heat exchanger designs, Qian says this work is the first to harness topology optimization and impose manufacturability constraints to ensure the design can be built and tested.

“Optimizing design on the computer is one thing, but to actually make and test it is a very different thing,” Qian says.

“It’s exciting that our optimization method worked. We were able to actually manufacture our heat exchanger design. And, through experimental testing, we demonstrated the performance enhancement of our optimized design. The excellent work performed by the students, postdoctoral researchers and scientists in the three research groups made this advance possible.”

Sicheng Sun, a recent Ph.D. graduate from Qian’s research group, is the first author on the paper. Additional co-authors include Tiago Augusto Moreira, Behzad Rankouhi, Xinyi Yu and Ian Jentz, all from UW–Madison.

The researchers patented their projected undercut perimeter technique through the Wisconsin Alumni Research Foundation.

For more information: International Journal of Heat and Mass Transfer.

Image: A rendering of a topologically optimized unit cell for a heat exchanger core. The optimized design has hot and cold fluid channels with intricate geometries and complex surface features.

Researchers uncover why cracks in materials break their symmetry while spreading

All materials, including those in our bodies and the structures around us, contain tiny imperfections like cracks, which can sometimes spread suddenly and dangerously—but also form fascinating patterns. Physicists have long struggled to explain why these cracks often branch unpredictably and slow down. However, two recent studies from the Weizmann Institute of Science have revealed that despite their chaotic appearance, crack propagation follows specific physical parameters that govern their behavior and explain the emergence of asymmetrical patterns.

Decades of controlled experiments in material failure have shown that even when a perfectly symmetrical crack is created under tensile forces, it spontaneously loses symmetry as it propagates, veering off course and moving more slowly than expected.

“These observations are the exact opposite of what we would expect based on theoretical calculations, which predict that even if we introduce a small obstacle in the path of a symmetrical crack under tension, the crack should return to a smooth, symmetrical trajectory,” says Prof. Eran Bouchbinder.

“Given the experimental evidence, we assumed that there must be missing links—overlooked physical properties that could account for the observed behavior.”

In one of the two studies led by Dr. Yuri Lubomirsky, then a doctoral student in Bouchbinder’s group in Weizmann’s Chemical and Biological Physics Department, the researchers used a computer model to simulate the propagation of cracks in three-dimensional materials.

“To understand crack propagation, we focused on the crack tip—the point where the material transitions from intact to fractured,” explains Lubomirsky. “While moderate conditions prevail throughout most of the material most of the time—meaning its behavior can often be understood by averaging its properties—the crack tip is governed by extreme conditions.

“Physical quantities such as force, temperature and velocity are so large there that they can be mathematically treated as approaching infinity, and the usual physical rules no longer apply. We postulated that the crack tip might reveal the hidden properties that explain asymmetrical crack propagation.”

The researchers’ arduous seven-year search for these missing physical properties was at times frustrating. “Ultimately, the breakthrough came from introducing significant disorder into the simulations—a factor previously overlooked in dynamic theories of material failure.

“We ran numerous simulations using advanced computing capabilities and observed that the crack initially moves straight until it reaches a point where it splits locally and then changes direction,” Bouchbinder says.

“The challenge was to extract from the vast amount of data the basic principle explaining why the crack branches out and deviates from a smooth, symmetrical path. One day, I asked Yuri to cross-reference two graphs, and that’s when it clicked: The intrinsic disorder of real-world materials, combined with the extreme conditions at the crack tip, turned out to be the missing link.”

The laws of physics explain the behavior of uniform materials fairly well, but most materials in the world are not truly uniform. Glass, for example, appears smooth and homogeneous, but a closer look at its particles and the connections between them reveals a structure lacking consistent order. This means that the internal forces acting within glass vary from one region to another.

Until now, engineers and scientists trying to understand fracture dynamics had relied on averaged material properties and thus failed to explain why cracks break symmetry. Bouchbinder and Lubomirsky realized that the answer lies in the extent of internal disorder—that is, how much the material’s strength varies from place to place.

The researchers applied varying fracture forces to their computer model and studied the relationship between crack propagation and material disorder. They observed that when fracture forces were weak, cracks propagated symmetrically without branching and were largely unaffected by disorder.

However, when fracture forces were moderate, cracks became sensitive to disorder: When the crack tip reached a weaker region, local instabilities developed, causing the crack to split locally instead of continuing in a straight line. These local branches competed with each other—one branch would stall while the other would continue as the main crack, often changing direction.

Retrospective examination of these regions revealed microcracks where the secondary branches had been arrested. In other words, in this regime the extent of branching depended directly on the degree of disorder.

Finally, when fracture forces exceeded a critical threshold, the crack no longer halted at points of instability but split into entirely separate branches that widened and penetrated deeper into the material. In this high-force regime, disorder once again played a minor role.

The deviation of cracks from their symmetry axis and the formation of branches come at an energetic cost: A larger amount of material is broken, and the crack’s velocity decreases relative to the speed it would have reached had it remained smooth and symmetrical.

Another phenomenon commonly seen in cracks—also linked to symmetry breaking—is the formation of steps composed of two interacting fracture surfaces. In a follow-up study the researchers investigated how this pattern forms.

They found that step formation depends not only on the degree of internal disorder but also on external tensile forces’ slight deviations from perfect symmetry. In addition to the tensile forces that open the crack, there are almost always perpendicular forces causing the crack’s faces to slide past each other in a rotational motion.

Incorporating both types of force and the internal disorder into their mathematical model, the scientists succeeded in predicting and explaining the emergence of the step pattern.

“These discoveries provide a physical and mathematical framework for understanding material failure through crack dynamics that we encounter in everyday life,” says Bouchbinder.

Lubomirsky adds, “Our findings could also help in designing materials that are more resilient to catastrophic cracking. We show that increasing disorder can slow crack propagation—an insight that could have significant implications for the design of structures and physical systems.

“Natural materials such as bones and teeth have evolved to resist failure, and it’s possible that their internal disorder is one of the key factors behind their resilience. This is where our findings also shed new light on the workings of nature.”

For more information: Nature Communications

Image: The crack driving force as a function of its propagation velocity in 2D and 3D, under different levels of disorder, and the emergence of a limiting crack velocity.

$11.5 million sponsorship creates new research institute

Epsilon Group, India, a leading innovator in carbon black and advanced battery materials for electric vehicles and energy storage, is partnering with Tufts University in Massachusetts to launch the Tufts Epsilon Materials Institute-a new research center made possible by an $11.5 million sponsorship and dedicated to advancing materials science and engineering for global energy and sustainability solutions.

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New spectroscopy technique extends device lifespan

High-resolution, full-color display devices like foldable smartphones and ultrathin televisions use organic light-emitting diodes (OLEDs) due to their flexibility, self-illumination, lightweight construction, ultra-thin profiles, high contrast ratios, and low-voltage operation. An OLED consists of multiple ultrathin organic film layers between two electrodes, each layer playing a specific role in the device’s operation. When voltage is applied, electrical charges accumulate and emit light at the interfaces between these layers. While this multilayer structure allows precise control of charge accumulation, transport, and light generation, it also leads to degradation of the organic layers over time, limiting the lifespan and efficiency of OLED devices.

Understanding how the electronic structure at these interfaces behaves during operation remains a significant challenge. To tackle this issue, Professor Takayuki Miyamae, together with Mr. Tatsuya Kaburagi and Dr. Kazunori Morimoto from Chiba University in Japan, employed a second-order nonlinear spectroscopic method known as sum-frequency generation (SFG). This technique enabled them to investigate the vibrational and electronic properties at the interfaces within operating OLEDs, offering new insights into their behavior under real-world conditions.

When voltage is applied to an OLED system, light is emitted via the recombination of charges at the organic interfaces. This alters the SFG output, allowing researchers to study how charge accumulates and what electronic structural changes occur at the interfaces under different operating conditions.

three different multilayer OLEDs with different types and combinations of organic layers were used. Electronic SFG (ESFG) spectroscopy was conducted on three OLED devices to examine spectral changes induced by the charge behavior and electronic structure at the interfaces. “We examined the differences in the electric field intensities inside the OLED devices based on the applied voltage dependence of the ESFG spectra. This clarifies the role of field strength differences that affect the ease of internal charge flow and the light emission characteristics for the first time,” explains Prof. Miyamae about the team’s study.

ESFG spectral bands corresponding to each organic layer were identified by comparing the absorption spectra and layer configurations among the three OLED devices. The researchers observed changes in spectral signal intensities when applying voltages to the OLED devices, which were related to the changes in the electric field and charge behavior inside the OLEDs.

Upon voltage application, the spectral signal intensity increased at the absorption band of the hole transport material (positive charge carriers inside the OLED), and signal intensity decreased at the absorption band of the light-emitting layer. This shows that internal charge flow across the organic layers within the OLEDs is different, leading to changes in spectra.

The team also applied square-wave pulse voltages on these devices to study how electric fields formed within these devices varied with time. They found that adding BAlq (a material used for electron transport in OLEDs) changes the position where the light is emitted in OLEDs. This shift in emission affects both the color and shape of the emitted light and how efficiently the device converts electricity into light.

“ESFG technique represents a novel, highly effective, nondestructive, and non-invasive spectroscopic approach for examining the electric field generation caused by injected charges in solid-state thin-film devices,” notes Prof. Miyamae about this innovative research work.

With this technique, material scientists can now design OLEDs with improved device lifetimes, energy efficiency, and cost reductions, eventually increasing the use of ultrathin organic devices in our everyday lives. “Moreover, this research can greatly shorten and rationalize materials development research, which now performs trial-and-error processes and long periods of degradation verification to assess device efficiency and lifetime,” adds Prof. Miyamae.

For more information: Journal of Materials Chemistry C

Fujitsu and RIKEN develop world-leading 256-qubit superconducting quantum computer

Fujitsu Limited and RIKEN have developed a cutting-edge 256-qubit superconducting quantum computer at the RIKEN RQC-FUJITSU Collaboration Center, building on the 64-qubit version launched in October 2023 with support from Japan’s Ministry of Education, Culture, Sports, Science and Technology (MEXT). This advancement incorporates high-density implementation techniques, marking a significant step toward practical applications of superconducting quantum computers to address complex global issues. Starting in the first quarter of fiscal 2025, the 256-qubit quantum computer will be integrated into a hybrid quantum computing platform and offered to companies and research institutions worldwide, enabling more complex analyses and sophisticated error correction algorithms.

Moving forward, both organizations will further enhance the platform’s usability by working to enable seamless collaboration between quantum and classical computers, enabling the efficient execution of hybrid quantum-classical algorithms.

Fujitsu and RIKEN’s 256-qubit superconducting quantum computer overcomes some key technical challenges, including appropriate cooling within the dilution refrigerator which is achieved through the incorporation of high-density implementation and cutting-edge thermal design. Other key features include:

1. Scalable 3D connection structure

  • Enables efficient scaling of qubit count without requiring complex redesigns by arranging 4-qubit unit cells in a 3D configuration
  • The 256-qubit machine utilizes the same unit cell design established in its 64-qubit predecessor, effectively demonstrating the scalability of this architectural approach

2. Quadrupled implementation density within dilution refrigerator

  • Quadrupled implementation density achieved within the dilution refrigerator, allowing the 256-qubit machine to operate within the same cooling unit as the 64-qubit system
  • Highly optimized design that carefully balances heat generation from control circuits with the cooling capacity of the refrigerator, while maintaining the necessary ultra-high vacuum and extremely low temperatures

Fujitsu is committed to accelerating the practical application of quantum computers from both hardware and software perspectives. Through its platform for hybrid quantum computing, Fujitsu will provide larger-scale quantum computers to global companies and research institutions conducting joint research in various fields, including finance and drug discovery.

Fujitsu and RIKEN will continue R&D efforts toward the launch of a 1,000-qubit computer, which is scheduled to be installed in a new building at Fujitsu Technology Park in 2026. In addition, the two organizations will extend the installation period of their Collaboration Center from March 2025 to March 2029, and will continue to work on the long-term R&D of technologies that will enable the realization of even larger superconducting quantum computers.

For more information: Fujitsu

Image: Newly developed 256-qubit superconducting quantum computer

OU and Oak Ridge National Laboratory launch strategic collaboration in additive manufacturing

The University of Oklahoma and Oak Ridge National Laboratory have partnered to create an advanced additive manufacturing center in Norman, OK, leveraging OU’s Sooner Advanced Manufacturing Laboratory and ORNL’s Manufacturing Demonstration Facility. This center aims to develop innovative metal additive manufacturing solutions for aerospace and national defense. The collaboration, involving OU’s Oklahoma Aerospace and Defense Innovation Institute (OADII) and ORNL, will enhance research, training, and workforce development in metal additive manufacturing, hybrid manufacturing, machining, and data analytics.

“This long-term partnership with Oak Ridge National Laboratory fully aligns with the recently published update of OU’s strategic plan,” said Gen Robin Rand (USAF, ret.), OADII’s executive director. “Our deliberate push to advance additive manufacturing research is fueling innovation and economic prosperity in Oklahoma and reducing risk to our nation’s defense.”

Through OADII and the Gallogly College of Engineering, the University of Oklahoma supports Department of Defense priorities such as sustainment and modernization, and ORNL brings unparalleled technical capabilities in materials science and advanced manufacturing, providing the partnership with the tools and talent to drive innovation.

“Our college is thrilled to enter into this partnership,” said Zahed Siddique, associate dean for research at the Gallogly College of Engineering. “Collaborating on cutting-edge manufacturing technology will enrich the student educational experience, expand research impact and enhance economic development opportunities in Oklahoma.”

The center is expected to play a key role in supporting sustainment and mission readiness at Tinker Air Force Base and other critical centers across the region, including the Air Force Sustainment Center and the Air Force Research Laboratory.

“This partnership between OU and ORNL will have substantial impact on our national security, particularly by advancing qualified additive manufacturing processes for the sustainment and readiness of U.S. Air Force assets,” said Moe Khaleel, ORNL associate laboratory director for National Security Sciences. “When the great people at our two institutions get together, with our collective resources, we will do big things for the nation.”

ORNL will leverage the capabilities and lessons learned in establishing the Manufacturing Demonstration Facility, the nation’s foremost advanced manufacturing research environment.

“By combining ORNL’s deep expertise in advanced manufacturing with OU’s strong academic and research foundation, we are creating a dynamic ecosystem for innovation,” said Craig Blue, ORNL’s chief manufacturing officer and director of Defense Manufacturing Programs. “This collaboration is not only about advancing technology—it’s about accelerating the transition of breakthrough solutions into real-world defense applications where speed, precision, and readiness matter most.”

For more information: Oklahoma Aerospace and Defence Innovation Institute

Image: Moe Khaleel, associate laboratory director, National Security Sciences, Oak Ridge National Laboratory, shakes hands with Carol L. Silva, interim vice president for research and partnerships, University of Oklahoma, during the signing ceremony. 

Bringing powerful 3D X-ray microscopy to smaller labs

Researchers at the University of Michigan have developed a technique that allows the study of microstructures inside metals, ceramics, and rocks using X-rays in a standard laboratory, eliminating the need to travel to a particle accelerator. This advancement makes 3D X-ray diffraction (3DXRD) more accessible, enabling rapid analysis of samples and prototypes in both academic and industrial settings, and providing more opportunities for student involvement. 3DXRD works by reconstructing 3D images from X-rays taken at multiple angles, similar to a CT scan, but with the material sample rotating in front of a powerful beam that emits about a million times more X-rays than a medical X-ray.

The huge X-ray concentration produces a micro-scale image of the tiny fused crystals that make up most metals, ceramics and rocks, known as polycrystalline materials.

Results help researchers understand how materials react to mechanical stresses by measuring thousands of individual crystals’ volume, position, orientation and strain. For example, imaging a sample from a steel beam under compression can show how crystals respond to bearing the weight of a building, helping researchers understand large-scale wear.

Synchrotrons were once the only facilities able to produce enough X-rays for 3DXRD as electrons spit off scads of X-rays as they travel through circular particle accelerators, which can then be directed into a sample.

While synchrotron X-ray beams produce state-of-the-art detail, there are only about 70 facilities worldwide. Research teams must put together project proposals for “beam time.” Accepted projects often must wait six months to up to two years to run their experiments, which are limited to a maximum of six days.

In an effort to make this technique more widely available, the research team worked with PROTO Manufacturing to custom build the first laboratory-scale 3DXRD. As a whole, the instrument is about the size of a residential bathroom, but could be scaled down to the size of a broom closet.

“This technique gives us such interesting data that I wanted to create the opportunity to try new things that are high risk, high reward and allow teachable moments for students without the wait-time and pressure of synchrotron beam time,” said Ashley Bucsek, U-M assistant professor of mechanical engineering and materials science and engineering and co-corresponding author of the study published in Nature Communications.

Previously, small-scale devices could not produce enough X-rays for 3DXRD because at a certain point, the electron beam pumps so much power into the anode—the solid metal surface that the electrons strike to make X-rays—that it would melt. Lab-3DXRD leverages a liquid-metal-jet anode that is already liquid at room temperature, allowing it to take in more power and produce more X-rays than once possible at this scale.

The researchers put the design to the test by scanning the same titanium alloy sample using three methods: lab-3DXRD, synchrotron-3DXRD and laboratory diffraction contrast tomography or LabDCT—a technique used to map out crystal structures in 3D without strain information.

Lab-3DXRD was highly accurate, with 96% of the crystals it picked up overlapping with the other two methods. It did particularly well with larger crystals over 60 micrometers, but missed some of the smaller crystals. The researchers note that adding a more sensitive photon-counting detector, which detects the X-rays that are used to build the images, could help catch the finest-grained crystals.

With this technique available in-house, Bucsek’s research team can try new experiments, honing parameters to prepare for a larger experiment at a synchrotron.

“Lab-3DXRD is like a nice backyard telescope while synchrotron-3DXRD is the Hubble Telescope. There are still certain situations where you need the Hubble, but we are now well prepared for those big experiments because we can try everything out beforehand,” Bucsek said.

Beyond enabling more accessible experiments, lab-3DXRD allows researchers to extend projects past the synchrotron six day limit, which is particularly helpful when studying cyclic loading—how a material responds to repeated stresses over thousands of cycles.

For more information: The Michigan Center for Materials Characterization

Image: Members of Professor Ashley Bucsek’s lab group are able to use three-dimensional X-ray diffraction to study polycrystalline materials on campus, a technique previously only available in specialized synchrotron facilities. Left to right: Ashley Bucsek, Sangwon Lee, Wenxi Li, Abdulhamit Sarac, Janice Moya and Yuefeng Jin. Image credit: Marcin Szczepanski, Michigan Engineering

One minute Mentor: Tool Steels Heat Treatment Simulation Example

The potential of high-temperature simulation (HTS) is demonstrated through the case of a low-silicon, vacuum-arc-melted and remelted H11 hot-work tool steel. To validate the HTS model, a cylindrical steel sample with a diameter and length of 100 mm (4 inches) was selected due to the efficiency benefits of using a simplified 2D geometry. The simulation was calibrated using time-temperature-transformation (TTT) diagrams and thermal expansion data obtained from dilatometer experiments. Initial validation focused on comparing simulated phase-transformation behavior with actual dilatometer curves, showing good agreement in key areas such as thermal expansion, austenite formation (with carbides), subsequent contraction, and the transformation kinetics of austenite into martensite, bainite, and pearlite. The model does not currently account for the precipitation of proeutectoid carbides.

For more information, click on the link below (subscription required). Then scroll to Figure 16. R Schneider; R. Mesquita; W Schützenhöfer, Distortion in Tool Steels, ASM International, 2014  https://doi.org/10.31399/asm.hb.v04d.a0005980

Nitrex division G-M enterprises sees surge in aerospace orders amid market recovery

Nitrex, Quebec, announced that its G-M Enterprises division in Corona, California, is experiencing robust growth, driven by renewed demand in the aerospace sector. 

The division recently secured a significant order from a long-standing aerospace customer for a 6-bar vacuum furnace engineered to meet stringent aerospace manufacturing requirements.

This latest order contributes to a strong fiscal performance for G-M Enterprises in FY2025. The division has already doubled its sales of new hot zone replacements compared to the same period last year, indicating a growing market demand and a sharpened focus on customer engagement.

Mark Hemsath, president of Nitrex and UPC-Marathon, noted that the uptick in aerospace activity is a positive development for the company. He highlighted the strength of G-M Enterprises’ California-based manufacturing capabilities and emphasized the importance of longstanding customer relationships in driving success.

With nearly 40 years of experience in vacuum furnace design and production, G-M Enterprises supports a wide range of applications including additive manufacturing, metal injection molding (MIM), and critical aerospace processes. As part of the Nitrex/UPC-Marathon group, the division leverages integrated heat-treating solutions, automation software, and process control technologies.

As aerospace industry demand continues to rebound, G-M Enterprises is well positioned to deliver high-capacity, precision-engineered systems backed by technical expertise and customer service.

Read further here.

Constellium publishes 2024 sustainability report outlining decarboConstellium publishes 2024 sustainability report outlining decarbonization and recycling milestonesnization and recycling milestones

Constellium, Paris, announced that it has released its 2024 Sustainability Report, detailing progress toward its environmental, social, and governance (ESG) goals and reinforcing its commitment to building a sustainable, circular economy. The report highlights advancements in aluminum recycling, decarbonization initiatives, workplace safety, and gender equity.

Among the year’s key accomplishments is the opening of a €130 million recycling facility in Neuf-Brisach, France, which increases the company’s global recycling capacity to more than 750,000 metric tons per year. The site enhances automotive and packaging recycling by 75%, reduces annual carbon emissions by approximately 400,000 metric tons CO₂eq, and integrates biodiversity assessments and energy-efficient technologies.

In line with its decarbonization strategy, Constellium also decommissioned its final coal-powered energy source at the Singen plant in Germany. The closure is projected to cut direct greenhouse gas emissions at the site by more than 25% between 2021 and 2025.

Further emphasizing innovation, Constellium completed its first industrial-scale hydrogen casting at its C-TEC R&D facility in July. This pilot project substituted natural gas with hydrogen to produce a 12-metric-ton aluminum slab for electric vehicle applications, showcasing the potential of hydrogen to lower emissions in industrial processes.

The company’s sustainability efforts have been validated through independent certifications. All Constellium operations were certified under the Aluminium Stewardship Initiative’s Performance Standard v3.0, recognizing best practices in emissions reduction, waste management, and human rights. Constellium also maintained a Gold rating from EcoVadis and an AA rating from MSCI for its ESG performance.

Jean-Marc Germain, chief executive officer, emphasized aluminum’s role in advancing low-carbon manufacturing, noting its recyclability and efficiency in lightweight applications. He reiterated the company’s commitment to delivering sustainable solutions across the aluminum value chain.

Read further here: Constellium’s sustainability page.

NUTEC Bickley secures major contract for advanced ceramic core sintering kiln

NUTEC Bickley, Monterrey, Mexico, announced that it has been awarded a contract to supply a four-car shuttle kiln to a leading global energy technology company. The kiln will support sintering of ceramic cores at the customer’s investment casting facility, with firing cycles ranging from 20 to 80 hours, depending on the core specifications.

The gas-fired shuttle kiln is engineered to operate at temperatures up to 2010°F (1100°C) and features a twin-deck kiln car setting. Each car offers setting dimensions of 47 inches long by 63 inches wide by 34 inches high (1.19m x 1.59m x 0.87m), delivering a total effective load volume of 230 cubic feet (6.55m³) across all four cars. The kiln is designed to handle an average total product weight of 970 pounds (440 kg).

Twelve individually controlled high-velocity nozzle-mix burners—firing in a staggered sequence above and below the load—enable optimal heat transfer and temperature uniformity. Each burner includes automatic ignition and a safety system.

The kiln incorporates NUTEC Bickley’s proprietary IMPS® combustion control system, which provides pulse control across eight independent temperature zones, alternating between high and low fire settings. The system allows programmable excess air levels during different stages of the cycle, enhancing fuel efficiency, process precision, and temperature uniformity without relying on constant excess air. IMPS also includes a cooling mode, introducing air through burners and dedicated nozzles for reduced cycle times.

The kiln’s insulation includes NUTEC’s patented Jointless® ceramic fiber system rated to 2600°F (1425°C), ensuring thermal efficiency and durability. Double-labyrinth refractory and insulation brick seals combined with sand seals reduce heat loss and cold air infiltration.

This project builds on NUTEC Bickley’s longstanding relationship with the customer, which includes the delivery of 15 furnaces and ovens over the past decade to its transformer manufacturing division. The award further underscores NUTEC Bickley’s reputation for delivering advanced thermal processing systems to global leaders in high-tech manufacturing.

Read further here: https://www.nutecbickley.com/

ACE press celebrates 150 years of forging innovation and industry leadership

ACE, Erie, PA, announced the celebration of its 150th anniversary, marking a significant milestone in the company’s history as a leader in forging and metal-forming technology. With roots tracing back to 1875, ACE has grown into North America’s largest supplier of forging and forming equipment, shaped by strategic mergers, decades of engineering expertise, and a commitment to customer success.

The company’s evolution was significantly driven by the merger of three industry pioneers—Ajax Manufacturing, Chambersburg Engineering Company (CECO), and Erie Press Systems. Together, they bring more than 400 years of combined experience in metal forming, enabling ACE to offer the most comprehensive range of forging and forming solutions in the industry.

Founded in 1875, Ajax Manufacturing built its reputation on high-quality forging hammers, presses, and upsetters. The company expanded in 2005 with the acquisition of CECO, a manufacturer specializing in hydraulic and mechanical forging technology since 1897. In 2019, Erie Press Systems, a specialist in stretch forming and hydraulic presses for aerospace and automotive applications, joined the group. This consolidation resulted in the formation of Ajax/CECO/Erie Press (ACE), a unified brand offering advanced equipment and services to a global client base.

Now operating under Park-Ohio Holdings Corp., a diversified industrial holding company based in Cleveland, ACE benefits from expanded engineering resources, global market access, and enhanced service capabilities. Its solutions support critical industries such as aerospace, automotive, energy, defense, and heavy machinery manufacturing.

The company’s current portfolio includes forging hammers, hydraulic and mechanical presses, upsetters, ring rolling mills, and hydroforming systems. To ensure high equipment performance and longevity, ACE emphasizes five operational pillars: preventive maintenance, parts and repair programs, rebuilding and remanufacturing, automation upgrades, and modern human-machine interfaces (HMIs). Training programs further support workforce development and operational efficiency.

The 150-year milestone not only highlights ACE’s legacy of innovation but also its ongoing commitment to supporting modern manufacturers with equipment and practices that reduce downtime, improve safety, and drive productivity. As the forging industry continues to evolve, ACE aims to remain a trusted partner in advancing manufacturing excellence.

 

Read further here : www.AjaxErie.com 

Flawed fillers in polymers boost heat transfer

A team of researchers, led by the University of Massachusetts Amherst, made an important discovery in their quest to design the next generation of materials for modern devices—ones that are lightweight, flexible, and excellent at dissipating heat: imperfection has its upsides.

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New material gives copper superalloy-like strength

Researchers from the U.S. Army Research Laboratory and Lehigh University have developed a nanostructured copper alloy (Cu-Ta-Li) with exceptional thermal stability and mechanical strength, potentially redefining high-temperature materials for aerospace, defense, and industrial applications. This groundbreaking alloy is one of the most resilient copper-based materials ever created. The research, supported by a $25 million cooperative agreement and Lehigh’s Presidential Nano-Human Interfaces Initiative, highlights the decade-long partnership between Lehigh and ARL in advancing materials science.

“This is cutting-edge science, developing a new material that uniquely combines copper’s excellent conductivity with strength and durability on the scale of nickel-based superalloys,” said Martin Harmer, the Alcoa Foundation Professor Emeritus of Materials Science and Engineering at Lehigh and a co-author of the study. “It provides industry and the military with the foundation to create new materials for hypersonics and high performance turbine engines.”

The ARL and Lehigh researchers collaborated with scientists from Arizona State University and Louisiana State University to develop the alloy, which can withstand extreme heat without significant degradation.

This and other innovative alloys will continue to be studied in Lehigh’s newly outfitted high-tech research labs, the Nanoalloy Lab and Nanoceramics Lab, which include high-pressure torsion systems, nanoindentation equipment and specialized high-temperature furnaces.

The breakthrough comes from the formation of Cu₃Li precipitates, stabilized by a Ta-rich atomic bilayer complexion, a concept pioneered by the Lehigh researchers. Unlike typical grain boundaries that migrate over time at high temperatures, this complexion acts as a structural stabilizer, maintaining the nanocrystalline structure, preventing grain growth and dramatically improving high-temperature performance.

The alloy holds its shape under extreme, long-term thermal exposure and mechanical stress, resisting deformation even near its melting point, noted Patrick Cantwell, a research scientist at Lehigh University and co-author of the study.

By merging the high-temperature resilience of nickel-based superalloys with copper — which is known for exceptional conductivity — the material paves the way for next-generation applications, including heat exchangers, advanced propulsion systems and thermal management solutions for cutting-edge missile and hypersonic technologies.

This new Cu-Ta-Li alloy offers a balance of properties not found in existing materials:

  • Nickel-based superalloys (used in jet engines) are extremely strong but lack the high thermal conductivity of copper alloys.
  • Tungsten-based alloys are highly heat-resistant but dense and difficult to manufacture.
  • This Cu-Ta-Li alloy combines copper’s exceptional heat and electrical conductivity while remaining strong and stable at extreme temperatures.
  • While not a direct replacement for traditional superalloys in ultra-high temperature applications, it has the potential to complement them in next-generation engineering solutions.

The team synthesized the alloy using powder metallurgy and high-energy cryogenic milling, ensuring a fine-scale nanostructure. They then subjected it to:

  • 10,000 hours (over a year) of annealing at 800°C, testing its long-term stability.
  • Advanced microscopy techniques, revealing the Cu₃Li precipitate structure.
  • Creep resistance experiments, confirming its durability under extreme conditions.
  • Computational modeling using density functional theory (DFT), which validated the stabilizing role of the Ta bilayer complexion.

A project such as this takes years of careful work and collaboration, said Christopher Marvel ’12 ’16 Ph.D., an author of the paper and professor of mechanical engineering at Louisiana State University.

“Lehigh has such a strong reputation for electron microscopy, and that is what interested the ARL in working with us on this material. It was our microscopy that was really key to understanding the material,” said Marvel, who helped lead that portion of the research over a six-year period. “The Lehigh faculty have worked on many high-level research projects over the years, and they’ve all taught me different things that I apply now as an academic.”

The ARL was awarded a U.S. patent (US 11,975,385 B2) for the alloy, highlighting its strategic significance, particularly in defense applications like military heat exchangers, propulsion systems and hypersonic vehicles.

Further research will include direct measurements of the alloy’s thermal conductivity compared to nickel-based alternatives, work to ready it for potential applications, and the development of other high-temperature alloys following a similar design strategy.

For more information: Science

Image: This groundbreaking nanostructured copper alloy that could redefine high-temperature materials for aerospace, defense and industrial applications.

LIFT launches Advanced Metallic Production and Processing (AMPP)

LIFT, a Department of Defense-supported national advanced materials manufacturing innovation institute, has opened the Advanced Metallic Production and Processing (AMPP) Center in Detroit’s Corktown district. This facility will enhance the U.S. industrial base by accelerating the design, development, and deployment of novel metallic materials, addressing a critical gap in defense manufacturing. By producing metals across all alloy classes and processing them into high-quality feedstocks, AMPP will expedite materials development, particularly for additive manufacturing, ensuring manufacturers have access to essential materials for next-generation defense and commercial technologies.

Advanced materials are critical across industries. According to a recent report from Siemens Digital Industries Software, ”Innovation is key to the survival and growth of all companies. Product and materials inno­vation are closely linked, with product innovation relying on materials innovation by almost 70 percent. Therefore, it’s clear that developing new materials or innovative applica­tions of existing materials are of paramount importance for the manufacturing industry.”

This capability de-risks materials development investment for our domestic manufacturers and unlocks faster time to market and overall reduced cost of development.

A National Collaboration to Drive Innovation
The AMPP Center will serve as a hub for collaboration between LIFT’s nearly 400-member network and key industry stakeholders, including:
– Original Equipment Manufacturers
– Systems Manufacturers
– Materials Producers & Developers
– Application Developers & Part Manufacturers
– Academia & Startups

LIFT’s new Advanced Metallics Production and Processing Center exemplifies the mission of the Department of Defense’s Manufacturing Innovation Institutes: to close critical advanced manufacturing gaps in the U.S. defense industrial base and ensure we remain the strongest and most lethal force in the world,” said Keith DeVries, Director of Manufacturing Technology (ManTech) under the Office of the Under Secretary of Defense for Research and Engineering (OUSD(R&E)).

Advancing American Manufacturing & Security
Nigel Francis, CEO & Executive Director of LIFT, emphasized the importance of AMPP in maintaining America’s competitive edge:
“The pace of advanced manufacturing innovation is accelerating, and the development of novel materials is crucial to keeping the U.S. ahead of global competitors. With AMPP, we can now rapidly move new materials from concept to prototype, feasibility testing, and full-scale production—all within our borders. This capability is a game-changer for both our warfighters and manufacturers across industries.”

“A decade ago, we welcomed LIFT to Detroit to research and develop the next generation of advanced materials for commercial and defense uses,” said Mike Duggan, Mayor, City of Detroit. “This expansion into the production and processing of these materials demonstrates the success of their work and is a great example of how Detroit is very much a national center for innovation.”

Key Capabilities of the AMPP Center
– Low to Medium Volume Material Production
– Accelerated Material Delivery & Availability
– Toll Processing & Contract Manufacturing
– Domestic Production Through a Nonprofit Public-Private Partnership

Bringing Next-Generation Materials to Market and Scaling-Up Additive Manufacturing

As LIFT celebrates its 11th year as a national manufacturing innovation institute, it continues to expand its impact and technologies across the country, recently opening a facility in Puerto Rico and exploring new expansion opportunities.

For more information: LIFT

Exploring quantum materials for a new generation of technology

Today’s technology, from computer chips to camera image sensors, relies heavily on silicon semiconductors, which have been shrinking for decades. However, physical limitations will soon halt further advancements. Consequently, scientists and engineers are developing a new generation of technology based on quantum mechanics. Electrons in “quantum materials” exhibit unique behaviors, such as magnetism and superconductivity, which are crucial for future quantum technologies.

“Our piece of the puzzle is understanding how these materials function as a prerequisite for using them in engineering devices,” said Mark Dean, a physicist at the U.S. Department of Energy’s (DOE) Brookhaven National Laboratory and leader of the Dynamics and Control Group in Brookhaven’s Condensed Matter Physics and Materials Science Department.

Dean characterizes quantum materials using a technique called resonant inelastic X-ray scattering, or RIXS. RIXS is particularly suited for probing samples as thin as one atomic layer and material states that change very rapidly. And with recent technological developments, researchers expect this technique to enable studies that were unthinkable only five years ago.

This progress gave Dean and three colleagues — Matteo Mitrano, Steven Johnston, and Young-June Kim — the impetus to chart where the field is going as a whole. So, they summarized the technique’s state of the art and how they expect the field to progress in a Perspective paper.

For more information: Physical Review X

Image: The graphic illustrates an ultrabright X-ray striking a quantum material’s electrons (gray circles) and scattering off the sample. In this example, the X-ray’s energy change will provide insight into an electron property called spin, represented by the arrows. (Brad Baxley/Part to Whole LLC)

Scientists observe exotic quantum phase once thought impossible

Rice University researchers have directly observed a superradiant phase transition (SRPT), a quantum phenomenon predicted over 50 years ago, which could revolutionize quantum computing, communication, and sensing. This occurs when quantum particles fluctuate collectively without external triggers, forming a new state of matter. The discovery was made in a crystal of erbium, iron, and oxygen, cooled to minus 457°F and exposed to a magnetic field of up to 7 tesla.

“Originally, the SRPT was proposed as arising from interactions between quantum vacuum fluctuations — quantum light fields naturally existing even in completely empty space — and matter fluctuations,” said Dasom Kim, a Rice doctoral student in the Applied Physics Graduate Program who is a lead author on the study. “However, in our work, we realized this transition by coupling two distinct magnetic subsystems — the spin fluctuations of iron ions and of erbium ions within the crystal.”

Spin describes the magnetic poles of electrons or other particles and can be envisioned as a tiny arrow attached to each particle, constantly twirling and pointing in a given direction. When spins align, they create magnetic patterns across a material. When the pattern of spins ripples across the material like a wave, the resulting collective excitation is known as a magnon.

Until now, whether or not an SRPT could actually take place was subject to debate as it runs against a limitation — called “no-go theorem” in theoretical physics — arising in light-based systems. By staging an SRPT in a magnetic crystal based on the interactions between two spin subsystems, the researchers were able to get around this barrier, creating a magnonic version of the phenomenon. Specifically, the iron ions’ magnons play the role traditionally attributed to vacuum fluctuations, and the erbium ions’ spins represent matter fluctuations.

Using advanced spectroscopic techniques, the researchers observed unmistakable signatures of an SRPT, with the energy signal of one spin mode vanishing and another showing a clear shift or kink. These spectral fingerprints match exactly what theory predicts for entering the superradiant phase, giving the team high confidence that they had indeed coaxed the long-sought state into being.

“We established an ultrastrong coupling between these two spin systems and successfully observed a SRPT, overcoming previous experimental constraints,” Kim said.

Researchers are excited not just because a 50-year-old physics prediction has been confirmed but also because of what this could mean for quantum technology. Collective quantum states at the SRPT have unique properties that could be harnessed for next-generation quantum technologies.

“Near the quantum critical point of this transition, the system naturally stabilizes quantum-squeezed states — where quantum noise is drastically reduced — greatly enhancing measurement precision,” Kim said. “Overall, this insight could revolutionize quantum sensors and computing technologies, significantly advancing their fidelity, sensitivity and performance.”

Sohail Dasgupta, a graduate student at Rice working with Kaden Hazzard, associate professor of physics and astronomy, theoretically modeled the SRPT, building on a model developed by their collaborator and co-author Motoaki Bamba, a professor at Yokohama National University.

“Although the basic mathematical model was already laid out before by Motoaki, we needed to account for some of the specific magnetic properties of the material to obtain the precise results. When your theory matches the experimental data ⎯ which happens rather rarely ⎯ it is the best feeling for a scientist,” Dasgupta said.

Hazzard said the achievement shows that concepts from quantum optics can be translated into solid materials.

“This opens a new way to create and control phases of matter using ideas from cavity quantum electrodynamics,” Hazzard said.

Moreover, the crystal used in this study is one example of a broader class of materials, which means the research paves the way for exploring quantum phenomena in other materials with similarly interacting magnetic components.

For more information: Science Advances

Image: Dasom Kim (Photo by Jorge Vidal/Rice University)