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Strategic Marketing Innovations, Incorporated Overview of the Advanced Ceramics Industry in the United States John E. Holowczak Chair, United States Advanced Ceramics Association Associate Director – Advanced Materials United Technologies Research Center Glen Mandigo and Doug Freitag, USACA 1020 Nineteenth St. NW Suite 375 Washington, D.C. 20036 This document does not contain any export controlled technical data. Introduction to USACA Established in 1985 to promote the research, development, and application of advanced ceramics 38 member companies and organizations USACA works to promote advanced ceramic materials, disseminate information about the materials, and interface with the U.S. government on behalf of the industry. Members advise federal agencies through technology roadmaps and conferences. Active technology roadmaps include: Advanced Ceramics Technology Roadmap, 2001 Advanced Ceramics for Distributed Energy, 2004 Ceramic Composites Affordability and Producibility Initiative, 2009 Transparent Ceramic Armor Producibility Roadmap, 2013 Transparent Ceramic Sensor Windows Roadmap, 2017 Ceramic Composites Affordability and Producibility Roadmap update, 2016 2 This page does not contain any export controlled technical data. What are Advanced Ceramics Lightweight, strong materials capable of performing in extreme environments: High Temperature and Pressure High Stiffness and Durability Ultra Hard & Tough Surface Not This! 3 This page does not contain any export controlled technical data. Membership Across the Supply Chain Design/Stds/ Raw Test & Research Fabrication Machining QC Integration Databases Materials Evaluation Rutgers UDRI GE GE NCDMM CeraNova UDRI Applied Materials UDRI SoRI COI Ceramics COI Ceramics PSI UDRI SoRI GE Alfred MR&D CeraNova CeraNova Bullen P&W Johns Hopkins Exothermics Boeing CoorsTek Rolls Royce Missouri S&T Specialty Materials Saint Gobain MillenniTek Raytheon Free Form Fibers PSI Boeing Lithoz America II-VI Westinghouse MATECH Composite Horizons Starfire Ceramic Tubular Products Harper CoorsTek Advanced Ceramic Lancer Systems Fiber Lithoz America Axiom Materials Raytheon ATC Materials Rolls Royce Applied Thin Films United Technologies Westinghouse Kyocera Harper Advanced Thin Films Triton Systems MillenniTek ATC Materials This page does not contain any export controlled technical data. 4 Comparison of Ceramics Focused and Related Organizations Japan Fine Ceramics Association U.S. Advanced Ceramics Assoc. Promote Fine Ceramics Promote Advanced Ceramics Develop Standards and Research Projects Advise Federal Agencies Cooperate Government & Industry Interface with U.S. Government Ceramic Society of Japan American Ceramic Society New Energy & Industrial Tech. U.S. Dept of Energy (METI -> NEDO) Acquisition, Technology U.S. Dept. of Defense & Logistics Agency (ATLA) This page does not contain any export controlled technical data. 5 USACA Leadership John Holowczak, United Technologies, Chair Tom Nixon, Rolls Royce, Vice Chair Craig Iwano, MR&D, Treasurer Andy Thomas, Coorstek, Secretary Glen Mandigo, Executive Director Doug Freitag, Technical Director 1020 Nineteenth St. NW Suite 375 Washington, D.C. 20036 This page does not contain any export controlled technical data. 6 Primary Activities (Excluding Conference Hosting) Two meetings per year in Washington, DC focused on federal programs of interest to the ceramics industry. Working Groups: Nuclear Materials Working Group Transparent Ceramics Working Group CMC Working Group Workforce Development Working Group Current and planned initiatives: Support DOE Accident Tolerant Fuels program for development and qualification of ceramic cladding Increase federal funding for High Temperature CMCs consistent with recommendations in the USACA CMCs for Advanced Gas Turbines Roadmap for CMC manufacturing. 1020 Nineteenth St. NW Suite 375 Washington, D.C. 20036 This page does not contain any export controlled technical data. 7 U.S. Agencies Funding Advanced Ceramics Department of Defense ($3-4 billion) Materials R&D and system development programs under Air Force, Army, Navy, and Defense Wide Department of Energy ($250-300 million) Materials and applications development for nuclear, fuel cell, gas turbine, and renewable energy NASA ($400-500 million) Materials R&D, Aeronautics, Space Exploration FAA ($25-35 million) Databasing (including CMH-17 Handbook development), flight certification, component demonstrations 8 This page does not contain any export controlled technical data. USACA Dept. of Defense Priorities Materials in extreme dynamic environments Energy efficient/increased performance gas turbine propulsion technologies High-speed strike weapon technologies Transparent armor for ground, air, sea vehicles Electro-optic/radar transparencies for sensor windows Defense Production Act Title III/ManTech 9 This page does not contain any export controlled technical data. USACA NASA Program Priorities Hypersonic Technology Aeronautics Space Exploration SLS and Orion Commercial Space 10 This page does not contain any export controlled technical data. USACA Dept. of Energy Program Priorities Accident Tolerant Fuels Advanced Turbines Solid Oxide Fuel Cells Concentrating Solar Harsh and Extreme Environment Materials 11 This page does not contain any export controlled technical data. Transparent Ceramics Working Group Developing roadmaps for use by DoD and Industry with the goals of delivering more affordable and capable transparent ceramic armor and sensor windows Participates from throughout the supply Electro-Optical Targeting System chain with leadership from key (EOTS) for F-35 manufacturers and end users. Technical challenges identified in feedstocks, shape forming, secondary processes, modeling and simulation and materials and component level characterization 1020 Nineteenth St. NW Suite 375 Naval Carrier Transparent Armor Washington, D.C. 20036 This page does not contain any export controlled technical data. 12 Workforce Development Working Group Focuses on enhancing communication and foster collaboration among industry, academia, and government, supporting recruitment and training efforts in fields enabled by advanced ceramics and composite materials. David Lipke from Missouri S&T, Rich Haber from Rutgers University are Co-Chairs of the working group. Recommends best practices and strategies for increasing quantity and quality of prospective workforce participants Outreach to students via the student page program at the annual Composites, Materials, and Structures Conference. This page does not contain any export controlled technical data. 13 Nuclear Materials Working Group Established to work with US Department of Energy and Congress to advance ceramic materials for nuclear energy applications. Ed Lahoda from Westinghouse, and Herb Feinroth from Ceramic Tubular Products are Co-Chairs of the working group. Supporting Department of Energy (DOE) and the nuclear power industry to develop and qualify ceramics for fuel rods and channel boxes as a safer and better performing alternative material to zirconium metal. Activities include advice to DOE on ceramic materials and manufacturing capabilities, and supporting Accident Tolerant Fuels program with the Department of Energy budget. This page does not contain any export controlled technical data. 14 CMC Working Group Established to create industry driven roadmaps for use in driving investment by DoD, DOE, NASA and Industry with the goals of delivering more affordable, producible and capable CMCs for use in aeropropulsion, aerostructure and stationary power generation. Boeing 787 CMC Exhaust Nozzle Participates from throughout the supply chain with leadership from key manufacturers and end users. Common technical challenges identified in raw materials, shape forming, secondary processes, attachments, materials characterization, databases, design tools, and sustainment. GE Leap Gas Turbine Shrouds This page does not contain any export controlled technical data. 15 CMC Working Group Why the Need for New Materials? Gas-inlet temperature (ºF) The National Academy of Sciences, Engineering, and 1500 2000 2500 3000 3500 4000 Medicine recently completed a study on Commercial Aircraft Propulsion and Energy Systems Research and concluded that additional Impact of 2700ºF CMC investment in gas turbine engine materials and coatings should be a high priority. "2700ºF uncooled materials are required to achieve future targets for gas turbine performance, efficiency and emissions.” Adapted from a) Nature Materials, V15, 8/16 and b) NAS Commercial Aircraft Propulsion and Energy Systems No comparable study on Research: Reducing Global Carbon Emissions, 2016. power gen This page does not contain any export controlled technical data. 16 CMC Working Group Industry Contributors Systems Components Materials, Machining, Test, Design, Equipment Research Working group includes OEM’s developing new materials for system level cost, performance, and reliability, the supply chain supporting development of new materials, and academia and National Labs creating fundamental knowledge of new material behavior. This page does not contain any export controlled technical data. 17 CMC Working Group - Summary Broad government / industry consensus that higher temperature CMCs offer the potential for large capability improvements and economic benefits – our immediate challenge is to quantify them. The High Temperature CMC Initiative aggressively attacks the major risk elements needed for successful development, certification, and acquisition.
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