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Amazing New Materials and Their Future Uses

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AMAZING NEW MATERIALS AND THEIR FUTURE USES COMPILED BY HOWIE BAUM AN INTRODUCTION TO THE DIFFERENT TYPES OF MATERIALS • Materials used in the design and manufacture of products • Plastics • Wood • Composites • Ceramics • Metals • Fabrics Linen,LayersTungstenBalsaSteel, cotton, ofAcrylic polycarbonate, wood carbidealuminium nylon,lens model tool Kevlar bit aluminium & acrylic Classification of Materials (Metals) •Metals can be further classified as Non- Ferrous (without iron) (shown first) and Ferrous (with iron) HighStainlessAluminium CopperSpeedBrass Steel steel Ferrous Non-Ferrous Steels Aluminium Stainless Steels Copper High Speed Steels Brass (Copper & Zinc) Cast Irons Titanium Stainless Steel Steel is alloyed with chromium (18%) and nickel (8%) (which is why sometimes, it is called 18-8 stainless steel. It won’t rust because of the outer layer of Chromium oxide ! Hard and tough Corrosion resistant Comes in different grades Sinks, cooking utensils, surgical instruments The most popular form is Type 304 stainless steel. 6 The 630-foot high, stainless-clad (type 304) Gateway Arch defines St. Louis's skyline. “CLOUD GATE” aka THE BEAN, IN CHICAGO It is made up of 168 stainless steel plates (Type 304) welded together and its highly polished exterior has no visible seams. It measures 33 by 66 by 42 feet (10 by 20 by 13 meters) and weighs 110 tons !! The outside skin of the DeLorean car (Back to the Future model shown) was also made of Type 304 stainless steel !! The operating flux capacitor from the DeLorean used in the movies “Back to the Future” !! NON-FERROUS METALS MOST METAL ZIPPERS ARE MADE OF ALUMINUM !! EXTRUSION OF ALUMINUM AND OTHER METALS Extrusion is a manufacturing process where a material, often in the form of a billet, is heated to about 900 degrees F and then it’s pushed and/or drawn through a die to create long objects of a fixed cross-section. What kind of foods are extruded? Chalk or Marker tray Extrusion has found a great application in Food Processing. Various products like pastas, breakfast cereals, hot dogs, ready to eat snacks, cookies like Fig Newtons, etc. are now manufactured by extrusion. Pasta Extrusion Methods GUMMI-BEARS MACARONI LITHIUM CARBONATE FOR BIPOLAR DISORDER LITHIUM BATTERIES, AND GREASE ZrOC ZrOC is a new coating technique using the physical vapor deposition method (PVD) in which a mixture of zirconium, oxygen, and carbon can be deposited on metal, plastic, wood, glass, or textiles. Depending on how those elements are mixed, you can get chrome in any color you choose. DISSOLVABLE, MAGNESIUM NERVE REGENERATION DEVICE An implantable, biodegradable wireless device that speeds nerve regeneration and improves healing of a damaged nerve. The device is the size of a dime and the thickness of a sheet of paper and dissolves in the body after about two weeks. https://www.youtube.com/watch?time_continue=38&v=BoOlL5LPb7o 1 minute Magnesium metal foams or 3D printed porous shapes can be formed into patient specific scaffolds, for bone regeneration. Over time, the bone grows into the scaffold and the Magnesium slowly dissolves away, which can eliminate the need for secondary removal surgeries. Magnesium alloys (mixtures) such as 98% magnesium and 2% calcium, have better mechanical properties and corrosion resistance, than pure magnesium by itself. PLASTICS Classification of Materials (Plastics) •Plastics can be further classified as; •Thermoplastic (melt when heated) •Thermoset (don’t melt) •Elastomers Thermoplastics Thermosets Elastomers Acrylics Epoxy resins Rubbers Nylons Phenolic Silicones PhenolUrea formaldehyde formaldehyde Poly Vinyl Chloride Polyesters PVCPolyurethanesPolyethylene gutters Polyethylene Rubber Polymeric Materials in Everyday Life 22 PLASTIC UNBREAKABLE BRICKS FROM RECYCLED PLASTIC 29-year-old Kenyan inventor Nzambi Matee is turning tons of plastic trash into super durable, lightweight bricks that cost a tenth of the price of normal bricks. Plastic materials that can’t be normally recycled are shredded, mixed with sand, put through a high- temperature extrusion machine that makes it into a slurry, and then compressed into beautiful, colorful bricks. https://www.youtube.com/watch?v=xUw2U8PB6EY 1.5 min REPLAST RECYCLED PLASTIC BLOCKS A new startup called ByFusion created an eco-friendly way to repurpose collected ocean plastic permanently, in the form of construction blocks called RePlast. Classification of Materials (Wood) • Wood can be further categorized as; • Hardwood • Softwood • Manufactured board ChipboardCedarMahoganyBeechOakAshPlywood with Veneer Hardwood Softwood Manufactured Board Oak Pine Plywood Ash Cedar Blockboard Beech Fir Medium Density Fiberboard Sycamore Spruce Melamine board 4D PRINTING OF PROGRAMMABLE WOOD MATERIAL Novel printing and composite material technologies can now overcome prior limitations of wood forming. Flat sheets of custom printed wood composite can be designed to self- transform in controlled and unique ways. https://www.youtube.com/w atch?v=3pMPWdQf-Mk 1 minute REWALL CEILING TILES They are made from recycled beverage containers–a mixture of cardboard, plastic bottles, and aluminum. The result is a material that has the same structural integrity as wood strand board and can be cut and screwed into like wood. It has much better resistance to moisture, so it can be used as a ceiling tile and exposed to the elements. WOOD SPONGE It is made by using chemicals to remove hemicellulose and lignin, which leaves just a porous piece of cellulose. It is a reusable, oil- wicking sponge made of wood that can absorb more than 40 times their weight in oil, to deal effectively with oil spills. It has a waterproof coating on it so it https://www.youtube.com/watch? can just absorb oils and not water. v=3JqiSrMflN4&t=15s Go to 1.39 Classification of Materials (Composites) • A composite is a combination of two or more chemically distinct materials (usually a fibrous material and a liquid resin) whose physical characteristics are superior to its constituents acting independently. • Because of their high strength/stiffness to weight ratio they are widely used in the: •Aerospace industry •Offshore structures •Boats •Sporting goods Classification of Materials (Composites) The 4 Types of composites include: • Reinforced Plastics • Ceramic-matrix • Metal-Matrix • Laminates OuterCarbonCombustionKevlar, skinGlassThrust reinforced panels Cylinder taffetaCylinderreinforced chamberchamber & polyesterplasticfuselage liningslinings plasticoffor jet rocket A380sailsengine hull Fiberglass molding method by spraying chopped glass fibers and mixing them with Polyester resin to form a strong laminate. METAL MATRIX COMPOSITES High temperature fibers dispersed in metal materials FIBER METAL LAMINATES GLARE: “GLAss-REinforced” Fiber Metal Laminate (FML), composed of several very thin layers of metal (usually aluminum) interspersed with layers of glass-fiber “pre-impregnated with resin, bonded together with a matrix such as epoxy. ARALL: Abbreviation for Aramid (Kevlar) aluminum laminate. Composite produced by adhesively bonding sheets of isotropic high- strength aluminum and tough aramid (Kevlar) fibers. The aluminum provides higher strength isotropic properties and metal- forming qualities to the composite laminate while the aramid (Kevlar) fiber supplies fatigue and fracture resistance. USE OF GLARE CERAMIC COMPOSITES: A brake disc (or rotor in U.S. English), usually made of cast iron or ceramic composites (including carbon, kevlar and silica), is connected to the wheel and/or the axle. Silicon Carbide Whisker-Reinforced Ceramic Composites FIBER MATERIALS USED FOR REINFORCEMENT IN PLASTIC COMPOSITES (KEVLAR) CARBON FIBER PARTS !! CARBON FIBER CELLO FIXED WING AIRCRAFT WITH MORPHING FLAPS FlexFoil™ adaptive control surfaces represent a major improvement over conventional aircraft flaps. By exploiting the natural elasticity of aviation grade materials, the FlexFoil™ control surface changes the angle of a wing during flight, by using small electric motors to change the flap shape. BIO-COMPOSITES • Bio-composites combine plant fibers with biodegradable resins to create natural based composite materials. BIODEGRADEABLE COMPOSITES Nearly all of the current types of Composites can’t be recycled or reused. The items shown are made with fibers from the Nettle plant which are very strong. Nettle fiber is from the stem of 3 types of plants - European nettle, Ramie, and Himalayan nettle, which is similar to flax. They can be mixed with Polylactic acid (PLA) resin, made from corn starch, to form a composite that is biodegradable. Classification of Materials (Ceramics) • Ceramics are compounds of non-metallic elements, examples include; •Oxides (alumina – insulation and abrasives, zirconia – dies for metal extrusion and abrasives, sandpaper •Carbides (tungsten-carbide tools) •Nitrides (cubic boron nitride, 2nd in hardness to diamond) Engine Products Kyocera engine products include cam rollers, turbocharger rotors, glow plugs, cylinder liners, seals, pistons, piston pins, valve and valve guides, fuel injection parts and various custom made components made from a wide selection of advanced ceramic materials. Ceramic Piston Ceramic Seal Head and Assembly Rings Ceramic Cam Ceramic Roller Turbocharger Rotor SILICON NITRIDE BALL AND OTHER TYPES OF BEARINGS CERAMIC COATINGS TIN-NITRIDE CHROMIUM NITRIDE TITANIUM ALUMINIDE CERAMIC KNIVES KYOCERA KITCHEN KNIFE CONCRETE It is one of the most frequently used building materials around the world. Ton for ton, its use is twice that of steel, wood, plastics,
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