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2003 TMS Annual Meeting & Exhibition: Special Programming Events
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Learn the latest technological improvements to enable you
to achieve greater production efficiency while reducing energy consumption.
Increasing energy prices offer manufacturers an excellent incentive to
improve productivity while decreasing production costs. Many times, making
a process more energy efficient involves utilizing waste heat or other
waste products, leading to a cleaner process as well. The goal of this
forum is to explore process improvements that result in energy savings
while producing an equal or better product with less waste. One obvious
target for improvement is processes involving melting and heating, but
all processes for shaping and forming raw materials into finished products
are also very energy intensive. This symposium will cover manufacturing
processes beginning at initial mineral extraction through packaging and
shipping strategies. Some materials are melted several times throughout
their processing cycle, and eliminating even one of these processes can
result in substantial savings. Even less obvious materials processes and
properties that can be improved for energy efficiency include wear, fatigue,
hot-cracking, and corrosion of surfaces in manufacturing equipment and
machine tools. Many such dies, rolls, cutting tools, and other equipment
must be repaired or replaced regularly, and an extension of their useful
life can be very cost effective and save significant energy. Near-net
shape and additive processes that reduce the need for machining certainly
increase energy efficiency as well. Manufacturing processes for metals,
ceramics, polymers, electronic materials, and composites are certainly
all available for improvements in energy efficiency, and all these materials
are used for manufacturing other products.
A special opening presentation to the 2003 Cast Shop Technology Symposium
Wednesday Evening, March 5, 2003, 6:00 PM – 8:00
Partnership Opportunities with the DOE-EERE Industrial Technologies
The NIST Advanced Technology Program (ATP) is a unique partnership between government and private industry to accelerate the development of high-risk technologies that promise significant commercial payoffs and widespread benefits for the economy. This presentation will describe the program, as well as provide examples of past and potential accomplishments/opportunities within ATP in the area of materials processing, including engineered surfaces, innovative forming techniques, joining, and other areas. Opportunities to work with the NIST Measurements and Standards Laboratories will also be described.
New Directions for the Air Force Ceramics Basic Research Program
Currently, renewed attention is focused on light-weight, high-temperature (>1500°C) resistant ceramics that may find applications in hypersonic aircraft and space structures. To facilitate their use, resistance to harsh environmental conditions must be improved. To this end, this program seeks to elucidate oxidation/reduction mechanisms of ceramic materials, with the goal of inhibiting environmental degradation. Moreover, the future of Air Force aerospace systems depends on the discovery of new and innovative ceramic materials that can address a myriad of environmental and operating conditions. To this end, ideas related to multifunctional ceramic materials will be a growing focus of the AFOSR Ceramic and Nonmetallic Materials Program over the next several years. The presentation will provide a general overview of currently funded projects within the portfolio and outline the future program emphasis.
Wednesday, March 5, 2:00 pm
This important session will examine what the Department of Defense has identified as R&D priorities in five classes of materials:
and how innovative management will also be needed to reduce risks in translating fundamental research into practical materials, and to promote cross-fertilization of scientific fields.
Tuesday, March 4, 8:30 am
This important event will present a series of updates and current research reports on projects, funded by the Department of Energy—Office of Information Technology and the aluminum industry, that seek to increase energy efficiency in the melting, casting, and processing of aluminum.
Two presentation highlights are expected to be:
Updating the Aluminum Industry Technology Roadmap
In 1997, under the leadership of The Aluminum Association Inc. and the U.S. Department of Energy, the aluminum industry developed the Aluminum Industry Technology Roadmap, a comprehensive, long-term technology agenda for the entire industry. The Roadmap outlined quantitative performance targets, technical barriers, and research and development needed to achieve industry goals for increasing productivity, reducing costs, expanding markets, saving energy, improving worker health and safety, and minimizing environmental impact. Over the past five years, the Roadmap and its five companion “sub-roadmaps” have stimulated over $100 million in cost-shared R&D projects with over 75 different organizations, including aluminum companies, suppliers, national laboratories, universities, and other research organizations. In November 2001, the aluminum industry published a new vision of its future. This vision, Aluminum Industry Vision: Sustainable Solutions for a Dynamic World outlines the new challenges that have emerged over the past five years and presents a bold vision of the industry’s future, including a new set of industry goals. To ensure technology development remains aligned with the industry’s vision, 50 representatives of aluminum companies, vendor companies, universities, national laboratories, and other researchers gathered in Pittsburgh, Pennsylvania in September 2002 to begin the process of updating the industry’s Roadmap. At the workshop, participants identified technical barriers and R&D priorities in four areas: primary production; melting, solidification, and recycling; fabrication; and finished products. The Aluminum Association’s Technical Advisory Committee has taken the lead responsibility in preparing and implementing this newly revised Roadmap.
Aluminum Research and Development
The Department of Energy - Industrial Technologies Program (DOE-OIT) is partnering with more than seventy organizations on over thirty research and development projects that reduce energy consumption and address research priorities identified in the Aluminum Industry Technology Roadmap. DOE-OIT will present an overview of its Aluminum R&D portfolio, covering technical progress, expected benefits, demonstration status, and market impacts. DOE- OIT’s focus is energy reduction and it uses technology roadmaps to ensure that its R&D programs address the industry’s energy needs. DOE-OIT recently participated in the development of an Alumina Technology Roadmap and will publish a new Aluminum Industry Technology Roadmap by the end of 2002 that will reexamine the technology needs outlined in the 1997 Roadmap and identify new needs based on changes to the industry. DOE-OIT will also present how roadmaps influence R&D priorities
Additional presentations include:
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