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Intermetallic Alloy Development: A Program Evaluation
INTERMETALLIC ALLOY DEVELOPMENT
A Program Evaluation
Panel on Intermetallic Alloy Development
Committee on Industrial Technology Assessments
National Materials Advisory Board
Commission on Engineering and Technical Systems
National Research Council
Publication NMAB-487-1
NATIONAL ACADEMY PRESS
Washington, D.C. 1997
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Intermetallic Alloy Development: A Program Evaluation
NOTICE: The project that is the subject of this report was approved by the Governing Board of the National Research Council, whose members are drawn from the councils of the National Academy of Sciences, the National Academy of Engineering, and the Institute of Medicine. The members of the committee responsible for the report were chosen for their special competences and with regard for appropriate balance.
This report has been reviewed by a group other than the authors according to procedures approved by a Report Review Committee consisting of members of the National Academy of Sciences, the National Academy of Engineering, and the Institute of Medicine.
The National Academy of Sciences is a private, nonprofit, self-perpetuating society of distinguished scholars engaged in scientific and engineering research, dedicated to the furtherance of science and technology and to their use for the general welfare. Upon the authority of the charter granted to it by the Congress in 1863, the Academy has a mandate that requires it to advise the federal government on scientific and technical matters. Dr. Bruce M. Alberts is president of the National Academy of Sciences.
The National Academy of Engineering was established in 1964, under the charter of the National Academy of Sciences, as a parallel organization of outstanding engineers. It is autonomous in its administration and in the selection of its members, sharing with the National Academy of Sciences the responsibility for advising the federal government. The National Academy of Engineering also sponsors engineering programs aimed at meeting national needs, encourages education and research, and recognizes the superior achievements of engineers. Dr. William A. Wulf is interim president of the National Academy of Engineering.
The Institute of Medicine was established in 1970 by the National Academy of Sciences to secure the services of eminent members of appropriate professions in the examination of policy matters pertaining to the health of the public. The Institute acts under the responsibility given to the National Academy of Sciences by its congressional charter to be an adviser to the federal government and, upon its own initiative, to identify issues of medical care, research, and education. Dr. Kenneth I. Shine is president of the Institute of Medicine.
The National Research Council was organized by the National Academy of Sciences in 1916 to associate the broad community of science and technology with the Academy's purposes of furthering knowledge and advising the federal government. Functioning in accordance with general policies determined by the Academy, the Council has become the principal operating agency of both the National Academy of Sciences and the National Academy of Engineering in providing services to the government, the public, and the scientific and engineering communities. The Council is administered jointly by both Academies and the Institute of Medicine. Dr. Bruce M. Alberts and Dr. William A. Wulf are chairman and interim vice chairman, respectively, of the National Research Council.
This study by the National Materials Advisory Board was conducted under Grant No. DE-FG41-95R110859 with the U.S. Department of Energy. Any opinions, findings, conclusions, or recommendations expressed in this publication are those of the author(s) and do not necessarily reflect the view of the organizations or agencies that provided support for the project.
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Cover: Scanning electron micrograph of a grain boundary in a weld of Ni3Al alloy. The two-phased, γ+γ', microstructure of the matrix is apparent. A particle of Ni-Ni5Zr eutectic is located on the grain boundary. Courtesy of Oak Ridge National Laboratory.
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Intermetallic Alloy Development: A Program Evaluation
PANEL ON INTERMETALLIC ALLOY DEVELOPMENT
NORMAN A. GJOSTEIN (chair),
NAE, materials engineering consultant, Dearborn, Michigan
JOHN V. BUSCH,
IBIS Associates, Wellesley, Massachusetts
TIMOTHY E. HOWSON,
Wyman-Gordon Company, North Grafton, Massachusetts
LYMAN A. JOHNSON,
GE Aircraft Engines, Cincinnati, Ohio
HARRY A. LIPSITT,
Wright State University, Dayton, Ohio
ANATOLY NEMZER,
FMC Corporation, Princeton, New Jersey
MAXINE L. SAVITZ,
NAE, AlliedSignal Aerospace Corporation, Torrance, California
National Materials Advisory Board Staff
THOMAS E. MUNNS, Senior Program Officer
AIDA C. NEEL, Senior Project Assistant
BONNIE SCARBOROUGH, Research Associate
National Materials Advisory Board Liaison
KATHLEEN C. TAYLOR,
NAE, General Motors Corporation, Warren, Michigan
Government Liaison
CHARLES SORRELL,
U.S. Department of Energy, Washington, D.C.
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Intermetallic Alloy Development: A Program Evaluation
COMMITTEE ON INDUSTRIAL TECHNOLOGY ASSESSMENTS
R. RAY BEEBE (chair),
NAE, consultant, Tucson, Arizona
GARY A. BAUM,
Institute of Paper Science and Technology, Atlanta, Georgia
PHILIP H. BRODSKY,
Monsanto Company, St. Louis, Missouri
JOHN V. BUSCH,
IBIS Associates, Wellesley, Massachusetts
NORMAN A. GJOSTEIN,
NAE, materials engineering consultant, Dearborn, Michigan
FRANCIS C. McMICHAEL,
Carnegie-Mellon University, Pittsburgh, Pennsylvania
MAXINE L. SAVITZ,
NAE, AlliedSignal Aerospace Corporation, Torrance, California
National Materials Advisory Board Staff
THOMAS E. MUNNS, Senior Program Officer
AIDA C. NEEL, Senior Project Assistant
BONNIE SCARBOROUGH, Research Associate
National Materials Advisory Board Liaison
KATHLEEN C. TAYLOR,
NAE, General Motors Corporation, Warren, Michigan
Government Liaisons
DENISE SWINK,
U.S. Department of Energy, Washington, D.C.
JAMES E. QUINN,
U.S. Department of Energy, Washington, D.C.
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Intermetallic Alloy Development: A Program Evaluation
NATIONAL MATERIALS ADVISORY BOARD
ROBERT A. LAUDISE (chair),
NAS/NAE, Bell Laboratories, Lucent Technologies, Murray Hill, New Jersey
G.J. ABBASCHIAN,
University of Florida, Gainesville
JAN D. ACHENBACH,
NAS/NAE, Northwestern University, Evanston, Illinois
MICHAEL I. BASKES,
Sandia/Livermore National Laboratories, Livermore, California
JESSE L. BEAUCHAMP,
NAS, California Institute of Technology, Pasadena
EDWARD C. DOWLING,
Cyprus Amax Minerals Company, Englewood, Colorado
FRANCIS DISALVO,
NAS, Cornell University, Ithaca, New York
ANTHONY G. EVANS,
Harvard University, Cambridge, Massachusetts
JOHN A. S. GREEN,
The Aluminum Association, Washington, D.C.
JOHN H. HOPPS,
Morehouse College, Atlanta, Georgia
MICHAEL JAFFE,
Hoechst Celanese Corporation, Summit, New Jersey
SYLVIA M. JOHNSON,
SRI International, Menlo Park, California
LIONEL C. KIMERLING,
Massachusetts Institute of Technology, Cambridge
HARRY A. LIPSITT,
Wright State University, Dayton, Ohio
RICHARD S. MULLER,
NAE, University of California, Berkeley
ELSA REICHMANIS,
NAE, Bell Laboratories, Lucent Technologies, Murray Hill, New Jersey
KENNETH L. REIFSNIDER,
Virginia Polytechnic Institute and State University, Blacksburg
EDGAR A. STARKE,
University of Virginia, Charlottesville
KATHLEEN C. TAYLOR,
NAE, General Motors Corporation, Warren, Michigan
JAMES WAGNER,
Johns Hopkins University, Baltimore, Maryland
JOSEPH WIRTH,
Raychem Corporation, Menlo Park, California
BILL G. W. YEE,
Pratt and Whitney, West Palm Beach, Florida
ROBERT E. SCHAFRIK, Director
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Intermetallic Alloy Development: A Program Evaluation
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Intermetallic Alloy Development: A Program Evaluation
Acknowledgments
The hospitality of the employees of Martin Marietta Energy Systems at Oak Ridge National Laboratories during the panel's site visit and their time and effort in meetings and presentations are greatly appreciated. Individuals who prepared presentations or conducted laboratory tours include Bill Appleton, Jim Stiegler, Linda Horton, C. T. Liu, Vinod Sikka, Mike Santella, Rod Judkins, Peter Angelini, and Larry Dickens, Mike Miller, Kathi Alexander, Joe Horton, and Cam Hubbard.
The panel on Intermetallic Alloy Development acknowledges Gary Hudson of United Defense LP/Steel Products Division, Jim Farago of General Motors Delphi Saginaw Steering Systems, and John Rogers of Sandusky International for providing an industrial perspective of the commercial potential of intermetallic alloys.
The panel is particularly grateful to Charles Sorrel and James Quinn of the Department of Energy Office of Industrial Technology and Peter Angelini of the Oak Ridge National Laboratory for assistance in conducting the meeting at Oak Ridge, Tennessee.
Finally, the panel gratefully acknowledges the support of Thomas E. Munns, National Materials Advisory Board (NMAB) senior program officer, Aida C. Neel, NMAB senior project assistant, and Bonnie Scarborough, NMAB research associate.
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Intermetallic Alloy Development: A Program Evaluation
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Intermetallic Alloy Development: A Program Evaluation
Preface
The Department of Energy Office of Industrial Technology (OIT) requested that the National Research Council, through the National Materials Advisory Board (NMAB), conduct a study to evaluate the OIT program strategy, to provide guidance during the transition to the new Industries of the Future strategy, and to assess the effects of the change on crosscutting technology programs. The Committee on Industrial Technology Assessments (CITA) was established to review and evaluate the program and plans of the overall OIT program, to review the plans and progress of selected OIT-sponsored research programs, and to conduct site visits and laboratory evaluations, when appropriate, to supplement program assessments. In the future, the committee will establish and oversee topical panels to review selected aspects of the program, conduct the site visits, and bring in additional members with expertise in the topical areas to be evaluated.
The purpose of the panel on Intermetallic Alloy Development, the first topical panel established under CITA, was to document and evaluate the progress of the Oak Ridge National Laboratory (ORNL) toward the development and commercialization of high temperature intermetallic alloys, to identify industrial applications and barriers to commercialization, and to recommend criteria for selecting and prioritizing future research projects. This topic was selected because the intermetallic alloy program is a mature program focused on crosscutting research and development projects.
The ORNL intermetallic alloy development program is a long-term, collaborative R&D program involving various Department of Energy program offices, including Basic Energy Sciences (BES), which sponsors fundamental research, and Fossil Energy (FE) and Energy Efficiency (EE), which sponsor applied
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Intermetallic Alloy Development: A Program Evaluation
research and development programs. The objective of the ORNL intermetallics program has been to develop high strength, ductile, intermetallic alloys that can be processed and utilized for high-temperature structural applications.
The panel met with key ORNL researchers, program managers, and industrial participants on June 6 and 7, 1996, at Oak Ridge, Tennessee, to discuss progress and plans, review program strategies and accomplishments, and tour the laboratory facilities. This report reviews and assesses the intermetallic alloy development program and offers recommendations for the focus of the program in the future, as well as assessing the implications of the lessons learned for the entire OIT program strategy.
The chair thanks the panel members for their efforts, dedication, and patience during the preparation of the report and the staff of the NMAB for their assistance in the publication of the panel's report. The diligence and goodwill of all who were involved made for an unusually effective team effort.
Comments and suggestions can be sent via Internet electronic mail to nmab@nas.edu or by FAX to the NMAB (202) 334-3718.
Norman a. Gjostein, chair
Panel on Intermetallic Alloy Development
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Intermetallic Alloy Development: A Program Evaluation
Contents
EXECUTIVE SUMMARY
1
1
INTRODUCTION
7
Committee on Industrial Technology Assessments
8
Panel on Intermetallic Alloy Development
8
2
OAK RIDGE NATIONAL LABORATORY INTERMETALLICS PROGRAM
10
History of Program Management
11
Technical Progress and Accomplishments
16
Interactions with Industry
21
Conclusions
28
References
30
3
PROGRAM STRATEGIES
32
Identifying and Prioritizing Projects
32
Balancing Industry-Focused and Crosscutting Programs
34
Metrics for Selecting and Prioritizing Projects
34
Commercialization
35
References
38
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Intermetallic Alloy Development: A Program Evaluation
4
CONCLUSIONS AND RECOMMENDATIONS
39
Prioritization and Metrics
40
Focus for the Research and Development Program
41
Implications for the Office of Industrial Technology Program
42
APPENDICES
A MEETING AGENDA
47
B BIOGRAPHICAL SKETCHES OF PANEL MEMBERS
50
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Intermetallic Alloy Development: A Program Evaluation
Tables and Figures
TABLES
1-1
Status of IOF Vision Documents,
9
2-1
Ni3Al Alloy Compositions,
18
FIGURES
1-1
Manufacturing energy use (1991),
8
2-1
Profile of funding (in then-year dollars) by Basic Energy Sciences (BES), Energy Efficiency (EE), and Fossil Energy (FE) offices of DOE,
12
2-2
Time line of program management and interactions,
13
2-3
Integration of research projects and mechanisms for technology transfer,
14
2-4
Mechanical properties of cast Ni3Al based alloys (IC-221M and IC-396M) and Fe-Ni-Cr steel alloy as a function of test temperature,
19
2-5
Cast and welded Ni3Al transfer roll,
24
2-6
Ni3Al carburizing grids,
25
3-1
Phases and activities in the commercialization process,
37
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Intermetallic Alloy Development: A Program Evaluation
Acronyms
AECC
Alloy Engineering and Casting Company
AIM
Advanced Industrial Materials
BES
Basic Energy Sciences
CITA
Committee on Industrial Technology Assessments
CRADA
cooperative research and development agreement
DOE
Department of Energy
ECUT
Energy Conversion and Utilization
EE
Energy Efficiency
FE
Fossil Energy
IOF
Industries of the Future
NRC
National Research Council
NMAB
National Materials Advisory Board
OD
outer diameter
OIT
Office of Industrial Technology
ORNL
Oak Ridge National Laboratory
UDLP
United Defense LP/Steel Products Division
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