Materials Australia Magazine | December 2023 | Volume 56

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CONTENTS

Reports Contents

From the President

Corporate Sponsors

Advertisers

MISE2023

Materials Australia News QLD Branch Report

CAMS2024

WA Branch Reports

VIC Branch Report

NSW Branch Report

Profile: Minh Nhat Dang Swinburne University of Technology, SEAM

CMatP Profile: Dr Jeff Gates

Our Certified Materials Professionals (CMatPs)

Why You Should Become a CMatP

Prof Julie Cairney awarded the Florence M. Taylor Medal

Industry News

Wearable Device Makes Memories and Powers Up with the Flex of a Finger

Smaller Lighter Lithium-Sulphur Battery Lowers Costs and Improves Recycling Options

Characterising Advanced Battery Anodes with Gas Adsorption Bet Surface Area and DFT Surface Energy

Generative Artificial Intelligence (AI) Opens New Territories in Material Science

Energy Materials Conference 2024

UQ Home to Australia’s First Superconducting Quantum Hardware Startuphy

Custom Metal Powder Production Using Ultrasonic Atomisation

Promising Material Provides a Simple Effective Method Capable of Extracting Uranium from Seawater

University Spotlight – La Trobe University

Breaking News

Feature – Virtual Reality in Manufacturing

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42 DECEMBER 2023 | 3

MATERIALS AUSTRALIA

From the President of materials science and technology. Together, we have accomplished significant milestones and strengthened the bonds within our community, both locally and globally. As my term concludes, I reflect with immense pride on the strides Materials Australia has made. Your passion for innovation and commitment to excellence have defined our collective journey. Together, we’ve navigated some incredibly complex challenges, embraced emerging technologies, and forged enduring connections within our diverse community. The collaborative spirit that permeates our technical society is a testament to your expertise and dedication. Welcome to the December 2023 edition of Materials Australia. The year is quickly drawing to a close, as is my tenure as President of Materials Australia—this is my final President’s Message. It has been a fantastic opportunity for me to serve as President over the past three and a half years. As mentioned at the recent AGM, at the end of 2023, I will be stepping down from the role as National President and moving to the role of Past President. It’s been an amazing experience for me to take on this role and see the organisation move from strength to strength. Serving as the President of Materials Australia has been an incredibly rewarding experience. I have had the privilege of working with a dedicated and talented group of individuals who share a passion for advancing the field

MANAGING EDITOR Gloss Creative Media Pty Ltd EDITORIAL COMMITTEE Prof. Ma Qian RMIT University Dr. Jonathan Tran RMIT University Tanya Smith MATERIALS AUSTRALIA

4 | DECEMBER 2023

I extend my heartfelt gratitude to each member for contributing to the success of our organisation. I am confident that Materials Australia members will continue to be at the forefront of technological advancement. I would also like to thank my employer, AWBell, for their sustained support throughout my term, enabling me to actively contribute to Materials Australia. From 1 January 2024, Professor Nikki Stanford, CMatP, (Dean of Programs, Engineering and Aviation at The University of South Australia) will be taking over the role of National President of Materials Australia. I know Nikki will work to support the organisation in its continued growth and advocacy for the materials science and engineering community in Australia. In the last message of the year, it is a great opportunity to look back on what we have done as an organisation, as well

We also hosted several world class conferences this year, including CAMS, APICAM, LMT and MISE. Local events have been growing in scope and attendance, and preparations are already being made for the events to be held in 2024 and beyond so keep an eye out for these opportunities. The publications arising from our membership continue to have world class impact, such as those appearing in top ranked journals. I’m also very pleased to say that Professor Jian Feng Nie from Monash University was recently elected to the Board of Governors for Acta Materialia. This is an especially prestigious role and one we can all be proud of as it highlights another opportunity for our advocacy globally. Materials Australia continued to work with Standards Australia throughout 2023 in a range of different committees. I would ask that our membership continues to contribute when expressions of interest are released for standards that are critical to Australian manufacturing industries.

From feature article on page 50.

PUBLISHER Materials Australia Technical articles are reviewed on the Editor’s behalf

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Some highlights for Materials Australia this year include the signing of Memorandums of Understanding with the Indian Institute of Metallurgists, the Japanese Institute of Light Metals and the Asian Light Metals Association, (bringing together professional organisations from Japan, Korea, China, Taiwan and Australia) (see photograph). The opportunities that these relationships will afford will have a lasting impact for Materials Australia.

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as what we have all achieved personally or professionally.

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Another topic that continued to arise this year is the registration of engineers in Victoria, in a manner similar to that already in effect in Queensland. Importantly, applications must have been received by 1 December 2023

with the Victorian Business Licencing Authority to continue working as a professional engineer, even if the application is incomplete.

forward to catching up with many of you in the near future at our Materials Australia events. I wish you, your friends and your families all the best for 2024.

As always, as we head towards Christmas and the end of the year, I look

Dr Roger Lumley FTSE, FIEAust., FIMMM President, Materials Australia

Dr. Roger Lumley (MA) , Prof. Shigeru Kuramoto (JILM), Prof. Wengfang Shi (CMRA), Dr JaeHwang Kim, (KIM), Dr Ho Lin Tsai, (TLMA)

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This magazine is the official journal of Materials Australia and is distributed to members and interested parties throughout Australia and internationally. Materials Australia welcomes editorial contributions from interested parties, however it does not accept responsibility for the content of those contributions, and the views contained therein are not necessarily those of Materials Australia. Materials Australia does not accept responsibility for any claims made by advertisers. All communication should be directed to Materials Australia.

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MISE2023 Conference - University of Queensland Source: Sally Wood

The Materials Innovations in Surface Engineering (MISE) Conference 2023 was held at the University of Queensland in Brisbane from 29 to 31 October. MISE offered delegates the chance to gain in-depth insights into innovative developments and trends throughout industry, and provided industry representatives, academic institutions and research centres the opportunity to showcase their skills and foster relationships vital for future collaboration. MISE2023 provided a focused forum for the presentation of advanced research and improved understanding for the diverse aspects of surface engineering.

A Dazzling Array of Speakers MISE 2023 marshalled a broad range of high-quality academic and industrial keynote speakers who delivered papers and presentations that illuminated the critical issues facing the field of surface engineering. The Conference Co-Chairs, Professor Mingxing Zhang (University of Queensland) and Dr Tuquabo Tesfamichael (Queensland University of Technology), did a fantastic job of developing a full and engaging program for the presentation of advanced research and improved understanding for the diverse aspects of surface engineering. The plenary speakers for MISE2023 are outlined below. Professor Cuie Wen

Cuie joined RMIT University as a Professor of Biomaterials Engineering in 2014. She was Professor of Surface Engineering at Swinburne University of Technology from 2010 to 2014. She worked at Deakin University from 2003 to 2010 as Research Fellow, Senior Researcher and Associate Professor. Cuie’s research interests include new biocompatible titanium, magnesium, iron, zinc and their alloys and 8 | DECEMBER 2023

scaffolds for biomedical applications, surface modification, nanostructured metals, alloys and composites, metal foams and nanolaminates. Professor Wen presented on the topic: ZnP-ZnO dual-phase coatings on Zn foam with excellent antibacterial ability and biocompatibility for biodegradable orthopedic applications. Associate Professor Jennifer MacLeod

Associate Professor MacLeod is Head of School and Associate Professor in the School of Chemistry and Physics at Queensland University of Technology (QUT). She holds MSc and PhD degrees in Physics from Queen’s University (Canada), where she worked on instrumentation development for scanning tunnelling microscopy studies of semiconductor surfaces. Her research interests include self-assembly and reactions of molecules at surfaces, and the growth and modification of graphene and other 2D materials. Professor Zhengyi Jiang

Distinguished Professor Zhengyi Jiang is the Director of both the ARC ITTC Rail and the ARC ITTC Composites and Mining at the University of Wollongong (UOW). His research interests includes multiscale materials processing, advanced rolling technology, tribology in metal forming, development of novel lubricants in metal forming, microforming, manufacturing of composites, contact mechanics and numerical simulation of metal forming. He has over 500 journal articles and 5 monographs. He has been awarded over 40 prizes and awards including ARC Future Fellowship, ARF (twice), Endeavour Australia Cheung Kong Research Fellowship and Japan Society for the Promotion of Science (JSPS) Invitation Fellowship. He presented on the topic: Innovative nanolubricant and its application in manufacturing process.

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Professor Matt Barnett

Professor Matt Barnett is an Australian Research Council Laureate Fellow and Director of the ARC Training Centre in Alloy Innovation for Mining Efficiency at Deakin University. He has a background in metallurgical research, beginning his career in BHP Steel.

Thank You Materials Australia would like to thank the MISE 2023 Co-Chairs, Professor Mingxing Zhang (University of Queensland) and Dr Tuquabo Tesfamichael (Queensland University of Technology), as well as the other members of the organising committee: • Professor Mingxing Zhang (The University of Queensland) • Dr Tuquabo Tesfamichael (Queensland University of Technology) • David Haynes (Orrcon Steel) • Dr Richard Clegg (Explicom and Engineering Investigators) • Dr Hamid Pourasiabi (The University of Queensland) • Associate Professor Daniel Fabijanic (Deakin University) • Dr Sebastian Thomas (Monash University) • Tanya Smith (Materials Australia) We also need to extend our gratitude to the generous sponsors who make this conference a possibility, including: Platinum Sponsor, the Composites for Sustainable Mining ARC Training Centre; Conference Partners, University of Queensland, SEAM, and Queensland University Technology; Exhibitors, ANFF, Anton Parr, ATA Scientific Instruments, DKSH and Evident Scientific; and Lanyard Sponsors, American Elements.

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MATERIALS AUSTRALIA

QLD Branch Report - MISE2023 Source: David Haynes - Branch Chair & Secretary: The Queensland Branch of Materials Australia was privileged to be a part of the organising committee that presented MISE 2023 at The University of Queensland (UQ), St Lucia campus. The event was held from 29 to 31 October and was well attended with over 100 delegates, speakers and exhibitors in attendance.

MISE 2023 was opened by Professor Ross McAree, Head of the School of Mechanical and Mining Engineering at UQ. Professor McAree’s words on the broad church that is mechanical engineering truly resonated, particularly as the conference proceedings included themes from molecular and biomedical surface engineering, through to thermal spray cladding and laser processing. The academic committee of Professor Mingxing Zhang, Doctor Tuquabo Tesfamichael and Associate Professor Daniel Fabijanic did an exceptional job reviewing abstracts and organising into single and parallel sessions featuring plenary and invited speakers along over the course of the two days. Session chairs did a commendable job on keeping the sessions on time and

questions flowing throughout the day. As a member of the organising committee, MISE 2023 very much lived up to its promise of being the premier international Materials Innovations in Surface Engineering conference. This was measured based on a survey of participants that revealed that over 80% indicated the venue, the program and the exhibitors were either excellent or outstanding. Some fantastic feedback was received from attendees which further helps to motivate all of us to improve future events for the Materials Australia community: “It had a great blend of researchers at different stages of their journeys, and there was a tremendous sense of shared enjoyment of learning new things.” The conference dinner was well attended at St Leo’s college and it was wonderful to see Professor Colin Hall presented with the Ray Reynoldson Award for his contribution to surface engineering. Ray Reynoldson was instrumental in the Heat Treatment and Surface

Professor Colin Hall (Right), excepting the Ray Reynoldson Award from Distinguished Professor Christopher Berndt.

Engineering industries here in Australia and played a big part in the inaugural MISE conference, so it was very appropriate to have this awarded presented at this time. MISE 2023 would not have been possible without the support of The University of Queensland in hosting the event and providing access to the wonderful amenities in the Advanced Engineering Building. Our thanks also go to the sponsors, including the Queensland University of Technology and ARC Training Centre’s SEAM and Composites for Sustainable Mining. There is, of course, some opportunity for improvement and the challenge was laid down as to how future MISE committees can better promote the involvement of, and engagement with, industry in Australia and overseas. The conference website is still available for anyone interested in better understanding MISE for future (https://www.mise2023.com.au/). And, as always, Materials Australia can be approached for any further feedback, information or interest to be involved in future events.

L to R: David Haynes & Trevor Overton

10 | DECEMBER 2023

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Advancing Materials and Manufacturing 4-6 December 2024 | University of South Australia | www.cams2024.com.au The 8th conference of the Combined Australian

CO CHAIRS

Materials Societies, incorporating Materials Australia and the Australian Ceramic Society. Our technical program will cover a range of themes identified by researchers and industry as issues of topical interest. Symposia Themes > Additive manufacturing > Advances in materials characterisation > Metals, alloys, casting & thermomechanical processing > Biomaterials & nanomaterials for medicine > Ceramics, glass and refractories > Corrosion & wear > Materials for energy generation, conversion and storage > Computational materials science - simulation & modelling > Nanostructured/nanoscale materials and interfaces > Progress in cements, geopolymers and innovative building materials > Surfaces, thin films & coatings > Polymer technology > Composite technology > Waste materials and environmental remediation/recycling > Semiconductors and electronic materials

Professor Nikki Stanford University of South Australia

Nikki.Stanford@unisa.edu.au

Associate Professor Pramod Koshy UNSW Sydney koshy@unsw.edu.au

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Opportunities for sponsorships and exhibitions are available. Conference Secretariat: Tanya Smith tanya@materialsaustralia.com.au | +61 3 9326 7266

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WA Branch Technical Meeting - 14 August 2023 The Effect of Surface Indents from Hydrotest Plugs on Sulphide Stress Cracking (SSC) Resistance Source: Niel Swanepoel, Integrity Engineering Solutions Niel Swanepoel (Metallurgical and Welding Engineer, Integrity Engineering Solutions) recently presented at a Western Australia Branch technical meeting on the topic: The effect of surface indents from hydrotest plugs on Sulphide Stress Cracking (SSC) resistance. Niel is a metallurgical and welding engineer with a master’s degree in metallurgical engineering. His experience in approximately 15 years’ experience in the petrochemical and oil and gas industries ranges from writing pressure equipment and piping specifications, supporting construction and fabrication through to conducting failure investigations, condition assessments and complex equipment repairs. While he describes his main area of expertise as welding engineering, Niel’s talk confirmed his remark that he enjoys being confronted by any physical metallurgy challenge. The context for Niel’s talk was hydrotesting of individual piping butt welds by isolating a section of pipe either side of the weld with internal

plugs. The internal hydrotest plugs resemble masonry anchor bolts, with internal conical sliding surfaces that force the plug to increase in diameter as the cones are brought together by tightening an axial screw. They remove the need for attaching temporary flanges and are also accepted for use in ASME PCC-2 Article 503. However, seating of the plugs creates some surface damage inside the pipe bore, which ASME PCC-2 warns may be deleterious to stress corrosion cracking (SCC) resistance during subsequent operation in certain services. The damage is caused by the grippers that lock the plugs into the internal surface of the pipe so that the plug does not move under the pressure of the hydrotest. Niel then proceeded to describe his investigation to determine whether this damage had observable effects on environmentally assisted cracking in common carbon- and austenitic stainless steel pipe materials. For environmentally assisted cracking to occur there must be a combination of a susceptible material, tensile stress, and a corrosive environment. When all three are present, local notches can act as geometric stress concentrators or initiators for corrosion, whereas local changes in microstructure due to strain hardening can also affect the susceptibility. Sulphide stress cracking (SSC) in wet sour service is a common environmentally assisted cracking mechanism experienced in industry known to be highly sensitive to local hardening, which is specifically mentioned by ASME. Even though there are some mechanistic differences to conventional SCC, the first scope of testing therefore evaluated the influence of the surface indents on the SSC resistance of A106 carbon steel pipe.

Niel Swanepoel.

12 | DECEMBER 2023

Niel examined the damage caused by two types of grippers. The wedge-type

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grippers produced indentations around 0.5 mm deep, while those produced by the carborundum-faced version was shallower, around 0.2 to 0.3 mm deep. The investigation involved 3D scans of indent geometry, microstructural analysis, micro-hardness testing, and finally SSC testing in accordance with modified NACE TM0177 method B, using undamaged pipe material as a reference. The grippers caused plastic deformation for depths of around 100 μm, and this marginally increased the peak hardness from a base of around 180 HV to averages of 220 HV (carborundum gripper) and 237 HV (metallic wedge-type gripper). These hardness values are less than would normally be expected to promote SSC. Consequently, SSC test results showed no evidence that the indentations had any effect on SSC resistance, even with conditions severe enough to challenge the inherent base material resistance. Reflecting on these results, Niel observed that pipe bores delivered in field are not ‘perfect’ either. He compared the damage caused by the grippers with what is deemed acceptable in various pipe standards. The observed damage was much less than the maximum acceptance criteria in all the considered pipe standards and would therefore be acceptable in new as-delivered pipe. It is also possible that the plastic deformation under indentations provided some residual compressive stress that could to some extent offset concentration of applied tensile stress. This prompted audience discussion, with a general agreement that this was quite likely. Niel intends to take the testing a step further with chloride SCC testing with 304L stainless steel. In agreement with expectations, preliminary testing shows substantially deeper plastic deformation and strain hardening in the stainless steel.

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palladium catalysts

nickel foam

thin film

perovskite crystals glassy carbon III-IV semiconducto europium phosphors buckyballs

Nd:YAG

MOFs

99.9999% aluminum oxide

1.00794

diamond micropowder

alternative energy additive manufacturing

metamaterials

borophene He osmium

organometallics

4.002602

Hydrogen

nanogels Li 3

Helium

2 1

6.941

YBCO

2 8 1

MOCVD

2 8 18 8 1

39.0983

AuNPs

(223)

Francium

3D graphene foam

2 8 8 2

2 8 18 18 8 1

Ba Ra (226)

44.955912

Ac (227)

Radium

2 8 18 18 9 2

Nb 92.90638

2 8 18 32 10 2

178.48

Actinium

104

Rf (267)

Db (268)

Rutherfordium

2 8 13 2

54.938045

2 8 14 2

55.845

Manganese

2 8 15 2

58.933195

Iron

2 8 16 2

58.6934

Cobalt

2 8 18 1

63.546

Nickel

95.96

2 8 18 32 12 2

183.84

Dubnium

106

Sg (271)

2 8 18 15 1

2 8 18 32 13 2

186.207

107

Bh (272)

Seaborgium

2 8 18 16 1

2 8 18 32 14 2

190.23

108

Hs (270)

Bohrium

2 8 18 18

2 8 18 32 15 2

192.217

109

Mt (276)

Hassium

2 8 18 32 17 1

Meitnerium

110

Ds (281)

2 8 18 32 18 1

2 8 3

2 8 18 32 32 18 1

Rg (280)

Roentgenium

112

Cn (285)

Nh (284)

Copernicium

2 8 18 32 18 3

Fl (289)

Nihonium

2 8 18 18 5

208.9804

Flerovium

2 8 18 18 6

Te Po

Moscovium

116

2 8 7

(293)

2 8 18 7

2 8 18 18 7

2 8 18 32 18 7

2 8 18 32 32 18 7

118

83.798

Xe Xenon

(210)

Livermorium

Ts (294)

Tennessine

2 8 18 18 8

131.293

2 8 18 32 18 8

(222)

Astatine 117

2 8 18 8

Krypton

Iodine

2 8 18 32 18 6

Invar

39.948

126.90447

2 8 18 32 32 18 6

2 8 8

Argon

79.904

(209)

2 8 18 32 32 18 5

h-BN

Neon

Bromine

Polonium

115

(288)

2 8 18 6

127.6

2 8 18 32 18 5

2 8

20.1797

35.453

Tellurium

Bismuth 2 8 18 32 32 18 4

78.96

121.76

Chlorine

Antimony 2 8 18 32 18 4

2 8 6

32.065

Fluorine

Sulfur

2 8 18 5

2 7

18.9984032

Selenium

207.2

114

74.9216

Lead 2 8 18 32 32 18 3

2 8 5

Arsenic

Tin

204.3833

113

2 8 18 18 4

118.71

Thallium 2 8 18 32 32 18 2

15.9994

30.973762

2 8 18 4

Oxygen

Phosphorus

72.64

114.818

2 8 18 32 18 2

Germanium

Indium

Mercury

111

2 8 18 18 3

69.723

2 8 4

2 6

14.0067

28.0855

Nitrogen

Silicon 2 8 18 3

2 5

12.0107

Gallium

200.59

Gold

Darmstadtium

Cadmium

196.966569

2 8 18 32 32 17 1

2 8 18 18 2

112.411

Silver

Platinum 2 8 18 32 32 15 2

107.8682

195.084

Iridium 2 8 18 32 32 14 2

2 8 18 18 1

Palladium

Zinc

106.42

Rhodium

Osmium 2 8 18 32 32 13 2

102.9055

Ruthenium

Rhenium 2 8 18 32 32 12 2

101.07

Technetium

Tungsten 2 8 18 32 32 11 2

(98.0)

Molybdenum 2 8 18 32 11 2

2 8 18 13 2

2 8 18 2

Carbon

26.9815386

65.38

Copper

ultralight aerospace alloys Mo Tc Ru Rh Pd Ag Cd 2 8 18 13 1

180.9488

105

51.9961

Tantalum 2 8 18 32 32 10 2

2 8 13 1

Chromium

2 8 18 12 1

Niobium

Hafnium 2 8 18 32 18 9 2

2 8 11 2

50.9415

Vanadium

Zirconium

138.90547

2 8 18 10 2

91.224

Lanthanum 2 8 18 32 18 8 2

47.867

Yttrium

2 8 18 18 8 2

2 8 10 2

Titanium

2 8 18 9 2

88.90585

137.327

2 8 9 2

Scandium

2 8 18 8 2

Barium 2 8 18 32 18 8 1

isotopes Y Zr

2 4

Aluminum

Strontium

Cesium

87.62

132.9054

nanodispersions

40.078

Rubidium

2 8 2

Calcium

85.4678

EuFOD

2 8 8 1

10.811

Magnesium

Potassium 37

2 3

Boron

24.305

Sodium

Beryllium

22.98976928

surface functionalized nanoparticles

9.012182

Lithium 11

2 2

Radon

Og (294)

2 8 18 32 32 18 8

GDC NMC CIGS

Oganesson

InAs wafers titanium aluminum carbide molybdenum TZM silver nanoparticles ITO niobium C103

2 8 18 19 9 2

140.116

232.03806

2 8 18 21 8 2

140.90765

Cerium

quantum dots Th

Praseodymium 2 8 18 32 18 10 2

Thorium

Pa 231.03588

2 8 18 32 20 9 2

Protactinium

transparent ceramics

2 8 18 22 8 2

144.242

238.02891

Uranium

2 8 18 23 8 2

Pm Sm (145)

Neodymium 92

Np (237)

2 8 18 32 22 9 2

150.36

Promethium 2 8 18 32 21 9 2

2 8 18 24 8 2

Neptunium

Pu (244)

Plutonium

2 8 18 25 8 2

151.964

Samarium 94

2 8 18 32 25 8 2

Americium

(247)

2 8 18 27 8 2

158.92535

Gadolinium

Am Cm (243)

2 8 18 25 9 2

157.25

Europium 2 8 18 32 24 8 2

Curium

Bk (247)

2 8 18 28 8 2

2 8 18 32 27 8 2

Berkelium

UHP fluorides

(251)

Californium

Es (252)

Einsteinium

2 8 18 30 8 2

167.259

Tm 168.93421

Erbium 2 8 18 32 29 8 2

100

Fm (257)

Fermium

2 8 18 31 8 2

101

Md (258)

2 8 18 32 8 2

173.054

Thulium

2 8 18 32 30 8 2

2 8 18 32 31 8 2

Mendelevium

102

No (259)

2 8 18 32 32 8 2

Nobelium

103

Lr (262)

2 8 18 32 32 8 3

mischmetal

Lawrencium

chalcogenides

scandium powder

laser crystals

zircaloy -4

Lutetium

biosynthetics

carbon nanotubes

Now Invent.

gold nanocubes OLED lighting

2 8 18 32 9 2

174.9668

Ytterbium

CVD precursors

endohedral fullerenes tungsten carbide

2 8 18 29 8 2

Holmium 2 8 18 32 28 8 2

Ho 164.93032

Dysprosium

radiation shielding rare earth optical fiber dopants sputtering targets

162.5

Terbium

2 8 18 32 25 9 2

deposition slugs

flexible electronics

platinum ink superconductors

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SOFC powder

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WA Branch Technical Meeting - 11 October 2023 Visit to Callidus Process Solutions Source: Steve Algie In early October, the Western Australia Branch facilitated a technical meeting that featured a visit to Callidus Process Solutions. Members were hosted by two key staff members from Callidus: Dominic Flaxman (General Manager of Engineering) and Dr Evelyn Ng (Materials Engineer). The Callidus Group is a class-leading service provider to the mining and oil and gas industry, with headquarters in Balcatta and several facilities throughout the Asia Pacific region. The Callidus Group includes Callidus Process Solutions and Callidus Welding Solutions. The company specialises in management, maintenance, servicing and diagnostics of valves, actuators, and instrumentation. Callidus has developed in-house capability in engineering and design, fabrication and supply. These capabilities have contributed to building strong client relationships through the development and provision of engineering solutions to erosion and corrosion challenges. Dominic Flaxman gave an overview of the firm’s history, starting with its founding in Western Australia in 1997, to service the Minara Nickel refinery. The initial focus was on valves, but capabilities extend to autoclaves, spools and piping. The severe operating

conditions in high-pressure leaching led to a market for specialised testing, materials testing and development, and surface modification treatments. Capabilities now extend to field work, maintenance planning, and shutdowns and overhaul repairs and fabrication.

can be used in oxygen at over 200°C.

Callidus Process Solutions has capacity for design from scratch, though most tailored design work is for modification of OEM equipment. Other engineering services include valve selection and sizing, failure, and root cause analysis. Dominic described an example of RCA of fatigue failure in a valve body, leading to an improved design.

• Solve the problem – not just diagnose it

Evelyn Ng then proceeded with some more background about the development of the proprietary valve coating technologies that she had described in her talk to the Branch at the June meeting. Typically, these are applied to valves where nothing else works, even though they may be made from tantalum, titanium, Hastelloy, Inconel or Super Duplex alloys.

To provide this service, Callidus has installed High velocity oxy-fuel (HVOF) thermal spray and atmospheric plasma spray coating equipment, and has also built its own specialised ASTM test equipment.

One is FM-1500, a fully dense-weld deposited coating of Titanium Nitride with additives; this survived the extreme conditions in high pressure acid leaching. Another is BM-1600 – a fused tantalum on a pure nickel welded coating, with a ceramic topcoat applied by physical vapour deposition (PVD) that

She explained how these had been developed as part of Callidus’ endto-end’ service offering, which she summarised as follows: • Investigate – history and knowledge

• Provide solutions that work with existing equipment • Do the engineering – develop compliant solutions • Provide and implement the solution on site

The talks were followed by a tour of the extensive facility. Valves up to 40 inch size, in various states of repair were shown, starting from strip-down, proceeding through coating, lapping to achieve seal, then reassembly and high-pressure testing before despatch. The materials testing laboratory and specialised ASTM testing used in quality control and new coating development were also shown.

Dr Evelyn Ng

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WA Branch Meeting Report - 13 November 2023 How Solar Cells Work at the Atom Scale Source: Dr Gilles Dour, Advisian The Western Australia Branch hosted a technical meeting in mid-November. Dr Giles Dour (Principal Integrity Engineer with Advisian) gave a presentation on the topic How solar cells work at the atom scale. Dr Dour recalled his time as a doctoral candidate in France in the mid-1990s, when he was undertaking research into silicon production for solar cell applications. He has maintained a strong interest in the development of photovoltaics (PV) ever since. Gilles explained that he had become involved with PV through a family connection. His uncle had founded a solar panel manufacturing business, subsequently sold to EDF. Gilles, who had just completed a Master’s degree in materials engineering, had been just the right person to work on a research project in continuous solidification of PV crystalline silicon. His research extended further into PV manufacturing processes, giving him a solid grounding in the business aspects of PV, and the continuing quest for higher conversion efficiency. Gilles referred the National Renewable Energy Laboratory (NREL) chart to show the remarkable progress of PV panel efficiency since the 1970s. Each of the silicon-based technologies has shown steady progress, but with step changes between technologies. The efficiency of multi-junction cells has now reached 48% in the laboratory. Some emerging (non-silicon) technologies, although only now approaching 20% efficiency, are advancing at faster rates than silicon technologies.

L to R: Ehsan Karaji, Dr Gilles Dour

the appropriate wavelength interacts with a semiconducting material, an electron is promoted from the valence band to the conduction band, leaving a positive electron hole. In the absence of an electric field, the electrons and electron holes diffuse separately and at random until they eventually collide and disappear by pair annihilation. Impurities, crystal defects and grain boundaries promote pair annihilation, which is why high-purity single crystal silicon allows higher efficiency, though not necessarily more cost-effective PV cells.

the waste silicon being diverted to much lower value uses. Gilles went on to describe how he had undertaken research into growing 250 μm ribbons of silicon direct from the melt. These are multi-crystalline, and not as efficient, but much cheaper than single crystal silicon.

The phenomenon at the heart of PV is that when electromagnet radiation of

This led to a description of how silicon ingots are cut into 250 μm wafers; this incurs about 50% wastage, with

Producing free electrons and holes is the start of the process, but the vital step in turning the phenomenon into a useful energy conversion device is creating the cell; this establishes the electric field which imposes a gradient on charge carrier diffusion. The cell is created by doping the silicon so that it is a p-type semiconductor, and then doping a very thin (less than 1 μm) n-type layer, usually on the light-facing (‘top’) surface. Electrical contacts are then formed on the p-type and n-type , typically with a conducting grid, with another electrical connection on the ‘bottom’. These are joined to form a circuit through an electrical load. In the absence of light, this is simply a semiconductor diode, but when light of the right wavelength range falls on the surface and free charge carriers are created in the bulk material, current will flow, with voltage related to current. Holes move through the p-type

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DECEMBER 2023 | 15

Gilles’ talk ranged from physics, with the quantised nature of electromagnetic radiation and the relationship between light wavelength and energy, through materials science, and band gaps in semiconductors, on to the materials engineering involved in silicon crystal growth, and then to manufacturing engineering in producing commercial solar PV panels.

Gilles then outlined the processes using producing high-purity silicon and growing single-crystal ingots. In explaining this, Gilles noted out the common misconception that the PV phenomenon is a surface effect. In fact, sunlight penetrates silicon to a depth of around 200 μm before it is completely absorbed. This is why the silicon in PV cells is typically in the form of wafers around 250 μm thick.

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silicon to the bottom surface, electrons move to the top n-doped surface, are collected, and then flow through the load to return through the bottom connector where they recombine with the holes, thus completing the circuit. Putting a conducting grid on the surface reduces the light entering the silicon, and hence reduces efficiency. This has led to several other architectures that Gilles summarised briefly. The PERC (passive emitter rear contact) cell developed at UNSW, in now very common, while the IBC (Interdigitated Back Contact) cell, with no contacts on the light-facing surface is another contender. Corrosion of connectors is a

major factor in determining the effective life of solar PV panels. Not all solar PV cells are based on silicon. The CIGS (Copper, Indium Gallium Selenide) cell has much higher light absorption than silicon, and therefore can be used in thin film form, only around 1 μm thick. These cells can be fabricated in several ways including coevaporation, electrodeposition and by printing. There are several technologies based on hydrogenated amorphous silicon, including multi-junction cells that are effective over wide ranges of light wavelengths. Among the alternatives, thin film

hybrid inorganic-organic materials with the perovskite crystal structure have progressed remarkably in just a few years. These are relatively cheap and easy to manufacture but, at first sight these would hardly seem very practical, as they are relatively unstable in oxygen, moisture, heat and light! Nevertheless, Gilles expressed confidence that these issues would be overcome and that the commercial target of a twenty-year useful life would be achieved. Silicon is not necessarily the ultimate material for solar PV cells, but the enormous established manufacturing base means that it is likely to remain dominant for a long time.

Sir Frank Ledger Breakfast Meeting - 29 November 2023 Challenges Associated with Safe and Efficient Operation of Large Scale, Multi‐Emitter Carbon Capture and Storage Projects Source: Stephen Stokes, Global Head of CO2 transport and storage, John Wood Group plc Stephen Stokes is a chemical engineer, and throughout his career he has had a continuing focus on the properties and flow of multiphase phase fluids. Before joining Wood, he had spent more than twenty years in oil & gas operations in the North Sea and in Western Australia, progressing from operations to carbon capture and storage (CCS). Wood is

currently involved in more than half the CCS projects worldwide. Most members of the audience were already familiar with vertically integrated CCS projects, in which producers of natural gas remove and re-inject CO2 to reduce greenhouse gas emissions. In this address, Stephen’s focus was

on multi-emitter projects, involving several diverse and geographically widespread industries including thermal power stations, hydrogen, and ammonia production plants. Liquefied CO2 is transported through branch and trunk pipelines to a collection hub and then transported to, and injected into, depleted petroleum reservoirs. Stephen referred to several such projects, including the European ‘Northern Lights’ project in which CO2 is to be collected and shipped by tanker to an injection platform the North Sea. Another project in Korea involves repurposing existing assets for an endof-life hydrocarbon platform to transport and inject CO2 into the depleted (low pressure) reservoir; this is financially attractive as it reduces abandonment cost (ABEX). Locally, the ExxonMobil SE Australia CCS project will collect CO2 from across the region and re-inject it into depleted Bass Strait formations. In the United States, the Gulf Coast CCS project envisages 400 km of pipeline, collecting 12 Mtpa by 2030. It has been estimated that this CCS market will grow to USD 4 trillion per year by 2050, together with increased

L to R: Stephen Stokes and Ehsan Karaji

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diversity in the industrial sources of the CO2 captured. The development of shared transport infrastructure within CCS hubs offers attractive economies of scale for emitters. However, the development of large‐scale CCS hub projects is complex, with many stakeholders responsible for various aspect of the value‐chain. All these projects rely on transportation of a CO2 -rich liquid. As Stephen stressed, this is not simply liquefied CO2 ; CCS hubs are in effect a garbage collection service. Transport can dominate the cost of these projects, in the cost of securing transport corridors, capital expenditure and operating costs. The transport network operation will have to deal with an impure CO2 ‐rich fluid and hence the requirements for asset integrity assurance will be onerous. The logistics involved in building hundreds of kilometres of 36 to 42-inch pipelines is a serious issue, particularly in the United States, where line pipe manufacturing capacity is currently limited. Stephen then turned to the technical issues in transporting these impure liquids, first dealing with the major non-condensable impurities, present in mol percent levels, mainly hydrogen but also nitrogen and ammonia. He explained the impact of the additional gases by referring to the CO2 pressuretemperature phase diagram, showing how impurities produce a two-phase region, with the result that higher pressures are needed to maintain the liquid state essential for economic transport. With 4 percent hydrogen, the pressure in the pipeline must be above 40 bar, and the density of the liquid is reduced by 20 percent. Together, these result in a loss of around 10 percent line capacity compared to transport of pure CO2 . Another consequence of the expanded two-phase region, and need for high operating pressure, is that a leak in the pipe, with isentropic expansion of the escaping fluid, a high pressure differential is maintained across the pipe wall. This means that high toughness is required in the pipeline material to arrest crack growth, with the issues exacerbated by the low temperature produced by the fluid expansion, and the potential for hydrogen embrittlement. Minor impurities, at the parts per million level, arising from hydrocarbon WWW.MATERIALSAUSTRALIA.COM.AU

processing include water vapour, amine, and glycols (MEG and TEG). Their impact is exerted mainly through their effect on water solubility, and hence pipeline corrosion. Traces of combustion products, such as SOx, NOx, and also hydrogen sulphide and oxygen, must also be dealt with. The general aim is for less than 50 ppm water vapour, zero glycols, and less than 10 ppm hydrogen sulphide. The approach taken to handling the potential for variable inputs is to develop a Network Code, specifying fluid composition limits, as well as metering protocols and responses to and recovery from excursions from normal operating conditions. Each emitter must condition the fluids to be sent to the system, and the operator will only accept the fluids if they meet the code. However, a balance has to be struck; if the code is overly restrictive, emitters won’t use the system, but if it is too lax, the integrity of the system will be compromised. A major joint industry project (JIP) is currently being undertaken to set CO2 specifications.

specification scenarios at any point a transportation system, and hence planning of operating responses. However, there are currently no methods to reliably predict the properties of dense-phase CO2 when water is present. The solution might need to be mandatory dehydration of input streams. This raised the point that CCS hubs are integrated projects. A systems approach is essential and ‘the right people have to be in the room at the same time’. There are balances to be decided between CAPEX, OPEX, and asset integrity, not only for the operator, but for every emitter who plans to use the system. In his concluding remarks, Stephen emphasised that CCS is happening now, driven by carbon pricing in Europe, and by government incentives in the US. Transportation of a CO2 -rich liquid is big issue, and it must be accepted that dealing with this will involve a steep learning curve.

Stephen then referred to Wood’s ‘Electronic Corrosion Engineer’ (ECE) model for accurately calculating phase behaviour, including dew point. This allows ‘what-if’ modelling of off-

Stephen’s presentation drew an audience of more than ninety members and guests, making this breakfast meeting a very successful celebration of Sir Frank Ledger and his role in founding what developed into the Western Australia branch.

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VIC Branch Report - 25th Annual Technologists' Picnic 25th Annual Technologists' Picnic “Cochlear Implants Present and Future” Cochlear Implants: Past, Present and: Past, Future Guest Speaker: Claire Hartmann

Guest Speaker: Claire Hartmann

Date: 24th November 2023

The 25th Annual Technologists Picnic was held recently. As always, the Technologists’ Picnic included members from the Australasian Institute of Mining and Metallurgy, the Australian Foundry Institute, Materials Australia, Engineers Australia, and the Australasian Corrosion Association. Attendees were treated to a very interesting and detailed presentation on the history of cochlear implants by Claire Hartmann. Claire is a Graduate Engineer working at the Bionics Institute, which was founded by Professor Graeme Clark, the developer of the first successful multichannel cochlear implant.

Claire discussed the research that Gary Bunn presents Claire Hartmann with a symbol of gratitude on behalf of the participants. guided the development of the first Gary Bunn presents Claire Hartmann with a symbol of gratitude on behalf of the participan successfully implanted cochlear presentation from a Biomedical questions and discussion later in the device in Melbourne in 1978, as well evening. Engineer and gave the attendees The 25th Annual Technologists Picnic eventually went ahead despite various as important aspects of the device’s an insight into a different area of Claire went on to explain improvements who persevered were richly rewarded design. Cochlear implants are known changes in date and venue. Those of us technological development happening to cochlear implants over the withmade a very interesting and detailed presentation on the history of cochlear worldwide as a life changing device in Australia. years, the directions of current research for people with severe to profound implants by Claire Hartmann. Claire Graduate Engineer working at the to continue to improve performance into is aClaire was loudly applauded for hearing loss who wish to improve Bionics Institute, which founded by Professor Graeme Clark, the future and the ways inwas which this her excellent presentation. She the developer their understanding of verbal research has led to the development of wasimplant. then asked many questions by communication. A key section of Claire'sthe first successful multichannel cochlear treatments for a range of neurological representatives of the five talk was a review of hearing function Claire discussed the research that guided the development ofparticipating first successfully and chronic conditions. groups that had come from Melbourne, and how our brains process the sounds implanted cochlear device in Melbourne in 1978, as well as important aspects o Geelong, Bendigo and Ballarat. The evening's talk was the first around us, leading to some interesting

Claire delivered a very informative and insightful presentation.

the device’s design. Cochlear implants are known worldwide as a life changing device for people with severe to profound hearing loss who wish to improve th understanding of verbal communication. A key section of the Claire’s talk was a review of hearing function and how our brains process the sounds around us, leading to some interesting questions and discussion later in the evening. Claire went onto explain improvements made to cochlear implants over the years, the directions of current research to continue to improve performance i the future and the ways in which this research has led to the development of treatments for a range of neurological and chronic conditions. The evening's talk was the first presentation from a Biomedical Engineer and gave the attendees an insight into a different area of the technological development happening in Australia. Claire was loudly applauded for her excellent presentation She was then asked many questions by representatives of the five participating groups that had com from Melbourne, Geelong, Bendigo and Ballarat. Claire was then presented with fluid expression of appreciation by the convenor, Gary Bunn.

A capacity audience thoroughly enjoyed another annual technologists' picnic.

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NSW Branch Report Source: Alan Todhunter - NSW President 2023 has been a year for adjusting to new committee members and President. This has resulted in less activity than anticipated with renewed enthusiasm for 2024. We will soon be planning our events for next year and engaging with NSW members in face-to-face meetings and online events.

NSW Student Presentations On Wednesday, 29th November 2023, NSW students from undergraduate degrees in materials-related courses had the opportunity to present their final year research projects to a panel of judges. For the first time the presentations were held at Western Sydney University Engineering Innovation Hub located in Parramatta CBD. This was a hybrid event allowing a wider audience to view and give commentary on the presentations. There were two sessions, presentations supported by PowerPoint and a poster session using physical posters and digital posters on screens. Our branch was very fortunate to receive sponsorship for student prizes with many thanks to Alan Hellier who not only contacted and facilitated sponsorship but as always ensured a rigorous rubric was in place to judge the students. For the oral presentations the judges critiqued the presentations with the following results. First place was presented to Ally Bradley, UNSW Materials with the topic Microstructural evolution in unique

geometries of additively manufactured Ni-based superalloy Inconel 718. (Dr Sam Moricca, Gravitas Technologies: $600) Second place was presented to Sreekanth “Chenna” Didugu, UNSW Mech Eng and ANSTO on Carbon-Carbon composite microstructural modelling. (Hassan Kanji, United Steel: $500)

First place in oral presentations Ally Bradley, UNSW Materials.

Third place was presented to Frederick M.C. Zhang, UNSW Materials and ANSTO: Dissolution Mechanisms of Calcium Perovskite (CaTiO3) for SYNROC Waste forms (Hassan Kanji, United Steel: $400) Fourth place was presented to Ratan Venkatesan, UNSW Materials and ANSTO: Pyrochlore Wasteforms for Immobilising Fluoride-Containing Nuclear Waste (Hassan Kanji, United Steel: $300) Fifth Place was presented to Paul Saliba, WSU: Compressive Strength of Magnesium Oxychloride Cement (MOC) Based Fibre Reinforced Cementitious Composites at Ambient and Elevated Temperatures. (Frank Soto, SOTO Consulting Engineers: $200) Other speakers with notable research presentations were: Matthew Gigliotti, UOW: MuscleInspired tough, strong hydrogel artificial muscles. Mengqing Zhao, UOW: Self- locking Electrochemical-enabled Liquid Metal Actuator Ben Fryer, UON: Exchange Reaction

First place in poster presentations Paul Saliba, WSU with NSW President Alan Todhunter.

Synthesis of MAB Phase Fe2AlB2 Following the oral presentations, the poster sessions were judged while having afternoon tea sponsored by Frank Soto, SOTO Consulting Engineers. First Prize: Paul Saliba, WSU: Compressive Strength of Magnesium Oxychloride Cement (MOC) Based Fibre Reinforced Cementitious Composites at Ambient and Elevated Temperatures (Frank Soto, SOTO Consulting Engineers: $300) Second Prize: David “Kaito” Callan, UNSW Mech Eng and ANSTO: Investigation of mixed uranium valences in nuclear materials using diffuse reflectance spectroscopy (Dr Sam Moricca, Gravitas Technologies: $200) Third Prize: Kimiko Trinidad, USYD: Developing Atom Probe Tomography for Bone Tissue and Bioceramic Scaffolds (Professor Anna Paradowska, ANSTO: $100 gift card) Another poster of interesting research was displayed by Haomin (Larry) Lyu, Microstructure Evolutions of a DualPhase High-Entropy Alloy Produced by Powder Arc Additive Manufacturing.

Presenters, judges, NSW members and guests in attendance at the presentations.

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The student presentations closed with great expectations for our next generation of materials researchers. DECEMBER 2023 | 19

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SEAM Profile: Minh Nhat Dang

PhD Candidate, ARC SEAM, Swinburne University of Technology recognised with a national consolation award for excellent undergraduate research and a Boston Fellowship to the hallowed hall of Harvard and MIT that reformed his mindset. Returning to Vietnam, Minh took the roles of Laboratories Manager and Lead Researcher in national and private projects at leading institutions. There, his work on the scalable plasma-assisted production of graphene-based materials for sustainable construction and energy solutions gained him a patent, as well as the hope of improving local miners’ lives through high-end applications of graphite ore. The quest for knowledge brought Minh to Swinburne, where he embarked on a PhD scholarship with ARC SEAM in partnership with Sutton Tools, an Australian leader in tool manufacturing with an over-100 year legacy of innovation. Minh's project aims to improve the edge preparation and surface finish of complex cutting tools with the integration of specialised hard wear-resistant thin-film coatings, by pushing the limits of mechanical polishing and developing agile electropolishing methods for tough tool materials like tungsten carbide and high-speed steel—resources once used in the trenches of world wars, now serving industries worldwide. Despite the century-long challenges in electrolytic polishing these stubborn materials, as well as commencing his PhD at the start of the longest Covid-19 lockdowns, he not only achieved an ultra-smooth mirror-like sub-100nm surface roughness but also honed cutting edges to micro-precision, positioning his work for potential patent applications—a significant step forward for the tool industry, furthering Sutton's commitment to delivering the world-finest tool life and performance.

Figure 1. Minh commissioning the latest Edge Preparation EPX-SF machine at Sutton"

Minh is a PhD Candidate with the Australian Research Council (ARC) Industrial Transformation Training Centre in Surface Engineering for Advanced Materials (SEAM) at Swinburne University of Technology. Born within the walls of a small, century-old house that predated the wars that once ravaged his hometown, Minh had used a footstool, crafted from leftover door scraps, as a studying desk for 15 years of schoolwork. Outside the confines of those four walls, the young dreamer’s passion for science took flight, with water rockets refashioned from garbage Coca-Cola bottles launching toward the heights he was destined to reach in academia. Minh's academic voyage began with a Bachelor in Nanotechnology from Vietnam-France University, where he graduated second in his class. He engaged himself in laboratory internships, studying a spectrum of materials from transition-metal dichalcogenide (TMDC) photocatalysts, gold quantum dots to nano-carbon structures. His dedication was 20 | DECEMBER 2023

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Minh's academic achievements are noteworthy, with nearly 20 publications and as many conference presentations, earning him top poster awards, a compliment message from the ARC Director for his industrial accomplishment and a Swinburne School of Engineering Postgraduate of the Year (Commendation) for his PhD excellence. At Sutton Tools, Minh's insights have informed multimillion-dollar investments in new machinery, and his dual understanding of academic research and industrial processes have made him an invaluable bridge between the two worlds. This unique perspective has led to a direct offer from ANCA, a global leader in CNC and machine technology, even before his thesis submission. Now, Minh joins ANCA as a full-time EPX Application Engineer to cultivate the state-of-the-art stream finishing concepts, bringing not only a wealth of experience but also the consistent support of the SEAM family, who have been of huge support on his path.

For more information about SEAM, please visit www.arcseam.com.au/ or email seam@swinburne.edu.au WWW.MATERIALSAUSTRALIA.COM.AU

F ounded in 2019 as a par tner s hip between thr ee univer s ities , S E AM’s mis sion is to help s olve cr itical s ur face engineer ing pr oblems faced by indus tr y, while tr aining up talented indus tr y- r eady gr aduates for our futur e.

Titomic partnered with SEAM to elevate the TKF cold-spray process to the next level — integrating advanced sensors to provide critical process insights in real-time, paired with a data analysis pipeline powered by machine learning, and all validated by testing and analytical capabilities at SEAM. This collaboration has expedited development and fortified quality, unlocking high-value applications and access to global markets.

MacTaggart Scott Australia delivers mission critical products and services to the Royal Australian Navy’s ships and submarines. The ongoing partnership with SEAM on the development of lightweight composite materials for marine applications, has yielded multiple significant improvements to existing and future product designs, through advances in the application of thermal spray technologies.

This partnership between SEAM and Sutton Tools achieved significant enhancements in the surface quality of intricate cutting tools, thereby improving their performance. Leveraging innovative state-of-the-art electropolishing techniques, coupled alongside precise mechanical polishing and specialized wear-resistant surface coatings, Sutton continues to deliver leadingedge products that meet global standardsof competitiveness.

See more: https://arcseam.com.au

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CMatP Profile: Dr Jeff Gates companies such as Bradken, Trelleborg and Molycop and by collaborative government funding schemes such as Innovation Connections and Advance Queensland Industry Research Fellowships.

What inspired you to choose a career in materials science and engineering?

Jeff Gates is an Honorary Senior Fellow in the School of Mechanical and Mining Engineering at The University of Queensland. From 1998 to 2019 he was Principal of UQ Materials Performance, a professional consultancy service within the University. His technical expertise covers: (1) Microstructure, properties, performance & failure of ferrous alloys and competing materials, especially for abrasion-resistant products; (2) Engineering failure investigation.

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Where do you work? Describe your job. I work in the School of Mechanical and Mining Engineering at The University of Queensland. Although I’ve been at UQ since my post-doctoral years, I’ve had a diversity of roles — from research & lecturing, to founding & operating a consultancy business, and now back to research. In the late 1990s I effectively changed careers (from academic to fulltime engineering consultant) without changing offices! Currently my focus is R&D projects funded by manufacturing

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Late in my first year at Monash University (1976), two of our Physics lecturers gave a presentation about a second-year subject called “Materials Science 205”. They were Bill Rachinger (1927-2023) and Paul Clark. Using benchtop demonstrations they compellingly illustrated diverse material properties, such as thermal conductivity. I and some of my classmates thought “that sounds cool” — and we were right! Virtually every day of my career, I apply some principle or piece of knowledge that I gained there in 1977.

Who or what has influenced you most professionally? Two people who have inspired me are Ian Polmear and Andrej Atrens. At Monash, Prof Polmear taught us a variety of topics within our materials courses, but two that stood out were Phase Transformations, and Micromechanics of Deformation & Fracture — topics that have informed both my research and my consultancy

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over the decades since. Ian is one of those exceptional people who combine intellectual brilliance with outstanding personal warmth & integrity. During my Postdoc at UQ, Andy Atrens taught me many lessons. One was the simple trick of roughly plotting a data trend while standing in a lab, armed with nothing more than pen and paper. Without any formal tools like graph paper & ruler (in those old days) or computers, or even a desk to sit at, hand-sketching a graph enabled us to visualise and understand the kind of effect that parameter X might have on variable Y. By his consistent example, Andy demonstrated the value of giving written feedback on a draft report — something I’ve endeavoured to emulate when mentoring my own students and staff.

What has been the most challenging job or project you've worked on to date and why? Serving as an expert witness in the Victorian Bushfires litigation in 20112013 tested me in numerous ways. Obviously it put my expertise under the spotlight, and it certainly tested my stamina — 5 weeks full-time in the Victorian Supreme Court is no picnic. But more than that, it tested my integrity — whether I was really committed to the expert witness code of conduct which states that an expert’s principal obligation is to the court, not to their client. So for example when I was asked in court whether I or the opposition’s expert had stronger expertise in fracture mechanics, I was happy to say it was the other guy. But I also saw that this strict independence is actually in the client’s interest; that my demonstrable integrity & impartiality are perhaps my client’s biggest asset.

What does being a CMatP mean to you? Being a Certified Materials Professional (and also Chartered Professional Engineer) has meant more to me in my career than the specific job titles I’ve held. The term “professional” holds a great deal of significance to me. At one level, a professional is someone with training & experience in a given field that are certified by authorities in that field as qualifying the person to perform analysis and make judgements which the community can rely on. At another level, I remember someone saying to me that WWW.MATERIALSAUSTRALIA.COM.AU

“an employee works till knock-off time; a professional works until the job is done”. That philosophy can be problematic, since it’s not right to sacrifice family for the sake of work. But the key attitude is to take responsibility; not to dismiss the matter as “someone else’s problem”.

What gives you the most satisfaction at work? Submitting a project report or scientific article which systematically sets out the question that was asked, the methods by which that question was investigated, the observations made, rigorous interpretation of those observations, and finally the answer to the question. Such a report tells a story — one that is factual, but also intelligible and compelling.

What is the best piece of advice you have ever received?

Pursue a career not in the field that has the most jobs on offer, or which you think will make you the most money, but in a field you enjoy and are good at (these two usually being the same). Your best chance of landing a good job is when you’re good at it.

What have been your greatest professional and personal achievements? Personal: That’s easy to answer — meeting and growing a life-long partnership with my wife of 33 years. She is by far the best friend I ever had, BACK TO CONTENTS

and I have tremendous admiration for her integrity, intellect and expertise in her field (medicine & preventive health). When it comes to diagnostic logic & evidence, there’s a lot of overlap between medicine and engineering failure analysis (including preventive maintenance!). Professional: My greatest achievement professionally was establishing the UQ Materials Performance consultancy business (registered in 1998), and then leading & developing it to become the thriving & authoritative entity (and harmonious & fun workplace) that it is today.

What are you optimistic about?

Lifelong learning. You learn something new every day, and learning new things is satisfying.

What are the top three things on your “bucket list”? • See widespread acceptance of our new suite of industrially realistic wear & fracture tests (ICAT, BMAT, BMECT), which are unique in their ability to measure the properties that actually determine service performance in the target industries. • Close the loop regarding the relationship between a material’s resistance to body-fracture and its resistance to microfracture wear mechanisms. • Swim with dolphins. DECEMBER 2023 | 23

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Our Certified Materials Professionals (CMatPs) The following members of Materials Australia have been certified by the Certification Panel of Materials Australia as Certified Materials Professionals.

A/Prof Alexey Glushenkov ACT Dr Syed Islam ACT Prof Yun Liu ACT Dr Karthika Prasad ACT Dr Takuya Tsuzuki ACT Dr Olga Zinovieva ACT Prof Klaus-Dieter Liss CHINA Mr Debdutta Mallik MALAYSIA Prof Valerie Linton NEW ZEALAND Prof. Jamie Quinton NEW ZEALAND Dr Rumana Akhter NSW Ms Maree Anast NSW Ms Megan Blamires NSW Dr Phillip Carter NSW A/Prof Igor Chaves NSW Dr Yi-Sheng (Eason) Chen NSW Dr Zhenxiang Cheng NSW Dr Evan Copland NSW Mr Peter Crick NSW Prof Madeleine Du Toit NSW Dr Ehsan Farabi NSW Dr Azdiar Gazder NSW Prof Michael Ferry NSW Dr Yixiang Gan NSW Mr Michele Gimona NSW Dr Bernd Gludovatz NSW Dr Andrew Gregory NSW Mr Buluc Guner NSW Dr Ali Hadigheh NSW Dr Alan Hellier NSW Prof Mark Hoffman NSW Mr Simon Krismer NSW Prof Jamie Kruzic NSW Prof Huijun Li NSW Dr Yanan Li NSW Dr Hong Lu NSW Mr Rodney Mackay-Sim NSW Dr Matthew Mansell NSW Dr Warren McKenzie NSW Mr Edgar Mendez NSW Mr Arya Mirsepasi NSW Mr Sam Moricca NSW Dr Ranming Niu NSW Dr Anna Paradowska NSW

Prof Elena Pereloma NSW A/Prof Sophie Primig NSW Dr Gwenaelle Proust NSW Miss Zhijun Qiu NSW Mr Waldemar Radomski NSW Dr Blake Regan NSW Mr Ehsan Rahafrouz NSW Dr Mark Reid NSW Prof Simon Ringer NSW Dr Richard Roest NSW Mr Sameer Sameen NSW Dr Luming Shen NSW Mr Sasanka Sinha NSW Mr Frank Soto NSW Mr Michael Stefulj NSW Mr Carl Strautins NSW Mr Alan Todhunter NSW Ms Judy Turnbull NSW Mr Jeremy Unsworth NSW Dr Philip Walls NSW Dr Alan Whittle NSW Dr Richard Wuhrer NSW Mr Deniz Yalniz NSW Mr Michael Chan QLD Prof Richard Clegg QLD Mr Andrew Dark QLD Dr Ian Dover QLD Mr Oscar Duyvestyn QLD Mr John Edgley QLD Dr Jayantha Epaarachchi QLD Dr Jeff Gates QLD Mr Payam Ghafoori QLD Mr Mo Golbahar QLD Dr David Harrison QLD Dr Janitha Jeewantha QLD Dr Damon Kent QLD Miss Mozhgan Kermajani QLD Mr Jaewon Lee QLD Mr Jeezreel Malacad QLD Dr Jason Nairn QLD Mr Sadiq Nawaz QLD Dr Saeed Nemati QLD Mr Bhavin Panchal QLD Mr Bob Samuels QLD Dr Mathias Aakyiir SA Mr Ashley Bell SA Ms Ingrid Brundin SA Mr Neville Cornish SA A/Prof Colin Hall SA Mr Nikolas Hildebrand SA Mr Mikael Johansson SA Mr Rahim Kurji SA Mr Andrew Sales SA Dr Thomas Schläfer SA Dr Christiane Schulz SA Prof Nikki Stanford SA Prof Youhong Tang SA Mr Kok Toong Leong SINGAPORE Mr Devadoss Suresh Kumar UAE Dr Shahabuddin Ahmmad VIC Dr Ossama Badr VIC Dr Qi Chao VIC Dr Ivan Cole VIC Dr John Cookson VIC Miss Ana Celine Del Rosario VIC Dr Yvonne Durandet VIC Dr Mark Easton VIC Dr Rajiv Edavan VIC

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They can now use the post nominal ‘CMatP‘ after their name. These individuals have demonstrated the required level of qualification and experience to obtain this status. They are also required to regularly maintain their professional standing through ongoing education and commitment to the materials community. We now have nearly 200 Certified Materials Professionals, who are being called upon to lead activities within Materials Australia. These activities include heading special interest group networks, representation on Standards Australia Committees, and representing Materials Australia at international conferences and society meetings.

Dr Peter Ford Mr Bruce Ham Ms Edith Hamilton Dr Shu Huang Mr Long Huynh Dr Jithin Joseph Mr. Akesh Babu Kakarla Mr Russell Kennedy Mr Daniel Lim Dr Amita Iyer Mr Robert Le Hunt Dr Michael Lo Dr Thomas Ludwig Dr Roger Lumley Mr Michael Mansfield Dr Gary Martin Dr Siao Ming (Andrew) Ang Mr Glen Morrissey Dr Eustathios Petinakis Dr Leon Prentice Dr Dong Qiu Mr John Rea Miss Reyhaneh Sahraeian Dr Christine Scala Mr Khan Sharp Dr Vadim Shterner Dr Antonella Sola Mr Mark Stephens Dr Graham Sussex Dr Kishore Venkatesan Mr Pranay Wadyalkar Dr Wei Xu Dr Ramdayal Yadav Dr Sam Yang Dr Matthew Young Mr Angelo Zaccari Mr Mohsen Sabbagh Alvani Dr Murusemy Annasamy Mr Graeme Brown Mr Graham Carlisle Mr John Carroll Mr Sridharan Chandran Mr Conrad Classen Mr Chris Cobain Mr Adam Dunning Mr Jeff Dunning Dr Olubayode Ero-Phillips Mr Stuart Folkard Mr Toby Garrod Prof Vladimir Golovanevskiy Mr Chris Grant Mr Paul Howard Dr Paul Huggett Mr Ivo Kalcic Mr Srikanth Kambhampati Mr Ehsan Karaji Mr Biju Kurian Pottayil Mr Mathieu Lancien Mr Michael Lison-Pick Dr Evelyn Ng Mr Deny Nugraha Mrs Mary Louise Petrick Mr Johann Petrick Dr Mobin Salasi Mr Daniel Swanepoel Mr James Travers

VIC VIC VIC VIC VIC VIC VIC VIC VIC VIC VIC VIC VIC VIC VIC VIC VIC VIC VIC VIC VIC VIC VIC VIC VIC VIC VIC VIC VIC VIC VIC VIC VIC VIC VIC VIC WA WA WA WA WA WA WA WA WA WA WA WA WA WA WA WA WA WA WA WA WA WA WA WA WA WA WA WA WA WA

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MATERIALS AUSTRALIA

Why You Should Become a Certified Materials Professional Source: Materials Australia Accreditation as a Certified Materials Professional (CMatP) gives you recognition, not only amongst your peers, but within the materials engineering industry at large. You will be recognised as a materials scientist who maintains professional integrity, keeps up to date with developments in technology, and strives for continued personal development. The CMatP, like a Certified Practicing Accountant or CPA, is promoted globally as the recognised standard for professionals working in the field of materials science. There are now well over one hundred CMatPs who lead activities within Materials Australia. These activities include heading special interest group networks, representation on Standards Australia Committees, and representing Materials Australia at international conferences and society meetings.

Benefits of Becoming a CMatP • A Certificate of Membership, often presented by the State Chapter, together with a unique Materials Australia badge. • Access to exclusive CMatP resources and website content. • The opportunity to attend CMatP only

networking meetings. • Promotion through Materials Australia magazine, website, social media and other public channels. • A Certified Materials Professional can use the post nominal CMatP. • Materials Australia will actively promote the CMatP status to the community and employers and internationally, through our partner organisations. • A CMatP may be requested to represent Materials Australia throughout Australia and overseas, with Government, media and other important activities.

standards. They are recognised as demonstrating excellence, and possessing special knowledge in the practice of materials science and engineering, through their profession or workplace. A CMatP is prepared to share their knowledge and skills in the interest of others, and promote excellence and innovation in all their professional endeavours.

The Criteria

• Networking directly with other CMatPs who have recognised levels of qualifications and experience.

The criteria for recognition as a CMatP are structured around the applicant demonstrating substantial and sustained practice in a field of materials science and engineering. The criteria are measured by qualifications, years of employment and relevant experience, as evidenced by the applicant’s CV or submitted documentation.

• The opportunity to assume leadership roles in Special Interest Networks, to assist in the facilitation of new knowledge amongst peers and members.

Certification will be retained as long as there is evidence of continuing professional development and adherence to the Code of Ethics and Professional behaviour.

What is a Certified Materials Professional?

Further Information

• A CMatP may be offered an opportunity as a mentor for student members.

A Certified Materials Professional is a person to whom Materials Australia has issued a certificate declaring they have attained all required professional

Contact Materials Australia today: on +61 3 9326 7266 or

imea@materialsaustralia.com.au or visit our website:

www.materialsaustralia.com.au

Prof Julie Cairney awarded the Florence M. Taylor Medal We would like to congratulate Professor Julie Cairney on being awarded the 2023 Materials Australia Florence M. Taylor Medal. The award is made to a female Materials Australia member for meritorious contributions to the advancement of materials engineering. Professor Julie Cairney is a global leader in materials science, with extensive international experience and industry knowledge. Professor Cairney is the Pro Vice Chancellor (Research – Enterprise and Engagement) at the University of Sydney and CEO of Microscopy Australia. Professor Cairney’s role is primarily focused

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on studying materials by using sophisticated microscopy techniques to study their matter down to the atomic scale. Through this approach, Professor Cairney contributes her expertise to the development of stronger and lighter materials that are sustainable and cost effective. These materials have practical utilisation objectives in the aerospace, manufacturing and construction sectors. Florence Taylor was the first female architect, structural engineer and civil engineer in Australia, and had a special role in the history of Materials Australia having been the publisher of our magazine for many years

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DECEMBER 2023 | 25

INDUSTRY NEWS

Wearable Device Makes Memories and Powers Up with the Flex of a Finger Source: Sally Wood

Researchers have invented an experimental wearable device that generates power from a user’s bending finger and can create and store memories, in a promising step towards health monitoring and other technologies.

The innovation features a single nanomaterial incorporated into a stretchable casing fitted to a person’s finger. The nanomaterial enabled the device to generate power with the user bending their finger. The super-thin material also allows the device to perform memory tasks. Multifunctional devices normally require several materials in layers, which involves the time-consuming challenge of stacking nanomaterials with high precision.

PhD scholar Xiangyang Guo holding the wearable device in a petri dish in the team's lab at RMIT University. Image Credit: Seamus Daniel, RMIT University.

The team, led by RMIT University and the University of Melbourne in collaboration with other Australian and international institutions, made the proof-of-concept device with the rust of a low-temperature liquid metal called bismuth, which is safe and well suited for wearable applications. Senior lead researcher Dr Ali Zavabeti said the invention could be developed to create medical wearables that monitor vital signs – incorporating the researchers’ recent work with a similar material that enabled gas sensing – and memorise personalised data.

The team’s innovation features a single nanomaterial incorporated into a stretchable casing fitted to a person’s finger. Image Credit: Seamus Daniel, RMIT University.

“The innovation was used in our experiments to write, erase and re-write images in nanoscale, so it could feasibly be developed to one day encode bank notes, original art or authentication services,” said Zavabeti, an engineer from RMIT and the University of Melbourne.

What Did the Device Achieve in Experiments? The team says the study revealed their invention exhibits “exceptional responsiveness to movements associated with human activities, such as stretching, making it a promising candidate for wearable technologies”. Bismuth metal and the team’s wearable device (left to right). Image Credit: Seamus Daniel, RMIT University.

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The device was able to perform the memory functions of ‘read’, ‘write’ and ‘erase’, which included using the RMIT logo and a square-shaped insignia as demonstrations of these capabilities. The device, which was not worn by a user during these memory experiments, wrote and stored the logo and symbol in a space that could fit 20 times within the width of a human hair.

How Did the Team Make the Invention and How Does it Work? Lead author and PhD student Xiangyang Guo from RMIT, said the team can print layers of bismuth rust, otherwise known as oxide, in just a few seconds. “We fundamentally investigated this instant-printing technique for the first time using low-melting point liquid metals,” said Guo, who works under the supervision of Dr Ali Zavabeti and Professor Yongxiang Li. The team demonstrated that engineering materials at the nanoscale can present enormous opportunities in a range of functions, from sensing and energy harvesting to memory applications, he said. “Bismuth oxide can be engineered to provide memory functionality, which is critical for many applications,” Guo said. “The material can act as a semiconductor, meaning it can be used for computation. It is a nanogenerator, meaning it is energy efficient with a green energy supply from environmental vibrations and mechanical movements.” Guo said bismuth oxide was likely to cause less irritation to skin, compared with silicon, and it was durable, so it was stretchable and can be integrated into wearable technologies.

“We tested natural motion behaviour with the device attached to a finger joint, with an average output peak of about 1 volt,” Zavabeti said. BACK TO CONTENTS

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Smaller, Lighter Lithium-Sulphur Battery Lowers Costs and Improves Recycling Options Source: Sally Wood

Researchers at Monash University have developed a new lithiumsulphur battery design with a nanoporous polymer-coated lithium foil anode that reduces the amount of lithium required in a single battery.

billionth of a metre – which allow lithium ions to move freely while blocking other chemicals that would attack the lithium. The coating also acts as a scaffold for lithium, and helps it charge and discharge repeatedly.”

With the transition to renewable energies a global mission, the need for more sustainable energy storage solutions is becoming critical.

“Metallic lithium is a bit of a doubleedged sword. Lithium is packed full of energy, but in a bad battery, this energy is wasted on side reactions. On the other hand, if the energy is channelled correctly, it can make some incredible energy storage devices that are easier to make. This coating is a step towards highly efficient, easily manufactured Li-S batteries,” McNamara said.

In their recent paper PhD student Declan McNamara, Professor Matthew Hill, and Professor Mainak Majumder of Monash Engineering, with Dr Makhdokht Shaibani of RMIT University, outline how applying the nanoporous polymer directly onto the lithium foil anode has created a new battery design that uses less lithium, has more energy per unit volume, lasts longer and will be half the price of lithium-ion batteries. Lithium-sulphur (Li-S) batteries are an emerging energy storage technology that utilise metallic lithium and sulphur to deliver more energy per gram than lithium ion batteries. While the Li-S batteries are highly efficient, the process of finding, extracting and transporting lithium leaves a significant environmental footprint, so using as little lithium as possible remains important.

The new design does not require nickel or cobalt, removing the need for minerals that have a significant environmental and social cost. Professor Majumder said these developments are promising steps towards more widespread adoption of Li-S batteries and other lithium

metal-based energy storage systems. “Li-metal protection technologies will become crucial in our quest towards energy dense and sustainable batteries of the future. The study establishes a new framework to protect Li-metal from rapid decay or catastrophic failure which has been an achilles heel for Li-S batteries,” Professor Majumder said. Professor Hill said the technology could make an immediate impact. "The market for electric vehicles, drones and electronic devices is on a steep growth pattern and this research is commercially ready for manufacturing to support that growth. Producing more economical and environmentally sensitive battery options in Australia would be a great use of this technology, and we look forward to working with commercial partners to develop and manufacture this technology," Professor Hill said.

Li-S batteries also have their limitations. Typically they contain a lithium anode (negative electrode) and sulphur cathode (positive electrode) with a separating layer. When the battery charges and discharges, large amounts of lithium and sulphur are reacted with one another, placing the lithium metal under a lot of strain. PhD student and lead researcher Declan McNamara of Monash Engineering said the thin polymer coating on lithium significantly improved the number of times the battery could be cycled. “The polymer contains tiny holes less than a nanometre in size – one WWW.MATERIALSAUSTRALIA.COM.AU

SEM image of nanoporous polymer-coated lithium. Image Credit: Monash University.

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DECEMBER 2023 | 27

INDUSTRY NEWS

Characterising Advanced Battery Anodes with Gas Adsorption Bet Surface Area and DFT Surface Energy Source: ATA Scientific Pty Ltd

Lithium-ion (Li-ion) batteries play a key role in the trend toward renewable solutions and the global shift towards electric vehicles. They have high energy density, high power density, and long cycle life which has driven their adoption. The anode is a key component of the battery of which graphite continues to be the dominant material because of low cost, abundance, non-toxicity, and structural stability. However, to improve the battery performance alternative materials are being investigated such as graphene and graphene oxide. In this case study, the commonly used anode material in lithium-ion batteries, graphite, was characterised by BET surface area and DFT surface energy distribution and compared with other alternative anode materials.

Materials and Equipment A commercial graphite anode powder, graphene and graphene oxide were analysed on three Micromeritics physisorption instruments: the Gemini, TriStar, and 3Flex. The Gemini is specifically designed for rapid surface area

area characterisation with nitrogen adsorptive gas, which can be more affordable than analysis with Krypton. The Tristar on the other hand is designed for a high-throughput lab environment, efficiently analysing three samples in a single Dewar flask. The Tristar also has the Krypton option available for low surface area BET analysis. The 3Flex is designed for high-throughput research with the most versatile functions including micropore and vapor analyses, as well as Krypton analysis, with additional options to support static or dynamic chemisorption experiments.

Experimental All the samples were degassed under evacuation at 300°C for 60 minutes on the Smart VacPrep. After weighing the samples to obtain the after-degas sample mass, they were installed on each instrument to be analysed with nitrogen adsorptive gas at liquid nitrogen temperature of 77K. Eleven points from 0.05 to 0.3 relative pressures were collected on the TriStar and Gemini. The full adsorption and desorption isotherms, up to saturation pressure, were collected on the 3Flex.

Bet Surface Area The BET surface area results collected from different Micromeritics’ physisorption devices shows excellent repeatability as shown in the table below.

measurement. It uses the adsorptive rate dosing method, where it doses at the rate the sample adsorbs gas, which allows higher speed than a typical manometric instrument. Also, having blank tube subtraction for each analysis yields accurate results with less error. This allows low surface 28 | DECEMBER 2023

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Figure 1. Nitrogen BET surface area results of commonly used anode materials.

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Figure 2. The BET transform plot of graphite anode from the 3Flex selecting the typical pressure range of 0.05-0.3 p/p0.

Interestingly, when the typical 0.05-0.3 relative pressure range was selected for the BET calculations, the typical linearity requirements for reliable the BET fit were not obtained for both graphite and graphene samples. The BET calculation is shown in Figure 2 when the typical range is selected. Both graphite and graphene were observed to have two linear regions in this range. These multiple linear regions are displayed more prominently on the Rouquerol transform plot shown in Figure 3, which serves as a helpful guide when selecting a proper relative pressure range for a BET calculation especially when the linear BET range deviates from the typical 0.05-0.3 relative pressures.

Figure 4: Depiction of the packing transition of nitrogen on the surface of a graphene sheet as the pressure increases from low (on left) to high pressure (on right).

When several sub-steps are present in a collected isotherm, the lower linear region should be selected for the best estimation of BET surface area of a sample to satisfy the linearity required for BET calculations. Selecting 0.05 to 0.2 relative pressure range for the presented samples yielded good linearity with the correlation coefficient greater than 0.999 as shown in Figure 5. This pressure range can vary sample to sample, so reporting the selected pressure range along with the BET surface area for a graphitic carbon would be necessary.

Figure 5. The BET transform plot of graphite anode from the 3Flex selecting the first linear range with better correlation coefficient.

DFT Surface Energy

Figure 3. The graphite anode data analysed on the TriStar II Plus is shown including BET transform plot on the upper left, the Rouquerol transform plot on the lower left, and the isotherm on the lower right provided by the MicroActive software.

These unusual isotherms with several sub-steps reflect the effect of the commensurate transition as well as the layering transitions. The commensurate transition is a packing transition of nitrogen on the surface of a graphene sheet as the pressure increases as shown in Figure 4. At low pressures, a nitrogen molecule favorably sits on top of a graphitic ring, slightly overlapping into the adjacent rings due to its larger size. As the pressure increases, more nitrogen molecules are introduced, and they become more tightly packed together on the surface, each molecule no longer in the favorable state of directly sitting on top of the graphitic ring. WWW.MATERIALSAUSTRALIA.COM.AU

DFT surface energy method characterises the surface energy heterogeneity by deconvoluting an experimental isotherm based on the library of model isotherms of nonporous surfaces with different surface energies. The DFT

Figure 6. DFT surface energy distribution for graphite anode collected from the 3Flex.

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DECEMBER 2023 | 29

INDUSTRY NEWS

surface energy data reveals the level of interactions with an adsorptive gas present on the surface of a sample. A surface energy distribution is obtained by plotting the incremental surface area against the adsorptive potential energy (ε/k) in Kelvin, which relates to the isosteric heat of adsorption. The colder the temperature means there are less interactions between the surface and the adsorptive gas, and the warmer temperature means there are stronger interactions. More importantly, the adsorption energy reveals the surface topology features of a graphitic surface. The adsorption potentials ranging 50-60K represents the basal planes, those below 50K represents the prismatic surfaces, and those above 60K represents the defects. The adsorption potentials near 20K and near 100K represent nitrogen condensation and presence of micropores, respectively, so they are unrelated to the surface energy of the material. The surface energy distribution for the graphite anode sample is shown in Figure 6. It was mainly consisted of the basal planes with the main peak nicely centered around 50-60K. Figure 7 shows the overlay of the DFT surface energy distribution of graphite anode, graphene and graphene oxide. The graphene sample was consisted of both basal and prismatic planes. The graphene oxide was consisted of the basal, prismatic planes as well as defects where the basal plane contributed the most to the total surface area. It also showed some presence of micropore with the peak near 100K. Comparatively, the graphene had stronger interactions with nitrogen than the graphite anode sample, and graphene oxide exhibited the strongest interactions with the most surface area.

Figure 7. DFT surface energy distribution overlay for graphite, graphene, and graphene oxide collected from the 3Flex.

for the DFT surface energy distributions can be rearranged to show the surface area distribution contributing to each plane as shown in Figure 8.

Conclusion A single run of a nitrogen adsorption isotherm can reveal in-depth information about a material. Selecting the pressure range for BET surface area for graphite and graphene deviated from the standard pressure range of 0.05 to 0.3 p/pº due to the presence of sub-steps in the isotherm that reflected the commensurate transition as well as layering transitions. The DFT surface energy reveals the surface topology features of the commonly used anode materials in lithium-ion batteries. Contact us for more information today!

By associating different ranges of adsorptive potentials to basal, prismatic planes and defects, the same data used

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Figure 8. DFT surface area distributions of graphite anode, graphene and graphene oxide obtained from the 3Flex.

Reference: 1. Micromeritics.com/lithium-ion/. CHARACTERIZING ADVANCED BATTERY ANODES WITH GAS ADSORPTION BET SURFACE AREA AND DFT SURFACE ENERGY. [online] Available at: https://www.micromeritics.com/ Repository/Files/AppNote-202-Anode.pdf [Accessed 27 March 2023]. See webinar https://youtu.be/iG69MuLLrQM?si=iEG2xrL-WJu0X2R

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Generative Artificial Intelligence (AI) Opens New Territories in Material Science Source: Andy Song

Generative AI, is a cuttingedge forefront in the field of Artificial Intelligence. It has gained the spotlight and acclaim in recent years, especially in early 2023. This new paradigm is fundamentally different from traditional AI technologies, which are typically designed for tasks that are quite specific, for example pattern recognition, prediction and optimisation. Generative AI, on the other hand, has the ability to create and generate new content, whether it be text, images, music, videos, designs or even entire virtual worlds. At its core, generative AI leverages diffusion models and deep learning models like GANs (Generative Adversarial Networks) and transformers, to foster creativity and generate content that is often indistinguishable from humangenerated content. The possible utilisation of generative AI is astonishingly diverse, impacting numerous fields, from art to business, engineering, science and beyond. It introduces new ways how we interact with technology, fostering creativity and innovation,

yet with a much faster pace. The success that generative AI has already achieved is remarkable, ranging from autonomous art generation, realistic humanmachine conversation, and even the development of novel structures in the field of architecture design. As generative AI continues to evolve and integrate further into industry applications and scientific studies, its potential for ground breaking discoveries remains limitless. As a traditional but critical field, material science often involves a time-consuming and resourceintensive process. The landscape of material science is on the brink of transformation due to the advent of generative AI. In this article, we will delve into the trend of generative AI in material science, exploring how it is revolutionizing the discovery and development of novel materials, and the potential it holds for future innovations. According to market research firm MarketResearch.BIZ [1], the market size of generative AI in material science is projected to reach USD 8.5 Billion by 2032 with a sharp growth rate of nearly 30% per

Figure 1. Market size forecast in Generative AI in Material Science by MarketResearch.BIZ, expecting an annual growth of 29.8% from 2022 to 2032, reaching USD 8,486 Million in 10 years’ time [1].

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annum. Generative AI can empower a range of activities in material science, e.g. facilitating the creation of new materials with tailored properties, reducing development cost through simulation and predication, diversifying and optimizing structures.

Accelerating Materials Discovery Traditional materials discovery is often a serendipitous process involving extensive trial-and-error. Generative AI expedites the process by predicting and generating new materials with desired properties, either from scratch or from an existing baseline. From input of desired characteristics, AI algorithms generate materials that fit the criteria. This not only saves time but also minimizes the resources required, making the entire material discovery process more cost effective and sustainable. It is well-known that one way to discover new materials and chemistries is through the combination of different elements (phase-fields). However such approach is not scalable in practice [2]. With MatGAN, a generative AI method, hypothetical compounds can be mass produced. In [3], 1.69 million compositions were generated, with 84 to 92% of them “obeyed charge neutrality rules and were electronegativity balanced” despite the absence of physical rules in the GAN. Noh et al. proposed iMatGen, which leveraged generative model’s ability in image creation, to incorporate material structure as image based fingerprints for materials [4]. The model was able to reproduce materials of new compositions as well as new polymorphs of known structures. Another example is generating photoacid generators (PAGs), a critical photosensitive complex in semiconductor manufacturing [5]. It remains a big challenge in industry to design, implement, test and market new PAGs. With IBO (IBM Bayesian Optimisation) process, the process WWW.MATERIALSAUSTRALIA.COM.AU

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Applications of Generative AI in Material Sciences The potential applications of generative AI are vast and impactful. Here are some of the notable areas where it is already making a difference. Drug Discovery, material sciences are closely tied to healthcare and pharmaceuticals. Generative AI can design and predict the properties of drug candidates, accelerating drug discovery with a much reduced costs and time span. Energy Storage, advanced materials are crucial for energy storage solutions, such as batteries and supercapacitors. Generative AI is being used to design new structures that can enhance energy density and charge-discharge cycles. Catalyst Development, Figure 2. Example of accelerating the workflow of designing PAGs with IBO (IBM Bayesian Optimisation) [5]. The goal is to achieve the ideal score with less number of molecules tested.

can be greatly accelerated (see the illustration in Figure 2). A more recent generative toolkit for material design can be found in [6].

Materials Simulation and Design Generative AI can simulate the behaviour of materials under different conditions, enabling researchers to design materials with specific properties. This level of precision is a game-changer, particularly in industries like aerospace and automotive, where materials must withstand extreme conditions. For example Gao et al show that generative techniques can obtain the missing fault samples and improve classification accuracy by creating more training samples [7]. Liu et al proposed an remarkable idea of utilising ChatGPT to enable an iterative and conversational process to generate material design [8]. The large language model (LLM) in this case has been turned into a CIF (Crystallographic Information File) generator. A detailed example from the study is shown in Figure 3. Barda et al, enabled generative design to produce full functional, load bearing 3D sheet metal components by combining high level specifications and structure characteristics [9]. WWW.MATERIALSAUSTRALIA.COM.AU

Figure 3. Example of generative AI with different prompt for creating and revising Crystallographic Information File (CIF) content of NaZr2(PO4)3 [8].

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INDUSTRY NEWS

Catalysts obviously play a pivotal role in chemical processes. Generative AI can help identify new catalyst materials similar to what can be done for other material design tasks. Ecofriendly Living, generative AI can also contribute to mitigate environmental challenges by assisting the development of eco-friendly and sustainable materials, e.g. recyclable and biodegradable.

Challenges and Limitations While generative AI offers significant advancements in material sciences, it is not without challenges and limitations. The most common one is the quality and the availability of seed data necessary for these generative models. Acquiring high-quality and comprehensive datasets for a diverse range of materials however can be quite arduous. In addition, generative AI often relies on deep learning models which are notoriously for their poor interpretability, hindering their application in some highly critical scenarios. The high computational power demanded by generative AI is another potential obstacle to its widespread adoption. Furthermore, the superb capability of generative AI undoubtedly raises serious ethical concerns as it may be misused for the creation of illegal materials, weapons and other hazardous or malicious purposes.

The Future of Generative AI in Material Sciences While the integration of generative AI in material sciences is still in its infancy stage, it has already showcased immense potential and numerous exciting possibilities. Material scientists can join forces collectively to embrace the bright future ahead. Firstly, generative AI ought to be used for good, e.g. customizing materials to improve quality of live, ensuring wider and easier access to advanced materials, and developing more sustainable technologies and solutions for our planet. Furthermore, fostering global collaboration and providing open access of data would immensely empower and accelerate advancements in material science, embracing the open-source nature of AI, in particular generative 34 | DECEMBER 2023

AI. Moreover, coupled with the development of quantum computing, generative AI stands to further revolutionize materials science, by not only modelling complex molecular interactions, which are usually computational prohibitive, but also unlocking novel materials with unprecedented properties.

Conclusion Generative AI is a transformative force in material sciences. It expedites the discovery of new materials, simulates molecular behaviors, and designs materials with tailored properties. Its application areas span widely, ranging from metals to chemical substances, from drugs to batteries. However, challenges such as data availability, model interpretability, and ethical concerns need to be addressed as generative AI continues to grow in the field. The future of generative AI in material sciences is filled with promise and exciting possibilities. As generative AI becomes more integrated into research and industry practices, we anticipate ground-breaking advancements that will shape the materials of tomorrow.

Andy Song

Andy Song is an Associate Professor in AI, and the manager of the Centre of Industrial AI Research and Innovation, at RMIT University. He specialises in solving complex industry problems such as task scheduling, computer vision, and market prediction, by cuttingedge AI techniques. He has extensive interdisciplinary and industry collaborations, spanning across a wide range of sectors, including health, transportation, logistics, food, waste and materials. He is the recipient of multiple awards and grants. He is the secretary of the National AI Committee of Australia, and directing AI development for several companies. He frequently appears on the media, advocating for AI awareness among the general public.

[1] https://marketresearch.biz/report/generative-ai-in-material-science-market/ [2] Fuhr Addis S., Sumpter Bobby G. Deep Generative Models for Materials Discovery and Machine Learning-Accelerated Innovation, Frontiers in Materials, VOLUME 9 (2022) https://www.frontiersin.org/articles/10.3389/fmats.2022.865270 [3] Dan, Y., Zhao, Y., Li, X., Li, S., Hu, M., and Hu, J. Generative Adversarial Networks (GAN) Based Efficient Sampling of Chemical Composition Space for Inverse Design of Inorganic Materials. Npj Computational Materials 6 (1), 84 (2020). doi:10.1038/s41524-020-00352-0 [4] Noh, J., Kim, J., Stein, H., Sanchez-Lengeling, B., Gregoire, J., Aspuru-Guzik, A., Jung, Y., Inverse Design of Solid-State Materials via a Continuous Representation, Matter 5 (1), 1370-1384 (2019), ISSN 2590-2385 [5] Pyzer-Knapp, E.O., Pitera, J.W., Staar, P.W.J. et al. Accelerating materials discovery using artificial intelligence, high performance computing and robotics. npj Computational Material 8, 84 (2022). https://doi.org/10.1038/s41524-022-00765-z [6] Manica, M., Born, J., Cadow, J. et al. Accelerating material design with the generative toolkit for scientific discovery. npj Computational Material 9, 69 (2023). https://doi. org/10.1038/s41524-023-01028-1 [7] Gao, Y., Liu, X., Xiang, J., "FEM Simulation-Based Generative Adversarial Networks to Detect Bearing Faults," in IEEE Transactions on Industrial Informatics, vol. 16, no. 7, pp. 4961-4971, July 2020, doi: 10.1109/TII.2020.2968370. [8] Liu, Y., Yang, Z., Yu, Z., Liu, Z., Liu, D., Lin, H., Li, M., Ma, S., Avdeev, M., Shi, S., Generative artificial intelligence and its applications in materials science: Current situation and future perspectives, Journal of Materiomics, Volume 9, Issue 4, 2023, Pages 798-816, ISSN 2352-8478, https://doi.org/10.1016/j.jmat.2023.05.001. [9] Barda, A., Tevet, G., Schulz, A., Bermano, A., Generative Design of Sheet Metal Structures. ACM Transactions on Graphics. 42, 4, Article 116 (August 2023), page 1-13. https://doi.org/10.1145/3592444

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8-9 July 2024 • RMIT, Melbourne Victoria • energymaterials2024.com.au

Energy materials define substances or materials that are intentionally designed or engineered for the purpose of storing, converting, or transmitting energy.

Co Chairs

These materials play a crucial role in various energy-related applications, including power generation, energy storage, and energy conversion. Energy materials can encompass a diverse range of substances, ranging from traditional fossil fuels like coal and natural gas to advanced materials used in renewable energy technologies, such as solar cells, batteries, and fuel cells. The development and utilization of energy materials are essential for addressing global energy challenges, improving energy efficiency, and reducing environmental impacts associated with energy production and consumption. This conference will include invited lectures from nationally distinguished

Professor Jianfeng Nie Monash University Jianfeng.Nie@monash.edu

researchers, contributed presentations and posters. Contributions will be encouraged in the following areas of interest:  Additive manufacturing  Battery materials

 Materials for CO2 capture and storage

L ightweighting materials for

 Materials for fuel-cell applications

energy saving applications

 Materials for gas and oil resources

 Environmental impacts

 Materials for gas turbines

E nergy and environmental issues

 Materials for hydrogen

in materials manufacturing and processing

harvesting and storage

Distinguished Professor Ma Qian RMIT ma.qian@rmit.edu.au

 Materials for nuclear energy

M agnetic and electronic materials

 Materials for solar energy conversion

M aterials for circularity economy

 Materials for water purification

 Materials in clean power

 Materials for wind energy

 Materials for coal power

 Metamaterials for energy absorption

Conference Host

Conference Partner

ABSTRACTS CLOSE: 1 MAY 2024

Opportunities for sponsorships and exhibitions are available. WWW.MATERIALSAUSTRALIA.COM.AU BACK TO CONTENTS DECEMBER Conference Secretariat: Tanya Smith tanya@materialsaustralia.com.au | +61 3 9326 72662023 | 35

INDUSTRY NEWS

UQ Home to Australia’s First Superconducting Quantum Hardware Startup Source: Sally Wood The University of Queensland’s Professor Tom Stace and Associate Professor Arkady Federov have cofounded Analog Quantum Circuits (AQC) after a decade of theoretical and experimental research on engineering quantum systems.

Professor Stace said AQC was working to commercialise microwave circulators 1,000 times smaller than what is currently available. “Commercial circulators are the size of a matchbox and we have managed to shrink them to a few tens of micrometres, which is a fraction of the width of a human hair,” Professor Stace said. “A quantum computer is measured by the number of elementary parts called qubits, and it is estimated that at least a million of these will be needed before they become useful for complex computations.” “We’re building miniature components that will scale with the quantum computer, so companies building the rest of the system are able to incorporate our technology.” AQC is the first superconducting quantum technology startup in Australia and its five-member team

works out of the Superconducting Quantum Devices Lab at UQ’s St Lucia campus, building on work started within the Australian Research Council (ARC) Centre of Excellence for Engineered Quantum Systems (EQUS). The work is carried out in cryogenic dilution refrigerators that operate at minus 273 degrees Celsius, which is 100 times colder than outer space. “Quantum hardware is exquisitely sensitive, and even the ambient electrical noise at room temperature is 10,000 times too loud, so the microwave circulator that we are building helps shield that noise,” Dr Fedorov said. “We are developing part of the communications channel between the outside world and the quantum computer others are trying to build, so that interface technology must sustain the temperature difference between the interior and exterior of the fridge.” The Queensland Government has announced plans to invest $76 million over the next four years through its Queensland Quantum and Advanced Technologies Strategy, which builds on the Federal Government’s National Quantum Strategy.

Dr Federov and Professor Stace with Federal Minister for Industry and Science, Ed Husic on a recent tour of AQC’s lab. Image Credit: University of Queensland.

“A nation or organisation that has access to quantum technology will have a head start in important areas that are related to national security, computation, and communication,” Professor Stace said. “It would be fair to describe it as a technological race and is something that requires significant investment and collaboration with close allies. “We are leading quantum hardware development for international markets by building on the basic research that was done in Queensland with the extremely talented people we have trained.” EQUS Director Professor Andrew White said AQC was the latest success to come out of the Centre’s Translational Research Program. “Arkady and Tom and their team have worked very hard to translate their technology from an idea on paper, to a prototype and now to a business,” Professor White said. “We look forward to seeing their devices in all future quantum computers.”

Associate Professor Arkady Federov, Professor Tom Stace and Mr Prassania Pakkiam at AQC. Image Credit: University of Queensland.

36 | DECEMBER 2023

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AQC secured $3 million in venture capital investment from Uniseed to fund further research and development. Uniseed Investment Manager Paul Butler said AQC was a great opportunity to support Australia’s quantum strategy. WWW.MATERIALSAUSTRALIA.COM.AU

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INDUSTRY NEWS

Custom Metal Powder Production Using Ultrasonic Atomisation By Dr. Cameron Chai and Peter Airey Processes such as metal additive manufacturing and thermal spraying rely on free flowing, spherical metal powder feedstocks. If your requirement only calls for standard alloys and off-the-shelf particle sizes, you are probably well catered for. But, if you need something else, like a specialty alloy, or your process doesn’t suit the standard product sizes, you might get a shock when you get a quotation for the metal powder you are after. Fortunately, the Amazemet rePowder ultrasonic atomisation system allows you to produce custom alloys and tailor your particle size to your own specific needs.

Traditional Powder Production Most metal powders are produced by a process called gas atomisation. It involves hitting a stream of homogenised molten metal with a jet of high-pressure inert gas and is suited to large production runs of the order of 50kg or more. Changing composition and modifying the process is an expensive undertaking, which will no doubt be passed on to you.

The Alternative – Ultrasonic Atomisation In 2016, Łukasz Żrodowski, a Ph.D. student looking for a small quantity

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of powder rediscovered ultrasonic atomisation that had been dormant for 40 years. The process involves pouring a stream of molten metal onto a vibrating plate or sonotrode. The rapidly vibrating sonotrode ejects droplets of molten metal that solidify in an inert atmosphere. The particle size is controlled by vibration frequency and amplitude. Over the coming years Łukasz refined the process and founded Amazemet in 2019. He commercialised ultrasonic atomisation technology in the form of the rePowder. With a modular architecture it can be tailored with an induction furnace (for alloys melting up to 1300°C) or arc/plasma furnace (for alloys melting up to 3500°C) and other feed systems. There are now more than 30 installations around the world including several in the USA and China.

Advantages of Ultrasonic Atomisation The Amazemet rePowder is ideal for small production runs in batches which makes it ideal for alloy prototyping and powder optimisation. Ultrasonic atomisation has many benefits including: • Compact Size – Enables systems to

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be easily located in labs close to AM equipment • Suitable for any alloy composition – Suits everything from pure elements to exotic/refractory alloys • Any form or feedstock – Caters for any source materialfrom chips, failed AM prints, damaged samples, rods, wire, powder, etc. • Controllable particle size – Alloy particle size is a function of sonotrode vibration frequency and amplitude • Low running costs – Relatively low gas consumption • Variable capacity – Process batches from just a few grams to multiple kg per day • Recycling – Use printed or failed parts or scrap material from DMLS, SLM and other processes as feedstock • Modularity – Add new modules to expand the system’s capabilities • Versatility - Prepare new compositions, alloy homogenisation, ultrasonic atomisation, suction casting and further options in development • Multiple alloys in one day – rePowder can be easily cleaned and configured to run multiple different alloys in a single day

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INDUSTRY NEWS Powder Properties Ultrasonic atomisation produces powders with unrivalled sphericity (>0.98) with a very tight particle size distributions, ensuring more consistent processing properties for both AM and thermal spray processes

Summary Ultrasonic atomisation systems like the Amazemet rePowder are ideal for researchers and commercial entities

looking to produce custom alloy powders with optimised composition and/or particle size in small batches from virtually any feedstock. Due to their small size and affordability, they can be located in almost any lab. The resultant metal powders have excellent sphericity and tight particle size distributions making them ideal for additive manufacturing and thermal spray processing. For more details, please contact info@axt.com.au

Process

Gas Atomisation

Ultrasonic Atomisation

Particle morphology

Various shapes

High sphericity

Particle size distribution (PSD)

Wide

Narrow

Throughput

High – suits industrial scale

Low – ideal for laboratories

Powder yield

Moderate

High

Flexibility

Poor

Excellent

Equipment size

Enormous

Compact

Feedstock

Any

Inert gas consumption

High

Low

Micro 3D Printing

High-speed ultrahigh-resolution

Microfluidic chip 35mm in length

Cell cage 1mm scaffold diameter

BMF microArch printer 2µm resolution

UpNano NanoOne printer 170nm resolution

AXT offers high-resolution 3D printing services

info@axt.com.au | axt.com.au

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DECEMBER 2023 | 39

INDUSTRY NEWS

Promising Material Provides a Simple, Effective Method Capable of Extracting Uranium from Seawater Source: Sally Wood An Australian-led international research team, including a core group of ANSTO scientists, has found that doping a promising material provides a simple, effective method capable of extracting uranium from seawater.

The research, published in Energy Advances and featured on the cover, could help in designing new materials that are highly selective for uranium, efficient, and cost-effective. Uranium is a highly valued mineral used as a fuel source in nuclear reactors around the world. “There's a lot of uranium in the oceans, more than a thousand times more than what is found in the ground, but it's really diluted, so it's very difficult to extract. The main challenge is that other substances in seawater, salt and minerals, such as iron and calcium, are present in much higher amounts than uranium,” explained lead scientist Dr Jessica Veliscek Carolan, who supervised co-author honours student Hayden Ou of UNSW with Dr Nicolas Bedford of UNSW. First author was Muhammad Zubair of UNSW. One of the co-authors, Bijil Subhash received a grant from the Australian Institute of Nuclear Science and Engineering (AINSE) to support his research at ANSTO. Layered double hydroxides, materials that have attracted interest for their ability to remove metals, are fairly easy to make and can be modified to improve the way they work.

40 | DECEMBER 2023

Because these layers have positive and negative charges, they can be tailored to capture specific substances such as uranium. Lanthanide dopants, neodymium, europium and terbium, were tested. Adding neodymium to layered double hydroxides (LDHs) improved their ability to selectively capture uranium from seawater, a highly challenging process that scientists have been working on for a long time. Synthesised materials were characterised using a variety of techniques, including Scanning transmission electron microscopy (STEM) and scanning electron microscopy (SEM) at ANSTO’s microscopy facility by Dr Daniel Oldfield and at UNSW by Yuwei Yang. When neodymium was added to LDHs (MgAlNd), these materials chose uranium over ten other more abundant elements found in real seawater. Importantly, the experiments were undertaken under seawater-like conditions. A crucial finding was that the dopant, neodymium, changes the way uranium binds to the LDHs. The research team also used X-ray absorption spectroscopy (XAS) and Soft X-ray spectroscopy at ANSTO’s Australian Synchrotron to clarify the octahedral coordination environment, oxidation state and adsorption mechanism, respectively. They were

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assisted by Instrument scientists Dr Jessica Hamilton and Dr Lars Thomsen, co-authors of the paper. X-ray measurements showed that under seawater conditions, the removal of uranium occurred through a process where uranium atoms formed complexes on the surface of LDHs by replacing nitrate ions in the LDH layers with uranyl carbonate anions from the seawater. By adding neodymium and other lanthanide elements to the LDH structure, the chemical bonding between metal atoms and oxygen in the LDH became more ionic. This improved ionic bonding made these materials much better at selectively binding to uranium via ionic surface interactions. The authors pointed out that the study demonstrated a way to adjust how well a material can capture uranium which could lead to creating new materials that are even better at separating uranium from other substances. The materials were not just useful for taking uranium from seawater but also had the potential to clean up uranium from radioactive wastewater near nuclear power plants. “There are additional benefits in that these materials are simple and inexpensive to make, making them a cost-effective choice for large-scale uranium extraction,” said Dr Veliscek Carolan.

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UNIVERSITY SPOTLIGHT

Innovation at the Surface: La Trobe University's Leadership in Materials Science Research Established in 1964, La Trobe University is a testament to educational excellence and forwardthinking research. Since its beginnings, La Trobe has committed itself to not only pushing the boundaries of knowledge but also shaping the future leaders of tomorrow.

Nestled amongst lush greenery in the Melbourne suburb of Bundoora, the main campus is a fusion of modern architecture and serene natural landscapes, providing students with an ideal environment for both study and relaxation. But beyond its picturesque settings, La Trobe has multiple campuses spread across Victoria, making it one of the state's most expansive tertiary institutions. What sets La Trobe apart is its relentless pursuit of innovation. The university has consistently ranked among the world’s top institutions. Its research-driven approach is reflected in the ground-breaking projects and collaborations that La Trobe undertakes every year. The university's state-of-the-art research facilities ensure that students and faculty are always at the forefront of their respective fields. La Trobe prides itself on its inclusive and diverse community. With students hailing from over 100 countries, it offers a multicultural tapestry that enriches the educational experience. This international perspective is pivotal, as the university prepares its students to thrive in an increasingly globalized world.

Centre for Materials and Surface Science The Centre for Materials and Surface Science (CMSS) brings together experts from physics, chemistry, materials science and electronic engineering, and offers world class capabilities in nano-characterisation focused on the surface science, analysis, imaging and synchrotron domains. The CMSS offers industry and research organisations expert surface analysis using Australia's most comprehensive suite of surface science equipment. It features a range of custom built ultra-high vacuum instrumentation, synchrotron end stations, and modern surface analytical instrumentation. Contemporary surface analytical techniques allow the elemental composition, chemistry and molecular structure of the outermost layers of solid surfaces to be determined.

A Brief History The CMSS was originally established in 1977 as the Research Centre for Electron Spectroscopy by staff from the Departments of Physics and Chemistry at La Trobe University, with the aim of providing a structure within the University to encourage and promote cooperative activities and programs in teaching and research in the general area of electron spectroscopy. 42 | DECEMBER 2023

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From the beginning, scientists from other local institutions with common research interests were included as Associates, and various workshops and meetings were organised on a state and national level. In 1990, the name of the Centre was enlarged to the Research Centre for Electron Spectroscopy and Surface Science, in order to explicitly include the substantial ongoing research in that latter field, and to include techniques other than electron spectroscopy. Then, in 1998, the name was changed once again, to the Centre for Materials and Surface Science, to reflect the continuing change in research emphasis. In 2007, CMSS was a founding member of the Australian National Fabrication Facility (ANFF) through the Victorian Node. This facility was established under the National Collaborative Research Infrastructure Scheme (NCRIS) with co-investment from the State of Victoria and the participating organisations. Success in further funding endeavours has seen ANFF grow into a $200 million enterprise. CMSS was also a foundation investor in the Australian Synchrotron.

Their Research CMSS analytical specialists have worked with more than 50 Australian and international companies over the WWW.MATERIALSAUSTRALIA.COM.AU

UNIVERSITY SPOTLIGHT

La Trobe University City of the Future A city born from a university where people, place and culture converge, and lives are transformed.

La Trobe University's Melbourne Campus at Bundoora is a special place that already provides a unique setting for learning, research and employment. With its substantial landholdings and location at the gateway to Melbourne's growing north, La Trobe provides unparalleled opportunities for the University and the wider community.

last 15 years, providing high quality surface analytical and X-ray imaging services. Just some of the techniques available at CMSS include: X-ray photoelectron spectroscopy (XPS); Time-of-flight secondary-ion mass spectrometry (ToF-SIMS); Scanning Auger Nanoprobe (SAN); ScanningProbe Microscopy (SPM); Scanning Electron Microscopy (SEM); X-ray Powder Diffraction (XPRD); X-ray fluorescence spectrometry (XRF); and X-ray Diffraction (XPD). CMSS aims to: • Promote co-operative activities and programs in education and research • Encourage collaboration between local and international organisations • Provide, receive and disseminate information in the areas of the centre Their research is focused on: • Electronic bandstructure determinations of III/V and II/VI semiconductors using angle resolved photoelectron spectroscopy in conjunction with synchrotron radiation • Investigation of the topology of the Fermi surface of metals and alloys • Development of novel high WWW.MATERIALSAUSTRALIA.COM.AU

resolution electron spectrometers • Molecular Beam Epitaxy of III-V and II-VI semiconductors • Surface analysis of polymer films • Surface science studies of antimony-free lead grid electrodes in low maintenance lead-acid batteries • X-ray Photoelectron Spectroscopy studies of new piezoelectric and magnetic materials, synthesised at La Trobe • XPS studies of rare-earth-fluoride ion-selective electrodes, with particular emphasis on crystal growth and surface reactivity • Irradiation-modification of Metal-Semiconductor interface properties. • X-ray Photoelectron Diffraction studies of Adsorbates • Electron Stimulated Desorption from GaAs surfaces

With Melbourne’s population expected to grow to almost nine million people by 2056, La Trobe has been identified as the anchor in the Victorian Government’s La Trobe National Employment and Innovation Cluster, one of seven clusters to be developed, to support the projected significant employment and residential growth in Melbourne’s North. As our population grows, over the next decade, La Trobe University will evolve into a world-class University City of the Future at our 235 hectare Melbourne Campus in Bundoora. The new infrastructure will turn the campus 'inside out' and welcome the local community onto the campus as a place to live, learn, work, socialise and stay healthy. The University City of the Future will create: • 20,000+ new jobs over ten years • Education facilities for 40,000+ students • Additional housing for 12,000 students, staff and private residents • $3.5 billion in Gross Regional Product (GRP) over the next ten years.

• Cluster-ion photodissociation spectroscopy directed to the study of weak molecular interactions • Electrospray mass spectrometry of ion-clusters in solution • Molecular orbital calculations on large molecules including buckminsterfullerene adducts and small polysaccharide and polypeptide systems BACK TO CONTENTS

Artists impression of the University City of the Future. Image credit: La Trobe University.

DECEMBER 2023 | 43

BREAKING NEWS Mimics Human Tissue, Fights Bacteria: New Biomaterial Hits the Sweet Spot A new lab-made substance mimics human tissue and could reduce or replace the use of animal-derived materials in biomedical research. Scientists at UNSW Sydney have created a new material that could change the way human tissue can be grown in the lab and used in medical procedures. The new material belongs to a family of substances called hydrogels, the essence of life’s ‘squishy’ substances found in all living things, such as cartilage in animals and in plants like seaweed. The properties of hydrogels make them very useful in biomedical research because they can mimic human tissue, allowing cells to grow in a laboratory. There are also human-made hydrogels that are used in a broad range of commodity products ranging from food and cosmetics to contact lenses and absorbent materials, and more recently in medical research to seal wounds and replace damaged tissue. While they might function adequately as space fillers that encourage tissue growth, synthetic hydrogels fall short in recreating the complex properties of real human tissue. But in a research paper published recently in Nature Communications, scientists from UNSW describe how a new lab-made hydrogel behaves like natural tissue, with a number of surprising qualities that have implications for medical, food and manufacturing technology. Associate Professor Kris Kilian from UNSW’s School of Materials Science & Engineering and School of Chemistry says the hydrogel material is made from very simple, short peptides, which are the building blocks of proteins. “The material is bioactive, which means that encapsulated cells behave as if they are living in natural tissue,” Associate Professor Kilian said. “At the same time, the material is antimicrobial, meaning that it will prevent bacterial infections. This combination lands it in the sweet spot for materials that might be useful in medicine. The material is also self-healing, which means that it will reform after being squished, fractured, or after being expelled from a syringe. This makes it ideal for 3D bioprinting, or as an injectable material for medicine.”

Dr Alessandro Tuniz (left) and Associate Professor Boris Kuhlmey in their Sydney Nanoscience Hub laboratory. Image Credit: Stefanie Zingsheim.

Superlensing Without a Superlens: Microscopes Boosted Beyond Limits Physicists at the University of Sydney have shown a new pathway to achieve superlensing with minimal losses, breaking through the diffraction limit by a factor of nearly four times. Their trick? Remove the superlens altogether. Ever since Antonie van Leeuwenhoek discovered the world of bacteria through a microscope in the late seventeenth century, humans have tried to look deeper into the world of the infinitesimally small. There are, however, physical limits to how closely we can examine an object using traditional optical methods. This is known as the ‘diffraction limit’ and is determined by the fact that light manifests as a wave. It means a focused image can never be smaller than half the wavelength of light used to observe an object. Attempts to break this limit with ‘super lenses’ have all hit the hurdle of extreme visual losses, making the lenses opaque. Now physicists at the University of Sydney have shown a new pathway to achieve superlensing with minimal losses, breaking through the diffraction limit by a factor of nearly four times. The key to their success was to remove the super lens altogether. The work should allow scientists to further improve superresolution microscopy, the researchers say. It could advance imaging in fields as varied as cancer diagnostics, medical imaging, or archaeology and forensics. Lead author of the research, Dr Alessandro Tuniz from the School of Physics and University of Sydney Nano Institute, said, “We have now developed a practical way to implement superlensing, without a super lens.” “To do this, we placed our light probe far away from the object and collected both high- and low-resolution information. By measuring further away, the probe doesn’t interfere with the high-resolution data, a feature of previous methods.”

The 'Trpzip' material will reform after being squished, fractured, or after being expelled from a syringe. Image Credit: UNSW Sydney.

44 | DECEMBER 2023

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Previous attempts have tried to make super lenses using novel materials. However, most materials absorb too much light to make the super lens useful.

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BREAKING NEWS Titanium Micro-Spikes Skewer Resistant Superbugs A new study suggests rough surfaces inspired by the bacteria-killing spikes on insect wings may be more effective at combatting drug-resistant superbugs, including fungus, than previously understood. The increasing rates of drug-resistant infection has health experts globally concerned. To avoid infection around implants – such as titanium hips or dental prosthesis – doctors use a range of antimicrobial coatings, chemicals and antibiotics, but these fail to stop antibiotic-resistant strains and can even increase resistance. To address these challenges, RMIT University scientists have designed a pattern of microscale spikes that can be etched onto titanium implants or other surfaces to provide effective, drug-free protection from both bacteria and fungus. The team’s study published in Advanced Materials Interfaces tested the effectiveness of the altered titanium surface in killing multi drug-resistant Candida – a potentially deadly fungus responsible for one in 10 hospitalacquired medical device infections. The specially designed spikes, each of a similar height to a bacteria cell, destroyed about half the cells soon after contact. Significantly, the other half not immediately destroyed were rendered unviable from the injuries sustained, unable to reproduce or cause infection. Lead Postdoctoral researcher, Dr Denver Linklater, said metabolic analysis of protein activity revealed both the Candida albicans and multi-drug resistant Candida auris fungi cells sitting injured on the surface were as good as dead. “The Candida cells that were injured underwent extensive metabolic stress, preventing the process where they reproduce to create a deadly fungal biofilm, even after seven days,” said Linklater, from RMIT’s School of Science. “They were unable to be revived in a non-stress environment and eventually shut down in a process known as apoptosis, or programmed cell death.”

Image Credit: Deakin University.

Textile Waste Pulverised into Powder to Produce Works of Art Pigments extracted from waste textiles have been turned into works of art by Indigenous artists for a free exhibition showing at Deakin University's Waterfront Campus. The 'Perpetual Pigments' exhibition is part of Geelong Design Week and also features screen printed fabric designs using the recycled pigments, including the test run of new t-shirts produced in collaboration with surf brand Rip Curl. The innovative works of art and design are the fruits of research, based at Deakin's Institute for Frontier Materials, exploring how to divert coloured textile waste from landfill and find new ways to use large volumes of recycled textiles. Lead researcher Associate Professor Rangam Rajkhowa said about 800,000 tonnes of textile waste end up in landfill in Australia each year. But he hopes his world-first pigment extraction process can provide new ways discarded clothes and other textiles can be reused in the circular economy. "We've found that particles produced from textile waste segregated by colour could be used for a range of applications. This includes pigments for printing or colouring textiles, and which can also be used to create art," Associate Professor Rajkhowa said. "Our simple but powerful approach could address the huge challenges of recycling textiles due to complexities of different colours, fibres and blends." Using textile waste sourced through industry partner Textile Recyclers Australia - which receives unwanted clothing and textiles from households, retailers and industry - the Deakin research team grinds down the materials to produce a fine powder.

An intact Candida cell on polished titanium surface (left), and a ruptured Candida cell on the micro-spiked titanium surface (right).

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For this project - supported with a grant from Sustainability Victoria's Circular Economy Markets Fund and Deakin's Science and Society Network - pigment powders have been produced in primary colours, black and ochre to provide to the participating artists to mix and use as they wish.

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DECEMBER 2023 | 45

BREAKING NEWS Nanostructure Explains the Behaviour of Molecules with Liquid-Like Properties ANSTO has supported research led by a University of Sydney team who gained insights into how oil molecules retain their ‘liquid-like’ properties when they are chemically attached as an extremely thin layer to solid surfaces. The findings open new possibilities for designing sustainable materials with non-stick characteristics. The research was led by Dr Isaac Gresham, Professor Chiara Neto and honours student Seamus Lilley from the School of Chemistry at the University of Sydney. The ‘liquid-like’ coatings, known as slippery covalentlyattached liquid surfaces (SCALS), are produced from silicones or polyethylene glycol – both of which break down into harmless by-products in the environment. SCALS are anti-adhesive without relying on problematic perfluorinated polymers (PFAS), known as ‘forever chemicals’ that are usually used for their low adhesion properties. “These liquid-like layers are extremely slippery to most contaminants: they shed liquid droplets effortlessly, which is great to increase the efficiency of heat transfer and for collecting water, they prevent the build-up of scale, and resist the adhesion of ice and bacteria, bringing us one step closer to a self-cleaning world,” said Professor Neto, who leads the Nano-Interfaces Laboratory. “We can correlate the exceptional performance of these layers with their nanostructure – meaning we now know what we’re aiming for when we design slippery surfaces, enabling us to make them even more effective and provide viable alternatives to fluorinated coatings.” Neutron reflectometry on the Platypus instrument at ANSTO's Australian Centre for Neutron Scattering was used to characterise structure at the nanoscale. The slippery nano-thin layers, between two and five billionths of a metre thick or 10,000 times thinner than a human hair, are made up of oil molecules that are only a hundred atoms long. The material comprises a surface layer with curly chains of polymer brushes that are attached to it.

(L to R): CEO of Jet Technology, Howard Ju, with Alfred Deakin Professor and Deakin Chair in Biotechnology, Colin Barrow.

REACH Partnership to Transform Organic Waste into New Products Australia is continuing to generate more landfill each year. A new partnership between Deakin’s Recycling and Clean Energy Commercialisation Hub (REACH) and Japanese-based company Jet Technology aims to turn this around by repurposing organic waste and transforming it into new products. Australia contributes more than 7.6 million tonnes of food to landfill annually, costing over $36.6 billion and producing 17.5 million tonnes of CO2. Deakin University scientist Alfred Deakin Professor and Chair in Biotechnology Colin Barrow and his team from the Centre for Sustainable Bioproducts will work with Jet Technology to explore the possible reuses of organic waste using Jet Technology’s Environmental Recycling System (ERS). The project will focus on converting organic waste from the agriculture, dairy and fishery sectors by drastically shortening composting time so it can be used to make new products. Jet Technology’s CEO Howard Ju says Australia is rich in agricultural and fishery resources, and these resources represent significant tonnage of organic product to be scaledup for commercialisation. “Through this pilot project we will develop a range of applications and solutions to resolve current organic waste issues for different sectors and improve Australia’s organic resource recovery,” he explained. “Our world leading ERS technology significantly reduces the organic recycling process from weeks or months to a few hours. It is a clean process with almost zero pollution to the environment that will produce organic products, such as fertiliser, cow feed and textiles.”

Dr Andrew Nelson with the Neutron Reflectometer Platypus. Image Credit: ANSTO.

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The four-year research project will be undertaken at the BioFactory at Deakin’s Waurn Ponds campus. It will initially focus on processing agricultural waste, converting apple pomace into a bioproduct for the textile industry. Apple pomace consists of the apple skin, pulp, seeds and stems left over from apple juice manufacturing. Its disposal in landfill can lead to greenhouse gas emissions and potential contamination of soil and groundwater. WWW.MATERIALSAUSTRALIA.COM.AU

BREAKING NEWS Carbon Copy: New Method of Recycling Carbon Fibre Shows Potential Ultra-light cars made from recycled carbon fibre are a step closer, thanks to a new method of recycling developed at UNSW Canberra. Carbon fibres are thin strands of carbon that are exceptionally strong and lightweight. The fibres are combined with plastic to create a composite that can be used to construct a variety of products. Carbon fibre is commonly used to build aircraft, wind turbines, and it is the primary material used in Formula 1 race cars, which need to be as light as possible to increase performance. You might encounter carbon fibre in highend bicycles or other sporting equipment such as hockey sticks or tennis racquets. UNSW Canberra researcher Di He said that, until now, recycling carbon fibre had always resulted in the material being heavily degraded. “This project was a collaboration with our partner in the automotive industry, who wants to investigate building cars out of recycled carbon fibre,” Dr He said. “But with the previous methods of recycling carbon fibre, the material was heavily compromised. The mechanical performance of objects made from the existing recycled fibres is degraded by 80 to 90 per cent, compared to using new fibres. Typically, it is only reused to make lowvalue products like tables or chairs, products that don’t experience heavy forces or loads.” “The existing method of recycling involves shredding the composite, which destroys the carbon fibre, before heating it to remove the plastic. After it has been shredded, the fibres look like individual hairs or cotton wool strands," he explained. “In our method, we don’t shred the carbon fibre and we optimised how we heat it in a furnace. This leaves the fibres intact, and therefore the new product made from the recycled carbon fibre is much stronger. Our method degrades the carbon fibre by less than 30%, which is a 50% improvement on existing methods.” While the recycled carbon fibre produced using Dr He’s method is not yet suitable for constructing a car, it is significantly closer to that goal than before. The new and improved recycled carbon fibre can potentially be used to construct individual parts of a car, such as a roof.

UNSW Canberra researcher Di He with a sample of carbon fibre recycled using a method he developed. Image Credit: UNSW Canberra.

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The Deakin Research team for the Xefco REACH project (from left): Research Fellow Frank Chen, Research Fellow Marzieh Parhizkar, Research Engineer Amol Patil, Research Fellow Surya Subianto and Associate Professor Alessandra Sutti. Image Credit: Deakin University.

Deakin Xefco Partnership Could be a GameChanger for Environmentally-Friendly Fashion Deakin has signed a partnership agreement with Geelongbased company Xefco as part of its Recycling and Clean Energy Commercialisation Hub (REACH) to conduct research to transform how our clothing, including jeans, get its colour. Jeans are one of the most worn garments in the world, but they are also one of the least environmentally friendly, using around 75 litres of water to dye just one pair. With funding through Deakin’s REACH, supported by the Australian Government’s Trailblazer Universities Program, Xefco’s co-founder and Chief Executive Officer Tom Hussey and Deakin scientists Associate Professor Alessandra Sutti and Dr Frank Chen from Deakin University’s Institute for Frontier Materials will explore if a waterless manufacturing process can replace the water intensive processes the clothing industry has used for hundreds of years. The technology in development is called ‘Ausora’. Associate Professor Sutti said it’s exciting to be on the commercialisation journey with Xefco, working with the company to discover what is possible and hopefully reduce the world’s fashion footprint. “If successful, the Ausora technology, which colours fabrics without the need for large quantities of water, will put us a step closer to more efficient and sustainable clothing manufacturing.” Founded in 2018, Xefco now employs 17 people and its products are already making a difference across the world. Its XReflex technology, which reduces consumption of insulation materials, is being used by some of the world’s leading apparel brands including The North Face. Backed by a $50 million grant from the Australian Government’s inaugural Trailblazer Universities Program, with industry and university support taking the total project value to $380 million, REACH is facilitating the development of greener supply chains and accelerating business success as markets move from a throughput economy to a circular economy. BACK TO CONTENTS

DECEMBER 2023 | 47

BREAKING NEWS Novel Approach to Advanced Electronics, Data Storage with Ferroelectricity Latest research from Flinders University and UNSW Sydney explores switchable polarisation in a new class of silicon compatible metal oxides and paves the way for the development of advanced devices including high-density data storage, ultra low energy electronics, and flexible energy harvesting and wearable devices. The study provides the first observation of nanoscale intrinsic ferroelectricity in magnesium-substituted zinc oxide thin films, such as metal oxide thin films with simple wurtzite crystal structures. Ferroelectrics akin to magnets exhibit a corresponding electrical property known as permanent electric polarisation, which stems from electric dipoles featuring equal but oppositely charged ends or poles. The polarisation can be repeatedly altered between two or more equivalent states or directions when subjected to an external electric field and, thus the switchable polar materials are under active consideration for numerous technological applications including fast nano-electronic computer memory and low-energy electronic devices. “The research findings offer significant insights into the switchable polarisation in a new class of much simpler silicon-compatible metal oxides with wurtzite crystal structures and lay a foundation for the development of advanced devices,” said author Dr Pankaj Sharma, Lecturer at Flinders University. “The demonstrated material system offers very real and important implications for new technology and translatable research,” said UNSW Sydney Professor Jan Seidel. Historically, this technologically important property has been found to exist in complex perovskite oxides that incorporate a range of transition metal cations leading to diverse physical phenomena such as multiferroicity, magnetism, or even superconductivity.

Distinguished Professor Zhengyi Jiang and Member for Cunningham Alison Byrnes cut the ribbon to open the ARC Training Centre. Image Credit: UOW.

ARC Training Centre for a More Sustainable Mining Future Launched at UOW On Thursday 12 October Federal Member for Cunningham Alison Byrnes officially launched the ARC Training Centre for Innovative Composites for the Future of Sustainable Mining Equipment at the University of Wollongong’s (UOW) Innovation Campus. In Australia, the Mining Equipment, Technology, and Service (METS) industry is projected to contribute over $50 billion to the Australian economy and generate 80,000 new jobs by the year 2030. This transformation of the sector is geared towards enhancing efficiency, cost-effectiveness, innovation, sustainability, and digitalisation of operations, necessitating the development of safer machinery and equipment capable of functioning in deeper mines and challenging environments. The Centre for Innovative Composites for the Future of Sustainable Mining Equipment, funded through a $5 million grant from the Australian Research Council (ARC), and with industry partners including Roobuck, Bisalloy Steels, SNS Unicorp, HBIS Group, Baosteel, Komatsu Australia, Top Iron, Australia L&Y Mine Equipment Manufacturing, will train and produce engineering graduates to be highly qualified professionals who will bring innovative solutions to the challenges facing the sector. The Centre’s research program will bring together industry and academia to focus on creating innovative steel composites and other materials. It will also give graduates the chance to learn by working in real industry settings, prompting fresh ideas for valuable technologies and products for the Australian METS sector. Over the next five years the Centre will develop brand-new, innovative materials for mining equipment that can be used in extreme underground conditions with a goal to make mining more eco-friendly and improving worker conditions. It will create advanced ways to manufacture new mining equipment and smart mining technology which will make the Australian mining industry safer, more reliable and efficient.

Professor Jan Seidel (UNSW), Dr Dawei Zhang (UNSW), and Dr Pankaj Sharma (Flinders University).

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The Centre will train the next generation of researchers in innovative approaches to manufacturing and mining, new steel composites, mining equipment, and sustainable mining practices and boost Australia's reputation worldwide within the industry and make the Australian mining industry more competitive internationally.

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BREAKING NEWS

The new technique shows remarkably good agreement with experimental results, essentially perfect at high temperature, with small discrepancies at lower temperatures. Comparison of theoretical (solid dark) and experimental (solid light) photoluminescence spectra at different lattice temperatures.

Solving Quantum Mysteries: New Insights Into 2D Semiconductor Physics Researchers from Monash University have unlocked fresh insights into the behaviour of quantum impurities within materials.

Researchers Create the Most WaterRepellent Surface Ever A research team in Finland, led by Robin Ras, from Aalto University, and aided by researchers from the University of Jyväskylä, has developed a mechanism to make water droplets slip off surfaces with unprecedented efficacy. Liquid-like surfaces are a new type of droplet-repellent surface that offer many technical benefits over traditional approaches. They have molecular layers that are highly mobile yet covalently tethered to the substrates, giving solid surfaces a liquid-like quality acting like a layer of lubricant between the water droplets and the surface itself. A research team led by Ras used a specially-designed reactor to create a liquid-like layer of molecules, called selfassembled monolayers (SAMs), on top of a silicon surface. “Our work is the first time that anyone has gone directly to the nanometer-level to create molecularly heterogenous surfaces,” said doctoral researcher Sakari Lepikko, lead author of the study.

The new, international theoretical study introduces a novel approach known as the ‘quantum virial expansion,’ offering a powerful tool to uncover the complex quantum interactions in two-dimensional semiconductors. This breakthrough holds potential to reshape our understanding of complex quantum systems and unlock exciting future applications utilising novel 2D materials.

By carefully adjusting conditions such as temperature and water content inside the reactor, the team could fine-tune how much of the silicon surface the monolayer covered.

The study of ‘quantum impurities’ has far-reaching applications across physics in systems as diverse as electrons in a crystal lattice to protons in neutron stars. These impurities can collectively form new quasiparticles with modified properties, essentially behaving as free particles. Although a straight-forward many-body problem to state, quantum impurity problems are difficult to solve.

“The results showed more slipperiness when SAM coverage was low or high, which are also the situations when the surface is most homogeneous. At low coverage, the silicon surface is the most prevalent component, and at high, SAMs are the most prevalent.”

“The challenge lies in accurately describing the modified properties of the new quasiparticles,” said Dr Brendan Mulkerin, who led the collaboration with researchers in Spain. The study offers a novel perspective on impurities in 2D materials known as exciton-polarons, bound electronhole pairs immersed in a fermionic medium. The Monash University team introduced the ‘quantum virial expansion’ (QVE), a powerful method that has long been indispensable in ultracold quantum gases.

“I find it very exciting that by integrating the reactor with an ellipsometer, that we can watch the self-assembled monolayers grow with extraordinary level of detail,” said Ras.

At low coverage, the water becomes a film over the surface, which had been thought to increase the amount of friction. ‘We found that, instead, water flows freely between the molecules of the SAM at low SAM coverage, sliding off the surface. And when the SAM coverage is high, the water stays on top of the SAM and slides off just as easily. It’s only in between these two states that water adheres to the SAMs and sticks to the surface.” The new method proved exceptionally effective, as the team created the slipperiest liquid surface in the world.

In this case, the integration of QVE into the study of quantum impurities meant that only the interactions between pairs of quantum particles needed to be taken into account (rather than large numbers of them), with the resulting, solvable, model shedding new light on the interplay between impurities and their surroundings in 2D semiconductors. The new approach is remarkably effective at ‘high’ temperatures (such as in a semiconductor anything above a few degrees Kelvin) and low doping, where the electrons’ thermal wavelength is smaller than their interparticle spacing, leading to a ‘perturbatively’ exact theory (referring to a quantum system being perturbed from a simple, solvable limit).

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Liquid-like surfaces are a new type of droplet-repellent surface that offer many technical benefits over traditional approaches. Image Credit: Ekaterina Osmekhina.

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DECEMBER 2023 | 49

FEATURE – Virtual Reality in Manufacturing

Beyond Reality: :

How Australia's Manufacturing Industry is Embracing VR

Augmented reality and virtual reality are among the emerging digital tools turning manufacturing on its head.

into various manufacturing sectors, showcasing a commitment to innovation and efficiency.

Virtual reality (VR) puts real people into virtual spaces, while augmented reality (AR) puts digital objects in real spaces.

For instance, virtual prototyping allows manufacturers to create and iterate designs without the material and time costs associated with physical prototypes. Collaboration in VR offers stakeholders across different locations a shared space for co-working, ensuring alignment and speeding up the design process.

Recent research by PwC revealed that the use of VR and AR in product and service development could add $1.5 trillion to the global economy by 2030, and deliver a $360 billion GDP boost to Australia by 2030. Not surprisingly then, Meta reports it has more than 10,000 people working in the space, while Apple has more than 2,000. Virtual reality (VR) has surged as a transformative force in manufacturing, reshaping how industries conceptualise, train, and execute production processes. In Australia, VR has been integrated

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Spatial visualisation through VR aids in acclimating new employees to complex industrial settings, minimising risks and enhancing operational understanding. Real-world applications have demonstrated VR’s utility, such as using VR models of oil rigs for safety training, employing digital twins for optimising machinery like turbines, and training aircraft technicians with 3D models to

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understand complex engines. Several companies are using virtual reality to ensure particular components are assembled properly. For example, Lockheed Martin, the defence and aerospace company, has an entire virtual reality lab dedicated to product design and manufacturing. After using VR to build the F-35, Lockheed Martin found that engineers could not only work faster, but with an accuracy of approximately 96%. The lab, which is one of the largest of its kind, allows engineers to evaluate the efficacy, cost and risk of designs and models in a lowstakes environment. Similarly, Boeing technicians use VR smart glasses that provide the necessary instructions for each wiring repair, reducing the necessary work time by 25%.

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FEATURE – Virtual Reality in Manufacturing

Joining automakers such as Ford, who has been using virtual technology since 1999, Hyundai now implements VR and 3D digital tools when designing new vehicles and parts. VR allows the designers to test models in specific contexts that mimic real-world scenarios — something that was impossible with the clay models of the past. Hyundai currently has a VR design review system, allowing team members around the world to thoroughly look at every step of the design and modelling process.

Learning Online Through Virtual Reality Deakin University has partnered with HYDAC Australia – a world leader in motion control and fluid technology – to train operators on their machines by use of sophisticated VR software. The training is unique in that it simulates hazardous events that would be impossible to demonstrate safely in real life. Students are able to virtually interact with equipment and receive real-time instructions and feedback from a professional, qualified technical trainer in the use of complex hydraulic machinery. Deakin is one of the leading Victorian universities providing virtual reality training solutions to industry and has

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a strong track record of successful collaborations. Virtual reality experts from Deakin’s Motion Lab virtually recreated one of HYDAC’s most sophisticated machines – the wheel lock hydraulics pressure unit – allowing user interaction within a virtual environment. The HYDAC Wheel Lock Hydraulics Pressure Unit virtual reality model and user experience design went through an iterative six-month development cycle, involving Deakin Motion Lab staff, HYDAC engineers and end users. The virtual reality model directly translates the real-world Hydraulics Pressure Unit device’s engineering plans, down to its minute details. Through the software, users communicate via voice, use natural hand gestures, and assemble and disassemble complex machinery with tools and hand movements that mimic real processes, whilst being guided by instructors and task panels. Hydraulics training requires expensive and heavy equipment. Hands-on training on complicated hydraulics machines is limited to specific locations and specific times. HYDAC’s virtual reality training provides an unprecedented opportunity for physically-distanced students to gain access to an expanded training program in the use of complex hydraulics machinery. For economic reasons, this level of training has not previously

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been possible on a broad scale. The VR technology removes the need for travel and provides training to staff located in remote areas, such as the mining sites in the Pilbara, where this type of machine is located. By removing the need to transport several tones of equipment around training centres throughout the country, the VR training also plays a role in reducing greenhouse gas emissions.

Deakin University’s MotionLab created mixed reality training for HYDAC Australia. Image credit: Deakin University’s MotionLab.

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FEATURE – Virtual Reality in Manufacturing

Australian Research Centre for Interactive and Virtual Environments The University of South Australia’s Australian Research Centre for Interactive and Virtual Environments is a unique alignment of computer science, art and design, brought together to transform industry and society and solve contemporary challenges. The Centre is a focal point for interdisciplinary AR and VR research into wearable computing, human-computer interactions (HCI), 3D visualisations and telepresence. In partnership with BAE, ASC Shipbuilding and IMCRC, the Centre worked on a project to innovate the Hunter Class Frigate Program by harnessing data visualisation to improve shipyard planning and problem-solving capacity. A first-of-its-kind digital environment of the entire ship design and

construction process will be created to improve productivity, quality and safety outcomes in Australia’s naval shipbuilding industry. Research focused on how narrative visualisation and big data processing can deliver, reshape and refine the highly complex manufacturing environment. The outcomes will be extended beyond the Hunter program, assisting critical local supply chains and future projects across the manufacturing landscape. In collaboration with Jumbo Vision International (JVI), the Centre has developed and commercialised smart manufacturing technologies. This partnership leveraged our researchers unique capabilities in AR visualisation of large system design and JVI’s expertise in the design and delivery of audiovisual solutions and command and control rooms. Current design processes for manufactured high-end instrumented

facilities, such as command centres and control panels, are flawed; the traditional process requires significant time, significant associated costs and can still result in a sub-optimal client experience. The Centre’s researchers, led by Professor Bruce Thomas, developed VR simulations that provide fly-through animations and guided tours, as well as AR solutions that offer the ability to physically walk around and touch objects; allowing for the modification of a design concept in real time. This AR technology can significantly assist a client’s appreciation of the design and the effects of any changes; resulting in a better, more efficient and cost-effective end result. These instances are mere snippets of VR's burgeoning role in Australian manufacturing, indicating a future where virtual and physical realities coalesce to drive industry advancements.

Image credit: Australian Research Centre for Interactive and Virtual Environments.

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FEATURE – Virtual Reality in Manufacturing

From Virtual to Reality: The Evolution of VR in Manufacturing Virtual reality (VR) technology has become a transformative force in manufacturing industries, integrating complex processes from design to production and beyond. This summary synthesises the findings from an extensive literature survey by SangSu Choi, Kiwook Jung, and Sang Do Noh, which maps the evolution of VR applications in manufacturing from its inception to current implementations and future prospects.

About the Survey The survey reviewed VR's integration within manufacturing, highlighting its role in product development and decision-making processes. The researchers collected data from 154 articles between 1992 and 2014, focusing on the application of VR in manufacturing, examining the types of VR technologies used, the extent of their implementation, and the trends in research and development. The authors created an analysis map to chart the adoption of VR technologies within the New Product Development (NPD) process. NPD, an essential process in manufacturing, benefits significantly from VR technology, particularly in the front-loading steps where design and conceptual decisions are critical. These include concept design (CD), detail design (DD), testing refinement (TR), and production rampup (PR). From the literature survey, the researchers identified a classification of VR technologies based on their function: expression (E), interaction (I), authoring (A), and collaboration (C). Expression technologies enhance human sensory systems, interaction technologies facilitate interfaces between humans and machines, authoring technologies enable the creation of VR content, and collaboration technologies support networking within a VR environment. Through bibliometric analyses and technology classification, the study reveals that while VR technologies have matured, particularly in expression and interaction, authoring and collaboration technologies lag behind. Notably, VR has been significantly implemented in concept design (CD) and detail design WWW.MATERIALSAUSTRALIA.COM.AU

(DD), but there is insufficient research and implementation in the subsequent NPD stages.

The Genesis and Growth of VR in Manufacturing Initially viewed as a high-cost investment with questionable return, VR has proven its value in the manufacturing industry through enhanced decision-making and intuitive problem-solving capabilities. In the front-loading steps of the New Product Development (NPD) process, VR stands out, facilitating complex tasks such as concept design (CD), detail design (DD), testing refinement (TR), and production ramp-up (PR), leading to substantial improvements in efficiency and accuracy.

From Past to Present: The Evolution of VR The research delineates the advancement of VR technologies applied in manufacturing, highlighting the transition from simple visualization tools to complex systems integrating various VR elements such as expression, interaction, authoring, and collaboration technologies. The implementation cases are manifold: from Boeing's use of VR to visualize and interact with the virtual prototypes of its aircraft, to Ford's immersive vehicle prototyping. VR's role in facilitating the detailed analysis of structural, thermal, and aerodynamic data cannot be overstated, offering a level of depth that traditional CAD systems can't match.

VR's Multifaceted Applications VR is not just transforming the way products are designed; it's also reshaping how they are produced. In the aerospace sector, where precision and safety are paramount, VR has been instrumental. For example, NASA has used VR to simulate and refine the assembly process of the International Space Station, enhancing both the efficiency and safety of operations. In the automotive industry, VR's impact is similarly profound. Ford's Immersive Vehicle Environment (FiVE) program utilizes VR to evaluate design concepts, ergonomics, and field of vision issues BACK TO CONTENTS

early in the product development cycle, long before physical prototypes are constructed.

Current Trends and Analysis The study's bibliometric analysis reveals a significant trend: the majority of VR research in manufacturing focuses on the application phase, particularly in CD and DD stages. The review notes that while VR's expression and interaction technologies are mature, authoring and collaboration technologies lag behind. This indicates a clear direction for future research and development: to enhance VR systems that enable simultaneous co-creation and collaboration among teams.

The Future of VR in Manufacturing Looking ahead, VR is poised to become an integral part of the envisioned cyberphysical systems (CPS), combining the digital and physical realms of manufacturing. The potential lies in real-time integration of virtual models with physical processes, allowing for the prediction and prevention of issues before they manifest in the real world. This VR-integrated CPS will not only predict and solve problems but will also control the entire production system, marking a monumental shift from reactive to proactive manufacturing.

Future Research Directions Despite VR's impressive growth in manufacturing, several challenges need to be addressed. The development of standards for VR integration and dynamic VR element technologies are crucial. Moreover, the actual efficiency of VR application and its impact on product design and manufacturing performance remains to be thoroughly assessed.

Reference Choi, S., Jung, K. and Noh, S.D. (2015) ‘Virtual reality applications in manufacturing industries: Past research, present findings, and future directions’, Concurrent Engineering Research and Applications DECEMBER 2023 | 53

FEATURE – Virtual Reality in Manufacturing

3D Laser Scanning in a Virtual Environment Enables Bespoke Prefabrication The promise of highly-accurate ‘bespoke prefabrication’ is becoming a reality on construction sites and in early design discussions, thanks to advanced 3D laser scanning technology. Watkins Steel is leading the charge; their 3D laser scanning technology is enabling them to create structures that are a ‘glove fit’ for specific site constraints. After 50 years in operation, Watkins Steel knew it needed to embrace technological change to safeguard the future of the company. As just one of over 400 fabricators in South-East Queensland, Watkins was competing on both man hours per tonne and price. According to Managing Director Des Watkins, “We had to come up with a way to be different to the other 400- odd fabricators against whom we were competing. So, we embraced technological change and transformed our traditional processes through innovative thinking.” “We invested in the market leading Faro Focus 3D X 130 Laser Scanner. This enables us to accurately capture the full external or internal detail of any building, site or environment. Shooting approximately 1 million laser points per second, data from the 3D laser scanner can be compiled to recreate a digital ‘3D point cloud model’ of the scanned site. We can capture height, length, surface

area, quadrant, slope—just about anything really,” said Watkins.

modify all the steelwork at our own cost.”

“Consequently, all our shop drawings completed in Tekla Structures Software can be cross referenced with the ‘3D point cloud model’ of a scanned site. This ensures that all drawings are accurate before moving to the steel processing and fabrication phase. In addition, by using 3D laser scanning technology, we can also collect 3D data of scanned sites with unparalleled speed, quality, detail, and accuracy.”

“Now, we can show the client our scans. We can easily demonstrate what should be on-site, versus what is actually onsite. And then—most importantly—we can fabricate for the conditions that actually exist, rather than the conditions that should exist. There’s no need for us to measure or trial fit fabricated components.”

“By detailing a modular building using technical software, we can now program any CNC machine without the need of additional data or human input. This means that we can scan a site, detail the building components in the ‘3D point cloud model’, and then feed this data into the robotics system, which processes the steel to suit.”

Why 3D Laser Scanning? Watkins Steel has been utilising this 3D laser scanning technology for some years now, adopting an end-to-end digital workflow that significantly increases accuracy, eliminates rework, and delivers more to clients. “We often found that what was on-site didn’t match what was on the plans. The builder might put the footings in the wrong location, or the blockwork would be off-grid. As a result, we’d have to

“We supply tailored pre-fabricated components made exactly for the site, including any existing anomalies. So, we know that they will fit like a glove when they arrive on-site and there will be virtually no construction issues. We can even galvanize or powder coat components before they’re delivered to site,” said Watkins. The results of embedding an end-to-end digital workflow in the metal fabrication and installation process has been significant. Watkins Steel can now claim near 100% accuracy on every job.

The Way Forward “It is exciting how fast things are moving. The laser scanning was our first step. Recently we have linked the photo geometry from our drones into the cloud. This means that we are able to capture a site to complete accuracy to +-2mm over 60m,” said Watkins.

Watkins Steel employees try the Microsoft HoloLens.

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FEATURE – Virtual Reality in Manufacturing

Watkins Steel employees try the Microsoft HoloLens.

“The next step that we’re working on now is animation within the point cloud, using augmented reality. By utilising the Microsoft HoloLens—the first selfcontained, holographic computer—we can visualise components within a holographic projection of a site. This amazing piece of technology allows us to view and interact with 3D models using mixed reality.” “For example, by overlaying a fabricated spiral staircase within a holographic projection of a site, we can undertake both quality control and quality assurance. Rather than transport the spiral staircase to site, we simply use the model to confirm that it is going to fit.” “Where we obtain the most value from the HoloLens is its ability to aid in design. Our clients can wear the HoloLens, and effectively ‘walk through’ a project design. They can change the design as they walk—they might increase the width or the length of gantry, or might decide that we need an extra column somewhere...It enables us to create structures that are a ‘glove fit’ for the specific site constraints in a form of bespoke prefabrication,” said Watkins. WWW.MATERIALSAUSTRALIA.COM.AU

The Results As a result of investing in advanced technology, Watkins Steel has removed around 3,000 man-hours per month from their business. They now operate 24 hours per day, and are competitive with some overseas markets when it comes to price. Watkins Steel is winning contracts for work that was being completed overseas, bringing work back to Australia. And they’re increasing their workforce. From a low of about 45 employees several years ago, Watkins now has over 70 staff, and has moved from a very traditional business working in steel fabrication to much more of an IT business. Plus, they’ve tackled some of the most high-profile projects around Queensland, including the Commonwealth Games athletes’ village, and have recently started working on projects overseas, including in New Zealand.

About Watkins Steel Watkins Steel was established in 1968 by Des Watkins Senior, initially specialising in metalwork (predominately handrails) for residential and unit developments. The company grew quickly, moving BACK TO CONTENTS

into its first factory by 1978, doubling in size by 1988, and again by 1998, and once again by 2008. In 2014, Watkins commissioned its first Voortman advanced robotic line, and in 2015 purchased its first 3D Laser Scanner and Realworks Software, and commenced development of its four step process for steel fabrication. Consequently, Watkins Steel now guarantees its clients: • Near 100% accuracy on every job the first time • Near 100% accuracy of site measurement with the Faro Focus 3D x 130 Laser Scanner • Near 100% accuracy of shop drawings in Tekla Structures 3D modelling Software • Near 100% accuracy of on-site layout with Trimble Robotic Total Station • Automated steel fabrication to plus or minus one millimetre over 12 meters This article first appeared in steel Australia magazine. For more information, visit: steel.org.au DECEMBER 2023 | 55

FEATURE – Virtual Reality in Manufacturing

The Sky's the Limit: Unveiling the Potential of Virtual Reality in Aerospace Engineering In the last decade, the aerospace sector has experienced a paradigm shift, courtesy of Virtual Reality (VR) technology. Innovations in VR have opened doors to immersive experiences that were once relegated to the imagination of science fiction. The Potential of Virtual Reality for Aerospace Applications, a recent study by Johanna Pirker from Graz University of Technology, illuminates the strides VR has made in this highly specialised field.

Redefining Aerospace with VR VR technology is revolutionising how engineers and scientists approach design, training, and operations in aerospace. No longer confined to rudimentary simulations, today's VR platforms enable intricate recreations of space missions, maintenance procedures, and even the visualisation of spacecraft before they manifest into physical reality. One significant advancement is the role VR plays in training. Early developments of virtual environments enabled flight team members of the Hubble Space

Telescope repair and maintenance mission of 1993 to build a 3D mental model of the Hubble Space Telescope and to practice the procedures necessary for maintenance and repairs. One hundred five flight team members trained with these virtual environments. The potential for virtual training has been shown for several scenarios by NASA and has become a fundamental training tool. This shift from physical mock-ups to digital twins in VR not only boosts efficiency but also safety, allowing for the rehearsal of emergency scenarios without the associated risks.

Innovation Through Simulation Simulations in VR extend beyond training. They serve as a test bed for design evaluation, offering a look into how a component might interact with a system before it is even built. This level of interaction was previously impossible, bogged down by the constraints of time and physical limitations. For instance, the development of a

Astronauts Jeffrey Hoffman and Story Musgrave install the Wide Field and Planetary Camera on the Hubble Space Telescope in December 1993. Image credit: NASA.

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Carbon-fibre-reinforced polymer (CFRP) drilling process was conducted entirely within a VR environment, which could herald new methodologies in material science and engineering. Remote communication has also benefited from VR, mitigating the delay due to distance, which is crucial for operations as far-reaching as those on the International Space Station or potential missions to the Moon. Realtime simulation and collaboration in VR environments break down the barriers of distance, allowing for a new dimension of remote operation.

Engineering with a Vision The design process is another facet of aerospace that VR is transforming. With VR, engineers can visualise and interact with the structural components and architecture of spacecraft, streamlining the design process and enhancing collaborative efforts. The ability to design within a three-dimensional space grants engineers a perspective that two-dimensional blueprints cannot offer.

A nearly full Moon sets as the space shuttle Discovery sits atop Launch pad 39A at the Kennedy Space Centre in Cape Canaveral. Image Credit: NASA/Bill Ingalls.

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FEATURE – Virtual Reality in Manufacturing

Astronaut Jeffrey Hoffman removes the Wide Field and Planetary Camera during the first Hubble servicing mission in December 1993. Image credit: NASA.

Moreover, VR applications in digital twin technology stand out, providing unprecedented opportunities to interact with and learn about systems, components, and performance in a safe, cost-effective environment. These digital twins serve as a dynamic blueprint that evolves alongside the real-world counterpart.

A Glimpse into the Future As we cast our eyes to the horizon, the potential of VR in aerospace engineering continues to expand. Research suggests that the next frontier for VR will tackle challenges such as enhancing the naturalness of interactions within the virtual environment, improving the intuitive controls, and perfecting collaborative experiences. Such advancements promise to deepen our understanding of complex systems and foster innovative design and problemsolving approaches.

Challenges and Considerations Despite the optimism, challenges remain. Accessibility to high-quality VR experiences is still limited by technology and cost constraints. Additionally, the development of VR applications that fully leverage the capabilities of current hardware is ongoing. Ensuring these experiences are as intuitive as natural interactions remains a significant hurdle. WWW.MATERIALSAUSTRALIA.COM.AU

Earth observation taken during a night pass by the Expedition 49 crew aboard the International Space Station (ISS). Docked Soyuz and Progress spacecraft visible. Image credit: NASA.

The advantages of integrating VR into aerospace are manifold. The immersive nature of VR offers an interactive environment that surpasses traditional methods in both efficacy and efficiency. The applications in training, design, and remote operation exemplify VR's impact on aerospace engineering, promising to reshape the field for the better. However, current VR simulations, as advanced as they are, still face limitations in delivering fully immersive situational awareness. The complexity of aerospace operations demands simulations that can replicate the intricate dynamics of real-world scenarios, a task that current VR technology is still striving to perfect. For remote operations, especially those spanning the vastness of space, realtime communication is vital. Current VR solutions struggle with latency issues, particularly when considering the delay between Earth and celestial bodies like the Moon. Researchers are actively seeking predictive systems and advanced VR interfaces to overcome these challenges, which will be critical for the support of future lunar and interplanetary missions. The fidelity of VR hardware and the intuitiveness of its interactions are also areas ripe for innovation. The goal is to create VR experiences that are as natural and intuitive as real-life BACK TO CONTENTS

interactions. Achieving this will require not just technological advancements but also a deeper understanding of human-computer interaction within the context of aerospace. The development of collaborative VR experiences that support multidisciplinary teams in aerospace engineering is another frontier. The challenge is to create seamless VR environments that can support complex collaborative tasks and facilitate a level of interaction that replicates physical co-location. The exploration by Johanna Pirker illustrates the transformative potential of VR in aerospace applications. The technology is not just a tool for engineers and scientists but also a conduit for collaboration, innovation, and education. As the aerospace industry continues to embrace VR, the boundaries of what's possible will inevitably be pushed further, paving the way for a future where VR and aerospace engineering are inextricably linked, propelling us toward the stars with every virtual step we take.

Reference Pirker, J. The Potential of Virtual Reality for Aerospace Applications, presented at the 2022 IEEE Aerospace Conference

DECEMBER 2023 | 57

FEATURE – Virtual Reality in Manufacturing

Augmented and Virtual Reality Training for Welders Created by Seaberry, Soldamatic is a proven, effective and patented stateof-the-art augmented reality based training solution with HyperReal SIM an exclusive proprietary feature that provides the most realistic welding simulator training experience—apart from actual welding. Augmented and virtual reality training systems are student-focused, allowing individual students to progress at their own pace. Welding apprentices learn and understand welding procedures and techniques through a more interactive training method, gaining hands-on experience in a controlled, safe environment. Augmented reality transforms training from boring theory and text books into high-quality interactive experiences that capture the imagination. With zero risks involved, apprentices can respond to realistic scenarios without pressure or fear of injury. Augmented and virtual reality training is enabling future welders to acquire the skills and the self-confidence they need before moving into real-world workshops. Soldamatic conducted tests comparing their augmented reality technology to traditional welding training. The results demonstrated that 34% more welders were certified in 56% less time, saving up to 68% on the overall cost of welder training. In addition, Soldamatic increases the time on arc by three to five times, and enables training institutes to

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educate four times more students. The new paradigm in vocational, technical and industrial training, augmented and virtual reality training technologies are proven to be efficient and environmentally sustainable, offering significantly reduced CO2 emissions when compared to traditional welding training and slashing consumable usage. These systems allow training centres and industry to save costs and time whilst training professional welders.

Soldamatics in Action Adavanced Welder Training Centres Weld Australia has worked with partners around the country to establish Advanced Welder Training Centres (AWTCs). Using the state-of-the-art Soldamatic augmented reality welding simulator, the training delivered at the AWTCs quickly qualifies welders to the only industry Standard in the world that is accepted in both Europe and America: ISO 9606-1 Qualification testing of welders – Fusion welding. TAFEs and RTOs across Australia have invested in the Soldamatic augmented reality welding simulators, preparing their students for a future in the industry. The combination of a curriculum based on global best practice delivered via advanced training technology will help ensure a strong supply of capable

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welders, both now and well into the future. Without a doubt, the successful implementation of this innovative training initiative is revolutionising welder training in Australia. It is raising the standard of welder education in Australia exponentially, putting our welder training on par with the best in Europe and America.

Advanced Manufacturing Schools Outreach Program The Advanced Manufacturing Schools Outreach Program is encouraging kids in secondary schools across New South Wales to explore a meaningful career in the trades. According to Geoff Crittenden (CEO, Weld Australia), “There is no magic solution to Australia’s skills crisis. We need a radical approach. The same old approach that we’ve taken for years will not arm Australia with the skilled workers needed to deliver the record number of projects we’re seeing in industries like defence and renewables, let alone the $237 billion pipeline of government infrastructure.” “A veritable army of skilled workers, including welders, will be required to build and install the infrastructure needed to achieve the Federal Government’s 43% emissions reductions target by 2030 and net zero by 2050. Unless action is taken now, Australia will be at least 70,000 welders short by 2030. And welding is just one trade: similar skills deficient can be

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FEATURE – Virtual Reality in Manufacturing

found in just about every trade across the nation.” “Industry is calling out for kids with a practical bent to go into the trades. We need parents to understand that a career as a tradesperson is full of potential and a whole raft of exciting opportunities. The Advanced Manufacturing Schools Outreach Program in New South Wales is helping to do exactly this. It is helping to reverse the mindset that the only path for kids post-high school is university,” said Crittenden. “Our STEM Program is unique because it actually engages kids. It is handson, fun and educational. It is not just about studying more maths and physics textbooks. The Program uses Seaberry’s Soldamatic augmented reality welding simulators to gamify the learning experience. Anyone can try their hand at the welding simulators and be a star. A lot of these kids have never passed a test in their lives—the light in the kids’ eyes when the simulators gives them the all-clear is really something to see.” “The gamification of learning is particularly effective when trying to encourage females, Indigenous Australians, people living with disabilities and those from a disadvantaged background into a career in STEM. Training in schools must be refocused to showcase the WWW.MATERIALSAUSTRALIA.COM.AU

opportunities in trades and encourage women and other underrepresented groups into careers in STEM.” Weld Australia has been working with the New South Wales Department of Education on the Advanced Manufacturing School Outreach Program to create a practical solution to the skills crisis in Australia. The Advanced Manufacturing School Outreach Program relies upon the use of augmented reality welding simulators to give kids a real welding experience. To date, 82 welding simulators are installed at 40 high schools across New South Wales. These simulators are used to teach students in Year 9 to develop an understanding of welding across all common processes in a completely safe and controlled environment. The technology is also being utilised by students in years 10-12 to support the delivery of Manufacturing and Engineering and Industrial Technology (Metal), as part of MEM20413 Certificate II in Engineering Pathways. Augmented reality simulators offer a raft of benefits for training. There are no safety issues, its gamified approach excites and challenges students, it appeals to both sexes helping encourage women into traditionally male-dominated career paths, and offers substantial cost benefits over traditional teaching techniques.

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Welder Training at HM Langi Kal Kal Prison In 2022, Corrections Victoria expanded its VET Centre of Excellence model to deliver Fusion Welding to ISO 9606 certification standard to complement their Metal Fabrication industry at Langi Kal Kal Prison. Federation University delivers the training program with the support of Weld Australia and on-site prison industry staff. As part of the program, augmented reality training was introduced to expand the welding skills of the prisoner learners to meet international standards. A welding workshop sits alongside the augmented reality training room so that participants can work on projects to use and practice their welding skills in the physical as well as virtual environments. To participate in the program, prisoners are invited to submit an Expression of Interest and then selected through an interview process. Up to eight participants can be accommodated in the intensive 14-week program. The VET Centre of Excellence model links participating prisoners with prospective employers and preand post-release support service providers. These connections provide prisoners with sustainable pathways to employment and support to reintegrate to society post-release. DECEMBER 2023 | 59

FEATURE – Virtual Reality in Manufacturing

Revolutionising Manufacturing: The Transformative Power of Augmented Reality and Virtual Reality Technologies Source: Dr Nilmini Weerasinghe & Dr Lei H In the dynamic landscape of manufacturing, maintaining a competitive edge is imperative for businesses to flourish. Among the myriad technological advancements that have reshaped the industry, Virtual Reality (VR) and Augmented Reality (AR) stand out as a game-changer. These immersive technologies transcend mere novelty, serving as potent tools that are fundamentally altering the way products are designed and manufactured. In the fiercely competitive world of manufacturing, where efficiency and precision are paramount, VR and AR have emerged as transformative forces, addressing longstanding challenges and ushering in new frontiers of innovation.

Virtual Design and Prototyping: VR and AR technologies have ushered in a new era of product development by enabling virtual prototyping and design. Traditionally, creating prototypes involved substantial time and resources. With VR, manufacturers can now visualise and manipulate 3D models in a cyber space, allowing for a more intuitive and immersive design process. This not only accelerates the product development cycle but also facilitates collaboration among teams regardless of geographical locations. Moreover, advanced Artificial Intelligence (AI) algorithms can also simulate and predict how a design will perform under various conditions, leading to early identification of potential issues and reducing the need for costly revisions later. This predictive analysis, when combined with VR and AR, allows for more accurate and efficient iterations of prototypes in the virtual environment.

Production and Workforce Safety: Augmented Reality has found its niche on the manufacturing shop floor, enhancing assembly and 60 | DECEMBER 2023

production processes. AR overlays digital information onto the physical world, providing real-time guidance to workers. By utilising AR devices such as smart glasses, technicians can receive step-by-step instructions, access relevant information, and even visualise virtual markers indicating the placement of components. This not only improves the accuracy and speed of assembly but also reduces the learning curve for new employees. Moreover, AR devices can highlight potential dangers, mark restricted zones, and display evacuation routes, fostering a safer working environment. The real-time nature of AR ensures that workers stay informed about evolving conditions, contributing to accident prevention. Consequently, manufacturers experience increased productivity and safety in their day-to-day operations.

Training and Skills Development: Training the workforce is a crucial aspect of manufacturing, and VR and AR technologies are transforming traditional training methods. VR and AR simulations provide realistic, hands-on training experiences in a safe and controlled environment. Employees can practice operating complex machinery, troubleshoot issues, and undergo emergency response training without any real-world consequences. Incorporating generative AI into the training process with VR and AR technologies significantly enhances the intuitiveness and efficiency of workforce training in manufacturing. Generative AI, acting as a virtual senior or mentor, can provide real-time assistance and guidance within various virtual environments. This integration allows for adaptive training scenarios, where the AI dynamically adjusts the complexity and nature of simulations based on the learner's progress and needs. This tailored approach ensures that training is not only immersive but also highly personalised, bridging the BACK TO CONTENTS

gap between theoretical knowledge and practical skills more effectively.

Remote Assistance and Collaboration: In today's globalised manufacturing landscape, collaboration among geographically dispersed teams is commonplace. VR and AR technologies facilitate real-time remote assistance and collaboration, allowing experts to provide guidance and support from anywhere in the world. AR enables technicians on the field to share their live view with experts who can provide instructions, annotate visuals, and offer insights, reducing downtime and improving problemsolving capabilities. This remote collaboration extends beyond internal teams to involve suppliers, partners, and customers, fostering a more connected and efficient ecosystem.

Maintenance and Repairs: VR and AR technologies are invaluable in the realm of equipment maintenance and repairs. Predictive maintenance becomes more feasible with VR, as sensors and data can be integrated into maintenance systems to help maintainers intuitively understand the changes of equipment status over time. This proactive approach to maintenance can prevent costly breakdowns and extend the lifespan of machinery. By using AR applications, technicians can access detailed information about machinery, view schematics, and overlay digital instructions onto physical components. This aids in quicker diagnostics, reduces downtime, and minimises the need for extensive training on specific equipment. The integration of AR and VR technologies in manufacturing is not just a technological evolution; it's a paradigm shift that is reshaping the industry from the ground up. From conceptualising and designing products to training the workforce WWW.MATERIALSAUSTRALIA.COM.AU

FEATURE – Virtual Reality in Manufacturing

and maintaining equipment, AR and VR are enhancing every facet of the manufacturing process. As manufacturers continue to embrace these technologies, we can anticipate even more innovative applications and a further blurring of the lines between the physical and virtual worlds. The transformative power of XR in manufacturing is not just about efficiency and cost-effectiveness; it's about empowering businesses to be more agile, adaptable, and competitive in an ever-evolving global market. As we move forward, the symbiotic relationship between humans and these technologies will undoubtedly lead to groundbreaking advancements, propelling the manufacturing industry into a new era of possibilities.

Do smart technologies enable a sustainable practice? With the rapid evolution of cuttingedge technology, it's undeniable that industries are swiftly transitioning to smarter workspaces. The conversion of traditional work practices into cyber-physical spaces within production environments and facilities promises enhanced efficiency and effectiveness, though it presents challenges. The real query here is the true benefits that digital technologies can deliver. Moreover, a crucial but often overlooked aspect is whether these technologies promote sustainable practices. Industries worldwide, in collaboration with governments, are actively embracing sustainable practices within their operations. Sustainability, encompassing social, economic, and environmental pillars, is pursued through various strategies. Emerging concepts like the circular economy are gaining prominence among practitioners and are driving efforts toward sustainability. Smart technologies are characterised by their capacity to establish a cyberphysical setting while analysing extensive data. The emergence of technologies such as the Internet of Things (IoT), Artificial Intelligence (AI), Additive Manufacturing, Robotics and Automation, Cloud Computing, Blockchain, Photogrammetry, Advanced Sensors, (AR), and (VR) enables the creation of this cyberphysical environment. While many WWW.MATERIALSAUSTRALIA.COM.AU

sectors, particularly manufacturing, are gradually integrating these technologies into their various work practices. Digital technologies can be designed to foster a social-technological culture. It facilitates collaboration and integration among supply chain actors. IoT, blockchain, and AI applications streamline relationships between these actors. Further, they help in creating a health and safety environment for workers. Smart systems such as IoT, exoskeleton, VR, and digital twin technologies aid in tracking and monitoring worker wellbeing. Automation, robotics, UAVs, and drones optimize certain tasks, enhancing employee satisfaction while potentially reducing job opportunities. Smart manufacturing or workplaces offer solutions to prevalent environmental issues like waste pollution, carbon neutrality, excessive energy use, and resource optimization. Technologies such as IoT and automation are instrumental in addressing these concerns, fostering green manufacturing. Integrating IoT or digital twin into manufacturing plants enables tracking of waste, carbon emissions, and energy use. AI integrated with automation aids in effective decision-making. Additive manufacturing caters to customer demands by producing customized materials and products with necessary resources and tools. Although many of these technologies are expensive, cost-effective implementation is possible. Automated work environments, coupled with AI, create financially viable and highly productive settings. However, choosing the right technology is crucial for cost-effective implementation. Digitization facilitates transition to smart work environments, playing a central role in achieving sustainability goals. However, these technologies are still in the developmental phase, lacking extensive experience and evidence in full adoption. Further, most of them have utilised these technologies for a limited functions within their operation. It is also noticed that integration of several technologies for a function could lead to more successful outcome. BACK TO CONTENTS

Nilmini Weerasinghe Dr Nilmini Weerasinghe is a lecturer, in Civil and Infrastructure Engineering Discipline, RMIT University. Her main research interests are digital technologies, sustainable construction, solar building envelop, asset management. She conducts various research projects with the collaboration of international and local research partners and has publish various research articles and reports

Lei Hou Dr Lei Hou is an Associate Professor at RMIT, specialising in computer visualisation and interaction digital twins, Building Information Modelling, Virtual and Augmented Reality, machine learning, and smart sensing and tracking. He serves the committees for the International Society of Computing in Civil and Building Engineering (ISCCBE) and the Australian Network of Structural Health Monitoring (ANSHM). He has published over 100 refereed papers, attracting over 3400 citations (Google Scholar h-index 27)

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SHORT COURSES

Short Courses - Study at Home

These short courses provide you with an engaging learning experience. Courses may include flash animations, video of instructors teaching the course in a classroom, video segments from ASM’s DVD series relevant to the learning material, and PDFs of instructor Power Points used in the instructor led training. All online courses require internet access for reading and viewing course content. Both HTML pages and PDF files for each lesson are downloadable and printable for easy offline access.

https://www.materialsaustralia.com.au/training-courses-and-workshops/online-training BASICS OF HEAT TREATING

Steel is the most common and the most important structural material. In order to properly select and apply this basic engineering material, it is necessary to have a fundamental understanding of the structure of steel and how it can be modified to suit its application. The course is designed as a basic introduction to the fundamentals of steel heat treatment and metallurgical processing. Read More

HOW TO ORGANISE AND RUN A FAILURE INVESTIGATION

Have you ever been handed a failure investigation and have not been quite sure of all the steps required to complete the investigation? Or perhaps you had to review a failure investigation and wondered if all the aspects had been properly covered? Or perhaps you read a failure investigation and wondered what to do next? Here is a chance to learn the steps to organise a failure investigation. Read More

MEDICAL DEVICE DESIGN VALIDATION AND FAILURE ANALYSIS

This course provides students with a fundamental understanding of the design process necessary to make robust medical devices. Fracture, fatigue, stress analysis, and corrosion design validation approaches are examined, and real-world medical device design validations are reviewed. Further, since failures often provide us with important information about any design, mechanical and materials failure analysis techniques are covered. Several medical device failure analysis case studies are provided. Read More

HEAT TREATING FURNACES AND EQUIPMENT

This course is designed as an extension of the Introduction to Heat Treatment course. It discusses advanced concepts in thermal and thermo-chemical surface treatments, such as case hardening, as well as the principles of thermal engineering (furnace design). Read More

NEW - INTRODUCTION TO COMPOSITES

Composites are a specialty material, used at increasing levels throughout our engineered environment, from high-performance aircraft and ground vehicles, to relatively low-tech applications in our daily lives. This course, designed for technical and non-technical professionals alike, provides an overarching introduction to composite materials. The course content is organised in a manner that guides the student from design to raw materials to manufacturing, assembly, quality assurance, testing, use, and life-cycle support. Read More

METALLURGY FOR THE NON-METALLURGIST™

An ideal first course for anyone who needs a working understanding of metals and their applications. It has been designed for those with no previous training in metallurgy, such as technical, laboratory, and sales personnel; engineers from other disciplines; management and administrative staff; and non-technical support staff, such as purchasing and receiving agents who order and inspect incoming material. Read More

PRACTICAL INDUCTION HEAT TREATING

This course provides essential knowledge to those who do not have a technical background in metallurgical engineering, but have a need to understand more about the technical aspects of steel manufacturing, properties and applications. Read More

Taking a fundamentals approach, this course is presented as an introduction to the world of induction heat treating. The course will cover the role of induction heating in producing reliable products, as well as the considerable savings in energy, labor, space, and time. You will gain in-depth knowledge on topics such as selecting equipment, designs of multiple systems, current application, and sources and solutions of induction heat treating problems. Read More

PRINCIPLES OF FAILURE ANALYSIS

TITANIUM AND ITS ALLOYS

METALLURGY OF STEEL FOR THE NON-METALLURGIST

Profit from failure analysis techniques, understand general failure analysis procedures, learn fundamental sources of failures. This course is designed to bridge the gap between theory and practice of failure analysis. Read More

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Titanium occupies an important position in the family of metals because of its light weight and corrosion resistance. Its unique combination of physical, chemical and mechanical properties, make titanium alloys attractive for aerospace and industrial applications. Read More

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Industry-leading quantitative nanomechanical and nanotribological test instruments are specifically designed to enable new frontiers in nanoscale materials characterisation, materials development, and process monitoring. Whatever your surface measurement and surface analysis needs, materials or scale of investigation, Bruker has a specialised high-performance solution for you.

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Materials Australia Magazine | December 2023 | Volume 56 | No.4

Articles inside

Short Courses - Study at Home

Beyond Reality: : How Australia's Manufacturing Industry is Embracing VR

Custom Metal Powder Production Using Ultrasonic Atomisation

Prof Julie Cairney awarded the Florence M. Taylor Medal

Why You Should Become a Certified Materials Professional

CMatP Profile: Dr Jeff Gates

SEAM Profile: Minh Nhat Dang

NSW Branch Report

VIC Branch Report - 25th Annual Technologists' Picnic

Carbon Capture and Storage Projects

MATERIALS AUSTRALIA WA Branch Meeting Report - 13 November 2023

MATERIALS AUSTRALIA WA Branch Technical Meeting - 11 October 2023

WA Branch Technical Meeting - 14 August 2023 The Effect of Surface Indents from Hydrotest Plugs on Sulphide Stress Cracking (SSC) Resistance

QLD Branch Report - MISE2023

MATERIALS AUSTRALIA MISE2023 Conference - University of Queensland

From the President