U.S. Department of Energy - Energy Efficiency and Renewable Energy

Industrial Technologies Program – Industrial Materials for the Future

Completed R&D Projects

The following publications are highlights of completed projects for Industrial Materials for the Future.

These project fact sheets are available as Adobe PDFs. Download Adobe Reader.

Fact Sheets & Final Reports

Pre-2004

• Advanced Inorganic Membranes Impact Chemical and Petrochemical Industries (PDF 532 KB)
• Advanced Materials and Processing (PDF 246 KB)
• Advanced High Intensity Infrared Preheating of Steel Strip (PDF 860 KB)
• Infrared Heating of Forging Billets and Dies (PDF 213 KB)
• Plasma Infrared Processing of Materials (PDF 164 KB)
• Development of Intermetallic Alloys (PDF 197 KB)
• Advanced Intermetallic Alloys (PDF 206 KB)
• Intermetallic Alloy Development for the Steel Industry (PDF 551 KB)
• Ni₃Al Enables Improvement in Forging Dies (PDF 1.2 MB)
• Materials Development for the Forest Products Industry (PDF 247 KB)
• Ceramic Composite Hot Gas Filters Fabricated Using a Fiber Slurry and Sol-gel Impregnation Process (PDF 509 KB)
  

  Final Report: December 2002

  (PDF 4.1 MB)
• Chemical Vapor Infiltration (CVI) Used to Fabricated Ceramic Composite Radiant Burner Screens (PDF 227 KB)
• Development of Improved Refractories for the Glass Production Industry (PDF 627 KB)
• Membrane Systems for Energy Efficient Separation of Light Gases (PDF 238 KB)
• Compressive Creep and Thermophysical Performance of Refractory Materials
  

  Final Report: June 2006

  (PDF 2.9 MB)

2004

• High Density Infrared Treatment of Refractories: CPS 1758 (PDF 152 KB)
  

  Final Report: March 2005

  (PDF 4.3 MB)
• New Class of Fe-3Cr-W(V) Ferritic Steel: CPS 1763 (PDF 104 KB)
  

  Final Report: March 2005

  (PDF 6.7 MB)
• High Energy Density Coatings: CPS 1775 (PDF 134 KB)
  

  Final Report: June 2006

  (PDF 5.2 MB)
• Inverse Process Analysis for the Acquisition of Thermophysical Data: CPS 1776 (PDF 93 KB)
  

  Final Report: June 2006

  (PDF 973 KB)
• Characterization of Spinel Glass Tank Refractories: CPS 1777 (PDF 1.2 MB)
  

  Final Report: October 2003

  (PDF 3.7 MB)
• Semi-Stochastic Algorithm for Optimizing Alloy Composition of High-Temperature Austenitic Stainless Steels (H-Series): CPS 1780 (PDF 112 KB)
  

  Final Report: June 2006

  (PDF 746 KB)
• Oxide Dispersion Strengthened Tubes: CPS 1783 (PDF 115 KB)
  

  Final Report: March 2006

  (PDF 2.8 MB)
• Ultrasonic Processing of Materials: CPS Agreement #5602 (PDF 196 KB)
  

  Final Report: June 2006

  (PDF 10.0 MB)
• Magnetic Field Processing of Materials: CPS 1792 (PDF 95 KB)
  

  Final Report: March 2005

  (PDF 3.2 MB)
• Advanced Chlor Alkali Technology: CPS 1797 (PDF 94 KB)
  

  Final Report: May 2005

  (PDF 1.4 MB)

2005

• Development of Cast Austenitic Stainless Steel: CPS 1772 (PDF 147 KB)
  

  Final Report: June 2006

  (PDF 13.2 MB)
• Virtual Welded Joint Design Integrating Advanced Materials and Processing Technologies: CPS 1773 (PDF 177 KB)
  

  Final Report: June 2005

  (PDF 4.3 MB)
• Ceramic and Refractory Components for Aluminum Melting and Casting: CPS 1764 (PDF 693 KB)
  

  Final Report: June 2006

  (PDF 3.6 MB)
• Advanced Nanoporous Composite Materials for Industrial Heating Applications: CPS Agreement 5612 (PDF 91 KB)
  

  Final Report: December 2005

  (PDF 381 KB)
• Combinatorial Methods for Alloy Design and Optimization: CPS 1778 (PDF 121 KB)
  

  Final Report: June 2006

  (PDF 7.1 MB)
• Advanced Wear and Corrosion Resistant Systems through Laser Surface Alloying: CPS 16946 (PDF 733 KB)
• Stress-Assisted Corrosion in Boiler Tubes: CPS 1762 (PDF 511 KB)
  

  Final Report: April 2006

  (PDF 11.5 MB)
• Novel Carbon Films for Next Generation Rotating Equipment: CPS 1785 (PDF 1.3 MB)
  

  Final Report: February 2006

  (PDF 1.8 MB)
• High-Density Infrared Transient Liquid Coatings: CPS 1765 (PDF 1.1 MB)
• New Class of Bainitic Chromium Tungsten Steels: CPS 1781 (PDF 1.1 MB)
  

  Final Report: June 2006

  (PDF 4.6 MB)
• Physical and Numerical Analysis of Extrusion Process for Production of Bi-Metallic Tubes: CPS 1782 (PDF 585 KB)
  

  Final Report: August 2006

  (PDF 7.8 MB)
• Advanced Tooling Alloys for Molds and Dies: CPS 1790 (PDF 124 KB)
  

  Final Report: January 2006

  (PDF 6.8 MB)

2006

• New Class of Ultra-Hard Borides (PDF 224 KB)
• Novel Superhard Materials and Nanostructured Diamond Composites (PDF 1.1 MB)
• Advanced Composite Coatings (PDF 1.1 MB)
• Thermochemical Models and Databases for High Temperature Materials (PDF 997 KB)
• Prediction of Corrosion of Advanced Materials and Fabricated Components (PDF 1.1 MB)
• Novel Modified Zeolites for Hydrocarbon Separations: CPS Agreement #11238 (PDF 223 KB)
  

  Final Report: November 2006

  (PDF 2.9 MB)
• Materials for High-Temperature Black Liquor Gasification: CPS 16540 (PDF 1.1 MB)
  

  Final Report: June 2006

  (PDF 1.3 MB)

2007

• Ultrananocrystalline diamond coatings for pump seals: CPS 1798 (PDF 1.1 MB)
• Materials for industrial heat recovery systems: CPS 16940 (PDF 301 KB)
• Development of functionally graded materials for manufacturing tools: CPS 16941 (PDF 140 KB)
• Structurally integrated coatings for wear and corrosion: CPS 16942 (PDF 111 KB)
• Multifunctional metallic and refractory materials for handling of molten metals: CPS 16943 (PDF 1.3 MB)
• Development of materials resistant to metal dusting: CPS 16944 (PDF 188 KB)
• Advanced integration of multi-scale mechanics and welding process simulation in weld assessment: CPS 16945 (PDF 1.3 MB)
• Advanced thermoelectric materials for efficient waste heat recovery in process industries: CPS 16947 (PDF 216 KB)
• Low-temperature surface carburizing of stainless steels: CPS 16948 (PDF 213 KB)
• Development of bulk nanocrystalline cemented WC for industrial applications: CPS 16949 (PDF 1.1 MB)
• Alkaline-resistant Fe-phosphate glass fibers as concrete reinforcement: CPS 16951 (PDF 267 KB)

MTI Projects

• Corrosion Monitoring System (CMS)
  

  Final Report

  (PDF 1.8 MB)
• Prediction of Corrosion of Alloys in Mixed-Solvent Environments
  

  Final Report

  (PDF 129 KB)
• Study of Metal Dusting Phenomenon and Development of Materials Resistant to Metal Dusting
  

  Final Report

  (PDF 57 MB)

Extended Portfolio

Chemicals

• Alloy Selection System: CPS 1243 (PDF 491 KB)
• Alloys for Ethylene Production (PDF 144 KB)
• Advanced Membrane Materials for Reducing Energy Consumption in P-Xylene Separation: CPS 885
• Metal Dusting Phenomena: CPS 1223 (PDF 77 MB)

Forest Products

• Development of Corrosion Resistant Chromium Rich Alloys for Gasifier and Kraft Recovery Boiler Applications (PDF 155 KB)
• Evolution of Ceramic Coating for Protection of HTHP BL Gasifiers

Metal Casting

• Casting Porosity-Free, Grain Refined Magnesium Alloys (E-SMARRT): CPS 17328
• Creep Resistant Zinc Alloy Development: CPS 1190 (PDF 111 KB)
• Development of Elevated Temperature Aluminum MMC Alloy and Process Technology (E-SMARRT): CPS 17328
• Grain Refinement of Permanent Mold Cast Copper-Base Alloys: CPS 1500 (PDF 141 KB)
• Improvement in Die Design to Improve Die Life as Affected by Thermal Fatigue Cracking, Erosion and Soldering (E-SMARRT): CPS 17328
• Innovative Semi-Solid Metal (SSM) Processing (E-SMARRT): CPS 17328
• The Development of Surface Engineered Coating Systems for Aluminum Pressure Die Casting Dies: Towards a "Smart" Die Coating (E-SMARRT): CPS 17328 (PDF 113 KB)

Mining

• Castcon Process for Mining Applications (PDF 448 KB)
• Fibrous Monolithic Composites as Wear Resistant Components for Mining: CPS 1620 (PDF 650 KB)
• Metal-Matrix Composites and Thermal Spray Coatings for Mining Machines: CPS 1618 (PDF 1.2 MB)