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Advanced Materials & Manufacturing

Medical-grade Alloy Deposit in Orthopedic Implants
Dr. Brent Stucker     

Analysis of Advanced Structures is a project investigating the use of a novel laser-based material deposition machine Laser Engineering Net Shaping, to deposit Cobalt/Chrome medical-grade alloys for use in orthopedic implants.  Initial results have indicated that the material microstructure and hardness are significantly improved using this laser process.  This should lead to improved implant life for knee replacement and other orthopedic implants.  By partnering with a Utah orthopedic research company, the primary financial benefits of this development will be experienced in Utah, even though the medical benefits will be available to people throughout the world.

 Microstructure Analysis of Titanium Alloys for Aerospace Applications
Dr. Leijun Li

Funded by the US Air Force and US Army, this project aims to characterize the microstructure and properties of titanium alloy joints used in advanced structures. The technology will eventually be used for manufacturing, repairing, and maintaining current and next-generation combat systems. Using advanced pulsed-wave GMAW system and Nd:YAG laser deposition systems, Dr. Leijun Li's group will study the optimal process parameters, model the heat and mass transfer during the process, and analyze the resulting microstructures using an advanced optical imaging system and electron microscopes. Participating students will get basic training in how to use the experimental equipment, how to conduct the experiments, how to analyze the results, and how to prepare technical reports. The energy profile for a laser beam, the optical imaging system, and an example titanium alloy joint.   
 

Analytical and Experimental Analysis of Gold-Gold Contact in JWST Thermal Switch for NASA
Dr. Leijun Li

USU has been awarded a contract to design a prototype thermal switch for NASA's Goddard Space Flight Center (GSFC). The Phase I effort includes the design, analysis, fabrication, and testing of a prototype thermal switch. The switch design consists of four copper anvils that contact a copper hub to transfer heat. Both the copper anvils and hub will be coated with a low-emissivity gold coating (pure, electrochemically deposited gold coating). GSFC has expressed concerns that the contacting gold surfaces may cold weld and stick together, constituting a failure of the switch. It is therefore necessary to analyze this joint to verify that cold welding will not occur. Phase II of the project will include testing of the contact surfaces to support the analysis results. Dr. Leijun Li and his research group undertook the research tasks for the resolution of the aforementioned cold welding issue. In Phase I study, a model has been developed for the problem and analytical solutions were obtained. Planned Phase II experimental study is going to start in Spring 2005.  

Control of Flows in Manufacturing
Dr. Barton Smith

This Center of Excellence  will focus on the application of flow control technologies, commonly studied for aerospace applications, to to manufacturing processes.  We are currently working on two technologies:  Aerodynamic Vectoring Particle Separation (AVPS)  and Coanda Assisted Spray Manipulation (CSM).      

There are many medical conditions requiring the introduction of a synthetic material into the body. The nano-scale chemical and physical properties of these biomaterials dictate subsequent events such as non-specific protein and cell adsorption that in turn result in fouling and possible rejection of the material by the body.         

We are investigating methods to improve materials biocompatibility for a range of biomaterials and devices, including hemodialysis membranes, artificial arteries, middle ear ventilation tubes, andorthopedicanddental implants.  Using a range of surface analytical techniques we are characterizing material surface properties and investigating the resulting interactions of proteins, bacteria, and lipopolysaccharides.