NATIONAL INSTITUTE OF STANDARDS &

TECHNOLOGY

Research Information Center

Gaithersburg, MD 20891

IR 87-3609

CANCELLED

UNAVAILABLE FOR BINDING

Institute for Materials Science and Engineering

ANNUA!

REPORT

1987

NAS-NRC

Assessment Panel

January 21-22, 1988

NBSIR 87-3610

U.S. Department of Commerce

National Bureau of Standards
Electrochemical phenomena play a fundamental role in providing

essential materials and devices

for modern society. In the

manufacture of high performance

metal matrix composites,

problems in their processing

technology include the high cost

of fabrication and difficulty in controlling the nature of the fiber- matrix interfaces. The figure

illustrates a theoretical model of

high speed deposition of alloys

onto continuously moving fibers

and wires. This model, developed

by researchers in the Institute’s

Electrodeposition Group, allows

the structure of the interfacial

regions to be tailored or controlled on nearly an atomic

scale. Illustration courtesy of

C.R. Beauchamp, Metallurgy

Division.
:

Institute for Materials Science and Engineered

AtMUAL

REPORT

1987

L.H. Schwartz, Director

U S. Department of Commerce

National Bureau of Standards

OFFICE OF THE DIRECTOR

INSTITUTE FOR MATERIALS SCIENCE AND ENGINEERING

DIRECTOR

Lyle H. Schwartz

( 301 ) 975-5658

ASSOCIATE DIRECTOR FOR RESOURCES AND OPERATIONS

Ronald B. Johnson

( 301 ) 975-5658

SCIENTIFIC ASSISTANTS

Daniel B. Butrymowicz

Samuel J. Schneider

( 301 ) 975-5655

iii

TABLE OF CONTENTS

Page

PREFACE vii

OVERVIEW 1

PERSONNEL 9

Summary of Staff 11

FY 1987 Postdoctorals 12

Academic Program 13

FY 1987 Visiting Scientist Program 14

Honors and Awards 15

TECHNOLOGY TRANSFER 21

Conference Program 23

Standards Committees Membership 28

Research Dissemination 29

Patents , SRMs , and Data Monographs 30

APPENDICES 33

A. 1987 Panel Members 35

B. An Evaluative Report on the Institute for

Materials Science and Engineering (1986) 37

C. An Evaluative Report on the Office of

Nondestructive Evaluation (1986) 46

D. NBS Organizational Chart 52

E. IMSE Organizational Chart 53

F. IMSE Functional Statement 54

v

PREFACE

The National Academy of Sciences -National Research Council (NAS-NRC) Board on Assessment of NBS Programs, and in particular the Panel for Materials Science

and Engineering, performs an important role in the programs and success of the

Institute for Materials Science and Engineering (IMSE) . The Panel is one of our most effective means for assuring a continuous interaction between our staff and counterparts in the scientific and engineering communities of U.S.

industry and academe. Each of the Panel members is selected by the National

Research Council on the basis of expertise and extensive experience in the areas of research and technology conducted by the Institute. In addition to

this Institute-wide Panel, we also have an Evaluation Panel for the

Nondestructive Evaluation Program and just recently we established a Panel for

Reactor Radiation.

The 1987 Annual Report was prepared for the NAS-NRC Board of Assessment of the

Institute for Materials Science and Engineering. It consists of two parts:

the first (this volume) contains background information on resources,

activities, and representative highlights of the Institute. The second part

details the technical activities of the Institute and is published separately

as National Bureau of Standards Internal Reports (NBSIR) for each

Division/Office

We look forward to your input and advice in both the evaluation and formulation process of our management decisions at all levels in the Institute.

During this last year, I know that you have spent time in visiting our Institute and discussing programs, progress, and plans with our staff. I appreciate the time that you give and look forward to working with you in the

future

Lyle H. Schwartz

December 7, 1987

Vll

OVERVIEW

OVERVIEW

I. Introduction

The Institute for Materials Science and Engineering (IMSE) is responsible for

providing the Nation with measurement methodology and technology, standards,

concepts, reference materials, critically evaluated data, and other technical

information on the fundamental aspects of processing, structure, properties,

and performance of materials. These outputs are directed to the needs of U.S.

industry, government agencies, academic institutions, and other scientific and

technical organizations. The programs of IMSE support a wide base of generic

technologies in materials, in order to provide their safe, efficient, and

economical use in service. The research activities of the Institute address

the science base underlying both advanced materials and conventional materials

technologies, together with the associated measurement methodology.

The Institute consists of five technical Divisions: Ceramics, Fracture and

Deformation (located at our Boulder, Colorado laboratories), Polymers,

Metallurgy, and Reactor Radiation; and one independent Office: Nondestructive

Evaluation, which sponsors cross-cutting research throughout NBS . Our budget

in FY 1987 was approximately $40 million, including capital equipment

acquisitions. IMSE has an NBS staff of 389, of which 88 percent are in

scientific or technical support positions. Seventy percent of our scientists

and engineers have Ph.D. degrees. The average age of our full-time scientist

and engineer staff is 47 years, compared to 48 years in 1985. This certainly

reverses an aging trend we have been experiencing.

In addition to the NBS staff, we had 374 visiting scientists and engineers

during 1987 involved in collaborative research or utilization of our special

facilities (e.g., research reactor). These visitors represented U.S.

industry, academe, other Federal agencies, and foreign institutions. Their

stay at IMSE ranged from several weeks to the entire year and their salaries

and associated costs were covered by the parent organization.

II. Major Organizational and Programmatic Events

1987 has been a significant year for the Institute. The Advanced Ceramics

Program is nearing full strength in both staff and facilities. The Cold

Neutron Research Facility is proceeding as planned: the source was inserted

in the reactor vessel in August 1987, the contract for the guide hall was signed in October, and the groundbreaking ceremony was held on November 20

with Deputy Commerce Secretary Brown and Congresswoman Morelia (R, MD) in

attendance, along with other dignitaries. In regard to FY 1988, we received

endorsement from both the Department of Commerce and the Office of Management

and Budget on our initiative involving High Performance Composites. We,

likewise, have been endorsed as contributors to the NBS FY 1988 initiatives

involving High Temperature Superconductors and Advanced Semiconductors. Funds

for these activities are included under our appropriation bill for FY 1988,

and as we go to print with this report, we are awaiting the decisions by

Congress and the White House in regard to reconciling the 1988 Budget. These

will be covered in more detail at one of the sessions of the Panel meeting.

3
In regard to FY 1989, we hope to expand the High Performance Composites

initiative. During this year, we have been involved in formulating a comprehensive budget initiative for 1990, which will involve all organizations

of IMSE. The theme of this proposal on the Automated Processing of Materials

will be presented at the Panel meeting.

We also have had a very busy year in regard to organizational matters. First, we all mourned the tragic death of Secretary Baldrige, who had been a strong

advocate for NBS . We look forward to working with new Commerce Secretary

Verity, who also has expressed strong support for the activities of NBS.

Congress has taken a strong interest in NBS and introduced legislation which

will result in major expansions in both our activities and mission. This will

be explained in detail at the Panel meeting. In the FY 1987 authorization

act, Congress instructed NBS to establish a Personnel Demonstration Project to

be conducted over a five-year period commencing January 1, 1988. This is an alternative personnel management system (to that which we now have) designed

to help NBS attract, retain, and motivate highly qualified staff. We have

spent this year in developing the new system and we will discuss this at the

meeting

During this year, we have had some changes affecting management positions.

Dick Reed asked to step down as Chief of the Fracture and Deformation Division

in order to catch up with his science endeavors. Harry McHenry has been

appointed as the new Chief of the Division. Les Smith is on detail from his

position as Chief of the Polymers Division to that of Chief, NBS Program

Office. This temporary action provides assurance of NBS maintaining

continuity of relations with Commerce, 0MB, Congress, and others. During Les'

detail, Bruno Fanconi will serve as Chief, Polymers Division.

We have been active, likewise, in realigning some of our Group- level

activities. The wear program in the Metallurgy Division was combined with the

similar activity in the Ceramics Division; the Synchrotron Radiation Analysis

Group was reassigned from the Metallurgy Division to Ceramics; the High

Temperature Chemistry Group was reassigned from Ceramics Division to

Metallurgy; the Chemistry and Bioprocessing Group was transferred from

Ceramics to Polymers; and, just recently, the time -dependent fracture activities of the Fracture and Deformation Division were combined with similar

programs in the Metallurgy Division. All of these realignments were in the

interest of program cohesiveness and more effective direction of the concerned

research activities.

III. Program Areas

The materials science and engineering programs of the Institute cover the

major classes of materials: metals, ceramics, polymers, and composites and

these involve the Divisions at various levels of intensity in four areas of

technology

4
MATERIALS PROCESSING

Solidification

Phase Diagrams for Metals, Ceramics, and Polymer Blends

Coatings and Thin Films

Welding

Diffusion

Chemical Synthesis of Ceramics

MICROSTRUCTURE CHARACTERIZATION

Nondestructive Evaluation

Neutron Scattering

Analytic Electron Microscopy

Image Analysis

Synchrotron X-rays

PROPERTIES

Mechanical, Optical, and Electrical Properties

Wear and Erosion

PERFORMANCE

Time Dependent Fracture

Environmentally Enhanced Fracture

Corrosion and Chemical Durability

The following are some of the highlights of 1987 and are representative of all

accomplishments for the year. Please refer to the individual Division and

Office reports for more detailed information on programs, progress, and

achievements

An industrial consortium was established with Crucible Materials Corporation, Hoeganaes Corporation, and General Electric in a three year program to

develop an intelligent processing technology for rapidly solidified metal

powders. Involves the development of in- situ sensors, process models, an expert computer system, and control devices

The Cahn-Hilliard-Cook equation has for the first time been proven to be

quantitatively correct. The equation was applied to spinodal decomposition of

a polystyrene/poly (vinylmethylether) blend system. Data verifying its

accuracy came from time resolved temperature jump and reverse quench light

scattering techniques, and from a structure factor measured by a SANS experiment

In collaboration with AT&T Bell Laboratories and the Naval Research

Laboratory, we provided some of the first and most accurate results on the

atomic scale structure, oxygen arrangements, and phonon density of states in new high TC superconductors. Key information also was obtained on the oxygen

chains whose removal is associated with the loss of superconductivity

5
Established an ultra-clean ceramic processing laboratory for producing

powders and sample materials with controlled levels of impurities and dopants.

The laboratory, which has several work areas where different experiments can

be conducted simultaneously without cross contamination, includes a laminar

flow work area with class 10 clean room condition, and such equipment as a rotary evaporator, drying oven, a press for making pellets, and controlled

atmosphere furnace. This will be available for use by industry, academe, and

other agencies

A collaborative program with the Aluminum Association resulted in the

successful testing of a prototype eddy current sensor for determining body

temperature of aluminum during extrusion. A modified version of the sensor

also has been used to sense density in- situ during hot isostatic pressing of

aluminum, copper, high TC superconductors, and titanium- aluminide intermetallic alloys

Constructed a simulator to study the thermomechanical processing of

steels in order to develop improved procedures for controlled welding and

accelerated cooling of high-strength steels

Computer graphics software developed earlier for binary systems has been

extended to ternary systems and successfully implemented with the computer

production of Volume 6 of "Phase Diagrams for Ceramists". A prototype PC

graphics database has been developed and demonstrated to the American Ceramics

Society, industrial groups, and phase diagram users. This prototype is one of

the most advanced graphics databases developed worldwide and should greatly

enhance the marketability and utility of the various NBS-American Ceramics

Society phase diagram hardcopy and computerized products

Two polyurethane Standard Reference Materials are being produced with

support from the Food and Drug Administration and the NBS Office of Standard

Reference Materials. These SRMs , with certified values of weight-average

molecular weight, will help meet a growing need for better methods of

characterizing polyurethane used in medical devices, both before use and after

degradation following implantation

Conditions were discovered which greatly increase the stability against

precipitate coarsening of precipitation- strengthened aluminum- iron-base powder

alloys. This stability depends on formation of phase sequences involving an amorphous phase, similar to sequences previously encountered in NBS quasicrystal studies. This result provides the prospect that bulk parts can be

made from these powder alloys without loss of the useful properties imparted

by their original rapid solidification

A theory to explain the observed rising fracture toughness (R-curve) of

monophase ceramic materials with growing crack size has been further

developed. The source of the toughness of ceramic materials originates in

interlocking grains and unbroken ligaments that cross between the crack faces.

These apply a closure force to the crack that must be overcome for fracture to

proceed. This theory implies that the toughness of ceramic materials can be

enhanced by microstructural design to increase the degree of interlocking of

fracture surfaces. Materials are currently being fabricated to optimize the

toughness characteristics

6
A single crystal aluminum- silicon carbide fiber sample preparation

technique has been perfected to allow fundamental studies of interfacial

effects on fracture of metal matrix composites. This approach has allowed

determination of the role of processing variables upon the cohesion and load

transfer properties of aluminum-silicon carbide composites.

7
'
PERSONNEL

SUMMARY OF STAFF

Full Time Permanent 1985 1986 1987

Physicist 68 67 65

Chemist 54 49 45

Metallurgist/Hatls . Scientist 38 44 39

Engineer 29 31 32

Other 3 3 3 Subtotal 192 194 184

Technical Support 31 33 35

Reactor Operators 15 15 16

Management Support 5 5 7

Secretarial 25 27 31

Subtotal 76 80 89

TOTAL FTP 268 274 273

Other

Postdoctorals 13 16 14

Part-Time and Temporary 29 42 43

Academic (Student and Faculty) 95 78 59

Subtotal 137 136 116

TOTAL STAFF 405 410 389

11
FY

1987

Postdoctoral

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Career

Appt.

(1-18-87)
FY 1987 ACADEMIC PROGRAM

Appointments

Students Permanent*

Faculty Totals

NDE 1 1

Ceramics 19 3 22

Fract & Deform 5 1 6

Polymers 6 4 10

Metallurgy 16 1 17

Reactor Radiation _2 _1 _3

Totals 49 10 59

Consultants (part-time)

13
VISITING SCIENTIST PROGRAM

Guest Researchers

Domestic

Federal

Academic

Industry

Self-Employed

Subtotal

Foreign

Subtotal

Research Associates

Federal

Academic

Industry

Subtotal

Intergovernmental Personnel Act

TOTAL

FY 1986 FY 1987

30 34

68 66

42 42

17 17

157 159

122 129

279 288

4 4

1 1 89 79

94 84

(Academic) 4 2

377 374

14
HONORS AND AWARDS

DEPARTMENT OF COMMERCE AWARDS

1985-1987

GOLD MEDAL (Exceptional Service)

Charles C. Han for his innovative use of small angle neutron

scattering to address significant problems in polymer

science. (1986)

James J. Rhyne for international leadership in critical research on advanced magnetic materials for high-technology

products and devices. (1987)

Robert S . Roth for meritorious authorship in the field of ceramic

phase equilibria, including editorship of the

internationally renown Phase Diagrams for Ceramists

volumes. (1986)

Robb M. Thomson for outstanding contributions as a world leader in

the field of fracture in materials. (1987)

SILVER MEDAL (Meritorious Service)

Stephen W. Freiman for outstanding research and leadership in

Brian R. Lawn

relating the structure and processing of ceramic

materials to final properties. (1987)

for innovative research on the fracture of

brittle materials and for pioneering work in the

field of fracture mechanics. (1986)

Harry I. McHenry for leading research and supervision in elasticplastic fracture mechanics, leading to new

fitness-for-service criteria. (1986)

Tawfik M. Raby for skillful management and leadership in

doubling the power of the NBS reactor from ten

to twenty megawatts. (1985)

Wen-li Wu for the development of a unique and powerful

technique for analyzing the molecular structure

of polymers used in composites. (1987)

15
BRONZE MEDAL (Superior Service)

Norman F . Berk for major contributions to the theory of small

angle scattering methods for the measurement of

materials microstructure. (1985)

Alfred V. Clark for outstanding contributions to the

nondestructive evaluation of materials and

components. (1987)

James G. Early for developing guidelines to compare domestic

and foreign specifications for alloys used in

the construction of ships. (1986)

Richard J. Fields for establishing the only database in the world

to predict large-scale crack arrest behavior of

nuclear-grade steels. (1985)

Charles M. Guttman for outstanding contributions to theoretical

studies of fundamental problems in polymer

science. (1987)

Roseann M. Hayes for contribution to the NBS Alloy Phase Diagram

Data Program through on-line database

administration and system management. (1985)

Camden R . Hubbard for extensive accomplishment in improving

materials characterization by x-ray powder

diffraction. (1986)

Chia-Soon Ku for development of oxidation measurements and

standards for the Nation's petroleum and

transportation industries. (1987)

David S . Lashmore for contributions to the development of

electrodeposited composition modulated alloys.

(1986)

J. David McColskey for developing experimental methods,

instrumentation, and fixtures which put NBS at

the forefront of fracture mechanics research.

(1986)

Gregory B . McKenna for contributions to descriptions of the

mechanical response of polymers and leadership

of the rubber SRM program. (1985)

Gregory J. Olson for important contributions to inorganic

materials biotechnology and bioengineering.

(1986)

16
Edwin J . Parks

John A. Tesk

S. Michael Thomas

Francis Wei-Yu Wang

for imaginative use of unique tailored

organometallic materials to advance technologies

servicing national needs. (1985)

for his exceptional leadership of a highly

diverse program that has improved the

performance of dental materials. (1986)

for consistently outstanding contributions to

the administrative and fiscal operation of the

Polymers Division. (1986)

for creative application of fluorescence

spectroscopy to fundamental problems of polymer

science. (1985)

SENIOR EXECUTIVE SERVICE

BONUS AWARD

Robert S. Carter (1985)

Richard P. Reed (1985, 1986)

John J. Rush (1985)

Lyle H. Schwartz (1985, 1986)

Robb M. Thomson (1986)

H. Thomas Yolken (1985)

PRESIDENTIAL RANK OF MERITORIOUS EXECUTIVE

John J. Rush (1986)

17
NBS AWARDS

1985-1987

STRATTON (Outstanding scientific or engineering achievements)

John Cahn for outstanding achievements in the field of physical

metallurgy. (1986)

EQUAL EMPLOYMENT OPPORTUNITY (For exceptionally significant

accomplishments and contributions to EEO and

Affirmative Action goals)

Jonice S. Harris for outstanding contributions to the NBS and IMSE

EEO/Affirmative Action Programs. (1986)

CRITTENDEN (Superior accomplishments by support staff)

David R. Kelly for outstanding and unique electroplating services to

the NBS staff. (1986)

SAFETY (Significant contributions to Safety Program)

Mario J. Cellarosi for outstanding contributions to the IMSE/NBS

Occupational Health and Safety Program. (1985)

Ralph F. Krause for outstanding tenure as Ceramics Division Safety

Officer, enhancing safety awareness and maintaining

an excellent safety record. (1987)

Elizabeth S. Sweitzer for outstanding contributions to the IMSE/NBS

Occupational Health and Safety Program. (1985)

FELLOW AND SENIOR FELLOW (Established by NBS Director to provide

recognition to outstanding scientists)

John Cahn

John J. Rush

Robb M. Thomson

Brian R. Lawn

Elected to Senior Fellow

Elected to Fellow

Elected to Fellow

Elected to Fellow

Sheldon M. Wiederhorn Elected to Senior Fellow

18
NATIONAL RECOGNITION

Ugo Bertocci

John Cahn

Robert S. Carter

J. Beverley Clark

Edwin Fuller

Charles Guttman

Charles Interrante

David S. Lashmore

Brian Lawn

M. Linzer, H. Wadley,

D. Kupperman (Argonne)

L. Spivak (Magnaflux)

John R. Manning

Fielding Ogburn

1985-1987

14th William Blum Award, National Capital Section of

the Electrochemical Society for his work on electrochemical noise to study the stability of

passive films (1986).

von Hippel Award of the Materials Research Society

for his lifelong achievement in materials research

(1985).

Elected Fellow of the American Society of Metals

(1985)

Elected Fellow of the American Nuclear Society

(1986)

Steering Committee for an Advanced Steady- State

Neutron Source in the U.S. (1986).

Elected Fellow of American Society for Metals

(1986) .

Ross Coffin Purdy Award of the American Ceramic

Society for his valuable contribution to the ceramic

technical literature (1987).

Elected Fellow of the American Physical Society

(1987).

George Kimball Burgess Memorial Award by the American

Society for Metals for significant contributions to

the field of metallurgy (1987).

Elected Vice President of Electrodeposition Division

of the Electrochemical Society (1986).

Elected Fellow of American Ceramic Society (1986).

I-R 100 Award for development of an Ultrasound Pipe

Porosity Sensor given by Research and Development

magazine (1987).

Elected Fellow of American Society for Metals (1986).

ASTM Award of Merit for research in the field of

electrodeposition and international standardization

(1985).

19
Elio Passaglia ASTM Award of Merit for outstanding contributions to

the advancement of voluntary standardization (1987).

Marshall Peterson ASME Mayo D. Hersey Award of the Society of

Tribologists and Lubrication Engineers for

outstanding contributions in lubrication research and

development (1987).

Lyle H. Schwartz Elected Fellow of ASM International (1987).

Samuel J. Schneider American Ceramics Society T.J. Planje-St. Louis

Refractories Award for distinguished achievements in

the field of refractory materials (1985).

Dan Shechtman International Prize for New Materials by the American

Physical Society for his experimental discovery of

phases of matter that exhibit icosohedral symmetry

(1987) .

T. Siewert

P. Purtscher

R. Trevisan

International Metallographic Society Award for their

development of a metallographic technique that

analyzes welds and welding processes by completely

exposing the weld fusion line (1986).

Gilbert M. Ugiansky Elected President of Federation of Materials

Societies (1987-88).

Sheldon M. Wiederhom American Ceramics Society Sosman Lecturer in

recognition of pioneering work in fracture mechanics

(1985)

H. Thomas Yolken Congressional Science Fellowship with Rep. Don Ritter

(R-PA) (1985).

20
TECHNOLOGY TRANSFER
'
CONFERENCE PROGRAM

(SPONSOR OR CO-SPONSOR)

FISCAL YEARS 1986 AND 1987

Workshop on the Investigation of Fundamental Interactions with Cold Neutrons

November 14-15, 1985 (M. Rowe-Reactor Radiation)

150 attendees

Fundamental physics and metrology opportunities using cold neutron beams.

Workshop on an Advanced Steady State Neutron Facility

December 16-17, 1985 ( J . Rush-Reactor Radiation)

50 attendees

Address the research and technological applications of a new advanced steady

state neutron source and consider a variety of different engineering

approaches for providing such a source in the U.S. before the year 2000.

A National Forum on the Future of Automated Materials Processing in U.S.

Industry- -The Role of Sensors

December 16-17, 1985 (T. Yolken-Off ice of Nondestructive Evaluation)

115 attendees

To identify and assess important issues affecting the competitive position of

U.S. industry related to its ability to automate production processes for

basic and advanced materials and to develop approaches for improved capability

through cooperative R&D and associated efforts.

ISO/TC 107/SC 3 on Coatings and Surface Finishings

April 7-11, 1986 (D. Lashmore -Metallurgy)

40 attendees

Establish international standards and test methods concerned with metallic and

inorganic coatings with specific interest to critical metals and corrosion

protection.

Crack Arrest Technology

April 10-11, 1986 (R. deWit- Fracture & Deformation)

40 attendees

Review the technological developments in dynamic fracture and crack arrrest.

Transfer this information to electric power and gas industry.

NBS Analytical Chemistry/Materials Science Workshop

April 13-18, 1986 ( J . Harris -Metallurgy)

50 attendees

To expose students and faculty of Historically Black Colleges and Universities

to state-of-the-art research and analytical methods in chemistry and to

23
present overview of current research activities in materials science and

engineering

Seminar on Micro-Analytical Techniques in Materials

April 21-22, 1986 (R. Fields-Fracture & Deformation)

40 attendees

Addresses current state of technology for determining microstructure and

composition of metallic materials.

ASTM C14 on Glass and Glass Products Workshop

April 22-24, 1986 (M. Cellarosi-Ceramics)

40 attendees

To discuss cooperative standardization/measurement programs with NBS.

Interagency Coordinating Committee on Ceramics Meeting

May 6-7, 1986 (S. Hsu-Ceramics)

46 attendees

Review of current government sponsored programs in structural ceramics by

government program managers.

Joint Services Technical Coordinating Group on Nondestructive Inspection

(JRCG/NDI) Specifications and Standards Subgroup

May 6-7, 1986 (L. Mordfin-Office of Nondestructive Evaluation)

15 attendees

To review progress on military standards and specifications for NDE.

IMSE Advanced Materials Symposium Series: Advanced Materials Characterization

Using Synchrotron Radiation

May 28, 1986 (M. Kuriyama- Ceramics)

100 attendees

To describe the recently commissioned IMSE x-ray beamline at the National

Synchrotron Light Source to the scientific community of prospective users. The capabilities of the Light Source and the beamline instrumentation will be

illustrated using recent research results.

Workshop on Materials Characterization by X-Rav Scattering

June 23-24, 1986 (C. Hubbard- Ceramics)

175 attendees

Status and future of industrial needs in materials characterization by

quantitative x-ray powder diffraction methods.

Steel Sensor Workshop

July 16, 1986 (H. Wadley-Metallurgy)

30 attendees

Reported progress made on top priority sensor needs for the steel industry and

outlined new directions for the steel sensor program.

24
Gordon Research Conference- -Solid State Studies in Ceramics

August 11-15, 1986 (B. Lawn- Ceramics)

100 attendees

Assessment of forefront developments in surface forces and microstructures as they apply to cracks and interfaces in ceramics.

ASM Materials Week 86- -Sessions on the Effect of Coal Cleaning on Materials Performance

October 12, 1986 (S. Dapkunas- Ceramics)

20 attendees

Review the economics, technology, and science of coal cleaning and its effect

on the performance of materials in coal combustion and gasification systems.

Universities Space Research Association Metals and Alloys Discipline

Working Group

October 23-24, 1986 (S. Coriell-Metallurgy)

20 attendees

Discussions of metals and alloys research for microgravity science and

applications

41st MFPG Meeting - Detection. Diagnosis and Prognosis of Rotating Machinery

October 28-30, 1986 (R. Shives- Fracture & Deformation)

200 attendees

To improve reliability, maintainability, and readiness through the application

of new and innovative techniques.

Workshop on Automated Processing of Rapidly Solidified Metal Powders by High

Pressure Inert Gas Atomization

October 30-31, 1986 (H. Yolken/L. Mordfin-Nondestructive Evaluation and

N. Pugh -Metallurgy)

40 attendees

To brief attendees and to solicit their views on establishing a consortium to

develop a major new program on automated technology for the production of

rapidly solidified metal powders.

2nd Interagency Tribology Research Coordinating Meeting

December 4, 1986 (S. Jahanmir- Ceramics)

20 attendees

Assessment of government programs in tribology and establishment of

cooperative research plans.

25
IMSE Symposium Series on Composites: Fracture Behavior of Fiber Reinforced.

Ceramic Matrix. Composites

March 19, 1987 (S. Freiman-Ceramics)

40 attendees

New test techniques were described which can be used to quantitatively

determine fiber/matrix interface properties and to ascertain the role of

crack/fiber interactions in governing the strength of the composite.

Workshop to Establish Standardization Plan for Real-Time Radioscopy

April 2-3, 1987 (T. Siewert- Fracture and Deformation)

25 attendees

To enhance the quantitative capabilities of industrial real-time radioscopy

and to make its measurements traceable to recognized standards.

NBS-BAM Symposium on Corrosion and Wear

April 13-14, 1987 (W. Ruff -Metallurgy)

50 attendees

To offer communication between staff of the two organizations on research

programs and projects. In addition, other professional individuals are made

aware of research activities.

Interagency Coordinating Committee on Structural Ceramics

May 6-7, 1987 (S. Hsu-Ceramics)

45 attendees

To coordinate central objective of various Federal agencies on structural

ceramic programs.

Third Annual Heavy Section Steel Technology Program Workshop on Dynamic

Fracture and Crack-Arrest Technology

May 13-15, 1987 (R. Fields - Fracture & Deformation)

65 attendees

Results from on-going dynamic - fracture and crack-arrest studies around the

world will be presented and discussed to stimulate technology transfer to US

industry

Joint Services Technical Coordinating Group on Nondestructive Inspection

(JRCG/NDI) Specifications and Standards Subgroup

June 1-2, 1987 (L. Mordfin-Nondestructive Evaluation)

12 attendees

To discuss progress and plans and to coordinate interagency efforts to develop

new and improved military standards and specifications for nondestructive

evaluation.

26
COMAT Subcommittee on Superconductors

June 12, 1987 (S. Dapkunas- Ceramics)

40 attendees

Coordination of Government Sponsored Research on High Temperature

Superconductors

ONR/NBS Workshop on Surface Forces

September 2-3, 1987 (B. Lawn/S . Wiederhorn-Ceramics)

25 attendees

Discussions on the application of new measurement technique to materials

science

U.S. -China Symposium on Advanced Ceramics Materials

September 8-11, 1987 (S. Freiman-Ceramics)

50 attendees

To exchange scientific information on advanced ceramic materials.

Workshop for U.S. Participants in IEA/Annex II Interlaboratorv Comparison

of Powder Characterization Methods

September 15-16, 1987 (A. Dragoo-Ceramics)

12 attendees

Discussion of technical issues related to physical and chemical

characterization of ceramic powders.

IS0/TC164. Standards for Hardness. Uniaxial, and Fracture Testing

September 14-25, 1987 (R. Fields - Fracture & Deformation)

60 attendees

To establish international standards for mechanical testing.

42nd MFPG Meeting - Technology Innovation - Key to International

Competitiveness

September 15-17, 1987 (R. Shives- Fracture & Deformation)

75 attendees

To provide a forum for the discussion of improving the position of the United

States in the world market through the utilization of technology innovation.

ASTM E-49 Workshop on Ceramic Specification for Property Databases

September 29, 1987 (C. Hubbard-Ceramics)

10 attendees

To develop draft guidelines for specification of advanced ceramics for entry

into a proposed materials property database.

27
STANDARDS COMMITTEES MEMBERSHIP

Unit Staff

Institute Office 3

Nondestructive Evaluation 1

Ceramics 16

Fracture & Deformation 11

Polymers 12

Metallurgy 21

Reactor Radiation 2

TOTAL 66

Includes: 26 chairs

2 secretaries

1 director

Representation

Organization As

American National Standards Institute

American Nuclear Society

American Society for Mechanical Engineers

American Society for Testing and Materials

Department of Defense/Technical Coordination/NDE

Electronic Industries Association

International Institute of Welding

International Standards Organization

Joint Committee on Powder Diffraction Standards

National Association of Corrosion Engineers

Safety Glazing Certification Council

Welding Research Council

TOTAL

Source: Directory of NBS Standards Committee Activities, 1987

Committee*

Assignments

5

12

68

31

42

79

4

241

signments

24

2

2 189

12

1 11

4

113

241

28
RESEARCH DISSEMINATION

FY 1987

UNIT PUBLISHED

PAPERS

INVITED

TALKS

PATENTS* SRMs* MONOGRAPHS*

INSTITUTE OFFICE 18 31

OFFICE OF NONDESTRUCTIVE

EVALUATION 5 13

CERAMICS 199 158 4 4

FRACTURE AND DEFORMATION 75 30 1

POLYMERS 113 85 6 3

METALLURGY 173 112 2 2 2

REACTOR RADIATION 83 25 -I-l -I-L _1

TOTAL 666 454 12 9 4

Listing on following pages.

29
PATENTS (In process)

Stress-free sintering of fiber-reinforced ceramic composites

Claudia Ostertag (Ceramics)

Quantitative and qualitative technique for assessing stresses during

densification of composites

Claudia Ostertag (Ceramics)

A hermetically sealed inert atmosphere cell for x-ray powder diffraction

Joseph J. Ritter (Ceramics)

Superconducting ceramic composites

Stephen W. Freiman (Ceramics)

Hydrophobic dental composites based on a polyfluorinated dental resin

J.M. Antonucci (Polymers)

Interpenetrating-network polymeric electrolytes

B.J. Bauer, C.K. Chiang, G.T. Davis (Polymers)

Method for obtaining strong adhesive bonding of composites to dentin, enamel,

and other substrates

R.L. Bowen (Polymers)

Simplified method for obtaining strong adhesive bonding of composites to

dentin, enamel, and other substrates

R.L. Bowen (Polymers)

Transducer hydrophone with filled reservoir

G. R. Harris and A.S. De Reggi (Polymers)

Arc -furnace for the production of small investment castings

R.M. Waterstrat (Polymers)

Method for determining subsurface property value gradients

H. N.G. Wadley (Metallurgy)

Automated device for determining and evaluating the mechanical properties of

materials

D.S. Lashmore, J.L. Mullins, C.E. Johnson, R. Polvani (Metallurgy)

30
SRMs PRODUCED

SRM 660 Profile, 20 XRD Std.

(Ceramics)

SRM 656 Alpha-Beta Silicon Nitride

(Ceramics)

SRM 658 Tridymite Quantitative SRM

(Ceramics)

SRM 717 Glass Viscosity (Renewal)

(Ceramics)

SRM 1488 Poly(methyl methacrylate)

(Polymers)

SRM 1489 Poly(methyl methacrylate)

(Polymers)

SRM 1497 Pigmented polyethylene gas pipe resin

(Polymers)

MONOGRAPHS

Cryogenics Prop's of Copper and Copper Alloys

(Fracture & Deformation)

Binary Alloy Phase Diagrams, 2 Vols. ASM

(Metallurgy)

Cor*SurTM Corrosion Data Software Vols. 1 and 2, NBS & NACE

(Metallurgy)

On-line capabilities for crystal data

(Reactor Radiation)

31

APPENDICES

1987 PANEL MEMBERS

APPENDIX A

Dr. Francois A. Padovani

Chairman (1990)

Vice President

Materials and Controls Group

Texas Instruments Incorporated

34 Forest Street, Mail Station 10/13

Attleboro, MA 02703

(617) 699-1102

Dr. Ian F. Hughes (1990)

Director, Product Research

Inland Steel Corporation

3001 E. Columbus Drive

East Chicago, IN 46312

(219) 392-3262

Dr. George R. Irwin (1989)

Department of Mechanical Engineering

University of Maryland

College Park, MD 20742

(301) 454-8856

Prof. Bernard H. Rear (1990)

Dept, of Mechanics and

Materials Science

College of Engineering

Rutgers University

P.0. Box 909

Piscataway, NJ 08855-0909

(201) 932-2245

Dr. R. Glen Kepler (1988)

Manager, Organic and Electronic

Materials Department 1810

Sandia National Laboratories

P.0. Box 5800

Albuquerque, NM 87185

(505) 844-7520

Prof. G. S. Kino (1989)

Edward L. Ginzton Laboratory

Stanford University

Stanford, CA 94305-2184

(415) 723-0205

Dr. Robert A. Laudise (1989)

Director, Physical and Inorganic

Chemistry Research

AT&T Bell Laboratories

600 Mountain Avenue, Room 1A-264

Murray Hill, NJ 07974

(201) 582-6220

Dr. William J. MacKnight (1988)

Department of Polymer Science

and Engineering

University of Massachusetts

Amherst, MA 01002

(413) 545-0433

Dr. John P. McTague (1990)

Vice President, Research

Ford Motor Company, Room S-2106

Scientific Research Labs Bldg.

2000 Rotunda Drive

Dearborn, MI 48121-1603

(313) 322-7105

Dr. John L. Mihelich (1989)

General Manager, Commercial

Development

AMAX Speciality Businesses

900 Victors Way, Suite 320

Ann Arbor, MI 48108

(313) 665-0100

Dr. Joseph N. Panzarino (1989)

High Performance Ceramics

Norton Company

Goddard Road

Northboro, MA 01532

(617) 393-5820

R. Byron Pipes, Dean (1988)

College of Engineering

134 du Pont Hall

University of Delaware

Newark, DE 19716

(302) 451-2401

35
Dr. Maxine L. Savitz (1990)

Director, Ceramic Components Div.

Garrett Processing Company

19800 South Van Ness Avenue

Torrence, CA 90509

(213) 618-7569

Dr. Sunil K. Sinha (1989)

Senior Research Associate

Exxon Research and Engineering

Company

Clinton Township

Route 22, East

Annandale , NJ 08801

(201) 730-2875

Prof. David Turnbull (1988)

Division of Applied Sciences

Harvard University, Pierce Hall 207

29 Oxford Street

Cambridge, MA 02138

(617) 495-2838

Prof. Julia R. Weertman (1990)

Department of Materials Science

and Engineering

Northwestern University

Evanston, IL 60201

(312) 491-5353

36
APPENDIX B

AN EVALUATIVE REPORT ON THE

INSTITUTE FOR MATERIALS SCIENCE AND ENGINEERING

Panel Members

Peter Cannon, Rockwell International, Chairman

Peter Bridenbaugh, Aluminum Company of America

William B. Hillig, General Electric Company

George R. Irwin, University of Maryland

R. Glen Kepler, Sandia National Laboratories

Robert A. Laudise, AT&T Bell Laboratories

John L. Mihelich, AMAX of Michigan, Inc.

Francois A. Padovani, Texas Instruments Incorporated

Joseph N. Panzarino, Norton Company

R. Byron Pipes, University of Delaware

Sunil K. Sinha, Exxon Research and Engineering Company

David Turnbull, Harvard University

Julia R. Weertman, Northwestern University

Unable to Attend

William J. MacKnight, University of Massachusetts

This report, submitted for the Panel by the Chairman, Peter

Cannon, covers the activities of the Institute for Materials

Science and Engineering during the 12 months preceding the Panel

meeting on January 20-21, 1987.

Functions of the Institute

The Institute for Materials Science and Engineering (IMSE), a

major organizational unit of the National Bureau of Standards

( NBS ) , provides measurements, data, standards, reference

materials, concepts, and other technical information fundamental

to the processing, structure, properties, and performance of

materials. This information is used by industry, government

agencies, universities, and other scientific organizations.

Much of it is made available through major new cooperative

programs with industry which ensure rapid dissemination and

application of IMSE technical output and provide IMSE managers

with immediate information on industry’s needs for measurement

science and data. The Institute, jointly with the American

Society for Metals and the American Ceramic Society, is creating

and disseminating phase diagrams. The societies provide

guidance and substantial financial support from industry.

The research programs of IMSE support generic technologies

in materials in order to foster their safe, efficient, and

economical use. Research in the Institute addresses the science

base underlying new advanced materials technologies. Rapid

37
solidification of metals, ceramics processing, alloy coatings,

polymer blends, and advanced composites are current examples.

IMSE has a beam line at the Brookhaven National Synchrotron

Light Source for frontier research in materials transformations,

kinetics, and advanced x-ray optics. Other unique facilities

are made available to industry and universities in cooperative

research projects. These include the NBS research reactor and

associated apparatus for the use of neutrons to characterize

materials, laboratories for the preparation and characterization

of rapidly solidified metal samples, and other state-of-the-art

measurement facilities. The Institute collaborates with other

NBS Centers and organizations in interdisciplinary programs in

materials science.

During fiscal year 1987, the Institute had a staff of about

410, and a total operating budget of $40 million.

Technical Quality

The quality of the staff and the research performed ranges from

competent to brilliant. At this point, it is well known that

the discovery and characterization of quasicrystals at NBS has

had a tremendous effect on solid-state physics, crystallography,

and materials science generally. The more recent development in

the electrodeposition group of improved understanding of pulsed

alloy deposition and its application to form artificially

layered structures with short wavelength composition modulations

is first-rate materials science. These achievements, along with

the more mundane ones, are certainly up to, and perhaps

considerably beyond, the norm of those in similar areas at other

leading national laboratories.

The new ability through electrodeposition to control

accurately alloy compositions over thicknesses of the order of

50 angstroms is truly outstanding. Such development could have

significant industrial impact as it should provide an economical

process for superlattice formation in contrast to techniques

such as molecular-beam epitaxy currently used in the

semiconductor industry. Superlattice material will offer

industry the ability to tailor material properties essentially

at will. Efforts should be directed in the coming year at

characterizing these materials and at developing a theoretical

basis for their understanding.

The IMSE strength in phase relationship determination,

modeling, evaluation, and codification is outstanding and of

high importance to American industry.

With respect to the new initiative in basic standards and

technology support for advanced ceramics, a high level of

efficiency and impact is being achieved with the resource level

now committed. Recent achievements include the following:

38
1. Unique models that fit a wide array of experimental

results for ceramic fracture.

2. New models for sintering tested against actual

experimental observations in real systems.

3. Models of the matrix-inclusion interface with insights

valuable to the understanding and optimization of composites.

4. The design and construction of novel clean-room

facilities that will be unique for the preparation of ceramics.

5. The full densif ication of ZrC>2 at room temperature.

Lack of reliability continues to be a major barrier to

successful use of advanced ceramics. This issue is addressed in

programs relating to ceramic processing science, ceramic powder

characterization, tribology, mechanical properties, and ceramic

matrix composites. High-temperature materials research and

additional analytical techniques such as the new Fourier

transform infrared setup and surface analysis capability

demonstrate awareness of the key problems facing advanced

ceramics

.

Among the areas where continuing programs are on target and

producing solid scientific results, the perspective applications

of SAXS and related techniques to polymers and the use of

synchrotron radiation to map perfection in materials for optical

applications are of note.

Fracture and deformation studies cover aspects of fracture

and deformation of metals, plastics, and composites. The

principal goal of the research is to establish the scientific

basis to minimize failure of materials. The work includes

developing theories of and models for deformation and fracture,

characterization of mechanical performance, and development and

application of fracture mechanics. Overall programs are on a solid science base with good progress being made on all fronts.

The staff is well managed, enthusiastic, and communicative.

The study of plastic fracture behavior covers fracture

mechanics, nondestructive evaluation, and welding. A533B steel

plate has been subjected to wide-plate crack-arrest tests, and

tests on plate heat treated to simulate radiation embrittlement

exhibited cleavage at a temperature above the upper shelf

determined by traditional impact testing with important

practical implication.

An electromagnetic acoustic transducer system has been

developed to accurately measure velocity-and-time interval to a precision of +1 ns. The system has been successfully applied to

measure residual stresses in welded, thin aluminum plate and in

railroad wheels. It appears to be suitable for on-line process

control for texture monitoring of aluminum used for can

manufacturing.

The programs of the Polymer Division continue to be of the

highest technical quality. The Division has a long history of

39
doing outstanding basic research and, as a consequence, can

attract people of the highest caliber. By and large, the

Polymer Division is in good shape equipment-wise.

The studies of the molecular mechanism for large strain

deformations in epoxies is one example of an outstanding program

in the Polymer Division. These studies involve neutron

scattering and, thus, represent the development of

state-of-the-art metrology and the demonstration of the

applicability of this state-of-the-art metrology to complex,

technologically important polymers like epoxies. This work is

also important to an ultimate understanding of the mechanical

properties of composites in which epoxies are the matrix,

materials that are of great interest to U.S. industry and its

industrial competitiveness.

The neutron and light-scattering studies of the binary

interaction parameter X represent another example of forefront

high-quality research. The X parameter is related to polymer

miscibility and is thus closely related to industry needs in

polymer-blend technologies.

The Reactor Radiation Division ( RRD) continues to produce

excellent research. The program fits well within the metrology

tradition of NBS. Communication with its constituency

(industry, government, and university) is being actively carried

out. One-on-one contact is made with the substantial number of

the RRD's industrial associates. A series of workshops is

planned; the first will be held in 1987 and will address

applications of small-angle neutron scattering (SANS),

ref lectometry , and diffuse scattering to obtain information on

microstructures and submicrostructures. Each workshop will

produce a document laying out opportunities for materials

measurements of interest to industry.

The internationally significant initiative of the cold

neutron source continues. The cryostat is being tested and will

be installed in the early part of 1987. The cold source will

greatly increase the flux of long-wavelength neutrons, and will

particularly enhance the performance of the SANS and new

time-of -flight spectrometers. Planning continues for the new

neutron guide hall. Note that three of the first five

instruments to be built will be of direct benefit to industrial

users: SANS, prompt Y , neutron depth profiling. Prompt Y is

the premiere method of measuring trace amounts of elements.

With cold neutrons the range of elements that can be detected by

neutron depth profiling will be extended and will include oxygen

and nitrogen. The lateral resolution will improve to a few

micrometers. Currently the depth profiling facility at NBS is

so heavily booked that satellite facilities have been set up at

reactors at State University of New York at Buffalo, the

University of Michigan, and North Carolina State.

40
Technical Health

In general, the performance of the work of IMSE is excellent and

the morale of the staff remains good. The pressure felt by many

in the required search for other-agency funds remains a concern

of the Panel and is always a threat to morale in situations of

excess. The organizational and management changes of the last

few years have been well accepted. A balanced though rather

restricted topical program has been built, and there is obvious

collegiality. The IMSE is probably now ready for its next step

to true contemporaneity.

Adequacy of Planning

Both strategic and short-term planning will be required to

ensure that IMSE’s role is effectively integrated with other

national laboratories and centers of research. The Panel has

seen much evidence of tactical planning and its beneficial

effects on programs, initiatives, and staff recruiting. A

significant role of longer-range planning should also be more

fully pursued in conjunction with other major laboratories to

ensure complementariness, minimum of duplication,

sharing/collaboration of resources. In addition, firm,

proactive linkages with U.S. industry should be established to

foster, for example, the advanced ceramics industry. Billions

of dollars are spent and funded each year for materials science

research and development, and real interagency strategic

planning and resource allocation could bring more efficient use

of the dollars available.

A yearly planning function could bring together IMSE

management and staff and the Panel for a session more truly

responsive to the letter request of the Chairman of the Board on

Assessment of NBS Programs to the Panels. The IMSE plan should

look forward at least 5 years and could project to 10 years

ahead using the broad guidelines available in, for example, the

National Academy of Sciences/National Academy of

Engineering/National Research Council studies on materials,

especially drawing on the industrial inputs to questions like,

"What are the trends in materials and what resources will likely

be needed?" Then, the time spent to assess the current program

and the plan for the next year will have much stronger context.

Appropriateness of Balanced Planning

The Panel considers that the IMSE has made progress toward a well-balanced scientific research program, and that real

progress has been made towards emphasis of contemporary

materials, but the Panel wishes to make it clear that a

substantially increased effort on longer-range planning and

topic selection that would naturally mesh with expected patterns

of industry need is not only justified, but very necessary.

Newer technologies such as metal and ceramic matrix composites,

life prediction methodologies, and a vigorous expansion into

41
electrical and electronic materials are typical of these

high-leverage fields of American competitiveness. Intense

industrial interest could be expected in well-planned,

well-communicated initiatives of this type, especially when

coordinated with the massive characterization capabilities of

the Department of Energy chain of national laboratories. Early

recognition of the technological trends and a commitment to

follow the new developments will ensure the responsiveness of

IMSE.

The communication of priorities should be with both the

external and the internal constituencies. There are some

remarkable discrepancies between the expressed and perceived

goals of NBS management on the part of the scientific staff;

such are normal in any large organization, but at a time of

change or stress, extra care and time must be taken to assure

uniform communication. Particular care must be taken not to mix

up or confound the responsibility of goal management with that

of scientific direction, when the overall purpose is to improve

the use of the output and to assure its relevance.

Responsiveness to National Needs

NBS was created over 85 years ago and the relation of the newer

organization components, like the IMSE, to the charter presents

difficulties of definition except in the broad sense of

provision of a technical service. A difficult but required task

for the IMSE planners is to express a closer relation between

the excellent work of scientific discovery and the principal

goals of the Bureau dealing with metrology. The IMSE staff

constitute a national asset in materials science, and great

clarity in expressing expectations for staff achievement is

needed to assure the timeliness and prospective industrial

relevance of the work in terms of the statutory charter. The

same issue arises in particular form throughout the various

divisions of the Institute, though some are clearly in

possession of excellent industrial constituencies. In general,

the IMSE ' s constituency in academia is excellent.

Assuming that the primary function of NBS is to be

supportive to the nation's business and industry, it is

important to identify to the extent practicable what the needs

are that can be addressed by a public technical institution

nominally focused on metrology, having the excellent facilities,

staffing, and tradition that make NBS a national resource. The

program of the IMSE reflects a technical logic in terms of

properties versus structure versus processing, but the

underlying logic in terms of the "customer's needs" is less

clear

An approach that could have major industry-wide implications

is the provision of design data, on line, for advanced

materials. A central clearing house for data, standards, etc.,

on such materials, particularly composites of all kinds, is

42
sorely needed along with programs both internal and cooperative

(such as the International Energy Agency round robin) to fill

the data bank and make it accessible. The above are certainly

within the charter of NBS and could have major implications for

IMSE , along with interesting revenue and proprietary protection

and access issues.

Communication with Constituencies

NBS programs necessarily take the lead from industry, but NBS

managers should strive to anticipate needs, so as to formulate

fast and effective responses to opportunity. In order that

industry benefit from the programs of IMSE, it is important that

business and the Institute know each other better. Workshops,

symposia, talks, and visits are helpful. However, some of the

key staff should have longer-term exposure to industrial

technical work and its culture. Both junior and senior

industrial scientists and engineers do work at NBS as visitors,

but the "return match" is played less frequently. Accordingly,

a more vigorous, bilateral program of exchange is recommended by

the Panel, with the explicit goals of providing a firmer,

lengthened planning horizon and a much-improved pattern of use

of the resulting cooperative work.

A good model for such exchanges was the exploration of

technology transfer opportunities in the domestic automobile

industry with the assistance of the Ford Motor Company. A year

of interaction in Detroit resulted in a number of

recommendations to achieve more efficient use of materials, and

a proposed follow-up with the whole industry will occur in

1987. A conscious incorporation of what has been learned into

NBS's plans is also called for. The Panel also notes that the

IMSE remains home to the only Bureau-wide program of technology

transfer, the Office of Nondestructive Evaluation (ONDE), and

lessons learned from its operation can usefully be taken up by

the Bureau.

Equipment

In general, the IMSE's equipment is acceptably recent and quite

appropriate; the IMSE does not match the capital intensity of

the best equipped industrial laboratories. A careful scrutiny

by NBS management of capital investment per worker by division

is needed.

Greatest Needs

Relationship of Science and Metrology

Probably the prime motivation of most of the IMSE staff is to

discover novel materials and processes and to develop deeper

understanding of structure-property relations. Freedom to

pursue these goals is, perhaps, what has enabled IMSE to attract

and retain the outstanding scientific talent that it has. There

43
is continuing concern that emphasis of these scientific goals

may detract from the metrological achievement, which is the

traditional mission of NBS . Most importantly, it should be

recognized that good metrology often is motivated by, and

follows, good science. When scientific breakthroughs occur,

development of new or improved metrology usually is essential

for their verification and characterization. For example, in

the rapid solidification processing (RSP) area, vital to the

U.S. aerospace industry, the NBS discovery of quasicrystals

called for a thorough reexamination of diffraction conditions

and some of the methods of high-resolution electron microscopy.

Also, the high rates of crystal growth in RSP motivated new

methods of measuring temperature at the rapidly moving

interface. A major initiative available to IMSE is the

integration of material science data, including process

kinetics, into metrologically based on-line measurement

techniques useful in statistical manufacturing process control.

To summarize, good science is symbiotic with good metrology;

the two go hand in hand. It should also be made clear, however,

that a diligence is needed to bring the new opportunities to

application, and that such is essential to the overall health of

the enterprise. The best science is useful; the challenge to

management is that there is no substitute for first-class

scientific discovery--which cannot be predicted, no matter how

much care goes into planning. This year's high temperature

superconductivity discoveries are an outstanding example. The

business of IMSE is discovery and use, and the special

responsibility of the managers is anticipation and advocacy of a

proper balance.

A Desirable Expansion

In the past, NBS expertise has provided the physical-chemical

foundations for, e.g., the exploitation of new families of

ferrites, dielectric ceramics, and other high-technology

electronic materials. Activities devoted to the understanding

of the crystal chemistry of inorganic materials and phase

relations should receive continuing and increased support.

Opportunities in, for example, superconductors, nonlinear optics

(NLOs), and new semiconductors should make the NBS expertise in

crystal chemistry-phase equilibria an ideal building block in a new initiative to electronic materials.

The Panel applauds and encourages the IMSE plans to enlarge

activities on electronic materials. Electronic materials are

the sine qua non of the electronic components and devices that

pace the competitiveness of telecommunications and information

systems. Thus, electronic materials have high leverage on

national competitiveness. The unique metrological strengths of

NBS and its new initiatives toward leveraging national

competitiveness can be especially profitably focused on

electronic materials. The device and electrical standards

strengths in other parts of NBS should synergistically reinforce

44
IMSE’s materials strengths. A number of possible areas for

emphasis present themselves: for example, (1) semiconductor

materials--Si , III-Vs, new semiconductors; (2) dielectric

materials--ceramics and organics; (3) optical materials --fibers

,

EOs, and NLOs; and (4) packaging and lithographic materials.

It is clear that focus on a subset of activities will be

essential. This choice should be based on the strengths of

staff and on facilities, together with an assessment of new

resources that can become available in the near future.

Consideration should be given to recruiting at least one senior

person to lead such a group. The activity should play to the

traditional strengths of the Bureau and IMSE, unimpeachable

measurement techniques and high-quality preparation techniques

and results that others can use with confidence.

A Suggestion

Industry is making rapid progress in the composites field and

consideration should be given to forming an Institute-wide

program, including the expertise in fracture and deformation,

perhaps similar to the ONDE. Such would be a useful point of

contact for industry, and for the assembly of standards -type

information. It could be a focus for industry-originated

techniques in composites to be evaluated for acceptance as

prospective standards, a partnership possibility that could do

much to help bring the entire Bureau back into regular contact

with industry. The Panel suggests that this programmatic

vehicle be planned and initiated promptly.

45
APPENDIX C

AN EVALUATIVE REPORT ON THE

OFFICE OF NONDESTRUCTIVE EVALUATION

Panel Members

G. S. Kino, Stanford University, Chairman

Laszlo Adler, Ohio State University

John R. Barton, Southwest Research Institute (Retired)

Joseph A. Giordmaine, AT&T Bell Laboratories

Edmund G. Henneke, II, Virginia Polytechnic Institute and State

University

Robert W. McClung, Oak Ridge National Laboratory

Unable to Attend

Peter Bridenbaugh, Aluminum Company of America

This report, submitted for the Panel by the Chairman, G. S.

Kino, covers the activities of the Office of Nondestructive

Evaluation during the 12 months preceding the Panel meeting on

December 8 - 9 , 1986.

Functions of the Office

The Office of Nondestructive Evaluation (ONDE), a part of the

Institute for Materials Science and Engineering (IMSE), provides

for enhanced reliability, productivity, and economy in the use

of materials, structural components, and systems, both during

their manufacture and in-service by conducting research leading

to the development, stimulation, and dissemination of (1) more

sensitive and reliable nondestructive evaluation (NDE)

measurement methods; (2) improved NDE physical measurement

standards, calibration services, and document standards; and (3)

information to relate NDE measurement results to material and

systems properties and performance.

During fiscal year 1987, the Office had a staff of about 6

and a total operating budget of approximately $2.4 million.

Organization

Nondestructive evaluation is an interdisciplinary field. It

requires knowledge of such subjects as materials processing,

signal processing, optics, acoustics, and a broad range of

physics, as well as the techniques for applying the basic

principles to field applications.

The organization of the ONDE, requiring a wide range of

talents, has a permanent nucleus to manage the interdisciplinary

programs and to recruit the necessary talent from the relevant

46
parts of NBS . They typically use a core of people with a long

and productive background in the field of nondestructive

evaluation, along with others on a less-permanent basis, who are

needed to address particular problems of interest.

The Panel believes that ONDE, by drawing upon the

interdisciplinary resources available within NBS, has devised a

very constructive approach for tackling the problems of

nondestructive evaluation. Such efforts are often difficult to

implement in university or, for that matter, industrial research

settings. The Panel is most enthusiastic about the way this has

been done at NBS and believes that the approach carried out by

ONDE is working extremely well.

Strategic Plan and Goals

As stated earlier, during fiscal year 1986, the Office had a staff of about 6 and a total operating budget of approximately

$2.4 million. Support for this program has been approximately

constant during the last 3 to 4 years. This represents a net

decrease in effective operating budget of the order of 15 to 20

percent during the same period.

There is a critical need to improve productivity and to make

the manufacturing process more efficient in the United States.

Research is needed on a number of critical problems associated

with manufacturing. One important need is that of furthering

research and applying NDE techniques to automated manufacturing

with the aim of measuring critical material and structural

parameters during the manufacturing process and to use these

measurements in a feedback loop to control the process itself.

The development of sensors and appropriate techniques of NDE are

needed for this purpose.

Previous Panels urged the ONDE to develop a strategic plan.

The nucleus of a strong contribution by ONDE to research on

applications of NDE to the manufacturing process has been

developing for a number of years, and is now guided by a

worthwhile strategic plan. As proposed in this strategic plan,

ONDE would focus on four primary activities: (1) NDE for metal

and ceramic powder production and consolidation, (2) NDE for

metal processing, (3) NDE for composites and interfaces, and (4)

NDE standards and methods

.

This has resulted in a reduction of the total number of

programs from 52 in 1985 to 24 in 1986. In the opinion of the

Panel, this concentration has led to a more efficient way to use

the limited resources available to ONDE.

47
Some Outstanding Programs

Automated Materials Processing

The Panel believes that the program on automated materials

processing is a major opportunity for NBS to exert leadership in

research on automated materials processing. The initial program

is a study of powdered metal production. It is planned to

demonstrate the use of NDE to evaluate the condition of the

materials being used during various stages of production in a

metal powder atomization system. The basic idea is to measure

droplet formation and particle size, and to modify the

atomization system by process feedback control.

A production system of this kind, costing approximately $1

million, has been built for this purpose. Initial project

funding by NBS is on the order of $250,000; a total funding on

the order of $1 million per year is needed. ONDE is attempting

to start an industrial consortium with each contributor giving

$75,000 per year in money or equivalent compensation (this may

include industrial scientists working at NBS). They will need

on the order of 8 to 10 industrial firms with a minimum of 4 to

provide the bare minimum of financing required.

It is the opinion of the Panel that the use of an industrial

consortium is an excellent way to obtain funding in a tight

funding situation. It also provides a good vehicle for transfer

of technology. Because of the importance of this work to the

country, and the leadership role being exerted by NBS, the Panel

suggests that it would be of great value, both to the country

and to NBS, to provide further up-front funding to get this

program under way as soon as possible and to encourage industry

to contribute matching funds.

It has been most difficult to start programs of this type in

the United States. There are very few, if any, examples of such

a coherent research program in automated materials processing.

ONDE has taken all the right steps to begin such a program.

They started with a workshop on the subject that was well

attended and most interesting to the industrial, university, and

government research participants. They were also involved with

a National Materials Advisory Board panel, examining the same

subject, whose participation and leadership in this work enabled

them to start a program of their own. In the opinion of the

Panel, this is a first-rate example of how NBS can provide a good bridge between fundamental research and industrial needs.

Sensors for Steel Process Control

A second program of cooperation with industry, which is being

conducted with the steel industry, is the measurement of

temperature profiles of steel billets. A demonstration system

has been set up as a cooperative effort with participants from

the steel industry. Members of the Panel who saw this work

48
found it most impressive. The type of cooperative effort is an

excellent way of transferring technology and for obtaining

financing for this type of applied research.

There are several other programs related to the steel and

aluminum industry. A very similar program on temperature

sensing is being started with the aluminum industry. Other

programs involve measurements of surface condition of metals

while being machined. This makes it possible to evaluate the

condition of the surface or the steel being machined, and tool

wear in lathes and milling machines.

In the opinion of the Panel, such research is most important

to production efficiency in this country. There are also

several other programs of importance, such as the measurements

of composites, evaluation of ceramics, measurements of

temperatures, and so on, all of which again should be encouraged

as ones of vital importance for manufacturing.

Standardization Programs

Along with these programs, there are some of the more

conventional NBS standards, such as those for acoustic emission

and leak standards, which have been done well and are vital

functions of NBS, that should receive continued encouragement

and support.

Management of ONDE

The Panel was impressed with the leadership being exerted by

ONDE. The Panel believes that there has been great progress in

the last few years. The focus on national needs and organizing

the internal program has been well thought out and is following

an excellent strategic plan.

ONDE has started a Gordon Conference on NDE and workshops on

materials processing subjects of great importance to this

country. Staff members have typically started research programs

of their own based on the findings of these workshops. By the

use of consortia and other cooperative efforts with industry,

they are attempting to find sources of other funding and to

improve the transfer of technology to industry.

Typically, staff members publish most of their scientific

results in journals such as the Journal of Applied Physics , as

indeed they should. However, the Panel would encourage them to

publish some of the results related to manufacturing in more

general magazines and trade journals, such as the Journal of

Research Development , the American Society for Testing and

Materials Standardization Journal , Semiconductor International , Sensors, Electronics , Laser Focus , and Robotics World . ONDE has

already begun to do this; more publications of this type will be

needed in order to communicate their findings to the relevant

people in industry.

49
Electron Devices

Last year, the Panel recommended that ONDE pay attention to the

NDE problems of electron devices. Very little progress has been

made in this direction. There is, already, in the Semiconductor

Electronics Division, a strong program in many aspects of NDE of

electron devices. However, the problems of packaging

semiconductor devices, which are of critical importance to the

electronics industry, are to a large extent structural in

nature, and lend themselves well to the types of acoustic and

photoacoustic techniques familiar to ONDE. A cooperative effort

between ONDE and the Semiconductor Electronics Division could be

a very productive way to make progress in this field.

The Panel recommends that NBS facilitate cooperative

programs of research between ONDE and the Semiconductor

Electronics Division on certain aspects of NDE of electron

devices. In certain cases, such as packaging, the expertise of

both groups is needed.

Survey of NDE Applications in Japanese Manufacturing

The Panel discussed the role of NDE in Japanese industry, where

many sectors have stressed the development and operation of

highly automated factories. There appears to be little

available information on the extent of Japanese NDE use in

manufacture for materials measurements, process control, and

product evaluations, or as features in the design of industrial

and consumer products.

A strong indicator of NDE penetration into Japanese industry

is the growth in research and development of sensors. Beginning

around 1975, sensor research and development has had the

sponsorship of a number of government research institutes, e.g.,

the Electrotechnical Laboratory, the National Research

Laboratory of Metrology, and the Mechanical Engineering

Laboratory. The work has also been coordinated by industry and

professional organizations, e.g., the Japan Electronics Industry

Promotion Association. Recent large-scale programs with

important sensor technology components include the R&D Project

of Basic Technology in Future Industries (begun in 1981) and the

Research and Development Program for Advanced Robotic Technology

( begun in 1983 ) . There is little applications literature on the introduction

of NDE and sensors into materials and product

development/manufacture in Japan. However, it is difficult to

imagine that the advances that the Japanese have reported in

factory automation and enhanced product features could have

occurred without extensive NDE applications.

The Panel recommends that ONDE consider a survey of NDE

applications in Japanese materials-intensive manufacturing to be

implemented in part by visits to representative processing.

50
electronic, and other factories. The survey, with ONDE

initiative, might be organized under auspices of the National

Research Council, the National Materials Advisory Board, or

other appropriate agencies. The results of such a survey would

be of substantial value in planning and resource allocation for

NBS and other U.S. research and development in this area.

Funding Level

The Panel applauds the new initiative in direction and the

research in the field of NDE at NBS. The Panel believes that

the work is of great importance to the country, and that it is

underfunded at the current time. The country would be served

well by a considerably increased funding level for ONDE along

with the provision of more people to enhance this effort. The

current funding level is of the order of $2,400,000. The

country would be well served by a 20 percent increase in funding

level per year for the next 5 years. This would reinforce

ONDE's initiatives in the transfer of technology to industry and

would encourage private-sector involvement with their research.

51
U.S.

DEPARTMENT

OF

COMMERCE

National

Bureau

of

Standards

APPENDIX D

52
Institute

for

Materials

Science

and

Engineering

L.

H.

Schwartz,

Director

R.

B.

Johnson,

Associate

Director

APPENDIX E

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APPENDIX F

FUNCTIONAL STATEMENT

INSTITUTE FOR MATERIALS SCIENCE AND ENGINEERING

Develops and maintains the scientific competences and experimental facilities

necessary to provide the Nation with a central basis for uniform physical

measurements, measurement methodology, and measurement services fundamental to

the processing, characterization, properties and performance of materials, and

to other essential areas in materials science; provides government, industry,

universities, and consumers with standards, measurement methods, data, and

quantitative understanding concerning metals, polymers, ceramics, composites,

and glasses; characterizes the structure of materials, chemical reactions, and

physical properties which lead to the safest, most efficient uses of

materials; improves materials technologies, provides the bases for advanced

material technologies, in basic and high-technology industries, and encourages

recycling; obtains accurate experimental data on behavior and properties of

materials under service conditions to assure effective use of raw and

manufactured materials; provides technical information such as reference data,

materials measurement methods, and standards to processors, designers, and users for selection of cost-effective combinations of materials, processes,

designs, and service conditions; uses the unique NBS reactor facilities to

develop neutron measurement methodology, develop sophisticated structure

characterization techniques, reference data, and standards; participates in

collaborative efforts with other NBS organizational units in the

interdisciplinary developments in materials science; and disseminates generic

technical information from the Divisions to private and public sector

scientific organizations through special cooperative institutional

arrangements and through conventional distribution mechanisms.

54
NBS-114A (REV. 2-80

U.s. DEPT. OF COMM. BIBLIOGRAPHIC DATA

SHEET (See instructions)

4. TITLE AND SUBTITLE

PUBLICATION OR

REPORT NO.

2. Performing Organ. Report No. 3. 87-3610

Publication Date December 1987

IMSE Annual Report, 1987

5. AUTHOR(S)

Lyle H. Schwartz

6. PERFORMING ORGANIZATION (If joint or other than NBS, see instructions) 7. Contract/Grant No. national bureau of standards

DEPARTMENT OF COMMERCE

WASHINGTON, D.C. 20234

8.

Type of Report & Period Covered

10/1/86 to 09/30/87

9.

SPONSORING ORGANIZATION NAME AND COMPLETE ADDRESS (Street. City. State . ZIP)

National Bureau of Standards

Institute for Materials Science and Engineering

Gaithersburg, MD 20899

10.

SUPPLEMENTARY NOTES

] Document describes a computer program; SF-185, FIPS Software Summary, is attached.

11.

ABSTRACT (A 200-word or less factual summary of most si gn i fi cant information. If document includes a significant

bi bliography or literature survey, mention it here) The 1987 Annual Report was prepared for the NAi-NRC Board of Assessment of

the Institute for Materials Science and Engineering. This volume contains

background information on resources, activities, and representative highlights

of the Institute.

12. KEY WORDS (Six to twelve entries; alphabetical order; capitalize only proper names; and separate key words by semicolon s) National Bureau of Standards; Institute for Materials Science and Engineering;

Review; resources; activities; highlights.

13. AVAILABILITY

Q Unlimited

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