Lawrence T. Drzal - US grants

9310944 Drzal The purpose of this Research Equipment Grant Award is to allow the purchase of an Environmental Scanning Electron Microscope (ESEM) by the Composite Materials and Structures Center at Michigan State University. This device will be used to perform processing and durability research in polymer, cement and ceramic matrix composites in order to increase their use on the durable goods industry. Studies will include investigations of the failure of composites under combined thermal, mechanical and moisture environments.

9412783 Hawley ABSTRACT Education and Training Program in Composite Materials for DoD and Durable Goods Industries Michigan State University (MSU) and the University of Delaware (UD) will develop new courseware and software to advance the dual-use potential of low-cost composite manufacturing. Education delivery mechanisms to be used include computer-based simulations and interactive learning, broadcasting of classes over satellite networks, and workshops on design and processing of composites. Resources available to the universities include the National Science Foundation's Center for Polymer Processing at MSU and the Center for Composite Materials at UD, sponsored by the Army Research Office. These centers are also supported by large industrial consortia, and have excellent research and manufacturing facilities. Industry involvement in this effort will include guest lectures and planning workshops. ***

9871355
Lucas

The acquisition of the mechanical properties microprobe (MPM) system (Nano Indenterfi II) is to be used primarily to support graduate education and training and conduct research in materials science and engineering. The MPM provides new dimensions in testing and analysis for many engineering research programs within the college, particularly in the Materials Science and the Electrical Engineering Departments, and the university at large. Ongoing research in the College of Natural Science will also benefit from having access to the nanoindenter. The naniondenter will be a first of its kind on site of Michigan State University. Many diverse research groups that are involved in the characterization of materials and in nanomechanical stress analysis will benefit significantly from the acquisition of the MPM. This is especially the case for characterization of the small-volumes, thin films and interfaces in materials. Some research programs will use the MPM to determine the hardness, modulus and fracture energy of thin films and nanolayered materials.

There is a growing need for a fast, robust, efficient and environmentally benign surface treatment process for plastics and metals that can be easily incorporated into the manufacturing environment. This New Technologies for the Environment project will emphasize high risk/high return, exploratory feasibility study into the ability to use UV light, in air, to clean and surface treat polymer and metals surfaces as a replacement technology for abrasion, solvent and detergent based cleaning methods to prepare surfaces to painting and/or adhesive bonding. The UV source will illuminate a surface with photons of sufficient energy and intensity in air to create atomic oxygen and ozone to both decompose surface contaminants and oxidize and increase the surface energy of the surface being illuminated. If this process could be accomplished, it would result in a reduction in VOCs; a reduction in detergent fouled waste water; and a reduction in fine particulates. This technology also has the potential to be very cost effective through its energy efficiency.

Preliminary research being conducted has shown the potential ubiquitous nature of this process to a large variety of polymer and metal surfaces. Research in this portion of the project will be directed at the fundamental scientific and engineering aspects of this process which would allow life-cycle considerations for costs and efficient materials reuse in a sustainable materials stream.

Bio-composites from Engineered Natural Fibers
for Housing Panel Applications

L. T. Drzal and A. K. Mohanty
Composite Materials and Structures Center
Michigan State University, MI 48824

This proposal will have as its objective, the development of natural fiber (bio-based) composites for housing panel applications as an environmentally friendly alternative to contemporary synthetic glass fiber - polyester composite materials. Research under this project will investigate the utility of combining surface treated bast fibers (e.g., kenaf, hemp) with leaf fibers (e.g. pineapple leaf) in order to synergistically obtain the desired mechanical properties of strength, stiffness and toughness. The bast fiber bio-composites alone show high flexural/tensile properties while the leaf fiber based bio-composites alone show the best impact properties. The agricultural origin of the biofibers will create a new value-added use for pineapple leaf, at present a waste/underutilized product. This project will be executed through effective collaboration of University (MSU), a housing panel manufacturing company (Kemlite), and a natural fiber company (Flaxcraft) in order to understand the changing demand and requirements of paneling systems by industry so that the use of bio-composites is maximized. The fundamental knowledge of the relevant structure-processing-property relationships gained will be the basis for the commercialization of biocomposites into the housing market.

This NSF/EPA Technology for a Sustainable Environment project seeks to address fundamental issues associated with replacing existing petroleum-based glass fiber - polypropylene composites with eco-friendly, sustainable, bio-composites from renewable resource-based natural/bio-fibers and bio-plastics for automotive applications. The research will focus on: (1) innovative bio-fiber surface treatments and the design of engineered natural fibers; (2) synthesis of cellosic bio-plastics with acceptable mechanical properties; and (3) research into the processing methods to produce void free bio-composites sheets for stamping processes. The use of an electrical field during the processing enhances control of fiber alignment.

It is expected that this will result in a break-through process for the new generation of bio-composites that is cost effective as well as environmentally friendly. University - industry collaboration is expected to add knowledge of the material and process engineering as well as to create a consciousness in designing value-added composite materials from bio-resources for the automotive and transporation industries. Knowledge gained from this research will enhance the education of students and practitioners in engineering design as well as manufacturing and production engineers concerned with environmentally benign manufacturing.

The funds provided by the NSF Instrumentation for Materials Research program support Michigan State university with the acquisition of a unique micro-compounding molding system to support research in emerging new bio-based materials and polymers, and related educational programs. The equipment will be used in support of research which includes: (i) investigation of fundamental phenomena in newly developed bio-based materials and polymers, (ii) optimization of processing parameters at the micro-scale - - to establish structure, property, and performance relations and (iii) expansion of the integration of research and education in the area of polymer blending, polymer compounding and nanocomposites.

The funds provided by the NSF Instrumentation for Materials Research program support the Michigan State University with the acquisition of a unique micro-compounding molding system. The system will support research in new bio-based materials and polymers, and related educational programs. The equipment will be used in support of research to establish structure, property, and performance relations and education in the area of polymer blending, polymer compounding and nanocomposites.

0210681
Drzal
This proposal was received in response to the Nanoscale Science and Engineering Initiative NSF 01-157, category NER.

Green nanocomposites are the wave of the future and are considered as the next generation of materials. The lofty goals set by U.S. Government for the creation of bio-based economy present significant challenges to Industry, Academia and Agriculture. This proposal seeks to replace/substitute existing petroleum derived polypropylene/TPO (thermoplastic olefin) based nanocomposites from compatibilized clay reinforced cellulosic bio-plastic through a novel approach for automotive applications. A new bio-based product derived through nano-science approach from renewable resources; having recycling capability and triggered biodegradability (i.e. stable in their intended lifetime and would biodegrade after disposal under compost conditions) with commercial viability and environmental acceptability is termed as sustainable green nanocomposites under this high-risk exploratory research (NER) proposal. The main objective of this proposal is to replace such petro-derived nonbiodegradable polymers with renewable resource-based biodegradable polymers. Compatibilization between the nanoclay and bioplastic is the key to achieving success. A new maleated compatibilizer is targeted to effectively bind both the clay and cellulosic bio-plastic in the compatibilized green nanocomposites.

Expected Results Our research has proved the "proof of concept" on promising potentiality of cellulosic bio-plastic in designing green nanocomposites for high impact and high strength applications. From our preliminary data we find encouraging results where the coefficient of thermal expansion (CTE) decreased by ~ 50% and water absorption decreased by ~ 14% on reinforcement of cellulosic plastic with 5 wt.% as received commercial clay. However with the presence of compatibilizer we expect to get much improved properties of our targeted nanocomposites. The synergy to be gained by maleated compatibilizer, bio-plastic development and novel processing will result in making sustainable eco-friendly green nanocomposites of industrial attractions. This intended research program through University-Industry interactions is expected to create a consciousness among young graduate/undergraduate students in adding knowledge of materials and process engineering of new green nanocomposites and to create the growing importance of unique nano-technology to generate eco-friendly affordable green materials for 21st century automotive industries.


Expected Results Our research has proved the "proof of concept" on promising potentiality of cellulosic bio-plastic in designing green nanocomposites for high impact and high strength applications. From our preliminary data we find encouraging results where the coefficient of thermal expansion (CTE) decreased by ~ 50% and water absorption decreased by ~ 14% on reinforcement of cellulosic plastic with 5 wt.% as
received commercial clay. However with the presence of compatibilizer we expect to get much improved properties of our targeted nanocomposites. The synergy to be gained by maleated compatibilizer, bio-plastic development and novel processing will result in making sustainable eco-friendly green nanocomposites of industrial attractions. This intended research program through University-Industry interactions is expected to create a consciousness among young graduate/undergraduate students in adding knowledge of materials and process engineering of new green nanocomposites and to create the growing importance of unique nano-technology to generate eco-friendly affordable green materials for 21st century automotive industries.

There is a growing urgency to develop novel biobased products and innovative technologies that can reduce the US dependence on fossil fuel. This PREMISE project seeks to replace existing petroleum-based glass fiber-nylon composites with sustainable, eco-friendly, 'green' composites produced from a combination of engineered natural/bio-fibers and a new, emerging bacterial-based bio-plastic (polyhydroxyalkanoate, PHA) for automotive applications. This 'green' composite material has the attributes of recyclability and 'triggered' biodegradability i.e. (stable during intended life but biodegradable only under composting conditions) to qualify it as a sustainable material. The objective is to strengthen the connection between "DESIGN" and "MANUFACTURING" of this novel 'green' composite so that they can have a positive impact upon industrial applications.

This project will address research issues related to the development of ideas and creation of tools for sustainable product development in the manufacturing enterprise. In order to achieve 'sustainability', all the components such as environment, economics, life cycle analysis, energy and education are included in this project. Product realization for industrial application of biocomposites requires complete Life Cycle Assessment, from production of bio-fibers and bio-plastics, to design and engineering of green biocomposites to their ultimate disposal or recycling. Energy calculations for the entire manufacturing system will be calculated from fiber/plastic production to their processing and manufacturing based upon the existing scientific literature and preliminary experimental data collected from the pilot-scale experiments. A strong collaborative partnership with representative industrial participants, METABOLIX (manufacturer of bioplastic), FLAXCRAFT (natural fiber company) and FORD (automotive OEM) insures relevancy and a high potential for industrial implementation in the future.

Abstract
The goal of this project is to develop a sustainable alternative to fiberglass load-bearing multi-purpose panels with novel cellular nano-biocomposites. Cellular nano-biocomposites. The cellular nano-biocomposite will be used to develop advanced panel components for multiple-use (i.e., housing floors, walls, roofs, bridge decks, RV panels) with tailorable integrated multi-functions (i.e., stiffness, strength, toughness, thermal insulation, fire protection, and user friendliness).
The research objectives will be achieved through a fundamental study guided by four general tasks:
I. Biobased Polyester Resin. Suitable biobased resin from a blend of petroleum-based polyester and functionalized soybean oil (~ 30 wt.%) is proposed to address both engineering and environmental requirements.
II. Clay/Biobased Polyester Nanocomposite. The properties of biobased resin will be enhanced with nanoclay reinforcement dispersed via exfoliation.
III. Nano-reinforced Polyester Biocomposite. The polymer nanocomposite will be additionally reinforced with "engineered" natural fibers.
IV. Cellular Structural Material and Panel Systems. The specific properties of the nano-reinforced biocomposite will be further enhanced through the topological design of the material in cellular arrangements.

The project is a multidisciplinary effort among the Departments of Civil and Environmental Engineering, Chemical Engineering and Materials Science, and Agriculture Economics. The research approach integrates the technical components of analysis, design and manufacturing with broad societal impact elements such as environment, economy, life-cycle analysis, energy, industrial collaboration, education integration, and outreach.
The project will allow education and research training of two graduate and two undergraduatestudents. Research and education will be integrated in advanced composite materials courses across departments and through multidisciplinary student activities. A determined attempt will be made to recruit underrepresented students using university programs. We expect to create a break-through concept for a new generation of high-performance load-bearing components through fundamental research. The research will add considerable knowledge in the engineering of naturally reinforced nanocomposites, innovative structural design, and will create consciousness in designing value-added, eco-friendly and affordable materials and components for the 21-st century.

This Nanotechnology in Undergraduate Education (NUE) award to Michigan State University supports a team of four faculty led by Dr. K. Jayaraman, Department of Chemical Engineering and Materials Science, to develop a new undergraduate laboratory experiment on transport properties of polymer nanocomposites with layered materials and a related web-based interactive teaching/learning module on the subject designed for sophomores. The new experiment will be added to an existing laboratory course titled Composite Materials Processing offered every year to juniors and seniors from chemical engineering, mechanical engineering and materials science. Undergraduate students in the course will investigate the mean particle aspect ratio, the polymer crystallinity, the diffusivity of gases and the electrical impedance in chosen nanocomposite specimens prepared with nanoscopically thin, silicate layers and expanded graphite in several polymers. Selected undergraduate students will be recruited as summer interns to work with the faculty on this project.

The web-based module will have three components - a virtual experiment on the permeability of layered silicate nanocomposites, a basic description of how electrically conductive nanolayers achieve conduction in a polymer nanocomposite; and a description of packaging applications including green nanocomposites based on sustainable polymers. The interactive web-based module will be combined with lectures in an undergraduate course on Plastics Packaging taken by 120 students. A total of up to 200 undergraduate students per year will be impacted by this development at Michigan State University alone.

The proposal for this award was received in response to the Nanoscale Science and Engineering Education announcement, NSF 03-044, category NUE and was funded by the Division of Engineering Education and Centers (EEC) in the Directorate for Engineering.

The objective of this research project is the advancement of fundamental knowledge for the processing and manufacturing of sustainable renewable resource-based "green" biocomposites from engineered natural/bio-fiber and bioplastics. The approach is to utilize new emerging bioplastics produced by bacteria and bioplastics derived from corn oil with plant biofibers as reinforcements to produce structural biocomposites via extrusion-injection molding and a new hydro-thermoforming process. An integrated research program will be conducted encompassing education, economics, environment and energy aspects to strengthen the connection between "Design" and "Manufacturing" in order to achieve 'sustainability'. A strong collaborative partnership with representative industrial participants from across the technology will add additional strength to insure relevancy and industrial implementation in the future.

This research will result in a framework that will serve as the foundation for transitioning away from petroleum based resources to biobased, sustainable resources in structural materials while maintaining a viable cost-performance structure. Advancement in the demand for and utilization of these new alternative 'sustainable" materials will create new sources of revenue for farmers, increase the use of biobased products and reduce the nation's dependence on petroleum resources. The project will also produce new educational modules that can serve to integrate the full range of important environmental considerations into traditional engineering education.

The objective of this Major Research Instrumentation (MRI) is for the acquisition of a thermo-hydroforming stamping press capable of forming sheet materials of varying thickness and composition under high pressure and temperature at varying strain rates. The research to be conducted includes design and synthesis of multifunctional composite materials (MCM) through incorporation of nano-reinforcements at both the interlaminar and intralaminar levels. The key principle will be to control the nanoparticle concentration, orientation and morphology through the thermo-hydroforming stamping process. The emphasis of the research would be on the development of fundamental materials-processing-property relationships that lead to polymer and composite multifunctional properties, particularly mechanical stiffness and toughness, reduced weight, thermal conductivity, dielectric properties, electrical conductivity, enhanced barrier performance, fire resistance and self-diagnostic capability. Examples of materials to be tested with the thermo-hydroforming press are (a) nanomaterial-reinforced composites, (b) engineered materials for RF devices, (c) tailorable materials and structures, (d) biobased structural composites, and (e) to shape-set and perforate thin nitinol shape memory alloy sheets for biomedical applications.

The thermo-hydroforming press will provide numerous educational and research opportunities for faculty, post-doc fellows, graduate and undergraduate researchers to learn more about forming of biobased composites, nanocomposites, and lightweight metals, as well as to verify the accuracy of existing material models and to develop new models for the forming simulation of nanocomposites. Through various workshops sponsored annually by the college of engineering, participation of first-generation, low-income and/or underrepresented college juniors and seniors in the thermo-hydroforming research will be encouraged. The multicultural apprenticeship program (MAP) will provide for the participation of underrepresented women high school students to learn more about career opportunities in biobased materials and nanotechnology. The new thermo-hydroforming press will also provide opportunities for local small businesses to have access to a research instrument. Finally, using summer workshops sponsored by the Society of Plastic Engineers (SPE), practicing engineers will be trained on the benefits of stamp thermo-hydroforming as a unique process for forming composite materials.

This award is funded under the American Recovery and Reinvestment Act of 2009 (Public Law 111-5).

The development of dye-sensitized solar cells represents one of the most exciting new areas of solar energy science. Composed of light-absorbing molecules coupled to an inexpensive semiconductor, these devices offer the promise of high efficiency at low cost relative to more conventional alternatives such as silicon. However, dye-sensitized solar cells have yet to realize their perceived potential, due in part to the myriad of chemical and physical processes that must be optimized. In addition, it is widely viewed that such a device must ultimately come in the form of a solid-state material in order to enhance the longevity of the device itself while at the same time lowering the cost of manufacture. In order to address the many challenges this problem presents, this research project combines the efforts of scientists with expertise in chemistry, materials science, and mathematics, with the goal of developing efficient, solid-state dye-sensitized solar cells. The program is based on a synergistic collaboration in which mathematical modeling will be coupled with the synthesis and characterization of novel polymer-based substrates for ion conduction, a key aspect of photovoltaic conversion in the solid state. Solar cells will be created based on these new materials and examined by a variety of methods in order to characterize their optoelectric properties; this information will then provide the feedback necessary to continue fine-tuning the solar cell in terms of both its performance and ease of fabrication. These efforts will result in the development of a new class of photovoltaics that will achieve high efficiency at low cost for use in solar electricity applications or in the creation of devices for the synthesis of solar fuels.

Warming of the Earth?s climate has dramatically heightened interest in the development of carbon-neutral sources of energy. Although all options for renewable energy -- solar, wind, hydro, geothermal, nuclear, and biomass -- can be part of an overall energy strategy, solar energy is the only source with total power sufficient to meet global energy needs. A central problem with solar energy remains one of economics: in the area of electricity production, for example, solar power is presently about ten times more expensive than power from fossil-fuel sources such as coal. Cost reductions in solar energy derived from current technologies will no doubt continue as their production becomes more widespread, but truly significant breakthroughs in solar energy conversion schemes will require new science that has yet to be discovered. This project -- the development of a high-efficiency, solid-state photovoltaic cells based on inexpensive materials -- is an example of the kind of basic research that promises to lead to new solar energy technologies.

0922999
Drzal

This proposal seeks financial support from the NSF towards the purchase of an Environmental Scanning Electron Microscope (ESEM) integrated with a Dual Beam FocusedIon Beam (FIB). This instrument will serve two purposes. First, the instrument will replace an early generation ESEM (purchased in 1994) widely used to support research of 30+ faculty members in 9 academic departments in 3 colleges, as well off-campus collaborators and second, to bring the nanoscale materials processing flexibility offered by a dual beam FIB to a wide range of research programs at MSU in the areas of nanoscale electronics and devices, bioengineering, metals and alloys, composites, ceramics, and polymers. The acquisition of this instrument will not only greatly enhance the portfolio of users by expanding the nanoscale research infrastructure and other government agencies and industry, but will also be an integral part of the educational infrastructure at the graduate, undergraduate, K-12 and lifelong learning levels.