Green and Sustainable Manufacturing of Advanced Material

676 Pages·2016·81.436 MB·English

by  Asthana, Rajiv, Ohji, Tatsuki, Singh, Mrityunjay

Green and Sustainable Manufacturing
of Advanced Materials
Green and Sustainable
Manufacturing of
Advanced Materials
Edited by
Mrityunjay Singh
Tatsuki Ohji
Rajiv Asthana
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Contributors
D. Andersson Swerea IVF AB, Mölndal, Sweden
R. Asthana University of Wisconsin-Stout, Menomonie, WI, USA
Marsha S. Bischel Armstrong World Industries, Inc., Lancaster, PA, USA
A. Dinsdale National Physical Laboratory, Teddington, United Kingdom
J. Fu School of Materials Science and Engineering, Zhengzhou University,
Zhengzhou, China
Manabu Fukushima National Institute of Advanced Industrial Science and
Technology (AIST), Nagoya, Japan
S. Gupta University of North Dakota, Grand Forks, ND, USA
I. Himoto Department of Molecular Design and Engineering, Graduate School
of Engineering, Nagoya University, Nagoya, Japan
Y. Hotta National Institute of Advanced Industrial Science and Technology
(AIST), Nagoya, Japan
Hideki Hyuga National Institute of Advanced Industrial Science and
Technology (AIST), Nagoya, Japan
H. Ipser University of Vienna, Department of Inorganic Chemistry/Materials
Chemistry, Wien, Austria
Toshihiro Ishikawa Tokyo University of Science, Yamaguchi, Japan
Kazumi Kato National Institute of Advanced Industrial Science and Technology
(AIST), Nagoya, Japan
Soshu Kirihara Joining and Welding Research Institute, Center of Excellence
for Advanced Structural and Functional Materials Design, Osaka University,
Osaka, Japan
H. Kita Department of Molecular Design and Engineering, Graduate School of
Engineering, Nagoya University, Nagoya, Japan
A. Kondo Joining and Welding Research Institute, Osaka University, Ibaraki
city, Osaka, Japan
Naoki Kondo National Institute of Advanced Industrial Science and Technology
(AIST), Nagoya, Japan
xvii
xviii Contributors
Kunihito Koumoto Department of Applied Chemistry, Graduate School of
Engineering, Nagoya University, Nagoya, Japan
A. Kroupa Institute of Physics of Materials, Brno, Czech Republic
Yin Liu Kazuo Inamori School of Engineering, New York State College of
Ceramics at Alfred University, Alfred, New York, USA
Yoshitake Masuda National Institute of Advanced Industrial Science and
Technology (AIST), Nagoya, Japan
H. Mohrbacher NiobelCon bvba, Schilde, Belgium
S. Mucklejohn Ceravision Limited, Milton Keynes, United Kingdom
M. Naito Joining and Welding Research Institute, Osaka University, Ibaraki
city, Osaka, Japan
H. Nakano Cooperative Research Facility Center, Toyohashi University of
Technology, Toyohashi, Japan
Zuoren Nie Beijing University of Technology, Beijing, China
Tatsuki Ohji National Institute of Advanced Industrial Science and Technology
(AIST), Nagoya, Japan
T. Sekino ISIR, Osaka University, Osaka, Japan
Shunzo Shimai Tokyo University of Agriculture and Technology, Tokyo, Japan
Mrityunjay Singh Ohio Aerospace Institute, Cleveland OH, USA
J. Tatami Graduate School of Environment and Information Sciences,
Yokohama National University, Yokohama, Japan
S. Wada Materials Science and Technology, Interdisciplinary Graduate School
of Medical and Engineering, University of Yamanashi, Yamanashi, Japan
A. Watson University of Leeds, Leeds, United Kingdom
Yiquan Wu Kazuo Inamori School of Engineering, New York State College of
Ceramics at Alfred University, Alfred, New York, USA
Q. Xu School of Materials Science and Engineering, Zhengzhou University,
Zhengzhou, China
S. Yamashita Department of Molecular Design and Engineering, Graduate
School of Engineering, Nagoya University, Nagoya, Japan
Yan Yang Kazuo Inamori School of Engineering, New York State College of
Ceramics at Alfred University, Alfred, New York, USA
Yu-ichi Yoshizawa National Institute of Advanced Industrial Science and
Technology (AIST), Nagoya, Japan
Preface
Over the past several years, sustainability has emerged as a recurring theme that
is increasingly recognized as pervading every sphere of human activity. The
interdependence of life and the ecosystem in which it resides has begun to drive
the need for sustainable growth and development. Perhaps nowhere does the
power of sustainability manifest itself more exquisitely than in the development
of new materials and manufacturing technology. Future progress in these areas
will critically depend on our engagement with sustainable practices in research
and technology development.
Materials and manufacturing processes constitute a huge segment of global
economy. It is thus fitting and proper that current industrial practices and new
developments in materials and manufacturing technology orchestrate with the
natural capacity of ecosystems. This demands global efforts to conserve energy
and materials, as well as a focus on recovery, recycling, and reuse in an envi-
ronmentally conscious manner. The integration of green practices is crucial to
sustain long-term technological development and the economic competitiveness
of modern society as well as future generations.
This book addresses green and sustainable practices by focusing on specific
classes of materials. The authors are all active and recognized researchers and
practitioners in their respective fields and represent universities, industry, and
government and private research organizations of eight different nations. We
hope that the book offers a vision for future developments and stimulates fresh
thinking to integrate green and sustainable practices in diverse materials and
manufacturing processes. We also hope that the book meets the educational and
research needs of advanced students across multiple academic disciplines. We
are grateful to all of our revered authors for their valuable contributions. We
thank the publication and editorial staff of Elsevier for their excellent support
during the preparation of this book.
Mrityunjay Singh,
Ohio Aerospace Institute, USA
Tatsuki Ohji,
National Institute of Advanced Industrial Science and Technology (AIST), Japan
Rajiv Asthana
University of Wisconsin-Stout, USA
xix
Chapter 1
Green and Sustainable
Manufacturing of Advanced
Materials—Progress and
Prospects
Mrityunjay Singh1, Tatsuki Ohji2 and R. Asthana3
1Ohio Aerospace Institute, Cleveland, OH, USA, 2National Institute of Advanced Industrial Science
and Technology (AIST), Nagoya, Japan, 3University of Wisconsin-Stout, Menomonie, WI, USA
1 INTRODUCTION
Manufacturing is a substantial part of global economy, and manufacturing
practices play a critical role in all aspects of modern life. Green and sustain-
able manufacturing has emerged as a globally recognized mandate. Sustainable
manufacturing is defined by the U.S. Department of Commerce as “the creating
of manufactured products that use processes that are nonpolluting, conserve
energy and natural resources, and are economically sound and safe for employ-
ees, communities, and consumers” (http://www.nacfam.org/PolicyInitiatives/
SustainableManufacturing/tabid/64/Default.aspx). It has given impetus to de-
velopment of green materials and technologies that orchestrate with self-healing
and replenishing capability of natural ecosystems. It has focused attention on
conservation of energy and precious materials, and recovery, recycling, and re-
use in virtually all industrial sectors including but not limited to transportation,
agriculture, construction, aerospace, energy, nuclear power, and many others.
Historically, industry and governments have been responsive to environmen-
tal issues even before sustainability became a recognized global movement. For
example, in the United States, a number of acts and Codes of Federal Regulations
(CFR) have addressed key environmental issues for several decades. Examples
included the Water Pollution Control Act (amended 1987 Clean Water Act),
Clean Air Act (amended 1990), Resource Conservation and Recovery Act
(amended 1984), Comprehensive Environmental Response, Compensation and
Liability Act (1980), and many others. These regulations provided “cradle-to-
grave” programs for protecting human health and the environment from the
improper management of hazardous materials including toxic effluents. Other
Green and Sustainable Manufacturing of Advanced Materials. http://dx.doi.org/10.1016/B978-0-12-411497-5.00001-1
Copyright © 2016 Elsevier Inc. All rights reserved. 3
4 PART | I Material Conservation, Recovery, Recycling and Reuse
CFRs specifically addressed the health and environmental effects of specific
chemicals and materials such as the known carcinogens formaldehyde (29 CFR
1910.1048) and cadmium (29 CFR 19190.1027).
Although a focus on sustainable technologies in various forms has been
around for a long time in part due to government regulations and sporadic pub-
lic support for isolated cases that impacted regional concerns, a paradigm shift
toward and awareness of the importance of transformative green and sustainable
materials and manufacturing has only recently begun to gain momentum. As
a field of academic enquiry and discussion, green manufacturing is relatively
young. As an emerging global movement, it has gained considerable traction as
part of the broader goals of sustainable development. It is now being increas-
ingly recognized that the integration of green practices is crucial to sustainable
technological development and the economic competitiveness of current society
as well as that of future generations.
A number of important and widely practiced industrial processes such as
case hardening, plating, casting, brazing, soldering, chemical vapor deposi-
tion, organic coatings, and numerous others involve consumption or release
of harmful ingredients that are injurious to both human health and the envi-
ronment. All such processes and technologies are candidates for a careful
reassessment of the efficiencies and structural changes that could potentially
make such processes sustainable. A classic example of sustainable practices
is the abolition of lead in electrical and electronic assemblies and in public
utility systems owing to the possibility of water and food contamination with
extremely serious consequences to human health and the environment. Major
initiatives in Europe, North America, China, Korea, and elsewhere have either
banned or strictly limited lead use. Major global initiatives are currently in
progress to develop green substitute materials for lead and similar hazardous
and/or scarce metals and materials. Critical materials including rare earths
have a major economic and strategic importance, but they are limited in sup-
ply. New materials need to be developed in an environmentally conscientious
manner to offset the dependence of naturally occurring critical and strategic
materials.
Another focus area of sustainable development involves component weight
reduction by use of light materials (foams, magnesium, and titanium) with high
specific strength and other key properties. This is being vigorously pursued
for reducing fuel consumption and waste emissions mainly in the transporta-
tion sector (automotive and aerospace). This also offers additional benefits
of lower losses, higher operating temperatures, and higher engine efficiency.
Environmentally friendly materials such as ecoceramics, ecobrass, ecosolders,
and ecocoatings, as well as energy-efficient light materials such as foamed met-
als and ceramics and composites have gained phenomenal ascendency in re-
search and technology. Additionally, energy and emission reduction with the aid
of established and novel technology such as microwaves, lasers, and biofuels
has become increasingly important.
Green and Sustainable Manufacturing Chapter | 1 5
New materials developed from natural and renewable arboreal and biologi-
cal resources should continue to gain importance into the future. Ceramics such
as silicon carbide developed from such resources consume less energy for their
production and less waste for disposal. Environmentally conscious ceramics
(ecoceramics) are produced out of renewable resources such as wood. For ex-
ample, biomorphic silicon carbide is obtained by pyrolysis and infiltration of
natural wood-derived preforms. It reduces energy consumption and chemical
by-products of conventional ceramic production methods such as hot pressing,
sintering, reaction bonding, and chemical vapor deposition (CVD). Other meth-
ods include freeze casting of ceramics and microwave sintering that are devoid
of binders and fugitive chemicals. Through conscious intervention, materials
and products can be designed and manufactured in a more environmentally
friendly manner to facilitate assembly, recycling, and reuse with reduced waste
emission and energy consumption.
A large proportion of the world’s energy originates from fossil fuels while
greener technologies such as nuclear, wind, and hydroelectrics generate the
remaining share of total energy. The wide variety of materials used in these
technologies—mainly metals, ceramics, and their composites—critically affect
the performance of such technologies. Materials are enablers of advanced tech-
nology, and their properties and performance determine the system function
and efficiency. Conversely, efficient development and production of current and
emerging materials depends on the availability of innovative technologies for
their production and fabrication. A competitive advantage in technology de-
velopment can be accelerated through the development and application of new
materials and processes. This complementary symbiotic relationship can help
promote and advance sustainable practices with the materials producer, prod-
uct designer, and manufacturer working in concert on shared concerns about
environmental impact and sustainability while pushing the boundaries of the
technology.
Over the next several decades, global demand for materials and energy is
projected to sharply rise. This inevitably will impact the environment via in-
creased carbon emission and energy consumption. In this context, an important
goal of sustainability is the training and educational needs of a new genera-
tion of workforce that can think and act holistically about “cradle-to-grave”
and “cradle-to-cradle” progression of materials and technologies. Many major
industrial mishaps in the past have been linked to mistakes that could have been
avoided with proper training and awareness. Examples include the mercury ac-
cumulated in fish originating from a fertilizer plant in Japan in the 1960s and
leakage of toxic methyl isocyanate (MIC) gas from a former Union Carbide
plant in India in the 1980s.
Nanotechnology is beginning to revolutionize modern manufacturing by of-
fering an unprecedented range of functionalities that are possible only in the nano-
meter range. Novel functionalities can be achieved via atomic- and molecular-level
design paradigms and methods. To achieve these functionalities, manufacturing
6 PART | I Material Conservation, Recovery, Recycling and Reuse
is poised to become ever more complex and sophisticated. This will require sus-
tainable practices to be built in production and the use or reuse of nanomaterials.
Because of the growing push to increase the use of nanomaterials and nanopro-
cessing, it is vital that their effect on and interaction with the environment is care-
fully assessed lest unanticipated effects of these new materials and technology
precipitate into unprecedented harm to the society and the environment.
It is thus evident that the environmental impact of materials and their manu-
facturing and use are vital to technological progress of modern society. In the
past, performance attributes and issues related to the cost of materials and man-
ufacturing were given precedence over environmental concerns, recyclability,
and reuse. There is now a shift toward addressing in a comprehensive fashion
all of the environmental attributes of materials, manufacturing, and products via
green and sustainable practices and life-cycle assessment (LCA). This includes
such vital issues as carbon footprint and global warming.
2 FOCUS AREAS
This book attempts to provide snapshots of selected developments and practices
in green and sustainable manufacturing, focusing mainly on new material and
process development. It does not purport to be a compendium on this vastly
important topic but rather a contemporary resource for up-to-date information
on select new developments. The collective knowledge about state-of-the-art
and new developments in green and sustainable manufacturing of advanced
materials from diverse fields presented in the following chapters is intended
to provide further impetus to research and exploration. The following survey
provides a brief overview of the main topics and issues that are discussed in
different chapters.
2.1 Material Conservation, Recovery, and Recycling
In this chapter, we present a brief overview of how the development and man-
ufacturing of advanced materials influence and are influenced by sustainable
practices to serve as a backdrop for the issues and themes that subsequent chap-
ters develop in greater depth. It is argued that future progress in developing
new materials and manufacturing processes to produce them will critically de-
pend upon purposeful engagement with sustainable practices in research and
technology. In Chapter 2, Bischel from Armstrong World Industries offers in-
sights into holistic assessment of material sustainability that relies on multiple
rather than single attributes in defining the material’s environmental impact.
She advocates design philosophies that concurrently and seamlessly address
multiple areas of material performance and sustainability and expose conflicts
and trade-offs among attributes, thereby facilitating a more complete evaluation
of the environmental impact of a product over its life span. The cornerstones of
such a holistic approach include LCAs, environmental product declarations, and