Materials development for improved durability and performance

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The focus of this work is "processing-microstructure-property relationships" with the aim of developing materials with improved performance characteristics through materials design (control of microstructure and/or composition) and/or improved materials processing technologies. In the area of materials design, "composition" includes such issues as functionally-graded materials (FGM), coatings and other surface-engineered materials. The performance characteristics generally incorporate the theme of long-term durability whether it be the degradation of coated Al and Mg alloy parts for automotive applications or metallic bipolar plates and electrocatalysts for fuel cells. Particular emphasis will be placed on further development of the PEO (Plasma Electrolytic Oxidation) process, a relatively environmentally friendly coating process that has enormous potential for coating light-weight materials (Al,Mg,Ti). Another processing technique that holds considerable promise is the electrochemical coating of a conducting polymer on a metallic substrate for bipolar plate applications in PEM fuel cells. Two materials synthesis methods that we have developed for the preparation of nanoparticles, namely chemical processing of colloids and the hydrolysis of intermetallics (magnides, aluminides and sodides), will be further investigated. This work will address two significant challenges presently facing industry, particularly the automotive industry. First, is the development of light-weight automotive components with improved durability and performance to improve fuel economy and reduce emissions. Second, is the development of alternatives to the internal combustion engine as a power source, including fuel cells.