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Materials for Energy Efficiency / Energy Efficient Materials
Dr. J. Michael McQuade Senior Vice President, Science & Technology
United Technologies Corporation
February 1, 2012
UTC Overview UTC Examples of the Impact of Materials Science Elevators Membranes Catalysts Materials Processing and Energy Additive Manufacturing Machine Modeling Materials Design/Manufacturing
2
Agenda
United Technologies
aerospace systems
power solutions
building systems
UTC Power
Otis UTC Fire & Security
Hamilton Sundstrand
Sikorsky Carrier
Pratt & Whitney Business units
3
United Technologies - 2011 Revenues: $58.2 billion
Hamilton Sundstrand
11%
Carrier 21%
Sikorsky 13% Otis
21%
Pratt & Whitney
23%
UTC Fire & Security
12%
Segment
54% Commercial & Industrial 46% Aerospace
Business unit revenues
Company Funded
Customer Funded
0.0
1.0
2.0
3.0
4.0
2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011
Company Funded
Customer Funded
($ Billions)
4
Operations Products Advocacy
UTC Sustainability Roadmap
UTC is leading voice in advocacy programs
U.S. Green Building Council (1993)
World Business Council for
Efficiency in Buildings project (2006-2009)
UTC launches the 2015 Sustainability Goals and establishes a LEED requirement for new construction
UTC energy efficient products
Otis launches the Gen2® elevator system
UTC Power introduces 400 kW PureCell® system
Pratt & Whitney flight tests PurePowerTM
PW1000G engine with Geared Turbofan technology
Energy Use 1997-2010 Water Use 1997-2010
5
Materials Science Enabling Technology
Iron and bronze Aluminum and stainless steel Plastics and synthetic fibers Nanostructured materials
have enabled advancements in railroads, automobiles,
aircraft, telecommunications, defense, and medicine, even if
Sanford L. Moskovitz, Wiley, 2009
6
overcome two basic forces of nature former CEO George David, 2006
system matters, our customer interactions matter, but in the end people buy products, services and solutions from us because they run faster, operate hotter, weigh less, make less noise, last longer,
Fundamental drivers for materials technology insertion at UTC
Durability Weight Cost Temperature Embodied energy Operating energy Enhanced features
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8
SOME EXAMPLES
Elevators
9
Cost reduction Weight reduction Material systems for brakes and safeties Electrical efficiency Super hi-rise lifting systems
Elevator Systems Enabled By Materials Technology
10
Conventional rope systems require Large machine size due to rope torque Rope diameter drives turning radius drives sheave diameter Lubricant systems
Otis Gen2® Elevator System Flat polyurethane-coated steel belts 3 mm x 30 mm belt Eliminates lubricants
Elevator Systems Enabled By Materials Technology
11
Gen2 ® Elevator System Up to 70% reduced machine volume
Reduced torque from smaller radius sheave (480 mm to 100 mm) 12mm dia rope vs. 1.6 mm dia. cord in flat belt Improved packaging; machine roomless
75% machine weight reduction Power consumption reduced by 50%
Gen2 ® Elevator Material Challenges
Material interactions in CSB cords
Advanced magnetics for motor drives
Materials for power electronics
Gen2® regenerating drive system achieves 75% improved energy efficiency
Rail interactions and lifting
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Silicon FET GaN
Equiv.
Elevator Topology Optimization
Design space and load/BCs
(10 load cases)
Optimal topology (stress, deflection
and frequency constraints)
Engineering interpretation CAD drawing
Baseline product
Material saving Reduced distinct parts Reduced operations
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Emerging ultra high rise buildings have needs beyond the capabilities of many of the components we produce today.
Otis Ultra High Rise Buildings R
ise
(m)
Al Burj (Dubai UAE)
Burj (Dubai UAE)
Russia Tower (Moscow)
Shanghai Center
(Shanghai SH)
Pentominium (Dubai UAE)
Chicago Spire
(Chicago)
Incheon Towers
(South Korea)
China 117
Tower (TJ China)
Dubai Tower 4
(Dubai UAE)
World Trade (NYC) 417 m
1100
1000
900
800
700
600
500
400
300
200
100
0
Elevator hoistway space Dispatching and elevator access Rope sway and elevation control Ride comfort and energy consumption Building evacuation and safety
Technology challenges...
Where Does It End - The Space Elevator
A cable anchored to the Earth's equator, reaching into space. (Tsiolkovsky, 1895)
A counterweight at the end keeps the center of mass above the level of geostationary orbit.
Inertia ensures cable remains stretched
Above the geostationary level, climbers have upward centrifugal force.
The cable must be made of a material with a large tensile strength/density ratio > 100,000 kN/(kg/m).
Optimize EM energy harvesting versus statics / potential differences.
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Membranes and Catalysts
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Global membrane separation technologies market to reach US $16 Billion by 2017 (Global Industry Analysts, Inc.)
Process 2002 2004 2006 2008 RO / NF 1716 1934 2222 2571
Ultrafiltration 1441 1653 1927 2265
Microfiltration 2091 2449 2928 3517
Liquid Separations 1786 2138 2605 3200
Gas Separations 453 547 679 846
Total 7487 8721 10361 12399
World Market (MM $US)
Source: Profile of the International Membrane Industry, Elsevier Ltd.,3rd Ed.
Membranes Market Overview
Key drivers are energy efficiency and environmental footprint
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Market growth between 2003 - 2008
Source: Profile of the International Membrane Industry, Elsevier Ltd.,3rd Ed.
Membrane Technology Development
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Materials
Process Structure
Polymers Ceramics
Metals
Flat sheets Pleated papers
Tubular/hollow fiber
Pressure-driven Concentration-driven
Electrical potential
33%
28%
39%
Membrane and Catalyst Applications at UTC
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Buildings
Air dehumidification Batteries and fuel cells
Industrial CO2 separation for power plants Waste-heat driven membrane distillation
Aircraft Fuel tank inerting
Fuel deoxygenation
Principles of FSU Operation
Fuel Out< 6 ppm O2
Fuel In70 ppm O2
vacuum or oxygen-free gas
O2 O2
Membrane Porous Support
Jet Fuel Fuel Out< 6 ppm O2
Fuel In70 ppm O2
vacuum or oxygen-free gas
O2 O2
Membrane Porous Support
Jet Fuel
vacuum or oxygen-free gas
O2 O2
Membrane Porous Support
Jet Fuel
vacuum or oxygen-free gas
O2 O2
Membrane Porous Support
Jet Fuel
O2 concentration gradient provides driving force
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Deposition as a function of oxygen level (20 mL / min flow rates)
Membrane-based deoxygenation prevents coke formation
0
5000
1 104
1.5 104
2 104
2.5 104
0 10 20 30 40 50 60 70 80
Dep
ositi
on, m
icro
gram
s
Dissolved O2 Concentration, ppm
Cok
e de
posi
tion,
g/
cm2
/kg
T fuel (F)0 200 400 600 800 1000
Auto
xida
tion
Pyro
lysi
s
Deoxygenated
Acceptable level
0 200 400 600 800 1000
Cok
e de
posi
tion,
g/
cm2
/kg
Cok
e de
posi
tion,
g/
cm2
/kg
T fuel (F)0 200 400 600 800 1000
Auto
xida
tion
Pyro
lysi
s
Deoxygenated
Acceptable level
0 200 400 600 800 1000
Coke formation prevents heating jet fuel to high temperature
Membrane Porous support
Principles of FSU Operation
Fuel in
O2 out
O2 out
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10X lower fuel leakage
5X higher oxygen permeance
2X lower membrane mfg. cost
40% less membrane needed
Oxygen Permeability
0.0
50.0
100.0
150.0
200.0
250.0
300.0
Gen1 Gen2
Oxy
gen
Perm
eabi
lity
(GPU
)
Conventional Construction
Modified Construction
Fuel Leakage
0.000
0.005
0.010
0.015
0.020
0.025
Gen1 Gen2
gr /
hr /
in2
Conventional Construction
Modified Construction
Bottleneck: oxygen transport from bulk flow to membrane surface
Backing
Support
Membrane
Membrane-based deoxygenation prevents coke formation
CO2 Separation Membrane Simulation Study
Simulated separation system (simplified) Membrane properties mapping
Porous substrate
Membrane module Synthetic analogue/
polymer thin-film
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CO2 N2, H2O, O2 CO2 N2, H2O, O2
~ 0.2 m
CO2 Separation Membrane
Current: Thin, dense polymer films with preferential CO2 affinity Low selectivity for CO2
Desired: CO2 within a barrier film Fast and reversible interaction sites
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PEM Fuel Cells Membrane Attributes and Challenges
24
Available membranes Desired attributes High proton conductivity Low gas cross-over High chemical /
mechanical durability
Challenges
Sufficient proton conductivity at low RH Stability at high temperature operation Trade-offs in durability and performance Cost
Function
Transport protons Separate the reactants (H2, O2)
PerFluoro Sulphonic Hydrocarbon
PEM Fuel Cells
25
H2 AIRH+
AIR H2
Macro porous layer
Micro porous layerAnode Cathode
Bipolar Plate
Catalyst
Mem
brane
0.3
0.4
0.5
0.6
0.7
0.8
0.9
1
0 500 1000 1500 2000
Voltage (V)
Current Density (mA/cm2)
<2004
2004-2009
2010
Membrane critical to fuel cell life and performance
Chemical stability Mechanical strength
Improved performance resulting in higher power densities
UTC Power Fuel Cell Bus Durability
26
Best in class PEM fuel cell durability enabled by improved systems understanding and advanced cell materials
400
500
600
700
0 2000 4000 6000 8000 10000 12000
(mVdc)
Load Hours
2006 Fleet Leader
2007 Fleet Leader
2011 Fleet Leader (in service)2008 Fleet Leader
2011 second bus (in service)
End of life
Fleet statistics 17 bus fleet 750,000 miles 70,000 hours 18,500 start-stops
H H 2
H2O2 Anode
Cathode
O 2 O H 2 O H 2 O
H2O2
OH
Measure in PEMFC effluent (FER) F-
Chemical degradation Mechanical degradation
H 2 O 2 formation
Radical formation
Attack of polymer weak sites
Material properties degrade
Localized stress promotes cracks, fissures
Crossover failure occurs
H 2 O 2 formation
Radical formation
Attack of polymer weak sites
Material properties degrade
Localized stress promotes cracks, fissures
Crossover failure occurs
Membrane Durability: Critical Fuel Cell Enabler
27
Membrane failure limits stack life (e.g. 10,000 vs 40,000 hours)
Renewable Energy Smoothing & time-shifting
Commercial Buildings Bill reduction & UPS
Transmission & Distribution Infrastructure deferral
Remote & Off Grid Minimize fuel usage
Flow Battery System
Reactant tanks (energy)
Electrolyte flow
Ion exchange membrane
Cell stack (power)
Power out
Ele
ctro
de
Ele
ctro
de
Flow Batteries
28
0
50
100
150
200
250
0 50 100 150 200 250
Vol
tage
loss
due
to
mem
bran
e re
sist
ance
(mV
)
Membrane T hickness (um)
80 mA/cm2
1000 mA/cm2
Flow Battery Performance
Lower membrane resistance enables higher power density operation If crossover limitations addressed, thin membranes are advantageous.
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30
The Skyrocketing Price of Rare Earths Cost increase begs a response
-‐
50
100
150
200
250
300
-‐
500
1,000
1,500
2,000
2,500
3,000
Jan-‐09
Apr-‐09
Jul-‐09
Oct-‐09
Jan-‐10
Apr-‐10
Jul-‐10
Oct-‐10
Jan-‐11
Apr-‐11
Jul-‐11
Oct-‐11
Jan-‐12
Nd $/Kg
Dy $/Kg
Key Magnet Rare Earth Elements
Dy $/kg PrNd $/kg
31
Demand for Rare Earths Magnets are largest share of RE market and share expected to increase
Data from: http://www.lynascorp.com/content/upload/files/ Presentations/Investor_Presentation_May_2011.pdf
UTC RE areas of Concern Magnets (Otis, Carrier, HS, Clipper) Coatings (PW) Alloys (PW, SIK) Primary focus
Area
MANUFACTURING PROCESS ADVANCES
Materials Processing and Energy
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Phase 4
In-Service
Phase 3
Validation
Phase 2
Design & Development
Phase 1
Concept Development
Phase 0
Opportunity Analysis
Stage 0
Opportunity Identification
Stage 5
Technology Readiness
Stage 4
Feasibility Demo
Stage 3
Critical Risk Reduction
Stage 1
Opportunity Analysis
Stage 2
Concept Synthesis
Innovation Process
Innovation planning and execution
33
Product development planning and execution
Superalloy Fan-Type growth modeling
ɣ -Type (FT) growth in Ni-based superalloys reduces low cycle fatigue (LCF) life
50 µm
Desired
Problem...
GBs
Grain
Undesired micro-structural defects limit alloy durability
10 µm
GB = grain boundary = triple point
Undesired
Acceptable
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0
2
4
6
8
10
12
14
16
0 1 2 3 4 5FT
siz
e [u
m]
Cooling rate [C/s]
TheoryExperiment [1]
Model predictions quantitatively agree with experiment
[1] D.Furrer, Ph.D. Thesis [2] Mitchell R.J. On the formation of serrated grain boundaries and fan type structures in an advanced polycrystalline nickel-base superalloy // journal of materials processing technology 209 (2009) 1011 1017
[2]
35
GB serration amplitude FT size
Superalloy Fan-Type growth modeling
Advanced Manufacturing
36
ATOM Additive Topology Optimized Manufacturing
Integrating Topology Optimization (TO) with Additive Manufacturing (AM):
Enables unlimited complexity (flexibility) in design 50% Reduction in time to market 35% Reduction in production cost > 50% Reduction in energy > 70% Reduction in raw materials consumption Provides an alternative to castings or forming
figure is from the Wikimedia Commons, a freely licensed media file repository.)Powder bed form of depositionVery good surface finish & precisionSmall parts only & Low production rateRequires extensive development for multiple
material instantaneous deposition
Powder feed form of depositionHigh production ratesMaterial utilization variesCan be used in hybrid processesCan be used for producing
functionally graded materialsRequires modification for 3
powder feeders applications
LENSEBM / SLM powder bed processes
Laser head Wire or
powder feeder
nozzleFeeding angle
Material deposition
Substrate
Forming cold spray
Casting - Laser melting AM
AFM-SKPFM Surface Kelvin Probe Mode Atomic Force Microscopy
12020kg
200mm
400mm400mm
Design envelopeOptimized topology
ATOM
Additive manufacturing with topology optimization for hierarchical structures Achieve revolutionary freedom in part design for multifunctional properties
ICME Approach to ATOM
Additive Manufacturing Powder Processing
Microstructure Variation
NDE
Topology Optimization
Process Modeling Composition and
Microstructure Evolution Prediction
Property Prediction
0.000 0.005 0.010 0.015 0.020 0.0250
200
400
600
800
1000
1200
1400
Engin
eerin
g stre
ss (M
Pa)
Engineering strain
Experimental data, <110> Models' results, <110> Experimental data, <001> Models' results, <001>
Cold spray simulation
Specific Performance Requirement of Feature
Functionally graded structure
Spray dried clad powder
Barrier coating on Al
Durable surfaces
Microstructure effect on micro-plasticity
X-ray scattering/diffraction
Baseline
Optimal topology
Hybrid Processes
Laser peening
Deep rolling
Milling
37
Traditional process development
Quality issues
Turn
back
s
Production
Force variation under constant feed
Machining time
Tool breakage surface quality
Forc
e
Feed
Too slow machining
Long process development time High development cost High process variations Long cycle-time and increased cost
Model-based approach
V
Contact Work Tool
Fc
Ff Ft
Constant force under variable feed
Machining time
Forc
e
Feed
Savings
Previous variable force
Reduced time and cost Less process variation
Physics-based Models Optimizing machining processes
Experience-based process parameters
38
Cycle-time and Cost Reduction
Multi-axis milling model
~ 30% time saving at suppliers
P&W machining
~ 40% time saving
HS 787 impeller machining
Technology enabler for small IBRs
Super abrasive machining model
P&WC blade and vane Feed and Dressing Rate
0
5
10
15
20
25
-1 -0.5 0 0.5 1 1.5 2 2.5 3
X Position (in)
Feed
Rat
e (IP
M)
0
5
10
15
20
25
30
Dres
s In-
feed
(uin/
rev)
F eed RateDres sing In-Feed
Optimized Feed and Dressing
Un-optimized Feed
Un-optimized Dress
Optimized Dress
Optimized Feed
Coating cracks
Blade grinding optimization ~ 40% time savings
39
Integrated Bladed Rotor process development
Integrated Computational Materials Engineering
40
Materials genome initiative
Optimization from ICME Perspective Integration is key
Computation working together at many levels (multi-scale) Experimentation still required Effective use of data
41
Traditional Design Space Evaluation
*
Full Design Space
Expert experience and opinion
Full Scale
Design and
Testing *
Several Iterations
* *
Excellent Knowledge
Major Concept Change
Full Design Space
Low fidelity modeling finds usable solution
space.
ICME Approach to Design Space Evaluation
Mid-high fidelity modeling to analyze small design space
*
Full Scale
Design and
Testing
Invention and Innovation
short run, this complementarity is not perfect; it is indeed possible to have one without the other.
But in the long run, technologically creative societies must be both inventive and innovative.
Without invention, innovation will eventually slow down and grind to a halt, and the stationary state will obtain.
Without innovation, inventors will lack focus and have
Mokyr, Oxford, 1990.
42
