^

Steel

Data-Driven Design Decision Support for Remanufacturing of High-Value Components in Industrial and Agricultural Equipment

Data-Driven Design Decision Support for Remanufacturing of High-Value Components in Industrial and Agricultural Equipment

This project aims to develop and validate a new tool package (D4Reman) for design decision analysis to improve the reuse rates of high-value components at end-of-life. The project is a continuation of exploratory project 18-02-DE-06. Upon completion, this project will create a software tool package (D4Reman) for data-driven design decision support consisting of a cloud-based software application along with an Excel plugin. It will utilize field reliability data and reman reuse data to identify design improvement decisions and quantitatively assess their influences on the initial cost, life-cycle warranty cost (LCWC), and energy and emissions. This project will reduce primary feedstock by 0.55 million metric tons (MMT) of steel and aluminum, 7 PJ energy reduction, 0.42 MMCO2e. Assumptions based on preliminary results of exploratory project.

Project Team:
Iowa State University (ISU), University of Illinois at Urbana-Champaign (UIUC), Mississippi State University, John Deere, Automotive Parts Remanufacturers Association (APRA)

21-01-DE-5071

Development of Manufacturing Technologies to Increase Scrap Steel Recycling into New Tires

Development of Manufacturing Technologies to Increase Scrap Steel Recycling into New Tires

This project seeks to develop innovative processing technologies that can enable a greater rate of recycling of steel scrap into the manufacturing of new tires. The goal of this proposal is to increase the scrap recycling rate from 20% to 80%. During the cold drawing process, the fine wires are subjected to high levels of stresses that are known to generate wire breakage when impurity levels such as Cu or Sn are too high.

Upon completion, this project will develop thermal and chemical processing techniques to ameliorate the micro-structure to tolerate higher Cu contents. This project will reduce primary feedstock by 0.682 million metric tons (MMT) of steel, 10.7 PJ energy reduction, 1.19 MMCO2e. Assumptions based on U.S. tire production and increase in recycled steel use from 20 to 80%.

Project Team:
Arizona State University (ASU), Michelin North America, Inc.

21-01-MM-5005

High Speed Laser Cladding Repair Process Development

High Speed Laser Cladding Repair Process Development

This project seeks to expand upon the exploratory project, 18-02-RM-03 results to more fully vet the capabilities of HSLC and investigate additional additive repair applications that are challenging due to strength requirements, distortion requirements, and wear requirement. Limitations to the performance of the developed HSLC system will also be addressed, including design of a nozzle with HSLC in mind that incorporates additional cooling and improved powder focus. The technology solution that will be delivered at the end of the project is HSLC material system repair techniques, including a new powder nozzle design, and a general process guide to describe application of the repair methods. This project will reduce primary feedstock by 0.014 million metric tons (MMT) steel, 13.8 PJ energy reduction, 0.8 MMTCO2e. Assumptions based on preliminary results of 18-02-RM-03. 

Project Team:
Rochester Institute of Technology (RIT), Caterpillar Inc., Synergy Additive Manufacturing

21-01-RM-5027

Development of Hybrid Repair and Nondestructive Evaluation Technologies for Aerospace Components

Development of Hybrid Repair and Nondestructive Evaluation Technologies for Aerospace Components

The objective of this project is to develop an integrated hybrid DED/insitu multi-modal data acquisition and NDE modeling of DED repairs for aerospace materials (i.e. medium carbon low alloy steel and a nickel-based superalloy) to increase the successful repair and reuse of these materials. This proposed project is a continuation exploratory project 18-01-RM-09.  

The final product will be a complete software package that can automatically perform multi-modal (surface topography and thermal imaging) in-situ data acquisition (residual stresses) and nondestructive evaluation (NDE) analysis for industry users without expertise in 3D scanning, thermal imaging, and XRD. This project will create embodied energy savings of 1.56PJ and GHG emissions reduction of 0.0915MMT of CO2, based on an increase in successful repair of 0.021MMT of aerospace parts such as turbine shafts.

Project Team:
Rochester Institute of Technology (RIT), Iowa State University (ISU), The Ohio State University (OSU), Simufact, Hybrid Manufacturing Tech, Proto Mfg. Inc., Pratt & Whitney

21-01-RM-5062

Remanufacturing of Surface-Hardened Steel Components by Ultrasonic Surface Modification

Remanufacturing of Surface-Hardened Steel Components by Ultrasonic Surface Modification

This project seeks to develop practical repair techniques to recover nominal ‘as-new’ fatigue life in used or worn surface-hardened steel components by i) forging closed preexisting microcracks, ii) introducing beneficial compressive residual stresses (CRS) deeper than conventional shot peening, and iii) generating a nanocrystalline microstructure at the surface. Surface repairs based on UIT (a form of high-frequency needle peening) will be developed for a range of usage-induced damage conditions that are commonly found in these components, but for which there is a lack of practical repair methods.

Project Team:
Rochester Institute of Technology (RIT), Caterpillar, Inc., University of Pittsburgh (PITT)

20-01-RM-4012

Demineralization of Carbon Black Derived from End-of-Life Tires

Demineralization of Carbon Black Derived from End-of-Life Tires

Alternative process technologies will be experimentally evaluated to upgrade carbon black recovered from end-of-life tires to meet carbon black market quality specifications. Approximately 3.87 Mt of waste tires accrue every year in the United States. If all these tires were processed to recover the carbon black, about 1.1 Mt of carbon black could be recovered to use as a secondary feedstock.

Project Team:
University of Utah, OTR Wheel Engineering/Green Carbon Inc., Idaho National Laboratory

18-01-RR-19

In-situ Nondestructive Evaluation of In-flight Particle Dynamics and Intrinsic Properties for Thermal Spray Repairs

In-situ Nondestructive Evaluation of In-flight Particle Dynamics and Intrinsic Properties for Thermal Spray Repairs

The quality of coated surfaces from thermal spray repairs is determined by the particles impacting the surface. A better understanding of in-flight particle dynamics will enable improved success rates for repairs in the remanufacturing industry.

Project Team:
Iowa State University, John Deere

18-01-RM-09

Remaining Life Determination

Remaining Life Determination

Non-destructive methods to measure accumulated mechanical damage (i.e., fatigue) prior to failure do not exist. Research will focus on methods to reliably detect features associated with early stage fatigue damage to predict the remaining useful life of the part.

Project Team:
Rochester Institute of Technology, University of Illinois at Urbana-Champaign, Caterpillar Inc.

18-01-RM-10

Pushing the State of the Art in Steel Recycling through Innovation in Scrap Sorting and Impurity Removal

Pushing the State of the Art in Steel Recycling through Innovation in Scrap Sorting and Impurity Removal

Increasing the utility of steel scrap through innovation in sorting and impurity removal will increase the use of secondary feedstock and achieve cost parity for secondary materials for steel products. This study will investigate: 1) physical methods such as optical sorting to upgrade scrap steel and 2) chemical or metallurgical treatment methods to remove or neutralize the effect of impurities in molten steel.

Project Team:
Colorado School of Mines

18-01-RR-16

Development of an Industrially Relevant RE-SOLAR Design Framework

Development of an Industrially Relevant RE-SOLAR Design Framework

Solar modules are creating a major surge in e-waste because inadequate attention is focused on designing for recycling or reuse. This project provides a design framework of high-efficiency modules that can be economically recycled, recovered, remanufactured, and/or reused.

Project Team:
University of Pittsburgh, University of California-Irvine, National Renewable Energy Laboratory, First Solar

18-01-DE-07

 

Stay Up to Date with REMADE