Jeffrey D' Smith Associate Professor of Ceramic Engineering Department of Materials Science and Engi

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Jeffrey D. Smith Associate Professor of Ceramic
EngineeringDepartment of Materials Science and
EngineeringSchool of Materials, Energy and Earth
ResourcesUniversity of Missouri-RollaLeoben,
AustriaFebruary 14, 2005
High Temperature Ceramics at the University of
Missouri-Rolla
Special acknowledgement to William G. Fahrenholtz
for his input
High Temperature Ceramics at UMRFIRE Founders
MeetingLeoben, Austria - February 14-16, 2005
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Rolla, Missouri is both the geographic and the
populous center of the United States.In the
heart of the Ozarks outdoor activities are the
norm students choose from hunting, fishing,
boating, canoeing, spelunking (cave exploring),
etc.Fairly close to major metropolitan areas
East (100 miles) St. Louis, 2.1 million
Northwest (200 miles) Kansas City, 2.4 million
Southwest (120 miles) Springfield, 200
thousand North (60-90 miles) - Jefferson
City and Columbia, 150 thousandSmall town of
17,000 (30,000 when including county)Low
crime and very low cost of living
Rolla, Missouri, United States of America?!?
High Temperature Ceramics at UMRFIRE Founders
MeetingLeoben, Austria - February 14-16, 2005
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Rolla Campus in the University of Missouri System
Missouri's premier technological university
other campuses have specialties (KC law, StL
medicine) 284-acre landgrant
campus University was founded in 1870 as the
Missouri School of Mines (MSM) and became the
University of Missouri - Rolla in 1964, portion
that was MSM became the School of Mines and
Metallurgy 320 faculty of which 99 of full-time
tenured and tenure-track faculty have Ph.D.s or
the highest degree awarded in their
field Currently 4500 undergrads, 1000 graduate
students Student to faculty ratio 13 to 1 with
average class size of 26 students
High Temperature Ceramics at UMRFIRE Founders
MeetingLeoben, Austria - February 14-16, 2005
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Department of Ceramic Engineering
In the mid-1920s, research problems related to
Missouri clays were being neglected and the local
university, the Missouri School of Mines and
Metallurgy, could offer no support On December
1, 1925, representatives from the Missouri
Refractories Association and the Missouri Clay
Association met in Rolla, Missouri and made a
request to the directors of MSM to establish a
chair of ceramic engineering Their bid was
successful and in the fall of 1926 the Ceramic
Engineering Department was established
Currently, Ceramic Engineering consists of seven
full time faculty members, two Curators
Professors Emeritus and a host of research
professors, specialists and technicians Enrollmen
t in Ceramics typically ranges from 50 to 70
undergraduates and 25 to 35 graduate
students Major areas of graduate research
include electronic ceramics (Drs. Anderson, Dogan
and Schwartz), glass, glass ceramics and
bio-materials (Drs. Day, Brow and Rahaman) and
advanced, structural and refractory ceramics
(Drs. Hilmas, Fahrenholtz and Smith)
High Temperature Ceramics at UMRFIRE Founders
MeetingLeoben, Austria - February 14-16, 2005
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Combined with Metallurgical Engineering to form
the Department of Materials Science and
Engineering in 2004.Programs remain independent
and curriculum is largely unaffected by the
change.Concurrently the School of Mines and
Metallurgy was transformed into the School of
Materials, Energy and Earth Resources.The new
school is the first based on the principal of
interdisciplinary research and education as
materials has become a focal point on the campus.
Ceramic Engineering at UMR
High Temperature Ceramics at UMRFIRE Founders
MeetingLeoben, Austria - February 14-16, 2005
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Undergraduate Program Properties Based Courses
(ABET accredited)128 Hours Required for
graduation semester systemHeavy Laboratory
Component six semester long courses and one
year long capstone senior design course Courses
Related to Refractories Phase Equilibria,
Thermodynamics, Mechanical Properties, Thermal
Properties, RefractoriesGraduate Program 9
hour core curriculum (Kinetics, Electro-optical
Properties, Phase Relations)MS 4 to 6
semesters (18hrs coursework, 12 hrs
research)PhD 6 to 10 semesters (40hrs
coursework, 40hrs research)
Ceramic Engineering Curriculum
High Temperature Ceramics at UMRFIRE Founders
MeetingLeoben, Austria - February 14-16, 2005
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Refractory Ceramic Group
Refractory ceramics group is led by Dr. Jeffrey
D. Smith, Associate Professor of Ceramic
Engineering Current group is made up of four
faculty, one staff, eight graduate students and
five undergraduate students Emphasis of the
group includes thermal shock, strength, creep
behavior, slag resistance, mix design, monolithic
systems as well as structural ceramics toughened
monolithics, fiber-reinforced glass and
glass-ceramic matrix composites, strength testing
of composites, and fiber-matrix
interactions Group is housed in 5
office/laboratory complexes totaling more than
15,000 square feet.
High Temperature Ceramics at UMRFIRE Founders
MeetingLeoben, Austria - February 14-16, 2005
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Refractory Ceramic Group Service Activities
St. Louis Section of the American Ceramic
Society American Ceramic Society Phase
Equilibria Advisory Board Unified International
Technical Congress on Refractories Refractories
Applications and News Refractories Applications
Transactions
High Temperature Ceramics at UMRFIRE Founders
MeetingLeoben, Austria - February 14-16, 2005
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Research Areas Nozzle Clogging

• Cross-section of SEN showing typical
  location of clog. Clog normally consists of
  alumina, spinel and/or calcium aluminates derived
  from the steelmaking process.

Investigators Jeff Smith - Cer Kent Peaslee
- Met Dave Van Aken - Met
Cathodoluminescence image of spinel / calcium
aluminate clog.
Funding US Department of Energy and American
Iron and Steel Institute
High Temperature Ceramics at UMRFIRE Founders
MeetingLeoben, Austria - February 14-16, 2005
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Research Areas Dewatering of Monolithics

• Computer and physical modeling related to the
• rapid dewatering of high temperature concretes
• Refinement of the models by Ahmed and Hurst and
  Gong and Mujumdar and Bazant
• Construction and operation of equipment for
  rapid heating of large concrete specimens, 61-cm
  by 61-cm by variable thickness
• Radar-microwave methods for location of "water
  wall" in the concrete
• Effects of polymeric fibers on the resistance
  of rapidly heated concretes to explode in one
  sided exposures
• Vacuum decay technique
• to provide a relative
• measure of very
• low permeability
• industrial concretes

Investigators Jeff Smith - Cer Bill
Headrick - Cer
Funding American Iron and Steel Instituteand
National Science Foundation
High Temperature Ceramics at UMRFIRE Founders
MeetingLeoben, Austria - February 14-16, 2005
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Research Areas Continuous Steelmaking
Research program to design a continuous steelmakin
g process that begins with steel scrap and
finishes with steel slabs.

• Investigators
• Kent Peaslee - Met
• Von Richards - Met
• David Robertson - Met
• Jeff Smith - Cer

Conceptual drawing of a proposed process to
continuously melt, refine, and cast high-quality
steel.
Funding US Department of Energy
High Temperature Ceramics at UMRFIRE Founders
MeetingLeoben, Austria - February 14-16, 2005
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Research Areas Steel Foundries

• Research program to identify
• combinations of refractory
• materials and foundry
• practices that yield
• reductions in production
• costs and energy consumption.
• Investigators
• Jeff Smith - Cer
• Kent Peaslee - Met
• Von Richards - Met
• Chris Ramsay - Met

Funding US Department of Energy and Steel
Founders Society of America
High Temperature Ceramics at UMRFIRE Founders
MeetingLeoben, Austria - February 14-16, 2005
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Research Areas - Channel Induction Build-ups
RL
Investigators Jeff Smith - Cer Musa Karakus
Cer
Acidic slag build-up gray iron melting channel
induction furnace
CL
Green - Spinel Red - Alumina Yellow - Anorthite
Funding American Foundrymans Society
High Temperature Ceramics at UMRFIRE Founders
MeetingLeoben, Austria - February 14-16, 2005
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Research Areas Aluminum Casting Tubes
Development of low permeability / aluminum
resistant ceramic and castable refractory shrouds
for low pressure casting of aluminum alloys.
Investigators Jeff Smith - Cer Bill Fahrenholtz
Cer ORNL
Funding US Department of Energy and Pyrotek,
Inc.
High Temperature Ceramics at UMRFIRE Founders
MeetingLeoben, Austria - February 14-16, 2005
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Research Areas Black Liquor Gasification

• Refractory Determination
• Develop new refractory systems for black liquor
  containment
• Perform thermodynamic modeling
• Microstructural and phase analysis
• Measure bulk properties, contact angle and
  smelt penetration.
• Simulative corrosion testing
• Industrial trails
• Model Development
• Analysis of heat flow and thermal
  stress/strain.
• Estimation of the expected lifetime
• Select cost effective refractory

CL image of a black liquor corrosion of
alumina
Investigators Bill Headrick - Cer Musa
Karakus - Cer Bill Fahrenholtz - Cer
Funding US Department of Energy
High Temperature Ceramics at UMRFIRE Founders
MeetingLeoben, Austria - February 14-16, 2005
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Research Areas Thermal Spray Coatings
Funding The Boeing Company
High Temperature Ceramics at UMRFIRE Founders
MeetingLeoben, Austria - February 14-16, 2005
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Research Areas Thermal Barriers
Benefits Higher engine temperature, improved
efficiency, reduction in
atmospheric pollution Research Effects of
composition and microstructure on properties and
reliability of zirconia-based
thermal barrier coatings
Investigators Len Rahaman - Cer Dave
Van Aken - Met Jeff Smith - Cer
Funding The Boeing Company and Wright Patterson
Air Force Base
High Temperature Ceramics at UMRFIRE Founders
MeetingLeoben, Austria - February 14-16, 2005
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Research Areas Microstructure Library

• UMR provides microstructures of refractory
  ceramic materials to be included in a database as
  a digital library
• The database includes properties such as
  porosity, density, thermal conductivity, strength
  and corrosion resistance

Investigators Jeff Smith - Cer Musa
Karakus - Cer Bill Headrick - Cer
Funding National Science Foundation
High Temperature Ceramics at UMRFIRE Founders
MeetingLeoben, Austria - February 14-16, 2005
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Research Areas Glass Industry
Pilot Scale Glass Melter 200kg/day Accessories
- gas chromatograph, video camera, spectrometer,
manual or automatic feed systems, NaOH/KOH
monitoring, atomic absorption Evaluate effects
of oxy-fuel firing, glass and vapor
corrosion, batching parameters, Iining thickness,
etc.
Investigators Jeff Smith - Cer Bill
Headrick - Cer
Funding National Science Foundation and Center
for Glass Research
High Temperature Ceramics at UMRFIRE Founders
MeetingLeoben, Austria - February 14-16, 2005
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Research Areas Glass Industry

• Characterization of key properties concerning
  refractory materials for improved thermal
  efficiency and management in industrial
  combustion environments.
• The glass industry desires thermal property data
  on alternative refractory materials such as
  magnesia-alumina spinel.

Investigators Jeff Smith - Cer Bill
Headrick - Cer ORNL
Funding National Science Foundation and Center
for Glass Research
High Temperature Ceramics at UMRFIRE Founders
MeetingLeoben, Austria - February 14-16, 2005
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Research Areas Glass Industry

• Glass Tank Sensors - chemistry of the combustion
  zone, monitoring refractory wall thickness, flame
  image analysis

Investigators Jeff Smith - Cer and David
Robertson - Met
Funding National Science Foundation and Center
for Glass Research
High Temperature Ceramics at UMRFIRE Founders
MeetingLeoben, Austria - February 14-16, 2005
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Research Areas Reactive Processing
Objective - Fabricate ceramic-metal composites
with improved stability and performance Approach
- Use displacement reactions to form two phase
materials composed of stable, refractory
phases Benefits - Interpenetrating structure,
improved mechanical performance, reduced
processing temperatures, high strength and
toughness Current Systems - Al2O3-Ni,
Al2O3-MoSi2, Al2O3-Nb, Al2O3-Ni3Al
Investigators Bill Fahrenholtz - Cer
Jeff Smith - Cer
Funding University of Missouri, Air Force
Office of Scientific Research and Caterpillar, Inc
High Temperature Ceramics at UMRFIRE Founders
MeetingLeoben, Austria - February 14-16, 2005
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Research Areas Ultra High Temp. Ceramics
Objective - Produce thermal protection materials
with improved performance for sharp
leading/trailing edge applications Solution - Use
reaction-based processing for improved control
of microstructure and
co-extrusion to tailor
meso/macrostructure Benefits - Use temperatures
above 2200C, improved aerodynamic performance,

elimination of communication black-out
during
re-entry Materials - Borides and carbides of
other
early transition metals such as
ZrB2,
HfB2, ZrC, HfC, ZrB2-SiC, ZrB2-MoSi2
etc. Investigators Bill Fahrenholtz -
Cer Greg Hilmas - Cer
Funding Air Force Office of Scientific Research
High Temperature Ceramics at UMRFIRE Founders
MeetingLeoben, Austria - February 14-16, 2005
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Research Areas Others
Refractory sheaths for sensor protection AccuTru
International Advanced monolithic refractory
formulations Missouri Refractories Company Iron
and CO2 recovery from BOF slags American Iron and
Steel Institute Refractories for containment of
nuclear waste glasses US Department of Energy and
DIAL Recycling of spent refractories Missouri
Department of Natural Resources
High Temperature Ceramics at UMRFIRE Founders
MeetingLeoben, Austria - February 14-16, 2005