Research Objectives:Significant Results: Approach: Broader Impact: This is the second note Did this work? Grant Number: Collaborative effort between DMI and DMI PI: Antoinette M. Maniatty and Wojciech Z. Misiolek Institutions: Rensselaer and Lehigh University Title: Collaborative Research: Modeling Microstructure Evolution during Hot Bulk Forming of Al-Mg-Si Alloys NSF Our objective is to develop an experimentally validated simulation tool which predicts key microstructural characteristics of hot, bulk deformed 6063 Al-Mg-Si aluminum alloy. These characteristics contribute to macroscopic mechanical behavior, and hence such a predictive tool will permit designers to develop processes which reduce costs and improve product characteristics. Our collaborative approach involves both the modeling and the characterization of material deformation and microstructure. Metallurgical experts at Lehigh University work closely with FEM experts at Rensselaer. These two paths iteratively and interactively co-operate; physical observations are made to provide initial parameters to the modeling software, which then simulates material deformation and predicts processing and microstructural characteristics, which in turn are then verified by experiments. This cycle continues until the model is optimized. The broader impact of this research is in its educational outreach as well as its technical rewards. Not only will the technical objective of the project reduce costs and improve product characteristics in one of the premier alloys of the automotive, aerospace, and construction industries, but the research path itself also involves the technical education of students all the way from K-12 up through college. Most significantly, this project has made great strides in its Educational Outreach aspect. Please visit the website which has been created both to educate young students about Materials Science and Engineering, as well as to provide teachers with lesson plans and educational resources. Additionally, Prof. Maniatty spent a semester collaborating with the team at Lehigh, who in turn visited Troy NY. As a result, although the project is still in its initial stages, the research methodology has been outlined, experimental techniques and simulation tools have been selected,. (click here for graphic)

Return to main slide Research Objectives Motivation “THE most important research need is to fully understand the relationships of aluminum alloy composition and processing and its effect on microstructure and properties that underlie the utilization of aluminum-based materials.” (from the Aluminum Industry Roadmap) Project Goals Macroscale Objectives Microscale Objectives Experimental and Modeling Objectives Characterization and prediction of bulk deformation Characterize and predict microstructural evolution Understand the relationship between process, properties, and performance -To develop a better understanding of the relationship between processing and performance -To develop a predictive capability to help design processes that are lower in cost and produce aluminum products with improved material characteristics

Define Model Physical Observations Model Equations Model Performance Validation Numerical Implementation Derived from experiments and proven models Model Deformation Modeling Grain Growth, Recrystallization and Precipitation Modeling Process Modeling Material Response Characterization Microstructure Characterization Relationship of Microstructure to Thermal History Experimental Characterization Inputs Wojciech Misiolek: Return to main slide MODELINGCHARACTERIZATION Research Approach

Engineering and Materials Science and Engineering specifically have many ties to the science and math curriculum at many levels; however, this connection is not always exact. Teachers have enough work with following the curriculum, which is often packed with too much information from the start. It is difficult then for teachers to search out for connections to engineering whenever they can. It is therefore the responsibility of the engineering world to make theses connections clear and tailored to their needs of the schools. To tackle this problem we met with science teachers of a local middle school. We discussed different topics which they will be teaching throughout the year and how they tie in with the materials world. The teachers were surprised about how easy it is to connect engineering with the subjects that they needed to teach. We taught three lesson presentations to the 6 th, 7 th, and 8 th grade at this middle school including electricity and magnetism, weathering and erosion, and forces and motion. The Web site explanations are easy to read for a middle school student. The students can read through the different pages like stories to get a better understanding of the vast world of materials. The pages link to more highly developed and technical sites for further investigation. The goal of this Web site is to introduce students to the world of materials and hopefully peak their interest. Classroom Experience: Engineers Connecting to the Curriculum In each presentation the students had the benefit of seeing real Materials Science and Engineering students. Often the students would focus questions on what it is like to be an engineer and what our educational experience was like. The students were excited to have college age teachers come in and use hands-on experiments. Telling students about what jobs there are in the materials field is very important. Students often do not realize how many opportunities lay before them. Talking about sports and video games will help make a connection from engineering into their everyday lives. Web site for Students Return to main slide Next educational outreach slide Broader Impact

Providing hands-on materials from industry, setting up design competitions, sending engineers to teach. Sending students to teach Providing undergraduate experience with outreach by offering programs, keeping a network with local schools Understanding curriculum topics Sharing how to integrate materials and science classes University K-12 Industrial The outreach program in the Institute for Metal Forming at Lehigh University was developed over this past year. Kelly Eaton was hired as a graduate student with the opportunity to spend part of her time focused on attending to the needs of an outreach program. This availability along with support, collaboration with other graduate students, and connections to local schools helped develop our outreach program. The program started with a Web site that would allow students to come and find out information about the materials world, and allow teachers to find out lessons and experiments. However, with the connection to local schools through Dr. Lisa Friedersdorf, the outreach program moved into the classroom. Overall, presentations were given to 2 elementary classes, 7 middle school classes, and 2 high school classes in four different schools. We have now made contacts with over a dozen teachers in the area who would like to become involved in the program. We learned through research into best practices that many presentations from other organizations are purely related to the topic of engineering. Our presentations were carefully planned out so that each topic would enhance and follow what the students were doing in school, this made it easy for teachers to give us whole class periods to teach. At each presentation we spent at least minutes talking about what we do at school, what it means to be a materials engineer and how many different aspects there are to the field. The plan for the future is to keep the outreach program growing. We have developed a network of almost a dozen schools, several of whom we have already taught at. Next Spring, Dr. Misiolek will head a 1 credit course through the Materials Science and Engineering Department at Lehigh University where undergraduates will develop modules to teach at different elementary, middle, and high schools in the area. These students will continue to make more networking connections and help the program to grow. The next step would be to involve industry more directly. With connections to so many companies, we hope to have some engineers in industry come and talk to students, and have the company offer a design competition that will bring awareness to the materials world and the company in particular. Return to main slide Last Educational Outreach Slide Broader Impact

Next Steps The Web site is designed to offer information that can then be taken into the classroom and made a part of everyday curriculum. The teacher’s page offers lessons, experiments, and resources on where a teacher could find out more about incorporating materials. The lessons are broken down by subject, and cover a variety of different areas that we have taught or have planned out for next year. This particular page is designed to involve industrial support. The lessons are outlined for a materials engineer to come into the school and teach for one hour a day for one week. This also outlines a design project that can then be offered to the students through the company. Web site for Teachers Early in the year a connection was made to the middle school to create a Web site called “Ask an Engineer”. The Website allows the students to questions about Materials Science and Engineering and other technical and science related questions. The students would be ing the two materials graduate students that had taught them throughout the year. The graduate students would then answer the questions and post them to this Web site. We had difficulty with the strict security and firewalls of this particular middle school. However, we have ensured that this site will be up for next year. The hope is to continually add to the information base of the Materials Fun Page where the students learn about materials fundamentals. At the moment the page does not contain much technical materials information Return to main slide Broader Impact