Rodney W. Trice

Research Interests

Development of Processes to Fabricate Complex Shaped Ceramics

We are investigating approaches to fabricate ceramics into complex shapes, building upon our Ceramic Suspension Gel (CeraSGel) technology that was developed at Purdue by Profs. Trice and Youngblood. CeraSGels are a combination of ceramic powder (greater than 50 vol.%), 3-4 wt.% water soluble polymer, water and dispersant.

There are several advantages to forming with CeraSGels. First, no heating or cooling of the CeraSGel is required as it is flowable at room temperature. Second, only a small amount of polymer is required, virtually eliminating defects that can arise due to binder burnout. Third, formed bodies in the green state can be machined very easily as they have sufficient green body strength for handling. Fourth, the stresses applied to the suspensions during forming can be used to align microstructural features. One research thrust in a recently funded Army Research Office (ARO) grant is to aligning b-Si3N4 seeds during injection molding, which in turn will influence the b-Si3N4 grains formed during sintering.

The approach to using CeraSGels to form complex ceramics is to design the rheology of the gel such that it has the requisite properties required for the particular forming process used. For example, the rheology of a CeraSGel suspension for injection molding is different than one used for 3D printing. To date we have formed with CeraSGels of Al2O3, B4C, Si3N4, and ZrB2 powders, however, the process is amenable to any powder system. Another aspect of the ARO grant is the development of complex shaped body armor made from B4C.

We have included several video links showing forming with the CeraSGel process. In the first, an alumina CeraSGel is being injection molded. In the second, an alumina CeraSGel is being 3D printed using a modified syringe style printer.

 3D Printing Video

 Injection Molding Video

 Design of High Emissivity Rare-Earth Oxides For Hypersonic Performance Informed by Atomistic Simulations

Hypersonic vehicles require sharp featured nose tips and wing leading edges to reduce drag on the vehicle. However, the geometry of these edges increase the convective heat flow to the surface, ultimately increasing the overall temperature of the component to temperatures as high as 2300 K. The current work sponsored by AFOSR is investigating approaches to reduce the heat the heat flow to these critical components. Further details on this work are available by contacting Prof. Trice.

Preparation of Ultra-Low Thermal Conductivity Coatings via Suspension Plasma Spray Using a Defect Clustering Approach (NSF CMMI-0853297):

The objective of this research is to investigate a novel processing method to produce ultra-low conductivity thermal barrier coatings that would overcome deficiencies of current yttria-stabilized zirconia coatings. Thermal barrier coatings are used in gas turbine engines to thermally protect the superalloy blades in the combustion area, affording hotter, more efficient operating temperatures. Our approach for preparing next generation thermal barrier coatings couples for the first time two newly developed techniques: suspension plasma spray and defect clustering. In suspension plasma spray, nanosized powders are dispersed in ethanol to form a colloidal suspension; the suspension is then sprayed into a hot plasma plume to evaporate the solvent and melt the powder. The second technique, defect clustering, involves doping yttria-stabilized zirconia with paired rare-earth ions (such as ytterbium and neodymium) to create immobile clusters in the plasma-sprayed coating. The presence of these clusters in a thermal barrier coating scatters phonons, reducing coating thermal conductivity by over one-half compared to current yttria-stabilized zirconia-only coatings.

Electrophoretic Deposition of Solid Oxide Fuel Cell Electrolytes

Solid oxide fuel cells (SOFCs) are a promising element of comprehensive energy policies due to their direct mechanism for converting the oxidization of fuel, such as hydrogen, into electrical energy. One emphasis of SOFC research is the development of dense, thin electrolytes in order to reduce internal ohmic loss and facilitate reduced operating temperatures that improve practical SOFC feasibility. Electrophoretic deposition (EPD) is a low cost and expeditious method to attain dense, thin electrolytes, requiring less investment than many competing technologies, such as the varieties of vapor and plasma deposition. At Purdue University, EPD has been used to create yttria -stabilized zirconia (YSZ) electrolytes of <10 µm thickness, which have been used in SOFC’s achieving 900 mW/cm2 power density at 800 °C. This work is performed in collaboration with Prof. Elliott Slamovich.

The image below shows a fracture cross section of a complete SOFC, composed of a dense YSZ coating electrophoretically deposited on a NiO/YSZ anode, with a screen printed LSCF cathode.

 

 

Current Funding Sources

  • U.S. Army Research Office (Dr. David Stepp Program Manager):  “Fabrication of Complex-Shaped Ceramic Components by Room-Temperature Injection Molding of Ceramic Suspension Gels”

  • Air Force Office of Scientific Research (Dr. Ali Sayir Program Manager ) :  “Design of High Emissivity Rare-Earth Oxides For Hypersonic Performance Informed by Atomistic Simulations”

  • Rolls-Royce Corporation: "Hot Corrosion Studies of Various High Temperature Materials"

Recent Presentations

  • Valerie Wiesner, R.W. Trice, and J. Youngblood, “Injection Molding of Ceramic Suspension Gels at Room Temperature for Production of Ultra-High Temperature Ceramics,” Presented at the 35th International Conference on Advanced Ceramics & Composites, Daytona Beach, January 2011.

  • M. Acosta, R.W. Trice, and J. Youngblood, “A Novel Method to Fabricate Ceramic Composites with Aligned Fiber Phases,” Presented at the 35th International Conference on Advanced Ceramics & Composites, Daytona Beach, January 2011.

  • V. Wiesner, R. Trice, and J. Youngblood, “Fabricating Complex-Shaped Ceramic Components by Injection Molding Ceramic Suspension Gels at Room Temperature,” presented at MS&T, Columbus, OH, October 2011.

  • M. Acosta, R. Trice, and J. Youngblood, “Horizontal Dip-Spin Casting for the Fabrication of Ceramic Composites with Aligned Strengthening Phases,” presented at MS&T, Columbus, OH, October 2011.

  • P. Lortrakul, R. Trice, and K. Trumble, “Effect of Applied Stress, Crystal Orientation, and Phase on Hot Corrosion of CMSX-4 by Sodium Sulfate,” presented at MS&T, Columbus, OH, October 2011.

  • J. Fleetwood, E. Slamovich, R.W. Trice, J. McCloskey, and A. Hall, “Solid Oxide Fuel Cell Electrolytes Produced by a Combination of Suspension Plasma Spray and Very Low Pressure Plasma Spray,” presented at the Internal Thermal Spray Conference, Hamburg, Germany, October 2011.

  • International Conference on Metallurgical Coatings and Thin Films, “Suspension Plasma Spray as a Route for Microstructural Design of New Thermal Barrier Coatings,” April 2010, San Diego, CA.

  • NASA Glenn Research Center, “High Temperature Materials Research on Ceramics and Superalloys,” September 2, 2010, Cleveland, Ohio.

  • Purdue College of Engineering Advisory Council, “Development and Assessment of Ethics and Engineering Practice,” October 8, 2010, W. Lafayette, IN.

  • Teaching Ethics in the Engineering Curriculum, Workshop taught at the American Society of Engineering Education, Vancouver, British Columbia, June 2011.

  • J. Fleetwood, E. Slamovich, R.W. Trice, J. McCloskey, and A. Hall, “Solid Oxide Fuel Cell Electrolytes Produced by a Combination of Suspension Plasma Spray and Very Low Pressure Plasma Spray,” presented at MS&T, Houston, Texas, October 2010.

  • Valerie Wiesner, R.W. Trice, and J. Youngblood, “Injection Molding of Ceramic Suspension Gels at Room Temperature for Production of Ultra-High Temperature Ceramics,” Presented at the 35th International Conference on Advanced Ceramics & Composites, Daytona Beach, January 2011.

  • M. Acosta, R.W. Trice, and J. Youngblood, “A Novel Method to Fabricate Ceramic Composites with Aligned Fiber Phases,” Presented at the 35th International Conference on Advanced Ceramics & Composites, Daytona Beach, January 2011.

  • M. Krane and R.W. Trice, “Development and Assessment of “Ethics in Engineering Practice”: A New Technical Support Elective,” Presented at the American Association for Engineering Education,” Vancouver, British Columbia, June 2011.

  • V. Wiesner, R. Trice, and J. Youngblood, “Fabricating Complex-Shaped Ceramic Components by Injection Molding Ceramic Suspension Gels at Room Temperature,” presented at MS&T, Columbus, OH, October 2011.

  • M. Acosta, R. Trice, and J. Youngblood, “Horizontal Dip-Spin Casting for the Fabrication of Ceramic Composites with Aligned Strengthening Phases,” presented at MS&T, Columbus, OH, October 2011.

  • P. Lortrakul, R. Trice, and K. Trumble, “Effect of Applied Stress, Crystal Orientation, and Phase on Hot Corrosion of CMSX-4 by Sodium Sulfate,” presented at MS&T, Columbus, OH, October 2011.

  • J. Fleetwood, E. Slamovich, R.W. Trice, J. McCloskey, and A. Hall, “Solid Oxide Fuel Cell Electrolytes Produced by a Combination of Suspension Plasma Spray and Very Low Pressure Plasma Spray,” presented at the Internal Thermal Spray Conference, Hamburg, Germany, October 2011.

  • R.W. Trice, “ Suspension Plasma Spray as a Route for Microstructural Design of Coatings“, 5th International Workshop on Suspension and Solution Thermal Spraying, Oct 2011, Tours, France. (Plenary)

  • M. Acosta, V. Wiesner, R. Trice, and J. Youngblood, “Design and Manufacture of Ultra-High Temperature Ceramics with Oriented Strengthening and Toughening Phases,” Presented at the 36th International Conference on Advanced Ceramics & Composites, Daytona Beach, January 2012.

  • V. Wiesner, R. Trice, and J. Youngblood, “Fabrication of Complex-Shaped Components by Room Temperature Injection Molding of Ceramic Suspension Gels,” Presented at the 36th International Conference on Advanced Ceramics & Composites, Daytona Beach, January 2012.

  • J. Yanke, R. Trice, and M. J. M. Krane, “The Effect of Slag Cap Thickness on Electroslag Remelting,” presented at the 2012 TMS Annual Meeting, Orlando, FL.

  • J. Yanke, R. Trice, and M.J.M. Krane, “A Numerical Simulation of the Influence of Droplet Impact Dynamics on the Microstructure of Plasma Sprayed Coatings,” presented at the 2012 TMS Annual Meeting, Orlando, FL.

  • J. Fleetwood, E. Slamovich, R.W. Trice, J. McCloskey, and A. Hall, “Solid Oxide Fuel Cell Electrolytes Prepared by a Combination of Suspension Plasma Spray and Very Low Pressure Plasma Spray,” presented at the Internal Thermal Spray Conference, Houston, Texas, 2012.

  • S. Gong and R.W. Trice, Preparation of Rare-Earth Doped Thermal Barrier Coatings via Suspension Plasma Spray,” presented at the Internal Thermal Spray Conference, Houston, Texas, 2012.

  • W. Tan, A. Strachan, R.W. Trice, “Design of High Emissivity Coatings for Hypersonic Applications Using Suspension Plasma Spray,” presented at the Internal Thermal Spray Conference, Houston, Texas, 2012.

  • Wiesner,V., Youngblood,J., and Trice, R.W., “Fabricating Complex-Shaped Ceramic Components by Injection Molding Ceramic Suspension Gels at Room Temperature,” Gordon Research Conference, Mount Holoke in South Hadley, MA, August 2012. (Poster Presentation)

  • Trice*, R.W., “High Temperature Materials Processing: Coatings and Structural Ceramics,” Universidad Nacional de Colombia Sede Medellín, Medellin, Columbia., August 2012.

  • Tan, W., Strachan, A., and Trice, R.W.,“Design of High Emissivity Coatings for Hypersonic Applications,” Materials Science and Technology Conference, Pittsburg, PA, October 2012.

  • Gong, S., and Trice,R. W., “Effect of Rare-Earth Dopants on Microstructures and Thermal Conductivity of Thermal Barrier Coatings Prepared by Suspension Plasma Spray,”, Materials Science and Technology Conference, Pittsburg, PA, October 2012.

  • Wiesner, V.,  Youngblood, J., and Trice, R.W., “Room-Temperature Injection Molding of Ceramic Suspension Gels for Fabrication of Complex-Shaped Ceramic Components,” Materials Science and Technology Conference, Pittsburg, PA, October 2012.

  • W. Tan, A. Strachan, and R. Trice, “Rare-earth Doped High Emissivity Coatings for Hypersonic Applications,” International Conference on Advance Ceramics and Composites, Daytona Beach, FL, Jan. 2013.

  • W. Tan, A. Strachan, and R. Trice, “Samarium and Thulium Doped High Emissivity Coatings for Hypersonic Applications Prepared by Plasma Spray,” Materials Science and Technology, Montreal, Oct. 2013. 

  • Wiesner, V.L.; Youngblood, J.P.; Trice, R.W.,  “Fabricating complex-shaped ceramic components by injection molding ceramic suspension gels at room temperature,” International Conference and Exposition on Advanced Ceramics and Composites (Daytona Beach, FL) Jan 2013.

  • Wiesner, V.L.; Trice, R.W.; Youngblood,  “Utilizing unique flow properties of polymer-ceramic suspensions to produce alumina parts with near-net shape geometries by room-temperature injection molding,” J.P. 246th American Chemical Society (ACS) National Meeting (Indianapolis, IN) Sep, 2013.

  • Wiesner, V.L.; Trice, R.W.; Youngblood “Green Manufacturing of Near-Net Shape Ceramic Parts by Room-Temperature Injection Molding,”, J.P. Materials Science and Technology (MS&T) Conference (Montreal, Canada) Oct, 2013.

  •  Wiesner, V.L.; Youngblood, J.P.; Trice, R.W. “Producing Ultra-High Temperature Ceramic Components with Near-Net Shape Geometries by Room-Temperature Injection Molding,” Materials Science and Technology Conference (Montreal, Quebec, Canada) Oct, 2013.

  • R.W. Trice, “Coatings for Hypersonic Applications ,”Cocoa Beach Meeting of the American Ceramic Society,  Daytona Beach, Florida, January 2014. Invited

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