Session: Rising Stars of Mechanical Engineering Celebration & Showcase

Paper Number: 148012

148012 - Advanced Surface Modification of Powders for Sintering-Based Manufacturing 

This work summarizes the research results related to the plasma-based surface modification methods of micro- and nano metal powders to enable thermodynamically favorable phase transformations during their use in sintering-based manufacturing processes. The exploration of multiphase core/shell structures as feedstock for powder manufacturing processes is driven by the possibility of having unique microstructures with unprecedented properties impossible to obtain when the same individual phases are blended and then processed. The core/shell of various combinations (e.g., aluminum-copper, titanium-copper, copper-chromium and nickel-chromium, etc.) will be the eutectic compositions for modeling because of their industrial relevance, an ability to form precipitation hardening alloys, and excellent high-temperature properties. Wet chemistry is the predominant method for core/shell micro- and nanopowders manufacturing, but a variety of challenges such as the restricted selection of materials, the low scalability potential, and surface contaminants limit their implementation in powder manufacturing. The ability to control the surface of micro- and nanopowders lies at the core of cutting-edge advanced manufacturing, and magnetron sputtering that have already revolutionized the microelectronic industry can provide novel methods to form core/shell powders and their investigation will open new fundamental understanding that will potentially transform powder-based manufacturing processes. The work also highlights the integrated educational plan and the broader impacts of the project at promoting research and learning experiences in advanced manufacturing at all levels in the community with an emphasis on recruitment and retention of women and underrepresented minorities into the future workforce in advance manufacturing.

Presenting Author: Carlos Castano Virginia Commonwealth University

Presenting Author Biography: Carlos Castano is an Associate Professor of the Mechanical and Nuclear Engineering Department at Virginia Commonwealth University (VCU). Dr. Castano has a B.S. in Engineering Physics and a M.S. in Engineering - Materials and Processes from the National University of Colombia. He worked for four years at Pintuco- (Today part of Akzo Nobel) as a formulator at the R&D Lab. Then, he obtained his Ph.D. in Materials Science and Engineering at Missouri University of Science and Technology. In 2014 he joined VCU holding various appointments as Postdoctoral Fellow, Research Professor, Assistant Professor and now Associate Professor with tenure. Honorary member of the ALPHA SIGMA MU, active member of TMS, ACERS. Dr. Castano has received numerous recognitions, including the NSF Career Award, NIRA 2023 Honoree at VCU, and inducted as a member of the National Academy of Inventors Chapter at VCU. He has published over 40 peer-review research papers, various book chapters, and conference proceedings.

Authors:

Carlos Castano Virginia Commonwealth University