Intelligent processing of materials (IPM) is the conversion of materials to value-added products using model-based control of processing variables. Information for real-time process control is provided by on-line sensors that measure material characteristics and/or processing conditions. Intelligent processing will enable industry to economically produce materials with improved quality, consistent properties, and enhanced functionality. The IPM Program makes important contributions to three MSEL strategic thrusts: advanced processes, advanced materials, and measurement technology.
The IPM concept is the principal approach used to achieve the MSEL goal to "foster the development and implementation of technologies for advanced processing of materials." The central elements of IPM are 1) process understanding expressed in terms of a process model, 2) real-time information on processing parameters and material condition obtained with on- line process sensors, and 3) a model-based sensing and control strategy to achieve the desired characteristics in the finished product. IPM projects advance each of the elements, and joint projects with industry are integrating these elements into improved processing capabilities.
The IPM Program is an important contributor to the MSEL goal to "foster the use of advanced materials in commercial products." Advanced materials are materials with microstructures that are designed and controlled to provide superior properties and performance for specific functions. Microstructural control is perhaps the most important application of IPM. The idea is to model microstructural evolution during processing, sense microstructural changes in real time, and use a model-based control strategy to achieve the desired microstructure in the finished product. Microstructural consistency is essential to the commercialization of advanced materials because it assures reliable properties and performance of the material.
The IPM Program contributes to MSEL's measurement technology goal. A major focus of the IPM projects is process sensors, which our industrial collaborators repeatedly identify as a crucial need. Sensor technology is a core competence of MSEL that has its roots in sensor development for nondestructive evaluation of materials. Unique MSEL capabilities are being used to measure thermophysical properties at elevated temperatures; these data are combined with model enhancements and then incorporated in industrial software for metal casting. In addition, specialized measurement capabilities such as nuclear magnetic resonance and small angle neutron scattering are used to understand microstructure/morphology evolution in ceramics and polymers.
Projects
For additional information about any aspect of the IPM Program, please call Tom Siewert, (303) 497-3523, or e-mail to siewert@micf.nist.gov.
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