Advanced Materials and Coating for Next Generation Technologies and Extreme Environments

Abstract: Thin film processing techniques such as EB-PVD, magnetron sputtering, and cathodic arc in conjunction with bulk material synthesis via field assisted sintering technology (FAST) and additive manufacturing (AM) provide the microstructural fidelity needed to tailor and enhance thermomechanical and thermochemical material properties of interest for a variety of applications. Research and development of unique design architectures including monolithic, nano/matrix-composites, nano-layered materials, and multi-layer coatings, functionally-graded coatings and bulk ceramics, and nano-grained structural materials have provided the scientific merit required to accelerate the prototyping of next generation technologies, while contributing fundamental science to the broader community. Scientific innovation and advancements towards the development of next generation technologies spanning, energy, defense, medical, transportation, and structural component market sectors has spurred the need for disruptive changes in material performance and processing methodologies. Synthesizing materials and optimizing structure-process-property-performance relationships for corrosion/erosion/ablation resistance, hypersonic vehicles, directed energy weapon systems, optical limiting devices, ultra-hard/ultra-high temperature ceramics, thermal barrier coatings and protection systems, and radiation detection are critical for performance in extreme operating conditions and to supersede the performance of current generation technologies.

Bio: Dr. Douglas E. Wolfe is currently a Professor of Materials Science and Engineering, Professor of Engineering Science and Mechanics, Professor of Nuclear Engineering, Professor of Additive Manufacturing and Design, and the Metals, Ceramics and Coatings Processing Department Head for the Applied Research Laboratory at The Pennsylvania State University.  Dr. Wolfe received his BS, MS, and Ph.D. from The Pennsylvania State University in 1994, 1996, and 2001, respectively.  Dr. Wolfe has over 190 peer reviewed journal articles/technical memorandums/reports, 10 patents/patents pending, and is a member of several professional societies. Professor Wolfe is a recognized international expert in the field of materials science whose research activities include the synthesis, processing, and characterization of nano, multilayered, nanostructured, functionally graded, ceramic, and metallic coatings, materials and systems deposited by reactive and ion beam assisted, electron beam physical vapor deposition (EB-PVD), cold spray, thermal spray  technologies, chemical vapor deposition (CVD), cathodic arc physical vapor deposition, sputtering (r.f, d.c., magnetron), plating (Ni, Cu, Pt), hybrid processes, and various other PVD processes. In addition to coating technologies, Dr. Wolfe’s laboratory includes a state-of-the-art ceramic additive manufacturing facility, Field Assisted Sintering Technology (FAST) laboratory, and High Heat Flux Testing Facility (HHFF), which all have provided revolutionary discoveries in relation to various materials and processing techniques for hypersonic applications. The FAST facility houses three FAST systems (25, 250, 325 ton) capable of fabricating components up to 14 inches in diameter, while the HHFF allows for testing of component performance up to 60 MW/m2.  Present work includes the enhancement of coating microstructure and composition to tailor and improve material properties such as optical materials and coatings, hypersonics, metamaterials, thermal barrier coatings (TBC), erosion resistant coatings, wear resistant, corrosion resistant, diamond like carbon, transition metal nitrides, carbides, and borides, and transition and rare-earth metal oxides for a variety of applications in the aerospace, nuclear, tooling, power, oil and gas, biomedical, and defense industries.  Professor Wolfe’s primary area of expertise includes structure-processing-property-performance relationships and the development and processing of monolithic, nanocomposite, nanolayered, and multilayer coatings, nano-grained structural materials, as well as materials characterization using a variety of materials analytical techniques.  Professor Wolfe’s research focuses on applied research with an emphasis of implementation, transitioning and commercialization and has resulted in over $400,000,000 in documented savings for Department of Defense (DoD).  Dr. Wolfe has been PI or Co-PI on >200 programs at a total funding of over $100,000,000.