3 min
Imagine if producing steel parts for agricultural equipment or even aluminum soda cans required only a fraction of the energy it does today. A University of Florida-led innovation may soon make this a reality. In a groundbreaking collaboration backed by a nearly $11 million federal grant, UF researchers have developed a first-of-its kind superconducting magnet that could advance metal production and position the United States as a global leader in alloy production. “This revolutionary technology has the potential to substantially reduce the cost and energy use of heat treatments in the steel industry, and we are excited to help pave the way for its adoption in industry.” —Michael Tonks, Ph.D., UF’s interim chair of Materials Science and Engineering Funded by the U.S. Department of Energy’s Advanced Manufacturing Office, the project uses Induction-Coupled Thermomagnetic Processing, or ITMP, an advanced manufacturing method that integrates magnetic fields with high-temperature thermal processing. The national consortium of industry, academic and national laboratory partners is now led by Michael Tonks, Ph.D., UF’s interim chair of Materials Science and Engineering, who succeeded Michele Manuel, Ph.D., the project’s long-time leader. “This revolutionary technology has the potential to substantially reduce the cost and energy use of heat treatments in the steel industry, and we are excited to help pave the way for its adoption in industry,” said Tonks. It’s not just any piece of equipment; it’s a custom-built superconducting magnet with a unique ability to combine magnetic fields with high-temperature thermal processing. In partnership with the UF physics department, Oak Ridge National Laboratory, or ORNL, and six companies interested in the technology, the magnet and cylinder induction furnace now sit atop a 6-foot-high platform. The prototype, which costs more than $6 million to purchase and install, is capable of processing steel samples up to 5 inches in diameter making it a rare asset for academic research. Yang Yang, Ph.D., UF materials science research faculty member, estimated ITMP could reduce steel processing time by as much as 80 percent, cutting energy use and operational costs. “Thermomagnetic processing changes a material’s phase stability and kinetic properties, accelerating carbon diffusion in steel, said Yang. “Traditional furnaces cannot achieve these advanced material properties.” The system works by modifying the driving forces for important steel phase changes, which shortens heat treatment. “What normally takes eight hours can be done in just a few minutes.” Yang explained. “The magnetic field acts as an external driving force to make atoms diffuse faster.” Unlike conventional energy sources like electricity or natural gas, the ITMP process uses volumetric induction heating along with high-static magnetic fields to lower energy consumption. The project is still in a pilot phase and requires additional research and testing. At ORNL, researchers emphasized the rarity of UF’s prototype, citing its unprecedented combination of magnetic field strength and ability to process large samples and components. “This could significantly advance U.S. manufacturing and process efficiency for heat treatment of materials such as metal alloys of steel or aluminum,” said Michael Kesler, Ph.D., ORNL research scientist and lead collaborator. Kesler noted successful implementation of this technology could contribute to a reliable energy grid and more efficient industrial electrification. UF researchers contend it could also reduce carbon emissions, supporting cleaner, more sustainable manufacturing processes. The tall, two-level magnet now resides in the Powell Family Structures and Materials Laboratory on UF's East Campus. MSE plans to officially unveil it in December, inviting representatives from national labs, industry and academia. While Engineering students will have future opportunities to use it for research and experiential learning, UF researchers are optimistic about potential industry adoption for industrial manufacturing in the next five to 10 years. The award is part of a $187 million DOE initiative to strengthen competitiveness in U.S. manufacturing. If successful, the innovation could redefine how the world shapes the materials of tomorrow.
