Research Focus

The Processing and Physical Metallurgy (PPM) Lab, led by Dr. Ming Chen, focuses on advanced manufacturing and in situ characterization of materials designed for extreme environments. The first focus is to fabricate metals and ceramics with novel compositions and engineered microstructures that achieve superior mechanical and functional performance. The second focus is to utilize in situ techniques to characterize materials properties under processing and service conditions to inform and optimize manufacturing strategies. The overarching goal is to develop advanced materials and architected structures that enable sustainable solutions in various applications, including energy, aerospace, and defense.

Research Highlights

Thrust 1: Additive manufacturing

01

Microstructure and properties of high-entropy-superalloy microlattices fabricated by direct ink writing

Acta Materialia 2024

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Direct ink writing, sintering, microstructure, and properties of high-entropy-superalloy microlattices
02

Microstructural engineering of a dual-phase Ti-Al-V-Fe alloy via in situ alloying during laser powder bed fusion

Additive Manufacturing 2022

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In situ alloying and microstructural engineering of a dual-phase titanium alloy during laser powder bed fusion
03

Ink Casting and 3D-Extrusion Printing of Yb14MnSb11 for High-Temperature Thermoelectric Material

Advanced Functional Materials 2024

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High-energy ball milling, ink preparation, extrusion printing, debinding, and sintering of thermoelectric material

Thrust 2: Metallic foams

04

Tungsten's Role in Enhancing Sintering Resistance of Fe-W Hierarchical Foams during Redox Cycling

Advanced Functional Materials 2024

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Schematic of low- and high-tungsten iron foams during oxidation and reduction cyclingElectron micrographs comparing iron-tungsten foams after repeated redox cycles
05

Tungsten Strongly Inhibits Sintering of Porous Iron During High-Temperature Redox Cycling

Small 2024

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Hierarchical porosity in freeze-cast iron, from macro channels and micropores to sintering-inhibition pores and nanoscale porosity

Thrust 3: Critical materials

06

Upcycling critical metals from spent lithium battery cathodes into stainless steel

Chemical Engineering Journal 2026

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Stepwise hydrogen reduction of metals recovered from spent batteries into stainless steel

Thrust 4: Micromechanics

07

Achieving micron-scale plasticity and theoretical strength in Silicon

Nature Communications 2020

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Micropillar fracture, slip bands, and slip offsets across decreasing silicon pillar sizes
08

Exploring defect behavior and size effects in micron-scale germanium from cryogenic to elevated temperatures

Matter 2023

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Temperature-dependent deformation and dislocation behavior in micron-scale germanium

Funded by

Research Showcases

Manufacturing

Direct ink writing

In situ testing

Silicon microcompression
Magnesium microcompression
Nanoindentation