Geelong & Melbourne | Victoria | Australia

Annual Report 2018

Institute for Frontier Materials

31 STUDENT COMPLETIONS

$22.8M NEW GRANTS AWARDED IN 2018

OUR STUDENTS COME FROM25 COUNTRIES

180 STAFF, INCLUDING 116 RESEARCHERS*

375 JOURNAL ARTICLES PUBLISHED

150 HDR STUDENTS

*FTE

YEAR AT A GLANCE

CONTENTS

8 Research Highlights 9 Nanotechnology9 - World First BNNT Breakthrough

10 Carbon Fibre & Composites10 - $15M R&D Project is Good News11 - Advancing Composites Science11 - Chemistry prize for Dan

12 Modelling12 - Modelling Key to Improving Fibre Properties

13 Infrastructure Materials13 - Probes Shed Light on Hidden Corrosion

14 Electromaterials14 - Sodium-Ion Batteries for Future Energy Storage15 - Strengthening the Spanish Connection

16 Fibres and Textiles16 - Rating System Targets Motorcycle Safety17 - Surface Treatments – Adding Value to Textiles

18 Metals18 - New Facility for Next-Gen Metal Fabrication

19 Deakin Advanced Characterisation Facility

21 Collaborative Centres22 ARC Research Hub for Future Fibres

24 ARC Training Centre in Alloy Innovation for Mining Efficiency (mineAlloy)

26 ARC Centre of Excellence for Electromaterials Science (ACES)

28 Energy Pipelines Cooperative Research Centre (EPCRC)

29 Innovative Manufacturing Cooperative Research Centre (IMCRC)

30 Carbon Nexus

31 Battery Technology Research and Innovation Hub (BatTRI-Hub)

32 Australian Centre for Infrastructure Durability (ACID)

2 Year at a Glance

4 From the Chair

5 From the Director

6 Our Vision and Mission

6 2018 IFM Executive Team

7 2018 Board Members

20 Seeing the Unseen

33 Student Completions

34 Industry Partners

COVER: Electrodeposited nano-grained nickel. Image from IFM's Advanced Characterisation Facility Leica s400 Scanning Electron Microscope.

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Throughout 2018, IFM researchers continued to make outstanding advances in a number of technological fields, including fibre recycling and advanced alloy development.

A team of nanotechnology researchers from IFM has produced the first bulk boron nitride with high thermal conductivity, which could potentially replace current heat dissipation techniques, allow the development of even smaller devices and make our mobile phones and computers cooler and safer. This work has been spun-out into a startup company, partly owned by Deakin.

BNNT Technology Ltd has received a grant of $1.4M from the Advanced Manufacturing Growth Fund for industrial scale production of BN nanotubes within two years (further details are included in this report).

During the year, the University took a number of important steps to grow its research base and profile. Continuing our investment in technology, the Battery Technology Research and Innovation Hub (BatTRI-Hub) has commissioned a robotic stacker to automate production of its advanced battery pouch cells. This work will be strengthened following the announcement in August 2018 of our successful bid for a $4.3M ARC Industrial Transformation Training Centre for Future Energy Storage Technologies.

The new centre, which will be led by Prof Maria Forsyth, includes chief investigators from the Institute for Intelligent Systems Research and Innovation and the School of Engineering.

A high priority for the University is infrastructure – equipment and platforms that provide a unique, competitive advantage and that we can use as a catalyst for transdisciplinary approaches to big problems. Providing the right mechanisms and infrastructure to encourage more interdisciplinary collaboration is high on the Deakin research agenda.

One aspect of the University’s mission is taking discovery research and translating it into innovations and applications that actually deliver material benefit for our communities. In this respect, IFM’s focus on re-designing materials for a circular economy will have large benefits addressing issues of waste, while harnessing the original value of materials as they evolve through multiple lives.

In the area of natural fibres, IFM researchers have established themselves as world leaders. In an ongoing collaboration with the Ear Science Institute Australia, as part of the ARC Research Hub for Future Fibres, the project to produce an artificial eardrum from silk is nearing clinical trials.

Dr Will Gates, Prof Frank Collins and SEBE’s Dr Damien Callahan received funding of $1M over three years for an ARC Special Research Initiative to provide a holistic waste-to-resource remediation strategy for PFAS contamination. They hope to improve the efficiency of remediation strategies for PFAS contaminated sites and to create new materials from combinations of waste streams to turn waste products into valuable resources.

In the area of training, a highlight was the announcement that Deakin is now officially part of the Erasmus Project, with the European Master Course ‘Materials for Energy Storage and Conversion’.

It is quite a coup for Deakin to be included in this program, which involves eight universities in six countries and is thanks largely to the efforts of A/Prof Jenny Pringle.

Our future challenge is to continue to grow while maintaining our commitment to excellence and relevance in the face of major challenges to manufacturing related research in Australia.

Professor Julie OwensDeputy Vice-Chancellor Research Chair, IFM Board

FROM THE CHAIR

$4.3M SUCCESSFUL BID FOR NEW ARC TRAINING CENTRE

4 Reports

We reorganised our leadership structure at the start of the year, with a small nimble Executive comprising the Director, Deputy Director (Maria Forsyth), General Manager (Michelle Gait) and Deakin Research Executive Director Finance and Operations (Virginie Hoareau). The old Executive has been broadened to include all Professorial staff and is now known as the IFM Steering Group.

Following a senior researcher retreat in February we re-focused our Mission on two key pillars:

• re-designing materials for a circular economy

• imparting materials with extraordinary functionality.

This will form the foundation of our next five-year strategic plan.

The transformation of a linear economy into a circular economy creates a unique suite of material design challenges. Over the course of 2018, many IFM researchers began refocusing their research direction to meet these challenges. Key is the need to tailor materials explicitly for a circular life right from the beginning. While, with many others, we are addressing the issue of how to deal with today’s waste through material and process innovation, we are increasingly seeking to use material re-design to eliminate tomorrow’s waste. To facilitate this, we were very pleased to appoint Catherine McMahon as manager major projects, with a brief to help galvanize IFM to address the circular economy.

We were successful in some significant grants during the year, including:

• a new ARC Industrial Transformation Training Centre for Future Energy Storage Technologies led by Prof Maria Forsyth ($4.3M from ARC)

• a CRC-project led by A/Prof Daniel Fabijanic on surface engineering and design innovations for components used in hydrometallurgical processing ($3.9M over three years)

• the Motocap star rating system for motorcycle protective clothing, led by Dr Christopher Hurren ($2M over four years)

• a $15M manufacturing research and development project, facilitated by the Innovative Manufacturing CRC (IMCRC), in collaboration with Carbon Revolution

Our flexible roll forming facility was launched in September by ARC Chief Executive, Prof Sue Thomas and former Deakin Deputy Vice-Chancellor Research, Prof Joe Graffam.

In other research news, one of the partners in the ARC Research Hub for Future Fibres, HeiQ and the short polymer fibre team successfully built a scale-up manufacturing facility for their technology in Manufutures.

The ARC MineAlloy Training Centre engaged several new industry partners and were successful in the CRC-P proposal with Callidus, Newcrest, Minara and CSIRO. Our research is delivering results with provisional patents being drafted on a number of innovations.

At Carbon Nexus, utilisation of the carbon fibre pilot line continued to grow. In the first half of the year, a major building extension was completed and new equipment was added to the line. Once operations recommenced, utilisation jumped to 61% in the third quarter and finished at 72% for the fourth quarter.

While 2018 was a great year for IFM, it was marred by the death of our good colleague Prof Mark Kirkland from brain cancer in February. Prof Kirkland worked at Deakin for more than 10 years and brought a real richness of character to IFM. It was very fitting that he was posthumously awarded an Order of Australia Medal.

Professor Matthew BarnettDirector, IFM

FROM THE DIRECTOR

A highlight of 2018 was the launch of our world-first, $1.5M flexible roll forming facility

The beginning of 2018 saw a new leadership team seeking to fill the shoes left by Xungai, Virginie and Darlene, while the researchers continued to do what they do so well, write papers, win grants, translate outcomes and graduate HDR students.

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OUR VISION AND MISSION

OUR VISIONTo lead and inspire innovations in materials science and engineering that have a transformational benefit to society.

OUR MISSIONTo create and translate knowledge at the frontier of materials science for globally raised standards of living by:

• Re-designing materials for a circular economy

• Imparting materials with extraordinary functionality

through excellence in research culture, research quality, translation and training.

Professor Matthew Barnett

Director, IFM

Professor Maria Forsyth

Associate Director, IFM

Ms Michelle GaitGeneral Manager,

IFM

Ms Virginie HoareauExecutive Director

Research Office, Deakin Research – Finance &

Operations

2018 IFM EXECUTIVE TEAM

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Professor Jane den Hollander

Vice-Chancellor Deakin University

Professor Trevor Day

Executive Dean, Faculty of Science Engineering

& Built Environment

Mr David MarinoExternal Independent

Director

Professor Matthew Barnett

Director, IFM

Professor Maria Forsyth

Associate Director, IFM

Dr Ben SpincerDirector,

Deakin Research Commercial

Mr Derek Buckmaster

Director, Carbon Nexus

Professor Peter HodgsonChair and Deputy

Vice-Chancellor Research (until July 2018)

Professor Gordon Wallace

External Independent Director

Professor Brendan Crotty

Executive Dean, Faculty of Health

Professor Julie Owens

Deputy Vice-Chancellor Research

(from Nov 2018)

Dr Leonie WalshExternal Independent

Director

2018 BOARD MEMBERS

The IFM Board is responsible for the governance and oversight of the research, development and commercialisation activities of IFM.

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RESEARCH HIGHLIGHTS

9 Nanotechnology

10 Carbon Fibre & Composites

12 Modelling

13 Infrastructure Materials

14 Electromaterials

16 Fibres and Textiles

18 Metals

INNOVATIONS IN MATERIALS SCIENCE WITH REAL-WORLD APPLICATIONS

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Boron nitride nanotubes (BNNTs) with a similar structure to carbon nanotubes possess excellent mechanical properties, thermal conductivity, thermal stability and high adsorption of neutron radiation. These properties make them ideal candidates as reinforcing and functional fillers in polymeric, metallic and ceramic composites for potential industrial application.

However, the high cost and enormous energy consumption of the existing method to produce BNNTs has greatly restricted their large-scale industrial manufacture and applications.

IFM nanotechnology researchers Prof Ying Chen and Dr Luhua Li have developed and patented a BNNT fabrication method, which can offer a high production rate of BNNTs with high energy efficiency, using a process that can be upscaled to industry.

Recognising the potential of the new process, AIC Investment Corporation Pty Ltd has invested $3M to establish a start-up joint venture company BNNT Technology Ltd with Deakin. The company will use the patented method developed at IFM to produce BN nanotubes at lower temperatures and with higher yields.

The project will also leverage local advanced manufacturing capabilities in the design, construction and commissioning of the world’s largest production line for BN nanotubes, capable of producing kilogram quantities. This production line is being established at Manufutures.

The BNNT commercialisation has been awarded a grant of $1.4M from the Advanced Manufacturing Growth Fund.

Economic benefits are expected to flow from the new facility, while the project also represents a strategic opportunity to put Australia ahead of the US and Canada in terms of BN nanotube production and commercialisation.

HIGHLIGHT PAPER: Shi, G; Chen, L; Yang, Y; Li, D; Qian, Z; Liang, S; Yan, L; Li, L; Wu, M;

Fang, H (2018), Two-dimensional Na-Cl crystals of unconventional stoichiometries on graphene surface from dilute solution at ambient conditions, Nature Chemistry, Vol. 10, PP. 776-779, Nature Publishing Group [Springer Nature].

HIGHLIGHT PROJECT: In a new ARC Linkage project, Prof Ian Chen will be

working on Improving battery safety with boron nitride nanotube separators by developing stable separators. These will enhance the ability of batteries to withstand high temperatures and avoid the current problem of short-circuiting of batteries being used in hot climates. Partner Organisations: Bolt Technologies Company, Ltd, Darvat PL ($401,850).

WORLD FIRST BNNT BREAKTHROUGH

NANOTECHNOLOGY

BELOW (FROM LEFT): Dr Arun Ambujakshan (BNNT Tech engineer), Dr Luhua Li, Dr Srikanth Mateti, Gary Walsh (BNNT Technical Manager), Prof Ian Chen and Dr Zhifeng Yi (BNNT Tech Engineer).

One giant leap towards world advanced large-scale production of boron nitride nanotubes.

CARBON FIBRE & COMPOSITES

The $15M research and development project, facilitated by the Innovative Manufacturing CRC (IMCRC), will mean increased collaboration between Carbon Revolution and IFM in a unique partnership to develop innovative and advanced manufacturing technologies.

Carbon Revolution CEO, Jake Dingle said the project will support a significant increase in terms of industrial scale and output of its products, which are exported to markets around the globe.

The research will take place at a dedicated collaborative Innovation Space and R&D Lab in Carbon Revolution’s building at the Deakin Waurn Ponds Campus.

Prof Russell Varley, who is part of the steering committee leading the project, said one of the goals was to make composite materials that are easier to process, more durable, stronger and tougher, at lower cost.

“The technology developed in this project will ensure Deakin and Carbon Revolution remain at the leading edge of global composite materials research, particularly in relation to lightweight structures, raw materials and fabrication technologies,” said Prof Varley.

The research project intends to catalyse change across a range of key commercialisation and industrialisation drivers, including:

• Research into raw material inputs, such as resin system development and fibre development

• Composite system elements and advanced process developments

• Manufacturing process automation and industrialisation

• Research into the integration of intelligent manufacturing and Industry 4.0.

$15M R&D PROJECT IS GOOD NEWS

Deakin and Carbon Revolution are collaborating in a new project to deliver innovative and advanced manufacturing technologies for composite wheel technology to the global automotive industry.

BELOW: The IFM-Carbon Rev-IMCRC project team.

Research Highlights10

CARBON FIBRE COMPOSITES

Deakin University will partner with leading wind energy solution provider, Vestas, to improve the compressive strength of carbon fibre composite materials for wind turbines.

The Wind Carbon Research Partnership with Carbon Nexus is a Deakin University initiative to research the next generation of carbon fibre specifically for use in wind turbine blades.

Along with the potential to improve wind turbine performance, the partnership underscores possible expansion of Geelong’s composite research and manufacturing footprint, as well as helping Victoria to achieve its Renewable Energy Target.

Carbon fibre composites are critical for the improvement of wind turbine blades due to their unmatched strength-to-weight ratio, enabling the manufacture of longer blades which improve efficiency.

The uptake of carbon fibre composites has been one of the main drivers behind the increased turbine efficiency and competitiveness of wind power in recent years. Turbine blades are now the largest single use for carbon fibre, accounting for more than 40 per cent of global production.

The new partnership leverages IFM’s leading composites research and Vestas’ expertise as a world leader in the wind energy sector.

ABOVE: Prof Russell Varley, IFM; Minister for Energy, Environment and Climate Change, Hon Lily D’Ambrosio and Head of Vestas Australia and New Zealand, Peter Cowling.

ADVANCING COMPOSITES SCIENCE

Chemistry prize for Dan

IFM student Dan Eyckens has received the University’s prestigious Rex Williamson prize.

While IFM has many excellent materials scientists and engineers, we also have a small number of chemists. So, it was particularly gratifying to see an IFM student taking away a University chemistry prize.

Dan completed his PhD in 2018, under the supervision of A/Prof Luke Henderson, with a thesis titled Applications of New Ionic Liquids for Organic Transformations. He is now working as an Associate Research Fellow at IFM, in the area of carbon fibre surface modification.

The Rex Williamson Prize was established at Deakin University in 1984 to encourage research in the chemical sciences and to reward excellence. The prize is funded from a capital donation made by Dr Rex Williamson (former Senior Lecturer in Chemistry) upon his retirement after more than 30 years’ service. It is awarded to the highest achieving PhD student enrolled in SEBE or IFM whose research involves a significant component of chemistry.

ABOVE: A/Prof Luke Henderson and Dr Dan Eyckens after Dan’s graduation.

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MODELLING KEY TO IMPROVING FIBRE PROPERTIES

Atomic scale modelling at IFM is providing the way for a world-leading Danish company to create next generation insulation materials.

Prof Tiffany Walsh is working on a project with colleagues at the Danish Technical University (DTU) and ROCKWOOL, a family owned manufacturer of construction materials, in particular thermal and acoustic insulation from mineral fibre.

Prof Walsh will be using her expertise in molecular modelling to predict the physico-chemical properties of the fibres used to create the insulating material.

The company’s product is based on a technology to spin rock into wool, making tiny fibres, which are arranged in different configurations for thermal and acoustic insulation.

“ROCKWOOL want to know more about the fibres themselves – their chemical composition at the fibre interface and how the fibre interacts with its environment, eg at different temperatures and different humidities,” explains Prof Walsh.

“Of particular interest is the interface between the fibre and its environment, which is where we come in, given that we specialise in atomic scale modelling of interfaces.”

The company’s philosophy aligns closely with IFM’s, with a strong commitment to the circular economy. Their products are 100 per cent recyclable, which is unusual for the construction industry, which produces a lot of waste.

From the fundamental information uncovered by Prof Walsh and her team, the collaborators at DTU will develop macro scale predictions about how the fibres behave. The information derived from modelling will be consolidated with the company’s vast experimental knowledge-base about the fibre properties. The four-year project includes funding for a PhD student.

“It shows how something so fundamental – modelling a material at the atomic scale – is clearly of high value to a very successful company,” says Prof Walsh.

“ROCKWOOL want to know so much more about their product because they want to grow and innovate, to maintain their world-leading position. They understand the necessity of fundamental research to accomplish this.”

The new project will see exchanges of personnel between the groups in Denmark and Australia.

ABOVE: An early planning meeting to map out the project. From left: Prof. Yuanzheng Yue, Aalborg University (Advisory group member); Prof Tiffany Walsh; Dr Mette Solvang, ROCKWOOL; Prof Susan Stipp, DTU; Dr Dorte Johansson, ROCKWOOL; Dr Dorthe Lybye, ROCKWOOL; A/Prof Martin Andersson, DTU; Prof Julian Gale, Curtin University (Advisory group member); Dr Denis Okhrimenko, ROCKWOOL.

HIGHLIGHT PUBLICATION: Prof Tiffany Walsh, together with collaborators in

the US and China, published a paper in Nature Communications. The paper reports on coral-shaped gold nanoparticles with exceptional optical properties, built by design using engineered peptoids. Yan et al. (2018) Controlled synthesis of highly-branched plasmonic gold nanoparticles through peptoid engineering. Nature Communications 9, Article number 2327.

MODELLING

Research Highlights12

PROBES SHED LIGHT ON HIDDEN CORROSION

INFRASTRUCTURE MATERIALS

Corrosion costs the world around US$4 trillion annually and affects the safety and durability of our vast network of underground gas and water pipelines.

Mike Tan NACE Fellowship

Prof Mike Yongjun Tan received a NACE Fellowship at the international NACE conference in Wisconsin. The honour was awarded in recognition of the development of an electrochemically integrated multielectrode array, namely the wire beam electrode method and its applications for localised corrosion and inhibitor studies.

Many of these pipelines are old and are under serious threat of corrosion. But, the lack of corrosion data from buried pipelines significantly hinders the ability to forecast when repairs are needed.

Over the past few years, Deakin researchers in the Energy Pipelines CRC (EPCRC) have developed new corrosion probes for detecting critical forms of localised corrosion found on buried pipelines.

The external surface of underground pipelines is usually protected by an organic coating that behaves as a barrier between the pipeline substrate and the environment, in conjunction with cathodic protection (CP) that electrochemically protects coating defect areas.

When the coating becomes disbonded from the pipe surface due to a process known as cathodic disbondment, a crevice forms between the steel substrate and the disbonded coating film, allowing corrosive soil and water to accumulate and locally attack the pipeline. To make things worse, the disbonded coating film can shield the steel substrate from CP currents and therefore CP may not mitigate corrosion under disbanded coatings.

In order to visualise this difficult form of localised corrosion, the researchers designed and carried out various tests on probes in aqueous solutions. However, how the probes behaved in underground soil conditions was still not well understood.

Over the past three years, the research team has carried out an extensive field testing campaign and comprehensive laboratory scenario modelling to demonstrate the applicability and performance of these probes in highly resistive and inhomogeneous underground soil environmental conditions.

They conducted field tests by deploying probes in four gas pipeline locations and in a large sand box in Melbourne and Geelong. There was good agreement between the corroded surface image and the corrosion condition of the water pipeline after the probe was withdrawn from the installation site, following 661 days of testing.

The results showed that cathodic protection potential is a critical factor affecting buried pipeline corrosion. The data obtained provide the possibility for engineers to perform more proactive maintenance of major infrastructure assets because the likelihood of corrosion can be monitored continuously in-situ and the system can be adjusted well before significant corrosion takes place.

The possibility of extending the life of pipelines by being able to reliably monitor their safety and health has huge potential economic benefits.

This work was funded by the Energy Pipelines CRC, supported through the Australian Government’s Cooperative Research Centres Program and in-kind support from the Australian Pipelines and Gas Association Research Standards Committee.

LEFT: Field testing was carried out by deploying the corrosion monitoring probes at a number of gas pipeline locations.

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SODIUM-ION BATTERIES FOR FUTURE ENERGY STORAGE

IFM researchers are investigating an alternative technology to address cost and safety issues associated with the lithium-ion batteries used in everything from mobile phones to microgrids.

New research from our Battery Technology Research and Innovation Hub (BatTRI-Hub) has proven the viability of sodium-ion batteries, which can be cheaper and safer than their lithium ion counterparts.

Sodium batteries are not affected by the explosive problems plaguing lithium-ion, which have caused recalls and bans of certain model phones on some airlines. Sodium batteries are also capable of charging and discharging at higher rates.

Another advantage of sodium-ion batteries is that they can be made using readily available materials, without mining for rare materials such as cobalt. Unlike lithium-ion batteries, the key components of sodium-ion batteries are synthesised from low-cost, abundant materials with secure supply chains.

Although sodium ion batteries have been investigated since the 1970s, until now the technology has not been optimised for mainstream use due to the discovery and widespread expansion of lithium-ion technology.

However, this is changing as the BatTRI-Hub team led by Prof Patrick Howlett and Prof Maria Forsyth have demonstrated through advances using high-stability electrolyte formulations to improve the technology.

Their latest findings have been presented as part of a specially curated edition of the journal Advanced Energy Materials, co-edited by Prof Forsyth with international experts Professors Teofilo Rojo, Yong-Sheng Hu and Xiaolin Li.

Prof Forsyth and her team used ionic liquids as electrolytes, which showed enhanced sodium battery performance during testing at the BatTRI-Hub.

The team’s breakthrough research has shown how sodium secondary cells could also be used in conjunction with lithium-based devices.

The global focus on alternative energy storage technologies and the similarities in electrochemistry between sodium and lithium has sparked the renewed interest in sodium batteries.

HIGHLIGHT PUBLICATION: Advanced Energy Materials 8(17) Special

Issue: Sodium-Ion Batteries, Eds T. Rojo, Y-S Hu, M. Forsyth and X. Li.

ELECTROMATERIALS

Research Highlights14

Prof Maria Forsyth has been awarded a Visiting Ikerbasque Professorship at the University of the Basque Country, Spain. The position is located within POLYMAT, a special research centre for polymer science and engineering.

In the new role Prof Forsyth will undertake collaborative projects in the area of novel functional polymers and their composites for applications in energy, corrosion and gas separation.

This is the first time this prestigious award has been offered to someone outside Europe. It opens up opportunities to collaborate on projects in Spain and other parts of Europe – two projects were started in 2018 and a cotutelle arrangement is being negotiated between Deakin and the University of the Basque Country.

The award will also allow Deakin to build stronger links with other partners including CIC EnergiGUNE and Tecnalia with whom we already have research agreements.

ABOVE: Testing in the BatTRI-Hub has shown enhanced performance of sodium batteries with ionic liquid electrolytes.

Strengthening the Spanish connection.

VISITING IKERBASQUE PROFESSORSHIP AWARDED TO PROF MARIA FORSYTH

LEFT: Prof Maria Forsyth and students from the European Master Course ‘Materials for Energy Storage and Conversion’ in Spain.

BEST POSTER AWARDIFM student Kalani Periyapperuma received the award for best poster at the IFM conference. Kalani's poster was 'Towards high rate Li metal anodes: enhanced efficiency at high current density in a superconcentrated ionic liquid'.

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FIBRES AND TEXTILES

The Motorcycle Clothing Assessment Program (MotoCAP), which was developed by IFM researchers Dr Christopher Hurren and Dr Liz de Rome with funding from Transport for NSW, will provide reliable, scientifically-based information to motorcylists about the safety and comfort of specific items and brands of clothing.

Road safety organisations around Australia and New Zealand joined forces to establish the rating program, recognising that clothing is a key factor in accident outcomes for motorcyclists.

In Victoria alone, in the past 10 years more than 10,000 riders and pillion passengers have been seriously injured on Victorian roads, which represents 17 per cent of hospitalised vehicle accident claims, while motorcycles represent only four per cent of registered vehicles.

MotoCAP will give clothing two separate star ratings – one for protection and one for comfort.

The team led by Dr Hurren developed a rigorous protocol for random selection and testing of clothing from the market to measure motorcyclist safety and comfort.

They will now oversee the project for three years, conducting tests on clothing purchased anonymously with the specialised equipment, purpose-built at IFM.

The protection star rating considers performance in abrasion resistance, seam strength and impact protection, while the comfort rating is based on how comfortable the clothing is when it is worn in the Australian climate.

MotoCAP is run by a consortium of government agencies, private organisations and motorcycle stakeholders.

RATING SYSTEM TARGETS MOTORCYCLE SAFETY

A world first ratings system for motorcycle clothing, developed by IFM researchers, has been launched in Australia.

ABOVE: Launch of the MotoCAP star rating system for protective motorcycle clothing. From left: David Andrews, Senior Advisor NSW State Insurance Regulatory Authority; Dan Leavy, Manager Safer Vehicles, NSW Centre for Road Safety; Dr Liz de Rome, IFM; and David Beck, NSW Centre for Road Safety.

Research Highlights16

The first product is a textile finishing technology, known as ‘HeiQ Real Silk’, which replicates some of the tactile and luxurious properties of silk. By applying short silk fibres to the fabric surface, the silk-like properties can be introduced to textiles such as polyester, cotton or blends. HeiQ Real Silk is being marketed through the Swiss parent company HeiQ Materials AG.

In a second process, known as ‘No Fuzz’ the team has developed a range of surface treatments that reduce pilling and abrasion damage, helping fabrics to look and feel newer for longer.

Pilling is a common problem for woollen and other knitted textiles. It is caused by mechanical friction, as loose fibres in a material rub together and become tangled, forming visible fuzzy ‘pill’ balls. Abrasion damage from wear and tear is one of the biggest problems affecting clothing, especially items made from wool and natural/synthetic blends.

The textile industry has tried to solve this issue for years but most existing fabric-based treatments result in an unpleasant feel to the fabric and reduced comfort.

The key to avoiding pilling is either to remove the fluffy fibres or to stabilise the fabric structure so that it is difficult for fibres to loosen and tangle.

The new treatment strengthens loose fibres with adhesive polymer structures, reinforcing fabric yarns and resulting in a significant improvement against pilling and abrasion damage.

The treatment can be applied to fabrics without affecting the feel or appearance. It makes clothing more robust to wear and tear, thereby extending the lifetime of the garment. It can be used on all fibre types but is particularly effective on spun yarns and natural/synthetic blends.

The research team is enabling scaled-up production helping HeiQ Australia get off the ground by developing new products and new devices to make those products. In 2018, this goal moved a step closer when the company moved into the purpose-built Deakin Manufutures facility at Waurn Ponds.

SURFACE TREATMENTS – ADDING VALUE TO TEXTILES

The collaborative research partnership between IFM and HeiQ Australia has delivered two commercial products based on the team’s cutting edge, short polymer fibre technology.

BELOW: In 2018, the short polymer fibres team received a Vice-Chancellor’s award for industry engagement in research.

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NEW FACILITY FOR NEXT-GEN METAL FABRICATION

METALS

Roll forming of structural and crash components is widely applied across the automotive industry, thanks to the creation of high-performance materials

The new flexible forming facility has the capacity for complex roll forming – a process with applications across the automotive, aerospace and rail industries.

The ARC chief executive, Prof Sue Thomas launched the facility with Deakin DVCR Prof Joe Graffam. The flexible forming facility will be used for proof-of-concept studies, rapid prototyping and the manufacture of complex profiles from hard-to- form materials.

Roll forming of structural and crash components is widely applied across the automotive industry, thanks to the creation of high-performance materials such as Ultra High Strength Steels, advanced aluminium alloys and metal laminates.

The facility features a dynamic 3D roll forming process developed, patented and manufactured by IFM’s German research partner data M Sheet Metal Solutions.

The new process allows for more parts flexibility, faster fabrication and greater potential cost savings compared to conventional forming methods such as metal stamping.

The facility was supported by a $280,000 ARC Linkage Infrastructure, Equipment and Facilities (LIEF) scheme funding grant.

ABOVE: data M Sheet Metal Solutions Founder and Managing Director, Albert Sedlmaier; Deakin DVCR, Prof Joe Graffam; ARC CEO, Prof Sue Thomas; and leader of Deakin’s roll forming group, Dr Matthias Weiss in front of the flexible forming facility.

HIGHLIGHT PUBLICATION: IFM researchers Dr Lu Jiang and colleagues have

a cover paper on the Journal of Materials Science. This work explores the effect of molybdenum alloying on the microstructural evolution of high-strength low-alloy strip-cast steel, which is a near-net-shape casting technology that produces thin strip material directly from the liquid metal, avoiding slab casting and hot rolling steps of conventional casting and thereby offering significant cost and energy savings. The work was part of Lu’s PhD research.

A world first, $1.5M facility dedicated to advanced metal development and 3D roll forming was launched at IFM in September 2018.

Research Highlights18

The Deakin Advanced Characterisation Facility (ACF) is an open-access facility, located and administered within IFM. It includes the Electron Microscopy (EM), X-ray and Nuclear Magnetic Resonance (NMR) facilities, delivering a unified platform of advanced characterisation capabilities and expertise. The ACF’s mission is to provide advanced characterisation service, training, teaching and support, as well as carry out collaborative research programs within Deakin and with industry.

Example case studies of such research are described below and over the page.

Nuclear Magnetic ResonanceRecent IFM PhD graduate Pierre Martin has used a combination of NMR spectroscopy and molecular dynamics simulations (in collaboration with Dr Fangfang Chen) to study

the interactions between charged molecules in a lithium battery electrolyte.

His recent cover article published in the Journal of Physical Chemistry Letters explains how average distances between atomic sites in different molecules can be measured by transferring magnetisation between them and then carefully analysing the resulting NMR signals.

It also provides the first experimental verification of an unusual theoretical prediction that relates the distances measured to the NMR frequencies of the nuclear isotopes.

This approach allows us to understand the structure of the ionic liquid and how the lithium interacts with the other species in unprecedented detail, paving the way for improved battery electrolytes and more efficient energy storage technologies.

Martin et al., J. Phys. Chem. Lett. 9 (2018) 7072

DEAKIN ADVANCED CHARACTERISATION FACILITY

One of Australia's premier collections of advanced characterisation instruments, including an $18M electron microscopy suite.

BELOW: The JEOL JEM-2100 high performance transmission electron microscope with LaB6 electron source is used for analyses at the sub-nanometre level (up to 1.5 million magnification).

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Electron microscopyA paper by Dr Ross Marceau and colleagues from Monash University has been published in Science. High-strength aluminium alloys are important for producing lightweight cars, trains and aeroplanes.

The traditional strategy for producing these materials this is through hours of high-temperature heat treatment to form precipitates in the alloy. Sun et al. developed a processing method that relies on mechanical cycling of the alloys at room temperature. This quickly creates many very fine precipitates that have the same strengthening effect as those characteristic of traditional thermal methods. This method should also work for other alloy systems.

Dr Marceau provided the microstructure characterisation by atom probe tomography to help explain what imparts the alloy properties.

Sun et al., Science 363 (2019) 972

X-rayThe X-ray facility has continued to facilitate new and improved X-ray techniques for the growing user base across the University and CSIRO. Furthermore, the Australian Synchrotron’s BRIGHT program has introduced new users to the potential of synchrotron X-ray capabilities.

Conflux Technology, an additive manufacturing start-up based at ManuFutures, has used large-scale micro X-ray computer tomography techniques to assess part manufacturability and to inform the development of additive manufacturing process parameters.

Some exciting new external projects have also commenced during the year. These include:

• Defence Science and Technology – development of a microstructural damage accumulation model to determine the fatigue life of aerospace materials.

• University of Otago (ICECOLDSCANZ) Catalyst funding – development of a proof of concept Antarctic ice core Laue diffraction scanner for Australia and New Zealand.

Seeing the Unseen

A new exhibition opened at Scienceworks in May 2018. ‘Beyond Perception: Seeing the Unseen’ is a permanent exhibition designed for teenagers, which explores the worlds of science and technology.

The curators of the exhibition visited IFM and recorded interviews with Dr Andrew Sullivan and Dr Ross Marceau.

The permanent exhibition is designed to inspire and intrigue teens to engage with science, technology, engineering and math (STEM). It reveals the invisible fields and forces that surround us, such as gravitational waves, invisible light, sound and aerodynamics. The exhibition was developed with a group of 12- to 15-year olds who were consulted in monthly meetings.

It is open at Scienceworks, daily from 10am – 4.30pm.

RIGHT: Dr Andrew Sullivan attended the opening of the Scienceworks ‘Beyond Perception: Seeing the Unseen’ exhibition.

Deakin Advanced Characterisation Facility (continued)...

NEW & IMPROVED X-RAY TECHNIQUES

BELOW: Solute clusters in aluminium alloy 2024, before and after cyclic strengthening.

Research Highlights20

COLLABORATIVE CENTRES

22 ARC Research Hub for Future Fibres

24 ARC Training Centre in Alloy Innovation for Mining Efficiency (mineAlloy)

26 ARC Centre of Excellence for Electromaterials Science (ACES)

28 Energy Pipelines Cooperative Research Centre (EPCRC)

29 Innovative Manufacturing Cooperative Research Centre (IMCRC)

30 Carbon Nexus

31 Battery Technology Research and Innovation Hub (BatTRI-Hub)

32 Australian Centre for Infrastructure Durability (ACID)

21

ARC RESEARCH HUB FOR FUTURE FIBRES

Creating a transformational impact on Australian industry through world-class fibre research.

In 2018 the Hub worked on 25 collaborative R&D projects with industry partners: HeiQ, Carbon Revolution, Quickstep, Ear Science Institute Australia and Draggin Jeans.

These projects are grouped across three research themes: short fibres and nanofibres; carbon fibre composites; and high value-added applications.

Research highlights:• A 1,000 L capacity short polymer

fibre (SPF) production plant was commissioned in Geelong by HeiQ in March 2018, with support from Hub researchers. A new family of products was released by HeiQ based on Hub research – No Fuzz, which provides anti-pilling properties to textiles.

• A provisional patent was also filed on an aspect of the short polymer fibre research. A second PCT patent application was filed by Hub Chief Investigators on a novel method to make porous scaffolds for biomedical applications.

• First generation silk-based biomaterials for eardrum reconstruction have been moved to a separate project, funded by the UK Wellcome Trust to progress towards clinical trials. Hub work has since developed new techniques for adding advanced functionality to silk membranes for other applications, including in the ear.

• Development of single layer denim for abrasion resistance is in the final stages of handover to the industry partner who is finalising production for product release.

Seven PhD students are now supported by the Hub, working on addressing challenging industry issues, for example: reducing residual stress in carbon fibre composites, recycling textile waste, novel high performance multi-functional materials, and the stabilisation of natural polymer-derived fibres in aqueous formulations.

BELOW: The second Future Fibres Hub symposium held at Deakin Waurn Ponds in August.

Collaborative Centres22

The 2nd Future Fibres Symposium was held in August 2018. Two international keynote speakers attended, Hub Partner Investigator Prof Jeffrey Wiggins from University of Southern Mississippi, and Prof David Kisailus from University of California, Riverside. The extended visit from Prof Kisailus, an expert in biomimetics and nanostructured materials, enabled discussions around joint research projects and future collaborations. More than 135 attendees registered to attend the symposium.

In October we held a smaller workshop to brainstorm topics including future directions, collaborative projects and student development.

The Hub also underwent an ARC Performance Review in 2018 with the site visit held in October. We welcomed the opportunity to show the panel our facilities and share our research outcomes, to very positive feedback.

The Hub strengthened relationships through welcoming numerous academic (24) and industry (50) visitors, from both Australia and internationally. Our members also visited 29 international laboratories. Advances in knowledge were demonstrated through the publication of 25 journal articles, 17 presentations at conferences, and 26 invited lectures given by Hub members.

Three media releases emerged from Hub research in 2018, which resulted in newspaper articles, radio interviews and other on-line articles. These were:

• Deakin researchers create strain sensing clothes to monitor your movements (an outcome from supported work by Hub Chief Investigator A/Prof Joe Razal)

• No Fuzz: New Deakin treatment does away with fabric pilling (an outcome from the short polymer fibre research)

• Deakin researchers discover how to transform jeans into joints (an outcome from Hub PhD student Beini Zeng’s project)

A tender worth ~$2M over four years was awarded to a Deakin team including Hub Chief Investigator Dr Chris Hurren to conduct ongoing testing and rating of motorcycle protective clothing (MotoCAP), building on previous work in this area, including in the Hub.

A Memorandum of Understanding was signed between Deakin University and international partner institution the University of Applied Sciences and Arts Northwestern Switzerland (FHNW).

The MoU allows expansion of the research collaboration and joint supervision of PhD students, further strengthening the relationship. One Hub PhD student is jointly supervised by the two institutions.

ABOVE: Hub PhD student Beini Zhang (right) and A/Prof Nolene Byrne – investigating a method of recycling denim to produce a material with cartilage-like properties.

HIGHLIGHT PUBLICATION: Collaborative research by Hub Deputy Director A/Prof Joe

Razal and team, with University of Texas at Dallas, Drexel University and Lintec of America, featured on the cover of Small. The work, demonstrates the use of yarn-shaped supercapacitors with a MXene based yarn, for energy storage solutions in wearable and portable electronics. Wang et al. (2018) High-performance biscrolled MXene/Carbon nanotube yarn supercapacitors. Small 14(37).

25 JOURNAL ARTICLES PUBLISHED

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In its second year of operations, the mineAlloy centre reached 90% allocation of its HDR scholarships and research fellowships. All partners met at Deakin Waurn Ponds in September 2018 for their annual review. The following is a summary of the research progress.

Stream 1: Alloy DevelopmentMartensitic and bainitic steels for abrasive wear resistant applications:

Researchers at Deakin University are using Computational Fluid Dynamics (CFD) to model the heat treatment process at industrial scale. In parallel, the researchers are designing steel grades capable of achieving a bainitic microstructure using the existing heat treatment facilities. Bainitic steels have promising properties for applications requiring high abrasion resistance, such as ground engaging tools.

ABOVE: mineAlloy annual meeting at Deakin Waurn Ponds, September 2018.

Development of a new generation of ‘NiHard’ alloys for ore chute liners:Computational thermodynamics software was used to design a range of alloys and optimise the chemical composition of the traditional NiHard white cast irons. A sub-set of alloys, with addition of exotic carbide forming elements, was cast and subjected to low-stress abrasive wear testing at Deakin University. The results revealed promising pathways to improve the performance of Ni-Hard4.

Control of carbide morphology in high chromium cast irons and high manganese steels: This project investigates the effect of alloying elements and inoculants on the carbides formed in white cast irons and Hadfield steels. These materials have applications in multiple components of mining equipment, mainly slurry pumps and rock crushers. The characteristics of the carbides (type, volume fraction, size, size distribution and shape) have a significant impact on the mechanical properties and performance of the components.

Stream 2: Manufacturing InnovationsIs additive manufacturing of a tungsten carbide component possible?

The additive manufacturing approach is interesting for cemented carbides because these materials are very difficult to process with subtractive methods (namely machining) given their high hardness and wear resistance. This project explores the feasibility of manufacturing cemented carbide components, of the WC-Co type, using an additive approach. The preliminary results obtained so far are very promising in terms of feasibility and resulting mechanical properties.

Stream 3: Systems UnderstandingSelection of ceramics for high-tonnage ore chutes:

This project aims to increase our understanding of the material structure-property-performance relationships.

ARC TRAINING CENTRE IN ALLOY INNOVATION FOR MINING EFFICIENCY (mineALLOY)

Making Australian manufacturers dominant in the multi-billion dollar mining equipment sector by training innovators to design the world’s best highly customised, long-life, wear-resistant components.

Collaborative Centres24

The testing program has started, aiming to compare ceramic and metallic materials used in ore chute liners and to produce reliable information about the relationship between readily measurable material characteristics (chemical composition, grain size, hardness, toughness) and industrial service performance.

Modelling wear of materials:

The objective of this project is to develop and refine a set of modelling tools, which can predict the wear performance of materials and components in service.

Good progress was made with Discrete Element Modelling (DEM) software, comparing the wear performance of different component and equipment designs. Current efforts are focusing on the true prediction of damage and wear from readily measurable material properties.

Wear sensing methodologies:

The project aims to develop sensors capable of detecting the wear of critical components installed in remote locations, thus reducing the need for inspections and the exposure of maintenance crews to dangerous environments.

The outcomes of this project have resulted in a preliminary patent application for a device.

Finally, 2018 saw mineAlloy increase its interaction with the METS and mining sector through site visits, tours of research facilities and attendance at conferences and other networking events.

RIGHT: mineAlloy Director, Prof Matthew Barnett and Chief Investigator, A/Prof Daniel Fabijanic on a visit to industry collaborators at Cape Lambert, Western Australia.

mineALLOY

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ARC CENTRE OF EXCELLENCE FOR ELECTROMATERIALS SCIENCE (ACES)

Turning fundamental knowledge about cutting-edge materials into the next generation of ‘smart devices’ to benefit the community.

Researchers in ACES continue to advance the discovery and development of electromaterials – materials that enable the transport of charged species (electrons and/or ions) as well as facilitating the exchange of charge to other materials.

Electromaterials under study include conducting polymers, conducting carbons such as graphene and carbon fibres, in addition to different types of electrolytes, electrocatalysts and light harvesting materials.

Applications of particular interest to the Centre are artificial muscles, energy conversion and storage devices, systems that interact with living tissue and soft robotics (i.e. prosthetics).

The ACES network of members and collaborators is substantial, creating a significant global reputation: over 50% of the 2018 publications had international collaborators across 33 countries (160 research institutions) as co-authors. In total 224 articles were published in 2018 with over 21 different subject areas; 35% were in the top 10% of world views.

Research training is always a strong focus for the Centre, to give our next generation of scientists a supportive start in their STEM careers. This training includes on-line courses and a range of workshops, such as media communications training (with three professional journalists), an entrepreneurship and innovation course, batteries and advanced electrochemistry workshops, and presentation skills training.

Research highlightsBatteries:

The BatTRI-Hub on the Waurn Ponds campus has been pivotal in research to develop cheaper, safer batteries using sodium-ion as an alternative to lithium-ion (see p. 30). This is also an important option in the drive to avoid materials of environmental and social concern, such as cobalt.

ACES researchers and collaborators continue to work together to increase the cyclability and performance of sodium-air batteries using ionic liquids (ILs) as advanced electrolytes. Researchers have shown that different electrolyte mixtures and concentrations produce different solvation environments for the Na+ ion, which influences the Na deposition. Publications in this area in 2018 include The Journal of Physical Chemistry C, Chemical Communications and Advanced Energy Materials.

Thermocells:

Research into devices for harvesting low-grade waste heat – called thermocells – focused primarily on developing new redox couples and quasi-solid state electrolytes. Four new cobalt based complexes were investigated, and the first use of a water soluble cobalt redox couple for thermal energy harvesting was reported. Hydrogels containing an iron based redox couple and ionic liquids were prepared, along with PVDF-based polymers for solidifying ionic liquids containing cobalt complexes.

224 JOURNAL PUBLICATIONS

LEFT: Thermocells are used to harvest low-grade waste heat.

Collaborative Centres26

These results were published in Sustainable Energy & Fuels, ChemSusChem, Electrochimica Acta, and the Australian Journal of Chemistry.

Modelling:

Modelling continues to be an important tool for the development of ionic liquids as electrolytes. An in-depth theoretical study of ion dynamics in a concentrated room temperature ionic liquid focussed on how the solvation structure of the cation changed with salt concentration and how this affected its dynamics. High salt concentration ionic liquids are an exciting new avenue for the development of more effective sodium and lithium batteries. This research was published in Journal of Physical Chemistry C.

The new method we developed that combines molecular simulation technique with quantitative HOESY Nuclear Magnetic Resonance analysis has demonstrated to be a powerful tool in unravelling ion-ion coordination structure at the microscopic level, and was used to investigate electrolyte materials in our research. This work has been published in Journal of Physical Chemistry Letters as a front cover paper (see p. 19).

International collaborations:

Deakin University and ACES are now Partners in a European Master Course 'Materials for Energy Storage and Conversion' (MESC) – a two-year education program in Materials Science and Electrochemistry. The partners in the program include five universities in four European countries (France, Poland, Slovenia and Spain), universities in USA (Drexel) and Australia (Deakin), a European Research Institute (ALISTORE), the French Network on Energy Storage (RS2E), the Slovenian National Institute of Chemistry (NIC) and a leading Research Center in Spain (CIC Energigune).

These universities host world-renowned, leading research teams in the field of energy related materials.

In 2018, ACES at Deakin University hosted two students for their research project, and we welcomed one of them back to begin her PhD studies at IFM Burwood. In 2019 a MESC student is working on a project on thermal energy harvesting, and we look forward to hosting many more MESC students in the coming years.

Our collaborations with CICEnergiGUNE and Polymat in Spain are going well in the energy storage area, with several activities during 2018.

Prof Forsyth is an Ikerbasque Professor in POLYMAT (the University Basque Country) where she collaborates with the Innovative Polymers group and supervises research projects related to sustainability. Dr Nagore Ortiz-Vitoriano visited IFM-Deakin University for two weeks to discuss ongoing projects as well as future collaborations on electrodes for sodium-oxygen batteries.

Dr Cristina Pozo-Gonzalo visited CICenergiGUNE and delivered an invited departmental presentation in 2018. This collaboration was translated into a paper published in Journal of Physical Chemistry C.

During 2018, we had several visitors from Polymat, including Asier Fernandez and Leire Meabe working on solid electrolytes for Na and Li batteries, respectively, in collaboration with different members of IFM-Deakin for four months within the framework of the European Project IONBIKE (H2020-MSCA-RISE-2018). As a result of this collaboration, two papers were published in Electrochimica Acta.

BELOW: ACES Director, Prof Gordon Wallace and Associate Director, Prof Maria Forsyth at the IFM Annual Conference in Geelong.

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The Energy Pipelines CRC (2010-2019) has enabled research and training to support Australia’s energy pipeline industry. Deakin University leads the EPCRC program on coatings and corrosion, which is headed by Prof Mike Yongjun Tan. The Deakin research has facilitated significant progress in developing a pipeline corrosion monitoring and prediction system (see page 13), and in understanding corrosion and protection of complex industry structures such as shore-crossing and HDD pipelines.

We have six PhD students graduated from EPCRC funded projects and have published a long list of leading journal and conference papers (for instance, some 19 journal and major conference papers were prepared based on these projects in 2018).

There are two major challenges facing the energy pipelines industry: The introduction of future new fuels such as hydrogen, and the aging of the pipelines.

Therefore some of our preliminary and pioneering work needs to be further explored in order to contribute to the future of the industry. In particular, several challenges have been identified as research issues for the new Future Fuels CRC.

• Potential infrastructure integrity and safety issues associated with decarbonised energy delivered to consumers using gas networks.

• Lack of confidence to repurpose existing infrastructure to transport and store future fuels safely, reliably and economically.

• Needs for solutions to address the impact of future fuels on the integrity of new and existing infrastructure.

• New materials for effective and safe transport and storage of new energy fluids.

All EPCRC research projects are due to be completed by April 2019. Deakin University is part of the new Future Fuels CRC which became operational at the end of 2018.

ENERGY PIPELINES COOPERATIVE RESEARCH CENTRE (EPCRC)

Enabling safer, more efficient and reliable pipelines to meet Australia's growing energy needs.

NFPCA

The National Facility for Pipeline Coating Assessment (NFPCA) provides research, development and testing for the Australian pipeline industry. It has successfully provided an independent testing service which is able to perform standard and custom-designed energy pipeline coating testing.

The NFPCA is unique in Australia and is essential for building up a capability for pipeline coating selection and development research. It also performs commercial independent coating tests for coating manufacturers, suppliers, applicators and end users in Australia and overseas.

LEFT: The NFPCA performs independent coating tests for the Australian and international pipeline industry in a NATA accredited laboratory.

BELOW: Corrosion is a major issue for Australia’s 35,000 km gas pipeline network.

Collaborative Centres28

Helping catalyse the transformation of Australian manufacturing.

INNOVATIVE MANUFACTURING COOPERATIVE RESEARCH CENTRE (IMCRC)

The IMCRC is a Cooperative Research Centre that helps Australian companies increase their global relevance through research-led innovation in manufacturing products, processes and services. IFM, with industry partner Carbon Revolution, was awarded a $15million research and development project, facilitated through the IMCRC.

This project, which is funded until mid 2020, will cover many different areas of carbon fibre composite materials and manufacturing. Specifically, these areas are new high temperature resin systems, low cost carbon fibre, preforming, inner core materials, surface finish, thermal protection, HP-RTM and Industry 4.0 initiatives.

Overall, the objectives are to develop materials and processes more suitable for high-volume manufacturing, which is a challenge for any carbon fibre product and particularly for a carbon fibre automotive wheel.

A unique aspect of the project is having the Deakin/IFM team based at the Carbon Revolution facility on the Deakin campus. This ensures a close alignment with a rapidly growing, high technology company that is a world leader in carbon fibre wheels for automotive applications. Vehicle manufacturers globally have shown a strong interest in accessing this technology, both for its efficiency and performance benefits, as well as its marketing impact.

The team in place to deliver this project are specialists from a variety of different areas, both local and international, and will be further expanded in 2019.

By being based onsite at Carbon Revolution, the team is able to collaborate closely with the product, materials and manufacturing teams, conduct real world trials and get rapid feedback about whether something is viable, while at the same time being able to utilise the world class facilities and expertise within the composites group at IFM.

Already the project has made inroads into a number of different areas with some promising results. It is expected some of this development work will be incorporated into future production carbon fibre wheels and be part of the continued innovation at Carbon Revolution.

RIGHT: Carbon Revolution’s carbon fibre wheel – new research aims to support high volume production.

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A globally unique, open-access carbon fibre/composite research facility is conducting strategic research projects with industry.

The Carbon Nexus research facility at IFM has continued to broaden its research activities and expand its operations. In 2018, we completed our fifth year of operation as the world’s only open-access carbon-fibre research facility.

Highlights• We extended our carbon fibre

processing building and installed new prototype equipment on the carbon fibre Pilot-Scale processing line to support the commercialisation of technology licensed to LeMond Composites.

• We signed a memorandum of understanding with the Open Hybrid LabFactory of the Technical University of Braunschweig, Germany, as part of the expansion of the international partnership network for this applied hybrid materials research centre.

• We announced a partnership with leading wind energy solution provider, Vestas, to improve the compressive strength of carbon fibre composite materials for wind turbines.

• We installed and commissioned a new Haake twin-screw reactive compounder to enable new research into thermoplastic composite materials.

• We commissioned an innovative new carbonisation research tool, the Carbonisation Simulator, developed in collaboration with Furnace Engineering and CSIRO.

Awards• The 2018 Advance Award for

Advanced Manufacturing was awarded to Carbon Nexus Director, Mr Derek Buckmaster. The Advance Awards celebrate international Australians, either living abroad or who have returned home following high achievement overseas, who exhibit remarkable talent, exceptional vision and ambition.

• Dr Omid Zabihi received the Alfred Deakin medal for best doctoral thesis at the October graduation ceremony. Omid’s thesis was on the topic of Chemically Modified Nanoparticles towards Multifunctional High-performance Polymer Nanocomposites. Omid completed his PhD under the supervision of A/Prof Minoo Naebe.

• Researcher Dr Azam Oroumei received a “best oral presentation” award at the 5th Global Conference on Polymer and Composite Materials 2018 in Kitakyushu City, Japan.

• PhD student Dan Eyckens was awarded Deakin University’s prestigious Rex Williamson prize (see p. 11).

Research Activities and Collaborations

Carbon Fibres:

• We commenced a two-year research agreement with LeMond Composites to support the scale-up and commercialisation of low-cost carbon fibre rapid oxidation technology licensed from Deakin University.

We completed several industry-funded research projects on carbon fibre processing, with companies including Solvay and Gale Pacific.

Carbon composites:

• A new research project was funded under the Victoria-Jiangsu Program for Technology investigating the development and industrialisation of flame retardant epoxy resins for aerospace carbon fibre composites, led by Prof Russell Varley.

CARBON NEXUS

ABOVE: Precursor fibre on the pilot line at Carbon Nexus.

HIGHLIGHT PUBLICATION: A/Prof Luke Henderson and his group, together with Prof John Moses from La Trobe University had a paper published on

the cover of ChemPhysChem. Their paper, Modification of Carbon Fibre Surfaces by Sulfur-Fluoride Exchange Click Chemistry, describes the first modification of a carbon surface (in this case carbon fibre) using the sulfur-fluoride exchange (SuFEx) reaction.

Collaborative Centres30

The BatTRI-Hub builds on IFM’s expertise in key energy technologies and advanced polymer materials. It has been a big year for the BatTRI-Hub with the announcement of storEnergy, the ARC’s $4.5M Industrial Transformation Training Centre on Future Energy Storage Technologies. storEnergy brings together five universities, 10 companies, as well as CSIRO and DSTG to help solve some of the challenges facing Australia’s emerging battery industry. There are 11 PhD projects across the Centre which focus on the three platforms of materials design and synthesis, manufacturing, and device integration.

BatTRI-Hub projects are centred around the development of advanced electrolytes based on the following classes of materials: • ionic liquids • plastic crystal composites • polymer composites.

HighlightsNew benchmark pouch cells:

We have successfully demonstrated the operation of lithium metal pouch cells using our ionic liquid electrolytes for over 200 cycles. The performance of these high capacity cells is amongst the very best lithium metal pouch cells reported in literature to date. This is a significant milestone for the validation of our materials.

Automated stacking unit:

A unique and locally built robotic stacker (by Sensorplex) has been installed to increase the capacity of the pouch cells for assembly into packs and demonstration in real devices.

High voltage electrodes:

We have started to investigate the ability of our electrolytes to operate with new low-cobalt electrode materials that can operate at voltages above 4.5V. We have achieved some promising early results with over 100 cycles demonstrated in a pouch cell.

Collaboration with UQ:

An exciting new collaboration is underway with Prof Lianzhou Zhang, from the University of Queensland, who is a leader into the development of new high voltage and low cobalt cathodes. The University will provide BatTRI-Hub with new electrode materials for assembling into prototype cells.

New separators needed: BatTRI-Hub researchers were the first to report on the critical role of the separator in determining the lifetime of lithium metal cells. We are now seeking to design new separators to boost the performance of our cells.

BatTRI-Hub Director, Prof Patrick Howlett, gave invited presentations at the USA’s National Renewable Energy Agency and NASA on advanced materials for beyond lithium-ion battery technologies. Dr. Robert Kerr presented to General Electric in Bangalore and was part of an Australian delegation to the first Australia-Japan Battery Workshop in Osaka, which included a meeting with Panasonic.

BELOW: The new robotic stacker increases our capacity to assemble pouch cells into packs and for demonstration in real devices.

BATTERY TECHNOLOGY RESEARCH AND INNOVATION HUB (BATTRI-HUB)

A unique, world class research and innovation centre focused on advanced battery prototyping and the commercialisation of energy storage technologies.

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The Australian Centre for Infrastructure Durability (ACID) connects industry with Australia’s leading researchers and facilities. In 2018, we worked with a number of new industry partners. In Australia:• Cement Concrete & Aggregates

Australia• GeelongPort• Port of Portland• Renex Op Co• Sydney Opera House Trust LTD• The Remediation Group PTY LTD

and internationally:• Concrete Repairs• RPCP

During 2018, ACID researchers commenced industry-funded projects to assess the remaining service life of large structures and to provide expert advice on remediation strategies. We progressed existing research projects on carbon nanotube reinforced concretes (an ARC Linkage with industry) and embedded wireless sensors for chloride detection in concretes (a PhD project), and initiated several others.

Lab tests of carbon nanotube reinforced concrete:

Field trials are underway (June 2019) to assess fresh and hardened properties of carbon nanotube reinforced concrete mixes. Miniaturised chloride sensors (the size of coarse aggregates) have been developed and tested and planning is currently underway to trial them in concrete mixes.

In early 2018, Dr Will Gates and Prof Frank Collins were awarded an ARC Special Research Initiative project to incorporate heat-treated soils (from soil remediation projects) into concretes to both add value to a waste resource and to minimise wastes going to landfill. Other research activities included:

• Trials on the use of calcined clays and calcined clays with limestone as partial replacements for ordinary Portland cement

• Addition of carpet fibre wastes to concrete for pavements

• Addition of waste textile (cotton fibre) in concretes for pavements

• Trials on the corrosion inhibition effects of rare-earth compound-modified polymer coatings for reinforcing steel

• Assessing the thermal-electric capacity of carbon-nanotube reinforced concrete

• Studying hydration processes of early cement hydration through investigations of bleed water and pore solution chemistry.

ACID personnel attended and presented at several conferences:

• Australasian Structural Engineering Conference, Adelaide

• 5th International Federation for Structural Concrete Conference, Melbourne

• 2nd World Congress on Industrial Minerals in Qingyang, Anhui, China

• 8th International Congress on Environmental Geotechnics, Hangzhou, China.

ACID PhD student Sobhan Hosseini was awarded second prize for his presentation at the IFM Research Conference. Sobhan spoke about his project: Innovative self-diagnosing civil infrastructure for ensuring durability.

BELOW: Sobhan Hosseini received an award for his presentation at the IFM conference.

AUSTRALIAN CENTRE FOR INFRASTRUCTURE DURABILITY (ACID)

An integrated national platform to connect industry with researchers to develop new solutions for corrosion and infrastructure durability.

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Name Course Thesis Title

Ajesh Antony PhD Microstructural evolution of deep cryogenically treated steel

Nicholas Babaniaris PhD Thermomechanical Streaking Defects in Architectural Aluminium Extrusions

Kathleen Beggs PhD Optimising Surface Functionalisation of Carbon Fibre to Enhance Interfacial Adhesion

Erwan Castanet PhD Manufacturing of Bio-composites for Automotive Applications

Jerome Cornu PhDEffect of Strip-Cast Induced Micro-Segregations on Phase Transformations in Nano-Bainitic Steels

Saeed Dadvar PhD 3D Printing of Carbon Preforms from a Bio-renewable Feedstock

Sharmistha Dhara PhD Precipitation Behaviour in Ti-Mo Bearing Microalloyed Steel

Ahmad Erfani Moghadam ME Flexible Roll Forming of Variable Depth Profiles

Seyed Fakhrhoseini PhDPathways to reduce energy consumption in thermal stabilisation process of polyacrylonitrile fibre

Aleksey Falin PhD Mechanical properties of two-dimensional nanomaterials

Ye Fan PhD Lithium-Sulfur Batteries with Improved Performance

Houlei Gan PhD RAFT Polymers Containing Fatty Acid Biomass Derived from Cotton Seed Oil

Qi Han PhD Green Solvent Approaches for Wool Surface Treatment

Lu Jiang PhDThe Effect of Molybdenum on Precipitation Behaviour in Low-Carbon Strip-Cast Steels Containing Niobium

Zahra Komeily Nia PhD Graphene radicals: manipulation and applications

Yujia Liang PhD UV Protective Properties and Applications of Melanin and Melanin-based Materials

Yuchen Liu MEComposite Nanosheets of Graphene and Boron Nitride for Lubrication ApplicationPlasma functionalized nanomembranes for environmental purification

Maxime Maghe PhDInvestigating novel stabilization treatments for economical polyacrylonitrile-based carbon fibre manufacture

James Maina PhD Metal Organic Framework based Catalytic Reactors for CO2 Conversion

Faezeh Makhlooghiazad PhD Novel solid state sodium electrolytes base on organic Ionic plastic crystals

Mohammad Maniruzzaman PhD Investigation of plasma-treated water for plant growth

Jonathan Lane McDonald PhD Novel Gas Separation Membranes Based On Organic Ionic Plastic Crystals

Keiran Pringle PhD An Investigation into Short Polymer Fibre Production in Fluid Systems

Jun Rao PhD Proton conducting membranes for energy applications

Matthew Russo MPhil Development of Quasi-Solid State Electrolytes for Thermal Energy Harvesting

Nishat Sharma PhD Short-nanofibre-based hierarchical structures for enzyme immobilisation

Irin Sultana PhD Alloy based anode materials for potassium-ion batteries

Arun T.A. PhDPlasma-Treated water as an Anodizing Electrolyte for Fabrication of Titanium Dioxide Nanotubes

Rameshkumar Ramkaran Varma PhD Study and development of Mg2Sn based thermoelectric alloys

Guilong Yan PhDAdvanced Slot Needleless Electrospinning and Air Filtration Properties of Slot Electrospun Nanofibres

Yundong Zhou PhDDevelopment of nano-structured plastic crystal/polymer composites as solid state electrolytes

STUDENT COMPLETIONS

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INDUSTRY PARTNERS

AustraliaAdvanced Metallurgical Solutions Pty LtdAECOMALS Global Pty LtdAMOG EngineeringAnti Corrosion TechnologyAPT Management Services (APA Group)ArcActive LtdAtterisAusComposites Manufacturing FacilityAusteng Engineering SolutionsAustmine LtdAustral Services GroupAustralia Defence ApparelAustralian Carbon Innovation (ACI)Australian Foundry InstituteAustralian Innovation CentreAustralian National Fabrication Facility Australian Pipeline Industry AssociationAustralian Roll Forming Manufacturers (ARM)Australian Wool Innovation LtdBackwell IXLBarwon WaterBHP BillitonBluescope Steel Pty LtdBrown Coal Innovation Australia LtdCallidus Welding SolutionsCapral LtdCarbon Revolution Pty LtdCarpenter Technology CorporationCast Bonding Australia Pty LtdCavalier Woolscourers LtdCharles Parsons Pty LtdCleanTeq LtdConfluxConveyor Products and Solutions Pty LtdCotton Research and Development CorporationCPE Systems Pty LtdCSL LtdCytomatrix Pty LtdDefabDefence Materials Technology Centre (DMTC Ltd)Defence Science Technology Group (DST Group)

Delaminating Resources Pty LtdDemtechDenso (Australia) Pty LtdDraggin Jeans Pty LtdEar Science Institute Australia IncorporatedEco2000 Pty LtdEden Energy LtdEnergy Pipelines CRCEP Robinson Pty LtdExcellerate Australia (formerly Auto CRC)FMP BendixFord Motor Company Research & Innovation CenterFuturis Pty LtdGale Pacific LtdGalvanisers Association AustraliaGeelong Abrasive BlastingGeelong Textiles Pty LtdGekko Systems Pty LtdGeneral Motors Holdings LLCGeofabrics Australasia Pty LtdGodfrey Hirst CarpetsGraphene Manufacturing Australia (GMA)GT RecyclingH-E PartsHeiQ AustraliaHonda R&D Co. LtdHorizon Fuel Cells TechnologiesHydrochem Pty LtdImagine Intelligent MaterialsITW ConstructionIXL Metal CastingsJemenaKeech Castings Australia Pty LtdLabelmakersLiberty OneSteel Pty LtdMaterials Solutions Pty LtdMcConnell DowellMETS Ignited Australia LtdMPC GroupMRI (Australia) Pty LtdMurphy Pipe and Civil Constructors (Aust) Pty LtdNacap AustraliaNanoCarbon Pty LtdNewcrest Mining Ltd

Nplex Pty LtdPlanet InnovationPPG Industries Australia Pty LtdQenos Pty LtdQIC Protective CoatingsQuickStep Technologies Pty LtdROC Oil (WA) LtdRockingham Desalination Research FacilityRural Industries R&D CorporationSantos Geelong Pty LtdSeagasShell Refinery (Australia) Pty LtdShinil Chemical CompanyStockbrands Co Pty LtdStudco Building SystemsSupacore CompressionSussex Materials SolutionsThyssenKrupp Mannex Pty LtdTransport for NSWTransurbanTrelleborg Engineered Systems Australia Pty LtdTunnelwellUnited Surface Technologies Pty LtdUniversal Corrosion CoatingsVolgrenWeir Minerals Australia Pty LtdXefcoZhik Pty Ltd

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InternationalAccident Compensation Commission (NZ)Air Force Office of Scientific ResearchArcActive Ltd (NZ)ATA Carbon Fibre Tech (Guangzhou)Baosteel (China)Bharat Forge (India)BOHN Environmental Engineering & Complete Equipment Corp Ltd (China)The Boeing Company (USA)BOLT Technologies (China)Carpenter Technology Ltd (USA)Central Silk Board (India)Chinese Iron and Steel Research Institute Cotton IncorporatedCytec (Canada)Data M Sheet Metal Solutions (Germany)Donaldson Co (USA)Dongfang Turbine Co (China)DowAksa (Turkey, USA)ELG Carbon Fibre (UK)Esquel (China)Fabric Plus Ltd (India)Ford USAGE (India)General Motors (USA)H&M Foundation (Sweden)Hebei Guanchengyuexing Technology Co LtdHeiQ Materials AG (Switzerland)Healthline Ltd (India)Holding Company Composites (Russia)Hydro-Quebec (Canada)Hyundai Motor Company (South Korea)Indian Oil Corporation (India)Jiangsu Shisong New Material Technology Co Ltd (China)Jilin Tangu Carbon Fiber Co Ltd (China)

Korea Institute of Industrial Technology (KITECH)LeMond Composites (USA)LG ElectronicsLincoln Agritech (NZ)Lintech (USA)Logistik Unicorp (Canada)Lubris Biopharma (USA)Mahindra & Mahindra (India)Metallicum Inc (USA)Motor Accidents Insurance Board (NZ)Multimatic (Canada)Nantong Xinau TechnologyOffice of Naval Research – Global (USA)Petroliam nasional Berhad (PETRONAS) (Malaysia)Plan InternationalPolygauss Ltd (UK)POSCO (South Korea)Reliance (India)ROCKWOOL (Denmark)SABIC Global TechnologiesSafran Power Units (France)Seeyao Electronics Company Ltd (China) Sichuan ShangZhiDeng New Materials Co (China)SMA TEX FAB (India)Solvay – Cytec Carbon Fibers (USA)Straumann Pty Ltd (Switzerland)Tata Steel (India)Tecnalia (Spain)Terves Inc (USA)Thermopore Materials Corporation (USA)Toyota Motor Engineering & Manufacturing (USA)

Universal Alloy Corporation (USA)US Air Force Office of Scientific Research (USA)US Asian Office of Aerospace Research and Development (USA)US Army International Technology Center, Pacific (USA)Wellcome Trust (UK)Wuhan Iron and Steel (Group) Corporation (China)Xiamen FilterTech (Runner Group) (China)Yuntong Nanomaterials Technology Co Ltd (China)

Contact usFor further information, please visit the Institute for Frontier Materials website at deakin.edu.au/ifm

Email: ifm-enquiries@deakin.edu.au Telephone: +61 3 5247 9255

Deakin University 75 Pigdons Road Waurn Ponds VIC 3216 Australia

Deakin University CRICOS Provider Code: 00113B

deakin.edu.au/ifm

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Environmental Credentials

FSC® Certified printers:Monza Recycled contains 99% recycled fibre and is FSC® Mix Certified, which ensures that pulp is derived from well-managed forests and recycled wood offibre. Monza Recycled is manufactured by an ISO 14001 certified mill.Other printers:Monza Recycled contains 99% recycled fibre, and elemental chlorine free pulp which ensures that pulp is derived from well managed forests and recycledwood of fibre. Monza Recycled is manufactured by an ISO 14001 certified mill.

Spicers Icons

Applications

Annual reports Books Brochures CalendarsDirect mail Folders Menus Posters Prospectus Wine Lists

Printing Tips

Scuff protection recommendedScoring recommended over 170gsmDigital printing compatible – NextPressDigital printing compatible – Indigo

We always recommend that the sheet is test and trialled before commencing a print job. This is to determine that the sheet is suitable for the particularmachine and the particular print job.

Product Range

Finish Colour GSMSatin White 90gsm, 100gsm, 115gsm,

130gsm, 150gsm, 170gsm,200gsm, 250gsm, 300gsm,350gsm,400gsm

Date of Issue Jun 2019

Environmental Credentials

FSC® Certified printers:Monza Recycled contains 99% recycled fibre and is FSC® Mix Certified, which ensures that pulp is derived from well-managed forests and recycled wood offibre. Monza Recycled is manufactured by an ISO 14001 certified mill.Other printers:Monza Recycled contains 99% recycled fibre, and elemental chlorine free pulp which ensures that pulp is derived from well managed forests and recycledwood of fibre. Monza Recycled is manufactured by an ISO 14001 certified mill.

Spicers Icons

Applications

Annual reports Books Brochures CalendarsDirect mail Folders Menus Posters Prospectus Wine Lists

Printing Tips

Scuff protection recommendedScoring recommended over 170gsmDigital printing compatible – NextPressDigital printing compatible – Indigo

We always recommend that the sheet is test and trialled before commencing a print job. This is to determine that the sheet is suitable for the particularmachine and the particular print job.

Product Range

Finish Colour GSMSatin White 90gsm, 100gsm, 115gsm,

130gsm, 150gsm, 170gsm,200gsm, 250gsm, 300gsm,350gsm,400gsm

Date of Issue Jun 2019