Jump-starting battery advancements

Steve Martin
Steve Martin of materials science and engineering has won a grant to study new and safter materials for batteries.

Solid electrolytes are key to making batteries more powerful and safer

For more than 30 years, Steve Martin has been studying and characterizing different materials to identify properties that would allow for optimal energy transfer and storage in batteries. He says ceramic-like sulfide glasses may hold the solution, and now he’s working on a project to scale up his fundamental research and ultimately assemble and test batteries with this technology.

Martin, an Anson Marston Distinguished Professor in Engineering in Iowa State University’s Department of Materials Science and Engineering and an associate of the U.S. Department of Energy’s Ames Laboratory, says his life’s work is inspired by the need to reduce the world’s reliance on fossil fuels.

“We’ve realized the negative consequences of burning oil, and we need to find ways to improve batteries to better support alternative energy sources and applications, like wind energy and electric automobiles,” he adds.

Martin’s latest project aims to create a new type of electrolyte based on solids instead of the liquid electrolyte we see in today’s lithium-ion batteries.

“The electrolyte’s job is to separate a battery’s electron-producing anode from its electron-accepting cathode. Because liquid electrolytes are highly flammable, batteries have been purposely designed with 10 times less energy density than is actually possible to avoid catching fire,” he explains.

The solid electrolyte Martin is developing is stronger and non-flammable compared to liquid electrolytes. These two factors alone will allow the researchers to create a battery that can store more energy at a higher voltage and that is safer for a wider range of temperatures, both hot and cold.

Finding the right chemistry for these electrolytes has taken Martin and several other researchers years to discover, but it’s been worth the wait. The new batteries will essentially be thin film, manufactured in such a way that they will be denser and more durable, and they will help improve a range of alternative energy technologies.

Martin’s work is most recently supported by a three-year, $2.5 million grant from the U.S. Department of Energy’s Advanced Research Projects Agency – Energy and its new Integration and Optimization of Novel Ion-Conducting Solids (IONICS) program. There’s additional, cost-share funding from Iowa State and the Iowa Energy Center.

The funding also supports the work of Jing Xu, a newly hired assistant professor of materials science and engineering, three postdoctoral researchers, two doctoral students and three undergraduates.

“With Dr. Xu’s expertise in assembling and testing batteries and my understanding of making electrolytes, we’re going to see some significant advancements through this project,” Martin says. “It’s great to see momentum picking up around battery research, because I know progress in this area will bring tremendous value to society.”

FactBoard: Visualizing Data

Guiping Hu
Guiping Hu, associate professor of
industrial and manufacturing
systems engineering

Creating a real-time data-driven visual decision support system for the factory floor

Guiping Hu has set out to make manufacturing production more efficient. The associate professor of industrial and manufacturing systems engineering is working on a project for the Digital Manufacturing and Design Innovation Institute (DMDII) to develop a shop floor decision support system called FactBoard.

DMDII is a federally-funded research and development organization of UI LABS focused on projects that demonstrate and apply digital manufacturing technologies to increase the competitiveness of American manufacturing. Hu says FactBoard fits the bill because it will help manufacturers respond to changes in real  time.

The project aims to convert thousands of existing, real-time data inputs into a collection of visual dashboards, creating a record of transactional data that can be used to make informed decisions about production.

“Each manufacturing floor is different – there may be a logistics problem or a production process that needs adjusted,” Hu says. “With FactBoard, we can use information based on data that is already available, set up parameters and organize data based on the needs of each shop.”

At Iowa State, four faculty members, five graduate students and several undergraduate research assistants are helping Hu with the project. Hu’s also working with Boeing, John Deere, Proplanner and Factory Right to develop the technology.

The group has been surveying manufacturing floors to identify 5-10 key problems that are common across industries. Narrowing that list down hasn’t been an easy task, but it’s why Hu says having a range of companies involved at the beginning of the project is so important.

She adds that because she has such a wide audience for FactBoard, the team is creating a system that can be incorporated within individual IT frameworks through XML integration methods.

Once FactBoard is implemented, Hu says manufacturing facilities can use it to improve how they manage inventory and on-time delivery methods as well as the efficiency and effectiveness of production equipment.

 

Ecosystems of support

Joe Zambreno
Joe Zambreno, associate professor of electrical and computer engineering

Promoting an accessible, responsive approach to engineering education

A new initiative in the Department of Electrical and Computer Engineering will help a pool of talented students pursue a degree in engineering.

The project, called ECSEL: Electrical, Computer, and Software Engineers as Leaders, is part of the National Science Foundation’s Scholarships in Science, Technology, Engineering, and Mathematics (S-STEM) program, which provides financial support to help low-income, academically talented students obtain STEM degrees and enter the workforce or graduate study.

The program will fund 582 scholarships over the next five years for students majoring (or preparing to transfer) in electrical engineering, computer engineering and software engineering.

“We’re also creating what we are calling an ecosystem of academic and co-curricular support for these students, providing them with an experience that will not only encourage them to stay in their STEM field of choice but also give them the tools to excel,” says Joe Zambreno, associate professor of electrical and computer engineering and principal investigator of the project.

The program is a multi-institutional, collaborative partnership between the Department of Electrical and Computer Engineering, Program for Women in Science and Engineering, Des Moines Area Community College and Kirkwood Community College, and Zambreno says the group will leverage the individual successes of each partner as the program grows.

“We are looking at the entire process of earning a degree in STEM and identifying ways to make it better, whether it’s making sure classes transfer from community college to Iowa State or offering leadership development opportunities that keep the students engaged in their learning and growth,” he adds.

An important aspect of the project will be the team’s research studies of the ecosystem of supports that will accompany the project. Zambreno says the group will investigate how underrepresented minorities, including women, in STEM fields develop their professional and career identity using both qualitative and quantitative metrics.

“Knowing what motivates individuals can help us make adjustments to the learning environment we offer,” he adds. “The more we can do to encourage diversity in thought and culture in STEM, the better the fields will be.”

Characterizing antimicrobial resistance

Adina Howe, Heather Allen, Tom Moorman, and Michelle Soupir
Adina Howe, assistant professor of agricultural and biosystems engineering, Heather Allen and Tom Moorman from USDA’s Agricultural Research Service, and Michelle Soupir, associate professor of agricultural and biosystems engineering.

Interdisciplinary team uses systems approach to sequence microbial genes

Historically, treatments for disease-causing microorganisms have relied heavily on the use of antimicrobial drugs.

Adina Howe says this very practice (both when it’s used properly and when it’s misused), along with naturally occurring phenomena, has accelerated how quickly microorganisms are evolving into resistant strains.

“If we continue to see bacteria, fungi, viruses and parasites increasingly becoming resistant to antimicrobial drugs, common treatments for infections and minor injuries will become ineffective,” explains Howe, an assistant professor of agricultural and biosystems engineering.

She adds that other factors, like poor infection control practices, inadequate sanitary conditions and inappropriate food handling, can encourage the spread of antimicrobial resistance.

To better understand antimicrobial resistance and how it enters the environment and food chain, Howe is leading a research team that is studying the phenomenon in agricultural environments.

The multidisciplinary group, which includes Michelle Soupir, an associate professor of agricultural and biosystems engineering at Iowa State, Heather Allen and Tom Moorman from USDA’s Agricultural Research Service, and Shannon Hinsa, an associate professor of biology at Grinnell College, recently received a nearly $1 million, three-year grant from the U.S. Department of Agriculture’s National Institute of Food and Agriculture.

The group will be using a systems approach in its research, adding insight from engineering, microbiology, soil science and health experts.

Iowa State’s team is working to improve a technology that Howe designed to efficiently sequence the genes of microbes. The tool, called DARTE-QM, will allow the group to hone in microbial resistant gene reservoirs in the environment.

To begin its work, the team is studying manure, soil and water samples gathered from swine operations.

“Using DARTE-QM, we can take DNA from the environment and look at its fingerprint to identify bacteria and which genes might allow antimicrobial resistance to develop. We can target hundreds of resistant genes at the same time,” Howe explains.

The group will also consider environmental factors, like production practices or weather-related occurrences, as it studies where antimicrobial resistance occurs and why it continues.

Howe says the group also studies various strategies to mitigate the emergence, spread and persistence of antimicrobial pathogens, and that this endeavor absolutely requires input from multiple disciplines and perspectives. Currently, the team is evaluating the effectiveness of various manure storage strategies and their impact on reducing resistant bacteria.

“If everyone on this team wasn’t participating in this project, there’s no way we would be able to accomplish our goals,” Howe says. “It’s a whole team of dedicated, hardworking people who bring their expertise to solve a very challenging problem. The end result will be a better understanding of how resistance develops and how we might reduce it.”

Safer, more sustainable aviation

Des Moines International Airport pavement testing area
Halil Ceylan’s research team has built the world’s first electrically conductive heated pavement test site at an airport. This photo shows the technology performing well during a snow event on Dec. 10, 2016, at the Des Moines International Airport.

Iowa State’s partnership in FAA program advances airport runways, operating technology

Engineers from Iowa State are part of a collaborative partnership to help navigate and improve the complex, ever-changing aviation industry with innovative ideas and new research projects.

“When you look at addressing any problem in the field, from the weather to security to operational efficiencies, you know it’s going to take a community of minds coming together to create solutions,” says Halil Ceylan, professor of civil, construction and environmental engineering and director of the Program for Sustainable Pavement Engineering and Research at Iowa State’s Institute for Transportation.

Ceylan also serves as a site director for the Federal Aviation Administration’s Center of Excellence Partnership to Enhance General Aviation Safety, Accessibility and Sustainability, or PEGASAS.

The partnership, which was established in 2012, is led by researchers at Purdue University and includes Iowa State, The Ohio State University, Georgia Institute of Technology, Florida Institute of Technology and Texas A&M University as core members.

Together, the researchers are working with the federal government and industry to study a variety of general aviation issues.

Ceylan is using his expertise in pavement engineering to lead a project that aims to create a hybrid heated pavement system. The system includes electrically conductive concrete, nanostructured superhydrophobic coatings and hydronic heated pavements that will keep airport pavement surface temperature above freezing during winter weather operations and reduce airport incidents related to unfavorable conditions.

Iowa State researchers are contributing to several other projects, including developing an FAA pavement marking presence tool, analyzing and processing data regarding airport safety, and testing how LED lighting performs under extreme conditions.

Ceylan says he’s also excited about the student outreach component of PEGASAS. Two Ph.D. students from Iowa State were able to travel to FAA’s William J. Hughes Technical Center for two months to learn and apply their skills in a real-world setting.

“I participated in a similar fellowship as a graduate student, and I can honestly say it changed the trajectory of my career in such a positive way. It’s programs like these that will help shape the future of the aviation field. We have so many brilliant minds with so much to offer, we just need a way to get them involved, and PEGASAS is a great way to do just that.”

Increasing electric steel performance

Jun Cui
Jun Cui, associate professor of materials science and engineering and senior scientist at the Department of Energy Ames Laboratory

Materials research will make electric motors more efficient, cost effective

Can electric steel, a popular material that’s already a key functional material for modern society, get better? Jun Cui, an associate professor of materials science and engineering and a senior scientist at the U.S.  Department of Energy Ames Laboratory, says it can.

That’s why he’s leading a team of researchers who want to increase the amount of silicon in electric steel to 6.5 percent. If the group succeeds, the new steel can be used as the stator material to create an efficient, sustainable, non-rare-earth electric motor.

The team is currently working on a project that would advance electric steel to be used in the motors of electric vehicles. The work is supported by a three-year, $3.8 million grant from the DOE’s Vehicle Technologies Program.

Cui says using electric steel to develop the magnetic stator core of a motor can reduce eddy currents and heat and power loss in the motor. The motor would then be able to run at higher frequencies and have a higher power density, resulting in a smaller, more efficient motor.

To get to this point, the team has to overcome an issue with electric steel – it becomes brittle once you reach more than 4 weight percent silicon.

“When iron atoms are being mixed with a large number of silicon atoms, the brittleness comes from the silicon atoms having time to find each other and pair up,” Cui explains. “To bypass this brittleness, we are rapidly cooling the alloy so the silicon atoms have no time to pair.”

The work combines modeling and experimentation, and brings in research partners from the United Technologies Research Center in East Hartford, Connecticut; and the University of Delaware in Newark.

Experts from Iowa State and the Ames Laboratory will also contribute to the project, including Scott Chumbley, a professor of materials science and engineering and scientist for the Ames Laboratory;

Peter Collins, the Alan and Julie Renken associate professor of materials science and engineering and an associate scientist of the Ames Laboratory; Iver Anderson, a senior metallurgist for the Ames Laboratory and an adjunct professor of materials science and engineering; Valery Levitas, a Schafer 2050 Challenge Professor of aerospace engineering and an associate scientist of the Ames Laboratory; Frank Peters, an associate professor and associate chair of operations in industrial and manufacturing systems engineering; and Matthew Kramer, director of the Ames Laboratory’s Division of Materials Sciences and Engineering and an adjunct professor of materials science and engineering.

Self-destructing batteries

Reza Montazami with graduate students
Reza Montazami (center) with graduate students, Reihaneh Jamshidi (left) and Yuanfen Chen.

A practical solution for powering transient electronics

Researchers at Iowa State have made significant progress in an effort to make transient electronic devices completely autonomous.

Reza Montazami, an assistant professor of mechanical engineering and an associate of the U.S. Department of Energy’s Ames Laboratory, is leading a team that has developed a transient lithium-ion (Li-ion) battery that offers nearly the same voltage as commercial products and can disintegrate in 30 minutes.

These transient batteries, and the materials research and structural design behind them, will be crucial as the field of transient
electronics continues to grow.

“Devices that operate for short, defined periods of time and then self-destruct can be used in a range of applications, from healthcare to military and homeland security,” Montazami explains. “They offer a great deal of promise, but they currently still rely on an outside, non-transient, power source. If we can change that, we can make the devices even more beneficial.”

And that’s exactly what Montazami has set out to accomplish.

He and his team have combined Li-ion battery technology with a new physical–chemical hybrid transiency approach that breaks down a battery and dissolves its electrodes.

transient battery
ISU scientists have developed a working battery that dissolves and disperses in water. Illustration by Ashley Christopherson.

“The casing for the battery uses polymers that swell when immersed in a liquid, causing the nanocomposite electrodes to break and  disperse,” he explains. “Because the battery is designed to disintegrate both chemically and physically, it is very difficult to trace back to the owner even if the device were still physically present.”

At this point, the batteries are 5 mm by 6 mm, and 1 mm thick and can power a desktop calculator for approximately 15 minutes. And while they don’t completely disappear, Montazami says he will continue experimentation to advance the technology because of the value it could bring to even mainstream electronics.

“If we look at the bigger picture, we could see a consumer battery that could be dissolved once a person was done using it instead of that battery ending up in a landfill,” he adds.

The team is continuing to study the physical–chemical hybrid transiency platform to improve understanding of what interactions are at play. The group is also working to improve the performance of the battery for devices that use more power. That could mean making electrodes with higher area density or finding ways to connect several batteries.

The road to biorenewable asphalt

a new $5. 3 million Bio-Polymer Processing Facility located at Iowa State’s BioCentury Research Farm
A new $5. 3 million Bio-Polymer Processing Facility located at Iowa State’s BioCentury Research Farm

Researchers scale-up plans to use soybean oil to produce bio-polymers

A new Bio-Polymer Processing Facility located at Iowa State University’s BioCentury Research Farm gives researchers a broader understanding of what it would take to commercialize bio-polymers so they can be added to materials like asphalt.

Eric Cochran, associate professor of chemical and biological engineering, and Chris Williams, the Gerald and Audrey Olson Professor of civil, construction and environmental engineering, have been working together since 2010 to develop bio-polymers with soybean oil.

The professors originally set out to create a soybean based styrene-butadiene rubber. Early in their research, a member of Cochran’s team figured out how to polymerize soybean oil into a thermoplastic. “A thermoplastic can be solid at room temperature, but if you heat it up you can make new shapes or dissolve it into another material such as asphalt. This is something that has not been feasible until now,” Cochran says.

Using the fundamental Flory-Stockmayer theory, the team can predict when a polymer system will gel. “The gelation is the point in which the individual polymer chains connect and form a giant molecule,” explains Cochran. “The goal is to stop the process right before the gelation point to achieve a thermoplastic.”

Discovering thermoplastics has fueled several projects over the years, including working with Argo Genesis Chemical LLC, a sister company to Seneca Petroleum Co. Inc., of Crestwood, Illinois. Williams, who manages the Institute for Transportation’s Asphalt Materials and Pavements Program, has partnered with Seneca for more than 20 years. He says the shared knowledge and resource has led to significant advancements.

The partnership also made the Bio-Polymer Processing Facility at Iowa State a reality. Argo Genesis Chemical built the pilot plant and turned it over to Iowa State last summer.

The plant, which was designed specifically to produce bio-polymers from soybean oil, contains several industrial tanks all connected through a series of tubes, pipes, wires and hoses. The sensors on the equipment must be extremely precise due to the sensitivity of the polymer and chemicals involved.

Cochran and Williams are working to get enough of the polymer into asphalt so it can be viable as an asphalt modifier, resulting in a more sustainable approach to paving roadways.

A new model of engineering education

Diane Rover, professor of electrical and computer engineering, promotes new educational approaches in the classroom through a new interdisciplinary project
Diane Rover, professor of electrical and computer engineering, promotes new educational approaches in the classroom through a new interdisciplinary project

Collaborative course design will transform education and develop the next generation of engineers

Electrical and computer engineering technologies have evolved from simple electronics and computing devices to complex systems that profoundly change the world in which we live.

Designing these complex systems requires a new way of thinking, including developing social, professional and ethical responsibility.

As these advancements continue, faculty members at Iowa State are transforming the way they educate and prepare the field’s future workforce.

A team from the Colleges of Engineering, Human Sciences, Design, and Liberal Arts and Sciences are working together to create a new instructional model for course design in electrical and computer engineering.

The project, “Reinventing the Instructional and Departmental Enterprise (RIDE),” received a $2 million National Science Foundation grant to transform approaches to teaching and learning in electrical and computer engineering, especially in relation to design and systems thinking, professional skills such as leadership and inclusion, contextual concepts, and creative technologies.

The changes in educational approaches will be driven by RIDE’s cross-functional, collaborative instructional model for course design and will lead to different department structures and a more agile environment able to respond quickly to industry and social needs–and ultimately serve as a model for electrical and computer engineering departments across the country.

Another impact of the RIDE project will be broadening the participation of underrepresented students, especially undergraduate women, in the field of electrical and computer engineering. Project activities will emphasize inclusive teaching practices and learning experiences.

The RIDE project began this summer by developing strategies for managing change processes. During the first year, the project strategies will get underway, and by the second year, new versions of selected courses will be piloted. The electrical and computer engineering department will continually develop and refine department and curricular practices.

The College of Engineering is currently in the process of hiring a new chair for the Department of Electrical and Computer Engineering. This individual will serve as the principal investigator for the RIDE project, joining 14 current members of the team that includes the College of Engineering’s Dean Sarah Rajala.

The project was awarded under an NSF activity known as “RED,” which was created to help universities transform department structures, policies, practices and curricula to enable groundbreaking changes in undergraduate engineering education.

Making progress toward invisibility cloaks

Liang Dong
Liang Dong, associate professor of electrical and computer engineering

Meta-skin suppresses scattering microwaves, hides objects from radar detection

Two professors in electrical and computer engineering have made significant headway in an innovative stealth technology.

Liang Dong, an associate professor who researches micro-nanofabrication, liquids and polymers, and Jiming Song, a professor who studies electromagnetics, have combined their areas of expertise to create a flexible, stretchable meta-skin material that can render an object virtually undetectable by radar.

The meta-skin is made of metamaterials, or man-made materials that have properties not found in nature. These materials include an array of split ring resonators (SRRs) embedded in layers of silicone sheets. The resonators are filled with the liquid metal alloy galinstan and create small, curved segments of liquid wire that can absorb radar waves.

The researchers stretched multiple layers of the meta-skins along the surface of an object in a planar direction while also changing the spacing between the meta-skin layers in a vertical direction to trap microwaves and reduce the reflected portion of the waves.

“Within our microwave testing chamber, we have successfully demonstrated a cloaking effect when we wrapped the meta-skin around a dielectric cylindrical rod,” says Dong. “We saw a suppressed scattered field, which is an improvement from the more traditional technologies in place that only reduce backscattering.”

These tests showed radar suppression was about 75 percent in the frequency range of 8–10 gigahertz.

While these advancements have fairly obviously applications for the military, the researchers also want to look at how to put this technology to use within different fields such as biomedical devices. They say they may be able to improve implanted medical devices that should not be exposed to microwaves or other electromagnetic waves.

Not to mention the possibility of creating a true invisibility cloak.

“We’ve seen that we can suppress microwaves, so we are now focusing on how to apply that same understanding to manipulate shorter wavelengths such as terahertz electromagnetic waves,” Dong said.

The current resonators can be tuned to absorbed different frequencies up to 9.15–12.38 GHz. Setting sights on shorter wavelengths could bring about more exciting cloak applications. “While this sort of technology would require new structures and design elements, we realize the potential is there to create it,” Dong says.

“This project started as a conversation about doing something interesting with wearable films, and we are excited about the results we’ve seen so far. We are looking forward to taking this concept to the next level.”

Nanostructures and Lego® Bricks

Ludovico Cademartiri (right foreground), assistant professor of materials science and engineering, and his research team use an interdisciplinary approach to tackle a wide range of challenges in materials science
Ludovico Cademartiri (right foreground), assistant professor of materials science and engineering, and his research team use an interdisciplinary approach to tackle a wide range of challenges in materials science

Advancing technology through practical and radical materials science

Materials science, chemistry, physics and life. These are the driving forces behind the research in Ludovico Cademartiri’s laboratory at Iowa State.

Cademartiri, assistant professor of materials science and engineering and associate scientist with the U.S. Department of Energy Ames Laboratory, says he and his graduate students work to go beyond understanding materials to exploring what’s happening at the edge of the discipline.

“The general approach of our lab is that we try to use our skills at making materials to answer fundamental questions, whether they are related to materials science, another discipline, or some space between,” Cademartiri explains.

The result is a good mix of interesting scientific problems, each with its own potential.

One project involves a big breakthrough but is also facing significant experimental challenges. The group wants to create a ceramic that behaves like a plastic. Combining the properties of these two classes of materials typically requires mixing them together in composites, which are difficult to process. No single material combines the properties of ceramics and plastics. Cademartiri says that while it’s considered fundamentally impossible, the group has evidence to the contrary.

“We’ve seen similarities between plastics and crystals when crystals are very thin, 50 thousand times thinner than a human hair. Plastics are composed of an entangled mess of thin strands, molecules specifically. These strands are very flexible in plastics, which allows them to behave the way they do. We have clear evidence that some extremely thin crystal strands are similarly flexible. Determining exactly how similar they are is important to apply these materials but is also extremely challenging.”

In another research program, the group has made significant headway in controlling microstructures in ceramics. The team has helped resolve an issue that had previously prevented making materials by selecting their individual components and then assembling and processing those components to create a material.

Cademartiri says in the past building a material from the bottom up has resulted in the material disintegrating during processing, making it hard to apply in devices. His team has found a new approach to avoid this issue entirely, thereby enabling an entirely new way of manufacturing materials with nearly complete control over their composition and structure. The findings will be published soon in two back-to-back articles in the journal Advanced Materials.

In a less traditional project, Cademartiri’s team has been working to use LEGO® bricks to simulate an ecosystem in the lab to study how plants interact with their environment. “We can control and understand pretty well a plant in isolation, but there’s so much more involved when you include the ecosystem wherein the plant exists,” he says. “If we can simulate this environment, and understand and predict how plants will respond to it, we should be able to improve the reliability of our food supply.”

While the group’s overall focus is to provide solutions for global problems (like improving food supply) and to resolve issues at the foundation of modern materials engineering (such as programming material properties, replacing extremely rare elements in materials, translating materials and processes from the lab to the outside world, and understanding what happens at the interface of two materials), Cademartiri says he encourages his team to think outside the box.

“Materials are, in most cases, the bottleneck in the development of new technology and new solutions,” he says. “Therefore, controlling materials or, in other words, knowing how to build things atom-by-atom, is one of the safest ways to have an impact on the world.”

Engineering better health

Surya Mallapragada, Carol Vohs Johnson Chair in Chemical and Biological Engineering
Surya Mallapragada, Carol Vohs Johnson Chair in Chemical and Biological Engineering

Polymeric biomaterials combined with nanoscale delivery devices can improve preventative medicine

Surya Mallapragada knows the value an engineering perspective can add to advancing the biomedical field.

For years, Mallapragada, the Carol Vohs Johnson Chair in Chemical and Biological Engineering, has been researching the best ways to synthesize copolymers and nanoscale delivery devices to treat illnesses. Now, she’s looking at ways to prevent disease.

“When we were focused on treatment technologies, we wanted to minimize the immune response to the drugs that were being delivered to a patient, creating an environment that would allow the medicine to be effective in fighting against a disease,” she explains.

Shifting her focus to preventative medicine like vaccines, Mallapragada says her team wants to maximize immune responses to different drugs so the patient is protected against a variety of diseases and stays healthy. “We have a good understanding of which chemistries will elicit the right response given the different applications,” she adds.

That information is being put to use within nanoscale drug-delivery devices Mallapragada’s team is designing. Her group is focusing on vaccines that carry just the proteins or DNA from pathogens, a change from traditional vaccines that have been created using live, or attenuated, pathogens.

“When we use attenuated pathogens, we have to consider a number of factors, including growing a virus somewhere like chicken eggs and transporting and storing the virus,” she says. “Since our work is using only part of a pathogen in a nanoscale delivery device made of a polymer, we can design materials that are more robust without having to worry about the disadvantages of working with live viruses.”

Mallapragada’s work is part of the polymers and materials research going on within the Nanovaccine Initiative at Iowa State. The initiative includes several researchers who are developing nanoparticle platforms that can be used in disease prevention.

“The platform technologies we are creating aren’t necessarily disease specific. It’s a bigger picture plan to improve both the effectiveness and accessibility of vaccines,” Mallapragada adds. One example would be having a team look at using proteins or pieces of pathogens to create a combination vaccine that fights both influenza and pneumonia since those diseases can often occur together.

The projects involve interdisciplinary teams that include researchers and medical professionals both on and off campus. “Immunologists are learning about materials science, and students and post docs in engineering are learning about cell cultures and animal models,” Mallapragada says. “The collaborative environment has allowed us to thrive, and we’re looking forward to seeing these projects eventually head to human clinical trials.”

ATHENA Lab augments human capabilities

Tom Schnieders and Rick Stone
Tom Schnieders (left) and Richard Stone

Engineering ideas and technologies enhance human performance, preserve safety and quality of life

Developing telerobotics control systems, applying biomechanics for improved sports performance, creating visualization tools that improve battle space awareness. These projects and more are going on within the Augmentation and Training of Humans with Engineering in North America Lab.

The lab, known as ATHENA Lab for short, is one of four labs of its kind in the world. And the only one the Augmented Human International Conference Series recognizes in North America.

“We want to make humans more capable and safer, and we’re using a mix of ergonomics, augmented reality and cutting-edge technologies to accomplish our goals,” says Richard Stone, an associate professor of industrial and manufacturing systems engineering, co-director and co-founder of the lab.

The ATHENA Lab evolved from the Human Performance and Cognitive Engineering Lab that Stone started when he came to Iowa State in fall 2008. Fast forward to 2015 and bring in Thomas Schnieders, a Ph.D. student in industrial engineering and the other co-director and co-founder of the lab, who talked with Stone about the potential of having a recognized human augmentation lab on campus.

“The ATHENA Lab takes what we were already doing and gives us more focus. It also shows us other areas where we could be adding value with our work,” explains Schnieders. “A lot of labs do great work individually in biomechanical, biomedical and cognitive science, but our lab tries to merge all these aspects to see how they work together.”

No two days at the ATHENA Lab are similar. The researchers are constantly running new experiments, testing body armor one day and the next they might be focused on figuring out what technologies could make wound suturing more consistent.

“Our setup is always changing, and we’re moving equipment around all the time,” Stone adds. “At any time you might see boxes of basketball shoes stacked to the ceiling or maybe robots tucked away on a shelf. It just depends on what problem we are working to solve.”

The ATHENA Lab is also equipped with a large variety of sensors, cameras, hardware and software the researchers use to gather data.

Stone says the students who work in the lab bring a lot of energy and excitement to the projects. “The work we are doing is very focused. They get to work on projects they can apply to their everyday life, and they get to see the end results of their time and effort,” he explains. “It’s fun to see young students come in and show them a different side of engineering.”

Leadership in multiphase flow discovery, education and practice

Multiphase flow scienceA cohesive group of researchers at Iowa State has joined together to accelerate discoveries in multiphase flow science and their transfer to industry.

The group known as CoMFRE initially started out in 2002 as an informal way for faculty to share insights about related research projects. Now, the team is more formally organized with a mission to bring ideas together to make computational and experimental multiphase flow research more cohesive and connected.

Shankar Subramaniam, professor of mechanical engineering, and Rodney Fox, distinguished professor in chemical and biological engineering, lead the group of 18 faculty members who make up CoMFRE. The group also collaborates with a number of experts in industry, academia and national laboratories.

Subramaniam says having a large number of faculty and experts involved has helped the group expand its impact. “We aren’t working on just one problem. We’re working on a set of techniques that can be rapidly realigned to various problems. I anticipate that over the next 20-25 years we can continuously reinvent ourselves to solve whatever the hard multiphase flow problem of the day happens to be.”

One major initiative within CoMFRE is biofuels. As biomass, such as corn stover, is heated to create fuel, multiphase flow researchers can analyze how changes in the composition of biomass and flow impact the reaction.

The team develops simulations of biomass reactors, analyzes computational data gathered during the process, and evaluates the economics of the facilities used to generate biomass and biofuels, effectively performing an entire life-cycle analysis that focuses on efficiency and sustainability.

“From a computational perspective, all of our work involves a variety of statistical and mathematical methods and visualization,” Subramaniam says. “While it’s relatively easy to compute large amounts of data, we take our research beyond information. We provide insight into the processes occurring and look for answers to research questions.”

As the long-term applications and science research being developed under the umbrella of CoMFRE continues to grow, Subramaniam says the group’s industry outreach will also expand. CoMFRE facilitates training, seminar and networking opportunities for industry collaborators, where the group shares rich knowledge and diverse expertise to advance research in the multiphase flow field.

Collaborators come from a variety of industries including energy, healthcare, materials design, advanced manufacturing, sustainability and infrastructure.

The team also incorporates training and workforce development for graduate students, providing them with skills that can be applied across industries to investigate multiple challenges. CoMFRE is even proposing to break away from the traditional Ph.D. structure to act as more of a learning community, where graduate students work with peer groups and a whole group of faculty members acting as advisers. In addition to refining their technical skills, the students will be trained on entrepreneurship, which would prepare them to adapt to changes that can occur in the research landscape over time.

“We want our graduates to be cognizant of how to connect their work to societal issues,” Subramaniam says. “We think we’ve set up CoMFRE to prepare these students to be industry leaders while we also make advancements in our research.”

New heights for materials science

With his plans to develop an open-source manufacturing platform, Peter Collins is determined to make additive manufacturing a mainstream technology.

Collins, who is an associate professor in materials science and engineering, says the advantages of additive manufacturing—using fewer resources, improving material performance and creating one-of-a-kind products—can be a game changer for manufacturers of all sizes.

nanoscale materialsThat’s why he’s working on a program that will reduce the amount of testing involved with the additive manufacturing process.

“When we look at creating a better material, additive manufacturing is a great place to start,” he explains. “Rather than taking a huge piece of material and sizing it down to fit within the parameters we have, researchers add small amounts of powder to specific areas of a material to achieve desired characteristics and geometries. It’s simply a more efficient and effective approach.”

Collins wants to tailor materials to exact specifications, such as designing high strength on one side of the material and high stiffness on the opposite side. He says being able to change composition of a material is useful for many industries, including energy, aerospace and automobile markets.

But testing materials created through additive manufacturing is a significant investment and a big part of why the process isn’t commercially available. “Manufacturers spend sizable amounts of money to create a large piece of material, then section it into smaller pieces to send off for mechanical, fatigue and composition tests,” Collins says. “As you can imagine, it’s expensive, and if something doesn’t meet the desired performance, you have to create a new piece of material and do it all over again.”

Material characterization, which involves looking at how the atoms and crystals in the material are arranged, can help researchers predict the composition of a material and reduce the expenses associated with testing. “Knowing how materials will respond after they go through specific processes will help us understand what elements we will lose and what characteristics the material we’ve developed will exhibit.”

A large part of his research with groups such as the Defense Advanced Research Projects Agency, National Science Foundation and the Boeing Company focuses on bringing this materials science mindset into additive manufacturing.

He also wants to reduce costs associated with additive manufacturing, which accumulate thanks to the equipment, like lasers and electron beams, used in the process. So he’s developing an open-source manufacturing platform with visions that every town could implement additive manufacturing. “Something like this would mean a farmer could go into town and repair or create a new piece of equipment instead of paying an exorbitant amount to have one made and shipped to them,” he explains.

While he knows there’s a lot of research that needs to be done before this vision becomes reality, he says his approach is definitely a step in the right direction.

“Adding material characterization to the process gives us the information necessary for exploring and creating superior materials for the manufacturing industry much quicker than has been done in the past.”

More data, more vulnerabilities

Protecting and securing data takes on many forms at Iowa State, where researchers in electrical and computer engineering are tackling big threats in the digital world: detecting malware on apps, improving online privacy and eliminating insider threats.

Mathematical abstraction and software reasoning

Suraj Kothari, Richardson Professor of Electrical and Computer Engineering, mixes theoretical ideas and practical application together as he looks for ways to improve the quality and security of software. The tools he has developed utilize visual mathematical models to dissect and conquer larger problems.

Recently, his models have been applied to detecting malware attacks within mobile applications for a Defense Advanced Research Projects Agency project. Kothari’s team designed a tool that gathered important information about an app as it scanned code for malware. This data is then presented in a compact form for a human analyst to review, allowing for more accurate assessments about an app’s intentions than systems currently in place. The tool is flexible enough to be refined and extended to address future malware attacks.

Machine learning to secure information

Morris Chang, associate professor of electrical and computer engineering, wants to make sure data collected by third-parties (think: healthcare workers or employers performing background checks) stays private. He says individuals providing personal information are increasingly exposed to vulnerabilities that may exist within a third-party’s data-collection system.

Through DARPA’s “Brandeis” Program, Chang is creating technology that helps secure privacy over the Internet through distributed algorithms that protect user’s data on mobile devices. Chang’s approach focuses on securing data before it is transmitted via Internet to remote cloud services. These services then use machine learning techniques to process data, allowing the data to be transferred in an irreversible way before reaching the Internet.

The project brings together researchers from several universities and segments the work to propose a solution to addresses the efficiency, privacy, security and flexibility of Internet computation.

Parsing big data to identify threats

Srikanta Tirthapura, associate professor of computer engineering, makes big data more manageable with methods that analyze extremely large data sets, especially data that quickly changes, which are often referred to as data streams.

Part of Tirthapura’s research is applied to cyber security, where he looks at how to convert, store and analyze information to find anomalous user behavior or unauthorized access. One example is insider threat detection, where someone within an organization who has authorized access to some parts of the system misuses his or her access.

He says detecting insider threats adds an extra challenge because the user is familiar with the system. In this case, technology is essential to search through gigabytes of files to identify unusual behaviors. That’s why Tirthapura has created tools that can be used across a variety of datasets and problems to efficiently retrieve and process information.

Engineers, elementary educators and future teachers partner to teach STEM

TrinectAt Iowa State, integrating engineering into K-12 classrooms is a collaborative effort that spans across campus and into surrounding school districts. Trinect, a program funded by the National Science Foundation STEM-C Partnerships, brings together three groups to introduce engineering concepts to young students: engineering graduate students, preservice teacher students and cooperating elementary teachers from Des Moines Public Schools.

“Trinect is about sharing knowledge and helping elementary teachers gain confidence in teaching STEM subjects,” says Adah Leshem, pre-college education program director at the NSF Engineering Research Center for Biorenewable Chemicals located on Iowa State’s campus. Leshem is Trinect’s project co-director and was a driving factor in establishing the program.

“We know there’s a crucial timeframe for engaging young students in STEM fields and there’s often a lack of opportunity for students to experience these subjects. We think Trinect can help fill those gaps.”

Each semester, 10 Trinect Fellows, who are engineering graduate students, work with 3rd-5th grade students and their teachers. The fellows help teachers understand the concepts of the engineering  design process as well as reaffirm common subjects such as math, science and technology.

“Instead of having graduate fellows teach the concepts, they act as a resource for teachers and students. The approach engages teachers as they develop innovative activities focused on STEM subjects,” Leshem explains.

Iowa State’s School of Education’s preservice teachers represent the third partner of Trinect. These students are placed in cooperating teacher classrooms for 16 weeks and participate in teaching STEM concepts. At the end of the program, they are better prepared to independently integrate these types of lessons into their own classrooms once they are in the workforce.

Leshem says an external partner will measure the overall effectiveness of Trinect. The data will evaluate how the triad functions as a team and how the approach the program is using compares to traditional learning methods.

“We’ll be continually improving our program as we receive feedback and looking for additional opportunities to expand collaborations,” Leshem says.

Market-ready solutions

Matt Darr
Matthew Darr, associate professor in agricultural and biosystems engineering

Advanced ag machinery technology developed at ISU transfers to industry

Matthew Darr’s research group strives to make an impact that extends knowledge and scientific development to the marketplace. “Seeing our results ported out to the public sector where we’re able to help agricultural producers with intelligent technologies — that’s our ‘why,’” he says.

Darr, an associate professor in agricultural and biosystems engineering, runs an industry-focused research program at Iowa State, working on innovations in the agricultural equipment and agricultural automation sectors.

“We’ve developed strong relationships with industry partners, which helps us better understand their needs. We then focus our research on addressing applied research questions through targeted applications of advanced technology, science and innovation,” he says.

Much of the group’s work is data driven, with researchers working to both collect and analyze complex data from a range of agricultural systems. Darr says analysis of vehicle sensor networks has become a focal point for the group’s research.

The team develops algorithms for sensors used within agricultural equipment for a range of purposes and then works with industry partners to get that intelligence integrated into a commercial product.

Because the agricultural field relies heavily on telematics to gather data, Darr’s group creates hardware and software solutions that integrate the process. One such project involved assessing the logistics behind cellulosic ethanol supply chains in the Midwest. Industry partners used technology from Darr’s team to gather data and then made informed changes to how the plants operate, saving time and money.

Another area Darr is exploring is unmanned aerial vehicles, which involves remote sensing with UAVs. “We are utilizing this technology to acquire plant health indicators for individual plants.  This allows us to create a quality index that is used to adapt farming operations and make decisions related to crop production,” he explains. “The data from these UAVs can help producers make decisions about everything from water management to fertilizer application.”

While most of the group’s work has a significant impact in the Midwest, Darr says there’s an international component to the team. Test research of the group’s technologies happens on four continents every year, something Darr says provides the group with a greater understanding of how technology could help in the less developed ag markets.

The team’s successful approach in partnering with industry to create transferrable technology is an accomplishment in and of itself. Thanks to Iowa State’s land-grant mission, the university has flexible options for industry partners that address intellectual property concerns and facilitate the process for all parties involved.

He adds that diversity in the research group, which includes computer scientists, researchers from a number of engineering disciplines, ag technologists and students, gives the team a broad perspective for approaching problems.

The team’s work recently contributed to three innovation Silver Medal awards at AGRITECHNICA 2015, a global showcase of ag machinery in Hannover, Germany. The award-winning innovations, which were developed at Iowa State University and licensed to John Deere, involved the operation of harvesting equipment.

“When we see the value our work creates for producers, we know we’re making contributions to the agricultural industry,” Darr says. “Iowa State creates an environment where this is possible, and we are able to make a difference because of it.”

Power management in smart robots

Ran Dai and student team
Ran Dai, foreground, an assistant professor in aerospace engineering and Black and Veatch Faculty Fellow is working to develop technologies that will help robots manage their energy use to improve efficiency and battery life

Designing solar-powered vehicles for long-duration, high-efficiency missions

Using renewable energy to power aerial and ground vehicles could change the way we handle aspects of environmental monitoring, search and rescue missions, surveillance, and agricultural practices.

To navigate these sorts of dynamic environments, Ran Dai, an assistant professor in aerospace engineering and Black and Veatch Faculty Fellow, says a solar-powered robotic system offers a lot of promise.

During her first year at Iowa State, she and undergraduate research assistants manufactured the first prototype of a solar-powered ground vehicle in her Automation and Optimization Laboratory.

The vehicle was capable of designing an efficient path to harvest energy from the environment while simultaneously allocating its available power among electric components. The team also created an indoor solar simulator to have a static environment for evaluating the robot’s performance.

Now, confident her ideas will work, Dai has moved forward with a second- and third-generation robot, adding real-time power tracking to record the vehicle’s power intake and consumption, along with a solar-powered unmanned aerial vehicle.

The project is supported by a $500,000 grant provided by the National Science Foundation’s CAREER program, which is designed to support the research and teaching of junior faculty, and will expand the usefulness of these unmanned vehicles even more with advancements that will improve their endurance and capability.

Dai says her biggest obstacle in this work is the weather. “Our algorithms can help the robot make decisions based on available solar energy, but if it’s cloudy, the robot could go into sleep mode to conserve energy, resulting in a delay in completing a mission.”

She says those sorts of delays could be offset with cooperative, back-up vehicles that harvest energy while the other robots are doing work. When the working robots need to recharge, the second group could step in to realize a persistent operation.

“The key to being able to make a system like this work is to find out how to make a robot energy-aware and autonomous,” she says. “That way it could recognize changing solar conditions and make necessary adjustments.”

Dai also plans to develop an open-source software program everyone can use. She hopes this will lead people who are interested in the technology to create their own solar-powered robots.

In the end, it’s the big picture that drives Dai forward — she wants to contribute to the country’s economic vitality, public health and security with these robots.

Soil and water samples illuminate antibiotic resistance

Michelle SoupirStudies of manure application reveal antibiotic resistance movement

While using manure as an organic source of fertilizer has helped the agricultural industry maintain balance in integrated crop and livestock systems, there is some risk the manure contains bacteria that may contaminate water bodies if transported off the field by rain.

Michelle Soupir, an associate professor in the Department of Agricultural and Biosystems Engineering, and her team of researchers are examining the transport of two pathogen indicators: E. coli and enterococci. Both are identified by the EPA as indicators of potential fecal contamination of water resources. She also looks for relationships between the traditional pathogen indicators and antibiotic resistance.

Soupir says identifying the resistance is incredibly difficult. “When you monitor environmental systems, you can be on a fishing trip of sorts when determining what resistance might be out in the environment. In our study, we targeted tetracycline and tylosin.” Both are antibiotics. Tetracycline treats bacterial infections like acne and genital or urinary infections, whereas tylosin isn’t prescribed to humans but is in the same class as other common human antibiotics like erythromycin.

The fieldwork is conducted at the North East Iowa Research Farm (NERF), near Nashua, Iowa. A different land-use treatment is applied to one-acre plots of crops, separated from other plots by berms and curtain drains to reduce cross-contamination from either above or below the surface. Manure is injected into some of the plots in bands close to the root system before the first hard frost.

“It’s applied in the fall so ammonia doesn’t volatilize, and we don’t lose the nitrogen we’re applying,” says Soupir. “It’s always a gamble, because you want to do it right before the soil freezes.” The manure is then held in the soil all winter at cold temperatures, which is a benefit to water quality as the cold temperatures tend to kill off some of the pathogens and resistant bacteria.

The team is getting data from three points in the system. Samples of the manure that is applied to specific plots tells them how much antibiotic resistant bacteria and pathogen indicators are going onto the plots. Measurements of the soil show how long the organisms survive. This leads the research team to take samples of water, which tells them what organisms are moving off site and could potentially be moving into surface water.

But the results of this have not been as expected. “We rarely see statistically significant differences between the manure amended and control plots in the tile drainage water,” says Soupir. “It’s been surprising that there aren’t more statistical differences. For the most part, it’s been pretty good news for pork producers because the method of manure application (injection in the fall) seems to be a good management strategy for preventing pathogens and resistant bacteria from moving into the tile drains.”

The project is on its fourth year, and while most of the results are on swine manure, the researchers have begun to look at a poultry-amended site as well as a beef-amended site. Soupir says these research sites are novel because they have received manure application for long periods of time. “It’s really made me appreciate the need for long-term studies.”