John W. Sutherland

John W. Sutherland
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John verified their affiliation via an institutional email.
Purdue University West Lafayette | Purdue · Division of Environmental and Ecological Engineering

PhD

About

410
Publications
170,271
Reads
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16,670
Citations
Additional affiliations
August 2009 - present
Purdue University West Lafayette
Position
  • Professor and Fehsenfeld Family Head

Publications

Publications (410)
Conference Paper
Triboelectric nanogenerators (TENGs) are cutting-edge energy harvesting devices to convert abundant mechanical energy sources into electrical power. High-throughput manufacturing of triboelectric surfaces with improved performance and reliability is the key for the large-scale deployment of TENG technology. In the present study, the cold spray (CS)...
Article
Additive manufacturing has found its niche in critical component applications in the aerospace and nuclear industries. For these industries, a need for a cost-effective quality assurance method has also increased to incorporate these components. Within laser powder bed fusion (LPBF), in-situ sensing has shown promise with various forms of defect de...
Article
Closed-loop recycling streams are increasingly taking importance on the development of a sustainable future. Neodymium-Iron-Boron (Nd-Fe-B) permanent magnets are applied in a variety of applications, including direct-drive wind turbines, electric motors for electric vehicles, hard disk drives (HDDs) in laptops, and other electric devices. End-of-li...
Article
Full-text available
As a key strategy for achieving a circular economy, remanufacturing involves bringing end-of-use (EoU) products or cores back to a ‘like new’ condition, providing more affordable and sustainable alternatives to new products. Despite the potential for substantial resources and energy savings, the industry faces operational challenges. These challeng...
Article
The circular economy (CE) shifts from a linear economy (LE) to prioritize preserving value improving resource efficiency through closed loops. This shift demands product designs that facilitate repurposing and recycling, reducing waste and new material use. Achieving this requires changes in industry practices, consumer behavior, and supportive pol...
Article
Full-text available
Advanced manufacturing is challenging engineering perceptions of how to innovate and compete. The need for manufacturers to rapidly respond to changing requirements and demands; obtain, store, and interpret large volumes of data and information; and positively impact society and our environment requires engineers to investigate and develop new ways...
Article
Near-infrared (NIR) spectroscopy is an efficient and non-destructive method for the identification and classification of mixed plastics. In the identification process of NIR spectroscopy, the dataset proportion of each type of plastic obtained is imbalanced due to the difficulty of obtaining or special application environments. When the backpropaga...
Article
Full-text available
Smart systems such as data-driven machine health monitoring are emerging as powerful technology for advanced manufacturing as a result of the availability of low-cost sensors, wireless communication, and advances in Machine Learning (ML) and Artificial Intelligence (AI). Predictive maintenance (PdM) has become increasingly popular in manufacturing,...
Article
Full-text available
Advanced manufacturing is challenging engineering perceptions of how to innovate and compete. The need for manufacturers to rapidly respond to changing requirements and demands; obtain, store, and interpret large volumes of data and information; and positively impact society and our environment requires engineers to investigate and develop new ways...
Conference Paper
Driven by growing decarbonization initiatives, looming energy security risks, and heightened environmental awareness, there is escalating attention devoted to clean energy technologies such as electric vehicles (EVs), and wind turbines. Data from the U.S. Environmental Protection Agency (EPA) in 2022 revealed that the transportation sector alone co...
Article
Aluminum is the world's second most consumed metal, and its production contributes substantially to global greenhouse gas (GHG) emissions. When formulating decarbonization strategies, it is imperative to ensure their coherence and alignment with existing industrial practices and standards. A material flow analysis (MFA) is needed to gain a holistic...
Article
Rare earth permanent magnets (REPMs) play a pivotal role in clean energy technologies like electric vehicles and wind turbines. However, their reliance on critical materials like dysprosium presents supply risks. This study introduces an innovative manufacturing approach for nanograin NdFeB magnets using a continuous hot-roll deformation process. T...
Article
Commercial aviation is adopting renewable biofuels to counter carbon emissions. A high-performance jet-fuel blend derived from biomass-derived ethanol is one approach to mitigate fuel consumption. However, there are many economic uncertainties associated with planning and operating a biorefinery. This study provides a techno-economic assessment for...
Preprint
Full-text available
Smart systems such as data-driven machine health monitoring are emerging as a powerful technology for advanced manufacturing as a result of the availability of low-cost sensors, wireless communication, and advances in computational capabilities. Machine learning represents a critical element of manufacturing equipment health monitoring due to its a...
Article
Accelerating the development of clean energy technologies is required to move towards a sustainable future. New design approaches are being proposed to help accelerate these developments. This study proposes and improves a novel design framework that incorporates life cycle assessment (LCA) and techno-economic assessment (TEA) with an optimization-...
Article
Full-text available
Recent advances in sensor technology and computing capabilities have enabled the creation of data-driven models that can support real-time decision making. Such a decision aid can allow for predictive maintenance (PdM) to be undertaken on a much greater scale in manufacturing plants. PdM includes data-driven prognostics and health management (PHM)....
Article
Disassembly is an inevitable step in the recovery of valuable materials from end-of-life (EoL) mobile phones. Although a Hybrid Graph is one of the prevalent method for disassembly modeling, it cannot accurately describe the subassembly disassembling process. In this paper, an improved disassembly hybrid graph model (IDHGM) for selective disassembl...
Article
The critical issue of part quality repeatability within and across multiple builds during metal additive manufacturing techniques presents a major roadblock to their adoption for large-scale manufacturing, particularly for sensitive applications like aerospace and nuclear. The property variations are a consequence of process fluctuations, which can...
Conference Paper
Fundamental mechanisms of cutting fluid mist formation via atomization are investigated. As the cutting fluid impacts a stationary flat workpiece surface, a liquid film develops over the surface and disintegrates into droplets. Past research has shown the Sauter mean diameter of the droplets to be proportional to the film thickness. For a cutting f...
Preprint
Full-text available
Recent advances in sensor technology and computing power allow for the generation/utilization of larger and more diverse sets of data. These developments enable the creation of data-driven models that can support real-time decision making. Such a decision aid can allow for predictive maintenance (PdM) to be undertaken on a much greater scale in man...
Article
The near-infrared spectra technique is an effective and non-destructive analysis method for polymer identification, and it has been applied in waste plastics classification. Since the near-infrared spectra are easily affected by instrumental noise, baseline drift and light scattering, spectral data preprocessing is indispensable for classification...
Conference Paper
Many of the materials needed for the production of electric vehicles (EVs), in particular batteries and motors, are subject to substantial supply chain uncertainty. A circular economy approach that recovers these materials/components from end-of-life (EoL) vehicles would reduce the dependence on primary (virgin) materials/components. However, there...
Article
The recycling of end-of-life (EoL) electronic products is motivated by the enormous investment of resources in their creation and the environmental concerns associated with electronic waste (e-waste). Hydrometallurgical methods that utilize conventional leaching and solvent extraction are often applied to extract target materials from e-waste; howe...
Article
The transition of additive manufacturing from rapid prototyping to large-scale manufacturing is being impeded by the limited repeatability of part quality within and across independent builds. The property variations are a result of process fluctuations, which can be random or systemic, like the location of the part on the build plate. In-situ sens...
Article
Full-text available
Smart manufacturing systems are considered the next generation of manufacturing applications. One important goal of the smart manufacturing system is to rapidly detect and anticipate failures to reduce maintenance cost and minimize machine downtime. This often boils down to detecting anomalies within the sensor data acquired from the system which h...
Article
With the increasing concern due to climate change caused by a higher atmospheric concentration of CO2 and other greenhouse gases, reducing environmental impact is becoming more important for every part of society. Manufacturing is responsible for a significant amount of energy/material consumption and environmental burden and, therefore, has a grea...
Article
Full-text available
Electric Vehicles (EVs) are considered among one of the ‘clean’ energy technologies in the transportation sector because the vehicles themselves do not generate combustion emissions. However, the substantial environmental footprint associated with the materials needed to create these technologies (extraction, manufacturing, and solid waste at end o...
Article
Circularizing end of life products such as electronic waste can open a new source for rare earth elements (REEs) that will decrease the demand pressure on conventional virgin production. The last step to produce REEs consists of a refining process to convert rare earth oxide (REO) to REE metal. One promising technology is processing REO via a room...
Article
Geometric characteristics and curvature of free-form surfaces have a great influence on multi-axis computer numerical control (CNC) machining performances such as processing efficiency, surface quality and energy consumption. The conventional machining methods with the whole tool path generation results in poor low machining efficiency, surface qua...
Article
Life cycle engineering of new products and technologies must consider not just the single product and product life cycle, but also the foreseeable growth in market volume that results from increases in population and affluence, in order to allow the associated total environmental impact to be taken into account during the product development. The e...
Article
Achieving sustainability is currently an important development direction for the manufacturing industry. With the consideration of all pillars of sustainability, valid evaluation of sustainability during scheduling optimization has become an emerging critical issue in the production scheduling loops. In view of absence of comprehensive sustainable...
Article
Forging is an industry with high emissions and high energy consumption. Due to the constant increase in the international energy price and the negative impact on the world's environment, researchers have begun to focus on transforming forging into information and sustainable development. However, there remains a substantial gap in the development o...
Conference Paper
The reliability of manufacturing equipment is critical for ensuring the productivity and energy efficiency of a manufacturing facility. An unexpected machine breakdown may lead to unexpected downtime, disruption of manufacturing schedule, lower production efficiency, higher operation and maintenance cost. The recent development in machine learning...
Article
Disassembly lines are the most effective way to address large-scale value recovery from end-of-life (EOL) products. Disassembly line balancing (DLB) greatly affects the economics and throughput of EOL product processing. Complete disassembly is generally not suitable for disassembly enterprises; most often, the maximum profit is realized through pa...
Article
The 718 Ni-based superalloy has gained enormous attention in the additive manufacturing community for its great weldability, allowing for complex geometries to be formed, and its superb mechanical strength. Here we explore the influence of a wide range of major build parameters on microstructures and mechanical properties of 718 Ni alloys. Volumetr...
Article
Full-text available
Industrial symbiotic networks (ISNs) can support the transition from a conventional linear economy to a circular economy by using industrial waste and by-products as resources. However, the early design and development stages of ISNs are fraught with challenges as a result of limited information (supply, demand, potential synergies, etc.), and the...
Article
The global society faces an existential threat if it fails to meet current and future material needs of its populations, while staying within the carrying capacity of our planet. An approach that has been put forwards to address this complex challenge is to aim to close our society's material flows through introduction of a Circular Economy (CE). T...
Preprint
Full-text available
Smart manufacturing systems are being deployed at a growing rate because of their ability to interpret a wide variety of sensed information and act on the knowledge gleaned from system observations. In many cases, the principal goal of the smart manufacturing system is to rapidly detect (or anticipate) failures to reduce operational cost and elimin...
Article
The fast-growing market for electric vehicles (EVs) offers great potential for reducing the carbon footprint of the transportation sector but is heavily reliant on electric motors and batteries, which are in turn dependent on the availability of critical materials, e.g., rare earth elements and lithium. Such critical materials are subject to substa...
Article
Thanks to the development of new technologies such as sensor networks and advanced computational power, the research field of condition-based monitoring (CBM) has drawn increasing attention in manufacturing. With the aim of enhancing equipment reliability, leading to a reduction in maintenance costs, one of the most crucial challenges dealing with...
Article
Over the centuries, the application of grassland and cutting of livestock have been the primary foundations for the production of food agriculture manufacturing. Growing human population, accelerated human activities globally, staggering food inequity, changing climate, precise nutrition for extended life expectancy, and more demand for protein foo...
Article
Full-text available
Predictive maintenance (PdM) is an advanced technique to predict the time to failure (TTF) of a system. PdM collects sensor data on the health of a system, processes the information using data analytics, and then establishes data-driven models that can forecast system failure. Deep neural networks are increasingly being used as these data-driven mo...
Article
The spindle system of a Computer Numerical Control (CNC) machine tool is essential for improving the machining efficiency and accuracy. Although there are many studies on the energy consumption of machine tool spindle, few comprehensively consider the energy consumption and dynamics characteristics of the mechanical transmission of the spindle syst...
Article
Much of the environmental footprint of a machine tool is due to the energy consumed during its use phase. A promising strategy for reducing this energy consumption is to minimize the mass of components through changes in the design of the machine tool. This paper explores the lightweighting of the machine slides (or tables) to achieve energy saving...
Article
Full-text available
Lightweighting is a design strategy to reduce energy consumption through the reduction of mass of a product. Lightweighting can be applied to machine tools to reduce the amount of energy consumed during the use phase. Thus, the energy cost of machine operation will be reduced. One might also hypothesize that since a lighter-weight machine tool requ...
Article
Full-text available
Greenhouse gas emissions have become one of the most prominent global concerns of sustainable development. To reduce product life cycle carbon footprint, planning should begin at embodiment design phase. The accurate assessment of carbon footprint is the foundation of carbon footprint reduction. However, existing carbon footprint models cannot be a...
Article
Full-text available
Prediction of manufacturing equipment’s energy consumption plays an important role in selecting appropriate process parameters for energy saving. However, it is difficult to model the energy consumption of metal forming equipment during the drawing process characterized by variable process parameters and dynamic loads. In this paper, a model was de...
Preprint
Full-text available
Predictive maintenance (PdM) is an advanced technique to predict the time to failure (TTF) of a system. PdM collects sensor data on the health of a system, processes the information using data analytics, and then establishes data-driven models that can forecast system failure. Deep neural networks are increasingly being used as these data-driven mo...
Article
Full-text available
Today's manufacturing industry still requires human labor and knowledge for Machining Process Identification (MPI). Before manufacturing a part, engineers need to judge the manufacturability and identify the machining processes according to CAD model, and then the customer needs to source for qualified suppliers based on the identified machining pr...
Article
Rare Earth Elements (REEs) are essential for sustainable energy technologies. Techno-economic Assessments (TEAs) have been conducted to evaluate innovative approaches to recover REEs from waste streams. However, most TEA studies do not consider the price volatility of REEs, which raises concern over the reliability of the analysis in an unpredictab...
Article
Reducing the energy consumption of machine tools is important from a sustainable manufacturing perspective. Much of a machine tool's environmental impact comes from the energy it consumes during its use phase. To move elements of a machine tool requires energy, and if the mass of those elements can be reduced, then the required energy would be redu...
Preprint
Full-text available
Greenhouse gas emissions have become one of the most attractive global concerns for sustainable development. To reduce product life cycle carbon footprint, planning should begin at embodiment design phase. Accurate assessment of carbon footprint is the foundation of carbon footprint reduction. However, existing carbon footprint models are not appli...
Preprint
Full-text available
IoT systems have been facing increasingly sophisticated technical problems due to the growing complexity of these systems and their fast deployment practices. Consequently, IoT managers have to judiciously detect failures (anomalies) in order to reduce their cyber risk and operational cost. While there is a rich literature on anomaly detection in m...
Article
Full-text available
The application of cutting-edge technologies such as AI, smart sensors, and IoT in factories is revolutionizing the manufacturing industry. This emerging trend, so called smart manufacturing, is a collection of various technologies that support decision-making in real-time in the presence of changing conditions in manufacturing activities; this may...
Article
Full-text available
Rare earth elements (REEs) such as Neodymium (Nd) and Dysprosium (Dy) are used in Rare Earth Permanent Magnets (REPMs). Neodymium-iron-boron (NdFeB) magnets offer the strongest magnetic field per volume among all the magnets available in the market, which enables lightweight and compact product designs. NdFeB magnets have thus become indispensable...
Article
Full-text available
Rare earth elements (REEs) are becoming ever more important and broadly used in rare earth permanent magnets (REPMs) for electric vehicles, wind turbines, cell phones, etc. While neodymium-iron-boron (NdFeB) magnets are very popular, samarium cobalt (SmCo) magnets are increasingly being viewed as an alternative REPM option due their better resistan...