Energy Intensive Processes (EIP)

Zhili Feng, fengz@ornl.gov, (865) 576-3797

Background: Friction Stir Welding (FSW) is a novel solid-state joining process which can reduce the energy used in welding by 60-80% while producing higher quality welds. FSW is now a very successful "specialty" welding process used for aluminum and other low melting materials. Current gantry systems for FSW are limited to in-house fabrication of simple geometry and thin sectioned structures. FSW has captured only a small fraction of overall welding market due to its limitations in steel, complex structures, thick-sections, and the lack of on-site construction capability.

Goal: The goal of this project is to transform friction stir welding into a mainstream materials joining technology by enabling on-site construction of large, complex and typically thick-sectioned structures of high-performance and high-temperature materials. The project will develop new materials for FSW tools, develop hybrid FSW with auxiliary heating to reduce forge load, and develop multi-pass multilayer technology for very thick-sections. The partners will then develop portable a field-deployable FSW system to provide flexibility and affordability for on-site construction. The initial application of this technology will be for large oil and gas pipelines.

Partners: ExxonMobil Corporation, ESAB Group, Inc, MegaStir Technologies, Edison Welding Institute

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Gail Mackiewicz Ludtka, ludtkagm@ornl.gov, (865) 576-4652

Background: High Magnetic Field Processing (HMFP) is a transformational materials processing technology that adds a new dimension to materials processing. Magnetic fields can enhance reaction kinetics and shift the phase boundaries targeted by heat treatment to enhance material performance and eliminate heat treatment steps. Huge energy savings are possible through the elimination of heat treatment steps and the use of superconducting magnets.

Goal: The goal of this project is to develop magnetic processing for industrial steels for use during continuous cooling operations through eliminating/optimizing high temperature processing treatments and eliminating: cryogenic processing. The project will also develop higher field (>9T), larger-bore-size (>6-inch) magnet technology designs for the next generation magnet system which will enable treatment of larger scale industrial components. ORNL will work with project partners to eliminate a processing step while improving performance of a steel alloy of interest to each partner.

Partners: American Magnetics Inc., AjaxTOCCO, American Safety Razor, Carpenter Technologies, Caterpillar Inc.

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Jim Keiser, keiserjr@ornl.gov, (865) 574-4453

Background: Greater utilization of biomass fuels offers a means to reduce U.S. dependence on imported fossil fuels. The efficiency of boilers in recovering heat is generally controlled by the maximum operating temperature. The maximum operating temperature in turn is frequently limited by the corrosion rate of the superheater tubes which is strongly dependent on the melting point of the deposits that accumulate on the tubes. Improved heat recovery can be accomplished by raising superheater temperatures, which requires decreasing the corrosion rate of the superheater tubes.

Goal: This project will identify the mechanisms responsible for rapid degradation of superheater tubes operated above the melting point of the inorganic deposits. Once these mechanisms are understood, the team will identify alloys and/or coatings that give improved resistance to superheater tube degradation and/or work with manufacturers to find improved superheater designs to minimize degradation. To accelerate deployment of this technology the group will develop software that will help determine the energy benefits from the use of superheater alternatives.

Partners: FPInnovations, SharpConsultants, University of Tennessee-Knoxville, Alstom Power, Andritz Oy, Babcock & Wilcox, Domtar Corporation, FM Global, Haynes International, International Paper, MeadWestvaco, OutoKumpu, Rolled Alloys, Special Metals , ThyssenKrupp VDM, Weyerhaeuser Company, Chalmers University, SKYREC

Bill Peter, peterwh@ornl.gov, (865) 241-8113

Background: Titanium offers superior strength, corrosion, and high temperature properties for industrial applications across broad range of markets, but is currently too expensive for widespread use. Titanium is now produced primarily by the Kroll process, which is expensive, energy intensive, and yields very high rates of scrap production. The recent development of low cost titanium powders offers a new lower cost route to titanium metal production that can be employed in a continuous process with the ability to fabricate prealloyed powders at competitive cost.

Goal: The goal of this project is the consolidation of new Armstrong titanium and titanium alloy powders into low cost net shape components for energy systems such as aerospace components and heat exchangers. The project team will explore consolidation via press and sinter, pneumatic isostatic forging (PIF), hot isostatic pressing (HIP), and adiabatic compaction.

Partners: Ohio State University, LMC, Inc., Ametek, Inc., Lockheed Martin, Aqua Chem

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Nanomanufacturing

Bill Peter, peterwh@ornl.gov, (865) 241-8113

Background: Researchers at ORNL have developed scaled melting, powder fabrication, and laser processing techniques that fuse and devitrify amorphous iron-based powders into ultra-hard nano-composite coatings which are 1.3 to 7 times harder than conventional steel tools. Nanocrystalline metals are harder than conventional metals and can help reduce the estimated $65B/yr cost of wear to the U.S. economy. In a previous project laboratory tests performed at ORNL showed that uncoated disc cutters for tunnel boring machines exhibited 3.5 times higher wear rates than disc cutter material coated with the wear resistant coatings. Subsequent field trials demonstrated a 20% improvement in wear resistance for disc cutters.

Goal: The new iron-based amorphous alloy powder precursors fused and devitrified with high heating/cooling rate furnace technologies at ORNL enable the determination of microstructures, the production of nano-structured coatings metallurgically bonded to substrate, and the fabrication of bulk nanocrystalline components. Carbon and boron supersaturated steels can be made which avoid segregation and develop nano-sized ceramic precipitates. This project will develop low-cost, scalable processes for incorporating nano-sized boron/carbide particles into metal matrix coatings and components for wide range of wear-resistant applications.

Partners: Carpenter Powder Products

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Lonnie Love, lovelj@ornl.gov , (865) 576-4630

Background: Oak Ridge National Laboratory has developed methods to control the properties of particles produced by particular strains of thermophilic anaerobic bacteria. Using a natural, fermentation process ONRL can control the size and shape of nanoscale magnetite produced in industrial size fermentors at low temperature. The ability to integrate a surfacant into the production enables a nanoproduct that is easily dispersed. This process is low cost, low temperature and easily scalable, and was awarded an R&D 100 award.

Goal: This is a Concept Definition Project. The goal is to apply this technology to the production of quantum dots for potential applications in energy efficient photovoltaics, such as CdS, CIGS, and CIGSe. The bacterial strains utilized by ORNL can facilitate production of other materials including compounds in quantum dots. This project will identify quality and scaling laws for bacterially synthesized CdS and CIGS quantum dots

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W. L. Griffith, griffithwl@ornl.gov , (865) 574-4970

Background: This is a Concept Definition Study of microwave activation of nanostructured metal oxide catalysts. Microwave activation is expected to lower process energy by selective heating and activation of catalyst surface sites. Selective activation is expected to lower bulk process temperature required and increase product yield by minimizing back reactions. Refining of heavy crude oil was selected for initial evaluation because the tremendous opportunities for energy savings. The three most energy intensive refining catalytic processes, catalytic cracking, reforming, and hydrotreating, are all used to convert heavy crude oils to consumer fuels, and these processes are also bottlenecks in many refineries.

Goal: Preliminary results from a previous ITP MPLUS study showed that heavy oils are microwave transparent in industrially permitted frequencies (915 MHz and 2.45GHz) which couple with refinery catalysts. A bench scale evaluation will delineate process conditions under which microwave activation of nanostructured catalysts enhances catalyst performance on compounds which model heavy crude oil. The research will to develop data about process specifications; technology options; performance; markets; risks; and customers for this technology. Microwave activation of nanocatalysts also has the potential to decarboxylate biomaterials at lower temperatures. Decarboxylation at lower temperatures via microwave activation could provide a direct route to petroleum-like streams which can be processed using petrochemical technologies.

Partners: Mach I Inc. and the Materials Technology Institute.

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James Hemrick, hemrickjg@ornl.gov, (865) 776-0758

Background: Nano-scale Interpenetrating Phase Composites (IPC’s) have been demonstrated to show improved mechanical, electrical, and thermal properties over traditional refractory materials that are subject to corrosion and mechanical degradation, which limit their use at high temperature. Nano-scale IPC’s have previously been demonstrated at the lab scale, but have been limited to thin films. IPC components of useable size have not been possible with current processes due to difficulties infiltrating preforms (low wetting) and closing pores within the preform.

Goal: This is a Concept Definition Project. The project will explore the technical and economic feasibility of producing nano-scale IPC components of a useable size for testing/implementation in real applications. The work will investigate methods to improve and scale up the current common low temperature IPC processing techniques, and evaluate the technical feasibility of modifying an alternative high temperature TCON process to produce nano-scale IPC components.

Partners: Fireline, TCON, Inc.

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Chaitanya Narula, narulack@ornl.gov, (865) 574-8445

Background: Diesel engines offer 30% better fuel economy than gasoline engines, but their use is limited by the ability to meet emission regulations. Emission requirements for on-road applications are becoming more stringent, and off-road engines are also coming under regulation. Urea-Selective Catalytic Reduction (SCR) of NOx is the leading approach for emission treatment, but the effectiveness of this treatment is limited by catalyst performance.

Goal: This project will develop durable zeolite nanocatalysts with broader temperature operating windows to treat diesel engine emissions. Zeolites are ultimate nano-catalysts where catalyst centers are isolated at atomic level. ORNL will analyze failure modes of zeolite catalysts under SCR operating conditions, then use this information to synthesize new nano-structure modified, hydrothermally stable, zeolite catalysts. The new catalysts will be evaluated under laboratory conditions then undergo Dynamometer testing. The goal of the project is to improve hydrothermal durability by 50ºC, and to improve the operating temperature window (NOx conversion at 150ºC).

Partners: John Deere Power Systems

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Jun Qu, qujn@ornl.gov, (865) 576-9304

Background: Superhydrophobic (water-repelling) materials have the potential for tremendous energy savings because of the ability to reduce friction and to reduce corrosion in a wide variety of applications. ORNL has developed oxide-based superhydrophobic powders which have nanoscale features precisely repeated and of highly uniform dimensions on the surface of each particle. These features are coated with a monolayer of a fluorinated compound treatment.

Goal: The project will work to produce commercially available powder based coatings with extreme water repellent properties. The team will optimize powder properties and binders to produce more uniform and durable coatings for use on a variety of substrates. The coatings will be optimized for drag reduction and corrosion resistance.

Partners: Ross Technology Corp. and Stevens Institute of Technology

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David DePaoli, depaolidw@ornl.gov, (865) 574-6817

Background: Energy storage devices are critical enabling technologies for a variety of renewable energy, transportation, and electrical grid, technologies. However, current electrodes for supercapacitors have cost, energy density, and performance issues. ORNL has developed a capability to synthesize novel carbon materials with tailored energy-storage performance to serve as electrodes in electrochemical capacitors (supercapacitors). Carbon materials with controllable, nanoscale pore size can now be produced by self-assembly using conventional manufacturing processes.

Goal: The new ORNL materials have competitive energy and power densities relative to commercial activated carbon materials. This project will optimize the materials for energy storage and water treatment applications, improve the economics of the materials, scale up manufacturing processes, and test the materials in prototypes.

Partners: Honeywell Specialty Materials and Campbell Applied Physics

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Technical Poster

Adrian Sabau, sabaua@ornl.gov, (865) 241-5145

Background: ORNL has developed a unique high-density plasma arc-based pulse thermal processing technology for rapid thermal annealing of thin-film light-emitting diodes and thin-film and nano-particle photovoltaic (PV) materials. This process has the potential to significantly increase PV collection efficiency and LED electrical properties, while increasing production rates and decreasing production costs. ORNL is working with a multitude of companies that are on the leading edge of their respective technologies.

Goal: This is a Concept Definition project. High-Density Infrared (HDI) plasma arc-based technology is an enabling tool for broad-area nanoscale processing. However, currently Individual nanostructures are rarely initially synthesized with appropriate phase and/or morphology. This project will use an experimental and computational approach to address critical additional steps of as-synthesized nanostructured materials, such as annealing, phase transformation, or activation of dopants over large areas. The project will develop a computer model based on first principles, and validate the process models based on comparison between measured and computed data for ZnO as a solid state lighting application.

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Sheng Dai, dais@ornl.gov, (865) 576-7307

Background: Separation processes account for more than 5% of the total national energy consumption in the US, and will significantly contribute to the anticipated overall increase in energy consumption. It is therefore necessary to focus on the development of highly selective and energy-efficient separation systems. Particularly selective gas separation is a demanding problem in petrochemical industry, which significantly contributes to the overall costs in the production of related chemicals. It is therefore indispensable to develop separation processes that combine low energy consumption with high selectivity and high throughput. These requirements can only be fulfilled by new types of smart nanoscopic filters featuring properties superior to conventional separation systems.

Goal: This project is focused on translating a novel class of material developed at ORNL - self-assembled mesoporous carbon – into robust, efficient membrane systems for selective industrial gas separations. These tailorable, nanostructured materials, described in US Patent Application 2006 057051, "Highly ordered porous carbon materials having well defined nanostructures and method of synthesis," consist of ordered mesopores and tunable micropores that are ideally sized for high throughput separation of gaseous species, such as O2, CO2, and alkanes. The carbon is synthesized by conventional chemical and materials processing approaches, which provides promise for cost-effective production of precision separations materials at large scale.

Partners: Georgia Institute of Technology

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Chad Duty, dutyc@ornl.gov, (865) 574-5059

Background: The unique properties of nanomaterials hold immense potential to impact various energy related technologies, such as solid state lighting, photovoltaics, and thermoelectrics. Unfortunately, the majority of nanomaterials cannot be manufactured and distributed in quantities sufficient to realize these benefits on a meaningful scale. For instance, the large scale production of nanocrystals, or quantum dots (QDs), is hindered by a high level of material defects and the propensity of the QDs to conglomerate into bundles that are not easily distributed across a surface.

Goal: ORNL is developing a chemical synthesis process for the mass production of quantum dots. This process involves the engineered self-assembly of the nanocrystalline particles onto a surface with a uniform spacing. The spacing between nanoparticles is defined by the length of an organic / inorganic molecule that can be tuned to achieve optimal performance. Initial experiments have demonstrated that correctly spaced QDs can constructively interact to improve optical properties –producing a five fold increase in photoluminescence efficiency. The proposed research will develop the quantum dot manufacturing system for roll-to-roll thin film processing. The project will include characterization of the QD thin films, demonstration of scalability toward commercial production, and economic and energy-impact analysis of various market opportunities.

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Michael Hu, hum1@ornl.gov, (865) 574-8782

Background: Oxide-based ionic conductors, such as oxygen- or proton-conducting ceramic membranes, are extremely important materials for a wide range of applications, such as in fuel cells (electrolytes or electrodes), sensors, gas separations, catalysis, microbatteries, thermoelectric generators, and other solid-state ionics-based devices. Recent work has documented the current development of various ionic or mixed conducting oxides. A major technological challenge is how to create and utilize these potential "candidate" conducting oxides in the form of thin-layer membranes that promise much higher ionic conductivity than any existing ceramic membranes.

Goal: The objective of this project is to explore the engineering concept studies and analyze the technological and economic impacts of a novel type of architecture in nanocomposite membranes. The nanoscale host-guest architecture contains oriented interfaces between nanotube/nanowire arrays perpendicular to the membrane layer. Membrane nanostructures determine the performance of a fuel cell, and also possibly, that of solar cells, thermal electric devices, and catalytic membrane reactors. This project will address the processing issues to enable the large-quantity production of such membranes in practical size, and then evaluate them for specific energy applications. Furthermore, the overall technical and economic impacts of such nanomembrane platforms upon various energy technologies (catalytic membrane reactors for petrochemical oil conversion, PEM fuel cells, solar cells, thermoelectric devices, etc.) will be evaluated.

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Joanna McFarlane, mcfarlanej@ornl.gov, (865) 574-4941

Background: Up to 100 million tons of lignin/year may be produced as a byproduct of cellulosic ethanol manufacture – a source of feedstock that has the potential to replace or supplement much of the US petrochemical demand. Recently, Oak ORNL successfully demonstrated biocatalytic and catalytic conversion of lignin to small molecular weight compounds of commercial value: including the aromatics benzene, toluene, styrene, xylenes, and substituted alkyl phenols. These represent building block feedstocks for commodity chemical manufacture and hence a major avenue for bringing new technology based on alternative chemical pathways into the domestic chemical industry. Methods for processing lignin still pose technological barriers that need to be addressed.

Goal: Nanocatalysts have been proposed as effective tools for cracking large refractory organic molecules. In particular, submicron layered heterogeneous particles have been developed, maximizing the surface area and hence sites available for catalytic reactions to occur. This concept project will investigate the use of clay-based nanocatalysts to facilitate the breakdown of refractory organics from unconventional sources: primarily lignin into feedstocks that can be used for fuel and for the chemical industry. A bench-scale experimental study will be carried out to test the efficacy of layer clay-based nanocatalysts in the breakdown of lignin into aromatic building block molecules. The results of these experiments will be used in an economic and feasibility analysis of this approach.

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Govindarajan Muralidharan, muralidhargn@ornl.gov (865) 574-4281

Background: There is a significant need for materials with good mechanical strength including creep resistance along with oxidation resistance or other corrosion resistant properties for operation at high temperatures. In such applications, an increase in temperature capability of the materials used will result in increased energy efficiency of the associated processes thus resulting in energy and cost benefits. Ferritic/martensitic alloys can typically be used for temperatures up to about 625ºC but fail to meet the required strength and oxidation/corrosion resistance requirements for higher temperatures. Oxide Dispersion Strengthened (ODS) ferritic alloys provide improved mechanical strength and corrosion resistance at temperatures up to and exceeding 1000ºC and are a good candidate material for applications such as heat exchanger tubes, gas turbine chambers, ultrasupercritical reactors, and diesel engine components. However, widespread use of these alloys has been hampered by difficulties in processing.

Goal: The objective of this project is to examine the feasibility of using Electromagnetic Stirring (EMS) techniques in dispersing the oxide nanoparticles uniformly within the liquid steel. Alternate techniques to agitate the molten pool will also be explored. Processing of both coatings and bulk materials will be subject of this work. Although the initial work is focused on applications to manufacture of ODS alloys, this technique has a wider application in processing and distributing nanoparticles in any liquid matrix and thus of significant importance to nanomanufacturing.

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Chad Duty, dutyc@ornl.gov, (865) 574-5059

Background: One of the major challenges to the improvement of thin film lithium battery technology is the efficient crystallization and sintering of the LiCoO2 cathode thin-films deposited by rf magnetron sputtering. Even though the as-deposited films, which are x-ray amorphous and possible nanocrystalline, can be used as cathodes, when crystallized to grain sizes approaching 100 nm, the cathodes can deliver a power density 10X higher. Typically, the crystallization requires conventional furnace annealing at 550ºC to 700ºC in an oxidizing atmosphere for several hours. Furthermore, the high temperature anneal step limits the choice of substrate materials to those stable at the high temperature oxidizing conditions. Ideally, the substrate for the thin film battery would be as thin, light, flexible, and inexpensive as possible. If the alumina substrates used in current prototype thin film batteries were replaced with Kapton® (polyimide), which can withstand temperatures to 400ºC, the cathode can be properly annealed by Pulse Thermal Processing.

Goal: ORNL has a unique revolutionary rapid thermal annealing capability that enables in-situ fabrication of nanoscaled materials. This technique utilizes a high density plasma arc-based technology and a methodology called Pulse Thermal Processing (PTP) that enables the manipulation of materials on the nanoscale. The unique characteristics of PTP with its high power densities (>20,000 W/cm²), short processing time (millisecond regime) and large processing area (up to 1,000 cm²) allows for rapid thermal processing of thin film and nanoparticle material systems on flexible temperature-sensitive substrates such as polymers without thermally affecting the underlying material. This research project will focus on the nanocrystallization of the LiCoO2 cathode thin films on polyimide substrates and evaluate the microstructural evolution and resistance as a function of PTP processing conditions. A significant decrease in the cathode resistance as measured by liquid electrolyte testing correlates to improved capacity and charge and discharge rate of the battery.

Partners: ITN Energy Systems, Inc.

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Jun Qu, qujn@ornl.gov, (865) 576-9304

Background: Vertically aligned, highly ordered TiO2 nanotube arrays are of great interest due to their high surface-to-volume ratios and size-dependent properties and, more importantly, have been proven to possess outstanding charge transport properties enabling a variety of advanced PV-related applications, including dye-sensitized solar cells, hydrogen generation by water photoelectrolysis, and photocatalysis.

Goal: The new approach proposed here for synthesis of TiO2 nanotubes using the so-called 'green solvents' ionic liquids that have great energy and environmental benefits: (1) Improve the PV characteristics by producing more preferable nanotube structures, such as finer tube diameter, higher aspect ratio, etc., (2) Reduce the energy consumption in the synthesis due to excellent electrical conductivities of ionic liquids, and (3) Make the synthesis more environmentally friendly because ionic liquids have negligible volatility, less toxicity, and non-flammability compared to the organic solvents-based electrolytes used in literature.

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Claus Daniel, danielc@ornl.gov, (865) 241- 9521

Background: A123 Systems Inc. is one of the leading battery developers in the United States enabling and revolutionizing energy efficient mobility. A123 Systems Inc. is successfully providing safe and affordable Li-ion batteries for limited mileage range HEV – PHEV conversion kits. A newly developed nano-composite material with potential to significantly improve device performance has been developed. However, in order to satisfy vehicle needs and bring the new material from the lab scale to market, there is a need to optimize the formulation and scale up the process while maintaining its nano-feature characteristics. Additionally, low cost processing and quality control measures have to be developed for successful implementation of this material into a safe and reliable lithiumion battery cell.

Goal: This project intends to develop process control and quality measures for a homogenous and reliable deposition and treatment of a nano-composite coating to be used in lithium ion battery technology with guidelines for scale-up and mass production of the product. It will develop fundamental understanding of the nanomaterial behavior, the process mechanisms, and the resulting functionality. It will integrate a quality control approach with a science and technology to produce a reliable product and enable lithium ion battery technology for transportation and stationary applications. New processing technology will be developed including advanced deposition techniques which offer sub-micrometer thickness control and a drying and post treatment technology, all while controlling the microstructure on the nano-scale. ORNL is providing unique facilities for ceramic processing, photonic processing, in-situ characterization and quality control.

Partners: A123 Systems, Inc.

Materials

Jim Keiser, keiserjr@ornl.gov, (865) 574-4453

Background: A prototype transport membrane condenser (TMC) system has been successfully demonstrated for the separation of water vapor and recovery of heat from a clean, controlled gas stream. This prototype membrane system employed a porous ceramic membrane on a porous ceramic tube to condense the water vapor in order to recover the heat. In order to utilize this novel system in a variety of industrial gas streams, new materials, particularly the substrate, must be identified that have sufficient corrosion resistance, strength, and toughness for the intended application.

Goal: Recovery of energy from relatively low-temperature waste streams has been a goal that has not been achieved on any large scale, but TMCs offer a means to achieve that goal. In this project, the goal is to identify materials that have improved thermal conductivity and robustness as well as sufficient corrosion resistance to serve in the anticipated industrial waste and process streams.

Partners: Gas Technology Institute, Media & Process Technology, Cleaver Brooks, and University of Tennessee-Knoxville.

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Stephen Nunn, nunnsd@ornl.gov, (865) 576-1668

Background: AlMgB₁₄-based composites are a new class of super-hard materials that were developed at Ames Laboratory. Initial studies of AlMgB₁₄ composites demonstrated the potential for obtaining a high-wear-resistance material through powder metallurgy processing, however, the approach employed to prepare these composite samples was based on research-scale mechanical alloying and hot pressing. To be used commercially, the composites will need to be produced in larger quantities and in a more cost efficient manner.

Goal: The goal of this project is to increase operating efficiency and operating lifetime of industrial pumping systems and other wear-intensive industrial components by developing and commercializing a family of ceramic-based composites that have shown outstanding wear resistance in laboratory tests. A major objective of the proposed effort is to develop a cost-effective, industrial-scale processing and synthesis method for making AlMgB₁₄ composites that is capable of producing bulk materials possessing comparable or even improved wear-resistance properties compared to the research-scale compacts. Optimization of composition and processing on the laboratory scale will serve as an initial milestone, providing industrial processing partners with a "template" for developing their industrial-scale procedures. Emphasis will be placed on examining alternate powder processing techniques and powder blending and densification methods to eliminate porosity and achieve products exhibiting a maximum combination of hardness and toughness. Successful development of these new wear-resistant composites is expected to result in U.S. energy savings of 31 trillion BTU/year by 2030.

Partners: This project is led by Ames National Laboratory. Other project partners include Carpenter Powder Products, IMI Vision / CCI Valve, University of Missouri, Rolla, and University of Alberta.

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Peter Blau, blaupj@ornl.gov, (865) 574-5377

Background: The development of high-hardness nano-coatings by Ames Laboratory (AL) presents an exceptional opportunity to increase durability and lower the friction in a range of industrial systems. Successful implementation will contribute to reduced material wastage and enhanced energy-efficiency. A joint industry-national laboratory project team reviewed the potential for energy savings and selected the two key technologies on which to demonstrate the benefits of novel nano-coatings: (I) Hydraulic system components: A typical industrial hydraulic system contains a pump, valve, actuator, and sump along with a controller. Eaton's vane pump, spool valve, and gerotor motor actuators were selected as the best test-beds for the study. (II) Tooling: Currently Greenleaf uses WC-6%Co and TiAlN-coated WC-6%Co for low-speed machining of Ti alloys such as Ti-6Al-4V. These coatings will serve as baselines against which to compare the new nano-coatings.

Goal: The project goal is to develop and commercialize degradation-resistance materials-nano-coatings of AlMgB₁₄ and AlMgB₁₄-TiB₂ - applicable to both industrial hydraulic and tooling systems, that result in surface hardness exceeding 30GPa. The project targets for the new Al nano-coatings are: i) sliding friction reduction of 50%; ii) torque-to-turn reduction of 50%; iii) volumetric loss reduction over simulated lifetime of 50% (resulting in pumping efficiency improvement of 3 to 5%); and iv) start-up torque reduction of 75%. For cutting tools these coatings are also targeted at increasing useful life by a factor of two. The technology advanced by this project is expected to result in U.S. energy saving of 31 trillion BTU/year by 2030, with associated energy cost savings of $179M/year. ORNL's role is to develop and apply test methods to investigate and establish the friction, wear, and durability the nano-coatings related to the stated applications.

Partners: This project is led by Eaton Corporation. Other project partners include GreenLeaf Corporation and Ames National Laboratory.

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James Hemrick, hemrickjg@ornl.gov, (865) 776-0758

Background: Currently available refractory materials are limited in their application by many factors including chemical reactions between the service environment and the refractory material, mechanical degradation of the refractory material by the service environment, temperature limitations on the use of a particular refractory material, and the inability to install or repair the refractory material in a cost effective manner or while the vessel is in service.

Goal: The objective of this project is to address the need for new innovative refractory compositions by developing a family of novel Mg-Al₂O₃, MgAl₂O₄, or other similar magnesia/alumina containing unshaped refractory compositions (castables, gunnables, shotcretes, etc) utilizing new aggregate materials, bond systems, protective coatings, and phase formation techniques. The newly developed materials are expected to offer alternative material choices for high-temperature, high-alkali environments that may be capable of operating at higher temperatures (goal of increasing operating temperature by 100-200°C depending on process) or for longer periods of time (goal of twice the life span of current materials). This will lead to less process down time, greater energy efficiency for associated manufacturing processes (more heat kept in process), and materials that can be installed/repaired in a more efficient manner. The overall project goal is a 5% improvement in energy efficiency resulting in a savings of 3.7 TBtu/yr (7.2 billion ft³ natural gas). Additionally, new application techniques and systems will be developed as part of this project to optimize the installation of this new family of refractory materials to maximize the properties of installed linings and to facilitate nuances such as hot installation and repair.

Partners: MINTEQ International, Inc., Aleris International, Eastman Chemical, PPG Industries and Weyerhaeuser Company.

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Bill Peter, peterwh@ornl.gov, (865) 241-8113

Background: Titanium has long been recognized by industry as a superior material for many applications due to its excellent corrosion resistance, high strength, low density/high strength to weight ratio, good elevated temperature performance, and allowance for damage tolerant design. However, titanium has historically been viewed as a specialty material due to high cost and limited availability. Also, the current fabrication process for titanium sheet makes it cost prohibitive for many applications. Recently, low cost titanium and titanium alloy powders have become available that could enable a paradigm shift in the U.S. titanium market. The powders are powder metallurgy grade, and can be used in solid state processing.

Goal: The goal of this project is to fully consolidate these new Ti powders into near net shape sheets/plates for heat exchanger applications. The focus is to develop a roll compaction materials manufacturing process to enable Ti powder to be formed into sheet/plate.

Read more about a related project

Govindarajan Muralidharan, muralidhargn@ornl.gov (865) 574-4281

Background: The major hurdle to the deployment of magnesium products by the transportation industry is the price barrier that currently exists due to the current cost of producing magnesium alloy sheet on a volume basis. Proven technology (e.g., twin roll sheet casting and hot reversing coil mill technology) exists which could lead to lower cost magnesium alloy sheet by as much as 50%.

Goal: Oak Ridge National Laboratory and its industry partners will work to develop shear rolling of magnesium sheet to improve the formability while addressing cost and lower energy consumption. New alloys will be developed that are specifically designed for shear rolling. A roll mill will be available at ORNL to independently control both rolls in order to induce shearing/texturing of the sheet. ORNL will use its extensive capabilities and knowledge in texture characterization to identify the optimum manufacturing process route. The alloy sheets will then be tested for formability and two industrial components will be fabricated from the sheets manufactured using the new shear rolling process.

Partners: Magensium Elektron, North America

Fred Baker, bakerfs@ornl.gov, (865) 241-1127

Background: Production of advanced carbon materials is critically important for development of advanced energy-efficiency systems. Successful deployment of technology in this project will establish a capability for scale-up of the production of advanced carbon materials, with two key applications: carbon fibers for graphite electrodes used in electric-arc furnaces and nanoporous carbons for electrical energy storage, water treatment, and high efficiency HVAC filters.

Premature failure of electrodes in electric arc furnaces (EAFs) results in considerable downtime, lost productivity, and increased energy consumption in steel and aluminum production. Carbon fiber reinforcement is known to toughen the electrodes against failure, but is currently far too expensive for this application. Lignin-based carbon fibers having the target mechanical properties for the application have been produced in lab scale work.

Nanoporous (activated) carbon is the dominant material in electrodes for advanced energy storage systems, but the high-activity materials required are currently far too expensive for large-scale applications. Recent lab-scale R&D on novel processes for the production of high-activity, nanoporous carbons has indicated significant promise for production of low-cost carbon materials from lignin.

Goal: A capability for pilot-scale thermal treatment and activation of carbon materials will be established at ORNL. The user facility will make expert staff available to support industrial and national laboratory users and will provide a test bed at a pilot-production scale for development and scale-up of manufacturing of advanced carbon materials. A facility at this scale is currently lacking and is needed for realistic evaluation and industrial advancement of emerging technologies as well as for the cost-effective production of samples of advanced carbon materials for testing in prototype applications. In addition to a capability for advancing commercialization of carbon-fiber technologies, this facility will provide a basis for cross-cutting applications, as it will enable a broad range of other heat-treatment processes under controlled atmospheres.

Read about the ORNL Carbon Fiber Technology Center
Link to ORNL's workshop on Low Cost Carbon Fiber Composites for Energy Applications

Bruce Pint, pintba@ornl.gov, (865) 574-5153

Background: AFA stainless steels boast an increased upper-temperature oxidation, or corrosion, limit that is 100 to 400 degrees Fahrenheit higher than that of conventional stainless steels. These new alloys deliver this superior oxidation resistance with high-temperature strengths approaching that of far more expensive nickel-based alloys without sacrificing the typical lower cost, formability and weldability of conventional stainless steels.

Goal: The purpose of the project is to develop and deploy high-temperature corrosion-resistant alumina-forming austenitic (AFA) steels into turbine and other energy-related applications (e.g. chemical process industry) in order to improve engine efficiency and/or durability at a potentially lower cost than current alloys. An increased database of the properties and performance of wrought and cast AFA steels will enable additional U.S. industrial partners to employ these materials in applications including fuel cells, boilers and chemical processing. AFA steels are a low-cost, high-performance alternative to conventional advanced austenitic steels and Ni-base alloys. The use of AFA steels, for example, can lead to turbines with increased energy efficiency, lower cost and higher durability that will improve the competitiveness of U.S. turbine manufacturers.

For a Poster on this R&D Award-winning technology (PDF 3.2 MB)

Bruce Pint, pintba@ornl.gov, (865) 574-5153

Background: CF8C-Plus cast austenitic steels are low-cost, high-performance alternatives to conventional cast steels. They may also become a more universal grade that replaces the wide range of similar more expensive custom or specialty steels. For diesel exhaust systems, the current 400 tons of CF8C-Plus steel used by Caterpillar to make the regeneration system burner housing for diesel particular filters has a direct materials value of over $5 million, but prevents the use of nickel-based superalloys that would cost $28 million for the same application, so the benefit is a savings of about $23 million. The CF8C+ steel exhaust components require no heat-treatments after casting, so there is another $ 5 million cost savings relative to cast-irons, steels or alloys that require heat-treating. This alloy was jointly developed by ORNL and Caterpillar. New Cu- and W-modified versions of CF8C-Plus have high-temperature strength properties rivaling more costly Ni-base alloys.

Goal: This effort is to deploy CF8C-Plus to new automotive and energy generation and use related applications. Potential industrial partners include 1) vehicle and diesel engine OEMs, 2) part and critical sub-system manufacturers, 3) gas and steam turbine, reciprocating engine and 4) boiler manufacturers. The required mechanical, physical and corrosion properties database for conventional and modified CF8C-Plus, on commercial heats and industrial sponsor for ASME boiler and pressure vessel code case, are needed in order to expand commercial opportunities for this new material. At the higher temperatures and more aggressive corrosion environments, CF8C-Plus will likely require an environmentally-resistant coating to maximize its durability and reliability in such environments. Increased deployment of CF8C-Plus and modified CF8C-Plus castings can lead to diesel engines and gas or steam turbines with increased efficiency, durability, and lower cost.

For an article on CF8C+ in Advanced Materials Process (PDF 1.12 MB)
For a Press Release on this 2003 R&D 100 Award-winning technology

Claus Daniel, danielc@ornl.gov, (865) 241- 9521

Background: Lithium ion battery technology is projected to be one of the energy storage enabling technologies for the full electrification of drive trains and for providing stationary storage solutions to enable the effective use of fluctuating renewable energy sources. In order to maintain needed nano-scale features for performance, industry will require assistance in scaling the nanomanufacturing approach to large scale industrial and vehicle applications.

Goal: ORNL will work with various companies on new technologies for battery separators and electrodes. ORNL will provide expertise in process scaling and quality control for the successful implementation of the new technologies within 12 to 18 months. ORNL’s expertise in process technology and quality control will enable the successful implementation and fabrication of large scale battery cells meeting the performance needs and cost targets for the described applications. Flexible packaging needs to be sealed for 15 years and 10 to 20 current collector foils (each~10 to 15 µm thickness) need to be joined reliably. ORNL’s joining expertise will help in developing state of the art joining methodologies and reliable solutions for companies.

For a Fact Sheet on Energy Storage at ORNL (PDF 122 KB)
Read more about a related project
For more about energy storage at ORNL

Chad Duty, dutyc@ornl.gov, (865) 574-5059

Background: The grand challenge for the wide spread use of thin film photovoltaic materials is obtaining a high conversion efficiency over large areas at a reasonable cost. Simultaneous optimization of these three parameters (efficiency, area, & cost) will not only demand a fundamental understanding of the material science involved in photovoltaics, but will also require careful characterization and process control to achieve large-scale performance on a flexible substrate. For instance, the lab-scale efficiency of CIGS solar cells is around 20%, but the best commercially available CIGS cells operate at only 5-11% efficiency.

Goal: The purpose of this project is to apply the vast resources and expertise of Oak Ridge National Laboratory to the challenges facing today’s manufacturers of thin film solar cells. ORNL has the capabilities in place and the expertise required to understand how basic material properties including defects, impurities, and grain boundaries affect the solar cell performance. ORNL also has unique processing capabilities to optimize the manufacturing process for fabrication of high efficiency and low cost solar cells.

ORNL recently established the Center for Advanced Thin-film Systems (CATS) which contains a suite of optical and electrical characterization equipment specifically focused on solar cell research. This facility has been lauded by the solar industry due to its unique and diverse solar characterization capabilities situated in one location. Under the current project, ORNL will make these facilities available to industrial partners who are interested in pursuing collaborative research toward the improvement of their product or manufacturing process. The project will also enable ORNL staff members to pursue a sustained level of research that addresses issues common to several members of the solar industry.

For more information on the ORNL Solar Technologies Program

Gail Mackiewicz Ludtka, ludtkagm@ornl.gov, 865-576-4652

Background: For decades, commercial steel and heat-treating operations have been plagued with costly conventional processing steps (e.g., cryogenic treatments, long double-temper cycles) needed to reduce the amount of retained austenite developed during standard steel processing. However, without these additional process steps, component life and product performance would be severely compromised and result in premature failures. Research at ORNL has demonstrated that high magnet field processing (HMFP) reduces residual stresses and destabilizes and reduces retained austenite, eliminating these energy intensive and costly specialized industrial thermal processing steps.

Goal: In this project, magnetic processing equipment and parameters for the HMFP technology will be developed to demonstrate the response and performance in a continuous processing line for the fabrication of razor blades. The new system will be developed and demonstrated for testing and use on a production floor. This effort will lead to facilitation and commercial implementation of this ThermoMagnetic Processing (TMP) Technology.

For a Poster about the 2009 R&D 100 Award (PDF 3.0 MB)
Read more about a related project

Other Projects

Patti Garland, garlandpw@ornl.gov, (202) 586-3753

Background: The Industrial Technologies Program (ITP) is committed to researching and developing technologies that will improve national energy security, climate and environment, and economic competitiveness. The Industrial DE program seeks to lead technology innovation and spur the widespread commercial deployment of combined heat and power (CHP) solutions and achieve significant energy intensity and greenhouse gas emissions reductions.

Goal: Partnering with private industry and states, the Industrial DE Program targets the acceleration and deployment of distributed energy and combined heat and power (CHP) systems and applications. CHP is a real, near-term solution for energy consumption issues and carbon constraints, in the U.S. However, CHP has not been fully deployed because of a number of market and technical issues. ITP activities help eliminate regulatory and institutional barriers to widespread commercialization, and increase market awareness of industrial distributed energy technologies. ITP also promotes education, technical assistance, and assessments through the CHP Application Centers.

Partners: UTRC, IBM and Frito Lay

For More information: See Combined Heat and Power: Effective Energy Solutions for a Sustainable Future (PDF 2.5 MB)

Ed Vineyard, vineyardea@ornl.gov, (865) 574-0576

Background: Boilers are a critical element of industrial operations in the United States, consuming roughly 20% of the natural gas used in the manufacturing sector. Within the U.S. manufacturing sector, the food processing industry alone utilizes over 10,000 boilers to serve its heating and power needs. More than 70% of these boilers consume natural gas, amounting to an annual consumption of 237 trillion Btu.

Goal: This Fuel and Feedstock Flexibility project aims to reduce the food processing industry's large natural gas consumption through the research, development, and demonstration of biomass boiler applications that can be widely commercialized throughout the industry in an effective and cost-competitive manner. The project will include the design and pilot demonstration of an innovative biomass boiler system utilizing a combination of wood waste and tire-derived fuel waste.

Partners: Burns & McDonnell Engineering Company, Inc., CPL Systems, Inc., Frito-Lay, Inc., and Alpha Boilers, Inc.

Fact Sheet (PDF 1.0 MB)