Completed R&D

Energy Intensive Industries
Crosscutting Technologies
MPLUS

Completed R&D

Energy Intensive Industries

Aluminum
Chemicals
Forest Products
Metal Casting

Mining
Petroleum Refining
Steel

Crosscutting Technologies

Industrial Materials for the Future
Supporting Industries

Metals Processing Laboratory Users (MPLUS)

Aluminum

Continuous Severe Plastic Deformation Processing of Aluminum Alloys: Gail Mackiewicz-Ludtka, Ludtkagm@ornl.gov, (865) 576-4652; Fact Sheet (PDF 210 KB); Final Report: (June 2006)

Degassing of Aluminum Alloys Using Ultrasonic Vibrations: Gail Mackiewicz-Ludtka, Ludtkagm@ornl.gov, (865) 576-4652; Fact Sheet (PDF 76 KB); Final Report: June 2006 (PDF 2.1 MB)

Effects of Impurities on the Processing of Aluminum Alloys: Gail Mackiewicz-Ludtka, Ludtkagm@ornl.gov, (865) 576-4652; Fact Sheet (PDF 71 KB); For a highlight about the Project (PDF 52 KB)

Improving Energy Efficiency in Aluminum Melting: Gail Mackiewicz-Ludtka, Ludtkagm@ornl.gov, (865) 576-4652; Fact Sheet (PDF 213 KB)

Modeling Optimization of Direct Chill Casting to Reduce Ingot Cracking: Gail Mackiewicz-Ludtka, Ludtkagm@ornl.gov, (865) 576-4652; Fact Sheet (PDF 96 KB); Final Report: June 2006 (PDF 5.3 MB)

Chemicals

Advanced Hydraulic and Mass Transfer Models for Distillation Column Optimization and Design: Valmor de Almeida, dealmeidav@ornl.gov, (865) 241-2906; Fact Sheet (PDF 817 KB); Final Report: (October 2005)

Alloys for Ethylene Production: Jim Keiser, keiserjr@ornl.gov, (865) 574-4453; Fact Sheet (PDF 131 KB)

Low-Cost Chemical Feedstocks using an Improved and Energy-Efficient Natural Gas Liquids Removal Process: Miting Du, mdu1@ornl.gov, (865) 576-8095; Fact Sheet (PDF 1.1 MB)

Oxidative Dehydrogenation of Ethane Present in Natural Gas to Ethylene: Chaitanya Narula, narulack@ornl.gov, (865) 574-8445; Fact Sheet (PDF 1.2 MB)

Forest Products

Corrosion in Kraft Digesters: Steve Pawel, pawelsj@ornl.gov, (865) 574-5138; Fact Sheet (PDF 512 KB)

Environmental Influences on Wood Chemistry and Density of Populus and Loblolly Pine: Gerald Tuskan, tuskanga@ornl.gov, (865) 576-8141; Fact sheet (PDF 125 KB); Final Report (PDF 249 KB)

Increasing Yield and Quality of Low-Temperature, Low-Alkali Kraft Cooks with Microwave Pretreatment: A.L. Compere, compereal@ornl.gov, (865) 574-4970; FY06 Peer Review Presentation (PDF 364 KB); Fact sheet (PDF 1.1 MB)

Microwave Pretreatment: In Mill Evaluation, Kiln Schedule, and Process Model: A.L. Compere, compereal@ornl.gov, (865) 574-4970; Fact Sheet (PDF 1.1 MB)

Wireless Microwave Wood Moisture Measurement System for Wood Drying Kilns: Gregory Hanson, hansongr@ornl.gov, (865) 574-9681; Factsheet (PDF 1.1 MB); Final Report (PDF 898 KB)

Rapid, Low Temperature Electron-beam, X-ray, and Gamma Ray Curable Resins for Wood Composites: William Griffith, griffithwl@ornl.gov, (865) 574-4970; FY06 Peer Review Presentation (PDF 2.6 MB); Fact sheet (PDF 1.1 MB)

Metal Casting

Advanced Scalable Clean Aluminum Melting System: Gail Mackiewicz-Ludtka, Ludtkagm@ornl.gov, (865) 576-4652; Fact sheet (PDF 118 KB)

Development of Computational Tools for the Assurance of High Strength and Fatigue Resistant Aluminum Castings: Gail Mackiewicz-Ludtka, Ludtkagm@ornl.gov, (865) 576-4652; Fact sheet (PDF 138 KB)

In-situ Real Time Monitoring and Control of Mold Making and Filling Processes: Ralph Dinwiddie, dinwiddierb@ornl.gov, (865) 574-7599; Fact sheet (PDF 213 KB)

Predicting Pattern Tooling And Casting Dimension For Investment Casting: Adrian Sabau, sabaua@ornl.gov, (865) 241-5145; Fact sheet (PDF 105 KB); For a highlight about the project (PDF 64 KB); Final Report (PDF 2.0 MB)

Sensors For Die Casting: Gail Mackiewicz-Ludtka, Ludtkagm@ornl.gov, (865) 576-4652; Fact sheet (PDF 390 KB)

Mining

Advanced Surface Enhancement Technology for Decreasing Wear and Corrosion for Mineral Processing: Gail Mackiewicz-Ludtka, Ludtkagm@ornl.gov, (865) 576-4652; Fact sheet (PDF 145 KB)

Mining Byproduct Recovery: Jan Berry, berryjb@ornl.gov, (865) 241-1939; Fact sheet (PDF 515 KB)

Petroleum Refining

Biocatalytic Desulfurization of Petroleum: Abhijeet Borole, borolea@ornl.gov, (865) 576-7421; Fact Sheet (PDF 91 KB),; Final Report (PDF 318 KB)

Steel

Aluminium Bronze Alloys to Improve the System Life of Basic Oxygen and Electric Arc Furnace Hoods, Roofs, and Side Vents

Aluminum Bronze Alloys to Improve the System Life of Basic Oxygen and Electric Arc Furnace Hoods, Roofs, and Side Vents: Mike Santella, santellaml@ornl.gov, (865) 574-4805; Fact Sheet (PDF 2.0 MB); Final Report (PDF 4.0 MB))

Automated Steel Cleanliness Analysis Tool (ASCAT): Ted Nolan, nolanta@ornl.gov, (865) 574-8422; Fact Sheet (PDF 81 KB); Final Report (PDF 7.0 MB)

Large-Scale Evaluation of Nickel Aluminide Rolls in a Heat-Treat Furnace: Govindarajan Muralidharan, muralidhargn@ornl.gov, (865) 574-4281; Fact Sheet (PDF 2.6 MB); Final Report (PDF 2.0 MB); 2005 E Bulletin Article; For a fact sheet on this R&D 100 award winning technology (PDF 370 KB)

Industrial Materials for the Future

Advanced Wear and Corrosion Resistant Systems through Laser Surface Alloying: Suresh Babu, babuss@ornl.gov, (865) 574-4806; Fact Sheet (PDF 733 KB); Final Report (click here)

Advanced Integration of Multi-Scale Mechanics and Welding Process Simulation in Weld Assessment: John Vitek, itekjm@ornl.gov, (865) 574-5601; Fact Sheet (PDF 1.3 MB); 2006 Project Summary (PDF 63 KB)

Characterization of Spinel Glass Tank Refractories: Matt Ferber, ferbermk@ornl.gov, (865) 576-0818; Fact Sheet (PDF 1.2 MB); Final Report: October 2003 (PDF 3.7 MB)

Ceramic and Refractory Components for Aluminum Melting and Casting:: Ron Ott, ottr@ornl.gov, (865) 574-5172; Fact Sheet (PDF 693 KB); Final Report: June 2006 (PDF 3.6 MB)

Combinatorial Methods for Alloy Design and Optimization: Easo George, georgeep@ornl.gov, (865) 574-5085; Fact Sheet (PDF 121 KB); Final Report: June 2006 (PDF 7.1 MB)

Development of Cast Austenitic Stainless Steel: Govindarajan Muralidharan, muralidhargn@ornl.gov, (865) 574-4281; Fact Sheet (PDF 147 KB); Final Report: June 2006 (PDF 13.2 MB); 2005 E Bulletin Article

High Density Infrared Treatment of Refractories: Terry Tiegs, tiegstn@ornl.gov, (865) 574-5173; Fact Sheet (PDF 152 KB); Final Report: March 2005 (PDF 4.3 MB)

High Energy Density Coatings: Govindarajan Muralidharan, muralidhargn@ornl.gov, (865) 574-4281; Fact Sheet (PDF 134 KB); Final Report: June 2006 (PDF 5.2 MB)

High-Density Infrared Transient Liquid Coatings: Gail Mackiewicz-Ludtka, Ludtkagm@ornl.gov, (865) 576-4652; Fact Sheet (PDF 1.1 MB)

Inverse Process Analysis for the Acquisition of Thermophysical Data: Adrian Sabau, sabaua@ornl.gov, (865) 241-5145; Fact Sheet (PDF 93 KB); Final Report: June 2006 (PDF 973 KB)

Low-Temperature Surface Carburizing of Stainless Steels: Govindarajan Muralidharan, muralidhargn@ornl.gov, (865) 574-4281; Fact Sheet (PDF 1.1 MB); September, 2006 article in Advanced Materials and Processes; December 2006 ITP E-Buletin Article; 2006 Project Summary (PDF 141 KB); Final Report: (click here)

Materials for High-Temperature Black Liquor Gasification: Jim Keiser, keiserjr@ornl.gov, (865) 574-4453; Fact Sheet (PDF 1.1 MB); Final Report: June 2006 (PDF 1.3 MB); December, 2005 ITP E-Bulletin Article; 2006 Project Summary (PDF 50 KB)

Magnetic Field Processing of Materials: Gerad Ludtka, ludtkagm1@ornl.gov, (865) 574-5098; Fact Sheet (PDF 95 KB); Final Report: March 2005 (PDF 3.2 MB)

Materials for Industrial Heat Recovery Systems: Jim Keiser, keiserjr@ornl.gov, (865) 574-4453; Fact Sheet (PDF 1.1 MB); Final Report (PDF 22 MB); 2006 Project Summary (PDF 54 KB)

Multifunctional Metallic and Refractory Materials for Handling of Molten Metals: James Hemrick, hemrickjg@ornl.gov, (865) 776-0758 $Multifunctional metallic and refractory materials for handling of molten metals$; Fact Sheet (PDF 1.3 MB); July 2007 ITP E-Bulletin Article; June 2006 ITP E-Bulletin Article; 2006 Project Summary (PDF 83 KB)

New Class of Fe-3Cr-W(V) Ferritic Steel: Mike Santella, santellaml@ornl.gov, (865) 574-4805; Fact Sheet (PDF 104 KB); Final Report: March 2005 (PDF 6.7 MB)

New Class of Bainitic Chromium Tungsten Steels: Mike Santella, santellaml@ornl.gov, (865) 574-4805; Fact Sheet (PDF 1.1 MB); Final Report: June 2006 (PDF 4.6 MB)

Physical and Numerical Analysis of Extrusion Process for Production of Bi-Metallic Tubes: Gail Mackiewicz-Ludtka, Ludtkagm@ornl.gov, (865) 576-4652; Fact Sheet (PDF 585 KB); Final Report: August 2006 (PDF 7.8 MB)

Real-Time Characterization of Nanomaterials Manufacturing: David DePaoli, depaolidw@ornl.gov, (865) 574-6817; Fact Sheet (PDF 165 KB)

Semi-Stochastic Algorithm for Optimizing Alloy Composition of High-Temperature Austenitic Stainless Steels (H-Series): Govindarajan Muralidharan, muralidhargn@ornl.gov, (865) 574-4281; Fact Sheet (PDF 112 KB); Final Report: June 2006 (PDF 746 KB)

Stress-Assisted Corrosion in Boiler Tubes: Steve Pawel, pawelsj@ornl.gov, (865) 574-5138; Fact Sheet (PDF 511 KB); Final Report: April 2006 (PDF 11.5 MB)

Structurally Integrated Coatings for Wear and Corrosion: Craig Blue, blueca@ornl.gov, (865) 574-4351; Fact Sheet (PDF 1.1 MB); 2006 Project Summary (PDF 47 KB)

Thermochemical Models and Databases for High Temperature Materials: Ted Besmann, besmann@ornl.gov, (865) 574-6852; Fact Sheet (PDF 997 KB); 2006 Project Summary (PDF 57 KB)

Ultrasonic Processing of Materials: Gail Mackiewicz-Ludtka, Ludtkagm@ornl.gov, (865) 576-4652; Fact Sheet (PDF 196 KB); Final Report: June 2006 (PDF 10.0 MB)

Virtual Welded Joint Design Integrating Advanced Materials and Processing Technologies: Suresh Babu, babuss@ornl.gov, (865) 574-4806; Fact Sheet (PDF 177 KB); Final Report: June 2005 (PDF 4.3 MB)

Supporting Industries

Enhancement of Aluminum Alloy Forgings through Rapid Billet Heating: Craig Blue, blueca@ornl.gov, (865) 574-4351; Final Report (PDF 4.2 MB); To view a poster about the project (PDF 599 KB); For a news release on this R&D 100 Award winning technology

Novel Optimization Methodology for Welding Process/Consumable Integration:: Suresh Babu, babuss@ornl.gov, (865) 574-4806; Final Report (PDF 2.0 MB)