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

For a Fact Sheet

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.

For a Fact Sheet (PDF 1.0 MB)

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

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

Fact Sheet (PDF 616 KB)

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

Read about this R&D 100 Award winning technology in Materials World

For a Fact Sheet (PDF 1.0 MB)

For a Poster about the 2007 R&D 100 Award (PDF 15.6 MB)

Nanomanufacturing

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 550?C to 700?C 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 400?C, 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.
For a Fact Sheet on this ITP project (PDF 469 KB)

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

For a Poster on the Project

For a Brochure on ITP Nanocoatings (PDF 2.1MB)

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 50?C, and to improve the operating temperature window (NOx conversion at 150?C).

Partners: John Deere Power Systems

For a Fact Sheet (PDF 1.0 MB)

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

For a Poster (PDF )

For a Poster about the 2008 R&D 100 Award (PDF 2.0 MB)

For a Fact Sheet (PDF 1 MB)

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

For a Fact Sheet (PDF 1.0 MB)

For a Poster (PDF 450 KB)

Technical Poster

Shannon Mahurin, mahurinsm@ornl.gov, (865) 241-3417

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

For a Fact Sheet on this ITP project (PDF 464 KB)

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.

For a Fact Sheet on this ITP project (PDF 454 KB)

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.

For a Fact Sheet on this ITP project (PDF 462 KB)

For a Fact Sheet (PDF 1 MB)

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.

For a Fact Sheet (PDF 410 KB)

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

Background: Nanofermentation is a novel approach to the synthesis of nanomaterials.  The basic process uses bacteria to facilitate the controlled growth of nanomaterials.  The specific organisms under investigation, thermophilic anaerobic bacteria, excrete copious amounts of materials external to their cell.  ORNL has demonstrated that, through the addition of chemical control agents, it is possible to control the particles size (from 3 nm to 300 nm) and shape.  Recent experiments have demonstrated that these bacteria can likewise synthesize a variety of candidate materials for quantum dots (CdS, ZnS, CIGS, CIGSulfur).  The specific advantage of nanofermentation, as demonstrated on a DARPA program, is scalability.  The potential for large scale production could truly be a disruptive technology.  A single 50,000 gallon fermentor could provide yields approaching 500 kg/month.  The basic process is energy efficient, only requiring the heating of the fermentor. 

Goal: There are three fundamental objectives of this project.  Our first objective is to demonstrate that the bacterially synthesized materials across scales have similar if not superior properties as quantum dots synthesized by traditional means.  We will explore the scaling of nanofermentation with respect to the synthesis of quantum dots.  We will expand the synthesis from mg samples to kg samples (6 orders of magnitude), comparing the yield, efficiency and quality of materials.  Second, we will demonstrate an ability to control particle stoichiometry.  Our hypothesis is that, by controlling stoichiometry at the particle scale, it is possible to finely control stoichiometry over a large area.  Finally, we will explore the deposition over large surface areas, controlling film thickness, and consolidating the particles into thin films using pulse thermal processing (PTP).  The combination of all of these objectives will enable a new class of low cost, high efficiency solar cells.

For earlier work on this project

 

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.

Fact Sheet (PDF 1.2 MB)

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.

Fact Sheet (PDF 1.1 MB)

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

For a Poster (PDF 716 KB)

For a Fact Sheet about our MOU with Canmet (PDF 135 KB)

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.

For a Poster (PDF 1.03 MB)
For a Brochure about ORNL Carbon Materials (PDF 2.1 MB)
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) 576-2897

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 (PDF 1.22 MB)
For a Poster on this R&D Award-winning technology (PDF 3.2 MB)
To view a Knoxnews.com article about AFA Steels
For more information about a related project
For more information on AFA steels visit ORNL AFA Steels R&D

Bruce Pint, pintba@ornl.gov, (865) 576-2897

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
For a poster about this R&D 100 Award winning technology (PDF 2.0 MB)
For more information on CF8C Plus visit ORNL CF8C Plus Steels R&D
Fact Sheet (PDF 513 KB)

David Wood, wooddl@ornl.gov, (865) 574-1157

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 ?m 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.

Partners: A123 Systems, Inc., Dow Kokam, LLC, Johnson Controls, Inc., Planar Energy Devices, Inc., and Porous Power Technologies, LLC

Fact Sheet (PDF 479 KB)
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 a Brochure about ORNL Solar Energy (PDF 1.3 KB)
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

Grand Challenge

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

Background: The proposed project, led by Eaton Corporation and involving ORNL, Ames Laboratory, Borg Warner Morse, and Pratt & Whitney Rockdyne, seeks to develop a new class of high-performance nano-composite coatings consisting of solid lubricating species in both metal and ceramic-based binders. These coatings will be capable of sustaining higher load-carrying capacity than current state-of-the-art coating compositions, while still maintaining low friction to save energy. Example applications include transmission gears, heavy-duty clutches, aerospace seals and conveyance systems, hydraulics, and automotive supercharger components.

Goal: ORNL tribology researchers will support this effort by conducting friction and wear tests to help down-select the best candidate coatings from those developed by the partners. The ORNL work will:

• Select and demonstrate a baseline friction and wear testing method suitable for laboratory-scale benchmarking of the best candidate nanocomposite coatings.
• Conduct baseline friction and wear tests of current materials that will allow quantitative rankings of candidate nanocomposite coatings. And
• Complete friction and wear characterization of candidate nanocomposite coatings and provide an analysis of their potential to offer superior load-carrying capabilities for highly-loaded bearing surfaces.

Mike Brady, bradymp@ornl.gov, (865) 574-5153

Background: Alumina-forming austenitic steels (AFA) are a new class of heat-resistant stainless steels with the potential for 10x order of magnitude improvement in high-temperature corrosion resistance over that of conventional stainless steels. The outstanding corrosion resistance of AFA stainless steels results from the formation of a protective aluminum oxide (alumina, Al2O3) surface layer, which can provide protection to higher temperatures and for longer times than can conventional chromium-oxide (chromia, Cr2O3)-forming stainless steels. The AFA alloys are candidates for a wide array of energy intensive industrial uses, ranging for example from chemical and petrochemical processing to industrial steam boilers.

Goal: The goal of this Carpenter Technology Corporation-led effort is to assess the potential for AFA alloys to deliver 10x order of magnitude improvement in high-temperature corrosion resistance over that of conventional stainless steels in a range of carburization, sulfidation, and steam environments relevant to chemical and petrochemical processing and industrial steam boilers. ORNL will evaluate trial heats of AFA alloy compositions using conventional casting and rolling techniques for high-temperature corrosion resistance.

For a related project on AFA Steels

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

Background: This project led by Southwire Company will develop and demonstrate the feasibility of a solid-state material synthesis process - direct solid-state metal conversion (DSSMC) technology that consolidates and converts powders, chips or other recyclable feedstock metals or scraps directly into useable product forms without re-melting the feedstock. Through mechanical alloying and processing, DSSMC makes it possible to produce nano-engineered bulk materials from recyclable feedstock. Since melting is avoided, the technology is extremely energy efficient, with a theoretical energy savings over 80% of the conventional metal casting processes.

Goal: The team will demonstrate production of nano-particle dispersion strengthened bulk materials and/or nano-composite materials toward eventual applications in future generation electric power delivery infrastructure and lightweight structures for automotive manufacturing. Initial applications will be for solid wires formed from multiple alloys.

For a Poster (PDF 7.0 MB)

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

Background: The objective of this project led by the Gas Technology Institute is to study and prove a nano-porous membrane based water vapor separation concept, which can be used for recovering energy and water from low-grade industrial waste heat streams with high moisture content. If proven successful, the proposed technology can recover not only the sensible heat but also high-purity water along with its considerable latent heat. Metallic substrate membranes have many advantages over ceramic substrate membranes including better heat transfer performance, more robust and easier to fabricate large modules for use in large industrial processes. Therefore, it is important to develop high performance metallic substrate membranes that are designed to provide optimum performance.

Goal: This project will improve the current outside membrane coating method used in a transport membrane condenser to achieve higher water transport flux by 1) using a thinner and more uniform membrane layer (an intermediate layer will likely be needed), 2) eliminating the membrane pin-hole defect problem, and 3) making the tube geometry more uniform so that it can be available for future large quantity industrial module fabrication. The project will evaluate membrane performance in a real industrial environment for long term testing.

For information about a related project

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

Background: Recent work at Cornell University has shown that the bandgap of the InN-GaN system can be tailored to span the entire solar spectrum. This work opens the possibility to fabricate multi-junction solar cells from a single material system, enabling a low-cost route to high-efficiency multi-junction solar cells with efficiency improvements of over 100%. However, materials growth issues and the high cost of the production technology, such as molecular beam epitaxy (MBE) or metal organic chemical vapor deposition (MOCVD) have impeded implementation. This project will support Structured Materials Industries, Inc. in their effort to develop a low-cost process called hydride organo-metallic vapor phase epitaxy (HOVPE) for the production of InGaN semiconductor materials for use in high efficiency photovoltaic systems.

Goal: In this effort, SMI, Cornell University and Oak Ridge National Laboratory will evaluate a new hybrid hydride organo-metallic vapor phase epitaxy (HOVPE) system that has the potential have a low cost-of-ownership (COO) and to produce InGaN layers of sufficient material quality for high-efficiency solar cells. ORNL will be primarily responsible for the structural, chemical, and electrical characterization of the materials fabricated using the novel HOVPE process. ORNL will characterize the materials using electron microscopy and x-ray/neutron scattering techniques as is appropriate. Of particular interest is the homogeneity of the structure and chemistry of the materials deposited using the novel process. Basic PV characteristics of the material will also be evaluated. The development of large-scale, low-cost, production of the material will be paramount to this development process.

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

Background: The purpose of this R&D is to develop a transformational approach to titanium aircraft component fabrication that utilizes emerging methods of titanium reduction technology which dramatically reduce energy consumption and material costs, and in turn enable the low-cost fabrication of titanium components. The team will examine two of the most promising innovative approaches to primary titanium production that are currently in the commercialization stage: the Armstrong Process, and the FFC Cambridge process.

Goal: ORNL's effort will focus on improving the handling and volumetric concerns associated with the new powders including attrition, ball milling, etc. while addressing components that the PM process will be applicable for the aircraft industry. A large portion of the effort will also look at the energy and cost savings associated with the process.

Click here and here for related efforts in Ti materials processing

Robert Norris, norrisrejr@ornl.gov, (865) 576-1179

Background: This project addresses detailed fundamental understanding, development, and demonstration of advanced carbon fiber conversion processes as well as specific formulation and processing requirements to facilitate utilization of polyolefin-based precursors for carbon fiber production. The advanced conversion processes will be based on previous ORNL work in Microwave-Assisted Plasma (MAP) and related technologies for carbonization.  Likewise, the precursor development builds on recent ORNL work and the resources of Dow Chemical Company to create cost-effective and technically sufficient alternatives.  The team will evaluate the overall energy usage of the hardware and materials systems to determine the energy efficiency of the technology of polyolefin-based carbon fiber and compare that with the conventional carbon fiber production from PAN-based fibers.

Goal: The objective of this project is to develop, demonstrate, and commercialize alternative technology to produce polymer fiber precursors and scaled energy-efficient advanced conversion technology to enable manufacturing of carbon fibers that are technically and economically viable in industrial markets. Industrial applications critical to efficient energy production and utilization, specifically transportation, wind energy, infrastructure and oil drilling applications, are targeted for lower cost carbon fiber applications where aircraft grade carbon fiber is not required. Manufacturing processes and precursor chemistry may be adjusted to meet specifications from these industrial targets at lower cost.

Partners: Dow Chemical Company, Michigan Economic Development Corporation

For a Brochure about ORNL Carbon Materials (PDF 2.1 MB)

 

STEELS

Wayne Manges, mangesww@ornl.gov, (865) 574-8529

Background: The National Research Council (NRC) identified advanced wireless sensors as a key research need for the DOE Industrial Technologies Program (ITP). 
Oak Ridge National Laboratory’s (ORNL) previous project ended with feasibility demonstrations at various industrial sites around the nation.

Goal: The project goal is to facilitate the deployment of wireless technology in the industries represented by DOE/ITP. Early stages of this activity included the commissioning and deployment of the DOE Extreme Measurement Communications Center (EMC2) at ORNL to characterize and simulate the performance of candidate industrial wireless telemetry devices in harsh industrial environments. The latest stage of the project focuses on establishing and promulgating industrial standards and demonstrations that facilitate large-scale deployment of industrial wireless technology in commercial facilities.

The ORNL team will also facilitate the instrumenting of industrial facilities, specifically steel mills, with wireless sensors to help realize the recognized potential energy efficiency gains in the steel-making process. The team went through a rigorous process of selecting an integrated mill and a mini-mill as deployment locations. This included evaluating each sites’ processes to characterize and determine what data monitoring points would be of most use to operations and have the greatest energy impacts.  The team took into consideration the budgetary constraints of the mill, issuance of request for proposal(s) from industrial suppliers, and selecting and commissioning the systems. As of January 2011, the integrated mill’s system had been selected, installed, commissioned, and is currently undergoing the operations test. The mini-mill’s system is scheduled for vendor selection and installation, currently estimated for completion in February 2011.

For a related project

Bruce Pint, pintba@ornl.gov, (865) 576-2897

Background: ORNL developed a series of 3Cr Super-Bainitic steels which offer outstanding creep properties up to 700°C, superior to the best ferritic 9Cr steels and rivaling some Ni-base alloys at this temperature at 1/10 of the cost.  With the lower Cr content, these alloys do not require a post-weld heat treatment, which is a significant advantage in manufacturing large pressure vessels and boiler waterwalls compared to 9-12%Cr ferritic-martensitic steels.  These 3Cr steels could replace 2¼Cr steels which are limited to ~550°C and potentially increase operating temperatures by 50°-150°C, permitting significant increases in operating efficiencies. 

Goal: The goal of this project is to accelerate the deployment of super-bainitic 3Cr steels.  Potential industrial partners include alloy and tube manufacturers and end-users such as boiler and turbomachinery manufacturers and the petrochemical industry. One concern about 3Cr steels operating at >550°C is the potential need for corrosion resistant coatings. ORNL has the creep, welding, coating and environmental testing facilities to conduct initial work to reestablish these materials with potential industrial users.

Partners: The Timken Corporation and University of California at Pomona

Michael Santella, santellaml@ornl.gov, (865) 574-4805

Background: It is believed that microstructures consisting of combinations of austenite with either ferrite or martensite should be capable of developing properties consistent with Gen III AHSS objectives.  It could be possible to produce austenite-ferrite or austenite-martensite sheet using high-deformation-rate rolling, such as accumulative roll bonding (ARB). Most published R&D on ARB is done using aluminum or copper alloys.  However, applying ARB to produce ultra fine-grained carbon steels is feasible.  A unique use of ARB would be for producing strips composed of ultra fine-grained layers of commercial grades of carbon steel and austenitic steel. Controlled heat treatments could produce both austenite-ferrite and austenite-martensite microstructures.  Not only could such composite sheets have strength properties in the Gen III AHSS range, but manipulation of the stacking sequence would produce sheets where the final exposed surfaces were austenitic alloy with inherent corrosion resistance.

Goal: This project will support the development of the Gen III steels by using a novel processing concept, accumulative roll bonding, to artificially create austenite-ferrite and austenite-martensite microstructures of controlled amounts and grain structures.  Accumulative roll bonding will be done with commercial grades of ferritic and austenitic steels. 

Alan Liby, libyal@ornl.gov, (865) 576-4221

Background: Hot isostatic pressing, or HIP, is the process of reducing porosity of a casting or consolidating a powder metallurgy component by applying pressure at an elevated temperature over a moderate time interval.  Avure has demonstrated improvements of 30-50% in wear performance of HIPed powder metallurgy components compared to conventionally processed steel.  Additional focused R&D is projected to extend the improvement to 3 to 4 times that of conventional processing. Wear components require a tough core and a hard surface to achieve a combination of wear resistance and fatigue strength for optimum performance.  Components requiring optimized properties between core and surface include gear components, camshafts, driving pinions, link components, axles and arbors. 

Goal: Friction and wear of components in transportation and energy generation equipment reduce system efficiencies, reduce lifetimes and parasitically consume energy.  Significant improvements in material wear performance will translate to enduring energy savings and lower systems cost.  ORNL and partners will explore improvements in wear component performance through HIP of high alloy steel powders for wear applications. 

Partners: Avure Technologies, Inc. and Carpenter Powder Products, Inc.

Related Projects:

For Related work on AFA Alloys
For more information on AFA steels visit ORNL AFA Steels R&D

For Related work on CF8C-Plus Alloys
For more information on CF8C Plus visit ORNL CF8C Plus Steels R&D

For Related Work on High Performance Steels for Fossil Energy Applications

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)

Bruce Pint, pintba@ornl.gov, (865) 576-2897

Background: The project led by Capstone Turbine Corporation will develop a new, high efficiency 370kW microturbine for a combined heat and power demonstration. In order to achieve the increase in electrical efficiency to 42%, several materials challenges will need to be addressed to meet the performance, durability and cost goals of the project. The objective of this project is to identify advanced materials solutions, evaluate their performance and durability and then assist in their implementation in the new engine design.

Goal: ORNL will evaluate the properties of components and materials including Higher pressure recuperator materials, silicon nitride turbine wheels, metallic turbine wheels, and high temperature combustors. For Capstone, ORNL will complete material evaluations for engine demonstration,assist in material procurement and characterize demonstration components.

For an ITP Announcement about this project