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Oak Ridge National Laboratory materials scientist Zhili Feng, left, looks on as senior technician Doug Kyle operates a welding robot inside a robotic welding cell. Credit: Carlos Jones/ORNL, U.S. Dept. of Energy

The U.S. Departments of Energy and Defense teamed up to create a series of weld filler materials that could dramatically improve high-strength steel repair in vehicles, bridges and pipelines.

Researchers found that moderate levels of ash — sometimes found as spheres in biomass — do not significantly affect the mechanical properties of biocomposites made up of corn stover, switchgrass and PLA thermoplastic. Credit: Andy Sproles/ORNL, U.S. Dept. of Energy

The presence of minerals called ash in plants makes little difference to the fitness of new naturally derived compound materials designed for additive manufacturing, an Oak Ridge National Laboratory-led team found.

Researchers at ORNL designed a recyclable carbon fiber material to promote low-carbon manufacturing. Credit: Chad Malone/ORNL, U.S. Dept. of Energy

Oak Ridge National Laboratory scientists designed a recyclable polymer for carbon-fiber composites to enable circular manufacturing of parts that boost energy efficiency in automotive, wind power and aerospace applications.

Xunxiang Hu, a Eugene P. Wigner Fellow in ORNL’s Materials Science and Technology Division, designed this machine to produce large, crack-free pieces of yttrium hydride to be used as a moderator in the core of ORNL’s Transformational Challenge Reactor and other microreactors. Credit: Xunxiang Hu/ORNL, U.S. Dept. of Energy

About 60 years ago, scientists discovered that a certain rare earth metal-hydrogen mixture, yttrium, could be the ideal moderator to go inside small, gas-cooled nuclear reactors.

A selfie from the Curiosity rover as it explores the surface of Mars. Like many spacecraft, Curiosity uses a radioisotope power system to help fuel its mission. Credit: NASA/JPL-Caltech/MSSS

Radioactive isotopes power some of NASA’s best-known spacecraft. But predicting how radiation emitted from these isotopes might affect nearby materials is tricky

Fuel pellets sometimes degrade to a sandlike consistency and can disperse into the reactor core if a rod’s cladding bursts. ORNL researchers are studying how often this happens and what impact it has, in order to let reactors operate as long as possible without increasing risk.

A developing method to gauge the occurrence of a nuclear reactor anomaly has the potential to save millions of dollars.

Simulation of short polymer chains

Oak Ridge National Laboratory scientists have discovered a cost-effective way to significantly improve the mechanical performance of common polymer nanocomposite materials.

This photo shows the interior of the vessel of the General Atomics DIII-D National Fusion Facility in San Diego, where ORNL researchers are testing the suitability of tungsten to armor the inside of a fusion device. Credit: General Atomics

The inside of future nuclear fusion energy reactors will be among the harshest environments ever produced on Earth. What’s strong enough to protect the inside of a fusion reactor from plasma-produced heat fluxes akin to space shuttles reentering Earth’s atmosphere?

3D-printed 316L steel has been irradiated along with traditionally wrought steel samples. Researchers are comparing how they perform at various temperatures and varying doses of radiation. Credit: Jaimee Janiga/ORNL

It’s a new type of nuclear reactor core. And the materials that will make it up are novel — products of Oak Ridge National Laboratory’s advanced materials and manufacturing technologies.

VERA’s tools allow a virtual window inside the reactor core, down to a molecular level.

As CASL ends and transitions to VERA Users Group, ORNL looks at the history of the program and its impact on the nuclear industry.