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Caption: Jaswinder Sharma makes battery coin cells with a lightweight current collector made of thin layers of aligned carbon fibers in a polymer with carbon nanotubes. Credit: Genevieve Martin/ORNL, U.S. Dept. of Energy

Electric vehicles can drive longer distances if their lithium-ion batteries deliver more energy in a lighter package. A prime weight-loss candidate is the current collector, a component that often adds 10% to the weight of a battery cell without contributing energy.

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.

ORNL researchers worked with partners at the Colorado School of Mines and Baylor University to develop a new process optimization and control method for a closed-circuit reverse osmosis desalination system. The work is intended to support fully automated, decentralized water treatment plants. Credit: Andrew Sproles/ORNL, U.S. Dept. of Energy

Oak Ridge National Laboratory scientists worked with the Colorado School of Mines and Baylor University to develop and test control methods for autonomous water treatment plants that use less energy and generate less waste.

Layering on the strength

A team including Oak Ridge National Laboratory and University of Tennessee researchers demonstrated a novel 3D printing approach called Z-pinning that can increase the material’s strength and toughness by more than three and a half times compared to conventional additive manufacturing processes.

Heat impact map

A detailed study by Oak Ridge National Laboratory estimated how much more—or less—energy United States residents might consume by 2050 relative to predicted shifts in seasonal weather patterns 

Desalination process

A new method developed at Oak Ridge National Laboratory improves the energy efficiency of a desalination process known as solar-thermal evaporation. 

Batteries—Polymers that bind

A team of researchers at Oak Ridge National Laboratory have demonstrated that designed synthetic polymers can serve as a high-performance binding material for next-generation lithium-ion batteries.

Low-cost, compact, printed sensor that can collect and transmit data on electrical appliances for better load monitoring

Scientists at Oak Ridge National Laboratory have developed a low-cost, printed, flexible sensor that can wrap around power cables to precisely monitor electrical loads from household appliances to support grid operations.

 

Laminations such as these are compiled to form the core of modern electric vehicle motors. ORNL has developed a software toolkit to speed the development of new motor designs and to improve the accuracy of their real-world performance.

Oak Ridge National Laboratory scientists have created open source software that scales up analysis of motor designs to run on the fastest computers available, including those accessible to outside users at the Oak Ridge Leadership Computing Facility.