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ORNL researchers used electron beam powder bed fusion to produce refractory metal molybdenum, which remained crack free and dense, proving its viability for additive manufacturing applications. Credit: ORNL/U.S. Dept. of Energy

Oak Ridge National Laboratory scientists proved molybdenum titanium carbide, a refractory metal alloy that can withstand extreme temperature environments, can also be crack free and dense when produced with electron beam powder bed fusion. 

Urban climate modeling

Researchers at Oak Ridge National Laboratory have identified a statistical relationship between the growth of cities and the spread of paved surfaces like roads and sidewalks. These impervious surfaces impede the flow of water into the ground, affecting the water cycle and, by extension, the climate.

ORNL researchers combined additive manufacturing with conventional compression molding to produce high-performance thermoplastic composites, demonstrating the potential for the use of large-scale multimaterial preforms to create molded composites. Credit: ORNL/U.S. Dept. of Energy

Oak Ridge National Laboratory researchers combined additive manufacturing with conventional compression molding to produce high-performance thermoplastic composites reinforced with short carbon fibers.

ORNL researchers used gas metal arc welding additive technology to print the die for a B-pillar or vertical roof support structure for a sport utility vehicle, demonstrating a 20% improvement in the cooling rate. Credit: ORNL/U.S. Dept. of Energy

A team of Oak Ridge National Laboratory researchers demonstrated that an additively manufactured hot stamping die – a tool used to create car body components – cooled faster than those produced by conventional manufacturing methods.

A 3D printed turbine blade demonstrates the use of the new class of nickel-based superalloys that can withstand extreme heat environments without cracking or losing strength. Credit: ORNL/U.S. Dept. of Energy

Oak Ridge National Laboratory researchers have demonstrated that a new class of superalloys made of cobalt and nickel remains crack-free and defect-resistant in extreme heat, making them conducive for use in metal-based 3D printing applications.

Merlin Theodore holding N95 mask filtration material produced at DOE's Carbon Fiber Technology Facility

Three technologies developed by ORNL researchers have won National Technology Transfer Awards from the Federal Laboratory Consortium. One of the awards went to a team that adapted melt-blowing capabilities at DOE’s Carbon Fiber Technology Facility to enable the production of filter material for N95 masks in the fight against COVID-19.

ORNL welder Devin Johnson uses a new orbital welder to seal a hollow target in a glovebox in the lab’s Radiochemical Engineering Development Center. The new welder makes a clean seam on the metal target, eliminating the need for hand-finishing afterward. Credit: Carlos Jones/ORNL, U.S. Dept. of Energy

A better way of welding targets for Oak Ridge National Laboratory’s plutonium-238 production has sped up the process and improved consistency and efficiency. This advancement will ultimately benefit the lab’s goal to make enough Pu-238 – the isotope that powers NASA’s deep space missions – to yield 1.5 kilograms of plutonium oxide annually by 2026.

Researchers at ORNL’s Center for Nanophase Materials Sciences and the University of Tennessee Health Science Center partnered to design a COVID-19 screening whistle for convenient home testing. Credit: Michelle Lehman/ORNL, U.S. Dept. of Energy

Collaborators at Oak Ridge National Laboratory and the University of Tennessee Health Science Center are developing a breath-sampling whistle that could make COVID-19 screening easy to do at home.

An X-ray CT image of a 3D-printed metal turbine blade was reconstructed using ORNL’s neural network and advanced algorithms. Credit: Amir Ziabari/ORNL, U.S. Dept. of Energy

Algorithms developed at Oak Ridge National Laboratory can greatly enhance X-ray computed tomography images of 3D-printed metal parts, resulting in more accurate, faster scans.