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ORNL Composites Innovation staff members David Nuttall, left, and Vipin Kumar use additive manufacturing compression molding to produce a composite-based finished part in minutes. AMCM technology could accelerate decarbonization of the automobile and aerospace industries. Credit: ORNL, U.S. Dept. of Energy

Researchers at ORNL are extending the boundaries of composite-based materials used in additive manufacturing, or AM. ORNL is working with industrial partners who are exploring AM, also known as 3D printing, as a path to higher production levels and fewer supply chain interruptions.

The sun sets behind the ORNL Visitor Center in this aerial photo from April 2023. Credit: Kase Clapp/ORNL, U.S. Dept. of Energy

In fiscal year 2023 — Oct. 1–Sept. 30, 2023 — Oak Ridge National Laboratory was awarded more than $8 million in technology maturation funding through the Department of Energy’s Technology Commercialization Fund, or TCF.

HFIR

Creating energy the way the sun and stars do — through nuclear fusion — is one of the grand challenges facing science and technology. What’s easy for the sun and its billions of relatives turns out to be particularly difficult on Earth.

Experts at the Manufacturing Demonstration Facility worked with Magotteaux-Pulaski to develop a more durable composition and new 3D-printing process for abrasion-resistant materials. Credit: Magotteaux

For more than 100 years, Magotteaux has provided grinding materials and castings for the mining, cement and aggregates industries. The company, based in Belgium, began its international expansion in 1968. Its second international plant has been a critical part of the Pulaski, Tennessee, economy since 1972.

Mali Balasubramanian made a rewarding mid-career shift to focus on studying new battery materials and systems using X-ray spectroscopy and other methods. Credit: Carlos Jones/ORNL, U.S. Dept. of Energy

Having passed the midpoint of his career, physicist Mali Balasubramanian was part of a tight-knit team at a premier research facility for X-ray spectroscopy. But then another position opened, at ORNL— one that would take him in a new direction.

The Fuel Pellet Fueling Laboratory at ORNL is part of a suite of fusion energy R&D capabilities and provides test equipment and related diagnostics for carrying out experiments to develop pellet injectors for plasma fueling applications. Credit: Carlos Jones/ORNL, U.S. Dept. of Energy

ORNL will team up with six of eight companies that are advancing designs and research and development for fusion power plants with the mission to achieve a pilot-scale demonstration of fusion within a decade.

Materials scientist Denise Antunes da Silva researches ways to reduce concrete’s embodied carbon in the Sustainable Building Materials Laboratory at ORNL, a research space dedicated to studying environmentally friendly building materials. Credit: ORNL, U.S. Dept. of Energy

Materials scientist Denise Antunes da Silva researches ways to reduce concrete’s embodied carbon in the Sustainable Building Materials Laboratory at ORNL, a research space dedicated to studying environmentally friendly building materials. Credit: ORNL, U.S. Dept. of Energy

Jim Szybist, Propulsion Science section head at ORNL, is applying his years of alternative fuel combustion and thermodynamics research to the challenge of cleaning up the hard-to-decarbonize, heavy-duty mobility sector. Credit: Carlos Jones/ORNL, U.S. Dept. of Energy.

What’s getting Jim Szybist fired up these days? It’s the opportunity to apply his years of alternative fuel combustion and thermodynamics research to the challenge of cleaning up the hard-to-decarbonize, heavy-duty mobility sector — from airplanes to locomotives to ships and massive farm combines.

Earth Day

Tackling the climate crisis and achieving an equitable clean energy future are among the biggest challenges of our time. 

ORNL used novel additive manufacturing techniques to 3D print channel fasteners for Framatome’s boiling water reactor fuel assembly. Four components, like the one shown here, were installed at the TVA Browns Ferry nuclear plant. Credit: Framatome

Four first-of-a-kind 3D-printed fuel assembly brackets, produced at the Department of Energy’s Manufacturing Demonstration Facility at Oak Ridge National Laboratory, have been installed and are now under routine operating