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Mars Rover 2020

More than 50 current employees and recent retirees from ORNL received Department of Energy Secretary’s Honor Awards from Secretary Jennifer Granholm in January as part of project teams spanning the national laboratory system. The annual awards recognized 21 teams and three individuals for service and contributions to DOE’s mission and to the benefit of the nation.

A 3D printed thermal protection shield, produced by ORNL researchers for NASA, is part of a cargo spacecraft bound for the International Space Station. The shield was printed at the Department of Energy’s Manufacturing Demonstration Facility at ORNL. Credit: ORNL, U.S. Dept. of Energy

A research team at Oak Ridge National Laboratory have 3D printed a thermal protection shield, or TPS, for a capsule that will launch with the Cygnus cargo spacecraft as part of the supply mission to the International Space Station.

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 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.

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.

Tungsten tiles for fusion

Using additive manufacturing, scientists experimenting with tungsten at Oak Ridge National Laboratory hope to unlock new potential of the high-performance heat-transferring material used to protect components from the plasma inside a fusion reactor. Fusion requires hydrogen isotopes to reach millions of degrees.