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Using a toolpath strategy for weight reduction, two near-net shape dies were manufactured using a gas metal arc welding additive manufacturing process at the Lincoln Electric Additive Solutions facility. Credit: Lincoln Electric

Recent advancements at the U.S. Department of Energy’s Oak Ridge National Laboratory show that 3D-printed metal molds offer a faster, more cost-effective and flexible approach to producing large composite components for mass-produced vehicles than traditional tooling methods.

Scientists used neutron scattering to study how tweaking the ionic clusters in ionizable polymer solutions affects their structure. The polymer building blocks are marked in gold and the ionizable groups in red. Findings could open doors to lighter, more efficient clean energy devices. Credit: Phoenix Pleasant/ORNL, U.S. Dept. of Energy

Electrolytes that convert chemical to electrical energy underlie the search for new power sources with zero emissions. Among these new power sources are fuel cells that produce electricity. 

Portraits of Kowalski and Salonvaara side by side

Stephen Kowalski and Mikael Salonvaara received the Distinguished Service Award, which salutes members who have served the society with distinction in chapter, regional and society activities.

Wang, Cook and Uddin portraits side by side

Three transportation researchers at the Department of Energy’s Oak Ridge National Laboratory have been elevated to senior member grade of the Institute of Electrical and Electronics Engineers, or IEEE.

Kashif Nawaz standing in front of a two story brick building that houses active research

Kashif Nawaz, distinguished researcher and section head for Building Technologies Research at the Department of Energy’s Oak Ridge National Laboratory, has been named a Fellow of the American Society of Mechanical Engineers, or ASME.

dog

After retiring from Y-12, Scott Abston joined the Isotope Science and Engineering Directorate to support isotope production and work with his former manager. He now leads a team maintaining critical equipment for medical and space applications. Abston finds fulfillment in mentoring his team and is pleased with his decision to continue working.

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.

Symposium guests view posters in the poster competition. Credit: Laetitia Delmau/ORNL, U.S. Dept. of Energy

The 21st Symposium on Separation Science and Technology for Energy Applications, Oct. 23-26 at the Embassy Suites by Hilton West in Knoxville, attracted 109 researchers, including some from Austria and the Czech Republic. Besides attending many technical sessions, they had the opportunity to tour the Graphite Reactor, High Flux Isotope Reactor and both supercomputers at ORNL.

Alexey Serov researches ways to improve hydrogen fuel cells and materials and the electrolysis process. Credit: Carlos Jones/ORNL, U.S. Dept. of Energy

It would be a challenge for any scientist to match Alexey Serov’s rate of inventions related to green hydrogen fuel. But this researcher at ORNL has 84 patents with at least 35 more under review, so his electrifying pace is unlikely to slow down any time soon.

Wire arc additive manufacturing allowed this robot arm at ORNL to transform metal wire into a complete steam turbine blade like those used in power plants. Credit: Carlos Jones/ORNL, U.S. Dept. of Energy

Researchers at ORNL became the first to 3D-print large rotating steam turbine blades for generating energy in power plants.