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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. 

Three ORNL researchers, from the left, Valentino Cooper, Howard Wilson and Jiaquiang

ORNL researchers Valentino Cooper, Howard Wilson and Jiaqiang Yan have been named Fellows of the American Physical Society, a distinction recognizing their outstanding contributions to their fields.

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.

Hood Whitson, chief executive officer of Element3, and Cynthia Jenks, associate laboratory director for the Physical Sciences Directorate, shake hands during the Element3 licensing event at ORNL on May 3, 2024. Credit: Carlos Jones/ORNL, U.S. Dept. of Energy

A collection of seven technologies for lithium recovery developed by scientists from ORNL has been licensed to Element3, a Texas-based company focused on extracting lithium from wastewater produced by oil and gas production. 

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.

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.