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Images showing distortion caused by residual stress in the horizontal and vertical axes of material. ORNL researchers found that simply adding material in critical regions mitigates the accumulation of stress. Credit: ORNL, U.S. Dept. of Energy

ORNL scientists have determined how to avoid costly and potentially irreparable damage to large metallic parts fabricated through additive manufacturing, also known as 3D printing, that is caused by residual stress in the material. 

ORNL engineer Canan Karakaya uses computational modeling to design and improve chemical reactors and how they are operated to convert methane, carbon dioxide, ammonia or ethanol into higher-value chemicals or energy-dense fuels. Credit: Carlos Jones/ORNL, U.S. Dept. of Energy

Canan Karakaya, a R&D Staff member in the Chemical Process Scale-Up group at ORNL, was inspired to become a chemical engineer after she experienced a magical transformation that turned ammonia gas into ammonium nitrate, turning a liquid into white flakes gently floating through the air. 

ORNL researcher Brian Williams prepares for a demonstration of a quantum key distribution system. Credit: Genevieve Martin/ORNL, U.S. Dept. of Energy

An experiment by researchers at the Department of Energy’s Oak Ridge National Laboratory demonstrated advanced quantum-based cybersecurity can be realized in a deployed fiber link. 

: ORNL climate modeling expertise contributed to an AI-backed model that assesses global emissions of ammonia from croplands now and in a warmer future, while identifying mitigation strategies. This map highlights croplands around the world. Credit: U.S. Geological Survey

ORNL climate modeling expertise contributed to a project that assessed global emissions of ammonia from croplands now and in a warmer future, while also identifying solutions tuned to local growing conditions.

Louise Stevenson uses her expertise as an environmental toxicologist to evaluate the effects of stressors such as chemicals and other contaminants on aquatic systems. Credit: Carlos Jones/ORNL, U.S. Dept of Energy

Louise Stevenson uses her expertise as an environmental toxicologist to evaluate the effects of stressors such as chemicals and other contaminants on aquatic systems.

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.

A small droplet of water is suspended in midair via an electrostatic levitator that lifts charged particles using an electric field that counteracts gravity. Credit: Iowa State University/ORNL, U.S. Dept. of Energy

How do you get water to float in midair? With a WAND2, of course. But it’s hardly magic. In fact, it’s a scientific device used by scientists to study matter.

2023 Battelle Distinguished Inventors

Four scientists affiliated with ORNL were named Battelle Distinguished Inventors during the lab’s annual Innovation Awards on Dec. 1 in recognition of being granted 14 or more United States patents.

SM2ART team members receive the CAMX Combined Strength Award at the Georgia World Congress Center in Atlanta. Pictured here are, from left, ORNL’s Dan Coughlin, Sana Elyas, Halil Tekinalp, Amber Hubbard, Soydan Ozcan; University of Maine’s Susan MacKay, Angelina Buzzelli, Scott Tomlinson, Wesley Bisson; and ORNL’s Matt Korey and Vlastimil Kunc. Credit: University of Maine

The Hub & Spoke Sustainable Materials & Manufacturing Alliance for Renewable Technologies, or SM2ART, program has been honored with the composites industry’s Combined Strength Award at the Composites and Advanced Materials Expo, or CAMX, 2023 in Atlanta. This distinction goes to the team that applies their knowledge, resources and talent to solve a problem by making the best use of composites materials.

ORNL’s additive manufacturing compression molding, or AMCM, technology can produce composite-based, lightweight finished parts for airplanes, drones or vehicles in minutes and could acclerate decarbonization for the automobile and aeropsace industries. 

An Oak Ridge National Laboratory-developed advanced manufacturing technology, AMCM, was recently licensed by Orbital Composites and enables the rapid production of composite-based components, which could accelerate the decarbonization of vehicles