DOE News
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    The DOE Science News Source is a Newswise initiative to promote research news from the Office of Science of the DOE to the public and news media.
    • 2016-12-02 15:05:19
    • Article ID: 665862

    Ames Laboratory Awarded $5 Million to Improve Metal Powders for Advanced Manufacturing

    Ames Laboratory and Oak Ridge National Laboratory have been awarded $5 million from the U.S. Department of Energy’s Advanced Manufacturing Office (AMO) to improve the production and composition of metal alloy powders used in additive manufacturing.

    Additive manufacturing, also known as 3D printing, has reached a widespread measure of success in manufacturing processes using polymers, or plastics. But the use of metal alloys for additive manufacturing has lagged due to lack of both materials and process development.

    “There’s a lot of intense interest focused on additive manufacturing with metal alloys, because there are so many potential applications,” said Iver Anderson, project leader and senior metallurgist at Ames Laboratory and adjunct professor in Materials Science and Engineering Department at Iowa State University. “Industry has demands for prototyping parts, design development, reducing waste of expensive materials, and efficiently producing custom and legacy components for their customers.”

    Because additive manufacturing uses metal alloy powders as its raw material, the ability to control the properties and quality of those powders becomes paramount to the quality of the final product, and achieving properties equal to cast and machined or, especially, cast/forged and machined parts.

    “Today, if a manufacturer went to metal powder producers with a shopping list of the alloys and powder specifications they needed for their manufacturing process, they very likely wouldn’t find what they want,” said Anderson. “The customization capabilities are just not there, and we need to get there. That is going to be the key to commercially competitive additive manufacturing processes.”

    The project will improve powder production by developing advances in a high pressure gas atomization process pioneered at Ames Laboratory and will design and customize alloys specifically for additive manufacturing processing methods. Modeling and simulation of gas atomization process stages at Ames Lab will use a flow simulation code developed by National Energy Technology Laboratory for part of the work. The experimental gas atomization work and alloy design calculations/verification also will be performed in the powder synthesis facilities at Ames Laboratory. Oak Ridge National Laboratory’s Manufacturing Demonstration Facility (ORNL-MDF) will conduct the corresponding additive manufacturing experiments.

    The Advanced Manufacturing Office (AMO) partners with industry, small business, universities, and other stakeholders to identify and invest in emerging technologies with the potential to create high-quality domestic manufacturing jobs and enhance the global competitiveness of the United States.

    Ames Laboratory is a U.S. Department of Energy Office of Science national laboratory operated by Iowa State University. Ames Laboratory creates innovative materials, technologies and energy solutions. We use our expertise, unique capabilities and interdisciplinary collaborations to solve global problems.

    DOE’s Office of Science is the single largest supporter of basic research in the physical sciences in the United States, and is working to address some of the most pressing challenges of our time. For more information, please visit science.energy.gov.

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    Ultrafast lasers probe elusive chemistry at the liquid-liquid interface

    Ultrafast lasers probe elusive chemistry at the liquid-liquid interface

    Real-time measurements captured by researchers at the Department of Energy's Oak Ridge National Laboratory provide missing insight into chemical separations to recover cobalt, a critical raw material used to make batteries and magnets for modern technologies.

    Dark Energy Survey census of the smallest galaxies hones the search for dark matter

    Dark Energy Survey census of the smallest galaxies hones the search for dark matter

    Scientists on the Dark Energy Survey have used observations of the smallest known galaxies to better understand dark matter, the mysterious substance that makes up 85% of the matter in the universe. The smallest galaxies can contain hundreds to thousands of times more dark matter than normal visible matter, making them ideal laboratories for studying this mysterious substance. By performing a rigorous census of small galaxies surrounding our Milky Way, scientists on the Dark Energy Survey have been able to constrain the fundamental particle physics that governs dark matter.

    Story Tips: Pandemic impact, root studies, neutrons confirm, lab on a crystal and modeling fusion

    Story Tips: Pandemic impact, root studies, neutrons confirm, lab on a crystal and modeling fusion

    ORNL Story Tips: Pandemic impact, root studies, neutrons confirm, lab on a crystal and modeling fusion

    Scientists propose a novel method for controlling fusion reactions

    Scientists propose a novel method for controlling fusion reactions

    Researchers at the DOE's Princeton Plasma Physics Laboratory have developed a pulsed method for stabilizing magnetic islands that can cause disruptions in fusion plasmas.

    Cementing the future

    Cementing the future

    Researchers from Argonne National Laboratory's Advanced Photon Source and Center for Nanoscale Materials are utilizing nano- and micro-scale imaging to better understand the chemical processes behind the formation of cement.

    Fat-Based Molecules are Key to Zika Virus Infection

    Fat-Based Molecules are Key to Zika Virus Infection

    Researchers from PNNL have helped colleagues at OHSU identify lipid molecules required for Zika infection in human cells. The specific lipids involved could also be a clue to why the virus primarily infects brain tissue.

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    A new study dives into a decades-old discrepancy from a Standard Model of particle physics pillar known as "lepton flavor universality," and provides strong evidence to resolve it.

    Influx of Electric Vehicles Accelerates Need for Grid Planning

    Influx of Electric Vehicles Accelerates Need for Grid Planning

    A new PNNL report says the western U.S. bulk power system can reliably support projected growth of up to 24 million electric vehicles through 2028, but challenges will arise as EV adoption grows beyond that threshold. This study is the most comprehensive of its kind, integrating multiple variables not evaluated before, such as growth in commercial delivery fleets and long-haul trucks, as well as large-scale and long-term EV charging scenarios and strategies.

    First results of an upgraded experiment highlight the value of lithium for the creation of fusion energy

    First results of an upgraded experiment highlight the value of lithium for the creation of fusion energy

    Initial results of the Lithium Tokamak Experiment-Beta (LTX-β) at PPPL show that the enhancements significantly improve performance of the plasma that will fuel future fusion reactors.

    Hybrid inverter integrates distributed energy resources, supports smart grid function

    Hybrid inverter integrates distributed energy resources, supports smart grid function

    Oak Ridge National Laboratory researchers have developed an intelligent power electronic inverter platform that can connect locally sited energy resources such as solar panels, energy storage and electric vehicles and smoothly interact with the utility power grid.


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    Magnum Venus Products licenses ORNL co-developed additive manufacturing technologies

    Magnum Venus Products licenses ORNL co-developed additive manufacturing technologies

    The Department of Energy's Oak Ridge National Laboratory has licensed two additive manufacturing-related technologies that aim to streamline and ramp up production processes to Knoxville-based Magnum Venus Products, Inc., a global manufacturer of fluid movement and product solutions for industrial applications in composites and adhesives.

    Berkeley Lab Part of Multi-Institutional Team Awarded $60M for Solar Fuels Research

    Berkeley Lab Part of Multi-Institutional Team Awarded $60M for Solar Fuels Research

    The Department of Energy has awarded $60 million to a new solar fuels initiative - called the Liquid Sunlight Alliance (LiSA) - led by Caltech in close partnership with Berkeley Lab. LiSA will build on the foundational work of the Joint Center for Artificial Photosynthesis (JCAP).

    Will Fox wins 2020 John Dawson Award for producing new insights into astrophysical shockwaves

    Will Fox wins 2020 John Dawson Award for producing new insights into astrophysical shockwaves

    Profile of PPPL winner of APS Dawson Award for outstanding achievement in plasma physics research.

    Jefferson Lab ES&H Deputy Director Receives Health Physics Society Honor

    Jefferson Lab ES&H Deputy Director Receives Health Physics Society Honor

    Bob May's career-long aspiration has been to keep people from all walks of life and in different work environments safe from radiation in the workplace. Now, the deputy director of Environment, Safety and Health at the U.S. Department of Energy's Thomas Jefferson National Accelerator Facility has been honored for his dedication to the field by being named a fellow of the Health Physics Society.

    Robert Ainsworth awarded $2.5 million to improve particle beams for high-intensity experiments

    Robert Ainsworth awarded $2.5 million to improve particle beams for high-intensity experiments

    Fermilab scientist Robert Ainsworth has won a $2.5 million Department of Energy Early Career Research Award to study different ways of ensuring stability in high-intensity proton beams. By studying how certain types of beam instabilities emerge and evolve under different conditions, his team can help sharpen scientists' methods for correcting them or avoiding them to begin with.

    PNNL's Vapor Detection Technology Named GeekWire's 'Innovation of the Year'

    PNNL's Vapor Detection Technology Named GeekWire's 'Innovation of the Year'

    A PNNL-developed technology that can quickly detect explosive vapors, deadly chemicals and illicit drugs with unparalleled accuracy has been named the 2020 Innovation of the Year by GeekWire, the Seattle-based technology news company.

    Accomplished early career physicist is first recipient of fellowship that honors pioneering PPPL physicist Robert Ellis Jr.

    Accomplished early career physicist is first recipient of fellowship that honors pioneering PPPL physicist Robert Ellis Jr.

    An early career physicist with a strong background in plasma physics has been named to a new postdoctoral fellowship named for Robert Ellis Jr., a pioneering physicist at PPPL, that is aimed at diversifying the plasma physics field.

    U.S. Department of Energy to announce "Launch to the Future: Quantum Internet" at UChicago

    U.S. Department of Energy to announce "Launch to the Future: Quantum Internet" at UChicago

    On Thursday, July 23, Secretary of the U.S. Department of Energy Dan Brouillette will join government, academic, and science leaders at the University of Chicago to unveil a report outlining a blueprint for the construction of a national quantum internet, bringing the U.S. to the forefront of the global quantum race and ushering in a new era of communications.

    Department of Energy Names Three Office of Science Distinguished Scientists Fellows

    The U.S. Department of Energy (DOE) named three National Laboratory scientists as DOE Office of Science Distinguished Scientists Fellows

    U.S. Department of Energy unveils blueprint for the quantum internet at 'Launch to the Future: Quantum Internet' event

    U.S. Department of Energy unveils blueprint for the quantum internet at 'Launch to the Future: Quantum Internet' event

    The U.S. Department of Energy unveils a report that lays out a blueprint strategy for the development of a national quantum internet, bringing the United States to the forefront of the global quantum race and ushering in a new era of communications. This report provides a pathway to ensure the development of the National Quantum Initiative Act.


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    Harvesting Energy from Light using Bio-inspired Artificial Cells

    Harvesting Energy from Light using Bio-inspired Artificial Cells

    Scientists designed and connected two different artificial cells to each other to produce molecules called ATP (adenosine triphosphate).

    Engineering Living Scaffolds for Building Materials

    Engineering Living Scaffolds for Building Materials

    Bone and mollusk shells are composite systems that combine living cells and inorganic components. This allows them to regenerate and change structure while also being very strong and durable. Borrowing from this amazing complexity, researchers have been exploring a new class of materials called engineered living materials (ELMs).

    Excavating Quantum Information Buried in Noise

    Excavating Quantum Information Buried in Noise

    Researchers developed two new methods to assess and remove error in how scientists measure quantum systems. By reducing quantum "noise" - uncertainty inherent to quantum processes - these new methods improve accuracy and precision.

    How Electrons Move in a Catastrophe

    How Electrons Move in a Catastrophe

    Lanthanum strontium manganite (LSMO) is a widely applicable material, from magnetic tunnel junctions to solid oxide fuel cells. However, when it gets thin, its behavior changes for the worse. The reason why was not known. Now, using two theoretical methods, a team determined what happens.

    When Ions and Molecules Cluster

    When Ions and Molecules Cluster

    How an ion behaves when isolated within an analytical instrument can differ from how it behaves in the environment. Now, Xue-Bin Wang at Pacific Northwest National Laboratory devised a way to bring ions and molecules together in clusters to better discover their properties and predict their behavior.

    Tune in to Tetrahedral Superstructures

    Tune in to Tetrahedral Superstructures

    Shape affects how the particles fit together and, in turn, the resulting material. For the first time, a team observed the self-assembly of nanoparticles with tetrahedral shapes.

    Tracing Interstellar Dust Back to the Solar System's Formation

    Tracing Interstellar Dust Back to the Solar System's Formation

    This study is the first to confirm dust particles pre-dating the formation of our solar system. Further study of these materials will enable a deeper understanding of the processes that formed and have since altered them.

    Investigating Materials that Can Go the Distance in Fusion Reactors

    Investigating Materials that Can Go the Distance in Fusion Reactors

    Future fusion reactors will require materials that can withstand extreme operating conditions, including being bombarded by high-energy neutrons at high temperatures. Scientists recently irradiated titanium diboride (TiB2) in the High Flux Isotope Reactor (HFIR) to better understand the effects of fusion neutrons on performance.

    Better 3-D Imaging of Tumors in the Breast with Less Radiation

    Better 3-D Imaging of Tumors in the Breast with Less Radiation

    In breast cancer screening, an imaging technique based on nuclear medicine is currently being used as a successful secondary screening tool alongside mammography to improve the accuracy of the diagnosis. Now, a team is hoping to improve this imaging technique.

    Microbes are Metabolic Specialists

    Microbes are Metabolic Specialists

    Scientists can use genetic information to measure if microbes in the environment can perform specific ecological roles. Researchers recently analyzed the genomes of over 6,000 microbial species.


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