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Danny Shechtman, Ames Laboratory Scientist and winner of the Nobel Prize in Chemistry 2011, returned to the Ames Lab on February 14, 2012. During this time, the Nobel Laureate met with the press as well as ISU students.
Ames Lab 101: Rare-Earth-Free Manganese Permanent Magnets
Senior Scientist, Bill McCallum, briefly discusses rare-earth magnets and their uses and how Ames Lab is research new ways to save money and energy using magnets.
Ames Laboratory scientist Deborah Schlagel talks about the Lab's research in growing single crystals of various metals and alloys. The single crystal samples are vital to researchers' understanding of the characteristics of a materials and what gives these materials their particular properties.
Ames Laboratory physicists have found a new way to switch magnetism that is at least 1000 times faster than currently used in magnetic memory technologies. Magnetic switching is used to encode information in hard drives, magnetic random access memory and other computing devices. The discovery potentially opens the door to terahertz and faster memory speeds.
Ames scientist, Igor Slowing, explains the 3D printing of catalytic devices in the lab.
Rana Biswas, a scientist with the Ames Laboratory, discusses his team's research in creating more efficient solar cells and working with Iowa Thin Film to produce these cells.
Ames Laboratory researchers are working to develop new electrical power cables that are stronger and lighter than the cables currently used in the nation's power grid. Nano Tube animation by Iain Goodyear
Ames Laboratory's Chief Research Officer Duane Johnson talks about using advanced computing to develop new materials and predict what types of properties those materials will have.
Rohit Trivedi, distinguished professor of materials science and engineering, discusses his research with NASA to grow crystals in space.
A new recycling method developed by scientists at the Critical Materials Institute, a U.S. Department of Energy Innovation Hub led by the Ames Laboratory, recovers valuable rare-earth magnetic material from manufacturing waste and creates useful magnets out of it.
Materials scientist, Bruce Cook, discusses the super hard, low friction, and lubricious alloy know as BAM (Boron-Aluminum-Magnesium). BAM was discovered by Bruce Cook and his team at the Ames Laboratory.
Recycling keeps paper, plastics, and even jeans out of landfills. Could recycling rare-earth magnets do the same? Perhaps, if the recycling process can be improved. Scientists at the U.S. Department of Energy's Ames Laboratory are working to more effectively remove the neodymium, a rare earth, from the mix of other materials in a magnet.
To meet one of the biggest energy challenges of the 21st century - finding alternatives to rare-earth elements and other critical materials - scientists will need new and advanced tools. The Critical Materials Institute at the U.S. Department of Energy's Ames Laboratory has a new one: a 3D printer for metals research. 3D printing technology, which has captured the imagination of both industry and consumers, enables ideas to move quickly from the initial design phase to final form using materials including polymers, ceramics, paper and even food. But the Critical Materials Institute (CMI) will apply the advantages of the 3D printing process in a unique way: for materials discovery.
A novel gas atomization reaction synthesis (GARS) method was developed in this project to enable production (at our partner’s facility) a precursor Ni-Cr-Y-Ti powder with a surface oxide and an internal rare earth (RE) containing intermetallic compound (IMC) phase. Consolidation and heat-treatment experiments were performed at Ames Lab to promote the exchange of oxygen from the surface oxide to the RE intermetallic to form nano-metric oxide dispersoids. Alloy selection was aided by an internal oxidation and serial grinding experiments at Ames Lab and found that Hf-containing alloys may form more stable dispersoids than Ti-containing alloy, i.e., the Hf-containing system exhibited five different oxide phases and two different intermetallics compared to the two oxide phases and one intermetallic in the Ti-containing alloys. Since the simpler Ti-containing system was less complex to characterize, and make observations on the effects of processing parameters, the Ti-containing system was selected by Ames Lab for experimental atomization trials at our partner. An internal oxidation model was developed at Ames Lab and used to predict the heat treatment times necessary for dispersoid formation as a function of powder size and temperature. A new high-pressure gas atomization (HPGA) nozzle was developed at Ames Lab with the aim of promoting fine powder production at scales similar to that of the high gas-flow and melt-flow of industrial atomizers. The atomization nozzle was characterized using schlieren imaging and aspiration pressure testing at Ames Lab to determine the optimum melt delivery tip geometry and atomization pressure to promote enhanced secondary atomization mechanisms. Six atomization trials were performed at our partner to investigate the effects of: gas atomization pressure and reactive gas concentration on the particle size distribution (PSD) and the oxygen content of the resulting powder. Also, the effect on the rapidly solidified microstructure (as a function of powder size) was investigated at Ames Lab as a function of reactive gas composition and bulk alloy composition. The results indicated that the pulsatile gas atomization mechanism and a significantly enhanced yield of fine powders reported in the literature for this type of process were not observed. Also it was determined that reactive gas may marginally improve the fine powder yield but further experiments are required. The oxygen content in the gas also did not have any detrimental effect on the microstructure (i.e. did not significantly reduce undercooling). On the contrary, the oxygen addition to the atomization gas may have mitigated some potent catalytic nucleation sites, but not enough to significantly alter the microstructure vs. particle size relationship. Overall the downstream injection of oxygen was not found to significantly affect either the particle size distribution or undercooling (as inferred from microstructure and XRD observations) but injection further upstream, including in the gas atomization nozzle, remains to be investigated in later work.
The Ames Laboratory was officially founded on May 17, 1947, following development of a process to purify uranium metal for the historic Manhattan Project. From 1942 to 1946, Ames Lab scientists produced over two-million pounds of uranium metal. A U.S. Department of Energy national research laboratory, the Ames Laboratory creates materials and energy solutions. Iowa State University operates Ames Laboratory under contract with the DOE.
Develop advanced bearing materials for hydrogen gas turbines and wind turbines. Two candidate materials have been selected based on Ames lab’s recent work on high entropy alloys and shape memory alloys. These materials are designed to exhibit a balance of hardness, strength, toughness, and corrosion resistance. The hydrogen diffusion coefficient in the NiTi based shape memory alloy is two order of magnitude lower than that of the conventional case hardened bearing steel. We plan to atomize these materials into powders, additive manufacture cylindrical bearings, then test these bearing for rolling-contact fatigue, corrosion properties, and hydrogen embrittlement. We are a vertically integrated team comprises of national labs, bearing manufacturers, raw material powders makers, and aircraft gas turbine manufacturer.
This work was a portion of a larger DOE/ITP Grand Challenge project led by Eaton Corporation and which included Ames Lab, Borg Warner Morse, and Pratt and Whitney Rocketdyne. The current report summarizes work done under a CRADA between ORNL and Eaton. Tests of two types were performed at ORNL during the course of this work: (1) simulations of timing chain wear and friction under reciprocating conditions, and (2) pin-on-disk screening tests for bearings undergoing unidirectional sliding. The four materials supplied for evaluation in a timing chain link simulation were hardened type 440B stainless steel, nitrided type 440B stainless steel, VC-coated type 52100 bearing steel, and (ZrTi)B-coated type 52100 bearing steel. Reciprocating wear tests revealed that the VC coating was by far the most wear resistant. In friction, the nitrided stainless steel did slightly better than the other materials. The results will also be included in the overall project report by Eaton Corp.