ITP Nanomanufacturing: Nanomanufacturing Portfolio .
INDUSTRIAL TECHNOLOGIES PROGRAMNanomanufacturingPortfolio:Manufacturing Processes andApplications to AccelerateCommercial Use of Nanomaterials
INDUSTRIAL TECHNOLOGIES PROGRAMContentsIntroduction 1Concept Definition Studies 4Nanomanufacturing ProcessDevelopment Projects 8Advances in Cost-EffectiveNanomanufacturing Can DeliverDiverse Energy Benefits—An Overview 12
INDUSTRIAL TECHNOLOGIES PROGRAMIntroductionNanotechnology is an important pathway for reducing the energy and carbon intensity ofmanufacturing processes to advance national goals. Applications in the chemicals, refining, maritime,and automotive sectors alone may save up to 1.1 quadrillion British thermal units (Btu) and avoid morethan 60 million metric tons of carbon dioxide emissions each year. Enabling the use of nanotechnologyto improve U.S. manufacturing processes and products will also open global markets for nano-enabledsolutions in energy generation, storage, and use.Nanomanufacturing Portfolio byProject Type and Funding SourceCountries around the globe are investing heavilyin nanotechnology to address some of the world’stoughest energy and environmental challenges. In 2009,nanotechnology investments by governments, corporations,and investors around the world totaled 17.6 billion.1Number of Projects20The U.S. government has made major investments in basicnanotechnology research for the past decade. To build on thisresearch and accelerate the use of nanotechnology, the U.S.Department of Energy’s (DOE’s) Industrial TechnologiesProgram (ITP) is now teaming with industrial partners andnational laboratories to develop the following: Manufacturing processes to deliver high-volume, reliable,1612840and consistent supplies of nanomaterialsConcept DefinitionProjects Scalable unit operations that enable nanomaterials to beincorporated into productsProcess DevelopmentProjectsType of ProjectCommercial-scale nanomanufacturing will deliver performanceenhancing nanomaterials to U.S. and global markets, help U.S.industry maintain its global competitiveness, and support climateand energy initiatives.ARRA FundingITP Core Program1Lux Research, “Ranking the Nations on Nanotech: Hidden Havens and False ThreatsThe Authority of Law,” (August 2010).continued 1
INDUSTRIAL TECHNOLOGIES PROGRAMNanomanufacturing Portfolio byTechnology Category and Type of ProjectITP supports research, development, and demonstration activitiesthat focus on the development and deployment of technologiesto produce uniform nanomaterials and cost-effectivelyincorporate them into manufactured goods that save energy. ITP’snanomanufacturing portfolio focuses on the following objectives:Technology Categories Develop low-cost manufacturing processes to expand thenear-term commercial use of innovative nanomaterials in1) industrial processing and 2) energy-saving and energyproducing products Develop technologies that enable the expanded use ofnanomaterials 1) directly as a material to enhance materialperformance and 2) indirectly as an intermediate device(e.g., nanosensors for thermal management)Projects in the portfolio seek to make revolutionaryimprovements in a broad range of energy production, storage,and consumption applications that will reduce energy andcarbon intensity in industrial processes. The projects are fundedthrough ITP’s core program and the American Recovery andReinvestment Act.In 2010, the ITP nanomanufacturing research anddevelopment portfolio supported 31 projects in two technicalareas: concept definition studies and process developmentprojects. A list of the projects by topic area and a descriptionof each project follows.Number of Projectsby Nanocoatings and thin films45Nanofluids/suspensions02Separation media20Nanomaterials for energyand sustainability34Nanomaterial fabrication22continued 2
INDUSTRIAL TECHNOLOGIES PROGRAMList of Projects in the Nanomanufacturing PortfolioConcept Definition StudiesProcess Development ProjectsHigh Power Impulse Magnetron Sputtering of Ultra-Hard andLow-Friction Nanocomposite CoatingsNanostructured Superhydrophobic CoatingsErosion-Resistant Nanocoatings to Improve Energy Efficiency in GasTurbine EnginesMicrowave and Beam Activation of Nanostructured Catalysts forEnvironmentally Friendly, Energy-Efficient Heavy Crude Oil ProcessingNanocatalysts for Diesel Engine Emission RemediationTransformational, Large Area Fabrication of Nanostructured MaterialsUsing Plasma Arc LampsAccelerated Deployment of Nanostructured Hydrotreating CatalystsNanocrystallization of LiCoO2 Cathodes for Thin Film BatteriesUtilizing Pulse Thermal Processing*Large-Scale Manufacturing of Nanoparticulate-Based LubricationAdditivesOxide-Nanoparticle Containing Coatings for High Temperature Alloys*Microchannel-Assisted Nanomaterial Deposition Technology forPhotovoltaic Material ProductionHighly Dispersed Metal Catalyst for Fuel Cell ElectrodesSelf-Assembled, Nanostructured Carbon for Energy Storage andWater TreatmentSelf-Assembled Biomimetic Nanostructured Anti-Reflection Coatingsfor Highly Efficient Crystalline Silicon Solar Cells*Mesoporous Carbon Membranes for Selective Gas Separations*Ultratough Thermally Stable Polycrystalline Diamond/Silicon CarbideNanocomposites for Drill BitsNanocatalytic Conversion of Biomass into Second-GenerationBiofuels*Modular Hybrid Plasma Reactor and Process for Low CostNanoparticle Production*Large Scale Nanofermentation of Quantum DotsApplication of Wear-Resistant, Nanocomposite Coatings Producedfrom Iron-Based Glassy PowdersFilled Carbon Nanotubes: Superior Latent Heat Storage Enhancers*Development and Application of Processing and Process Control forNanocomposite Materials for Lithium Ion Batteries*Pulsed Thermal Processing of Self-Assembled Quantum DotStructures*Process Development for Nanostructured Photovoltaics*Architectured Nanomembranes for In-Situ Energy ConversionTechnologies*Development and Demonstration of Nanofluids for Industrial CoolingApplicationsInfrared Absorbing Nanoparticles for Reducing Cure Temperatures inIndustrial Coatings*Manufacturing of Superhydrophobic Surfaces with Nanoscale andMicroscale FeaturesSynthesis of Highly Ordered TiO2 Nanotubes Using Ionic Liquids forPhotovoltaics Applications*Nanoparticle Technology for Biorefinery of Non–Food SourceFeedstocksNanostructured Materials for Renewable Energy* Funded through the American Recovery and Reinvestment Actcontinued 3
INDUSTRIAL TECHNOLOGIES PROGRAMConcept Definition StudiesConcept definition studies are early-stage, laboratory-scale research studies that explore anddefine technical concepts or answer a specific technical question. The studies will includetechnical and economic feasibility analyses as well as a complete life-cycle analysis for aproposed nanotechnology—from synthesis to disposal. The studies focus on promisingnanotechnologies such as catalysts, coatings and thin films, separations media, nanocomposites,and other nanodevelopments.High Power Impulse Magnetron Sputteringof Ultra-Hard and Low-FrictionNanocomposite Coatingsbeams in order to take advantage of nanostructured catalysts.Microwave activation is expected to lower required processenergies by selectively heating catalyst surface sites, ratherthan heating the bulk of the materialbeing processed. The microwaveactivated catalyst technology usedProject Partnersin heavy crude oil processing willenhance catalytic cracking, reforming, Oak Ridge NationalLaboratoryand hydrotreating—with up to 50Oak Ridge, TNtimes improvement in catalysisMach I, Inc.rates—in the chemical, biorefinery,King of Prussia, PAand petrochemical processingMaterials Technologyindustries, while operating atInstituteSt. Louis, MOtemperatures approximately 100 Cless than conventional methods.High Power Impulse Magnetron Sputtering (HIPIMS), arevolutionary coating method for industrial-scale depositionsystems, can overcome nanocoating delamination by enablingsuper-toughness and super-strong adhesion and cohesion. HIPIMSseeks to achieve extremely high levels of adhesion ( 40 newtons)between super-hard ( 30 gigapascals [GPa]) nanocompositecoatings and the surfaces of tools or other mechanical parts.HIPIMS of ultra-hard and low-friction nanocomposite coatingscould prevent wear, cracks, anddelamination that commonly occurunder harsh operating conditions,Project Partnersignificantly lowering friction and wearArgonne Nationallosses in rolling, drilling, milling, andLaboratoryArgonne, ILforming operations across multipleindustrial sectors.Transformational, Large Area Fabricationof Nanostructured Materials Using PlasmaArc LampsMicrowave and Beam Activation ofNanostructured Catalysts forEnvironmentally Friendly, Energy-EfficientHeavy Crude Oil ProcessingCritical steps are needed to synthesize nanostructuredmaterials over large areas and dramatically reduce theprocessing costs of the solid-statelighting and photovoltaic materials.Project PartnerFocusing specifically on a zinc oxideOak Ridge NationalLaboratorysystem for light-emitting diodeOak Ridge, TNapplications, this nanomanufacturingResearchers are evaluating and developing energy-efficientprocesses activated by microwave, radio frequency, or radiationcontinued 4
INDUSTRIAL TECHNOLOGIES PROGRAMHighly Dispersed Metal Catalyst for FuelCell Electrodesconcept study employs high-density plasma arc lamp (PAL)technology to perform critical processing steps. The use ofPAL technology incorporates nanostructure features intoactual materials over large areas (as large as 1,000 cm2) withthe desired phase and/or morphology.This project utilizes finely dispersed platinum as an activecomponent in fuel cells (as single atoms or monolayers)throughout the electrode to increase electrocatalyticactivity. By increasing the electrocatalytic activity of afuel cell, smaller amounts of the noble metal are requiredto retain electrical output. This project seeks to increaseelectrocatalytic activity by improvingmetal dispersion in electrodesystems by 1–2 orders of magnitudeProject Partner(10–100 times) compared toSavannah River Nationalcurrent dispersion methods, therebyLaboratoryAiken, SCsignificantly reducing the total costof the fuel cells.Nanocrystallization of LiCoO2 Cathodes forThin Film Batteries Utilizing Pulse ThermalProcessingNanostructured architectures will increase the performanceof energy-storage devices by 10 times; and improve capacity,charge time, and cycle lifetime; and augment overallbattery energy efficiency. Researchers are studying andevaluating the nanocrystallization of lithium cobalt dioxide(LiCoO2) cathode thin films as a function of Pulse ThermalProcessing (PTP) conditions in order to enable thin filmbatteries. PTP’s high power densities, short processing time,and large processing area allow for rapid fabrication ofthin-film and nanoparticle material systems on temperaturesensitive flexible substrates. PTP’s characteristics permitthin film annealing temperatures of 550 C–700 C withoutthermal degradation of the underlying substrate (maximumoperating temperature of 150 C)or other material system. PTP canProject Partnersalso influence other thin film andOak Ridge Nationalnanoparticle material systems,Laboratoryincluding magnetic media,Oak Ridge, TNphotovoltaics, solid-state lighting,ITN Energy Systemsthermoelectrics, and thin filmLittleton, COtransistors.Self-Assembled Biomimetic NanostructuredAnti-Reflection Coatings for Highly EfficientCrystalline Silicon Solar CellsAnti-reflection coatings (ARC) for solar cell technology canreduce reflective losses and increase the efficiency of siliconbased photovoltaics. This research aims to enable economicallyfeasible and more efficient silicon-based photovoltaic (PV)technology while testing the coating stability in simulatedenvironments. Evaluating the conversion efficiency andmaterial stability of silicon cells with templated ARCs inearth- and space-like environments iscritical for the new nanofabricationplatform to increase energy efficiency. Project PartnersSavannah River NationalThis project is developing new ARCsLaboratorywith reflectivity values of less thanAiken, SC35% for wavelengths of 400–1,100University of Floridanm in order to increase the efficiencyGainesville, FLof solar cell technology.Oxide-Nanoparticle Containing Coatings forHigh Temperature AlloysIn an effort to develop advanced high-temperaturematerials, researchers are examining the feasibility ofusing electromagnetic stirring techniques to disperse oxidenanoparticles uniformly within liquid steel. Desirablecharacteristics of these advanced materials include goodhigh-temperature strength, oxidation resistance, and creepresistance (the ability to resist time-dependent elongationor distortion under loading). Oxide-dispersion-strengthenedferritic steels provide improved mechanical strength andcreep resistance at temperatures exceeding 1,000 C, whichcan be several hundred degrees higher than conventionalsteels. These advanced materialscould be useful in heat exchangers,Project Partnerradiant burner tubes, hydrogenOak Ridge Nationalreforming tubes, and otherLaboratoryOak Ridge, TNapplications.Mesoporous Carbon Membranes forSelective Gas SeparationsSeparation processes that combine low energy consumptionwith high selectivity and high throughput can reduceoverall production costs in the petrochemical industry. Thisproject targets the fabrication ofnanostructured materials with poresizes between 4 and 10 nm, whichProject Partnerswill enable the easy separation ofOak Ridge Nationalselect gases such as oxygen, carbonLaboratorydioxide (CO2), and alkanes. TheseOak Ridge, TNmaterials will allow the separationGeorgia Institute ofof CO2 from exhaust stacks andTechnologyAtlanta, GAenable CO2 sequestration at variousindustrial plants.continued 5
INDUSTRIAL TECHNOLOGIES PROGRAMNanocatalytic Conversion of Biomass intoSecond-Generation BiofuelsPulsed Thermal Processing of SelfAssembled Quantum Dot StructuresInvestigators are exploring the use of clay-basednanocatalysts to facilitate the breakdown of refractoryorganics, such as those from lignin and bitumen, to enablethe use of biomass as a biofuel. Advances in the use of clayminerals as economical catalysts will be coupled with theadvantages posed by nanomaterials to greatly enhance theefficiency and economics of refractory organics processing,and will be compared withhomogeneous catalysis technologies.Project PartnerIn particular, the project seeks to useOak Ridge Nationalnanotechnology in order to achieveLaboratorylower-temperature conversions andOak Ridge, TNmore rapid processing.This study focuses on the chemical synthesis and processing ofvarious quantum dots (QD) nanocrystals for solid-state lightingapplications. Some of the developed nanocrystals may be of usein additional applications, such as photovoltaics. A chemicalsynthesis process for the mass production of QD enables themanufacture and distribution of nanomaterials in quantitiessufficient to realize benefits on a meaningful scale. Ultimately,this project may develop a QD manufacturing system forroll-to-roll thin film deposition andprocessing, characterization of QD thin Project PartnerOak Ridge Nationalfilms, and demonstration of scalabilityLaboratorytoward commercial nanocrystalsOak Ridge, TNproduction and film nanofabrication.Large Scale Nanofermentation ofQuantum DotsArchitectured Nanomembranes for In-SituEnergy Conversion TechnologiesThis project is quantifying bacteria-synthesized materialsfor their potential in photovoltaic and solid-state lightingmaterials. The thermophilic anaerobic bacteria underinvestigation excrete copious amounts of functional materialsoutside their cells. With the addition of chemical controlagents that allow control over particle size and shape, thesebacteria can synthesize a variety of candidate materials forquantum dots (QD). This project aims to demonstrate thefeasibility of scaling up bacteriasynthesized materials for QDs fromProject Partner10-milliliter (mL) to 30-liter (L)Oak Ridge Nationalbatches, and to assess depositionLaboratoryand transformation of theOak Ridge, TNQDs as a thin-film.This project has synthesized composite membranes withunique architectures that contain parallel, cross-membranenanochannel arrays, and is evaluating the membranes forlarge-quantity production for specific energy applications.This orientation of nanochannels could produce membraneswith superior performance (upwards of 200 times greatercapabilities in ionic conductivity when compared toconventional means) in energy production or conversionprocesses, such as fuel cells, solar cells, catalytic membranereactors, and thermoelectric devices.Researchers are assessing theProject Partnertechnical and economic impacts ofOak Ridge Nationalthe nanomembrane platforms in these Laboratoryapplications and conducting lifeOak Ridge, TNcycle analyses.Filled Carbon Nanotubes: Superior LatentHeat Storage EnhancersInfrared Absorbing Nanoparticles forReducing Cure Temperatures in IndustrialCoatingsDemonstrations of the feasibility of filled carbon nanotubes(CNT) as latent heat storage enhancers are focusing on high-rateheat transfer and thermal energy storage. This project seeks toshow significant thermal conductivity improvements comparedto existing capabilities. Nanotube uniformity in planned thermalexperiments is critical for accurate data interpretations, anda simple and effective method hasbeen developed to fully control thediameter, length, and packing densityProject Partnersof CNTs. Potential applicationsArgonne NationalLaboratoryfor this technology include nextArgonne, ILgeneration thermal managementUniversity of Illinoisfluids for microelectronic cooling,at Chicagomanufacturing, power generation,Chicago, ILtransportation, and solarenergy storage.Researchers are examining the ability of infrared (IR)-absorbingnanoparticles to reduce cure temperatures for industrial coatingsat the laboratory scale. The IR additives improve the energyefficiency of drying coatings and softening resins for molding,which enables these materials to reduce cure temperatures orbake cycles in thermoset coating formulations. Incorporatingnanoparticles with the required IRabsorbing characteristics specificallybenefits applications that requireProject Partnersvisible light transparency, such asNational Energytransparent coatings. This study seeksTechnology LaboratoryPittsburgh, PAto reduce cure temperatures for aPPG Industriescoating process from 400 F to 350 FPittsburgh, PA &through the addition of transparentLongmont, COIR-absorbing nanocoatings.continued 6
INDUSTRIAL TECHNOLOGIES PROGRAMSynthesis of Highly Ordered TiO2 NanotubesUsing Ionic Liquids for PhotovoltaicsApplicationsResearchers are developing highly ordered titanium dioxide(TiO2) nanotube arrays using ionic liquids-based electrolytes.The effort includes synthesizing highly ordered TiO2nanotubes using ionic liquids, nanostructural characterization,understanding of synthesis mechanisms, and evaluation ofphotovoltaic (PV) characteristics. Promising photoelectricperformance was previously observed in a proof-of-conceptproject. Compared to nanotubes grown in conventionalorganic electrolytes, TiO2 nanotubes produced in ionic liquidsshow a light absorbance two times higher for ultraviolet(UV) light, a much-increased light absorbance for visibleand infrared light, and more than double the photocurrentdensity in water splitting. Potentialapplications include TiO2-polymerProject Partnerhybrid cells, dye-sensitized solarOak Ridge Nationalcells (DSSC), water splitting, wasteLaboratorydecomposition, photocatalysis, andOak Ridge, TNgas sensoring.continued 7
INDUSTRIAL TECHNOLOGIES PROGRAMNanomanufacturing Process Development ProjectsNanomanufacturing process development projects focus on enabling processes fornanomaterials production or nanomaterial use in industrial processes. DOE national laboratoriespartner with industrial companies to 1) design production systems that will generate uniformmaterial in production-scale quantities or 2) identify and modify promising processingtechniques to handle nanomaterials at one-tenth of the smallest scale in use in industry today.Nanostructured SuperhydrophobicCoatingsErosion-Resistant Nanocoatings to ImproveEnergy Efficiency in Gas Turbine EnginesNanostructured superhydrophobic (SH) silica-based coatingsthat substantially reduce friction between water and a givensubstrate’s surface result in surfaces that are more waterrepellent and durable than anything found in nature. The newclass of nanostructured SH coatings will extend equipmentlifetimes, improve productivities, and generate substantialenergy savings for various industrial, transportation, andconsumer products. These oxide-based powders containgrains that have porous nanotextured properties that trap alayer of air on the coating’s surface, making it remarkablywater-repellent. The contactangles for the Oak Ridge NationalProject PartnersLaboratory (ORNL) powdersapproach 180º (non-wetting) underOak Ridge NationalLaboratorylaboratory conditions. ORNL canOak Ridge, TNnow reproducibly create highlyStevens Institute ofwater-repellent surfaces that areTechnologyboth well bonded and durable whenHoboken, NJcoated on steel and aluminumRoss TechnologyCorporationsubstrates. This project seeks toLeola, PAreplicate these performance resultsRoss Technology Oakwhen the technology is scaledRidgeup and implemented onOak Ridge, TNcomponent surfaces.This project is optimizing and validating erosion-resistant(ER) nanocoatings to reduce the erosion of compressor airfoilsin gas turbines, which are used in power plants and aircraftengines. The ER nanocoatings areapplied using a cathodic arc physicalvapor deposition process, and thenumber of coating layers and theirProject Partnersindividual thicknesses will varyNational Energyaccording to each compressor airfoil’s Technology LaboratoryPittsburgh, PAerosion pattern. Reducing compressorMDS-Coatingsairfoil erosion extends componentTechnologies Corporationlife and operational efficiency whileSlemon Park P.E., Canadareducing engine emissions and fuelCalpine Corporationcosts. The application of these robustHouston, TXnanocoatings may double the lifetimeDelta AirlinesAtlanta, GAof aviation and power plant turbinecomponents.Nanocatalysts for Diesel Engine EmissionRemediationThis project is developing a zeolite-based nanocatalyst systemthat can perform in extreme environments, which will enable itsuse with urea selective catalyst reduction (urea-SCR) technology,a leading approach in diesel engine exhaust treatment for theremoval of nitrogen oxide (NOx) emissions. The project iscontinued 8
INDUSTRIAL TECHNOLOGIES PROGRAMMicroreactor-Assisted NanomaterialDeposition Technology for PhotovoltaicMaterial Productionmodifying the zeolite catalyst’s nanostructure and widening itsoperating temperature window, allowing it to operate at bothlower and higher temperatures thanProject Partnersconventional catalysts and improvinglifetime functionality. ImprovedOak Ridge Nationalcatalyst performance will enable wider LaboratoryOak Ridge, TNdeployment of diesel systems, whichJohn Deere Power Systemsare approximately 30% more fuelWaterloo, IAefficient than gasoline engines.Researchers are developing energy- and materials-efficientmanufacturing processes for greener, low-cost production ofsolar cells in order to improve photovoltaic (PV) production.Microreactor-Assisted Nanomaterial Deposition (MAND )demonstrates a new, scalable pilot platform for the production ofsolution-phase synthesis, purification,functionalization, and deposition ofProject Partnersnanomaterials for PV applications.MicroproductsEnhancing PV manufacturing practices TheBreakthrough Institutewill reduce costs, lower processing(Pacific NorthwestNational Laboratory &temperatures, and improve solventOregon State University)usage and materials utilization.Corvallis, ORThis project seeks to improveCH2M HILLmanufacturing efficiency and at leastPortland, ORdouble the materials utilization ratesVoxtel, Inc.Beaverton, ORof cadmium sulfide in Gen II PV andquantum dots in Gen III PV.Accelerated Deployment of NanostructuredHydrotreating CatalystsThis project targets improvements in hydrotreating catalystreactivity in the removal of sulfur and other contaminantsfrom crude oil fractions. An atomic layer deposition (ALD)system is being designed and deployed to manufacturehydrotreating catalysts that reduce energy use and improvehydrotreating performance for oil recycling or “re-refining.”About 70% of used oil is recoverable base oils; these catalystswill reduce the required re-refining temperature and enablerefiners to recycle more oil. The new nanostructured catalystproduct will potentially provideenergy savings of at least 20% byProject Partnerslowering operating costs as well asArgonne Nationalby lowering process temperatures,Laboratorywhich will also increase theArgonne, ILcatalyst’s lifetime. In addition, theUniversal Lubricants, Inc.new nanostructured catalyst willWichita, KSdecrease byproduct formation andChemical Engineeringreduce greenhouse gas and otherPartnersIrvine, CAemissions compared to conventionalhydrotreating processes.Self-Assembled, Nanostructured Carbon forEnergy Storage and Water TreatmentThe development and implementation of reliable, scalable,cost-effective processes for manufacturing self-assemblednanostructured carbon materials is supporting new solutions topressing problems in energy storage and water treatment. In energystorage, the development of carbon nanomaterials for improvedultracapacitors can enhance the commercial viability of renewableenergy technologies. In water treatment, the development andimplementation of carbon nanomaterials can improve capacitivedeionization (CDI) systems for water treatment processes. Thisproject is producing two forms of material: an unconsolidated formto displace activated carbon in current capacitor production, anda sheet form for CDI applications. Toensure successful device performance,it is important that the materials betweenProject Partnersthe electrode surfaces and the electrolyteOak Ridge NationalLaboratoryhave high surface areas and poresOak Ridge, TNaccessible for ions. The project aims toHoneywell Specialtyreliably produce materialsMaterialswith nanometer-scale pores in orderMorristown, NJto provide sufficient charge/dischargeCampbell Applied Physicsrates and capacitance for theEl Dorado Hills, CAdesired applications.Large–Scale Manufacturingof Nanoparticulate-Based LubricationAdditivesThe large-scale production of boron-based nanoparticulatelubrication additives can drastically lower friction and wearin a wide range of industrial and transportation applications.This project is focusing on nanocolloidal versions of boronbased lubricants, such as boric acid. Researchers are alsoinvestigating hybrid lubricants, suchas boric acid with molybdenumProject Partnersdisulfide (MoS2). Improved lubricantArgonne Nationalperformance plays a vital role inLaboratoryextending machine life, augmentingArgonne, ILperformance, reducing friction andPrimet Precisionwear, and preventing componentMaterials, Inc.Ithaca, NYfailure. This project seeks to reduceValvolineboundary friction by as much asLexington, KY80% through the formation of slickUniversity of Arkansasboundary films for applications in theFayetteville, ARtransportation and industrial sectors.Ultratough Thermally Stable PolycrystallineDiamond/Silicon Carbide Nanocompositesfor Drill BitsResearchers are developing and producing novel superhardand ultratough thermally stable polycrystalline diamondnanocomposites for drill-bit applications and multipleindustrial functions. Industrial drilling, mining, cutting, andgrinding require superhard materials with superior wearcontinued 9
INDUSTRIAL TECHNOLOGIES PROGRAMresistance. This project is applying a novel nanosynthesistechnique of high-pressure andtemperature-reactive sinteringProject Partnersto synthesize diamond/SiCLos Alamos Nationalnanocomposites that offer superbLaboratoryhardness ( 50 GPa), enhanced yieldLos Alamos, NMstrength comparable to that of aU.S. Synthetic Corporationdiamond ( 16 GPa), and a 200%Orem, UTimprovement in fracture toughness.stationary storage applications. Nanocomposite materials usedwith lithium-ion (Li-ion) batteries improve the performance ofhigh-power and high-energy applications. This project seeks toprovide a 30% improvement in power delivery, breakthroughhigh-temperature durability, andlower cell costs. Improving the cycleProject Partnerslife, high-temperature durability, andOak Ridge Nationalpower characteristics of batteriesLaboratorywill lead to the implementationOak Ridge, TNof effective, energy-efficientA123 Systemstransportation vehicles and gridAnn Arbor, MIstabilization technologies.Modular Hybrid Plasma Reactor and Processfor Low Cost Nanoparticle ProductionThis project is researching and developing new approaches—such as plasma reaction processes and new plasma reactordesigns—to produce low-cost, high-performance nanoparticlesfrom inexpensive solid feedstocks. An energy-efficient, one-step,low-cost nanomaterial bulk production method that producesdesirable surface properties will enable manufacturers to takeadvantage of enhanced properties from composite systems byutilizing nanoparticles blended with raw materials. This projectis evaluating and optimizing a chosen modular hybrid plasmareactor concept to produce nanomaterial with consistent particlemorphology and particle size ( 95% of nanomaterial less than100 nm), desirable surface chemistry,and reduced contaminants ( 99.5%purity). The plasma reactor systemProject Partnersmust be able to run continuously withIdaho National Laboratoryfeed materials for a minimum of eightIdaho Falls, IDhours, which is
through ITP’s core program and the American Recovery and Reinvestment Act. In 2010, the ITP nanomanufacturing research and development portfolio supported 31 projects in two technical . areas: concept definition studies and process development projects. A list of the projects by topic area and a description of each project follows.
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The ITP Stage-Gate Model ITP‘s model for the Stage-Gate process focuses project management activities on the delivery of energy saving technologies and information to U.S. industrial energy users. The Process directs ITP and its partners to consider the prospects for commercialization from the start of a project to its conclusion.
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