From vehicles and airplanes to solid-phase processing of metals—how Curt Lavender and his team at PNNL solve industry problems with practical ingenuity.

Shear Assisted Processing and Extrusion (ShAPE) imparts significantly more deformation compared to conventional extrusion. The latest ShAPE system at PNNL, ShAPEshifter, is a purpose-built machine designed for maximum configurability.

PNNL researchers have developed a new, physics-informed machine learning model that accurately predicts how heat accumulates and dissipates during friction stir processing.

PNNL researchers will pursue both fundamental and applied projects with this support from the Department of Energy

Leaders from the DOE Office of Energy Efficiency and Renewable Energy visited PNNL October 19–20 for a firsthand look at capabilities and research progress.

A PNNL-developed computational framework accurately predicts the thermomechanical history and microstructure evolution of materials designed using solid phase processing, allowing scientists to custom design metals with desired properties.

Research published in Journal of Manufacturing Processes demonstrates innovative single-step method to manufacture oxide dispersion strengthened copper materials from powder.

Direct visualization of metal atoms during shear deformation has broad applications from battery design to vehicle lightweighting.

A new extrusion process eliminates pre-heating to provide significant energy savings during production of extruded aluminum alloys.

The first-ever simulation of aluminum conductivity offers a recipe for an inexpensive, lightweight alternative to copper.

Developed at PNNL, Shear Assisted Processing and Extrusion, or ShAPE™, uses significantly less energy and can deliver components like wire, tubes and bars 10 times faster than conventional extrusion, with no sacrifice in quality.

An energy-efficient method to extrude metal components wins Association of Washington Business Green Manufacturing Award. PNNL’s Shear Assisted Processing and Extrusion™ technology consumes less energy and enhances material properties.

PNNL’s suite of Solid Phase Processing tools like Cold Spray is helping to strengthen hydroelectric dam materials such as turbines.

Rotational Hammer Riveting, developed by PNNL, joins dissimilar materials quickly without preheating rivets. The friction-based riveting enables use of lightweight magnesium rivets and also works on aluminum and speeds manufacturing.

Three recent doctoral graduates are beginning their research careers at Pacific Northwest National Laboratory after completing the WSU-PNNL Distinguished Graduate Research Program this spring.

Materials scientists at PNNL are demonstrating materials with improved properties using solid phase processing.

Researchers at PNNL have increased the conductivity of copper wire by about five percent via a process called Shear Assisted Processing and Extrusion. General Motors tested the wire for application in vehicle motor components.

Twelve energy-related technologies developed at PNNL have been selected for additional technology maturation funding to help move them from the laboratory and field tests to the marketplace.

Two forms of magnesium material were processed into tubing using PNNL’s Shear Assisted Processing and Extrusion™ technology. Both materials were found to have quite similar and improved properties—even though they began vastly different.

A PNNL study that evaluated the use of friction stir technology on stainless steel has shown that the steel resists erosion more than three times that of its unprocessed counterpart.