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Breadcrumb

  1. Research
  2. Scientific Discovery
  3. Materials Sciences
  4. Solid Phase Processing

Solid Phase
Processing

Revolutionizing research
for new metal and
multi-material products

Friction stir wielding machine

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Building on a rich history of materials science research and engineering development, Pacific Northwest National Laboratory (PNNL) is paving the way for adoption of new manufacturing methods that could revolutionize the energy, automotive, aerospace, and other industries. Solid phase processing (SPP) has the potential to significantly decrease the energy used in manufacturing and deliver higher-performing components—all at a lower cost.

This scalable approach produces metal and composite products that, in some cases, simply cannot be made by conventional means.

No melting required

Historically, metal alloy and composite production has required that the metal first be melted and then subjected to several energy intensive steps, such as heat treatment, forging, rolling, and drawing, to produce end products. With SPP, metals are not melted, resulting in a significant decrease in the energy intensity of alloy and component manufacture.

SPP applies mechanical energy—in the form of high shear strain—to the metals to create friction heat for deformation. This process enables the microstructure of the metal to be tailored to yield superior properties.

As a result, SPP can circumvent the constraints imposed by conventional manufacturing methods and produce materials and components with truly extraordinary properties.

PNNL’s award-winning SPP methods can create entirely new alloys and composites, enable production of difficult-to-fabricate products, join dissimilar materials, repair damage in components, or create protective coatings.

Energy savings and agile manufacturing

These patented technologies have the potential to provide more efficient and scalable manufacturing approaches that will allow a variety of industries to incorporate higher-performance materials into their products.

Friction Stir icon

PNNL’s specialized friction stir methods can join similar and dissimilar materials to produce high-performance joins, while using up to 80 percent less energy than traditional welds. In addition to traditional friction stir welding approaches, PNNL has developed several friction-assisted welding techniques to join materials with different melting points and to form metallurgical bonds for stronger joints.  

Three researchers with friction stir welding machines
Friction stir techniques developed by PNNL enable lighter- weight military vehicles to be more agile and fuel efficient. (Photo by Andrea Starr | Pacific Northwest National Laboratory)
ShAPE icon (120x120)

Friction extrusion can provide a pathway to entirely new alloys and composites, and PNNL’s patented Shear Assisted Processing and Extrusion (ShAPE™) process extends friction extrusion to tubular products. Using PNNL’s first-of-its-kind ShAPE machine, copper wire can be extruded with higher conductivity; magnesium can be more ductile; aluminum alloys can be extruded faster with less energy; and metal scrap can be recycled directly into products with better performance than the original material.

Shear Assisted Processing and Extrusion or ShAPE. (Video by Eric Francavilla | Pacific Northwest National Laboratory)
Cold Spray icon

A third SPP technique, called cold spray, can repair or refurbish worn or failing metal parts—in hydropower or nuclear power plants, for example. Cold spray deposits, at supersonic speeds, coatings that add functionality to materials and/or protect them from harsh service environments.

Researcher holding cold spray component.
A PNNL researcher holds component repaired by cold spray technology. (Photo by Andrea Starr | Pacific Northwest National Laboratory)

Solutions for industry

SPP provides more products in less time with less effort. These methods are scalable, affordable, environmentally friendly solutions to a wide range of technology challenges for the energy, transportation, national security, and health sectors.

These technologies are available for licensing. Industry and university researchers are encouraged to collaborate with PNNL on SPP technologies for specific applications and to further demonstrate them in a variety of industrial settings.

Related Links

Solid Phase Processing Publications Available SPP TechnologiesAwardsSPP @ PNNL

Top Stories

JULY 19, 2022
Feature

Aluminum Alloy Manufacturing Now 50 Percent More Energy Efficient

Read
A researcher stands in front of the ShAPE machine holding a piece of aluminum alloy 7075, with the words "50% Energy Savings High-Performance Aluminum Alloy" in the background.
JUNE 29, 2022
Feature

Cooking Up a Conductive Alternative to Copper with Aluminum

Read
Coils of copper and aluminum
OCTOBER 26, 2021
Feature

Speedier Manufacturing for Stronger Aluminum Alloys

Read
Aluminum Alloy extrusion 10 times faster
SEE MORE RELATED NEWS

Research Topics

Materials Sciences Sustainable Energy Lightweight Materials Vehicle Technologies

Facilities

Applied Process Engineering Laboratory Solid Phase Processing Demonstration Facility

Related Divisions

Energy Processes & Materials Division
Physical Sciences Division

Contacts

Cindy Powell
Chief Science and Technology Officer
cynthia.powell@pnnl.gov
(509) 375-3645
David Gotthold
Strategic Advisor, Advanced Materials and Manufacturing
david.gotthold@pnnl.gov
(509) 375-2073

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