THE PROBLEM: Conventional alloys used in power generation degrade over time due to corrosion-causing water vapor, combustion, and sulfur atmospheres at high temperatures. The layer of chromia that protects the underlying alloy grows quickly, leading to cracking or chipping that further damage the material. The repeated chipping and increase in oxidation reduce the material’s thickness, load-bearing capacity, and lifetime. To compensate, operating temperatures must be decreased to maintain the component’s durability, but this reduces efficiency and increases emissions. 

THE SOLUTION: Oak Ridge National Laboratory (ORNL) has created a cast alumina-forming stainless-steel alloy to address these shortcomings of traditional alloys used in power generation, steel, industrial manufacturing, and chemical and petrochemical industries. Compared to traditional alloys, ORNL’s alumina scale is more stable, slows chromia growth, and reduces oxidation — which can help components last 300% longer, increasing productivity, energy savings, and more. Its castability allows production close in size and shape to the finished product, reducing production time, cost, and waste. The new alloy also maintains stability and strength at high temperatures. 

THE TECH TRANSFER MECHANISM: ORNL’s inventors received commercialization funding in 2014 through an ORNL Technology Innovation Program project to gather data on the ORNL-patented alloy. This attracted the interest of two U.S.-based commercial players: Duraloy Technologies, a foundry, and Cleveland-Cliffs, North America’s largest producer of flat-rolled steel. The interest from Duraloy and Cleveland-Cliffs helped ORNL secure an Advanced Research Projects Agency-Energy grant for $3.9 million. Cleveland-Cliffs ran large-scale tests of the prototype in 2018 and validated component performance. Duraloy licensed the technology in 2019. The collaborative efforts among ORNL and its partners took the alloy from foundational discovery to disruptive market penetration in a short time. 

THE IMPACT: High demand for components produced with the new alloy has led to a 20% increase in jobs at Duraloy’s plant outside of Pittsburgh, Pennsylvania. Industrial components made from this alloy have shown a remarkable 300% increase in longevity and a significant reduction in maintenance costs. Just in the steel industry, represented by Cleveland-Cliffs, the enhanced process efficiency achieved with longer running equipment and components has increased the production period and significantly cut costs. The ability to operate at higher temperatures improves manufacturing efficiency and reduces emissions, enhancing energy security. The alloy’s long-term economic benefits also include reduced reliance on foreign suppliers for critical components and lower operating costs that ultimately translate to savings for customers. Finally, the company has established partnerships with local trade schools, including involvement with advisory and scholarship committees and paid internships for college students in need.