METALKRAFT TECHNOLOGIES LLC — Department of Energy STTR Phase I: C54-09a

Description

Immense global electrification has placed great burdens on power grid output and associated environmental concerns. Roughly 25% of the electricity produced is used by industrial electric motors using copper wire for the coil windings. Hence, an increase in electric motor efficiency would have a massive impact to reduce energy usage, reduce industrial operating costs, while also reducing CO2 emissions related to fossil fuel plants. Electrical efficiencies, performance, and transmission are ultimately limited by the inherent conductor material properties. Thus, there has been intense research to improve metal conductor performance. Much of this work involves copper metal matrix composites using carbon nano-particles such as graphene. The most promising work to-date to improve bulk electrical properties has been with solid-phase processing of copper-graphene composites. Yet there exists a distinct lack of fundamental science to guide material synthesis and processing. This work seeks to fill this vital technological void by analytically and experimentally establishing process-structure-property relationships to produce enhanced copper-graphene electrical ultra-conductors. Development of enhanced conductivity behavior in copper-graphene composites is specifically dependent on the graphene type, quality, and content used in the composite, as well as the effects of thermo-mechanical processes on the composite nano and micro-structures. At the current state of product development, these factors are not completely understood to maximize the electrical performance needed. General Statement of how this problem or situation is being addressed MetalKraft will work with Pacific Northwest National Laboratory (PNNL) to develop and apply modeling and characterization tools to guide solid-phase processing of copper-graphene composite s with improved electrical properties. MetalKrafts’s patent pending solid-phase processing is a cost effective, scalable approach to improve electrical properties beyond any conventional conductor material. Phase I Plan The Phase I work will involve performing a detailed process-structure-property analysis of copper-graphene composites using the conductivity modeling framework developed at PNNL. This will guide process and material design. MetalKraft will manufacture composite wire using the process conditions and graphene identified through modeling. The copper-graphene wire will be tested and characterized at PNNL’s world class imaging facilities and Environmental Molecular Sciences Laboratory (EMSL), to validate modeling and performance goals.