Worcester Polytechnic Institute

Aluminum Company of America

Spx Corporation

Melt Cognition, LLC

Rheinfelden Alloys Gmbh & Co. Kg

Diran Apelian

Yan Wang

Haiyang Zou

Deepak Saha

Reinhold Ludwig

Mark Musser

Zach Brown

Dayne Killingsworth

C Edward Eckert

Sergey N Makarov

Rajakkannu Mutharasan

David B Spencer

David H DeYoung

Souheil Benzerrouk

Thomas R Hornack

Ronald E Miller

Joseph Heelan

Robert De Saro

Sumanth Shankar

Makhlouf M Makhlouf

Aaron M Birt

Ali Valamanesh

Ryan Mocadlo

Anacleto M De Figueredo

Matt M Findon

Nicholas Saddock

Shaymus W Hudson

Michael Scott Mellen

Robert DeSaro

Yang Bai

Rajakkannu Mutharason

Wenhuan Li

John A Kaems

Joseph C Craparo

George E Lyness

Clarence J Cox

Makhlouf M Maklouf

Cathode material from exhausted lithium ion batteries are dissolved in a solution for extracting the useful elements Co (cobalt), Ni (nickel), Al (Aluminum) and Mn (manganese) to produce active cathode materials for new batteries. The solution includes compounds of desirable materials such as cobalt, nickel, aluminum and manganese dissolved as compounds from the exhausted cathode material of spent cells. Depending on a desired proportion, or ratio, of the desired materials, raw materials are added to the solution to achieve the desired ratio of the commingled compounds for the recycled cathode material for new cells. The desired materials precipitate out of solution without extensive heating or separation of the desired materials into individual compounds or elements. The resulting active cathode material has the predetermined ratio for use in new cells, and avoids high heat typically required to separate the useful elements because the desired materials remain commingled in solution.

Method and apparatus for recycling lithium-ion batteries

A rechargeable lithium-ion (Li-ion) battery employs a low temperature approach to battery manufacturing that forms charge material from kinetic energy of high velocity particles impelled into an aggregation such that bombardment of the particles against other particles in the aggregation forms a charge conveying structure. High velocity bombardment from a carrier gas nozzle accumulates an active charge material in a layered arrangement for the finished battery. Preparation of the particles, such as by ball milling or spraydrying, arranges particle agglomerations. The particle agglomerations, when impelled against other agglomerations or a current collector, forms a layer of cathodic, anodic or electrolytic battery material. The metallic binder conveys charge for mitigating or eliminating a need for a planar current collector underlying the sprayed layer. The resulting layers are suitable for battery operation, and are manufactured in an absence of any solvent drying or disposal.

Sprayed formation of batteries

A molten metal inclusion test apparatus includes a spectroscopic appliance for gathering data indicative of the contents of a quantity of molten metal. Laser induced emissions provide spectral data based on the elements present in the melt. Analysis of a series of samplings, or 'shots' of laser induced emissions indicates a presence of elements above a background or expected level. These elements appear as spikes in a graphical rendering of the spectral data, defined by a wavelength of the detected element. Correlation of the elements detected in the same shot indicates a composition of the inclusion, typically a particle of an extraneous compound in the melt. Such spectral analysis provides immediate feedback about melt quality, allowing corrective measures to be taken prior to casting.

Molten metal inclusion testing

According to some aspects, a system for producing a target molten metal composition is provided. The system includes a sorting device that sorts input pieces of metal based on a control signal. Sorted pieces of metal are melted in a furnace, and a sensor measures the composition of molten metal in the furnace and in response generates a control signal that is sent to the sorting device.

Metal sorting, melting and fabrication apparatus and methods

Cathode material from exhausted lithium ion batteries are dissolved in a solution for extracting the useful elements Co (cobalt), Ni (nickel), Mn (manganese), Li (lithium), and Fe (iron) to produce active cathode materials for new batteries. The solution includes compounds of desirable materials such as cobalt, nickel and manganese dissolved as compounds from the exhausted cathode material of spent cells. Depending on a desired proportion, or ratio, of the desired materials, raw materials are added to the solution to achieve the desired ratio of the commingled compounds for the recycled cathode material for new cells. The desired materials precipitate out of solution without extensive heating or separation of the desired materials into individual compounds or elements. The resulting active cathode material has the predetermined ratio for use in new cells, and avoids high heat typically required to separate the useful elements because the desired materials remain commingled in solution.

A flow battery employs a solid suspension charge material to maintain high charge density via stability of a suspension including a binder, conductive carbon and an electrolyte. A cathodic suspension employs carbon powder as a stabilizing agent in a suspension form to avoid precipitation of solids and maintain a high surface area of the suspended solids. The stabilizing agent undergoes agitation and milling to reduce a particle size and increase the change density due to the conductive nature of the fine powdered stabilizing agent exhibiting high energy density. The resulting suspensions are circulated in a charge cell connected to a load for providing electrical power.

Battery electrolyte suspension

A pulsed thermography defect detection apparatus including active and passive infrared (IR) thermography for non-destructive testing (NDT) of powdermetallic (P/M) components for on-line and off-line inspection.

Infrared defect detection system and method for the evaluation of powdermetallic compacts

Described herein are alloys substantially free of dendrites. A method includes forming an alloy substantially free of dendrites. A superheated alloy is cooled to form a nucleated alloy. The temperature of the nucleated alloy is controlled to prevent the nuclei from melting. The nucleated alloy is mixed to distribute the nuclei throughout the alloy. The nucleated alloy is cooled with nuclei distributed throughout.

Alloy substantially free of dendrites and method of forming the same

Preferred embodiments of the present invention include methods that allow for casting alloys, and preferentially casting wrought alloys to circumvent problems such as, for example, hot tearing. Preferred embodiments of the present invention provide for alloys having predominantly spherical primary &#x3b1;-aluminum grains in their microstructure (i.e., substantially free of dendrites) formed by mixing two liquids of differing compositions that are held at predetermined temperatures, such that when mixed they produce a predetermined alloy composition at a predetermined temperature that is inclined to solidify with a predominantly spherical grain structure that minimizes the alloy's tendency towards hot tearing.

Casting of aluminum based wrought alloys and aluminum based casting alloys

A method for the refining of primary aluminum in hypoeutectic alloys by mixing a titanium based grain refiner into a solid/semi-solid hypoeutectic slurry is described. The method provides control of the morphology, size, and distribution of primary Al in a hypoeutectic Al&#x2014;Si casting by mixing a hypoeutectic Al&#x2014;Si liquid with titanium boron alloys. The invention enables grain refining techniques for SSM casting of hypoeutectic Al&#x2014;Si alloys.

Semi-solid casting process of aluminum alloys with a grain refiner

A method for the refining of primary silicon in hypereutectic alloys by mixing at least two hypereutectic alloys into a solid/semi-solid hypereutectic slurry is described. The method provides control of the morphology, size, and distribution of primary Si in a hypereutectic Al&#x2014;Si casting by mixing a hypereutectic Al&#x2014;Si liquid with solid hypereutectic Al&#x2014;Si particles. The invention enables SSM processing of hypereutectic Al&#x2014;Si alloys.

Semi-solid metal casting process of hypereutectic aluminum alloys

A method for the refining of primary aluminum in hypoeutectic alloys by mixing at least two hypoeutectic alloys into a solid/semi-solid hypoeutectic slurry is described. The method provides control of the morphology, size, and distribution of primary Al in a hypoeutectic Al&#x2014;Si casting by mixing a hypoeutectic Al&#x2014;Si liquid with solid hypoeutectic Al&#x2014;Si particles to impart desirable mechanical properties. The invention enables SSM molding of hypoeutiectic alloys without the need for secondary processing steps associated with other rheocasting processes.

Semi-solid metal casting process of hypoeutectic aluminum alloys

Growing community of inventors

West Boylston, MA, United States of America

Diran Apelian