Diran Apelian found a way to recycle EV batteries and co-founded the billion-dollar company Ascend Elements, one of TIME'S America's Top Ten Green Tech companies of 2024. Find out about the cutting-edge technology his lab uses to upcycle metal at UC Irvine's Samueli School of Engineering. Transcript: [sound of Tesla starting] [sci fi music] NATALIE TSO, HOST: What happens to EV batteries when we’re done with them? Diran Apelian invented a way to recycle them and co-founded a billion dollar company Time magazine named one of America’s Top Ten Green Tech Companies of 2024. Apelian is a distinguished professor of materials science and engineering at UC Irvine’s engineering school. What inspired him to get into metallurgy – the science of metals? DIRAN APELIAN: Even in my teenage years, I was very interested in rocks, minerals. I sort of had a connection with the Earth, you know. I found it to be beautiful, actually. Then I was exposed to a tour of a steel mill, United States Steel. And for the first time, I saw molten steel, but not in a few grams, but in tons of it being poured. I was completely taken back. I was fascinated. There was something magical about the smell, the visual Earth and the fire. And I got attracted to it. And the same time the Sputnik age was coming up, you know, where we were sending missiles up to the moon and trying to get to the moon and everything in the headlines was all the material problems. You know, the tiles protecting the vessel, they were falling off. I put two and two together and that's how I got interested in metallurgical engineering. TSO: And the world is better for it. He not only made aluminum foil stronger, he put aluminum in cars. APELIAN: Many years ago, most of the cars were mostly steel, and in the nineties or so we moved from steel to aluminum because aluminum is three times lighter. So we want to decrease the weight of the car so we don't use as much fuel. So we actually got involved in developing the alloys for the Audi, all aluminum. TSO: That was the Audi A8 — the first mass market car with an all aluminum body. He also tells us what led to the billion dollar company he co-founded, Ascend Elements, which is a major recycler of EV batteries. APELIAN: The battery comprises of anode and cathodes. The cathode has a lot of prescious metal in it – cobalt, nickel. So when these things are end of life, they need to be recovered, all these precious metals. So we developed the technologies to recover the cobalt, the nickel and lithium, all the important elements that are not critical, but near critical and reuse them into a new cathode. And ironically, the recycled material has better properties than the virgin material because we can manipulate the morphology of the powder sizes and all that to control the conductive electronic charges and all that. TSO: Apelian’s lab is a leader in upcycling end-of-life metal products. [sounds of ultrasound machine melting metal] [RAQUEL JAIME: It’s only going to be a small amount] TSO: That’s Ph.D. student Raquel Jaime. She’s melting scrap aluminum in their lab and it does look pretty cool. She’s giving them an ultrasonic treatment that can potentially remove impurities in the metal. She’s researching how the ultrasound – which is not yet used in industry - can make stronger metals for cars and jets. [JAIME: There we go cool, and then we’ll just remelt it in a little bit.] TSO: As for the molten metal that captivated her professor? She loves it too. JAIME: - That’s like my favorite thing that I get to do in here, that treating it with the ultrasound. It all sounds very crazy. It's not something I would have imagined myself doing as a kid. It sounds weird. I always say that it sounds like the two combination things that you need to get like a Marvel super villain. Ultrasound frequency and molten metal, it sounds like if I fell in, I would turn into some weird sort of character. I don’t know. [Jaime laughs] [sound of cold spray machine] TSO: Another cutting-edge technology in the lab is the cold spray machine which you hear in the background. Now cold is relative because here it means at least 1000 degrees Fahrenheit. Graduate student Michael Ross explains what’s special about this million-dollar 3D printer: ROSS: So the big advantage of cold spray is that you don't need to actually melt the metal that you're processing so you can make solid metal parts without melting your material, which really opens up the possibilities of using more advanced materials that melt at higher temperatures. And that's important for applications in extreme environments like aerospace, where they need to withstand higher temperatures. TSO: That’s the cold. As for the spray, it runs at three times the speed of sound or Mach3. Ph.D. student Jack Webster explains what happens in cold spray: WEBSTER: We have a robotic arm that moves this substrate plate around while a nozzle flings powder at a super high ...
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