STARFIRE INDUSTRIES LLC — Department of Energy SBIR Phase I: 33b

Description

Scalable manufacturing techniques are needed for high-quality coatings on nuclear fuel to provide: (1) enhanced safety during design basis and beyond design basis (>1200°C) accident conditions, (2) provide better performance to enable higher linear heat (>7kW/ft, >20% uprate) generation during baseline operation to enable more energy production from existing nuclear plants, (3) enable higher fuel burn up (>80 MWd/kg U) for less frequent fuel replacement, (4) be cost effective (+$30/cladding) and (5) integrate into existing production flow, inspection and certification. The technical approach is to validate a high-throughput fabrication method for nanolayered corrosion- resistant and fracture-resistant coatings using high-power impulse magnetron sputtering (HiPIMS) with a recent innovation to increase deposition rates, adjust coating micro/nanostructure, modify film stress and control morphology. The fabrication technique is suitable for coating LWR cladding and pellets, as well as fast reactor fuels. Both metals and ceramics can be precision deposited with excellent adhesion, graded composite nanostructures and layering, radiation hardness, thermal shock- and oxidation-resistance. Proof of concept feasibility will be demonstrated in a lab environment paving the way for Phase II implementation readiness.The HiPIMS technology for accident-tolerant fuels would improve: (1) nuclear safety and reliability, (2) power generation capacity with existing plants for the nation, (3) competitiveness of US nuclear power industry, (4) domestic manufacturing for advanced high-temperature coatings and processing, (5) high- power turbines for aviation and power generation, high-temperature aerospace/hypersonics, tooling and materials manufacturing, and (6) support emerging small businesses and job creation in the Midwest.