Physical Optics Corporation — Department of Energy SBIR Phase II: 08b

Description

Limitations of the existing nuclear grade SiC composites as applied to high-performance nuclear systems include difficulty joining complex geometries and instability of those joints under irradiation, poor initial thermal conductivity and significant conductivity degradation after irradiation, matrix micro-cracking, and difficulty in producing complex shaped components at low cost. Thus, while the current generation of nuclear composites is undergoing active development, for the most commonly anticipated applications of these materials, no composite solution exists. General statement of how this problem or situation is being addressed. The proposed SiC/SiC composite material is based on a mixture of SiC particles combined with a SiC precursor slurry. During processing, this slurry is infiltrated into a SiC fiber preform which enhance radiation resistance. The fabrication process consists of a combination of vacuum assisted resin transfer molding and chemical vapor infiltration, and directly addresses the requirement for low cost manufacturing. What is to be done in Phase I? During Phase I, the material composition will be developed, sub-scale tubes and panels will be fabricated and tested for radiation resistance, mechanical strength, and bonding properties to determine feasibility of this approach. Commercial Applications and Other Benefits. The proposed technology will result in a high strength, radiation and temperature resistant Si-C composite able to be joined together, and produced at low cost. It will have commercial applications in areas such as structural components and blanket structures for nuclear power plants and fuel cladding (in particular, Generation IV gas-cooled and liquid fluoride salt-cooled reactors), aerospace, and industrial applications. Finally, a large commercial market is envisioned in aerospace rocket and engine components which require high strength, high temperature, and lightweight materials.