Optimized Alloy Composites Using Wire-fed Direct Energy Deposition

This project addresses the critical challenge of material failure in next generation nuclear reactors due to the ex- treme conditions posed by liquid metal coolants and molten fuel salts. The project's mission is to innovate materials that can resist corrosion, wear, and thermal damage, ensuring the longevity and efficiency of advanced reactors critical for sustainable energy. Phase I will be dedicated to the development and testing of alloy composite materials that merge the properties of different metals to achieve unprecedented levels of durability. By utilizing wire-laser metal deposition, the project endeavors to fabricate representative coupons as prototypes of end-use components currently not commercially available. Joining dissimilar materials using this method enables the creation of new alloy composites that, if suc- cessful, will provide a robust supply chain for functionally graded alloys. These prototypes will undergo rigorous testing to ensure their suitability for high-temperature, corrosive environments, paving the way for future phases of development. Commercially, this technology has potential applications in multiple high-demand sectors requiring resilient materi- als, including aerospace, defense, and beyond. The project aligns with government goals by fostering the advance- ment of secure, clean energy and enhancing domestic leadership in nuclear technology.