In-Line Metrology for Real-Time Manufacturing of Thin-Film PVD ATF Coatings Using IMPULSE« HiPIMS + Positive Kick┐

This SBIR project addresses the need for scalable manufacturing techniques for high-quality coatings for accident tolerant fuel (ATF) for current nuclear power plants 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 (+$20-50/cladding) and (5) integrate into existing production flow, inspection and certification. A in-line manufacturing technique embodying a hollow-cathode inverted cylindrical magnetron (HC-ICM) system to process full-length 4m-long cladding has been demonstrated as a viable pathway for high-throughput fabrication of precision engineered thin-film coatings for ATF claddings. The in-line HC-ICM system offers a unique opportunity to perform real-time QA/QC, electro-optical and metrology inspection for a variety of parameters, including thickness, surface roughness, density, conductivity, scratches, etc. while the ATF cladding is being coated. This DOE Phase I SBIR project would develop specialized QA/QC methods for Industry 4.0 advanced manufacturing. Commercial Applications and Other Benefits A successful SBIR/STTR will increase manufacturing readiness for advanced nuclear cladding materials for use in commercial power reactors. This incremental step will further the DOEĺs comprehensive nuclear energy portfolio. Benefits include increased safety, higher electrical generating efficiency, and longer time between refueling outages.