C56-40f - 3D Printing of Functionally Graded in-situ Sacrificial Anode Claddings for Enhanced Corrosion and Irradiation Resistance in MSR Applications.

Advances in nuclear energy technologies critically depend on high- performance materials that can withstand harsh environmental conditions in nuclear reactors. The design of new materials that exploit the unusual characteristics of additive manufacturing processes to create materials with enhanced performance is urgently required for the early deployment of advanced nuclear reactors. In this proposed research, a two- pronged approach will be investigated using high-pressure cold spray technology as an additive manufacturing process of depositing a thicker protective coating. The first approach involves macroscopic damage of coatings that will be healed by distributing core-shell configured micro- capsules. A second approach will look into 3D Printing of functionally graded in-situ sacrificial anode claddings for enhanced corrosion and irradiation resistance of molten salt nuclear reactor components. Two different types of coating will be developed based on the cold- spray process and their mechanical and corrosion properties will be evaluated. The first type of coating is considered self-healing and it is capable of healing cracks with enhanced mechanical properties. The second type is considered sacrificial anodic coating and it imparts exceptional corrosion resistance for molten fluoride nuclear reactors. The proposed concept can also be used in a wide range of applications, including advanced nuclear power plants, fossil fuel-based power generation, gas turbines in aircraft, aerospace and defense applications, and various applications in oil and chemical industries (incineration of waste and toxic materials). The proposed technology will increase the safety and reliability of the components exposed to harsh environments, increase the lifetime of the components and conserve natural resources, increase the operating temperature and efficiency of operation and thus decrease the greenhouse gas emissions, reduce the downtime of the equipment, decrease the maintenance cost, and increase the profitability of the business. All these result in better environments for doing business and result in the better utilization of taxpayersĺ money.