Hybrid SiC-SiC CMCs

This DOE SBIR Phase I proposal builds upon two major manufacturing technology breakthroughs to answer DOE’s call for: (1) New innovative accident tolerant LWR fuel cladding/assembly concepts that have the potential to support achieving very-high fuel burnups and (2) Improved fabrication techniques or characterization techniques for silicon carbide accident tolerant LWR fuel cladding and fuel structures to improve the overall fuel performance. Free Form Fibers comes at the table with manufacturing-ready solutions that can now address the next challenge: Testing of the products enabled by these manufacturing advances. In this instance, we propose to put to the test, with the support of a major Prime partner, a technology it calls “the ultimate solution for Light Water Reactor (LWR) Accident Tolerant Fuel (ATF).” In this instance, we are proposing a hybrid metal-silicon carbide composite, whereby the silicon carbide composite is fabricated over a zirconium cladding at a temperature low enough to prevent phase change in the zirconium, and yet ensure bonding between the ceramic matrix composite and the metal base. Looking beyond the technical challenge, the silicon carbide fiber products created by Free Form Fibers and demonstrated in silicon carbide composites are far more economical and their processing far simpler than alternate ceramic matrix composite production processes. This means a commercialization path is now opening that not only serves nuclear but has the potential to sustain a much larger market base.