Nickel-Based Composite Metal Foam (CMF) in Nuclear Energy Applications

C56-40f-272264Generation IV reactors expect to operate at significantly higher temperature and pressures while using novel coolants. This introduces new challenges by way of increased stresses, fatigue, and the effects of reactor coolant chemistry interactions. Continuous development of higher performance materials must improve all performance criteria while being easily manufacturable and staying economical; in effect, reducing requirements for construction capital. The firm proposes the advanced research and development of Nickel-based Composite Metal Foam (CMF)—a patented, novel, lightweight, next-generation material—to meet the demanding conditions of these harsh service environments. Nickel-based alloys are widely used in the power production systems, such as nuclear reactors, due to their high temperature strength, corrosion resistance, and heat resistance properties; however, they are heavy and are unable to dampen impacts, vibrations, and shocks. Steel-CMF has an average density of only 2.7 g/cm3 (as light as aluminum) and can absorb impact energy over 100 times better, resist extreme temperatures at least seven times longer, and helps isolate the system from shocks, sounds, and vibrations better than solid steel. As such, the firm proposes to study the manufacturing of CMF from Nickel-based alloys for the first time. This material innovation can be used to improve an array of nuclear reactor components, combining the corrosion and temperature resistance properties of Nickel-based alloys with the already impressive list of CMF properties. In Phase I, the firm will (1) identify prime applications for Ni-based CMF within the nuclear reactor systems, (2) identify operating parameters/requirements, (3) produce Ni-based CMF samples, and (4) test their microstructural and mechanical properties, optimizing composition and makeup for manufacturability. For this purpose, the firm will construct CMF using Ni alloys including Inconel (alloy 690, 617 and X-750), Incoloy, and Monel. Using Ni-based CMF to replace the standard metals would result in substantial improvements to the performance and safety of current and next-generation advanced nuclear reactors, making those more resilient and economically competitive. In Phase II of the program, the stability of the microstructure and properties of the final Nickel-based Composite Metal Foam candidate materials during long service life (exposure to extreme heat, radiation and corrosive environments) will be demonstrated through accelerated testing and/or model predictions. This research not only impacts the nuclear reactor industry, but also can improve products in a variety of applications, from space vehicles to automotive, military vehicle- and personal-armors. Ultimately, the scope of the proposed technology’s applications is near limitless as it can be applied for an advantage in nearly every product that uses metallic materials today.