Coatings for SiC LWR fuel claddings using quasi-conformal PVD and e-CVD IMPULSE® HiPIMS coatings direct onto the CMC

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.Complete changeover to SiCf/SiC cladding is a favored long-term (2035) transition point; however, SiC has issues related to hermeticity and hydrothermal corrosion under normal LWR operating conditions that must be overcome. Recent published work has shown Cr-based PVD coatings using IMPULSE® next-generation bipolar HiPIMS with Positive Kick™ may provide a long-term solution to these SiC challenges. There is an opportunity to verify and validate a manufacturing technology for advanced nuclear fuels.Commercial Applications and Other BenefitsA successful SBIR/STTR will pathfind means to stabilize SiC advanced nuclear cladding materials for use in commercial power reactors. This incremental step will further the DOE’s comprehensive nuclear energy portfolio. Benefits include increased safety, higher electrical generating efficiency, and longer time between refueling outages.