Scalable Manufacturing Using IMPULSE® + Positive Kick For Corrosion-Resistant, High-Temperature Multilayer Films For Accident Tolerant Nuclear Fuel

Scalable manufacturing techniques are needed for high-quality coatings on nuclear fuel 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 (+$30-40/cladding) and (5) integrate into existing production flow, inspection and certification. The technique should be “future proof” and useable for current, near-term, and longer-term fuel designs.Phase IIA builds on the successful demonstration of layered, corrosion-resistant thin-films using the next- generation IMPULSE® + Positive Kick™ and a novel in-line, continuous deposition platform to increase deposition rates, adjust coating micro/nanostructure, modify film stress and control morphology. The technique is scalable, lower-cost and both metals and ceramics can be precision deposited with excellent adhesion, graded composite nanostructures and layering, radiation hardness, thermal shock- and oxidation-resistance. Phase II demonstrated coating full-length Zr claddings. Phase IIA will retire technical risk to verify implementation readiness.Commercial Applications and Other BenefitsThe IMPULSE® + Positive Kick™ technology for accident-tolerant fuels would improve: (1) nuclear safety and reliability, (2) power generation capacity with existing plants for the nation, (3) competitiveness of US nuclear power industry, (4) domestic manufacturing for high-performance fiber composites, (5) biocompatible, functionalized medical coil and stent coatings, (6) advanced high-temperature coatings for turbines for aviation and power generation, high-temperature aerospace/hypersonics, tooling and materials manufacturing, and (7) support emerging small businesses and job creation in the Midwest