Metal additive manufacturing of functionally graded materials for roller bearings in high temperature sodium systems

The rising demand for renewable energy requires a reinvestment of American effort into nuclear power. Next gen-eration liquid metal-cooled reactors can operate at higher temperatures, leading to enhanced efficiencies and overall reduction in the levelized cost of energy. Further reduction in costs can be achieved by using advanced robotic systems to handle refueling, but substantial technical challenges associated with thermal expansion and corrosion prevent this technology from moving forward. Advances in material science and advanced manufacturing are being deployed into the nuclear energy sector to support the technical challenge of refueling systems. The overarching objective for this Small Business Innovation Research effort is to evaluate the feasibility of functionally graded metamaterial solutions for roller bearings in so-dium reactor fuel handling systems. The proposed approach uses additively manufactured metal alloys, and will involve alloy design, product prototyping, and coupon characterization to validate the results. In Phase I of this effort, the team will determine the range of technical requirements necessary for roller bearing solutions tailored to the needs of high temperature liquid sodium reactors. Computational design work will identify optimal compositions with the highest likelihood of survivability in the harsh sodium environment. Rapid prototyp-ing, testing, and validation activities will lead to an analysis of the technical performance and commercial viability. If the proposed technology is feasible, future efforts will seek to mature the fuel handling system’s operational concept, design integrated prototype products, and perform field testing by qualified customers or stakeholders. The technical effort will lead to commercial insertion of the technology into customer systems in the nuclear en-ergy industry, supporting domestic energy, environmental, and economic needs. Overall, the proposed effort sup-ports the Department of Energy Office of Nuclear Energy’s goals by enabling deployment of advanced nuclear reactors and maintaining domestic leadership in nuclear energy technology.