3D Printed Polymer Derived Ceramics for Joining Nuclear Grade SiC Composites

The Department of Energy’s Basic Energy Science Office has identified a need for high- performance materials and innovative solutions for joining nuclear grade SiC composites. Specifically, state-of-the-art radiation resistant high temperature durable solutions are needed. The goals for this program are to demonstrate joining and durability of 3D SiC nuclear power generation components at operating temperatures of 850 °C through fused filament fabrication of polymer derived ceramics. The objective of this program is to develop and demonstrate innovative siloxane and polycarbosilane materials suitable for use as extremely high temperature polymer derived ceramics PDC) compatible with various forms of SiC. The proposed innovation for this program involves the development of new PDC based filaments enriched with various forms of SiC for use in fused filament fabrication FFF) 3D prints. In Phase I, new SiC based filaments shall be reactively extruded as 1.75 mm and 2.85 mm diameter filaments that will be fed into our custom built 3D printer for a down-selection study to reach a Technology Readiness Level 4. 3-D printed nuclear grade SiC parts shall be printed and tested alongside standard SiC joined parts for a benchmark study to reach TRL 5. A plan to reach Technology Readiness Level 7 in Phase II shall be established via irradiation within the representative environment at BNL during Phase I. Radiation resistant nuclear grade SiC composites shall benefit Generation IV gas-cooled and liquid fluoride salt-cooled reactors as well as dual-use medical, military, and space systems. Importantly, new filaments may allow for in-situ production of 3D nuclear power generation components such as corrosion resistant liners, heat exchangers, fuel containment systems, and thermowells.