WO2011029031A1 - Matériau composite à rapport robustesse/poids et température élevés - Google Patents

Matériau composite à rapport robustesse/poids et température élevés Download PDF

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Publication number
WO2011029031A1
WO2011029031A1 PCT/US2010/047863 US2010047863W WO2011029031A1 WO 2011029031 A1 WO2011029031 A1 WO 2011029031A1 US 2010047863 W US2010047863 W US 2010047863W WO 2011029031 A1 WO2011029031 A1 WO 2011029031A1
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WO
WIPO (PCT)
Prior art keywords
layer
silicon carbide
aerogel
inner layer
fusion
Prior art date
Application number
PCT/US2010/047863
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English (en)
Inventor
Edward I. Moses
Joseph C Farmer
Joshua D. Kuntz
Scott Groves
Luis Zepeda
Original Assignee
Lawrence Livermore National Security, Llc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
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Application filed by Lawrence Livermore National Security, Llc filed Critical Lawrence Livermore National Security, Llc
Publication of WO2011029031A1 publication Critical patent/WO2011029031A1/fr

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Classifications

    • G—PHYSICS
    • G21—NUCLEAR PHYSICS; NUCLEAR ENGINEERING
    • G21B—FUSION REACTORS
    • G21B1/00—Thermonuclear fusion reactors
    • G21B1/11—Details
    • G21B1/13—First wall; Blanket; Divertor
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B15/00—Layered products comprising a layer of metal
    • B32B15/01—Layered products comprising a layer of metal all layers being exclusively metallic
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B15/00—Layered products comprising a layer of metal
    • B32B15/04—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B15/00—Layered products comprising a layer of metal
    • B32B15/04—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B15/06—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material of natural rubber or synthetic rubber
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2305/00—Condition, form or state of the layers or laminate
    • B32B2305/02—Cellular or porous
    • B32B2305/022—Foam
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2305/00—Condition, form or state of the layers or laminate
    • B32B2305/02—Cellular or porous
    • B32B2305/024—Honeycomb
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/30—Properties of the layers or laminate having particular thermal properties
    • B32B2307/306—Resistant to heat
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/762—Self-repairing, self-healing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2311/00—Metals, their alloys or their compounds
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2607/00—Walls, panels
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E30/00—Energy generation of nuclear origin
    • Y02E30/10—Nuclear fusion reactors

Definitions

  • This invention relates to composite materials with high strength-to-weight ratios, and capable of withstanding high temperatures and extreme radiation doses.
  • Such structural components have particular utility in high temperature applications where intense neutron bombardment occurs, for example, as structural components in fusion or fusion-fission applications. These materials are also promising structural materials for nuclear reactor applications.
  • Nuclear energy a non-carbon emitting energy source
  • nuclear reactors In the United States alone, nuclear reactors have already generated more than 55,000 metric tons (MT) of spent nuclear fuel (SNF). In the near future, the US will have enough spent nuclear fuel to fill the Yucca Mountain geological waste repository to its legislated limit of 70,000 MT.
  • ICF Inertial Confinement Fusion
  • D deuterium
  • T tritium
  • MFE Magnetic Fusion Energy
  • thermonuclear fusion ignition and burn utilizes laser energies of more than one megajoule (MJ).
  • a challenge for any commercial power plant relying upon fusion or fusion-fission reactions is the extreme environment which materials situated near such reactions must withstand.
  • materials are expected to be required to operate continuously at temperatures over 1000°C, and perhaps higher than 1300°C.
  • the materials will be subjected to a combination of 14-Mev neutron flux, severe neutron dosage, and highly corrosive environments from molten salts or other material used for cooling.
  • 14-Mev neutron flux severe neutron dosage
  • highly corrosive environments from molten salts or other material used for cooling.
  • such materials will find uses in other demanding environments.
  • silicon carbide, silicon carbide fiber, and aerogel-based materials are capable of operating continuously at temperatures in excess of 1000°C in environments with intense 14-Mev neutron flux, severe neutron dose, even when exposed to highly corrosive molten salts.
  • a structural material which consists of an aerogel sandwiched between appropriate outer layers, which can be made from material such as, silicon carbide plates, a silicon carbide fiber wrapped structure, oxide-dispersed ferritic steel, tungsten-, tantalum-, vanadium- and other refractory-metal alloys.
  • Such a structure is not only lightweight and heat resistant, but the aerogel is self healing in the presence of intense neutron bombardment.
  • silicon carbide fiber winding technology is used to enable the manufacture of large scale complicated shapes, with silicon carbide/silicon carbide fiber composite panels and aerogel layers for thermal isolation.
  • the high-temperature composite structure includes an inner layer of relatively rigid material, an outer layer of relatively rigid material, and an intervening layer of nano-structural foam disposed between the inner layer and the outer layer.
  • the nano-structural foam is an aerogel, such as a silicon carbide aerogel or a zirconium tungstate aerogel.
  • the inner and outer layers may be formed from silicon carbide, oxide-dispersion strengthened steel, or other suitable materials.
  • a layer comprising tungsten is disposed on the inner layer adjacent the fusion source to further protect that side of the inner layer.
  • a refractory tantalum-tungsten alloy known to be resistant to corrosion by high-temperature molten fluoride salts, is used for the fabrication of an embedded cooling channel, disposed within the structure, or is used as one of the inner or outer layers or plated onto those layers.
  • Figure 1 is a cross sectional view of the chamber wall showing the inner layer, the aerogel, and the outer layer;
  • Figure IB is a cross sectional view illustrating in more detail the cooling portion of the structure shown in Figure 1.
  • Figure 2 is a more detailed view of the structure of Figure 1.
  • Figure 3 is a detailed view illustrating the effect of ion energy on aerogel.
  • Figure 4 is a diagram illustrating the relationship of yield strength to temperature for a variety of materials.
  • one approach is to combine aspects of nuclear fusion and fission by providing power using both fusion and fission.
  • One approach surrounds a relatively modest inertial confinement fusion neutron source with a subcritical fission fuel blanket.
  • the point source of fusion neutrons acts as a catalyst to drive the fission blanket, which obviates the need for a critical assembly to sustain the fission chain reaction.
  • a single engine will be able to generate 2000 to 3000 megawatts of thermal power (MW t ) in steady state for periods of years to decades, depending on the fuel and engine configuration. Because neutrons are provided by the fusion targets, the fission blanket in a fusion-fission system can be subcritical. This enables the engine to burn any fertile or fissile nuclear material, including un-enriched, natural or depleted uranium and spent nuclear fuel, and to extract virtually 100% of the energy content of its fuel.
  • the fusion-fission hybrid approach results in enhanced energy generation per metric ton of nuclear fuel, and reduces the amount of nuclear waste. Even the resulting waste has vastly reduced concentrations of long-lived actinides. Such fusion- fission engines thus can provide substantial amounts of electricity, yet reduce the actinide content of nuclear waste, thereby extending the availability of low cost nuclear fuels for thousands of years.
  • the fusion-fission hybrid also provides a pathway for burning excess weapons grade plutonium.
  • fusion or fusion-fission engines offer a path toward sustainable and safe power.
  • inertial confinement fusion is used to produce 14 MeV neutrons from a fusion reaction of deuterium and tritium.
  • the neutrons in turn, either produce heat in a blanket of coolant surrounding the engine, or in a fusion-fission hybrid, drive a subcritical blanket of fissile or fertile fuel.
  • the inertial confinement fusion reaction can be implemented using various mechanisms.
  • Indirect drive uses energy from lasers to heat a hohlraum which contains the fusion fuel, preferably a small pellet containing deuterium and tritium.
  • the hohlraum emits x-rays which compress and heat the fuel, causing fusion, ignition and burn.
  • direct drive no hohlraum
  • fast ignition separate compression and ignition lasers
  • Figure 1 is a diagram illustrating a preferred cross-section of a wall for a fusion or fusion-fission implementation.
  • An inner layer 20 closest to the fusion source
  • an outer layer 40 with an nano-structural foam layer 30 disposed between them provides the basic structure for the wall.
  • an additional layer of material 10 for example, tungsten, is provided between the inner layer and the fusion source of the neutron bombardment.
  • the nano-structural foam itself may be any appropriate foam, for example, a silicon-carbide based aerogel. Such materials can be formed using well-known techniques, e.g. chemical vapor deposition of silicon onto a carbon foam, followed by a heating step to produce SiC aerogel in situ.
  • Aerogels are particularly advantageous because of their self-healing property in intense neutron environments. Aerogels have the advantage of providing extraordinarily low thermal conductivity, typically less than 0.2 Watts per meter per degree Kelvin.
  • aerogels other than SiC based aerogels may be used for applications in fusion and fusion- fission systems.
  • the aerogel composition zirconium tungstate (ZrW 2 0 8 ) has low thermal conductivity, low coefficient of thermal expansion, chemical compatibility and radiation resistance.
  • the inner and outer layers supporting the aerogel advantageously are resistant to the thermal and neutron environments.
  • silicon carbide for these layers.
  • Silicon carbide is resistant to very high temperatures, and the use of silicon carbide fibers allows complex shapes to be manufactured.
  • the silicon carbide fibers themselves may be composite structures, e.g. SiC wrapped tungsten fibers or SiC wrapped graphite fibers. In manufacturing such structures, after the winding, the material can be infiltrated with another material, for example material which when heat treated forms silicon carbide to fill in the interstitial spaces of the structure. In such structures the cooling channels, fittings and fasteners may be incorporated into the wrapping at the time of formation.
  • the inner layer 20 and outer layer 40 containing the aerogel 30 may themselves each be composite structures.
  • the inner layer may consist of a silicon carbide fiber structure in which the fibers nearest the inner wall 10 are SiC wrapped tungsten fibers while those nearer the aerogel are SiC wrapped graphite fibers.
  • the inner and outer layers may comprise materials other than SiC based materials, for example, ODS steel.
  • the chamber structure for a fusion or fusion-fission engine is a complex shape in view of its need to provide openings for the incoming laser beams, openings for the injection and ejection of targets, and channels for coolant.
  • One technique for manufacturing such a structure is fiber winding. This technology has been used to manufacture complex shapes, e.g. Boeing 787 aircraft aerodynamic components. Such fiber winding may be performed over a thermally sprayed tungsten mandrel, or over a removable mandrel, for example one which is inflatable or frangible. Such large fiber winding systems are known in the industry and can be used with silicon carbide fiber.
  • the materials and structures described herein have applicability to many other applications where lightweight structural materials are desired.
  • the ply structure can be used to provide a structural component such as an aerodynamic surface having low weight and high strength.
  • the porosity of the nano-structural material allows fluid to flow through the material, or be stored therein, enabling cooling fluid to be in close proximity to the plates containing the foam.
  • the porosity also permits storage for fuel or other liquids integrally within the structure itself.
  • Figure IB illustrates in more detail the coolant/structure portion of Figure 1.
  • a molten salt flows in proximity to the outer layer.
  • the molten salt is eventually routed to a heat exchanger, where the heat can be extracted and used for power generation.
  • the channels may be formed integrally with the outer layer, or attached to it.
  • tantalum tungsten alloys are used to form, or at least plate, the walls of the cooling channels.
  • the tantalum tungsten alloys are formed integrally with the structure, for example, by forming the outer layer 40 of tantalum tungsten itself, or by forming a composite structure with tantalum tungsten plating adjacent the cooling channels.
  • the coolant can pass within the pores of the micro-porous stiffening material.
  • the formation of the inner and outer layers with aerogel between them can be achieved using a variety of techniques.
  • a fixture secures the two layers at the desired spacing, then the aerogel is blown in between the layers.
  • bracing for example, a honeycomb structure, is provided between the two layers to secure them in position. Then aerogel is blown in between the layers, with the bracing remaining within the aerogel.
  • tantalum tungsten alloys provide improved corrosion resistance.
  • Iron- chromium alloys such as ODS ferritic steel produce corrosion products such as chromium fluoride (CrF 2 ) which has a free energy of formation of -75.2 kcal per g-mole at 1000°K. Tantalum allows only slight grain boundary penetration at 900°C, similar to that found for ODS ferritic steel at 600°C.
  • the tantalum tungsten alloys thus better resist corrosion when exposed to a mixture of lithium fluoride (LiF) and beryllium fluoride (BeF 2 ) [FLiBe] or lead- lithium coolant.
  • LiF lithium fluoride
  • BeF 2 beryllium fluoride
  • lead- lithium coolant a mixture of lithium fluoride (LiF) and beryllium fluoride (BeF 2 ) [FLiBe] or lead- lithium coolant.
  • ODS steel, or other composition, fasteners and fixtures may be embedded in the cooling chamber structure material
  • the materials and structures described above enable a fusion based engine to operate at higher temperature, yet have a high strength-to-weight ratio, and a low coefficient of thermal expansion. Such materials can survive intense neutron flows and highly corrosive environments of molten salt coolant materials.
  • the materials described herein can also have many other applications, for example in other energy-related technology, in aerospace applications such as re-entry vehicles, as well as other applications where weight, temperature resistance, and strength are important.
  • Figure 2 is a diagram illustrating in further detail the composite inner
  • the nano- structural foam provides a stiffener between two plates which may be formed of the same or different materials.
  • the inner and outer layers comprise ODS ferritic steel, silicon carbide, or a tungsten- or vanadium-based alloy layers.
  • Figure 3 illustrates the radiation resistance of the aerogel material used as the structural stiffener. Note that the damage cascade in the materials is comparable to the size of the particular ligaments, making the material relatively radiation resistant. The radiation resistance is believed to be a result of migration of the defects to the surface of the material, where they diffuse into the surface of the "nano-struts," recombine, and therefore heal.
  • Figure 4 is a diagram illustrating the relationship between yield strength and temperature for different materials. Note that as temperatures increase, the yield strength for essentially all materials depicted, which include various ferritic steels, decreases
  • SiC wound structures with aerogel stiffeners provide sufficient strength at high temperatures for fusion and fusion-fission applications.
  • Another advantage of the SiC based structures for high temperature applications is that they exhibit relatively low swelling at the irradiation temperatures expected in a fusion based engine.
  • the inner layer is assumed to be a 15 mil thick first metallic cladding, adjoining a 0.5 cm thick nano structural (aerogel) foam stiffener, with an outer layer of 15 mil thick second cladding.
  • the first cladding is faces the heat source, and is tungsten or vanadium; the stiffener is a silica aerogel; and the second cladding faces away from the heat source, and is oxide dispersion-strengthened ferritic steel (having properties comparable to either 304 stainless steel, or carbon steel).
  • the assumed properties are summarized below: Material Density Thermal Conductivity Coefficient of Comments
  • the temperature drop across the individual layers is estimated with Fourier's first law.
  • the surface area of this chamber is estimated to 38.5 x 10 6 cm 2 .
  • the thickness of the first layer thin metallic cladding in the tri-layer laminate is assumed to be 38.1 x 10 "3 cm.
  • the temperature differential across this layer is then estimated:
  • the radius of curvature that would be induced in the aerogel stiffener would be approximately 3.13 meters, which is larger than the radius of curvature of the assumed spherical fusion chamber, and would therefore be insignificant in most cases.
  • Estimates for temperature-induced curvature of the backside cladding are no worse than for the front side.
  • the radius-of-curvature due to thermal distortion of the proposed laminated composite does not appear to be problematic.
  • the bending moment in the constrained case appears insignificant.

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  • Physics & Mathematics (AREA)
  • Engineering & Computer Science (AREA)
  • Plasma & Fusion (AREA)
  • General Engineering & Computer Science (AREA)
  • High Energy & Nuclear Physics (AREA)
  • Manufacture Of Alloys Or Alloy Compounds (AREA)

Abstract

L'invention porte sur une structure composite résistant aux températures élevées, devant être utilisée de préférence dans des systèmes à fusion et des systèmes à fusion-fission, et qui comprend une couche interne en matériau relativement rigide et une couche externe en matériau relativement rigide. Entre les couches interne et externe est disposée une couche intermédiaire de mousse nanostructurelle. La mousse permet d’obtenir un niveau élevé d'isolement thermique, tout en étant cependant résistante aux détériorations par les neutrons venant de la source de fusion. De préférence, les couches interne et externe sont du carbure de silicium ou une structure à enroulement de fibre de carbure de silicium afin de permettre la fabrication de formes complexes.
PCT/US2010/047863 2009-09-04 2010-09-03 Matériau composite à rapport robustesse/poids et température élevés WO2011029031A1 (fr)

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US61/240,126 2009-09-04

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CN104015427A (zh) * 2014-06-13 2014-09-03 苏州新颖新材料科技股份有限公司 绝热杀菌3d彩钢板
CN104015426A (zh) * 2014-06-13 2014-09-03 苏州新颖新材料科技股份有限公司 绝热pcm彩钢板
US11784454B1 (en) 2022-12-22 2023-10-10 Blue Laser Fusion, Inc. High intensity pulse laser generation system and method

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Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN104015427A (zh) * 2014-06-13 2014-09-03 苏州新颖新材料科技股份有限公司 绝热杀菌3d彩钢板
CN104015426A (zh) * 2014-06-13 2014-09-03 苏州新颖新材料科技股份有限公司 绝热pcm彩钢板
US11784454B1 (en) 2022-12-22 2023-10-10 Blue Laser Fusion, Inc. High intensity pulse laser generation system and method

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