2024 Undergraduate Research Showcase

Additive Manufacturing of Zirconium Carbide Structures for Nuclear Thermal Propulsion

Document Type

Student Presentation

Presentation Date

4-19-2024

Faculty Sponsor

Dr. Brian Jaques

Abstract

To power long range space missions to Mars and beyond, NASA is investigating nuclear thermal propulsion (NTP) for its energy density, shorter travel times, and its longevity without refueling. NASA is researching using uranium carbide (UC) which has a higher uranium density (13g-U/cc), a higher thermal conductivity (20.4 W/m-K at 570°C) and allows for higher operating temperatures, as a replacement for liquid propellant due to its chemical efficiency, space efficiency, and lower cost when compared to other uranium-based [BJ2] fuels. Additive manufacturing is investigated to produce these structures because of its geometric versatility and lower costs compared to conventional fabrication techniques. In this study, zirconium carbide (ZrC) was used as a surrogate for UC due to its similar thermal conductivities, melting temperatures, and crystalline phases. 3D ZrC structures were fabricated using direct-ink-writing (DIW), with an optimized polyethylenimine based ink for printing layered structures. After printing, structures were characterized for phase purity using X-Ray Diffraction (XRD), density using Archimedes Density, light element impurities using oxygen/nitrogen analysis, and carbon/sulfur analysis. The findings from this study will advance the understanding of additive manufacturing techniques for nuclear thermal propulsion applications, making way for efficient production of UC-based fuel structures for future space exploration missions.

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