Silicon Carbide May Replace Zirconium Alloys For Nuclear Fuel Rod Cladding

December 8, 2024 by Maya Posch 28 Comments

Since the construction of the first commercial light water nuclear power plants (LWR) the design of their fuel rods hasn’t changed significantly. Mechanically robust and corrosion-resistant zirconium alloy (zircalloy) tubes are filled with ceramic fuel pellets, which get assembled into fuel assemblies for loading into the reactor.

A 12' SiGa fuel assembly, demonstrating the ability to scale to full-sized fuel rods. (Credit: DoE) — A 12′ SiGa fuel assembly, demonstrating the ability to scale to full-sized fuel rods. (Credit: DoE)

Now it seems that silicon carbide (SiC) may soon replace the traditional zirconium alloy with General Atomics’ SiGa fuel cladding, which has been tested over the past 120 days in the Advanced Test Reactor at Idaho National Laboratory (INL). This completes the first of a series of tests before SiGa is approved for commercial use.

One of the main advantages of SiC over zircalloy is better resistance to high temperatures — during testing with temperatures well above those experienced with normal operating conditions, the zircalloy rods would burst while the SiC ones remained intact (as in the embedded video). Although normally SiC is quite brittle and unsuitable for such structures, SiGa uses a SiC fiber composite, which allows it to be used in this structural fashion.

Although this development is primarily part of the Department of Energy’s Accident Tolerant Fuel Program and its focus on melt-down proof fuel, the switch to SiC could also solve a major issue with zirconium, being its use as a catalyst with hydrogen formation when exposed to steam. Although with e.g. Fukushima Daiichi’s triple meltdown the zircalloy fuel rods were partially destroyed, it was the formation of hydrogen gas inside the reactor vessels and the hydrogen explosions during venting which worsened what should have been a simple meltdown into something significantly worse.

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Microwave Forge Casts The Sinking-est Benchy Ever

September 15, 2024 by Dan Maloney 7 Comments

As a test artifact, 3DBenchy does a pretty good job of making sure your 3D printer is up to scratch. As an exemplar of naval architecture, though — well, let’s just say that if it weren’t for the trapped air in the infilled areas, most Benchy prints wouldn’t float at all. About the only way to make Benchy less seaworthy would be to make it out of cast iron. Challenge accepted.

We’ve grown accustomed to seeing [Denny] over at “Shake the Future” on YouTube using his microwave-powered kilns to cast all sorts of metal, but this time he puts his skill and experience to melting iron. For those not in the know, he uses standard consumer-grade microwave ovens to heat kilns made from ceramic fiber and lots of Kapton tape, which hold silicon carbide crucibles that get really, really hot under the RF onslaught. It works surprisingly well, especially considering he does it all on an apartment balcony.

For this casting job, he printed a Benchy model from PLA and made a casting mold from finely ground silicon carbide blasting medium mixed with a little sodium silicate, or water glass. His raw material was a busted-up barbell weight, which melted remarkably well in the kiln. The first pour appeared to go well, but the metal didn’t quite make it all the way to the tip of Benchy’s funnel. Round two was a little more exciting, with a cracked crucible and spilled molten metal. The third time was a charm, though, with a nice pour and complete mold filling thanks to the vibrations of a reciprocating saw.

After a little fettling and a saltwater bath to achieve the appropriate patina, [Denny] built a neat little Benchy tableau using microwave-melted blue glass as a stand-in for water. It highlights the versatility of his method, which really seems like a game-changer for anyone who wants to get into home forging without the overhead of a proper propane or oil-fired furnace. Continue reading “Microwave Forge Casts The Sinking-est Benchy Ever” →

More Microwave Metal Casting

April 16, 2024 by Dan Maloney 10 Comments

If you think you can’t do investment casting because you don’t have a safe place to melt metal, think again. Metal casting in the kitchen is possible, as demonstrated by this over-the-top bathroom hook repair using a microwave forge.

Now, just because it’s possible doesn’t mean it’s advisable. There are a lot better ways to fix something as mundane as a broken bathroom hook, as [Denny] readily admits in the video below. But he’s been at the whole kitchen forging thing since building his microwave oven forge, which uses a special but easily constructed ceramic heat chamber to hold a silicon carbide crucible. So casting a replacement hook from brass seemed like a nice exercise.

The casting process starts with a 3D-printed model of the missing peg, which gets accessories such as a pouring sprue and a thread-forming screw attached to it with cheese wax. This goes into a 3D-printed mold which is filled with a refractory investment mix of plaster and sand. The green mold is put in an air fryer to dry, then wrapped in aluminum foil to protect it while the PLA is baked out in the microwave. Scrap brass gets its turn in the microwave before being poured into the mold, which is sitting in [Denny]’s vacuum casting rig.

The whole thing is over in seconds, and the results are pretty impressive. The vacuum rig ensures metal fills the mold evenly without voids or gaps. The brass even fills in around the screw, leaving a perfect internal thread. A little polishing and the peg is ready for bathroom duty. Overly complicated? Perhaps, but [Denny] clearly benefits from the practice jobs like this offer, and the look is pretty cool too. Still, we’d probably want to do this in the garage rather than the kitchen.
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Silicon Carbide Chips Can Go To Hell

May 3, 2021 by Al Williams 75 Comments

IEEE Spectrum had an interesting read about circuits using silicon carbide as a substrate. [Alan Mantooth] and colleagues say that circuits based on this or some other rugged technology will be necessary for missions to Venus, which they liken to hell. That might seem like hyperbole, but at about 460C with an atmosphere full of sulphuric acid, maybe it isn’t such a stretch. When the Soviets sent Venera 13 to Venus, it was able to send data for just over two hours before it was gone. You’d hope 40 years later we could do better.

Silicon carbide is a semiconductor made with an even mix of silicon and carbon. The resulting components can operate for at least a year at 500C. This high-temperature operation has earned them a place in solar energy and other demanding applications. [Alan], with the University of Arkansas along with colleagues from the KTH Royal Insitute of Technology in Stockholm are building test circuits aimed at developing high-temperature radios for use in environments like the one found on Venus.

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New Silicon Carbide Semiconductors Bring EV Efficiency Gains

November 25, 2019 by Lewin Day 47 Comments

After spending much of the 20th century languishing in development hell, electric cars have finally hit the roads in a big way. Automakers are working feverishly to improve range and recharge times to make vehicles more palatable to consumers.

With a strong base of sales and increased uncertainty about the future of fossil fuels, improvements are happening at a rapid pace. Oftentimes, change is gradual, but every so often, a brand new technology promises to bring a step change in performance. Silicon carbide (SiC) semiconductors are just such a technology, and have already begun to revolutionise the industry.

Mind The Bandgap

A graph showing the relationship between band gap and temperature for various phases of Silicon Carbide.

Traditionally, electric vehicles have relied on silicon power transistors in their construction. Having long been the most popular semiconductor material, new technological advances have opened it up to competition. Different semiconductor materials have varying properties that make them better suited for various applications, with silicon carbide being particularly attractive for high-power applications. It all comes down to the bandgap.

Electrons in a semiconductor can sit in one of two energy bands – the valence band, or the conducting band. To jump from the valence band to the conducting band, the electron needs to reach the energy level of the conducting band, jumping the band gap where no electrons can exist. In silicon, the bandgap is around 1-1.5 electron volts (eV), while in silicon carbide, the band gap of the material is on the order of 2.3-3.3 eV. This higher band gap makes the breakdown voltage of silicon carbide parts far higher, as a far stronger electric field is required to overcome the gap. Many contemporary electric cars operate with 400 V batteries, with Porsche equipping their Taycan with an 800 V system. The naturally high breakdown voltage of silicon carbide makes it highly suited to work in these applications.

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A Microwave Kiln, From Scratch

July 20, 2019 by Jenny List 15 Comments

We are normally told that microwave ovens are strictly for food only, and that anything else will cause all sorts of bad things to come our way. There can be few readers who haven’t at some time seen the shower of sparks when an inadvertent metallic object finds its way onto the turntable.

A particularly useful non-food application for a microwave oven comes in the form of the small kilns sold for glass fusing. These are ceramic cylinders coated internally with silicon carbide, and [ShakeTheFuture] shows us how to make your own.

Key to the process is ceramic fibre insulation, which is bonded both to itself and to the fused silicon carbide grit by a cured solution of waterglass, sodium silicate. The result can easily reach the required temperature for fusing glass, but also has an application in burning out surplus wax or PLA from a plaster mould. It’s particularly interesting to see the technique with the waterglass in action, and you can see a run-down of the whole thing in the video below the break.

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Homemade Silicon Carbide LED

June 5, 2012 by Mike Szczys 18 Comments

Here’s an LED indicator which was made at home out of a Silicon Carbide (SiC) crystal (Internet Archive Mirror). The concept is simple, but a bit of trial and error goes into getting that tiny amber spot to light up.

The guesswork comes in finding the right piece of crystal. First [KOS] broke it into tiny pieces, then he started poking the chunks with electrified probes to see if he could get some light out of them. Once an active area was found he needed a base for the crystal. The image above shows the two nails which he used. This provides a large mounting area that also acts as a heat sink to make sure the LED won’t burn itself out. There’s a solder blob which he kept molten with his iron until the crystal could be pushed into place. That holds it securely as the pin which serves as the cathode is positioned.

The whole setup is soldered to some protoboard and is ready to use. This is the second time we remember seeing this technique used to fabricate LEDS. The first time was an accident.