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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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Sol-gel Micro- Mini-Sphere Development

The Advanced Fuels Campaign ceramic fuels R&D effort, within The Department of Energy Fuel Cycle R&D Program, has undertaken an R&D approach that integrates fundamental R&D on ceramic fuel feedstock, fuel fabrication development, and separate effects irradiation testing. The goal is to achieve a fundamental understanding of the inter-relationships that exist between nuclear fuel materials properties, processing, and performance. In parallel with this type of basic research, it is important to advance the state of the art with respect to processing of nuclear fuel materials that must be handled in a controlled environment. Toward that end, it is important to consider ways to minimize processing losses associated with the synthesis and fabrication of nuclear fuel. One option may be to transition away from the standard powder-type fuel synthesis and pellet fabrication process and to use flowable, near-dustless spherical particles that can be pressed directly into pellets thus avoiding the use of dust generating milling and blending processes.

Feestock↗

Development of Aluminum Feedstock for Additive Manufacturing

The rapid evolution of materials science and manufacturing technologies in recent years has offered new pathways to manipulate materials for bespoke manufacturing. Here we aim to develop feedstocks for applications such as radiator panels, fuel tanks, and structural components for outfitting. As a strong, light weight and thermally conductive material aluminum is ideal for these applications. An often-overlooked source of aluminum waste is food packaging used on the International Space Station. Reusing this waste stream will reduce the cost and logistics of regular sparing. In Space Manufacturing (ISM) will utilize this technology is such areas as sparing and outfitting. However, processing aluminum can present challenges, especially in the context of additive manufacturing and sintering, due to its high reactivity and tendency to form a tenacious oxide layer. Identifying appropriate binders and sintering profiles can overcome these challenges. Herein we present our work on obtaining aluminum powder derived from food packaging, binder selection for aluminum feedstock, and a demonstration of bound metal deposition printing.

aluminum↗