Collaboration developing silicon carbide ceramic matrix composites for fusion

Funded by the Royce Materials Challenge Accelerator Programme (MCAP) and led by UKAEA, HASTE-F is focused on addressing key engineering challenges in the use of silicon carbide composites (SiC/SiC) as a fusion material. Working with UKAEA, the NCC has identified a step change in SiC/SiC manufacturing that has the potential to transform the fusion sector, developing an efficient, scalable and cost-effective manufacturing route for ‘fusion-grade’ SiC materials.

In a statement, Dr James Wade-Zhu, senior materials engineer, UK Atomic Energy Authority, said: “Silicon carbide composites have the potential to enhance fusion by enabling reactors to operate at higher temperatures for improved thermal efficiency, greatly increasing the commercial viability of fusion energy production. We are pleased to be working closely with the National Composite Centre to address concerns around the scalability, formability, and performance of current SiC/SiC grades, bringing about the generation of new UK IP in the process.”

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SiC/SiCs are damage-tolerant materials which exhibit excellent radiation resistance and have operating temperatures of up to 1600^oC. The materials also exhibit low density, delivering advantages over traditional metallic materials. Compared with advanced steel designs, SiC/SiC components used in fusion reactors reportedly have the potential to double the electricity generated from every gigawatt of thermal energy produced.

According to the NCC, the collaboration has resulted in a significant process innovation that reduces the cost of manufacturing to one-fifth of what can currently be achieved whilst shortening cycle times. Haste-F also increases design freedom for fusion components by enabling more complex shapes and thicker sections than can be made with current manufacturing methods.

Virtudes Rubio, principal engineer, National Composites Centre, said: “The National Composites Centre is accelerating net-zero energy generation by developing high-value composites for extreme environments such as fusion reactors. This could unlock high-volume, high-performance SiC/SiC to the UK, driving a major transformation in sectors that utilise high-temperature CMCs, such as nuclear, defence, space and aerospace.”