Overview of materials technologies for space nuclear power and propulsion

A wide range of different space nuclear systems are currently being evaluated as part of the DOE Special Purpose Fission Technology program. The near-term subset of systems scheduled to be evaluated range from 50 kWe gas-, pumped liquid metal-, or liquid metal heat pipe-cooled reactors for space propulsion to 3 kWe heat pipe or pumped liquid metal systems for Mars surface power applications. The current status of the materials technologies required for the successful development of near-term space nuclear power and propulsion systems is reviewed. Materials examined in this overview include fuels (UN, UO2, UZrH), cladding and structural materials (stainless steel, superalloys, refractory alloys), neutron reflector materials (Be, BeO), and neutron shield materials (B4C,LiH). The materials technologies issues are considerably less demanding for the 3 kWe reactor systems due to lower operating temperatures, lower fuel burnup, and lower radiation damage levels. A few reactor subcomponents in the 3 kWe reactors under evaluation are being used near or above their engineering limits, which may adversely affect the 5 to 10 year lifetime design goal. It appears that most of these issues for the 3 kWe reactor systems can be accommodated by incorporating a few engineering design changes. Design limits (temperature, burnup, stress, radiation levels) for the various materials proposed for space nuclear reactors will be summarized. For example, the temperature and stress limits for Type 316 stainless steel in the 3 kWe Na-cooled heat pipe reactor (Stirling engine) concept will be controlled by thermal creep and CO2 corrosion considerations rather than radiation damage issues. Conversely, the lower operating temperature limit for the LiH shield material will likely be defined by ionizing radiation damage (radiolysis)-induced swelling, even for the relatively low radiation doses associated with the 3 kWe reactor.