Binder jet additive manufacturing of ceramic heat exchangers for concentrating solar power applications with thermal energy storage in molten chlorides

Journal Article · Wed Jun 01 00:00:00 EDT 2022 · Additive Manufacturing

DOI:https://doi.org/10.1016/j.addma.2022.102937· OSTI ID:1891711

Kelly, J. P. ^[1]; Finkenauer, L. R. ^[1]; Roy, P. ^[1]; Stolaroff, J. K. ^[1]; Nguyen, D. T. ^[1]; Ross, M. S. ^[1]; Hoff, A. T. ^[1]; Haslam, J. J. ^[1]

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1. Lawrence Livermore National Lab. (LLNL), Livermore, CA (United States)

Triply periodic minimal surface (TPMS) geometries can only be fabricated by additive manufacturing methods and are of interest for heat exchangers. Ceramic TPMS heat exchangers can operate at higher temperatures and pressures with superior performance and increased operating efficiencies compared to metal heat exchangers. The properties of ultra-high temperature ceramic (UHTC) materials are also favorable for heat exchangers and potentially suited to concentrated solar power (CSP) systems, such as those based on a molten chloride salt thermal energy storage (TES) medium used to heat CO₂ in a closed-loop Brayton power cycle. We intended to demonstrate binder jet additive manufacturing feasibility of a UHTC-TPMS structure by printing and sintering a null candidate. We aimed to achieve parts with a relative density ≥ 92 % of theoretical and to provide a TPMS part demonstration. The target density indicates the transition from intermediate to final stage sintering, a requirement to inhibit gas permeability and for sintering complex near net shapes to full density with sinter-HIP technology. The goal of the TPMS part demonstration was to determine if printing and sintering parameters developed from test coupons apply to the complex geometries that will eventually be used in a heat exchanger design. Our objective was to print cubic TPMS parts with a 9 cm³ volume and sinter it without distorting and cracking. We report we were able to sinter ZrB₂-MoSi₂ composite parts based on the Schwarz-D TPMS and achieve isotropic shrinkage up to 60 % by volume, resulting in densities ranging from 92 % to 96 % of theoretical.

• Research Organization: Lawrence Livermore National Laboratory (LLNL), Livermore, CA (United States)
• Sponsoring Organization: USDOE National Nuclear Security Administration (NNSA); USDOE Office of Energy Efficiency and Renewable Energy (EERE), Renewable Power Office. Solar Energy Technologies Office
• Grant/Contract Number: AC52-07NA27344; 35929; 38477
• OSTI ID: 1891711
• Alternate ID(s): OSTI ID: 1877310
• Report Number(s): LLNL-JRNL-822217; 1034514
• Journal Information: Additive Manufacturing, Vol. 56; ISSN 2214-8604
• Publisher: Elsevier
• Country of Publication: United States
• Language: English

Related Subjects

36 MATERIALS SCIENCE