Modified polymer derived ceramics for additive manufacturing, additive manufacturing using same, and ceramic bodies manufactured thereby
Pre-ceramic particle solutions can prepared by a Coordinated-PDC process, a Direct-PDC process or a Coordinated-Direct-PDC process. The pre-ceramic particle solution includes a polymer selected from the group consisting of (i) an organic polymer including a metal or metalloid cation, (ii) a first organometallic polymer and (iii) a second organometallic polymer including a metal or metalloid cation different from a metal in the second organometallic polymer, a plurality of particles selected from the group consisting of (a) a ceramic fuel particle and (b) a moderator particle, a dispersant, and a polymerization initiator. The pre-ceramic particle solution can be supplied to an additive manufacturing process, such as digital light projection, and made into a structure (which is pre-ceramic particle green body) that can then be debinded to form a polymer-derived ceramic sintered body. In some embodiments, the polymer-derived ceramic sintered body is a component or structure for fission reactors.
1. A pre-ceramic particle solution, comprising:
an organic polymer of Formula 1:
wherein M + is a metal or metalloid cation functional group selected from the group consisting of Si, Ti, Be, B, U, Hf, Zr, Nb, and Gd and mixtures thereof;
a plurality of fuel particles;
a dispersant; and
a polymerization initiator,
wherein the plurality of fuel particles have a composition including a fissionable material.
2. The pre-ceramic particle solution according to claim 1 , wherein M + is selected from the group consisting of Ti, Be, U, Nb, and Gd and mixtures thereof.
3. The pre-ceramic particle solution according to claim 1 , wherein the fissionable material is uranium oxide, uranium with 10 wt. % molybdenum, or uranium nitride.
4. The pre-ceramic particle solution according to claim 1 , wherein the fissionable material is enriched uranium oxide.
5. The pre-ceramic particle solution according to claim 1 , wherein the polymerization initiator is a photoinitiator.
6. The pre-ceramic particle solution according to claim 5 , wherein the photoinitiator is a UV photoinitiator or an EBeam initiated photoinitiator.
7. The pre-ceramic particle solution according to claim 1 , wherein the metal or metalloid cation is U.
8. The pre-ceramic particle solution according to claim 1 , wherein the metal or metalloid cation is Ti.
9. The pre-ceramic particle solution according to claim 1 , wherein the metal or metalloid cation is Be.
10. The pre-ceramic particle solution according to claim 1 , further comprising a plurality of moderator particles having a composition including beryllium or carbon or mixtures thereof.
11. A pre-ceramic particle green body, comprising:
a matrix of an organic polymer of Formula 1:
wherein M + is a metal or metalloid cation functional group selected from the group consisting of Si, Ti, Be, B, U, Hf, Zr, Nb, and Gd and mixtures thereof; and
a plurality of fuel particles,
wherein the plurality of fuel particles are contained within the matrix, and
wherein the plurality of fuel particles have a composition including a fissionable material.
12. The pre-ceramic particle green body according to claim 11 , wherein M + is selected from the group consisting of Ti, Be, U, Nb, and Gd and mixtures thereof.
13. The pre-ceramic particle green body according to claim 11 , wherein the fissionable material is uranium oxide, uranium with 10 wt. % molybdenum, or uranium nitride.
14. The pre-ceramic particle green body according to claim 11 , wherein the fissionable material is enriched uranium oxide.
15. The pre-ceramic particle solution according to claim 11 , wherein the metal or metalloid cation is U.
16. The pre-ceramic particle solution according to claim 11 , wherein the metal or metalloid cation is Ti.
17. The pre-ceramic particle solution according to claim 11 , wherein the metal or metalloid cation is Be.
18. The pre-ceramic particle green body according to claim 11 , further comprising a plurality of moderator particles,
wherein the plurality of moderator particles are contained within the matrix, and
wherein the plurality of moderator particles have a composition including beryllium or carbon or mixtures thereof.
19. A polymer-derived ceramic sintered body formed by debinding the pre-ceramic particle green body of claim 11 ,
wherein the polymer-derived ceramic sintered body includes:
a matrix of sintered metal or metalloid from the organic polymer including the metal or metalloid as a cation functional group; and
the plurality of fuel particles contained within the matrix.
20. The polymer-derived ceramic sintered body according to claim 19 , wherein M + is selected from the group consisting of Ti, Be, U, Nb, and Gd and mixtures thereof.
21. The polymer-derived ceramic sintered body according to claim 19 , wherein the fissionable material is uranium oxide, uranium with 10 wt. % molybdenum, or uranium nitride.
22. The polymer-derived ceramic sintered body according to claim 19 , wherein the fissionable material is enriched uranium oxide.
23. The polymer-derived ceramic sintered body according to claim 19 , wherein the metal or metalloid cation is U.
24. The polymer-derived ceramic sintered body according to claim 19 , wherein the metal or metalloid cation is Ti.
25. The polymer-derived ceramic sintered body according to claim 19 , wherein the metal or metalloid cation is Be.
26. A polymer-derived ceramic sintered body formed by debinding the pre-ceramic particle green body of claim 18 ,
wherein the polymer-derived ceramic sintered body includes:
a matrix of sintered metal or metalloid from the organic polymer including the metal or metalloid as a cation functional group;
the plurality of fuel particles contained within the matrix; and
the plurality of moderator particles contained within the matrix.