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Advanced space propulsion systems are essential for future complex space missions, with nuclear thermal propulsion (NTP) systems being one of the most promising options. NTP systems typically employ CERMET fuel elements, which are challenging to manufacture due to their complex structures and the high melting point and hardness of tungsten or tungsten alloys. To realize the production of the shaped CERMET fuel elements, specific shaped pellets were prepared by a novel additive manufacturing technology, powder extrusion printing (PEP), using 93 tungsten-nickel-iron (93W-Ni-Fe) alloy feedstocks. The printed pellets were degreased using trichloroethylene or n-heptane and sintered in pure hydrogen. The microstructure and elemental changes of the samples were analyzed using scanning electron microscopy (SEM), energy dispersive spectrometry (EDS), and metallurgical microscopy. The results demonstrated that PEP could achieve near-net shaping of NTP CERMET fuel elements, yielding green pellets with sufficient mechanical strength. The sintered pellets achieved densities exceeding 95% of the theoretical density. Trichloroethylene showed superior degreasing performance compared to n-heptane. At the highest sintering temperature of 1460 °C, Ni and Fe wetted the solid-phase W and rearranged the W particles, significantly increasing the density of the sintered pellets. This study highlights the potential of the PEP-solvent degreasing-sintering route for fabricating CERMET fuels with complex geometries.

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Preparation and Characterization of CERMET Fuel Pellet Matrix Using Powder Extrusion Printing

  • 会议论文

  • 发表日期：

    2026年

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  • Yumeng Zhao,
  • Zongyi Shao,
  • Yuxuan Xun,
  • Yu Li,
  • Zongshu Li,
  • Wentao Liu,
  • Wei Liu,
  • Pengbo Ji

摘要

Advanced space propulsion systems are essential for future complex space missions, with nuclear thermal propulsion (NTP) systems being one of the most promising options. NTP systems typically employ CERMET fuel elements, which are challenging to manufacture due to their complex structures and the high melting point and hardness of tungsten or tungsten alloys. To realize the production of the shaped CERMET fuel elements, specific shaped pellets were prepared by a novel additive manufacturing technology, powder extrusion printing (PEP), using 93 tungsten-nickel-iron (93W-Ni-Fe) alloy feedstocks. The printed pellets were degreased using trichloroethylene or n-heptane and sintered in pure hydrogen. The microstructure and elemental changes of the samples were analyzed using scanning electron microscopy (SEM), energy dispersive spectrometry (EDS), and metallurgical microscopy. The results demonstrated that PEP could achieve near-net shaping of NTP CERMET fuel elements, yielding green pellets with sufficient mechanical strength. The sintered pellets achieved densities exceeding 95% of the theoretical density. Trichloroethylene showed superior degreasing performance compared to n-heptane. At the highest sintering temperature of 1460 °C, Ni and Fe wetted the solid-phase W and rearranged the W particles, significantly increasing the density of the sintered pellets. This study highlights the potential of the PEP-solvent degreasing-sintering route for fabricating CERMET fuels with complex geometries.