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DOE OSTI · 3682481

Polymer coatings on zirconia microspheres via rotating flow fluid dynamics

Ravi, Nivetha [University of Alabama, Birmingham]·Behera, Kishore [University of Alabama, Birmingham]·Cholayil, Shilpa [University of Alabama, Birmingham]·Lopez Honorato, Eddie [ORNL] (ORCID:000000017948798X)·Lu, Kathy [University of Alabama, Birmingham]
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Abstract

Conventional tristructural isotropic (TRISO) coatings for nuclear fuels require multi-step and expensive formation processes; any breakage of the coatings may lead to fission species release. Polymer derived ceramic (PDC) coatings can be a suitable alternative to address these issues. In this study, allylhydridopolycarbosilane (SMP-10) coatings were created on yttria stabilized zirconia (YSZ) microspheres using a Rotating Flow Fluid Dynamics (RFFD) coating method. The effects of curing temperature, rotation speed, and coating cycle/time on the coating were analyzed. Surface functionalization of YSZ microspheres with NaOH resulted in good adhesion between the polymer precursor and the YSZ kernel particles. Spectroscopy analysis revealed complete curing of SMP-10 coated YSZ at 160 °C. Rotation speed and coating time significantly affect the coating characteristics. After 3 cycles at lower rotation speed (50 rpm) for 10 min each, the coating obtained was uniform and homogeneous. In comparison, the coating showed almost 10 times less eccentricity at a high rotation speed of 300 rpm. Compared with the coatings prepared at 300 rpm condition, the coatings have higher sphericity and lower eccentricity at 50 rpm. Overall, this study provides a novel and effective route for fabricating and curing SMP-10 precursor coatings on YSZ microspheres.

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Ravi, Nivetha [University of Alabama, Birmingham], Behera, Kishore [University of Alabama, Birmingham], Cholayil, Shilpa [University of Alabama, Birmingham], Lopez Honorato, Eddie [ORNL] (ORCID:000000017948798X), Lu, Kathy [University of Alabama, Birmingham]. 2026-06-01. Polymer coatings on zirconia microspheres via rotating flow fluid dynamics. https://doi.org/10.1016/j.apsusc.2026.167441

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