This project will investigate the next generation of materials and devices for latent heat thermal energy storage (LHTES) at ultra-high temperatures of up to 2000ºC, which are well beyond today's maximum operation temperatures of ~1000ºC. We will synthetize new phase change materials (PCMs) with latent heat in the range of 2-4 MJ/kg (an order of magnitude greater than that of typical salt-based PCMs); we will develop advance thermal insulation and PCM casing designs, along with novel solid-state heat to power conversion technologies able to operate at temperatures up to 2000ºC. Using these new materials and devices, we aim at realizing the proof of concept of a new kind of extremely compact LHTES device with unprecedented high energy density. The key enabling technologies are: novel PCMs based on the silicon-boron system with ultra-high melting temperature and latent heat, novel refractory lining composites based on carbides, nitrides and oxides for the PCM container walls, advanced thermally insulated PCM casing for ultra-high temperature operation, and novel solid-state heat-to-power converters based on photovoltaic and thermionic effects. In this regard, we will perform the proof of concept of a new kind of hybrid thermionic-photovoltaic converter (TIPV) that has been recently formulated theoretically. TIPV cells combine the ionic and photovoltaic phenomena to convert high temperature heat directly into electricity at very high power rates. The final goal of this project is to demonstrate the proof-of-concept of this idea and kick-starting an emerging research community around this new technological option.

Europe’s industry is facing many challenges such as global competition and the big change towards energy and resource efficiency. topAM can contribute to these demands by development and application of novel processing routes for new oxide-dispersoid strengthened (ODS) alloys on FeCrAl, Ni and NiCu basis. Novel ODS materials offer a clear advantage for the process industry by manufacturing e.g. topology-optimized, sensor-integrated high temperature devices (gas burner heads, heat exchangers) that are exposed to aggressive environments. Alloy and process development will be targeted by an advanced integrated computational materials engineering (ICME) approach combining computational thermodynamics, microstructure and process simulation to contribute to save time, raw materials and increase the component’s lifetime. Physical alloy production will be realized by combining nanotechnologies to aggregate ODS composites with laser-powder bed fusion and post-processing. The ICME approach will be complemented by comprehensive materials characterization and intensive testing of components under industrially relevant in-service conditions. This strategy allows to gain a deeper understanding of the process-microstructure-properties relationships and to quantify the improved functionalities, properties and life cycle assessment. This will promote cost reduction, improved energy efficiency and superior properties combined with a significant lifetime increase. The consortium consists of users, materials suppliers and research institutes that are world leading in the fields relevant for this proposal, which guarantees efficient, high-level, application-oriented execution of topAM. The industrial project partners, in particular the SMEs, will achieve higher competitiveness due to their strategic position in the value chain of materials processing, e.g. powder production, to strengthen Europe's leading position in the emerging technology field of AM in a unique combination with ICME.