ANNUAL TECHNICAL PROGRESS REPORT OF RADIOISOTOPE POWER SYSTEM MATERIALS PRODUCTION AND TECHNOLOGY PROGRAM TASKS FOR OCTOBER 1, 2004, THROUGH SEPTEMBER 30, 2005

The Office of Space and Defense Power Systems of the Department of Energy (DOE) provides Radioisotope Power Systems (RPS) for applications where conventional power systems are not feasible. For example, radioisotope thermoelectric generators were supplied by the DOE to the National Aeronautics and Space Administration for deep space missions including the Cassini Mission launched in October of 1997 to study the planet Saturn. For the Cassini Mission, ORNL produced carbon-bonded carbon fiber (CBCF) insulator sets, iridium alloy blanks and foil, and clad vent sets (CVS) used in the generators. The Oak Ridge National Laboratory (ORNL) has been involved in developing materials and technology and producing components for the DOE for more than three decades. This report reflects program guidance from the Office of Space and Defense Power Systems for fiscal year (FY) 2005. Production activities for prime quality (prime) CBCF insulator sets, iridium alloy blanks and foil, and CVS are summarized in this report. Technology activities are also reported that were conducted to improve the manufacturing processes, characterize materials, or to develop information for new radioisotope power systems