Ultramet and Digital Materials Solutions made substantial progress in the development and demonstration of a manufacturable flow channel insert consisting of silicon carbide open-cell structural foam with solid silicon carbide facesheets. The FCI structure was the first to demonstrate zero lead-lithium ingress while exposed to pressure and temperature. The goal of this project was to further optimize FCI design (under operational conditions in ITER and DEMO), materials, and scaleup. The focus is on (1) development of an additional insulating foam filler material to prevent lead-lithium ingress in the event of facesheet damage; (2) Reliability assessment of manufactured FCI. Testing is being performed in static lead-lithium and in a representative, flowing lead-lithiumenvironment in the MHD PbLi loop at UCLA. Reliability assessment was completed at DMS.

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