Multilayer ceramic and metal containing fuel rod cladding and methods of forming the same

Abstract

The present invention relates to a ceramic and metal containing multilayer fuel rod cladding and method of forming the same. The multilayer coating includes an inner layer, an intermediate layer, and an outer layer. The inner layer can form a cladding structure, the intermediate layer includes a composite material including mechanically self-locking ceramic fibers including braided or woven silicon carbide fibers providing mechanical support and a matrix selected from the group including silicon carbide, alumina, and mixtures or combinations thereof. Alternatively, the composite material includes mechanically self-locking ceramic fibers including braided or woven silicon carbide fibers providing mechanical support in the absence of a mechanically constraining matrix between the fiber bundles of the mechanically self-locking ceramic fibers. The intermediate layer exhibits the ability to retain fuel debris. The outer layer is ductile and reformable, deposited on the outer surface of the intermediate layer, including iron-chromium-aluminum alloy with yttrium. The multilayer cladding effectively protects the contents of the cladding structure from exposure to high temperature environments.

Description

[0001] This divisional application is based on Chinese Invention Patent Application No. 201680069853.8 (International Application No. PCT / US2016 / 058384), entitled "Multilayer Composite Fuel Coating System with High Temperature Sealing and Disaster Recovery," filed on October 24, 2016. Technical Field

[0002] This invention relates to cladding made of multilayer composite materials for use in high-temperature environments as a barrier protecting the cladding's contents. The invention also relates to methods for manufacturing the composite materials. More specifically, this invention relates to multilayer composite fuel cladding for use in reactors with water, liquid metal, or liquid salt coolants. Background Technology

[0003] A power reactor may comprise a reactor core with numerous fuel assemblies, each consisting of multiple elongated fuel elements or fuel rods. The size and design of the fuel assemblies vary depending on the desired core and reactor size. The fuel rods contain fissile fuel materials, such as uranium containing some amount of fissile U235 or U233 and / or fuel pellets containing plutonium. Fission of the fissile assemblies results in heat generation. Coolants such as water, liquid salts, gaseous or liquid metals (e.g., lead) are pumped through the reactor core to extract the heat generated within the reactor core, producing useful work such as electricity.

[0004] Each fuel rod is clad, which serves as a container to hold the radioactive fuel material and separate it from the coolant medium. Furthermore, during operation, fission produces highly radioactive gaseous, volatile, and non-volatile fission products, which are also confined by the cladding. In conventional metal-clad systems, over time, radiation causes damage to the metal in terms of hardening and embrittlement, as well as material expansion.

[0005] Figure 1 illustrates a prior art fuel cladding design, showing a stack 16 of fuel pellet 10, zirconium-based cladding 12, spring-loaded device 14, and end plug.

[0006] Recent developments in this field have provided fuel rod cladding made of ceramic-containing materials, such as silicon carbide (SiC). SiC has been shown to exhibit the desired performance in accidents exceeding design baselines, such as at temperatures above 1200°C in light water reactors, and can therefore be considered a suitable structural material for nuclear fuel rod cladding. However, due to the inherent inelasticity of ceramic materials, it is generally difficult to maintain fission gas impermeability during buckling caused by handling, accidents, or natural phenomena (such as earthquakes). It is also difficult to secure end plugs to SiC tubes in a high-volume, economical manner to achieve a hermetically tight seal at temperatures exceeding 1200°C.

[0007] There is a need in the art to provide a coating material that offers high-temperature mechanical strength and stability, resistance to expansion and corrosion, while also providing protection and airtightness against external environments. No single material has yet been found that can provide all the desired properties for a coating. Therefore, the object of the present invention is to provide a composite material comprising more than one material, each exhibiting different properties advantageous to the coating. Summary of the Invention

[0008] In one aspect, the present invention provides a multilayer cladding comprising ceramic and metal, the multilayer cladding comprising: an inner layer having an inner surface and an outer surface and being made of metal or a metal alloy; an intermediate layer having an inner surface and an outer surface, the intermediate layer being formed on the outer surface of the inner layer and comprising a composite material or interlocking ceramic fibers, the composite material comprising interlocking ceramic fibers and a matrix, the matrix being selected from the group consisting of a ceramic matrix, a metal matrix, or a combination thereof; and an outer layer deposited on the outer surface of the intermediate layer and being made of metal or a metal alloy.

[0009] The composite material may include a silicon carbide matrix and woven or braided silicon carbide fibers, or an alumina matrix and woven or braided alumina fibers.

[0010] The outer layer may comprise an alumina-forming metal alloy having an anti-oxidation coating. In some embodiments, the outer layer comprises an iron-chromium-aluminum alloy, optionally with yttrium added.

[0011] In another aspect, the present invention provides a method for forming a multilayer shell comprising ceramics and metal. The method includes forming an inner layer having an inner surface and an outer surface and being made of metal or a metal alloy; applying an intermediate layer having an inner surface and an outer surface to the outer surface of the inner layer, wherein the intermediate layer comprises a composite material or interlocking ceramic fibers, the composite material comprising interlocking ceramic fibers and a matrix selected from the group consisting of a ceramic matrix, a metal matrix, or a combination thereof; and depositing an outer layer made of metal or a metal alloy on the outer surface of the intermediate layer.

[0012] Applying an intermediate layer may include: obtaining ceramic fibers in the form of fiber bundles; wrapping, winding, or weaving the fiber bundles onto an inner layer; forming a woven ceramic fiber structure in which pores are formed; and depositing the matrix onto the woven ceramic fiber structure using a process selected from chemical vapor deposition, chemical vapor infiltration, and sol-gel infiltration to at least partially fill the pores.

[0013] In some embodiments, the outer layer is formed by a process selected from electric arc, liquid phase, or cold spray. Attached Figure Description

[0014] A further understanding of the invention can be obtained from the following description of preferred embodiments, taken in conjunction with the accompanying drawings, in which:

[0015] Figure 1 is a schematic diagram illustrating a fuel cladding according to the prior art; and

[0016] Figure 2 This is a schematic diagram showing an axial cross-sectional view of a multilayer shell according to certain embodiments of the present invention. Detailed Implementation

[0017] This invention relates generally to multilayer materials for forming cladding, methods for preparing multilayer materials, and methods for preparing cladding composed of multilayer materials. Multilayer cladding includes combinations of ceramic and metallic components. Multilayer materials include an inner layer, an intermediate layer, and an outer layer. Generally, the inner layer may be made of metal or alloy to form an airtight barrier for fission products, and may also provide some mechanical support for the remainder of the cladding structure; the intermediate layer may include a ceramic composite material or a ceramic-containing composite material composed of a matrix material and interlocking woven or braided fibers (e.g., fiber bundles wrapped around the inner layer to form a woven structure); and the outer layer may be made of metal or metal alloy, such as in the form of a coating. Generally, multilayer cladding is an effective barrier for protecting contents contained within a cladding structure from exposure to high-temperature environments and mechanical stresses. For example, the cladding may be suitable as a fuel cladding for containing nuclear fuel in reactor environments with water, liquid salt, or liquid metal coolants circulating at very high temperatures, such as, but not limited to, lead-cooled fast reactors. The fuel cladding has the capability to withstand normal and accident conditions associated with the reactor. For ease of description, the invention is described herein in the context of a fuel cladding for containing or holding radioactive fuel pellets, wherein the cladding is placed in the reactor core and exposed to a high-temperature coolant circulating around the cladding and through the core. However, it should be understood that the invention is not limited to this context. The multilayer composite cladding of the invention is contemplated for application in non-radioactive (e.g., non-nuclear) applications and may include any high-temperature heat or mass transfer application in which at least one fluid (liquid or gaseous) phase needs to be separated from another solid, fluid (e.g., gaseous or liquid) phase or mixed-phase system (such as solid fuel pellets with gaseous fission products), such as in high-temperature energy generation and storage applications (including, but not limited to, combustion in the case of solar energy (using high-temperature heat transfer) and fossil-based power technologies).

[0018] Fuel rod cladding is typically in the shape of an elongated tube with a cavity formed therein and two opposing open ends. The thickness of the tube wall can vary. In some embodiments, the wall thickness is from about 100 micrometers to about 1000 micrometers. The cavity contains fuel pellets and typically has pressing devices (such as springs) to hold the fuel pellets in place (e.g., stacking). Sealing mechanisms are typically located at or within each open end of the cladding to provide a seal and prevent coolant circulating in the core from entering the cavity of the fuel rod cladding. As shown in Figure 1, the fuel rod cladding is located in the core of a nuclear reactor.

[0019] Fuel rod cladding is typically used primarily to contain fissile fuel pellets and to separate the fuel pellets and fission products from the coolant medium, in which fission generates heat. The cladding is typically made of metallic materials (metals or metal alloys) or alternatively, ceramic materials. Each of these materials has its own advantages and disadvantages. For example, metallic cladding provides good airtightness, good ductility, adjustable strength, and a reformable corrosion-resistant layer. In contrast, ceramic cladding provides high rigidity, high-temperature strength, and high-temperature survivability in oxidizing and corrosive environments. The fuel rod cladding according to the invention provides a multilayer material system that combines both metallic / metal alloy and ceramic materials, such that the properties and advantages associated with each of these materials are exhibited within the cladding.

[0020] Typically, fuel rod cladding composed of multilayered material systems avoids the problems associated with conventional ceramic composite systems, such as the difficulty in achieving hermeticity while maintaining material ductility and high-temperature strength. Not intended to be bound by any particular theory, this property conflict is considered to stem from the need for fine-scale matrix cracking within the composite ceramic matrix, which promotes elongation during strain in the ceramic material (e.g., pseudo-ductility). Furthermore, the cladding according to the invention can provide accident tolerance based on the unique manufacturing of the ceramic composite material. As a result, the fuel rod cladding of the invention can provide high-temperature performance and corrosion resistance to fuel in hot or fast reactors. The coolant is a liquid- or gas-based coolant, and in particular, can be a molten metal, such as lead.

[0021] Figure 2 A multi-layered cladding 21 in the form of a cylindrical tube is shown. It is contemplated and understood that the shape of the cladding is not limited and can include a wide variety of shapes and configurations. For example, the cladding can be a box-shaped structure or other enclosed form, including structures extending in two dimensions axially or conically. Furthermore, the structure can be uniformly shaped or non-uniformly shaped; that is, the shape can be adjusted to accommodate variations in diameter along its length. Moreover, it is conceivable that the cylindrical tube can be used in various environments, such as, but not limited to, reactors, where fuel elements are housed within the cladding 21. Figure 2 In the shell 21, there is an inner layer 23, a middle layer 29, and an outer layer 35. For example... Figure 2As shown, the inner layer 23 is in the form of a tube. As a non-limiting example, it can be a pre-formed cylinder comprising an inner cavity 24, an inner surface 25, and an outer surface 27. The inner layer 23 is made of metal or a metal alloy. Typically, the material of the inner layer 23 is chosen to exhibit good airtightness, a compliant surface, moderate strength, and good ductility. Suitable metals and metal alloys for forming the inner layer 23 include, but are not limited to, austenitic steel, ferritic martensitic steel, zirconium alloys, ferroalloys, titanium alloys, or layered combinations thereof. Austenitic steel and ferritic martensitic steel are commonly used in fast spectrophotometer reactors, while zirconium alloys (such as, but not limited to, zirconium alloys) are commonly used in thermal spectrophotometer reactors. The selection of a particular steel can depend on a balance of factors such as toughness, radiation brittleness, expansion, and neutron absorption. The thickness of the inner layer 23 can vary. For example, the inner layer 23 can have a thickness ranging from about 100 micrometers to about 300 micrometers. The inner layer 23 is typically formed using conventional equipment and processes, such as those used for forming tubular fuel cladding. For example, the inner layer 23 can be formed by conventional tube manufacturing processes, such as tube drawing or Pierce rolling. However, the inner layer 23 can be manufactured by performing deposition processes such as liquid or arc spraying, liquid impregnation, or solid-state sintering on a removable core. In these processes, additional processing steps can be used to maintain the removable core, facilitating the multilayer fabrication of the multilayer structure.

[0022] Intermediate layer 29 is applied to the outer surface 27 of inner layer 23. For example... Figure 2As shown, the intermediate layer 29 has an inner surface 31 and an outer surface 33. The intermediate layer 29 may be composed of a ceramic composite material comprising a ceramic matrix and interlocking woven or braided (e.g., wound) ceramic fibers. Optionally, the intermediate layer 29 may be composed of interlocking woven or braided ceramic fibers in the absence of a ceramic matrix. Furthermore, the intermediate layer 29 may optionally be composed of a ceramic-containing composite material and a metal matrix, the ceramic-containing composite material comprising interlocking woven or braided ceramic fibers. In some embodiments, the interlocking woven or braided fibers may comprise a combination of ceramic fibers and metal fibers. A key feature of the invention is that the ceramic fibers are woven or braided in a mechanically self-interlocking structure, enabling them to provide mechanical support in the absence of a mechanically constrained matrix between the fibers / fiber bundles. The ceramic components of the intermediate layer 29 (e.g., both fibers and matrix, when utilized) exhibit high strength and stiffness at normal reactor operating temperatures and at higher temperatures typical of design-base and beyond-design-base accidents. Brittleness is known to be associated with ceramics; therefore, the intermediate layer of the cladding material may be formed from a combination of ceramic fibers and a matrix. This material structure allows for limited but subdivided suppressed localized cracking within the material matrix while effectively maintaining most of the strength and stiffness of the interlocking fiber structure. The retention of mechanical properties is enhanced by confining the ceramic composite material (intermediate layer 29) between the inner and outer layers (inner layer 23 and outer layer 35). Suitable ceramic fiber and ceramic matrix materials for forming the intermediate layer 29 include, but are not limited to, silicon carbide, alumina, and mixtures and combinations thereof. For example, silicon carbide fibers, alumina fibers, or combinations thereof may be combined with a silicon carbide matrix, an alumina matrix, or combinations thereof. Suitable metallic materials for the matrix may include iron-based or nickel-based alloys, titanium-based or zirconium-based systems, and combinations or mixtures thereof. The thickness of the intermediate layer 29 can vary. In some embodiments, the intermediate layer 29 may have a thickness ranging from about 200 micrometers to about 600 micrometers.

[0023] Intermediate layer 29 is typically formed using conventional equipment and processes. For example, intermediate layer 29 can be formed by applying prestress to the fiber components to form the fibers into bundles, and by wrapping or winding them under or above the bundles, for example at + / -45 degrees, to form a cross-weave. As a result, intermediate layer 29 not only provides support under operating conditions but also ensures continued support for the internal fuel pellets under accident conditions, such as in the form of a sheath, where metal components (e.g., inner layer 23 and outer layer 35) may be lost, perforated, corroded, or oxidized.

[0024] In some embodiments, the cladding tube (e.g., Figure 2The inner layer 23) is wrapped, wound, or woven with ceramic (e.g., silicon carbide and / or alumina) fibers. The wrapping, winding, or weaving can be performed such that processing begins at one end of the casing tube (which can be open or sealed) and ends at the opposite end. The thickness of the deposited fibers can vary, and for example, a layer from about 200 micrometers to about 600 micrometers thick can be formed. Typically, pores exist between single fibers or multiple groups of fibers, and therefore, after the wrapping, winding, or weaving step, a ceramic (e.g., silicon carbide and / or alumina) or metallic matrix material is applied to at least partially fill the pores formed between the fibers.

[0025] Substrate materials can be deposited or applied using chemical vapor infiltration (CVI) or chemical vapor deposition (CVD) techniques. As used herein, CVI refers to depositing substrate material in pores using a decomposed gaseous matrix precursor, while CVD refers to depositing substrate material on a substrate surface using a decomposed gaseous matrix precursor. In some embodiments, depending on the specific CVI process and equipment used, CVI is performed at temperatures ranging from about 300°C to about 1100°C. Conventional decomposition-based CVI is performed between about 900°C and about 1100°C. In some embodiments, atomic layer deposition-based SiC deposition is performed at temperatures ranging from about 300°C to about 500°C.

[0026] Alternatively, sol-gel infiltration, drying, and sintering processes can be used to form composite materials, for example, Figure 2 The middle layer 29.

[0027] The outer layer 35 is coated or deposited in the form of a coating on the outer surface 13 of the intermediate layer 29. For example... Figure 2As shown, the outer layer 35 has an inner surface 37 and an outer surface 39. The outer layer 35 is made of metal or a metal alloy. Typically, the material of the outer layer 35 is chosen to separate the external environment (e.g., water, gas, liquid salt, or liquid metal) from the intermediate layer 29 and to provide a protective layer on the intermediate layer 29; particularly, in the event that the ceramic matrix cracks due to the composite material straining to accommodate mechanical deformation. Typically, the material of the outer layer 35 has sufficient ductility to ensure that the layer remains intact throughout the coating and that the protective aspect of the surface can be restored in the event of cracking or damage to the protective outer surface 39. This restorable protective layer provides a chemical and physical barrier against the intrusion of liquid coolants into the fibrous fabric of the intermediate layer 29. Suitable metals and metal alloys used to form the outer layer 35 may include, but are not limited to, alumina-type metal alloys with an anti-oxidation coating. In some embodiments, an iron-based Fe-Cr-Al alloy incorporating nickel (Ni) and rare earth elements such as yttrium (Y) is preferred. However, other stable alloys with environmentally compatible coatings (such as high-temperature nickel alloys and stainless steel) can be used for the outer layer 35. In a preferred embodiment of the fuel cladding in a lead-cooled reactor, the outer layer is in the form of a coating of a yttrium-added iron-chromium-aluminum alloy, which has high metallic ductility but retains the ability to reform its protective alumina coating in the event of cracking of the outer surface 39. The coating thickness of the outer layer 35 can vary. For example, the outer layer 35 can have a thickness ranging from about 20 micrometers to several millimeters. However, the optimal thickness can be in the range of about tens of micrometers at one limit (a lower thickness to accommodate the surface variability formed by the wrapped ceramic fiber bundles), and about 1 mm at another limit. (The upper thickness provides a ductile coating that can deform with the underlying ceramic material without cracking). Depending on the thickness of the intermediate layer, the thickness of the outer layer is preferably from tens of micrometers to one hundred to two hundred micrometers. That is, the thickness of the outer layer should be about 10% of the thickness of the intermediate layer.

[0028] The outer layer 35 is typically formed using conventional coating equipment and deposition processes. For example, the outer layer 35 can be formed by arc, liquid phase, or cold spraying to create a thickness sufficient to fill the surface gaps of the underlying composite intermediate layer 29, providing complete coverage of the cladding surface and maintaining the ability to reform the protective surface layer throughout the cladding's lifetime. In some embodiments, the aluminum in the outer layer is oxidized to form a protective, adhesive alumina layer. In such embodiments, an alumina-rich metallic material is deposited as a metal system in a vacuum or non-oxidizing atmosphere, and once the metallic layer has been deposited, air or oxygen can be applied to the surface of the deposited material, either as a general atmosphere or a directed gas flow. Heating the metallic structure and / or gas under controlled conditions will affect the oxidation of the top of the metallic layer and the formation of the desired protective oxide outer layer.

[0029] The use of the inner metal layer 23 and outer metal layer 35 allows for control of the proximal structure, enabling conventional metal-to-metal bonding techniques to be used to seal the ends of the tube. In some embodiments, at least one of the inner layer 23 and outer metal layer 35 extends beyond the intermediate layer 29, such that the extensions or overlaps at each end can be joined together by conventional bonding techniques (e.g., brazing or welding) to seal each open end of the cladding tube. For example, fuel pellets can be loaded into the cavity of the fuel cladding, and then the outer layer 35 can be applied thereon, with a portion of the outer layer 35 extending beyond the intermediate layer 29, and this overlap joining together at each end of the cladding tube to seal the open end. Alternatively, an end seal can be formed, for example, by welding, to close the open end of the cladding, by loading the fuel pellet into the cavity, and then sealing the other open end of the cladding.

[0030] In some embodiments, one or more of the inner, intermediate, and outer layers may be manufactured before or after fuel is loaded into the cavity of the cladding. Furthermore, multilayer cladding may be constructed (e.g., laid out) and formed (e.g., co-extruded) to provide improved shaping and consolidation.

[0031] Compared to conventional cladding known in the art, the fuel rod cladding according to the present invention provides at least one or more of the following benefits.

[0032] The airtightness of the inner surface of the cladding tube relative to the fission products of gaseous and volatile fuels;

[0033] It exhibits high-temperature strength and toughness, as well as resistance to swelling and porosity in response to irradiation;

[0034] Mechanical resistance to very high temperatures and high mechanical strain;

[0035] Mechanical support and containment of fuel debris in accident conditions based on the woven structure (intermediate layer); and

[0036] The multilayer material system provides corrosion resistance and oxidation protection to the surface, while also offering hermetic sealing of the ceramic composite surface in the event of microcracks in the ceramic matrix and the ability to reform an external protective oxide layer.

[0037] During reactor operation, the internal pressure generated by the gases produced by the fuel is confined by the cladding. The cladding functions include containing the fuel and fuel fission products, providing mechanical strength and stability, and offering protection and airtightness to the external environment through an inner layer, a ceramic or ceramic-containing composite intermediate layer, and an outer layer. This avoids the need for high-temperature strength, expansion resistance, and corrosion resistance in a single material. The inner and outer metal layers can provide a certain level of mechanical strength, but the key mechanical property of these layers is their ability to deform together with the ceramic intermediate layer without breaking. Therefore, in the event of an accident, it is necessary to withstand high temperatures for a short period and to maintain the separation of various fuel elements, but 100% mechanical integrity for reusability is not required. Extensive oxidation / corrosion failure of the cladding system's metal components would not be catastrophic. The remaining post-accident structure of the fuel cladding is essentially composed of high-temperature resistant ceramic and a specially preserved mechanical support fibrous structure (intermediate layer 29), which exhibits the ability to contain fuel debris, i.e., allowing the remaining oxidized structure to function as a woven "sheath" to hold the fuel pellets.

[0038] Although specific embodiments of the invention have been described in detail, those skilled in the art will recognize that various modifications and changes to these details can be developed based on the general teachings of this disclosure. Therefore, the specific embodiments disclosed are intended to be illustrative only and do not limit the scope of the invention, which will be given by the overall scope of the appended claims and any and all equivalents thereof.

Claims

1. A multilayer nuclear fuel rod cladding (21) comprising ceramic and metal, said multilayer nuclear fuel rod cladding comprising: The inner layer (23) has an inner surface (25) and an outer surface (27) and the inner layer comprises a metal alloy selected from the group consisting of iron alloys, zirconium alloys, titanium alloys, and stacked combinations thereof; A cavity is formed by the inner layer (23) to accommodate nuclear fuel; An intermediate layer (29) is formed on the outer surface (27) of the inner layer (23), the intermediate layer (29) comprising: Composite material, the composite material comprising: Including mechanically self-locking fibers, including woven or braided silicon carbide fibers and metal fibers, wherein the mechanically self-locking fibers provide mechanical support; and The matrix, selected from the group consisting of iron-based or nickel-based alloys, titanium-based or zirconium-based systems, and mixtures or combinations thereof, is used to fill the pores formed between the fibers. The intermediate layer (29) exhibits the ability to retain fuel debris; and A stretchable and reformable outer layer (35) is deposited on the outer surface (33) of the intermediate layer (29). The stretchable and reformable outer layer (35) comprises an iron-chromium-aluminum alloy with yttrium, the iron-chromium-aluminum alloy with yttrium being FeCrAl(Y). The thickness of the outer layer is about 10% of the thickness of the intermediate layer.

2. The multilayer nuclear fuel rod cladding (21) according to claim 1, wherein, The inner layer (23) is configured to form a cylindrical tube.

3. The multilayer nuclear fuel rod cladding (21) according to claim 1, wherein, The mechanically self-locking fibers are in the form of fiber bundles, which are constructed in a braided or wound structure.

4. The multilayer nuclear fuel rod cladding (21) according to claim 1, wherein, The matrix is ​​deposited onto and into the woven or wound ceramic fiber structure.

5. The multilayer nuclear fuel rod cladding (21) according to claim 1, wherein, The stretchable and reconfigurable outer layer (35) is in the form of a coating.

6. The multilayer nuclear fuel rod cladding (21) according to claim 1, wherein, The stretchable and reformable outer layer (35) has an antioxidant coating thereon.

7. The multilayer nuclear fuel rod cladding (21) according to claim 1, wherein, The stretchable and reconfigurable outer layer (35) extends beyond the intermediate layer (29) and the inner layer (23).

8. The multilayer nuclear fuel rod cladding (21) according to claim 7, wherein, The stretchable and reconfigurable outer layer (35) extends such that the extensions or overlaps at each end can be joined together to seal each open end of the multilayer nuclear fuel rod cladding.

9. The multilayer nuclear fuel rod cladding (21) according to claim 1, wherein, The inner layer (23) and the stretchable and reconfigurable outer layer (35) extend beyond the intermediate layer (29).

10. The multilayer nuclear fuel rod cladding (21) according to claim 9, wherein, The stretchable and reconfigurable outer layer (35) extends such that the extensions or overlaps at each end can be joined together to seal each opening of the multilayer nuclear fuel rod cladding, and wherein the inner layer (23) extends such that the extensions or overlaps at each end can be joined together to seal each opening of the multilayer nuclear fuel rod cladding.

11. A method for forming a multilayer nuclear fuel rod cladding (21) comprising ceramic and metal, the method comprising: An inner layer (23) is formed having an inner surface (25) and an outer surface (27). The inner layer (23) comprises a metal alloy selected from the group consisting of iron alloys, zirconium alloys, titanium alloys, and stacked combinations thereof. The inner layer (23) is configured to form a cavity (24) to accommodate nuclear fuel; An intermediate layer (29) is applied to the outer surface (27) of the inner layer (23), comprising: A mechanically self-locking fiber is obtained, the mechanically self-locking fiber comprising silicon carbide fiber and metal fiber, and the mechanically self-locking fiber is in the form of a fiber bundle; Wrap, coil, or weave the fiber bundles onto the inner layer (23); and A woven fiber structure is formed, wherein the mechanically self-locking fibers provide mechanical support in the absence of a mechanically constrained matrix between the fiber bundles of the mechanically self-locking fibers, and pores are formed in the woven fiber structure, wherein the intermediate layer (29) exhibits the ability to retain fuel debris. A deposition matrix, selected from the group consisting of iron-based or nickel-based alloys, titanium-based or zirconium-based systems, and mixtures or combinations thereof, is used to fill the pores formed between fibers. A malleable and reformable outer layer (35) is deposited on the outer surface (33) of the intermediate layer (29) by a process selected from the group consisting of electric arc, liquid phase or cold spray, the malleable and reformable outer layer comprising an iron-chromium-aluminum alloy with yttrium, the thickness of the outer layer being about 10% of the thickness of the intermediate layer.

12. The method according to claim 11, wherein, The deposited, stretchable, and reformable outer layer includes an encapsulation shell for nuclear fuel rods.

13. The method according to claim 11, wherein, The deposition matrix includes: depositing silicon carbide, alumina, and mixtures or combinations thereof on a woven fibrous structure using a process selected from chemical vapor deposition, chemical vapor infiltration, and sol-gel infiltration to at least partially fill the pores.

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