Mesh-covered fuel cladding

Abstract

In various aspects, a nuclear fuel rod cladding is disclosed. The cladding may include a base tube and a mesh structure having gaps. The base tube may include an elongated tubular wall and may be configured to contain the nuclear fuel. The mesh structure may be disposed along at least a portion of the elongated tubular wall and may be configured to provide structural support to the base tube. In one aspect, the gaps in the mesh structure are designed to allow neutrons emitted by the nuclear fuel to pass through the gaps and exit the fuel rod cladding.

Description

[Technical field]

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS This application claims the benefit of and priority under 35 U.S.C. § 120 to U.S. patent application Ser. No. 17 / 662,692, entitled "FUEL CLADDING COVERED BY A MESH," filed May 10, 2022, the contents of which are incorporated herein by reference in their entirety.

[0002] Government Contracts This invention was made with Government support under Contract No. DE-NE0009033 awarded by the Department of Energy. The Government has certain rights in this invention.

[0003] The present disclosure relates generally to nuclear fuel rod cladding, and more particularly to fuel rod cladding including a mesh structure, a porous structure, a coating, or a combination thereof. In some embodiments, the mesh structure, the porous structure, and the coating help inhibit oxidation of the cladding, maintain the structural integrity of the cladding, and / or limit neutron loss caused by the cladding. Summary of the Invention

[0004] The following summary is provided to facilitate understanding of some of the innovative features unique to the embodiments disclosed herein and is not intended to be a complete description, A complete understanding of the various embodiments disclosed herein can be obtained by taking the entire specification, claims, and abstract as a whole.

[0005] In various aspects, a nuclear fuel rod cladding is disclosed. In some aspects, the cladding includes a base tube and a mesh structure having gaps. The base tube may include an elongated tubular wall and may be configured to contain the nuclear fuel. The mesh structure may be disposed along at least a portion of the elongated tubular wall and may be configured to provide structural support to the base tube. In one aspect, the gaps in the mesh structure are designed to allow neutrons emitted by the nuclear fuel to pass through the gaps and exit the fuel rod cladding.

[0006] In various aspects, methods of manufacturing nuclear fuel rod cladding are disclosed. In some aspects, the methods include providing a base tube including an elongated tubular wall. The elongated tubular wall may have an exterior surface, and the base tube may be configured to contain nuclear fuel. The methods may further include forming a mesh structure on the exterior surface of the elongated tubular wall. The mesh structure may be configured to provide structural support to the base tube.

[0007] In various aspects, a nuclear fuel rod cladding is disclosed. In some aspects, the cladding includes a base tube and a porous layer having gaps. The base tube may include an elongated tubular wall and may be configured to contain the nuclear fuel. The porous layer may be disposed along at least a portion of the elongated tubular wall and may be configured to provide structural support to the base tube. In one aspect, the gaps in the porous layer are designed to allow neutrons emitted by the nuclear fuel to pass through the gaps and exit the fuel rod cladding.

[0008] These and other objects, features, and characteristics of the present disclosure, as well as the method of operation and function of the associated elements of construction, and the combination of parts and economies of manufacture, will become more apparent from a study of the following description and the appended claims, taken in conjunction with the accompanying drawings, in which it is to be expressly understood, however, that the drawings are for the purpose of illustration and description only and are not intended as a limitation of the aspects disclosed herein. [Brief description of the drawings]

[0009] The various aspects described herein, together with their objects and advantages, will be best understood by reference to the following description taken in conjunction with the accompanying drawings, in which:

[0010] [Figure 1] FIG. 1 illustrates a cross-sectional elevation view of a fuel assembly according to at least one non-limiting embodiment of the present disclosure.

[0011] [Diagram 2] FIG. 1 illustrates a cross-sectional view of a fuel rod according to at least one non-limiting embodiment of the present disclosure.

[0012] [Diagram 3] 1 illustrates a longitudinal cross-sectional view of a portion of a nuclear fuel rod cladding including a base tube and an oxidation-resistant coating according to at least one non-limiting embodiment of the present disclosure.

[0013] [Figure 4] 1 illustrates a longitudinal cross-sectional view of a portion of a nuclear fuel rod cladding including a base tube and a mesh structure according to at least one non-limiting embodiment of the present disclosure.

[0014] [Diagram 5] FIG. 1 illustrates a longitudinal cross-sectional view of a portion of a nuclear fuel rod cladding including a base tube, a mesh structure formed on an outer surface of the base tube, and an oxidation-resistant coating applied to the outer surface of the mesh structure, according to at least one non-limiting embodiment of the present disclosure.

[0015] [Figure 6] FIG. 1 illustrates a longitudinal cross-sectional view of a portion of a nuclear fuel rod cladding including a base tube, an oxidation-resistant coating applied to an outer surface of the base tube, and a mesh structure formed on the outer surface of the oxidation-resistant coating, according to at least one non-limiting embodiment of the present disclosure.

[0016] [Figure 7]FIG. 1 illustrates a longitudinal cross-sectional view of a portion of a nuclear fuel rod jacket including a base tube, an oxidation-resistant coating applied to an outer surface of the base tube, and a mesh structure formed on an inner surface of the base tube, in accordance with at least one non-limiting embodiment of the present disclosure.

[0017] [Figure 8] 1 illustrates various examples of mesh structure patterns having gaps, according to certain non-limiting aspects of the present disclosure. [Figure 9] 1 illustrates various examples of mesh structure patterns having gaps, according to certain non-limiting aspects of the present disclosure. [Figure 10] 1 illustrates various examples of mesh structure patterns having gaps, according to certain non-limiting aspects of the present disclosure.

[0018] [Figure 11] 1 illustrates a flowchart of a method for manufacturing nuclear fuel rod cladding in accordance with at least one non-limiting embodiment of the present disclosure.

[0019] Corresponding reference characters indicate corresponding parts in the various views. The exemplifications described herein illustrate various aspects of the present disclosure by way of example, and such exemplifications are not to be construed as limiting the scope of the aspects disclosed herein. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0020] Numerous specific details are described to provide a thorough understanding of the overall structure, function, manufacture, and use of the embodiments described in this disclosure and illustrated in the accompanying drawings. Well-known operations, parts, and elements are not described in detail so as not to obscure the embodiments described herein. Upon reading this disclosure, it will be understood that the embodiments described and illustrated herein are non-limiting examples, and that the specific structural and functional details disclosed herein may be representative and exemplary. Variations and modifications may be made without departing from the scope of the claims.

[0021] In the following description, like reference characters in the several views indicate like or corresponding parts, and it should be understood that in the following description, terms such as "front", "rear", "left", "right", "upper", "lower", "upper", "lower" and the like are used for convenience and should not be construed as limiting.

[0022] In a typical nuclear reactor, such as a pressurized water reactor (PWR), heavy water reactor (e.g., CANDU), or boiling water reactor (BWR), the core may include multiple fuel assemblies, each including a plurality of elongated fuel elements or fuel rods. For example, FIG. 1 illustrates a cross-sectional elevation view of a fuel assembly 10 according to at least one non-limiting embodiment of the present disclosure. The fuel assembly 10 includes an array of elongated fuel rods 22. The fuel rods 22 may contain a plurality of fuel pellets 26, each of which is comprised of fissile material capable of undergoing a nuclear fission reaction to produce the reactor's reaction power.

[0023] The fuel rods 22 may be supported by one or more transverse grids 20 attached to guide thimbles 18. The guide thimbles 18 extend longitudinally between the top nozzle 16 and the bottom nozzle 12, and the control rods 34 are configured to operatively move through the guide thimbles 18. The ends of the guide thimbles 18 may be attached to the top nozzle 16 and the bottom nozzle 12, respectively. The bottom nozzle 12 may be configured to support the fuel assembly 10 on a lower core plate 14 of a nuclear reactor vessel in a core region of a nuclear reactor (not shown). A coolant, such as water or water containing a neutron absorbing material, such as boron, may be pumped upwardly toward the fuel assembly 16 through a number of flow openings in the lower core plate 14. The bottom nozzle 12 of the fuel assembly 10 may channel the coolant along the fuel rods 22 of the assembly 10 to extract heat generated as a result of nuclear fission reactions occurring within the fuel assembly 10.

[0024] FIG. 2 illustrates an enlarged cross-sectional view of a fuel rod 22 according to at least one non-limiting embodiment of the present disclosure. Referring now to FIGS. 1-2, as described above, each fuel rod 22 may include a plurality of nuclear fuel pellets 26. The fuel pellets 26 are contained in a long cladding 38 tube closed at both ends by an upper end plug 28 and a lower end plug 30. The pellets 26 may be maintained in a stack by a plenum spring 32 disposed between the upper end plug 28 and the top of the pellet stack. However, in other embodiments, the pellets 26 may be in other configurations by other mechanisms.

[0025] In various embodiments, the fuel pellets 26 may be comprised of a fissile material capable of producing the reactor's reaction power through a nuclear fission reaction. For example, the fissile material may be uranium dioxide (UO 2 ), plutonium dioxide (PuO 2 ), thorium dioxide (ThO 2 ), uranium nitride (UN), uranium silicide (U 3 S 2 ), or mixtures thereof. Fuel pellets 26 may also include neutron absorbing materials, such as boron or boron compounds, gadolinium or gadolinium compounds, erbium or erbium compounds, or combinations thereof. However, in other embodiments, pellets 26 may include a variety of suitable substances capable of producing and / or controlling the reaction output.

[0026] In various embodiments, the tube with coating 38 may be made of a material including zirconium (Zr), iron (Fe), or a combination thereof. For example, the tube with coating 38 may be composed of a zirconium (Zr) alloy that includes other metals, such as niobium (Nb), tin (Sn), iron (Fe), and / or chromium (Cr).

[0027] The cladding 38 of the fuel rods 22 is used in a hostile environment. For example, the cladding 38 can withstand temperatures up to 1200° C. under normal operating conditions. oC and potentially even higher under accident conditions. Additionally, fission reactions occur within the fuel rods 22, generating fission gases that build up pressure within the fuel rods 22 and exert forces against the inner surface of the tubes that are coated with the cladding 38.

[0028] The exterior surface of the tube with the coating 38 is also exposed to a hostile environment. For example, when immersed in the coolant, external pressure is exerted on the coating 38. Additionally, reactions with oxygen and hydrogen atoms in the coolant's chemical structure can cause the material of the coating 38 (e.g., a zirconium alloy) to oxidize and degrade over time. As oxidation progresses, the structural integrity of the tube with the coating 38 can be weakened. Eventually, the tube with the coating 38 can become weak enough to oxidize and partially fracture.

[0029] Other factors may also cause the cladding 38 tubes to rupture. For example, as discussed above, the fission gases may build up pressure within the fuel rods 22. Under normal circumstances, the external pressure applied by the coolant can counteract the internal fission gas pressure. However, in the absence of cooling, the internal fission gases may cause the cladding 38 tubes to rupture if the cladding 38 tubes have been degraded (e.g., by oxidation). Furthermore, the increased temperature and / or exposure to steam resulting from the lack of cooling may accelerate the oxidation process.

[0030] A break in the cladding 38 tube can cause a variety of problems. For example, coolant (e.g., water) can enter the cladding 38 tube through the break. The fuel pellets 26 (e.g., UO 2) when exposed to water, other gases such as hydrogen can be released, which can further degrade the tubes on which the cladding 38 is provided. Furthermore, if a fracture occurs and the fuel pellets 26 or portions thereof are introduced into the coolant, extensive cleanup efforts can be required. Also, if the fracture is large enough, the structural integrity of the fuel rods 22 and / or fuel assemblies 10 can be weakened. Thus, there is a need for devices, systems, and methods that can help prevent fractures from occurring and minimize damage if a fracture does occur by reducing oxidation of the fuel rod cladding and / or improving the structural integrity of the fuel rod cladding.

[0031] 3 illustrates a longitudinal cross-sectional view of a portion of a nuclear fuel rod cladding 100 including a base tube 102 and an oxidation-resistant coating 110 according to at least one non-limiting embodiment of the present disclosure. The base tube 102 may be composed of materials similar to those described above with respect to the cladding 38. For example, the base tube 102 may include zirconium (Zr) and / or other metals such as niobium (Nb), tin (Sn), iron (Fe), chromium (Cr), and the like. In various embodiments, the base tube 102 may include a zirconium (Zr) alloy. The zirconium (Zr) alloy may include niobium (Nb), tin (Sn), iron (Fe), and / or chromium (Cr).

[0032] The base tube 102 may include an elongated tubular wall 104 having an inner surface 108 and an outer surface 106. An oxidation-resistant coating 110 is formed on the outer surface 106 of the tubular wall 104 to protect the base tube 102 from oxidation that may result from exposure to a coolant. That is, the oxidation-resistant coating 110 also helps maintain the structural integrity of the cladding 100 by preventing and / or slowing degradation of the tubular wall 104 of the base tube 102.

[0033] The oxidation-resistant coating 110 may be composed of any suitable oxidation-resistant material. For example, the oxidation-resistant coating 110 may include alloys of chromium (Cr), iron (Fe), yttrium (Y), and / or aluminum (Al), and / or any combination thereof. Furthermore, the oxidation-resistant coating 110 may be applied to the base tube 102 using a variety of surface treatment techniques, such as, for example, cold spray, thermal spray, physical vapor deposition (PVD), slurry coating, and the like.

[0034] The oxidation-resistant coating 110 may have a thickness Tc. In some embodiments, the thickness Tc of the coating 110 may range from 5 microns to 100 microns, such as 10 microns, 15 microns, 20 microns, 25 microns, 30 microns, 35 microns, 40 microns, 45 microns, or 50 microns. In other embodiments, the thickness Tc of the coating 110 may be greater than 100 microns.

[0035] The thickness Tc of the oxidation-resistant coating 110 may be optimized based on various considerations. For example, various materials of the coating 110, such as chromium (Cr), may be neutron absorbers as well as oxidation-resistant materials. Thus, the coating 110 may cause neutron losses that may adversely affect reactor efficiency. Furthermore, the greater the thickness Tc of the coating 110, the greater the neutron losses that may occur. Thus, it may be desirable to apply a very thin oxidation-resistant coating 110 (e.g., Tc of 20 microns or less, 15 microns or less, or 10 microns or less) to limit the neutron losses caused by the coating 110. However, depending on the processing techniques used to apply the coating 110, it may be difficult to achieve a very thin layer of the oxidation-resistant coating 110. Furthermore, a very thin coating 110 may be less effective at preventing oxidation and ensuring the structural integrity of the base tube 102 compared to a thicker coating. Thus, there is a need for a coating and / or other surface treatment that can provide oxidation resistance and structural support to the base tube 102 while reducing neutron loss.

[0036] 4 illustrates a longitudinal cross-sectional view of a portion of a nuclear fuel rod cladding 200A including a base tube 102 and a mesh structure 210 according to at least one non-limiting embodiment of the present disclosure. Similar to the oxidation-resistant coating 110 of FIG. 3, the mesh structure 210 is formed on the outer surface 106 of the tubular wall 104. However, according to the non-limiting embodiment of FIG. 4, unlike the oxidation-resistant coating 110 of FIG. 3, the mesh structure 210 does not cover the entire outer surface 106 of the tubular wall 104. Instead, the mesh structure 210 may have gaps (not shown in FIG. 4) that selectively allow portions of the outer surface 106 of the tubular wall 104 not to be covered by the mesh structure 210.

[0037] For example, FIGS. 8-10 show various examples of patterns of mesh structures 210 having gaps 216. FIG. 8 shows a rectangular mesh pattern, FIG. 9 shows a diamond mesh pattern, and FIG. 10 shows a spiral mesh pattern. Each of the mesh structures 210 includes a plurality of mesh segments 214 that form various patterns. The mesh segments 214 are configured such that gaps 216 are formed therebetween. That is, referring again to FIG. 4 and further to FIGS. 8-10, the mesh segments 214 partially cover the outer surface 106 of the tubular wall 104, while other portions of the outer surface 106 of the tubular wall 104 are exposed by the gaps 216. Although FIGS. 8-10 depict rectangular, diamond, and spiral patterns, the mesh structures 210 may be formed in any suitable pattern (e.g., triangular, pentagonal, hexagonal, non-structural, etc.).

[0038] Alternatively, a suitable mesh structure may include two or more void patterns. For example, the mesh structure may include a first pattern and a second pattern that is different from the first pattern. Also, in some embodiments, the mesh structure may include a random pattern. In at least one example, the mesh structure may define a porous layer having a predetermined porosity.

[0039] 4 and further with reference to Figures 8-10, in some embodiments, mesh structure 210 may be constructed from any suitable oxidation-resistant material. For example, mesh structure 210 may be constructed from materials similar to oxidation-resistant coating 110 of Figure 3, such as alloys of chromium (Cr), iron (Fe), yttrium (Y), and / or aluminum (Al), and / or any combination thereof.

[0040] Still referring to Figure 4 and further referring to Figures 8-10, the mesh structure 210 may have a thickness Tm. In some embodiments, the thickness Tm of the mesh structure 210 may range from 5 to 100 microns, such as 5 microns, 10 microns, 15 microns, 20 microns, 25 microns, 30 microns, 35 microns, 40 microns, 45 microns, or 50 microns. In other embodiments, the thickness Tm of the mesh structure 210 may be greater than 100 microns.

[0041] Still referring to FIG. 4 and further referring to FIGS. 8-10, the mesh segments 214 may have a width Wm. In some embodiments, the width Wm of the mesh segments 214 may range from 0.1 mm to 5 mm, such as from 0.5 mm to 3 mm. For example, the mesh segments 214 may have a width Wm of 0.5 mm, 0.6 mm, 0.7 mm, 0.8 mm, 0.9 mm, 1.0 mm, 1.1 mm, 1.2 mm, 1.3 mm, 1.4 mm, 1.5 mm, 1.6 mm, 1.7 mm, 1.8 mm, 1.9 mm, 2.0 mm, 2.1 mm, 2.2 mm, 2.3 mm, 2.4 mm, 2.5 mm, 2.6 mm, 2.7 mm, 2.8 mm, 2.9 mm, or 3.0 mm. In some embodiments, each of the mesh segments 214 may have the same width Wm or approximately the same width W. In other embodiments, mesh segments 214 of the same mesh structure 210 may have different widths Wm. For example, vertical mesh segments may have different widths Wm, mesh segments may have alternating widths Wm for rows and / or columns, mesh segments may have different widths Wm at different portions along the length of the covering 200, etc.

[0042] The distance between the mesh segments 214 may be selected to limit the size of the gaps 216. For example, in the non-limiting embodiment of FIGS. 8-9, the rows of mesh segments 214 are spaced apart by a distance Dr, and the columns of mesh segments 214 are spaced apart by a distance Dc. As another example, in the non-limiting embodiment of FIG. 10, the rows of mesh segments 214 are spaced apart by a distance Dr. In some embodiments, the distances Dr, Dc between the various rows and / or columns of the mesh structure 210 may be the same or approximately the same throughout the mesh structure 210. In other embodiments, the distances Dr, Dc between the various rows and / or columns of the mesh structure may be different.

[0043] As mentioned above, materials such as chromium (Cr) used to construct the oxidation-resistant coating 110 may be neutron absorbers. Similar materials may be used to construct the mesh structure 210. That is, the mesh structure 210 may also have neutron absorbing properties. However, the mesh structure 210 may include gaps 216 that allow the outer surface 106 of the tubular wall 104 to remain partially uncovered by the mesh segments 214. Neutrons emitted by the nuclear fuel in the cladding 200A may pass through the tubular wall 104 of the base tube 102 and exit the cladding 200A by passing through the gaps 216 of the mesh structure 210. In other words, the gaps 216 provide a path for at least some neutrons to exit the cladding 200A without passing through the material of the mesh structure 210. Thus, the width Wm of the mesh segments 214 and / or the distance between the mesh segments 214 (e.g., Dr, Dc) may be optimized to suppress neutron losses caused by the mesh structure 210. Additionally, because some neutrons exiting the base tube 102 will strike the mesh segments 214, the thickness Tm may also be optimized to reduce neutron losses caused by the mesh structure 210. Those skilled in the art will appreciate that even if the thickness Tm of the mesh structure 210 is greater than the thickness Tc of the coating 110, the mesh structure 210 can be configured to cause lower overall neutron losses compared to the oxidation-resistant coating 110 described above.

[0044] Additionally, as discussed above, exposure of the base tube 102 to the coolant can cause degradation of the tubular wall 104 over time. This degradation, coupled with the pressure of the fission gases exerting a force against the inner surface 108 of the tubular wall 104, can cause fracture of the clad base tube 102. The mesh structure 210 can protect the portions of the outer surface 106 of the tubular wall 104 that are covered by the mesh segments 214 from oxidation. The mesh structure 210 can also limit oxidation of the base tube 102 to the portions of the outer surface 106 of the tubular wall 104 that are left uncovered by the gaps 216. Thus, the mesh structure 210 can prevent the formation of large oxidized areas in the tubular wall 104 that are susceptible to fracture. Additionally, if a fracture does occur, the mesh structure 210 can provide additional strength to hold the base tube 102 together and prevent the formation of large fracture holes. Accordingly, the thickness Tm of the mesh structure 210, the width Wm of the mesh segments 214, and / or the distance between the mesh segments 214 (e.g., Dr, Dc) may be optimized to minimize neutron losses caused by the mesh structure 210 while ensuring that the mesh structure 210 provides structural support and corrosion resistance to the base tube 102.

[0045] In some embodiments, various parameters of the mesh structure 210 described above may be selected and / or optimized such that the portion of the outer surface 106 of the long tubular wall 104 remaining uncovered by the gaps 216 of the mesh structure 210 is between 5% and 90% of the total surface area of ​​the outer surface 106 of the long tubular wall 104. For example, the portion of the outer surface 106 of the long tubular wall 104 remaining uncovered by the gaps 216 of the mesh structure 210 may be 5%, 10%, 15%, 20%, 25%, 30%, 35%, 40%, 45%, 50%, 55%, 60%, 65%, 70%, 75%, 80%, 85%, or 90% of the total surface area of ​​the outer surface 106 of the long tubular wall 104.

[0046] In various embodiments, the nuclear fuel rod cladding 200 may include both the oxidation-resistant coating 110 and the mesh structure 210. For example, Figure 5 shows a longitudinal cross-sectional view of a portion of a nuclear fuel rod cladding 200B including a base tube 102, a mesh structure 210 formed on the outer surface 106 of the tubular wall 104, and an oxidation-resistant coating 110 applied to the outer surface 212 of the mesh structure 210. Although not shown in the cross-sectional view of Figure 5, the oxidation-resistant coating 110 is also applied to the portion of the outer surface 106 of the tubular wall 104 that remains uncovered by the gaps in the mesh structure. That is, the oxidation-resistant coating covers the entire outer surface of the fuel rod cladding 200B.

[0047] Various characteristics of the mesh structure 210 and oxidation-resistant coating 110 of the cladding 200B may be similar to those described above with respect to FIGS. 3-4 and 8-10. That is, the nuclear fuel rod cladding 200B may have the structural and neutron loss mitigation advantages of having the mesh structure 210 while also having the oxidation resistance advantages of having the oxidation-resistant coating 110 surrounding the entire outer surface of the cladding 200B. Additionally, the thickness Tm, width Ws, and / or distances Dr, Dc associated with the mesh structure 210, as well as the thickness Tc of the coating 110 may be optimized to obtain these advantages. For example, the mesh structure 210 may be configured to minimize the size of possible oxidation patches and / or fractures and provide structural support to the base tube 102. Additionally, the oxidation-resistant coating 110 may be configured to have a very small thickness Tc (e.g., about 5-10 microns) to provide corrosion protection to the entire outer surface of the cladding 200B while limiting neutron loss.

[0048] The configuration of the nuclear fuel rod cladding 200B shown in Figure 5 may, in some embodiments, have a smoother outer surface as compared to the configuration of the cladding 200A illustrated in Figure 4. For example, the coating 110 may smooth out ridges that protrude from the cladding 200B due to the mesh structure 210. Thus, the thickness Tm of the mesh structure 210 may be increased in the configuration of the cladding 200B shown in Figure 5 because the coating 110 may mitigate issues related to roughness and subcooled boiling that may occur as the coolant flows along the outer surface of the cladding 200B.

[0049] In the configuration of the nuclear fuel rod cladding 200B shown in FIG. 5, in some embodiments, a mesh structure 210 that does not have oxidation-resistant properties may be used. As described above, the mesh structure 210 of the fuel rod cladding 200B is covered with an oxidation-resistant coating 110. Thus, in some embodiments, the mesh structure 210 material used in the fuel rod cladding 200B may be selected for its structural properties. Any suitable mesh structure 210 material may be selected, such as, for example, the mesh structure 210 materials disclosed above, zirconium alloys, silicon carbide, and / or other ceramic or ceramic composite materials.

[0050] 6 illustrates a longitudinal cross-sectional view of a portion of a nuclear fuel rod cladding 200C including a base tube 102, an oxidation-resistant coating 110 applied to the outer surface 106 of the tubular wall 104, and a mesh structure 210 formed on the outer surface 112 of the oxidation-resistant coating 110. Although not shown in the cross-sectional view of FIG. 6, portions of the oxidation-resistant coating 110 remain uncovered by gaps 216 in the mesh structure 210.

[0051] 6 and further with reference to FIGS. 8-10, in some embodiments, the portion of the outer surface 112 of the oxidation-resistant coating 110 that remains uncovered by the gaps 216 of the mesh structure 210 is between 5% and 90% of the total surface area of ​​the outer surface 112 of the oxidation-resistant coating 110. For example, the portion of the outer surface 112 of the oxidation-resistant coating 110 that remains uncovered by the gaps 216 of the mesh structure 210 may be 5%, 10%, 15%, 20%, 25%, 30%, 35%, 40%, 45%, 50%, 55%, 60%, 65%, 70%, 75%, 80%, 85%, or 90% of the total surface area of ​​the outer surface 112 of the oxidation-resistant coating 110.

[0052] Various characteristics of the mesh structure 210 and oxidation-resistant coating 110 of the cladding 200C may be similar to those described above with respect to FIGS. 3-4 and 8-10. That is, the nuclear fuel rod cladding 200C may have the structural and neutron loss reduction advantages of having the mesh structure 210, while also having the oxidation resistance advantages of having the oxidation-resistant coating 110 surrounding the entire base tube 102. Furthermore, the thickness Tm, width Wm, and / or distances Dr, Dc associated with the mesh structure 210, as well as the thickness Tc of the coating 110, may be optimized to obtain these advantages. For example, the mesh structure 210 may be configured to minimize the size of possible oxidation patches and / or fractures and provide structural support to the base tube 102. Furthermore, the oxidation-resistant coating 110 may be configured to have a very small thickness Tc (e.g., about 5-10 microns) to provide corrosion protection to the entire exterior surface 106 of the base tube 102 while limiting neutron loss.

[0053] FIG. 7 illustrates a longitudinal cross-sectional view of a portion of a nuclear fuel rod cladding 200D including a base tube 102, an oxidation resistant coating 110 applied to the outer surface 106 of the tubular wall 104, and a mesh structure 210 formed on the inner surface 108 of the tubular wall 104.

[0054] Various characteristics of the mesh structure 210 and oxidation-resistant coating 110 of the cladding 200D may be similar to those described above with respect to FIGS. 3-4 and 8-10. That is, the nuclear fuel rod cladding 200D may have the structural and neutron loss reduction advantages of having the mesh structure 210, while also having the oxidation resistance advantages of having the oxidation-resistant coating 110 surrounding the entire base tube 102. Furthermore, the thickness Tm, width Ws, and / or distances Dr, Dc associated with the mesh structure 210, as well as the thickness Tc of the coating 110, may be optimized to obtain these advantages. For example, the mesh structure 210 may be configured to provide structural support to the base tube 102 along the inner surface 108 of the tubular wall 104. Furthermore, the oxidation-resistant coating 110 may be configured to have a very small thickness Tc (e.g., about 5-10 microns) to provide corrosion protection to the entire outer surface 106 of the base tube 102 while limiting neutron loss.

[0055] In the configuration of nuclear fuel rod cladding 200D shown in Figure 7, in some embodiments, a mesh structure 210 that does not have oxidation resistance properties may be used. As described above, the mesh structure 210 is formed on the inner surface 108 of the tubular wall 104. Thus, in some embodiments, the mesh structure 210 material used in the fuel rod cladding 200D may be selected for its structural properties. Any suitable mesh structure 210 material may be selected, such as, for example, the mesh structure 210 materials disclosed above, zirconium alloys, silicon carbide, and / or other ceramic or ceramic composite materials.

[0056] 4-10, the mesh structure 210 disclosed herein may be formed using any suitable technique. For example, the mesh structure 210 may be formed using a variety of known deposition, additive manufacturing, coating, subtractive manufacturing, and / or reduction techniques.

[0057] In some embodiments, cold spray techniques may be used to form the mesh structure 210 on the base tube 102 and / or the oxidation-resistant coating 110. For example, cold spray may be used to directly apply (e.g., print, spray) mesh segments 214 having a desired pattern to the surface of the base tube 102 and / or the surface of the oxidation-resistant coating 110. As another example, a masking material may be applied to the surface of the base tube 102 and / or the surface of the oxidation-resistant coating 110. Cold spray may be used to apply the mesh structure material, and the masking material may be removed to form the desired gaps 216 in the mesh structure.

[0058] In some embodiments, a deposition technique such as physical vapor deposition (PVD) may be used to form the mesh structure on the base tube 102 and / or on the oxidation-resistant coating 110. For example, a masking material may be applied to a surface of the base tube 102 and / or a surface of the oxidation-resistant coating 110. PVD may be used to apply the mesh structure material, and the masking material may be removed to form the desired gaps 216 in the mesh structure 210.

[0059] In various other embodiments, techniques such as chemical vapor deposition (CVD), selective laser melting (SLM), or electrical discharge machining (EDM) may be used to form the mesh structure 210. If necessary, a masking material may be used to form the desired gaps 216 in the pattern of the mesh structure 210. In still other embodiments, the mesh structure material may be deposited on the base tube 102 and a suitable etching technique may be used to form the desired gaps 216 in the mesh structure 210.

[0060] Various methods may be used to manufacture the nuclear fuel rod cladding 100, 200 disclosed herein with respect to Figures 3-10. Figure 11 illustrates a flow chart of a method 1000 for manufacturing nuclear fuel rod cladding in accordance with at least one non-limiting embodiment of the present disclosure. Referring primarily to Figure 11 and further to Figures 3-10, the method 1000 includes providing 1002 a base tube 102 including an elongated tubular wall 104 having an outer surface 106, the base tube 102 configured to contain nuclear fuel. Additionally, the method 1000 includes forming 1004 a mesh structure 210 on the outer surface 106 of the elongated tubular wall 104, the mesh structure 210 configured to provide structural support to the base tube 102.

[0061] In some embodiments of the method 1000, the base tube 102 comprises zirconium, iron, or a combination thereof. In other embodiments of the method 1000, the coating is comprised of chromium, yttrium, iron, or a combination thereof.

[0062] In some embodiments of the method 1000, forming 1004 the mesh structure includes forming gaps 216 in the mesh structure, whereby portions of the exterior surface 106 of the elongated tubular wall 104 remain uncovered by the gaps 216 of the mesh structure 210. In other embodiments of the method 1000, the portions of the exterior surface 106 of the elongated tubular wall 104 remaining uncovered by the gaps 216 of the mesh structure 210 are between 5% and 90% of the surface area of ​​the exterior surface 106 of the elongated tubular wall 104.

[0063] In some embodiments, the method 1000 includes applying an oxidation-resistant coating 110 to an outer surface of the mesh structure 210 and to portions of the outer surface 106 of the base tube 102 that remain uncovered by the gaps 216 of the mesh structure 210.

[0064] In some embodiments of the method 1000, forming 1004 the mesh structure 210 includes forming a square pattern, a diamond pattern, a spiral pattern, or a combination thereof. In other embodiments of the method 1000, forming 1004 the mesh structure 210 includes depositing the mesh structure 210 using physical vapor deposition, depositing the mesh structure 210 using cold spray deposition and a masking material, depositing the mesh structure 210 using chemical vapor deposition, or depositing a mesh material and forming gaps 216 in the mesh material using etching.

[0065] Various aspects of the devices, systems, and methods described herein are illustrated in the following examples.

[0066] Example 1: Nuclear fuel rod cladding comprising: a base tube having an elongated tubular wall and configured to contain nuclear fuel; and a mesh structure having gaps and disposed along at least a portion of the elongated tubular wall, the mesh structure configured to provide structural support to the base tube, and the gaps of the mesh structure designed to allow neutrons emitted by the nuclear fuel to pass through the gaps and exit the fuel rod cladding.

[0067] Example 2: The cladding of example 1, wherein the base tube is made of zirconium, iron, or a combination thereof.

[0068] Example 3: The coating of any of Examples 1-2, wherein the mesh structure is made of chromium, yttrium, iron, or a combination thereof.

[0069] Example 4: A coating as described in any of Examples 1-3, wherein a mesh structure is formed on an exterior surface of the elongated tubular wall, and a portion of the exterior surface of the elongated tubular wall is left uncovered by gaps in the mesh structure.

[0070] Example 5: A coating according to any of Examples 1 to 4, wherein the portion of the exterior surface of the elongated tubular wall that remains uncovered by gaps in the mesh structure is between 5% and 90% of the surface area of ​​the exterior surface of the elongated tubular wall.

[0071] Example 6: The coating of any of Examples 1-5, further comprising an oxidation resistant coating applied to an outer surface of the mesh structure and a portion of the outer surface of the base tube that remains uncovered by the gaps in the mesh structure.

[0072] Example 7: The coating of any of Examples 1-6, further comprising an oxidation-resistant coating applied to an exterior surface of the elongated tubular wall, wherein a mesh structure is formed on the exterior surface of the oxidation-resistant coating, and portions of the oxidation-resistant coating remain uncovered by gaps in the mesh structure.

[0073] Example 8: A coating as described in any of Examples 1-7, wherein a mesh structure is formed on the inner surface of the elongated tubular wall, and portions of the inner surface of the elongated tubular wall are left uncovered by gaps in the mesh structure.

[0074] Example 9: The coating of any of Examples 1-8, further comprising an oxidation resistant coating applied to an exterior surface of the elongated tubular wall.

[0075] Example 10: A coating according to any of Examples 1-9, wherein the mesh structure is configured in a square pattern, a diamond pattern, a spiral pattern, or a combination thereof.

[0076] Example 11: A coating according to any of Examples 1 to 10, wherein the mesh structure comprises a plurality of mesh segments, the mesh segments having a width in the range of 0.5 mm to 3 mm.

[0077] Example 12: A coating according to any of Examples 1-11, wherein the mesh structure comprises a plurality of mesh segments, the mesh segments having a thickness in the range of 10 microns to 30 microns.

[0078] Example 13: A method of manufacturing nuclear fuel rod cladding, the method including: providing a base tube having an elongated tubular wall, the elongated tubular wall having an outer surface, the base tube configured to contain nuclear fuel; and forming a mesh structure on the outer surface of the elongated tubular wall, the mesh structure configured to provide structural support to the base tube.

[0079] Example 14: The method of example 13, wherein the base tube comprises zirconium, iron, or a combination thereof.

[0080] Example 15: The method of any of Examples 13-14, wherein the coating comprises chromium, yttrium, iron, or a combination thereof.

[0081] Example 16: The method of any of Examples 13-15, wherein forming the mesh structure includes selectively depositing material in a predetermined pattern, and a portion of the outer surface of the elongated tubular wall remains uncovered by gaps in the mesh structure.

[0082] Example 17: The method of any of Examples 13-16, wherein the portion of the exterior surface of the elongated tubular wall that remains uncovered by gaps in the mesh structure is between 5% and 90% of the surface area of ​​the exterior surface of the elongated tubular wall.

[0083] Example 18: The method of any of Examples 13-17, further comprising applying an oxidation-resistant coating to an outer surface of the mesh structure and to a portion of the outer surface of the base tube that remains uncovered by the gaps in the mesh structure.

[0084] Example 19: The method of any of Examples 13-18, wherein the predetermined pattern is a square pattern, a diamond pattern, a spiral pattern, or a combination thereof.

[0085] Example 20: The method of any of Examples 13-19, wherein forming the mesh structure includes depositing the mesh structure using a physical vapor deposition method, depositing the mesh structure using cold spray deposition and a masking material, depositing the mesh structure using a chemical vapor deposition method, or depositing a mesh material and forming gaps in the mesh material using etching.

[0086] Example 21: A nuclear fuel rod cladding comprising: a base tube having an elongated tubular wall and configured to contain nuclear fuel; and a porous layer having gaps and disposed along at least a portion of the elongated tubular wall, the porous layer configured to provide structural support to the base tube, and the gaps in the porous layer designed to allow neutrons emitted by the nuclear fuel to pass through the gaps and exit the fuel rod cladding.

[0087] Example 22: The coating of example 21, wherein the porous layer comprises chromium, yttrium, iron, or a combination thereof.

[0088] Example 23: A coating according to any of Examples 21-22, wherein a porous layer is formed on the outer surface of the long tubular wall, and a portion of the outer surface of the long tubular wall remains uncovered by gaps in the porous layer.

[0089] Example 24: The method of any of Examples 21-23, wherein the portion of the outer surface of the elongated tubular wall that remains uncovered by the gaps of the porous layer is between about 5% and about 90% of the surface area of ​​the outer surface of the elongated tubular wall.

[0090] Those skilled in the art will recognize that the terms used in this specification, in general, and in the appended claims in particular (e.g., the body of the appended claims) are generally intended to be "open" terms (e.g., the term "comprising" should be interpreted as "including, but not limited to," the term "having" should be interpreted as "having at least," and the term "including" should be interpreted as "including, but not limited to"). Those skilled in the art will further recognize that if a specific number of introduced claim elements is intended, such intent will be expressly recited in the claim, and in the absence of such recitation, no such intent exists. For example, as an aid to understanding, the appended claims below may use the introductory phrases "at least one" and "one or more" to introduce claim elements. However, the use of such phrases should not be construed as meaning that introducing a claim element with the indefinite article "a" or "an" limits a particular claim containing the introduction of such claim element to claims containing only one such element, even if the same claim contains the introductory phrase "one or more" or "at least one" and an indefinite article such as "a" or "an" (e.g., "a" and / or "an" should ordinarily be construed to mean "at least one" or "one or more"). The same applies with respect to definite articles used to introduce claim elements.

[0091] In addition, even if a particular number of elements of an introduced claim is explicitly recited, one of ordinary skill in the art will recognize that such recitation should generally be interpreted to mean at least the recited number (e.g., the mere recitation of "two elements" without other modifiers generally means at least two elements, or two or more elements). Furthermore, when a conventional phrase similar to "at least one of A, B, and C, etc." is used, such a phrase is generally intended to have the meaning that one of ordinary skill in the art understands the conventional phrase (e.g., "a system having at least one of A, B, and C" includes, but is not limited to, a system having only A, a system having only B, a system having only C, a system having A and B, a system having A and C, a system having B and C, and / or a system having A, B, and C). When customary phrases similar to "at least one of A, B, or C, etc." are used, such phrases are generally intended to have the meaning that one of ordinary skill in the art would understand the customary phrase (e.g., "a system having at least one of A, B, and C" includes, but is not limited to, a system having only A, a system having only B, a system having only C, a system having A and B, a system having A and C, a system having B and C, and / or a system having A, B, and C). As one of ordinary skill in the art would further appreciate, disjunctive words and / or disjunctive phrases presenting two or more alternative terms, whether in the specification, claims, or drawings, should generally be understood to contemplate the possibility of including one of the words, either of the words, or both of the words, unless the context dictates otherwise. For example, the phrase "A or B" is generally understood to include the possibilities of "A", or "B", or "A and B".

[0092] It should be noted that references such as "one embodiment," "one embodiment," "one example," "one example," and the like mean that a particular feature, structure, or characteristic described in connection with that embodiment is included in at least one embodiment. Thus, the appearances of the phrases "in one embodiment," "in one embodiment," "in one example," and "in one example" in various places throughout this specification do not necessarily all refer to the same embodiment. Furthermore, particular features, structures, or characteristics may be combined in any suitable manner in one or more embodiments.

[0093] Any patent applications, patents, non-patent publications, or other disclosure materials referred to herein and / or set forth in the Application Data Sheet are incorporated herein by reference to the extent such materials are not inconsistent with the present specification. Therefore, to the extent necessary, the disclosures expressly set forth herein shall supersede any conflicting material incorporated herein by reference. If any material, or any portion thereof, purported to be incorporated herein by reference conflicts with any existing definitions, descriptions, or other disclosure material set forth herein, it shall be incorporated only to the extent that such material does not conflict with the existing disclosure material.

[0094] "Comprises" (and any form of "comprises", such as "comprises" or "comprising"), "has" (and any form of "comprises", such as "had" or "having"), "include" (and any form of "includes", such as "included" or "comprising"), and "contains" (and any form of "contains", such as "contained" or "containing") are open-ended linking verbs. As a result, a system that "comprises", "has", "includes", or "contains" one or more elements has those one or more elements, but is not limited to having only those one or more elements. Similarly, a system, device, or apparatus element that "comprises", "has", "includes", or "contains" one or more features has those one or more features, but is not limited to having only those one or more features.

[0095] The terms "substantially", "about", or "approximately" as used in this disclosure, unless otherwise specified, refer to an acceptable error for a particular value as determined by one of ordinary skill in the art, which depends in part on how the value is measured or determined. In certain embodiments, the terms "substantially", "about", or "approximately" refer to within 1, 2, 3, or 4 standard deviations. In certain embodiments, the terms "substantially", "about", or "approximately" refer to within 50%, 20%, 15%, 10%, 9%, 8%, 7%, 6%, 5%, 4%, 3%, 2%, 1%, 0.5%, or 0.05% of a given value or range.

[0096] In summary, numerous advantages have been described by employing the concepts described herein. The foregoing description of one or more embodiments has been presented for purposes of illustration and description. The foregoing description is not intended to be exhaustive or to be limited to the disclosed embodiments. Modifications or variations are possible in light of the above teachings. The one or more embodiments have been selected to illustrate the principles and practical applications and have been described so that one skilled in the art can utilize the various embodiments, with various modifications, as appropriate for the particular application contemplated. The claims presented herein are intended to define the overall scope.

Claims

1. 1. A nuclear fuel rod cladding comprising: a base tube having an elongated tubular wall and configured to contain nuclear fuel; a mesh structure having interstices and disposed along at least a portion of the elongated tubular wall; the mesh structure is configured to provide structural support to the base tube; A nuclear fuel rod cladding, wherein the gaps in the mesh structure are designed to allow neutrons emitted by the nuclear fuel to pass through the gaps and exit the fuel rod cladding.

2. 10. The nuclear fuel rod cladding of claim 1, wherein said base tube is comprised of zirconium, iron, or a combination thereof.

3. 10. The nuclear fuel rod cladding of claim 1, wherein said mesh structure is comprised of chromium, yttrium, iron, or combinations thereof.

4. the mesh structure is formed on an exterior surface of the elongated tubular wall; 2. The nuclear fuel rod cladding of claim 1, wherein a portion of said exterior surface of said elongated tubular wall is left uncovered by said gaps in said mesh structure.

5. 5. The nuclear fuel rod cladding of claim 4, wherein the portion of the exterior surface of the elongated tubular wall left uncovered by the gaps of the mesh structure is between about 5% and about 90% of a surface area of ​​the exterior surface of the elongated tubular wall.

6. 5. The nuclear fuel rod cladding of claim 4 further comprising an oxidation resistant coating disposed on an exterior surface of said mesh structure and said portions of said exterior surface of said base tube left uncovered by said interstices of said mesh structure.

7. an oxidation resistant coating disposed on an exterior surface of the elongated tubular wall; the mesh structure is formed on an outer surface of the oxidation-resistant coating; 2. The nuclear fuel rod cladding of claim 1, wherein a portion of said oxidation resistant coating is left uncovered by said gaps in said mesh structure.

8. the mesh structure is formed on an interior surface of the elongated tubular wall; 2. The nuclear fuel rod cladding of claim 1, wherein a portion of said inner surface of said elongated tubular wall is left uncovered by said gaps in said mesh structure.

9. 10. The nuclear fuel rod cladding of claim 8, further comprising an oxidation resistant coating applied to an exterior surface of said elongated tubular wall.

10. 10. The nuclear fuel rod cladding of claim 1, wherein said mesh structure is configured in a square pattern, a diamond pattern, a spiral pattern, or a combination thereof.

11. the mesh structure comprises a plurality of mesh segments; The nuclear fuel rod cladding of claim 1, wherein said mesh segments have a width ranging from about 0.5 mm to about 3 mm.

12. the mesh structure comprises a plurality of mesh segments; The nuclear fuel rod cladding of claim 1, wherein said mesh segments have a thickness in the range of 10 microns to 30 microns.

13. 1. A method of manufacturing nuclear fuel rod cladding, comprising: providing a base tube having an elongated tubular wall, the elongated tubular wall having an exterior surface, the base tube configured to contain nuclear fuel; forming a mesh structure on the exterior surface of the elongated tubular wall, the mesh structure configured to provide structural support to the base tube.

14. The method of claim 13 , wherein the base tube is made of zirconium, iron, or a combination thereof.

15. The method of claim 13 , wherein the mesh structure is comprised of chromium, yttrium, iron, or a combination thereof.

16. forming the mesh structure includes selectively depositing material in a predetermined pattern; The method of claim 13 , wherein a portion of the exterior surface of the elongated tubular wall is left uncovered by gaps in the mesh structure.

17. 17. The method of claim 16, wherein the portion of the exterior surface of the elongated tubular wall left uncovered by the gaps of the mesh structure is between about 5% and about 90% of a surface area of ​​the exterior surface of the elongated tubular wall.

18. 17. The method of claim 16, further comprising applying an oxidation resistant coating to an exterior surface of the mesh structure and to portions of the exterior surface of the base tube left uncovered by the gaps in the mesh structure.

19. The method of claim 16 , wherein the predetermined pattern is a square pattern, a diamond pattern, a spiral pattern, or a combination thereof.

20. 14. The method of claim 13, wherein forming the mesh structure comprises depositing the mesh structure using a physical vapor deposition process, depositing the mesh structure using a cold spray deposition process and a masking material, depositing the mesh structure using a chemical vapor deposition process, or depositing a mesh material and forming gaps in the mesh material using etching.

21. 1. A nuclear fuel rod cladding comprising: a base tube having an elongated tubular wall and configured to contain nuclear fuel; a porous layer having gaps therebetween and disposed along at least a portion of the elongated tubular wall; the porous layer is configured to provide structural support to the base tube; A nuclear fuel rod cladding, wherein the gaps in the porous layer are designed to allow neutrons emitted by the nuclear fuel to pass through the gaps and exit the fuel rod cladding.

22. 22. The nuclear fuel rod cladding of claim 21, wherein said porous layer is comprised of chromium, yttrium, iron, or combinations thereof.

23. the porous layer is formed on an exterior surface of the elongated tubular wall; 22. The nuclear fuel rod cladding of claim 21, wherein a portion of said exterior surface of said elongated tubular wall is left uncovered by said gaps in said porous layer.

24. 24. The nuclear fuel rod cladding of claim 23, wherein the portion of the exterior surface of the tubular wall left uncovered by the gaps in the porous layer is between about 5% and about 90% of a surface area of ​​the exterior surface of the tubular wall.

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