Fiber-reinforced multilayer abrasion-corrosion coatings for zirconium alloy nuclear fuel cladding tubes.

Abstract

A cladding for reinforcing a substrate of a nuclear fuel cladding tube is provided. The cladding includes a first layer configured to cover a first portion of an outer surface of the substrate of the nuclear fuel cladding tube, a second layer surrounding the first layer and the substrate, and a third layer surrounding the second layer. The first layer includes a fiber-based material, the second layer includes an interface material, and the third layer includes chromium. Reinforced cladding tubes for nuclear fuel and methods for manufacturing the reinforced nuclear fuel cladding tube are also provided.

Description

[Technical Field]

[0001] (CROSS-REFERENCE TO RELATED APPLICATIONS) This application claims the benefit of and claims priority under 35 U.S.C. § 120 to U.S. Patent Application Serial No. 17 / 934,733, filed September 23, 2022, entitled "FIBER REINFORCED MULTI-LAYERED WEAR AND CORROSION COATINGS OF ZIRCONIUM ALLOY NUCLEAR FUEL CLADDING," the contents of which are incorporated herein by reference in their entirety.

[0002] (Government support) This invention was made with government support under Government Contract No. DE-NE00009033 awarded by the Department of Energy. The government has certain rights in this invention. Summary of the Invention [Problem to be solved by the invention]

[0003] Currently, chromium-based coatings are used on zirconium alloy-based cladding tubes for accident-tolerant fuel applications. Conventional cladding tubes are inexpensive to apply and can effectively slow cladding oxidation at off-design-basis event temperatures. However, at high temperatures, zirconium-chromium intermetallic compounds form, accelerating oxidation rates and ultimately leading to cladding rupture. Alternative cladding materials with higher oxidation and / or rupture resistance are more expensive and / or require more complex manufacturing techniques than conventional materials. Therefore, there is a need to develop alternative cladding tubes and manufacturing methods to optimize the reliability and cost of accident-tolerant fuel without compromising cladding integrity at high temperatures.

[0004] The following summary is provided to facilitate an understanding of some of the innovative features unique to the aspects disclosed herein, but is not intended to be a complete description. A complete understanding of the various aspects disclosed herein can be gained by taking the entire specification, claims, and abstract as a whole. [Means for solving the problem]

[0005] In various aspects, a cladding for reinforcing a substrate of a nuclear fuel cladding tube is disclosed. In some aspects, the cladding includes a first layer configured to cover a first portion of an outer surface of the substrate of the nuclear fuel cladding tube, a second layer surrounding the first layer and the substrate of the nuclear fuel cladding tube, and a third layer surrounding the second layer. In some aspects, the first layer includes a fiber-based material, the second layer includes an interface material configured to inhibit chemical interaction between the substrate and the third layer, and the third layer includes chromium. In some aspects, the second layer is configured to secure the first layer to the substrate of the nuclear fuel cladding tube.

[0006] In various embodiments, a reinforced cladding tube for nuclear fuel is disclosed. In some embodiments, the reinforced cladding tube comprises a tube comprising a zirconium alloy and a covering for the tube. In some embodiments, the exterior surface of the tube comprises a first portion and a second portion. In some embodiments, the covering comprises a first layer comprising a fiber-based material, a second layer comprising a material having a melting point higher than a design basis event temperature, and a third layer comprising chromium. In some embodiments, the first layer covers a first portion of the exterior surface of the tube, a second portion of the exterior surface of the tube is the surface not covered by the first layer, the second layer surrounds the first layer and the second portion of the exterior surface of the tube, and the third layer surrounds the second layer.

[0007] In various embodiments, methods of manufacturing nuclear fuel-enhanced cladding are disclosed. In some embodiments, the methods include helically wrapping a length of fiber tape around an outer surface of a tubular substrate from a first end of the substrate to a second end of the substrate to form a first layer, wherein a portion of the outer surface of the helically wrapped substrate is exposed, depositing an interface material over the fiber tape and the exposed portion of the outer surface of the substrate to form a second layer, and forming at least one chromium-based layer around the second layer to produce the enhanced fuel 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 combination of parts and economies of manufacture, will become more apparent from a study of the following description and appended claims, taken in conjunction with the accompanying drawings, which are to be read in conjunction with the accompanying drawings, but which are to be expressly understood as being for the purposes of illustration and description only and are not intended as a definition of the limits of the embodiments disclosed herein.

[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: [Brief explanation of the drawings]

[0010] [Figure 1] 1 is a schematic cross-sectional view of a coating for a substrate of a cladding tube, according to at least one non-limiting embodiment of the present disclosure.

[0011] [Figure 2] FIG. 2 is a schematic diagram of a first layer and a base layer according to at least one non-limiting embodiment of the present disclosure.

[0012] Corresponding reference characters indicate corresponding parts throughout the various views. The exemplifications set forth herein illustrate various aspects of the present disclosure in one form, and such exemplifications are not to be construed as limiting the scope of the aspects disclosed herein. DETAILED DESCRIPTION OF THE INVENTION

[0013] Certain exemplary embodiments of the present disclosure will be described to provide a thorough understanding of the principles of the compositions, functions, manufacture, and use of the compositions and methods disclosed herein. One or more examples of these embodiments are illustrated in the accompanying drawings. Those skilled in the art will understand that the compositions, articles, and methods specifically described herein and illustrated in the accompanying drawings are non-limiting exemplary embodiments, and that the scope of various examples of the present disclosure is defined only by the claims. Features shown or described with respect to one exemplary embodiment can be combined with features of other embodiments. Such modifications and variations are intended to be within the scope of the present disclosure.

[0014] References herein to "various examples," "several examples," "one example," "one example," etc., mean that a particular feature, structure, or characteristic described in connection with that example is included in that example. Thus, the appearances of phrases such as "in various examples," "in several examples," "in one example," and "in one example" in various places throughout this specification do not necessarily all refer to the same example. Furthermore, particular features, structures, or characteristics may be combined in any suitable manner in one or more examples. Thus, a particular feature, structure, or characteristic illustrated or described in connection with one example may be combined, in whole or in part, without limitation, with a feature, structure, or characteristic of one or more other examples. Such modifications and variations are intended to be included within the scope of the present examples.

[0015] In the following description, like reference characters in the drawings indicate like or corresponding parts. It should also be understood that in the following description, terms such as "front," "rear," "left," "right," "upper," "lower," "above," "below," etc. are used for convenience only and should not be construed as limiting terms.

[0016] In a nuclear reactor environment, nuclear fuel in a fuel rod is contained in a sealed, thin-walled, tubular fuel cladding to transfer heat predictably from the fuel to the surrounding coolant. For example, zirconium (hereinafter "Zr") alloy cladding is typically employed for nuclear fuel rods in water reactors. Under normal reactor operating conditions, Zr alloy cladding can be exposed to coolant without compromising cladding properties, such as structural integrity and / or overall heat transfer characteristics. Because the corrosion resistance of Zr alloys to a given coolant chemistry varies with operating temperature, the surface properties of the Zr alloy determine the suitability of the Zr alloy for a given reactor environment and / or operating temperature.

[0017] Accident-tolerant fuels (ATFs) have been developed to enhance the protection of nuclear fuel under unexpected high operating temperatures and / or accident conditions. For example, chromium (Cr) coatings are compatible with the chemistry and accident environments of pressurized water reactors (PWRs) and CANDU reactors and are also fairly inexpensive to apply to Zr alloys. Therefore, Cr coatings are sometimes applied to Zr alloy cladding tubes to obtain relatively inexpensive ATFs for PWRs and CANDU reactors. The application of Cr coatings can reduce the oxidation rate of the cladding surface at beyond-design-basis-event (BDBA) temperatures, e.g., above 1200°C.

[0018] In fact, currently available Cr-Zr cladding materials can undergo undesirable phase transformations. For example, at temperatures above approximately 1000°C, intermetallic compounds containing ZrCr2 begin to form at the eutectic Cr-Zr interface. ZrCr2 is brittle, easily oxidizes, and begins to melt at approximately 1332°C. At temperatures above 1332°C, the eutectic Cr-Zr layer expands as Zr dissolves in the Cr, accelerating the oxidation rate of the Cr layer. Furthermore, at temperatures above 800°C, fuel rods can swell and rupture, potentially releasing fission products and fuel into the primary system and potentially transporting these materials beyond the secondary loop and plant boundary. A ruptured cladding tube not only obstructs the cooling path around itself, but also around adjacent cladding tubes, potentially amplifying the cascading effect of overheating and rupture of adjacent tubes. Therefore, exposure to temperatures as low as 800°C, or as high as 1000°C or 1332°C can compromise the inherent protection of the Cr coating.

[0019] Furthermore, while Cr is highly compatible with the reactor environment of PWRs and CANDU reactors, it is not compatible with the chemistry of normally operating boiling water reactors (hereinafter "BWRs"), which have high levels of oxygen, such as approximately 1-10 ppm oxygen in the form of O2. Approximately 25% of the world's nuclear reactors are BWRs, so many of these reactors cannot take advantage of the ATF properties of Cr-coated Zr alloy fuel.

[0020] With regard to the mechanical properties of the Cr coating, a Cr coating applied using cold spray techniques onto a Zr alloy substrate can provide a harder coating than Cr coatings applied using other techniques, such as physical vapor deposition (hereinafter "PVD") or thermal spray techniques, and therefore can provide additional protection against debris and grid wear failure. However, the inventors of the present disclosure have found that cold sprayed Cr coatings may not be hard enough to prevent all Zr alloy wear failure during normal operation of all types of water reactors.

[0021] Other ATF claddings based on ceramic composite materials have also been considered, such as cladding made of composite silicon carbide (hereinafter "SiC"). Composite SiC cladding can provide resistance to expansion and / or bursting, and resistance to excessive oxidation at temperatures up to about 1800°C. Additionally, composite SiC cladding is very hard and highly resistant to abrasion failure. However, the process for manufacturing these composite claddings is very complex and requires expensive materials, resulting in a very high cost per cladding.

[0022] Methods and apparatus according to the present disclosure optimize the technical and economic aspects of providing cladding for ATF in nuclear reactors, such as PWR, CANDU, and / or BWR reactors. In some embodiments, this optimization can provide increased protection under accident conditions, e.g., temperatures up to about 1600°C, and / or reduce and / or eliminate cladding expansion and / or rupture, without requiring complex manufacturing processes or expensive materials. Thus, various aspects of the present disclosure provide various methods and apparatus for maintaining the structural integrity of fuel rods under accident conditions without the material limitations and / or high cost of currently available ATF cladding.

[0023] 1 , a cross-sectional schematic diagram of a cladding 100 for a base layer 10 of a nuclear fuel cladding tube is shown, in accordance with at least one non-limiting embodiment of the present disclosure. In various examples, the cladding 100 is comprised of a first layer 110, a second layer 120 surrounding the first layer 110, and a third layer 130 surrounding the second layer 120. In some examples, the cladding may optionally include a fourth layer 140 surrounding the third layer 130, as shown in FIG. 1 .

[0024] Referring now to FIG. 2 , a perspective schematic view of a first layer 110 disposed around a substrate 10 is shown, according to at least one non-limiting embodiment of the present disclosure. The first layer 110 is constructed of a fiber-based material and partially covers the outer surface of the substrate 10. For example, the first layer 110 may include a SiC-based material or a carbon fiber-based material, which is configured to cover a first portion 10a extending along the length of the outer surface of the substrate 10 over about 40% to about 70% of the outer surface area of ​​the substrate 10, with the remaining outer surface area of ​​the substrate 10 constituting a second portion 10b of the substrate. In some examples, the first portion 10a and / or the first layer 110 are configured to have a helical shape extending along the length of the substrate 10. In some examples, the shape of the second portion 10b is configured to determine the spacing between adjacent sections of the first layer 110. For example, second portion 10b may be sandwiched within and / or complementary to the shape of first layer 110 and / or first portion 10a. First layer 110 may have a thickness of approximately 5 microns to 50 microns. Other configurations of first layer 110 are contemplated by the present disclosure. For example, in some embodiments, the shape of first layer 110 and / or first portion 10a may be configured as a mesh or any patterned network with well-defined spacing.

[0025] With further reference to FIG. 2 , the first layer 110 may be configured as a woven fiber tape. For example, the first layer 110 may be configured as a length of SiC or carbon fiber tape wrapped around the length of the substrate 10 to cover the spirally wound first portion 10a. In some examples, the width of the fiber tape may be between about 1 millimeter and about 5 millimeters. In some examples, the second portion 10b may be a spiral portion having a width between about 1 millimeter and about 5 millimeters between the spirally wound first layer 110. In examples where the first layer 110 is configured as a spirally wound woven fiber tape, the spacing between adjacent edges 110a of adjacent turns of the spirally wound first layer 110, as defined by the width of the fiber tape and / or the width of the spirally wound second portion 10b, as shown in FIG. 2 , may be adjusted to provide the desired coverage of the substrate 10 by the first layer 110. Other configurations of woven fiber tapes are contemplated by the present disclosure. For example, in some embodiments, the woven fiber tape may be configured as a tape woven from multiple fiber compositions, such as, for example, SiC fibers and carbon fibers having similar cross sections.

[0026] By applying a spiral configuration of the first layer 110 onto the base layer 10, it is possible to impart burst resistance and / or expansion resistance properties to the SiC composite cladding tube without the associated high manufacturing complexity and cost. Surprisingly, the inventors have discovered that these characteristics can be achieved by coating about 40% to about 70%, about 40% to about 60%, or about 50% of the exterior surface of the base layer 10 with the first layer 110, thereby reducing the amount of expensive materials typically required in SiC composite cladding tubes. Furthermore, the first layer 110 incorporating carbon fiber tapes can provide the burst resistance and / or expansion resistance benefits typically found in SiC-based materials at a relatively low cost.

[0027] Furthermore, in embodiments comprising woven fiber tapes, the thickness and spacing of the first layers 110 may be predetermined, thereby avoiding complex application procedures. Thus, the coating 100 comprising first layers 110 of this configuration may optimize the technical and economic aspects of manufacturing a coating for an ATF tube, without compromising protection against expansion and / or bursting at high temperatures.

[0028] 1 and 2, in various examples, second layer 120 is formed of an interface material and is configured to secure first layer 110 to base layer 10. For example, second layer 120 may be a continuous layer of interface material that covers first layer 110 and the underlying second portion 10b of base layer 10. In certain examples, second layer 120 has a thickness of about 1 micron to about 10 microns.

[0029] The second layer 120 may be configured as a continuous layer, with the second layer 120 seamlessly covering the first layer 110 and the second portion 10b of the underlying substrate 10. In examples where the second layer 120 is configured as a continuous layer on the spirally wound first layer 110, the second layer 120 is directly attached to both the exposed second portion 10b of the underlying substrate 10 and the outer portion of the first layer 110, continuously connecting them along the edge 110a of the first layer 110 that interfaces with the second portion 10b. Thus, the number of transitions from the first layer 110 to the second portion 10b and / or the length of the interface between the first layer 110 and the second portion 10b that is connected to the second layer 120 may be such as to provide a desired fixation strength between the first layer 110 and the substrate 10. Thus, the second layer 120 can secure the first layer 110 without requiring any bonding interaction between the first layer 110 and the underlying first portion 10a.

[0030] In the example of the covering 100 in which the first layer 110 and the second portion 10b on the outer surface of the substrate 10 are configured in an alternating spiral shape, a desired anchoring strength of the first layer 110 to the substrate 10 having a predetermined axial length can be achieved by adjusting the spacing between turns of the first layer 110, as determined by the width of the first layer 110 and / or the width of the second portion 10b. Furthermore, by maintaining the width ratio between the first layer 110 and the second portion 10b, the anchoring strength of the first layer 110 to the substrate 10 can be adjusted without substantially changing the coverage rate of the first layer 110, thereby ensuring reliable coverage of the substrate 10 and reliable positioning of the first layer 110. Thus, the covering 100 can provide the advantage of predictable resistance to expansion and / or bursting.

[0031] In some examples, the interface material has a melting point above the BDBA temperature, above 1200° C., above 1400° C., above 1600° C., or above 2000° C. Therefore, functionality of the second layer 120 that depends on its physical state at lower temperatures is maintained even under accident conditions or other high temperature operating conditions. In particular examples, the interface material may be composed of molybdenum, niobium, tantalum, or tungsten.

[0032] Referring now to FIG. 1 , the third layer 130 is configured to provide enhanced protection to the ATF under BDBA, high temperatures, and / or normal operating conditions. For example, the third layer 130 may be comprised of a metallic Cr-based material and may have a thickness of about 2 to about 50 microns. In various examples, the Cr-based material of the third layer 130 is a coating comprised of a chromium or Cr-based alloy. In some examples, the third layer 130 may be comprised of a chromium alloy containing yttrium, molybdenum, iron, aluminum, or a combination thereof. These alloying elements can produce a chromium alloy with a higher tensile strength than chromium alone. Thus, the composition of the third layer 130 is configured to provide a coating with a higher tensile strength than a coating comprised solely of chromium. In certain examples, the third layer 130 is comprised of a chromium alloy containing yttrium or molybdenum, or a chromium alloy containing iron and / or aluminum.

[0033] While the third layer 130 may be comprised of a Cr-based material, the cladding 100 may be configured to avoid the formation of a low-melting eutectic layer or the undesirable properties of such a layer. For example, if the second layer 120 is formed as a continuous layer of molybdenum, niobium, tantalum, or tungsten on the Zr-based substrate 10, the Cr component of the third layer 130 is inhibited from migrating into the second portion 10b of the Zr-based substrate 10 under high temperature conditions, such as BDBA temperatures. In this manner, the cladding 100 is configured to prevent the formation of a low-melting eutectic Cr-Zr layer and / or intermetallic Zr-Cr compounds under BDBA or high temperature conditions, thereby providing the corrosion resistance benefits of Cr-based coatings without the inherent limitations of cladding tubes with Cr-Zr interfaces.

[0034] In examples where the cladding 100 includes the optional fourth layer 140, the fourth layer is configured as an outer layer composed of a Cr-based material to further enhance the cladding's accident resistance. For example, the optional fourth layer 140 may be configured as a Cr-based alloy or a Cr-based ceramic material. In some examples, the fourth layer 140 includes a Cr alloy containing yttrium or molybdenum, or a Cr alloy containing iron and / or aluminum. In other examples, the fourth layer 140 is configured as a Cr-based ceramic material containing nitrogen and / or niobium. These alloys and ceramics are known to withstand coolants containing, for example, up to about 10 ppm O. Thus, the cladding 100 including the fourth layer 140 can provide protection in BWR applications.

[0035] As described herein, the present disclosure provides a reinforced cladding tube for nuclear fuel. In various examples, the reinforced cladding tube includes a tube constructed of a Zr alloy and a cladding disposed on an outer surface of the tube. The outer surface of the tube includes a first portion and a second portion. In some examples, the first portion of the outer surface of the tube is configured as a spiral having a plurality of turns. In configurations in which the first portion of the outer surface of the tube is a spiral, each of the plurality of turns of the first portion can be axially separated by a second portion of the outer surface of the tube.

[0036] The coating of the reinforced cladding tube is similar in many respects to other coatings disclosed elsewhere in this disclosure, and for the sake of brevity, these other coatings will not be described again in detail here. Thus, the coating of the reinforced cladding tube may include a first layer configured to surround a first portion of the exterior surface of the tube, a second layer surrounding the first layer and a second portion of the exterior surface of the tube, a third layer surrounding the second layer, and, optionally, a fourth layer surrounding the third layer. In various examples, the first layer is comprised of a fiber-based material, the second layer is comprised of a material having a melting point above the BDBA temperature, and the third layer is comprised of a Cr-based material.

[0037] Each layer of the cladding may be configured similarly to layers 110, 120, 130, and 140 of the cladding 100 described hereinabove. Thus, the first layer may be configured to provide protection against high-temperature expansion and / or bursting, and the second layer may be configured to secure the first layer to the Zr alloy tube and prevent intermetallic compound formation between the Zr alloy tube and the third Cr-based layer. Thus, the third layer may be configured to provide better corrosion resistance under BDBA conditions without the drawbacks of cladding tubes with Zr-Cr interfaces. Furthermore, in the example of a reinforced cladding tube including an optional fourth layer, the fourth layer may be configured to further enhance the cladding's accident resistance, such as in BWR coolant chemistries. A reinforced cladding tube with this configuration can protect the nuclear fuel contained therein at temperatures up to about 1600°C, about 1700°C, or about 1800°C without the cost disadvantages or risk of excessive corrosion of currently available cladding tubes.

[0038] As discussed herein, the present disclosure provides a method for manufacturing the reinforced cladding tube for nuclear fuel described above. In various examples, the method includes helically wrapping a length of fiber tape around an outer surface of a tubular substrate from a first end of the substrate to a second end of the substrate to form a first layer, depositing an interface material on the first layer to form a second layer, and forming at least one Cr-based layer around the second layer to produce the reinforced fuel cladding tube. After forming the first layer, a portion of the helically wrapped outer surface of the substrate remains exposed, and the interface material of the second layer is deposited both on the fiber tape and on the exposed portion of the substrate.

[0039] The fiber tape is similar in many respects to other fiber tapes disclosed elsewhere in this disclosure, and for the sake of brevity, these other fiber tapes will not be described again in detail herein. Accordingly, the fiber tape may be configured to include SiC fibers and / or carbon fibers. In some examples, the method includes retaining lengths of fiber tape at the first and second ends of the fuel cladding tube prior to forming the second layer. In some examples, the fiber tape is wrapped around the length of the tubular substrate layer to cover between about 40% and about 70% of the outer surface of the substrate. In some examples, the fiber tape is wrapped around the length of the tubular substrate layer to cover about 50% of the outer surface of the substrate.

[0040] In some examples, the formation of the second layer may include either a physical vapor deposition (PVD) process or a thermal spray process. These processes can protect the underlying fiber tape. For example, when the interface material is a metal such as molybdenum, niobium, tantalum, or tungsten, PVD and thermal spray processes form the layer of interface material without deformation of hard particles of the interface material and / or collision of the hard particles with the surface, and therefore do not impart significant stress to the surface of the underlying layer. Therefore, the formation of the second layer can avoid abrasion of the underlying fiber tape. Therefore, the methods described herein can provide a reinforced cladding tube with predictable resistance to bursting and / or expansion.

[0041] In some examples of the method, each of the at least one Cr-based layer may be formed separately by a physical vapor deposition process, a thermal spray process, or a cold spray process. In some examples, the method may include forming a third layer around the second layer and forming an outer layer around the third layer. The third layer may be comprised of a chromium-based alloy or a Cr-based alloy, and the outer layer may be comprised of a Cr-based alloy or a Cr-based ceramic material.

[0042] Various aspects of the present disclosure include, but are not limited to, the aspects listed in the following numbered paragraphs:

[0043] Item 1 - A coating for reinforcing a substrate of a nuclear fuel cladding tube. The coating comprises a first layer including a fiber-based material, a second layer including an interface material, and a third layer including chromium. The first layer is configured to cover a first portion of an outer surface of the substrate without covering a second portion of the outer surface of the substrate of the nuclear fuel cladding tube. The second layer surrounds the first layer and the substrate of the nuclear fuel cladding tube. The third layer surrounds the second layer. The second layer is configured to secure the first layer to the substrate of the nuclear fuel cladding tube. The interface material of the second layer is configured to inhibit chemical interaction between the substrate and the third layer.

[0044] Item 2 - The coating of item 1, wherein the first layer comprises at least one of silicon carbide fibers and carbon fibers.

[0045] Item 3 - The cladding according to any one of Items 1 and 2, wherein the first layer covers about 40% to about 70% of the area of ​​the outer surface of the base layer of the nuclear fuel cladding tube.

[0046] Item 4 - The cladding of any one of Items 1 to 3, wherein the first portion of the substrate of the nuclear fuel cladding tube is a spiral portion of the outer surface of the substrate.

[0047] Item 5 - The covering of any one of items 1 to 4, wherein the first layer is configured as a fiber tape.

[0048] Item 6 - The covering of item 5, wherein the fiber tape has a width ranging from about 1 millimeter to about 5 millimeters.

[0049] Item 7 - The coating of any one of items 1-6, wherein the interface material has a melting point greater than the off-design-basis event temperature.

[0050] Item 8 - The coating of item 7, wherein the second layer comprises molybdenum, niobium, tantalum, or tungsten.

[0051] Item 9 - The coating of any one of items 1 to 8, wherein the third layer comprises a chromium-based alloy.

[0052] Item 10—The coating of item 9, wherein the chromium-based alloy includes yttrium or molybdenum.

[0053] Item 11 - The coating of paragraph 9, wherein the chromium-based alloy comprises iron, aluminum, or a combination thereof.

[0054] Item 12 - The coating of any one of items 1 to 8, wherein the third layer comprises a chromium-based ceramic material containing nitrogen, niobium, or a combination thereof.

[0055] Item 13 - The coating according to any one of items 1 to 12, wherein the coating comprises a fourth layer configured to surround the third layer, and the fourth layer is configured from a chromium-based alloy or a chromium-based ceramic material.

[0056] Item 14 - Reinforced cladding tube for nuclear fuel. The reinforced cladding tube comprises a tube and a cladding for the tube. The tube is composed of a zirconium alloy, and the outer surface of the tube comprises a first portion and a second portion. The cladding for the tube comprises a first layer including a fiber-based material, a second layer including a material having a melting point higher than the design basis event temperature, and a third layer including chromium. The first layer covers the first portion of the outer surface of the tube, and the second portion of the outer surface of the tube is the surface remaining uncovered by the first layer. The second layer surrounds the first layer and the second portion of the outer surface of the tube. The third layer surrounds the second layer.

[0057] Item 15 - The reinforced cladding tube according to item 14, wherein the first layer comprises at least one of silicon carbide fibers and carbon fibers.

[0058] Item 16 - The reinforced cladding tube according to any one of Items 14 to 15, wherein the first layer covers about 40% to about 70% of the outer surface of the tube.

[0059] Item 17 - The reinforced cladding tube according to any one of Items 14 to 16, wherein the first layer is configured as a spiral having a plurality of turns.

[0060] Item 18 - The reinforced cladding tube according to item 17, wherein each of the plurality of turns is axially separated by a second portion of the outer surface of the tube.

[0061] Item 19 - A method of manufacturing a reinforced nuclear fuel cladding tube. The method includes helically wrapping a length of fiber tape around an outer surface of a tubular substrate from a first end of the substrate to a second end of the substrate to form a first layer, with a portion of the helically wrapped outer surface of the substrate being exposed. The method further includes depositing an interface material on the fiber tape and on the exposed portion of the outer surface of the substrate to form a second layer, and forming at least one chromium-based layer around the second layer to produce the reinforced nuclear fuel cladding tube.

[0062] Item 20 - The method of item 19, wherein the second layer is formed by a physical vapor deposition process or a thermal spray process.

[0063] Item 21 - The method of any one of items 19-20, wherein each of the at least one chromium-based layer is separately formed by a physical vapor deposition process, a thermal spray process, or a cold spray process.

[0064] Item 22 - The method of any one of items 19 to 22, wherein forming at least one chromium-based layer includes forming a third layer around the second layer and forming an outer layer around the third layer, wherein the third layer includes chromium or a chromium-based alloy, and the outer layer includes a chromium-based alloy or a chromium-based ceramic.

[0065] Various features and characteristics are described herein to provide an understanding of the composition, structure, manufacture, function, and / or operation of the present disclosure, including the disclosed methods and systems. It will be understood that various of these features and characteristics of the present disclosure described herein may be combined in any suitable manner, whether or not such combinations of features and characteristics are explicitly described herein. The inventors and applicants expressly intend that such combinations of features and characteristics be included within the scope of the disclosure described herein. Accordingly, the claims may be amended to recite any combination of features and characteristics explicitly or inherently described or explicitly or inherently supported herein. Furthermore, applicants reserve the right to amend the claims to affirmatively disclaim any features or characteristics that may exist in the prior art, even if those features or characteristics are not explicitly described herein. Accordingly, any such amendments will not add new matter to the specification or claims, but will comply with the requirements of the specification, specification sufficiency, and additional matter.

[0066] With respect to the appended claims, those skilled in the art will understand that the operations described therein may generally be performed in any order. Additionally, while various operational flows are depicted in a sequential order, it should be understood that various of these operations may be performed in orders other than those depicted, or may be performed simultaneously. Examples of such alternative orders include overlapping, interleaved, interrupted, reordered, incremental, preparatory, supplemental, concurrent, reversed, or other variations, unless the context dictates otherwise. Furthermore, terms such as "in response to," "related to," and other past tense adjectives are generally not intended to exclude such variations, unless the context dictates otherwise.

[0067] The inventions described herein may comprise, consist of, or consist essentially of various features and characteristics described herein. The words "comprise" (and any form of "comprise," such as "comprises" or "comprising"), "have" (and any form of "have," such as "had" or "having"), "include" (and any form of "include," such as "included" or "comprising"), and "contain" (and any form of "contain," such as "contained" or "containing") are open-ended linking verbs. Thus, a method or system that "comprises," "has," "includes," or "contains" one or more features and / or characteristics has that one or more features and / or characteristics, but is not limited to having only that one or more features and / or characteristics. Similarly, an element of a composition, coating, or process that "comprises," "has," "includes," or "contains" one or more features and / or characteristics has those one or more features and / or characteristics, but is not limited to having only those one or more features and / or characteristics, and may have other features and / or characteristics as well.

[0068] As used herein, including the claims, the grammatical articles "a," "an," and "the" are intended to include "at least one" or "one or more," unless expressly stated otherwise. Accordingly, articles are used herein to refer to one or more than one (i.e., "at least one") of the grammatical object of the article. As an example, "a component" means one or more components, and thus, it is conceivable that one or more components may be employed or used in the practice of the described compositions, coatings, and processes. That being said, it should be understood that the absence of "at least one" or "one or more," when used in some cases, should not be construed as limiting the object of the grammatical articles "a," "an," and "the" to one. Furthermore, the use of a singular noun includes the plural, and the use of a plural noun includes the singular.

[0069] As used herein, unless otherwise noted, all numerical parameters should be understood to be prefaced and modified in all instances by the word "about." Such numerical parameters have the inherent variability characteristic of the underlying measurement techniques used to determine the numerical value of such parameters. At the very least, and not as an attempt to limit the application of the doctrine of equivalents to the scope of the claims, each numerical parameter set forth herein should at least be construed in light of the number of reported significant digits and by applying ordinary rounding techniques.

[0070] Numerical ranges recited herein include all subranges subsumed within the recited range. For example, a range of "1 to 10" includes all subranges between the recited minimum value of "1" and the recited maximum value of "10," inclusive, i.e., all subranges with a minimum value of 1 or greater and a maximum value of 10 or less. Also, all ranges recited herein include their endpoints. For example, a range of "1 to 10" includes the endpoints 1 and 10. Each maximum numerical limitation recited herein is intended to include all subranges subsumed therein, and each minimum numerical limitation recited herein is intended to include all subranges subsumed therein. Accordingly, applicants reserve the right to amend this specification, including the claims, to expressly recite any subranges subsumed within any explicitly recited range. All such ranges are inherently set forth herein.

[0071] As used herein, particularly in reference to layers, the terms "on," "upon," "over," and variations thereof (e.g., "coated on," "formed on," "deposited on," "provided on," "located on," etc.) mean coated, formed, deposited, provided, or positioned on the surface of a substrate, but not necessarily in contact with the surface of the substrate. For example, a layer "coated" on a substrate does not exclude the presence of another or other layer, of the same or different composition, between the coated layer and the substrate. Similarly, a second layer "coated" on a first layer does not exclude the presence of another or other layer, of the same or different composition, between the coated second layer and the coated first layer.

[0072] While particular examples of the present disclosure have been described above for purposes of illustration, it will be apparent to those skilled in the art that many changes may be made in the details of the present disclosure without departing from the disclosure as defined in the appended claims.

Claims

1. A cladding for reinforcing a base layer of a nuclear fuel cladding tube, comprising: The coating is a first layer including a fiber-based material and configured to cover a first portion of an outer surface of the substrate layer of the nuclear fuel cladding tube, wherein a second portion of the outer surface of the substrate layer is not covered by the first layer; a second layer surrounding the first layer and the base layer of the nuclear fuel cladding tube, the second layer including an interface material, the second layer configured to secure the first layer to the base layer of the nuclear fuel cladding tube; a third layer surrounding the second layer and including chromium; The interface material of the second layer is configured to inhibit chemical interaction between the base layer and the third layer.

2. The coating of claim 1 , wherein the first layer comprises at least one of silicon carbide fibers and carbon fibers.

3. The cladding of claim 1 , wherein the first layer covers between about 40% and about 70% of the area of ​​the exterior surface of the substrate of the nuclear fuel cladding tube.

4. 10. The cladding of claim 1, wherein the first portion of the substrate of the nuclear fuel cladding tube is a spiral portion of the outer surface of the substrate.

5. The covering of claim 1 , wherein the first layer is configured as a fibrous tape.

6. The covering of claim 5, wherein the fiber tape has a width ranging from about 1 millimeter to about 5 millimeters.

7. The coating of claim 1 , wherein the interface material has a melting point greater than a design basis event temperature.

8. The coating of claim 7 , wherein the second layer comprises molybdenum, niobium, tantalum, or tungsten.

9. The coating of claim 1 , wherein the third layer comprises a chromium-based alloy.

10. 10. The coating of claim 9, wherein the chromium-based alloy comprises yttrium or molybdenum.

11. The coating of claim 9 , wherein the chromium-based alloy comprises iron, aluminum, or a combination thereof.

12. The coating of claim 1 , wherein the third layer comprises a chromium-based ceramic material containing nitrogen, niobium, or a combination thereof.

13. the coating comprises a fourth layer configured to surround the third layer; The coating of claim 1 , wherein the fourth layer is comprised of a chromium-based alloy or a chromium-based ceramic material.

14. A reinforced cladding tube for nuclear fuel, comprising: The reinforced cladding tube is a tube constructed from a zirconium alloy, the tube having an exterior surface comprising a first portion and a second portion; a coating for the tube; The coating is a first layer including a fiber-based material covering the first portion of the exterior surface of the tube, the second portion of the exterior surface of the tube not being covered by the first layer; a second layer surrounding the first layer and the second portion of the outer surface of the tube, the second layer comprising a material having a melting point greater than a design basis event temperature; a third layer surrounding the second layer and comprising chromium.

15. The reinforced cladding of claim 14 , wherein the first layer comprises at least one of silicon carbide fibers and carbon fibers.

16. The reinforced cladding tube of claim 14, wherein the first layer covers between about 40% and about 70% of the exterior surface of the tube.

17. The reinforced cladding of claim 14 , wherein the first layer is configured as a spiral having a plurality of turns.

18. 18. The reinforced cladding tube of claim 17, wherein each of the plurality of turns is axially separated by the second portion of the outer surface of the tube.

19. 1. A method for manufacturing a nuclear fuel reinforced cladding tube, comprising: spirally wrapping a length of fiber tape around an outer surface of a tubular substrate from a first end of the substrate to a second end of the substrate to form a first layer, wherein a portion of the spirally wrapped outer surface of the substrate is exposed; depositing an interface material on the fiber tape and on the exposed portion of the outer surface of the base layer to form a second layer; forming at least one chromium-based layer around the second layer to produce the nuclear fuel enhanced cladding tube.

20. The method of claim 17 , wherein the second layer is formed by a physical vapor deposition process or a thermal spray process.

21. 18. The method of claim 17, wherein each of the at least one chromium-based layer is separately formed by a physical vapor deposition process, a thermal spray process, or a cold spray process.

22. forming the at least one chromium-based layer forming a third layer comprising chromium or a chromium-based alloy around the second layer; and forming an outer layer comprising a chromium-based alloy or a chromium-based ceramic around the third layer.

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