Universal inverted reactor and method for design and manufacture of universal inverted reactor

Abstract

The fission reactor has a shell surrounding a reactor space that is a central longitudinal channel, and a plurality of axially extending rings having adjacent rings form an annular cylindrical space in which a plurality of primary axial tubes are located circumferentially. The circumferentially adjacent primary axial tubes are separated by one of a plurality of secondary channels, and a plurality of webbings connect at least a portion of the plurality of primary axial tubes to an adjacent structure. The fissile fuel composition is located in at least a portion of the plurality of secondary channels, and the primary coolant passes through at least a portion of the primary axial tubes. Addition and / or subtraction manufacturing techniques form an integral and single structure for the fuel-loaded reactor space. During manufacturing and construction, the reactor design can be analyzed using a computational platform that integrates and analyzes data from on-site monitoring during manufacturing.

Description

Technology Field

[0001] The present invention claims priority to U.S. Provisional Patent Application No. 62 / 688,255 filed June 21, 2018, pursuant to 35 USC§119(e), the entire contents of which are incorporated herein by reference. Background Technology

[0002] The present invention generally relates to a fission reactor and a structure related to the active reactor space of a fission reactor. In particular, the fission reactor and reactor space of the present invention comprise fissionable fuel loaded in the space between channels for coolant flow, and while the size is expandable, each location containing the fissionable fuel maintains the same cross-sectional area and / or volume regardless of the reactor size. The size of support and auxiliary equipment, such as control rods, control rod drivers, and moderators, is also expandable. The present invention also relates to a method for manufacturing such a reactor and structure by an additive manufacturing technique that forms an integral and single structure, particularly for the fuel-loaded reactor space, and provides predictive quality assurance for the manufacturing of such a reactor and structure.

[0003] In the following discussion, references are made to specific structures and / or methods. However, the following references should not be construed as an acknowledgment that such structures and / or methods constitute prior art. The applicant expressly reserves the right to demonstrate that such structures and / or methods are not recognized as prior art for the present invention.

[0004] Traditional fission reactors use fissile nuclear fuel, such as uranium-based fuel, placed inside fuel elements that may be circular tubes, plates, or hexagonal shapes. These fuel elements are collected and arranged into fuel assemblies, which are the basic elements of the reactor core. A conventional fuel assembly (10) (see FIG. 1) is a composite device of, for example, fuel elements (12) (including fuel (14) and combustible poison), mechanical supports for the fuel assembly structure, spacer grids (16) (to ensure spacing between components), and non-fuel tubes for, for example, control rods (18) or in-core devices (20). Depending on the design, the reactor vessel may have dozens of fuel assemblies (10) (also called fuel bundles), each of which may contain more than 200 fuel elements (12).

[0005] In the core, a primary coolant (e.g., water) flows through and / or around the fuel assembly (10) and provides both a moderator for the fission reaction (in the case of a water-cooled reactor) and a heat extraction medium for the heat generated by the fission reaction in the fuel element. The heated primary coolant circulates within the primary cycle (i.e., means the system in contact with or exposed to the primary coolant), transferring thermal energy to a secondary system, where a thermally excited fluid is formed and flows to a turbine, which can then be used to rotate a generator.

[0006] The complexity of the structure extends to other systems within the reactor that include various components of the primary cycle, depending on the design, piping, pumps, equipment, heat exchangers, and steam generators. Accordingly, the composition of fuel elements, fuel assemblies, the reactor core, and the reactor system is all subject to strict design and manufacturing standards, as well as extensive pre-manufacturing, in-manufacturing, and post-manufacturing controls related to sourcing, handling, installation, inspection, and testing.

[0007] Therefore, it is advantageous to have such complex structures, particularly fuel elements and fuel assemblies, and improves the design, manufacturing, and quality assurance of such complex structures. means of solving the problem

[0008] Generally, the present invention relates to a fission reactor in which fissionable fuel is positioned in a location in the reactor core between and around non-fuel tubes for a primary coolant, a moderator, control rods, scram rods, and / or auxiliary equipment. This arrangement of fissionable fuel and non-fuel tubes is opposite (or reverse) to the conventional arrangement of fissionable fuel located in tubes and primary coolant flowing between and around the fuel tubes.

[0009] The embodiments described herein include a fission reactor having a shell comprising a reactor space having a longitudinal axis and an axial cylinder comprising an inner diameter surface defining a central longitudinal channel having an axis located at the same position as the longitudinal axis of the reactor space. A plurality of axial extension rings are located within the reactor space and are positioned concentrically with respect to the axial cylinder. The plurality of axial extension rings are radially separated to form both a radially inner adjacent ring and a radially outer adjacent ring for any two adjacent axial extension rings. The outer diameter surface of the radially inner adjacent ring and the inner diameter surface of the radially outer adjacent ring form an annular cylindrical space. The fission reactor includes a first plurality of primary axial tubes located circumferentially within each annular cylindrical space. Each primary axial tube includes an inner diameter surface and an outer diameter surface forming a primary channel. A plurality of webbings connect at least some, alternatively all, of a plurality of primary axial tubes to an adjacent structure, for example, the outer diameter surface of each of the plurality of primary axial tubes is connected to a ring adjacent to the radially inner side by a first webbing and to a ring adjacent to the radially outer side by a second webbing. A fission reactor comprises a plurality of secondary channels within each annular cylindrical space, wherein circumferentially adjacent primary axial tubes are separated by one of the plurality of secondary channels. A fissile fuel composition is located in at least some of the plurality of secondary channels.

[0010] The embodiments described herein also include a method for manufacturing a fission reactor. An embodiment of the method prepares a model of the fission reactor by applying prediction and causal analysis, manufactures the fission reactor layer by layer using additive manufacturing technology, on-site monitors the manufacturing of the fission reactor with machine vision during manufacturing, analyzes data from the on-site monitoring, and adjusts the manufacturing of the fission reactor based on real-time analysis data. In some cases, manufacturing equipment, particularly additive manufacturing equipment, has a limited manufacturing volume that affects the maximum size of a single monolithically manufactured part (although positioning technology may accommodate an increase in the size of such monolithically manufactured parts). Accordingly, for example, for a fission reactor (or other structure), the manufacturing method described herein may be applied to manufacture the structure on a monolithic basis or on a segmented basis for subsequent assembly.

[0011] An embodiment of the method can also prepare a digital version of a manufactured fission reactor and correlate the characteristics of the manufactured fission reactor based on an analysis of the digital version of the manufactured fission reactor.

[0012] Furthermore, the embodiments described herein may be used to recognize the design of a fission reactor as well as its individual components, and to verify acceptable manufacturing. For example, the method for manufacturing a fission reactor described herein may also be used to determine and verify the performance and integrity of a structure in its constructed state. Accordingly, this method may be utilized by third parties, such as government regulatory agencies, government agencies and departments, and commercial entities like power companies, as a new means of verifying the reactor or providing information on approval criteria. Effects of the invention

[0013] Although the described reactor and core have complex mechanical geometry, the inverted reactor can be manufactured more easily through the integration and iterative fabrication of elemental metals, metal alloys, or ceramics (e.g., using these materials in the form of particles, wires, or powders), such as 3D printing. Other advantages include an improved power-to-weight ratio, reduced internal stress, and scalability by adding additional dimensional units, for example, in the form of rings or ring spacing. Brief explanation of the drawing

[0014] The following detailed description of the foregoing summary and embodiments can be better understood with reference to the attached drawings. It should be understood that the illustrated embodiments are not limited to the exact arrangement and means depicted. FIG. 1 illustrates a conventional fuel assembly having a fuel element comprising a rod of fissile fuel and a non-fuel tube, through which a primary coolant passes and / or around. FIG. 2a shows an axial cross-sectional perspective view of an exemplary fission reactor, and FIG. 2b shows an enlarged perspective, radial cross-sectional view of an exemplary shell containing a reactor space. Figure 3a shows a radial cross-sectional perspective view of a part of a nuclear fission reactor, and Figure 3b shows an enlarged radial cross-sectional perspective view of the part of Figure 3a. FIG. 4 shows a radial cross-sectional and axial cutaway perspective view of a part of a nuclear fission reactor and an exemplary fuel element. FIG. 5a is a schematic perspective view showing support and auxiliary equipment located in multiple primary channels. Figures 5b and 5c illustrate examples of rod-shaped neutron moderating materials. FIG. 5d is a schematic perspective view showing the control rod system and its location in a partial cutaway view of a nuclear fission reactor. FIG. 6 shows a cross-sectional perspective view illustrating the exemplary number and distribution of control rods and moderators in an exemplary embodiment of a nuclear fission reactor. FIG. 7 is a schematic diagram illustrating a portion of a radial cross-section of an exemplary embodiment of a fission reactor that includes a space or gap to reduce stress arising from the nuclear transmutation of elements due to the fission of fissile nuclear fuel. FIG. 8 illustrates the 6-fold rotational symmetry of an exemplary embodiment of a disclosed fission reactor. FIG. 9 summarizes an embodiment of an additive manufacturing method for manufacturing an integral and single structure for a fission reactor and a fuel-loading reactor space disclosed in this specification. Figures 10a and 10b show screenshots related to an embodiment of a universal inverted reactor computational platform ("UIRCP") used to investigate an embodiment of a nuclear fission reactor. Figures 11a and 11b show details of the geometric structure and dimensions for the geometrically related variables used in Example 2. Figure 12 shows an example of a solid CAD model formed from the universal inverted reactor computational platform process of Example 2. Figure 13 is an example of a temperature contour map formed from the universal inverted reactor computational platform process of Example 2. Figures 14a-c show profiles of temperature and neutron characteristics associated with exemplary embodiments of a nuclear fission reactor. Specific details for implementing the invention

[0015] FIG. 2a illustrates an axial cross-sectional perspective view of an exemplary fission reactor. The fission reactor (100) comprises a shell (102) containing a fissionable fuel composition (an example thereof is illustrated as a fissionable fuel composition (104) in FIG. 2b), control rods and auxiliary equipment (106) movably penetrating the shell (102) and the reactor space (108), a reflector (110) around the outer diameter surface of the shell (102), a tube (112) for primary coolant flow toward or from the shell (102), and a containment housing (114). FIG. 2b illustrates an axial cutaway perspective view as a radial section enlarged with some features of FIG. 2a. For the sake of example and clarity, other features of the fission reactor and fission power plant, such as other features of the primary system and secondary system, are not illustrated in FIG. 2a-b, but are known to those skilled in the art.

[0016] FIG. 3a illustrates a radial cross-sectional perspective view of a portion of a fission reactor (100). The illustrated shell (102) has a longitudinal axis (120) extending from a first end to a second end of the reactor space (108). The shell (102) includes the reactor space (108) having internal features similar to a honeycomb structure in both the radial and axial directions in this embodiment. For example, within the shell (102) there is an axial cylinder (130) having an inner diameter surface (132) defining a central longitudinal channel having an axis (134) positioned together with the longitudinal axis (120) of the reactor space (108).

[0017] Additionally, a plurality of axial extension rings (140) are arranged concentrically with respect to an axial cylinder (130) within the reactor space (108). Referring to FIG. 3b, which shows a radial cross-sectional perspective view that is an enlarged portion of FIG. 3a, at least some of the plurality of axial extension rings (140) are separated radially, and when considering any two axial extension rings (140), they form a radially inner adjacent ring (140a) and a radially outer adjacent ring (140b). The outer diameter surface (142) of the radially inner adjacent ring (140a) and the inner diameter surface (144) of the radially outer adjacent ring (140b) form a cylindrical space (150).

[0018] There are a plurality of primary axial tubes (160) positioned circumferentially within an annular cylindrical space (150). Each primary axial tube (160) includes an inner diameter surface (162) and an outer diameter surface (166) that form a primary channel (164) (used primarily for flow). A plurality of webbings (170) connect the outer diameter surface (166) of each of the plurality of primary axial tubes (160) to a radially inner adjacent ring (140a) in a first example and a radially outer adjacent ring (140b) in a second example. In some embodiments, the axial tube (160) is connected to at least one or both of the radially inner adjacent ring (140a) and the radially outer adjacent ring (140b) by the webbings (170); In another embodiment, only a portion of the axial tube (160) is connected to at least one or both of the radially inner adjacent ring (140a) and the radially outer adjacent ring (140b) by the webbing (170). The number of uses, locations of use, and frequency of use of the webbing (170) may vary based on the dimensional completeness provided to the overall design by connecting using the webbing (170).

[0019] The inner diameter surface of the primary axial tube (i.e., primary flow channel) may be uniform or vary as a function of axial position. For example, in some embodiments, the inner diameter surface of the primary axial tube forming the primary channel may vary as a function of the axial position relative to the longitudinal axis of the primary axial tube to affect, for example, the flow characteristics of the primary coolant. Also, for example, in other embodiments, the primary channel is formed with chambers to form different regions or zones along its axial length. These zones may be used to accommodate instruments and / or other equipment or materials to monitor or influence reactor performance.

[0020] In some embodiments, one or more of the central longitudinal channel and primary channel (164) of the axial cylinder (130) are accessible from the outer surface of the fission reactor. Where accessible, the central longitudinal channel and / or primary channel(s) can be used to produce irradiated samples such as irradiated medical equipment, medical isotopes, scientific isotopes, etc.

[0021] Additionally, a plurality of secondary channels (180) are located within the reactor space (108). Referring to FIG. 3b, the plurality of secondary channels (180) are located within an annular cylindrical space (150) and separate the circumferentially adjacent primary axial tubes (160a, 160b). For example, the inner surface of the secondary channel (180) includes a portion of the outer diameter surface (166) of the circumferentially adjacent primary axial tubes (160a, 160b), the surface of the first webbing (170) and the second webbing (170) associated with each of the circumferentially adjacent primary axial tubes (160a, 160b), a portion of the outer diameter surface (142) of the radially inner adjacent ring (140a), and a portion of the inner diameter surface (144) of the radially outer adjacent ring (140b). Generally, primary axial tubes (160a, 160b) adjacent in the circumferential direction are distributed non-contactually within the cylindrical space (150) to form a secondary channel (180).

[0022] Additionally, a fissile fuel composition (190) is located within the reactor space (108). For example, as schematically illustrated in FIG. 4, the fissile fuel composition (190) may be located in at least some of the plurality of secondary channels (180). The fissile fuel composition (190) comes into contact with at least some, if not all, of the inner surface of the secondary channels (180) to transfer heat. During operation, the primary coolant may flow through the primary channels (164) of each of the circumferentially adjacent primary axial tubes (160) separated by one of the plurality of secondary channels (180) containing the fissile fuel composition (190) to perform heat transfer. In the illustrated embodiment, the cross-section of the secondary channel perpendicular to the longitudinal axis has the cross-sectional shape of a sheet of hyperboloid, but other cross-sectional shapes may be used. Suitable fissile fuel compositions include uranium oxide enriched to less than 20%, uranium containing 10 wt% molybdenum (U-10Mo), uranium nitride (UN), and other stable fissile fuel compounds including metallic fissile fuel and ceramic fissile fuel.

[0023] As is known in the industry, during the fission reaction of fissile nuclear fuel, the decomposition of uranium produces many replacement elements in different phases (gas, liquid, or solid). Due to the design of a secondary channel (180) containing the fissile nuclear fuel composition (190) disclosed herein, the increase in internal pressure of the secondary channel (180) caused by the nuclear transmutation of these elements compresses the secondary channel (180), i.e., the fuel chamber, and improves resistance to failure. This phenomenon also occurs when thermal expansion occurs. In contrast, in the case of traditional nuclear reactor fuel containing uranium in a tube typically made of zirconium, the internal pressure of the tube rises due to the nuclear transmutation of the elements, causing hoop stress (a type of tensile hoop stress) in the tube, which may lead to structural failure such as cracking. Furthermore, materials subjected to tensile stress are more susceptible to various types of corrosion mechanisms, such as stress corrosion cracking, compared to materials subjected to compressive stress. In addition, hydride-forming metals (e.g., zirconium) are prone to hydrogen embrittlement, brittleness, and fracture, which worsens when the relevant parts are subjected to tensile stress compared to compressive stress.

[0024] It should be noted that in the illustrated embodiment of FIG. 3a, the innermost plurality of primary axial tubes are not separated from the axial cylinder (130) by the axial extension ring (140). Accordingly, the reactor (100) comprises a plurality of primary axial tubes (160) positioned circumferentially between the inner diameter surface of the radially innermost axial extension ring (140) and the outer diameter surface of the axial cylinder (130). Similar to what is described in relation to FIG. 3b, the outer diameter surface of each of these plurality of primary axial tubes is connected to the outer diameter surface of the axial cylinder (130) by a first webbing (170) and to the axially innermost axial extension ring (140) by a second webbing (170).

[0025] Additionally, it should be noted that in the exemplary embodiment of FIG. 3a, the plurality of outermost primary axial tubes are not separated from the shell (102) by the axial extension ring (140). Accordingly, the reactor (100) comprises a plurality of primary axial tubes (160) positioned circumferentially between the inner diameter surface of the shell (102) and the outer diameter surface of the radially outermost axial extension ring (140). Similar to what is described in relation to FIG. 3b, the outer diameter surface of each of these plurality of primary axial tubes is connected to the outer diameter surface of the radially outermost axial extension ring (140) by a first webbing and connected to the inner diameter surface of the shell (102) by a second webbing.

[0026] Various support and auxiliary equipment may be located in one or more primary channels (164). For example, at least one of scientific instruments such as a moderator, control rods, temperature sensors, or radial detectors may be located in one or more primary channels. FIG. 5a is a schematic diagram of multiple primary channels (164) in which support and auxiliary equipment in the form of control rods (200), such as iridium control rods, and moderators (210), such as zirconium hydride neutron moderators, are located. The control rods (200) may also include neutron poisons that absorb neutrons and may be used to control the criticality of a nuclear reactor. Additionally, the toxic material may be able to absorb enough neutrons to stop the fission reactor (100) (e.g., when the control rod (200) is fully inserted into the reactor space (108)) or may be positioned axially to maintain the criticality of the fission reactor (100) (e.g., when the control rod (200) is withdrawn from the core (109) by a certain distance to enable a continuous fission chain reaction). In some embodiments, the moderator (210) is cooled by flowing helium (He) and stabilized in a 3-pin design. Any suitable number of control rods (200) and moderators (210) may be used and appropriately distributed throughout the reactor space (108) to obtain one or more of the desired flux profile, power distribution, and operating profile. In an exemplary embodiment, the control rod (200) is threaded, which contributes to saving axial space, maximizes the control rod diameter, and enables direct roller nut contact for reliable SCRAM operation. All or a subset of the control rods (200) may be individually controlled by independent motors to provide individual responsive control and / or be used for power shaping.

[0027] In some embodiments, an insert of a rod-shaped neutron moderator material having one or more axial protrusions may be positioned in the primary channel (164). FIGS. 5A and 5B illustrate an example of such a rod-shaped neutron moderator material in the primary channel (164). The rod (210) includes one or more pins (212) or other protrusion(s) that contribute to maintaining a consistent gap (214) between the inner diameter surface of the primary channel (164) and the outer surface (or at least most of the outer surface) of the moderator rod (210). The pins / protrusions (212) may extend axially along the length of the rod (210). This design is particularly relevant to gas-cooled reactors where the gap (214) allows sufficient flow of gas to generate thrust for, for example, a space reactor, or to drive a closed-loop power generation system and cool the moderator material. The moderator also plays a role in degrading neutrons to form a more neurologically efficient core.

[0028] Individual moderator rods can advantageously be inserted at any number of desired locations within the core, can be replaced or maintained independently as needed, and allow for larger diameter coolant holes during core manufacturing.

[0029] The moderator rod (210) may also take the form of a ring to allow for additional cooling or to accommodate the insertion of a control rod (200) or other material, as shown in an alternative embodiment of the moderator rod (210) illustrated in FIG. 5c. To restrict or prevent the movement of hydrogen, which is an important component of neutron moderation from the metal, a cladding material may be used on the hydride. The cladding material may also be used as a barrier between the moderator material and the coolant gas.

[0030] As discussed in FIG. 2a, the fission reactor (100) includes control rods that movably penetrate the shell (102) and the reactor space (108). The position and operation of the control rods, such as the control rods (200), are controlled by a control rod system (220) (see FIG. 5d). An embodiment of the control rod system (220) includes the following three main components: a control rod drive motor (230) used to move the control rods (200) in and out of the reactor space (108); a threaded drive shaft (240) connected to the control rods (200) to drive the control rods (200) in and out of the reactor space (108); and a control rod (200), which is a cylindrical neutron-absorbing poison that moves in and out of the primary channel (164). Driving the control rod (200) into and out of the reactor space (108) is generally performed by rotating a threaded nut located inside the control rod drive motor and coupled to a threaded drive shaft so that the rotation of the internal threaded nut causes translational movement, i.e., longitudinal movement, of the control rod (200).

[0031] In some applications, such as space reactors, the size and weight of the fission reactor and its components are limited by the weight / cost penalty incurred when such systems are launched into space. Therefore, other embodiments of control rod systems seek to simplify the design because maintenance or replacement of reactor components cannot be performed once the system has been launched or put into operation. Thus, it is beneficial to reduce the size, weight, and complexity of components in a control rod system. Although size and weight are not strictly limited, ground-based reactors can benefit from similar design improvements due to reduced maintenance and component replacement. To address these design challenges, embodiments of the control rod system may combine a threaded drive shaft with a control rod dock by manufacturing the threaded drive shaft itself from a neutron-absorbing material. By manufacturing the threaded drive shaft using a neutron-absorbing material, a separate control rod dock can be reduced or eliminated in a fission reactor.

[0032] The control rod (200) of FIG. 5a illustrates an exemplary embodiment of such a threaded control rod that is manufactured from a neutron-absorbing material or incorporated into its structure. Suitable materials that can be used to manufacture the control rod (or incorporated into its structure) include iridium, hafnium, stainless steel, tungsten, boron carbide (Al2O3-B4C) in an aluminum oxide matrix, molybdenum, and tantalum. While one or more of various high-temperature metallic neutron-absorbing materials may be used, iridium is currently considered to be used as a neutron-absorbing material.

[0033] FIG. 6 illustrates, in a cross-sectional perspective view, an exemplary number and distribution of control rods (200) and moderators (210) in an exemplary embodiment of a nuclear fission reactor.

[0034] As discussed above, the nuclear transmutation of elements increases the internal pressure associated with the space occupied by the fissile fuel. To reduce this internal pressure, embodiments of the fissile reactor may be designed with flexibility in the components of the fissile reactor to reduce the stress generated. For example, instead of a continuous volume of fuel, the disclosed embodiments of the fissile reactor may include spaces, gaps, holes, or other openings between sections of the fissile fuel composition within the secondary channel (180) or within the fissile fuel composition (190) itself. An example of such a space or gap is illustrated in FIG. 7, where one or more gaps (250) are incorporated into the fissile fuel composition (190). Exemplary locations for the gap(s) (250) include between the fissile fuel composition (190) and the webbing (170) (see region (252)) and the body of the fissile fuel composition (190) (see region (254)). Stress modeling in a design including the gap showed lower stress in the active reactor space (108) in the gap-containing region compared to the gap-free region. Additionally, the overall hoop stress of the shell (102) was reduced. Furthermore, the fissile fuel composition (190) exhibits a better interface with the surfaces and structures forming the secondary channel (180), thereby providing better heat transfer performance. For example, incorporating a gap (250) into the design has been shown to improve contact with the outer diameter surface (166) of each of the multiple primary axial tubes (160) (compared to a design without such a gap (250)), which contributes to improved heat transfer between the fissile nuclear fuel composition (190) and the primary coolant flowing through the primary channel (164) formed by the inner diameter surface (162) of the primary axial tube (160).

[0035] In some embodiments, the fission reactor (100) is the core of a gas-cooled nuclear reactor, where heat transfer occurs through gas flowing through holes in the reactor space (108), such as primary channels (164) of a size that enables efficient heat transfer from the solid reactor core, as illustrated in FIGS. 3a-b, FIGS. 4, and FIGS. 5a. In embodiments of the gas-cooled nuclear reactor, the primary coolant removes heat from the reactor core, which in turn heats the gas. The heated gas can be used for thrust, as in a nuclear thermal rocket, or to drive a closed-loop power system. To generate heat from the fissionable fuel delivered to the primary coolant, the nuclear reactor relies on a neutron moderator to degrade or slow down the neutrons released during the fission process. The slowdown of neutrons is necessary to sustain the nuclear chain reaction in the core and thus generate heat. Water-cooled reactors rely on water to cool and slow down the neutron population, whereas gas-cooled reactors require additional materials for slowdown. Using additional moderating materials to degrade neutrons allows degraded neutrons to separate fission atoms more efficiently, thereby reducing the amount of fuel and consequently the weight of the fission reactor.

[0036] In some embodiments, features of a fission reactor comprising at least a shell, an axial cylinder, a plurality of axial extension rings, a plurality of primary axial tubes, and a plurality of webbings are integral single structures. That is, these features of the fission reactor are formed integrally, for example, by an additive manufacturing process. Examples of suitable additive manufacturing processes form the structural features noted by using 3D printing of metal alloys such as molybdenum-containing metal alloys, Zircalloy-4, or Hastelloy X. In other embodiments, the fissionable fuel composition may be contained within an integral single structure when a suitable multimaterial additive manufacturing process using multiple metals in the feedstock is utilized. Other alloys for which a suitable multimaterial additive manufacturing process using multiple metals in the feedstock may be utilized are as follows: steel alloys, zirconium alloys, and molybdenum-tungsten alloys (for shells); beryllium alloys (for mirrors); and stainless steel (for containment housings). Powder feedstocks may also be used.

[0037] The reactor shown and described in this specification has six rotational symmetry with respect to the longitudinal axis of the reactor space. For example, referring to FIG. 8, it can be seen that similar features within the reactor space (108) are arranged with six rotational symmetry with respect to the longitudinal axis (120) of the reactor space. An example of such six rotational symmetry is shown in FIG. 8 superimposed on a radial cross-sectional view of an exemplary embodiment of a fission reactor. For example, a first six rotational symmetry (300) is shown between the control rods (200), a second six rotational symmetry (310) is shown between the moderators (210), and a third six rotational symmetry (320) is shown between a plurality of primary axial tubes (160) in the cylindrical space (150) corresponding to such features.

[0038] It should be noted that the reactor space (108) (by expansion, the reactor (100)) can be expanded by adding or reducing one or more axial extension rings (140) and primary axial tubes (160) as long as the basic six-fold rotational symmetry with respect to the longitudinal axis of the reactor space is maintained. For example, the radial configuration should be geometrically six times, for example, 1, 6, 12, 18, 24, 30, 36 rods, etc. This allows each secondary channel containing fissile fuel to have the same volume regardless of its position in the reactor space (108) and promotes uniform and optimal heat transfer between the fissile fuel, the material of the reactor space, and the primary coolant. Accordingly, for example, a fissile fuel composition located in at least some of the plurality of secondary channels forms a set of fissile fuel elements that are volumetrically identical throughout the fissile reactor. Additionally, for example, the ratio of the radial cross-sectional area of ​​the secondary channel to the radial cross-sectional area of ​​the primary channel is constant throughout the fissile reactor (considered between one or more primary channels and one or more secondary channels).

[0039] Additive manufacturing technologies, such as 3D printing technology using multiple feedstocks, can be used to form monolithic and single structures for the fission reactors and fuel-loading reactor spaces described herein. For example, additive manufacturing technologies can form complex geometric structures, and when combined with field sensors, machine vision images, and artificial intelligence, manufacturing quality can be controlled because components are built based on layer-by-layer stacking (often these layers are on the scale of 50 microns), providing predictive quality assurance for the manufacturing of such reactors and structures.

[0040] The additive manufacturing technology for manufacturing integral and single structures for fission reactors and fuel-loaded reactor spaces described herein comprises the following steps: (a) a prediction and causal analysis step; (b) an on-site monitoring step combined with machine vision and accelerated processing during layer-by-layer fabrication of the structure; (c) an automated analysis step combined with machine learning components; and (d) a virtual inspection step of a digital representation of the structure in a constructed state (also referred to herein as a “digital twin”). FIG. 9 summarizes the additive manufacturing method (400) for manufacturing integral and single structures for fission reactors and fuel-loaded reactor spaces described herein.

[0041] The method (400) includes prediction and causal analysis (410) in which existing and experimental data are used to determine an initial Critical-to-Quality (CTQ) factor and to provide training for an initial machine learning algorithm. The initial input data for the machine learning algorithm may be one or more of the following: organically developed, provided by a third party, or based on past data sets (e.g., based on open source and / or operations and experiments capturing prior experience in additive manufacturing technology recorded as potential features and observations related to the current additive manufacturing process). In each case, the initial machine learning algorithm represents not only each step of the manufacturing process as an algorithm but also the ideal final structure as an algorithm. For example, complexity may be added to the initial machine learning algorithm by including additional variables regarding manufacturing conditions, such as input, output, environmental conditions, supply quality, etc. It is expected that the algorithm applied to the aforementioned initial input data alone will help explain the final Critical-to-Quality (CTQ) factor for the reactor product, but will not be sufficient to verify the quality of the manufactured product.

[0042] Data science methods applicable to the stages of prediction and causal analysis (410) include: (1) a step of defining defects; (2) a step of converting into measured outputs (layer fusion, shape, location, etc.); (3) a step of organizing the dataset using “organized data” principles (variables in columns, observations in rows, linked tables, test reproducibility); (4) a step of splitting the data into training, test, and validation sets; (5) a step of evaluating the characteristics of the dataset, exploratory analysis, and investigation of physical theories; (6) a step of extracting candidate features; (7) a step of specifying hypotheses about relationships to be tested in existing data; (8) a step of constructing a multivariate regression algorithm using resampling techniques for randomization; (9) a step of evaluating the inflow and outflow of sample errors; (10) a step of evaluating hypotheses and establishing basic parameters for physical testing; (11) a step of generating known additive manufacturing shapes, validating the prediction model, and generating causal relationships and output parameters; and (12) a step of re-evaluating hypotheses and updating machine learning-based basic defect definitions. A successful initial machine learning algorithm uses existing data prior to physical testing to determine basic hypotheses regarding important factors possible for additive construction and forms the basis of machine learning. Then, a final prediction model is used to inform field measurement plans for actual production and initial machine learning conditions.

[0043] The prediction and causal analysis (410) step generally occurs before the layer-by-layer deposition of material to manufacture the structure of the manufactured object.

[0044] The method (400) includes on-site monitoring combined with machine vision and accelerated processing during the layer-by-layer manufacturing of the structure (420). In this step, data related to the layer-by-layer manufacturing of the structure is captured by appropriate on-site monitoring, processing is accelerated, and data to be input into machine learning for analysis is digitized. On-site monitoring can be performed by any appropriate means. For example, industrial machine vision cameras can provide visual information including positional information, thermocouples can provide temperature information of both the supplied material and the deposited material, current and voltage sensors can provide information regarding deposition conditions, monitor deposition rates and rates, and monitor environmental conditions, and X-ray technology can not only monitor material properties but also provide material characterization, infrared thermal imaging of temperature distribution, and weld pool characteristics including structure and stress states, these are examples of feasible on-site monitoring, and the results are utilized in the additive manufacturing method. Other parameters that may be included in on-site monitoring include cooling profiles, void detection, porosity measurement, and defect detection such as cracks, deposition, and dimensional irregularities. It should be noted that the additive manufacturing method presents sensor issues. This is because cameras and other sensors must be placed between the film layer and the deposition head to collect data, for example, to detect structural placement and alignment. Parallel processing, such as GPU acceleration, can be advantageous for processing large amounts of data in field monitoring and handling dozens of desired functions to return real-time corrections when not required. The output of the accelerated processing is fed back to machine control within the loop for identification for offline analysis using self-correcting or built-in models.

[0045] Since the integral and single structures for the fission reactor and fuel-loading reactor spaces described herein are manufactured, continuous feedback on the manufacturing process is enabled by repeating the on-site monitoring and automated analysis steps for each layer. This feedback forms the basis for: (i) layer-by-layer adjustments in the additive manufacturing process; (ii) storing monitored and analyzed information in a digital twin to allow for subsequent analysis and evaluation; and (iii) updating and adjusting manufacturing protocols and layer-by-layer instructions for use in the future additive manufacturing of the integral and single structures for the fission reactor and fuel-loading reactor spaces described herein.

[0046] While manufacturing the structure of the manufactured object layer by layer, the method (400) includes automated analysis combined with a machine learning component (430). The machine learning generates intelligence from inputs from machine vision and its field monitoring, applies said inputs to existing data, updates processing through machine training, and performs predictive qualification analysis by self-adjusting during the additive manufacturing process.

[0047] Machine learning may include anomaly detection algorithms for monitoring process functions. For example, anomaly detection algorithms can identify changes in deposition rate, unexpected delay time or volume consumption, temperature, alignment, or chemistry. In the automated analysis of this process data, one or more characteristics X1 representing anomalies can be selected, parameters U1 can be fitted, the distribution of each selected characteristic can be characterized, and the probability that the observed X falls within the acceptable Gaussian error of each characteristic U can be calculated.

[0048] Machine learning can also include image classifiers for detecting anomalies within the process. For example, pixelated images can be used as input data, where each sample is a small pixel area of ​​the image. The number of areas fitting into the image represents the number of dimensions that can be used to differentiate and classify anomalies or shapes. By using vectorized images with hundreds of dimensions (part of the image), the machine can learn how appropriate shapes or anomalies look through optimization functions for each feature. Once the classifier is trained to detect anomalies, it can be further trained to identify previously detected deposition conditions leading to anomalies (within a specific statistical confidence level), apply that information to the abnormal state before it actually occurs, and actively intervene in the additive manufacturing process to avoid the anomalies. This iterative correction capability is crucial for performing in-process adjustments before depositing multiple defective layers.

[0049] Neural networks can be utilized for nonlinear hypotheses related to machine learning. For example, neural networks use hidden layers to correctly predict output conditions and develop weight parameters, employing a set of functions that take input conditions and fit the model. Forward propagation algorithms provide prediction capabilities, while backpropagation is used to reveal the weight scheme learned by the system. By using hidden layers, viable solutions can be achieved when the number of features is large (as in image data), interactions are complex, or both.

[0050] The method (400) also includes a virtual inspection of a digital representation of a structure in a built state (also referred to herein as a “digital twin”) (440). Typically, the virtual inspection step of the digital twin (440) occurs after the layer-by-layer deposition of material to manufacture the structure of the manufactured object is completed. The digital twin can be analyzed using various computer-aided structural analysis and modeling techniques, such as finite element analysis, to investigate structural analysis, heat transfer, fluid flow, and mass transfer characteristics. Additionally, internal and hard-to-reach features of the built state structure can be easily accessed, verified, and analyzed in the digital twin. This provides a complete 360-degree inspection as well as “inside-out” verification capabilities. Because the digital twin replicates the actual built state structure, these analysis results for the digital twin are highly correlated with the actual built state structure. Therefore, the reliability of the built state product (for desired parameters such as strength) can be statistically evaluated based on the test results for the digital twin.

[0051] In contrast to the countless pre-manufacturing, in-manufacturing, and post-manufacturing quality assurance methods of conventional manufacturing, which are often destructive-based techniques and / or inspection-limited, establishing quality assessment during the manufacturing process of integral and single structures for fission reactors and fuel-loading reactor spaces described herein not only offsets the difficulty of post-construction verification of complex products but also renders unnecessary the more direct assurance provided by internal flip-over assessment, which inspects with regressed high-resolution layer-by-layer (at least) resolution against continuous input of process monitoring data along each additively manufactured layer.

[0052] Additionally, virtual inspection may be performed using a model (e.g., a "digital twin" of the actual built product) composed of built data that is analytically processed when collected during manufacturing. Combined with the machine's predictive ability to learn anomalies in quality results and the function of monitoring, interpreting, and reporting the status of the final built product, the additive manufacturing method described herein not only prevents defects before they occur but also statistically evaluates the reliability of the viability of the built product on a global basis across the entire built product, based on the manufacturing status monitored and recorded during the manufacturing process.

[0053] Example 1

[0054] A fission reactor with a diameter of 16 inches and a height of 24 inches was modeled. The reactor has six cylindrical chambers, and the axial height is divided into 20 equally spaced axial levels to form 2,520 individual primary channels and 2,520 individual secondary channels for potential fuel loading. Fig. 3a illustrates the characteristic arrangement of the axial levels from a top perspective. Example dimensions for structural considerations are as follows: (a) outer circumference of the shell (102) of 0.75 inches, (b) primary channel wall thickness of 3 mm, and (c) thickness of the axial extension ring and webbing of 2 mm. However, smaller dimensions may be used to provide potential for additional fuel loading, or larger dimensions may be used to provide strength. The following are the volumes of the shell metal, primary channels, and secondary channels (uranium metal).

[0055] Shell metal volume 2258.9 in 3( 46.8% of core volume Primary channel volume 1202.2 in 3( 24.9% of core volume Secondary channel volume (fuel volume) 1364.3 in 3( 28.3% of core volume)

[0056] The uranium capacity for Example 1 was calculated. The combined secondary channel volume (fuel volume) was 1,364.3 in 3In the above 16” x 24” configuration, a maximum U235 weight of 187 pounds is possible when all secondary channels are filled with U235 at 20% enrichment. However, each chamber incorporates a plenum allowing 10% of the exhaust gas volume. This results in a maximum U235 weight of 149.6 pounds at 20% enrichment. While this is significantly more than required for criticality, this excess capacity allows for radial and axial reinforcement adjustments for optimal fuel cycle efficiency and cycle length.

[0057] The size of the primary channel was arbitrarily selected as 18 mm in diameter with 3 mm walls to provide a balance between intensity and flow area. As a result, 50 in 2 127 holes were formed with the above combined flow areas. The number of holes and the size of the flow areas can accommodate as many flow channels, moderator rods, control rod positions, scram rod positions, and instrumentation needs as possible. The desired output level, fluid selection, moderator material, control rod material, and concentration lead to specific purposes for each hole.

[0058] As can be seen in the drawing, all secondary channels containing fissile fuel, such as uranium, are connected to the two halves of two different primary channels. Therefore, as long as all other primary channels are dedicated to fluid flow, each secondary channel containing fuel transfers heat to an adjacent primary channel for heat transfer purposes. Additionally, 60 primary channel positions can be designated exclusively for non-fluid requirements (moderator, control, scram, and instrumentation). Considering a plug design, heat transfer in non-fluid positions becomes possible by not utilizing the entire 18mm primary channel size. For example, a fin-shaped control rod design can simultaneously provide reactivity control and appropriate flow in the primary channels.

[0059] Exemplary reactors possess the advantages of radial and axial enrichment. Since each secondary channel using fissile fuel is independent of all other secondary channels using fissile fuel, customized enrichment can be selected in both the radial and axial directions. Experience shows that this can improve fuel cycle efficiency by up to 20% and balance shell temperatures. It is also conceivable to provide an infinite number of uranium enrichments through additive manufacturing. For example, enrichment between these two extremes is possible by using only a combination of depleted uranium wire and 20% enriched uranium wire (conversely, in traditional practice, nuclear manufacturers generally limit themselves to fewer than 10 different enrichments due to the complexity of non-additive manufacturing).

[0060] The exemplary reactor is expandable and scalable. Although it is modeled with the dimensions of a 16" x 24" reactor, any reactor larger than 12" x 18" is possible. Additionally, if the chamber radial width is maintained in detail within this design and follows the concept of six-fold radial symmetry discussed above, any number of additional axial extension rings (140) may be added. As a result, regardless of the reactor size, all secondary channels using fissile fuel of the same size are provided, and the configuration remains highly symmetrical.

[0061] Example 2

[0062] A computing platform (hereinafter referred to as “UIRCP”) consisting of ANSYS engineering simulation and 3D design software, SolidWorks solid modeling computer-aided design and computer-aided engineering computer programs, and Monte Carlo N-Particle (“MCNP”) was utilized and applied to solve the ideal thermal configuration of a universal inverted reactor design. Because the fuel and cladding are in contact with each other in the universal inverted reactor design described herein (e.g., see FIG. 4 and related descriptions in this specification), thermal stress is likely to increase due to the varying thermal expansion rates of the two materials sharing the aforementioned interface. To address this problem, UIRCP was applied, and fuel enrichment and reactor geometry were repeated to homogenize the radial thermal gradient. It should be noted that the axial thermal gradient and the overall peak temperature are unavoidable due to the nature of linear heat exchange and were not part of the UIRCP process.

[0063] MCNP was applied to the UIRCP process for a modeled universal reversed reactor design to calculate the MeV / g of each continuous fuel element and verify criticality. First, the input deck must be constructed based on the user's geometric and material inputs. Other user inputs may include materials for coolant, fuel, cladding, and reflectors. This is accomplished by reading the user inputs, outputting the geometric structure in MCNP format (binary geometry), labeling each cell with the desired material, and setting neutron physics. The input deck is then executed, providing the user with the option to review the geometric structure at this point using MCNP's visualization software capabilities. The MCNP output is retrieved to find the MeV / g associated with each fuel element and W / m² 3It is converted and saved to a separate file. All these steps are controlled by a management batch file that calls the necessary commands and subprograms. FIG. 10a shows a screenshot (500) of the initial user interface, and FIG. 10b shows a screenshot (510) of the MCNPX geometric structure review.

[0064] SolidWorks was applied to the UIRCP process to update a Computer Aided Design (CAD) solid model of a reference reactor geometry based on user input. The user input was the selection of the basic geometry. The variables updated by the user were geometric variables such as ring spacing, number of rings, clad thickness, passage ID and OD, number of axial segments, and total height. Figures 11a and 11b illustrate diagrams (600, 610) having the geometry and dimensions for the geometry-related variables used in this example. It should be noted that there is a similarity between the geometry of Figures 11a-b and the design of the reactor space (108) of Figures 3a-b.

[0065] Using a universal inverted reactor design as the basic design (e.g., the design illustrated and described in relation to FIGS. 11a-b), solid models of fuel, cladding, and passages exist a priori. The UIRCP process calls a batch file that opens SolidWorks, executes a subprogram that updates geometric global variables, and executes a Visual Basic for Applications (VBA) program to suppress unwanted geometry, reconstruct the design with new geometric parameters, and preserve 1 / 6 of the core parameters. Parasolid (700) (see FIG. 12) is an example of a core parasolid generated from the process. It should be noted that there is a similarity between this core parasolid (700) of FIG. 12, which includes a shell, axial cylinders, a plurality of axial extension rings, a plurality of primary axial tubes, a primary channel, a plurality of webbings, and a plurality of secondary channels, and the design of the reactor space (108) of FIG. 3a-b. UIRCP process and SolidWorks modeling can optimize universal inverted reactor designs by changing and updating the number of rings, passage size, fuel size, total reactor size, and interstitial cladding.

[0066] ANSYS was applied to the UIRCP process to solve the thermal-hydraulic problem of generating heat in which fuel warms the coolant flowing through the passage. Computational fluid dynamics (CFD) tools such as ANSYS FLUENT and structural analysis tools such as ANSYS Mechanical-based finite element analysis (FEA) can be used. Using ANSYS FLUENT and ANSYS Mechanical, a j_script journal was invoked to insert a core parasolid, such as a core parasolid (700), obtained from the UIRCP process applied in SolidWorks. Then, ANSYS Mechanical was opened to mesh the parasolid by distinguishing between solid and fluid. A script was created to control FLUENT. The script invocation began with opening FLUENT. The script contained user input references for fuel, cladding, and coolant materials and was updated based on these inputs. All mesh interfaces between the fuel and the cladding were divided (to prevent erroneous results that occur because the solid mesh considers the interface as a uniform piece). The coolant inlet and outlet were set to the user input speed and ambient temperature. The fuel element was provided with appropriate internal heat based on the MCNP output. Then, FLUENT ran a thermo-hydraulic simulation and generated a temperature contour map. FIG. 13 is an example of a temperature contour map (800) obtained as a result of running FLUENT as outlined by the above steps.

[0067] The UIRCP process interfaces the ANSYS, SolidWorks, and MCNP programs into a single software automation, allowing the individual software to iterate toward the final result based on the user's identified optimization techniques. The interface operation was performed by storing necessary information from the output of one software, which waits until called upon while the other software is being automated. For example, the SolidWorks and ANSYS programs communicate via solid modeling. After SolidWorks performs geometry updates and saves the parasolid, ANSYS invokes that parasolid as the base geometry to perform thermo-hydraulic analysis. In another example, the MCNP and ANSYS programs communicate through the relationship between fuel enrichment and the radial thermal gradient. During the first iteration, MCNP runs an initial neutron simulation using the initial fuel enrichment levels for all fuel elements, which calculates internal heat generation (W / m²) per fuel element. 3 It is identical to ). The internal heat values ​​are stored and wait for ANSYS to call. When ANSYS runs the thermo-hydraulic simulation, it stores the radial thermal profile. The thermal profile tells MCNP what the next enrichment iteration is in an attempt to maintain a zero-gradient trend for the radial thermal gradient (if the optimization technique is verified). This process is repeated until an acceptable level of thermal gradient is reached. This serves as the main iteration loop of the UIRCP process.

[0068] Example 3

[0069] Neutronics of an exemplary embodiment of a fission reactor (100) were investigated. The investigated fission reactor (100) used low enriched uranium (LEU) with 19.75 wt% U-235. The fission reactor has 10 fuel rings located within the reactor space inside the shell. The core diameter was 434.7 mm and the core height was 800 mm. A 15 cm thick beryllium reflector surrounds the core. The neutronics were modeled using the Monte Carlo N-Particle Transport Code 6 ("MCNP6") nuclear process simulation program. It was determined that steady-state operation (k-effective value = 1.0) requires a series of control rod maneuvers during the core's operating life. Figures 14a and 14b show the core power peak profiles of the MCNP6 nuclear process simulation program when the control rods are removed from the core. The profile (900) of FIG. 14a shows power (normalized to the mean) as a function of core height (meters, from top to bottom), with a peaking factor (all control rods fully retracted) of 1.49, an axial peaking position of 0.39 m, and a k-effective value of 1.06375 ± 0.00036 (control rods fully retracted). The profile (910) of FIG. 14b shows power (normalized to the mean) as a function of radial distance (meters), with a peaking factor of 1.12 (all control rods fully retracted), an axial peaking position of 0.0186 m, and a k-effective value of 1.06375 ± 0.00036 (control rods fully retracted). FIG. 14c shows the profile (920) of neutron flux (normalized with respect to total flux) as a function of neutron energy (MeV), with a k-effective value of 1.06375 ± 0.00036 (all control rods fully withdrawn). For shutdown purposes, the k-effective value of the modeled reactor with the control rods fully inserted was 0.94211 ± 0.00034.

[0070] The UIRCP and process described above provide engineers with the flexibility to change the reactor type, materials, and basic geometry. The end result is a reactor design that can be manufactured using additive manufacturing technology, providing engineers with tools for various power applications. Furthermore, specific functions of the described fission reactor can be optimized through dedicated routines of the UIRCP process. For example, in addition to the enrichment optimization discussed above, the UIRCP process can be used to optimize the following: (a) passage size based on one or more of the coolant-material heat transfer efficiency, radial thermal gradient, and axial thermal gradient; (b) ring width based, for example, the radial thermal gradient; and (c) cladding thickness based, for example, the radial thermal stress.

[0071] Additionally, the UIRCP and processes described herein can be effectively applied to new reactor designs. Engineers are tasked with investigating criticality, thermal-hydraulic, and material details. This initial project design and evaluation takes several months (up to one year), and obtaining an initial answer regarding the feasibility of a new reactor design can cost millions of dollars. However, the UIRCP and processes described herein provide thermal-hydraulic, neutron, and geometric knowledge for a new reactor within days. Consequently, preliminary decisions regarding the utility of the reactor design can be made, and the design can be optimized with reduced time and cost compared to current practices.

[0072] The fission reactor (100) of FIG. 2a has standard characteristics including a power output of 1 MWth (+250 kWe), ZrH moderation, helium cooling, a Brayton thermodynamic cycle, and a monolithic structure with rotational symmetry. However, the fission reactor (100) can be larger or smaller, i.e., scalable, and can have alternative characteristics as disclosed and described herein.

[0073] The fission reactor (100) described in this specification may be used for suitable applications including ground power sources, remote power or off-grid applications, space power, space propulsion, isotope production, directed energy applications, commercial power applications and desalination.

[0074] Although generally described herein in relation to pressurized water reactors (PWR reactors) and water as a primary coolant, the structures and methods described herein may also be used in other reactor systems including boiling water reactors (BWR reactors), deuterium oxide (heavy water) moderator reactors, such as CANDU reactors, light water reactors (LWR reactors), pebble bed reactors (PBR reactors), nuclear thermal propulsion reactors (NTP reactors), commercial and research reactors, and other primary coolants such as helium, hydrogen, methane, molten salt, and liquid metal.

[0075] Although the use of additive manufacturing technology has been described herein, separate manufacturing technology as well as combinations of additive and subtractive manufacturing technologies may be used to manufacture fission reactors and related structures. Accordingly, field technologies and predictive quality assurance methods may be adapted for use in such subtractive manufacturing / combined manufacturing environments. Examples of subtractive manufacturing technology include machining such as milling and boring, machining of the body into rough semi-finished forms, and subsequent finishing machining such as electrical discharge machining (EDM). Other subtractive manufacturing methods, such as electron beam machining (EBM), may be used.

[0076] Although described herein in relation to the manufacture of a general-purpose reverse-type reactor, the additive manufacturing method and predictive quality assurance method described herein may be applied to the manufacture of other technologies, including the petrochemical industry (e.g., chemical reaction vessels), the aerospace industry (e.g., turbine components including turbine blades and housings, and missile and rocket components including combustion chambers, nozzles, valves and coolant piping).

[0077] Although reference has been made to specific embodiments, it is evident that other embodiments and variations may be devised by those skilled in the art without departing from their spirit and scope. The appended claims are intended to be interpreted as including all such embodiments and equivalent variations.

Claims

Claim 1 A step of applying prediction and causal analysis to prepare a model of a fission reactor core structure; a step of manufacturing said fission reactor core structure layer by layer using additive manufacturing technology; a step of in-situ monitoring the manufacturing of said fission reactor core structure using machine vision during manufacturing; a step of analyzing data from said in-situ monitoring; The method comprises the step of coordinating the manufacture of a fission reactor core structure based on analyzed data, wherein the fission reactor core structure comprises: a shell including a reactor space having a longitudinal axis; an axial cylinder including an inner diameter surface defining a central longitudinal channel having an axis located at the same position as the longitudinal axis of the reactor space; a plurality of axial extension rings provided within the reactor structure and positioned concentrically with respect to the axial cylinder, wherein the plurality of axial extension rings are separated radially to form both a radially inner adjacent ring and a radially outer adjacent ring for any two adjacent axial extension rings, and the outer diameter surface of the radially inner adjacent ring and the inner diameter surface of the radially outer adjacent ring define an annular cylindrical space; a first plurality of primary axial tubes positioned circumferentially within the annular cylindrical space, wherein each of the primary axial tubes includes an inner diameter surface and an outer diameter surface forming a primary channel; and a plurality of webbings, wherein the outer diameter surface of each of the plurality of primary axial tubes is formed by a first webbing radially Connected to a ring adjacent to the inner side in the direction and connected to a ring adjacent to the outer side in the radial direction by a second webbing; a plurality of secondary channels within the annular cylindrical space, wherein the primary axial tube adjacent in the circumferential direction is separated by one of the plurality of secondary channels;A method for manufacturing a fission reactor core structure comprising a fissionable nuclear fuel composition located in at least some of the plurality of secondary channels. Claim 2 A method for manufacturing a fissile reactor core structure according to claim 1, wherein the fissile fuel composition located in at least some of the plurality of secondary channels forms a set of fissile fuel elements that are volumetrically identical throughout the entire fissile reactor core structure. Claim 3 A method for manufacturing a fission reactor core structure according to claim 1 or 2, wherein the ratio of the area of ​​the radial cross-sectional area of ​​the secondary channel to the radial cross-sectional area of ​​the primary channel is constant throughout the fission reactor. Claim 4 A method for manufacturing a fission reactor core structure according to claim 1 or 2, wherein the inner surface of the secondary channel comprises a portion of the outer diameter surface of the primary axial tube adjacent in the circumferential direction, the surface of the first webbing and the second webbing associated with each of the primary axial tube adjacent in the circumferential direction, and a portion of the outer diameter surface of the radially inner adjacent ring and a portion of the inner diameter surface of the radially outer adjacent ring. Claim 5 In claim 4, a method for manufacturing a fission reactor core structure in which the fissionable nuclear fuel composition comes into contact with the inner surface of the secondary channel to transfer heat. Claim 6 A method for manufacturing a fission reactor core structure according to claim 1 or 2, wherein a primary coolant can flow through the primary channel of each of the circumferentially adjacent primary axial tubes separated by one of the plurality of secondary channels containing the fissile nuclear fuel composition. Claim 7 A method for manufacturing a nuclear fission reactor core structure according to claim 1, wherein the primary axial tubes adjacent in the circumferential direction are distributed non-contactually within the annular cylindrical space. Claim 8 A method for manufacturing a fission reactor core structure according to claim 1 or 2, wherein the fission reactor core structure comprises a second plurality of primary axial tubes positioned circumferentially between the inner diameter surface of the most radially inward axially extending ring and the outer diameter surface of the axial cylinder, wherein the outer diameter surface of each of the second plurality of primary axial tubes is connected to the outer diameter surface of the axial cylinder by the first webbing and connected to the most radially inward axially extending ring by the second webbing. Claim 9 A method for manufacturing a fission reactor core structure according to claim 1 or 2, wherein the fission reactor core structure comprises a third plurality of primary axial tubes positioned circumferentially between the inner diameter surface of the shell and the outer diameter surface of the most radially outward axial extension ring, and each of the third plurality of primary axial tubes is connected to the outer diameter surface of the most radially outward axial extension ring by the first webbing and connected to the inner diameter surface of the shell by the second webbing. Claim 10 A method for manufacturing a nuclear fission reactor core structure according to claim 1 or 2, wherein the shell, the axial cylinder, the plurality of axial extension rings, the plurality of primary axial tubes, and the plurality of webbings are an integral single structure. Claim 11 A method for manufacturing a fission reactor core structure according to claim 1 or 2, wherein the shell, the axial cylinder, the plurality of axial extension rings, the plurality of primary axial tubes, and the plurality of webbings are formed of a metal alloy. Claim 12 A method for manufacturing a fission reactor core structure according to claim 1 or 2, comprising a reflector around the outer diameter surface of the shell of the fission reactor core structure. Claim 13 A method for manufacturing a fission reactor core structure according to claim 1 or 2, wherein at least one of a moderator, a control rod, and a scientific instrument is located in one or more primary channels. Claim 14 A method for manufacturing a fission reactor core structure according to claim 1 or 2, wherein the first plurality of primary axial tubes within each of the annular cylindrical spaces have six rotational symmetry with respect to the longitudinal axis of the reactor space. Claim 15 A method for manufacturing a fission reactor core structure according to claim 1 or 2, wherein one or more central longitudinal channels of the axial cylinder and one or more primary channels of the primary axial tubes are accessible from the outer surface of the fission reactor comprising the fission reactor core structure. Claim 16 A method for manufacturing a fission reactor core structure according to claim 1 or 2, wherein the primary axial tube has a longitudinal axis parallel to the longitudinal axis of the reactor space. Claim 17 A method for manufacturing a fission reactor core structure according to claim 16, wherein the inner diameter surface of the primary axial tube forming the primary channel varies as a function of the axial position with respect to the longitudinal axis of the primary axial tube. Claim 18 A method for manufacturing a nuclear fission reactor core structure in which the primary axial tube is chambered, according to claim 1 or 2. Claim 19 A method for manufacturing a fission reactor core structure according to claim 1 or 2, wherein the cross-section of the secondary channel perpendicular to the longitudinal axis of the reactor space has a hyperbolic cross-sectional shape of a sheet. Claim 20 A method for manufacturing a fission reactor core structure according to claim 1 or 2, further comprising: a step of preparing a digital version of the manufactured fission reactor core structure; a step of analyzing the characteristics of the digital version of the manufactured fission reactor core structure; a step of associating the analyzed characteristics of the digital version of the manufactured fission reactor core structure with the characteristics of the manufactured fission reactor core structure; and a step of evaluating the characteristics of the manufactured fission reactor core structure based on the analysis of the digital version of the manufactured fission reactor core structure. Claim 21 In claim 20, the characteristics of the digital version of the manufactured fission reactor core structure are selected from the group consisting of structural characteristics, heat transfer characteristics, fluid flow characteristics and mass transfer characteristics, and the characteristics of the manufactured fission reactor core structure are identical to the characteristics of the digital version of the manufactured fission reactor core structure, a method for manufacturing a fission reactor core structure.

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