Gravity Die-Casting Spent Nuclear Fuel in Copper Alloy
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Solution Overview
Problem
Current methods for disposing of spent nuclear fuel (SNF) assemblies are inefficient, costly, and pose risks due to corrosion and radionuclide migration, particularly in deep geological repositories.
Innovation Solution
A gravity die-casting process is used to embed SNF rods in a copper alloy, creating a solid composite matrix that minimizes voids and enhances corrosion resistance, thereby reducing the risk of radionuclide migration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional disposal methods are used for spent nuclear fuel assemblies, then disposal can be implemented, but corrosion resistance is insufficient and radionuclide migration risk increases
Solution Approach 1:
The patent applies composite materials by embedding spent nuclear fuel assemblies in a copper alloy matrix to form a composite casting. The copper alloy provides superior corrosion resistance compared to traditional disposal methods, while the composite structure prevents radionuclide migration by creating a dense, monolithic system with minimal voids. This directly resolves the contradiction by improving corrosion resistance and eliminating migration pathways simultaneously.
Solution Approach 2:
The patent changes the physical and chemical parameters of the disposal system by using gravity die-casting to create a dense composite structure. The casting process transforms the fuel assembly from a porous, corrosion-vulnerable structure into a compact, corrosion-resistant composite with controlled density and minimal void content. This parameter change resolves the contradiction by improving both corrosion resistance and preventing radionuclide migration through the dense structure.
2Reliability
If gravity die-casting is used to embed SNF rods in copper alloy, then corrosion resistance and density are improved, but manufacturing complexity increases
Solution Approach 1:
The patent merges multiple functions into a single gravity die-casting process: embedding the fuel assembly, forming the copper alloy matrix, creating the dense composite structure, and providing corrosion protection all in one operation. This merging reduces overall manufacturing complexity compared to sequential processes while achieving superior corrosion resistance and density simultaneously.
Solution Approach 2:
The gravity die-casting process is self-service in that the molten copper alloy automatically flows and embeds the fuel assembly without requiring complex external manipulation or assembly steps. The gravity-driven process simplifies manufacturing while producing the dense, corrosion-resistant composite structure, resolving the contradiction between improved reliability and reduced manufacturing complexity.
3Object-affected harmful factors
If voids are minimized in the composite matrix, then radionuclide migration is reduced, but manufacturing precision requirements increase
Solution Approach 1:
The gravity die-casting process changes the manufacturing parameters by using controlled cooling and solidification of the copper alloy matrix. This parameter control naturally minimizes void formation during the phase change from liquid to solid, achieving dense composite structure without requiring excessively tight manufacturing tolerances. The process inherently reduces radionuclide migration pathways while maintaining feasible manufacturing precision requirements.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The process results in a dense, monolithic system that is more resistant to corrosion and can withstand high external pressures, ensuring safe and long-term disposal of SNF in deep geological repositories.
Implementation Method 1
A gravity die-casting process is used to embed SNF rods in a copper alloy
Implementation Method 2
The process results in a dense, monolithic system that is more resistant to corrosion
Data Source
AI summary
Nuclear waste, such as, but not limited to, spent nuclear fuel (SNF) assemblies (or portions thereof), are placed within diecast molds, and then gravity fed molding occurs within those loaded diecast molds and around and in the emplaced SNF assemblies (or portions thereof) that are located within those diecast molds, using molten alloy(s) for filling the diecast molds, to form solid metal castings upon sufficient cooling after the gravity fed operations. The molten alloy(s) may contain a copper alloy. The molten alloy(s) may also contain neutron absorbers. After the casting is formed, the casting is not separated from its diecast mold, as the diecasting mold and it's casting now form an integral unit. The integral units may be converted into waste capsules. The waste capsules may be landed in deeply located horizontal wellbores. The deeply located horizontal wellbores may be at least partially located within deeply located geologic formations.