EDM-Formed Nuclear Fuel Elements for Lower-Waste Production
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Solution Overview
Problem
Existing nuclear fuel manufacturing methods are inefficient, costly, and prone to defects, especially for non-cylindrical shapes, requiring significant investment in tooling and infrastructure, and result in material wastage.
Innovation Solution
The use of electrical discharge machining (EDM) processes to form nuclear fuel elements directly from a cast ingot, allowing for scalable, defect-reduced, and time-efficient production of metallic or ceramic fuels without the need for breakable bits, and incorporating a heat exchanger system with modular heat pipes and tube bundles for efficient heat transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional manufacturing methods are used for non-cylindrical fuel shapes, then tooling and infrastructure investment is required, but manufacturing cost and complexity increase significantly
Solution Approach 1:
The patent replaces conventional mechanical machining processes with electrical discharge machining (EDM), which uses electrical discharges to remove material. This substitution eliminates the need for physical tooling that would be required for conventional machining, thereby reducing device complexity while maintaining the ability to produce various fuel shapes including non-cylindrical forms
Solution Approach 2:
The patent employs electrical discharge machining parameters (such as pulse duration, current density, and dielectric fluid flow) to control the material removal process. By adjusting these electrical parameters rather than mechanical tooling parameters, the system achieves versatility in fuel shape production without requiring different physical tools for each shape type
2Productivity
If conventional machining processes are used, then manufacturing time is extended, but production efficiency decreases
Solution Approach 1:
The patent replaces slow mechanical machining with electrical discharge machining, which removes material through controlled electrical discharges. This process is significantly faster for producing complex fuel shapes, thereby reducing manufacturing time and improving production efficiency without compromising dimensional accuracy
Solution Approach 2:
The EDM process enables continuous material removal through rapid sequential electrical discharges, maintaining productive action throughout the manufacturing cycle. The dielectric fluid continuously removes debris and enables uninterrupted discharge cycles, ensuring continuous useful action and minimizing idle time during fuel element production
3Loss of substance
If traditional manufacturing methods are used, then material wastage occurs, but cost increases
Solution Approach 1:
The patent uses electrical discharge machining to remove material with precision control, minimizing waste compared to conventional mechanical methods. The EDM process allows for accurate material removal only where needed, reducing fuel material wastage and subsequently lowering manufacturing costs
Solution Approach 2:
The patent implements a system to collect and recover dielectric fluid and debris from the EDM process. By recovering the dielectric fluid for filtration and reuse, and properly disposing of or recycling fuel debris, the system reduces material loss and associated costs while maintaining manufacturing efficiency
4Reliability
If breakable tooling is used for machining, then manufacturing reliability decreases, but production consistency is compromised
Solution Approach 1:
The patent replaces mechanical tooling with electrical discharge machining, eliminating breakable physical tools. The EDM process uses electrical fields that cannot break or wear, thereby improving manufacturing reliability while maintaining consistent precision across all fuel elements through repeatable electrical parameter control
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
EDM enables cost-effective, rapid, and uniform production of non-cylindrical nuclear fuel elements with reduced defects and wastage, while the heat exchanger system effectively transfers heat from the reactor, enhancing modularity and maintenance capabilities.
Implementation Method 1
the use of electrical discharge machining (EDM) processes to form nuclear fuel elements directly from a cast ingot
Implementation Method 2
Each heat exchanger can include a heat pipe that removes heat using alkali metals, halide salts, or other suitable working fluids
Implementation Method 3
the tube bundle removes heat from the heat pipe and can transfer the heat to a power conversion system
Data Source
AI summary
Fuel, heat exchangers, and instrumentation for nuclear reactors are disclosed. A nuclear power system includes a plurality of nuclear fuel elements, each of the nuclear fuel elements including an annulus; and a plurality of heat pipes, each of the plurality of heat pipes configured to pass through the annulus of a respective one of the nuclear fuel elements in conductive thermal contact with the respective nuclear fuel element. A nuclear instrumentation module includes an assembly of optical fibers, each optical fiber comprising one or more sensors and configured for removable installation at one of the plurality of heat pipes. A heat exchanger includes a heat pipe including an evaporating region and a condensing region; and a tube bundle configured to wrap around the condensing region of the heat pipe and including one or more adjacent, parallel tubes, each tube forming a helix that is coaxial to the heat pipe.