Segmented Fuel Assembly With Additive Manufacturing for Higher Burnup
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Solution Overview
Problem
Existing nuclear fuel assemblies face limitations in manufacturing methods, leading to issues such as fretting, debris, pellet cladding interaction, fuel fragmentation, relocation, and Zircaloy-steam reactions, which affect performance and licensing concerns.
Innovation Solution
A segmented fuel assembly design utilizing additively manufactured fuel segments with enclosures and interlocking features, allowing for optimized geometries and improved fuel management, reducing performance issues and enhancing accident tolerance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional manufacturing methods are used for fuel assemblies, then manufacturing processes are well-established, but performance issues such as fretting, debris, pellet cladding interaction, fuel fragmentation, relocation, and Zircaloy-steam reactions occur
Solution Approach 1:
The fuel assembly is divided into multiple fuel segments that can be manufactured separately using additive manufacturing, then assembled together. This segmentation allows for optimized geometries and reduced performance issues while maintaining manufacturing feasibility through modular assembly processes
Solution Approach 2:
The manufacturing approach changes from traditional subtractive or formative methods to additive manufacturing, fundamentally altering the manufacturing parameters and enabling new design capabilities that improve fuel performance while managing complexity through digital fabrication
2Duration of action of stationary object
If segmented fuel assembly design is implemented, then higher burnup and longer life cycle are achieved, but manufacturing precision and assembly complexity increase
Solution Approach 1:
Dividing the fuel assembly into segments enables longer operational life and higher burnup capabilities while using additive manufacturing to achieve precise geometries. The modular nature allows for controlled assembly with standardized interfaces
Solution Approach 2:
Traditional mechanical manufacturing processes are replaced with additive manufacturing, which provides superior geometric precision and complex internal structures. This substitution enables the required manufacturing precision for segmented assemblies without the limitations of conventional methods
3Reliability
If interlocking features are added to fuel segments, then fuel management is improved and accident tolerance is enhanced, but device complexity increases
Solution Approach 1:
The segmented design with interlocking features improves fuel management and accident tolerance by containing fragmentation and controlling debris. The modular segments with standardized interlocking mechanisms manage complexity through repetition of simple, reliable connection features
Data Source
AI summary
A segmented fuel assembly for use in a nuclear reactor is disclosed. The segmented fuel assembly comprises a lower nozzle, an upper nozzle, a plurality of guide tubes positioned intermediate the lower nozzle and the upper nozzle, and a plurality of fuel segments positioned intermediate the upper nozzle and the lower nozzle. The plurality of guide tubes are arranged in a first array. Each guide tube defines a longitudinal axis. Each fuel segment comprises a body defining a plurality of coolant flow channels and a plurality of guide tube openings. The guide tube openings are arranged in a second array corresponding to the first array. The guide tubes are positioned in the guide tube openings.