US 2022/0115151 A1 · CERMET FUEL ELEMENT AND FABRICATION AND APPLICATIONS THEREOF, INCLUDING IN THERMAL PROPULSION REACTOR

Abstract

CERMET fuel element includes a fuel meat of consolidated ceramic fuel particles (preferably refractory-metal coated HALEU fuel kernels) and an array of axially-oriented coolant flow channels. Formation and lateral positions of coolant flow channels in the fuel meat are controlled during manufacturing by spacer structures that include ceramic fuel particles. In one embodiment, a coating on a sacrificial rod (the rod being subsequently removed) forms the coolant channel and the spacer structures are affixed to the coating; in a second embodiment, a metal tube forms the coolant channel and the spacer structures are affixed to the metal tube. The spacer structures laterally position the coolant channels in spaced-apart relation and are consolidated with the ceramic fuel particles to form CERMET fuel meat of a fuel element, which are subsequently incorporated into fuel assemblies that are distributively arranged in a moderator block within a nuclear fission reactor, in particular for propulsion.

Claims31

Dependent claims

A CERMET fuel element, comprising:

a CERMET fuel meat having a composition including high-assay low-enriched uranium (HALEU) with a U-235 assay above 5 percent and below 20 percent;
and
a plurality of tubular-shaped, fuel element coolant channels including a cladding having a composition including a tungsten-containing alloy, wherein the CERMET fuel element has an axial centerline defining a longitudinal axis,
wherein the plurality of fuel element coolant channels extend in a longitudinal direction relative to the longitudinal axis of the CERMET fuel element from a first end surface of the CERMET fuel element to a second end surface of the CERMET fuel element, and
wherein, in a cross-section of the CERMET fuel element when viewed perpendicular to the longitudinal axis of the CERMET fuel element, the plurality of fuel element coolant channels are distributively arranged in the CERMET fuel meat.

2 more elements

A method of manufacturing a CERMET fuel element including a CERMET fuel meat and a plurality of fuel element coolant channels, comprising:

assembling a plurality of channel blanks in spaced-apart relation inside a can assembly for a HIP process, wherein assembling includes attaching a first end of each channel blank to a fixture of the can assembly and forming, by the spaced-apart relation, a void space between the plurality of channel blanks, and wherein an outer surface of each channel blank includes a plurality of spacer structures and each of the plurality of spacer structures is sized to provide uniform separation distance between each channel blank;
adding a first plurality of ceramic fuel particles to the void space;
sealing the can assembly;
and
consolidating the first plurality of ceramic fuel particles to form the CERMET fuel meat,
wherein the ceramic fuel particles have a composition including a high-assay low-enriched uranium (HALEU) with a U-235 assay above 5 percent and below 20 percent and a fuel particle coating containing tungsten or containing molybdenum and tungsten.

3 more elements

Dependencies are inferred from the claim text.

Cermet fuel element and fabrication and applications thereof, including in thermal propulsion reactor

Life of this patent

Cermet fuel element and fabrication and applications thereof, including in thermal propulsion reactor

Life of this patent

Abstract

Claims31