FUEL CLADDING COVERED BY A MESH

In various aspects, a nuclear fuel rod cladding is disclosed. The cladding can include a base tube and a mesh structure including gaps therein. The base tube can include an elongated tubular wall and can be configured to house nuclear fuel therein. The mesh structure can be positioned along at least a portion of the elongated tubular wall and can be configured to provide structural support to the base tube. In one aspect, the gaps of the mesh structure are designed to permit neutrons emitted by the nuclear fuel to pass therethrough to escape the fuel rod cladding.

FIELD

The present disclosure is generally related to nuclear fuel rod claddings, and more particularly, to fuel rod claddings including mesh structures, porous structures, coatings, or a combination thereof. In some aspects, the mesh structures, porous structures, and coatings can help to control the oxidation of the cladding tube, help to maintain the structural integrity of the cladding tube, and/or help to limit the neutronic penalty imposed by the cladding.

SUMMARY

The following summary is provided to facilitate an understanding of some of the innovative features unique to the aspects disclosed herein, and is not intended to be a full description. A full appreciation of the various aspects disclosed herein can be gained by taking the entire specification, claims, and abstract as a whole.

In various aspects, a nuclear fuel rod cladding is disclosed. In some aspects, the cladding includes a base tube and a mesh structure including gaps therein. The base tube can include an elongated tubular wall and can be configured to house nuclear fuel therein. The mesh structure can be positioned along at least a portion of the elongated tubular wall and can be configured to provide structural support to the base tube. In one aspect, the gaps of the mesh structure are designed to permit neutrons emitted by the nuclear fuel to pass therethrough to escape the fuel rod cladding.

In various aspects, a method for manufacturing a nuclear fuel rod cladding is disclosed. In some aspects, the method includes: providing a base tube including an elongated tubular wall. The elongated tubular wall can have an outer surface and the base tube can be configured to house nuclear fuel therein. The method can further include forming a mesh structure on the outer surface of the elongated tubular wall. The mesh structure can be configured to provide structural support to the base tube.

In various aspects, a nuclear fuel rod cladding is disclosed. In some aspects, the cladding includes a base tube and a porous layer including gaps therein. The base tube can include an elongated tubular wall and can be configured to house nuclear fuel therein. The porous layer can be positioned along at least a portion of the elongated tubular wall and can be configured to provide structural support to the base tube. In one aspect, the gaps of the porous layer are designed to permit neutrons emitted by the nuclear fuel to pass therethrough to escape the fuel rod cladding.

Corresponding reference characters indicate corresponding parts throughout the several views. The exemplifications set out herein illustrate various aspects of the present disclosure, in one form, and such exemplifications are not to be construed as limiting the scope of any of the aspects disclosed herein.

DETAILED DESCRIPTION

Numerous specific details are set forth to provide a thorough understanding of the overall structure, function, manufacture, and use of the aspects as described in the disclosure and illustrated in the accompanying drawings. Well-known operations, components, and elements have not been described in detail so as not to obscure the aspects described in the specification. The reader will understand that the aspects described and illustrated herein are non-limiting examples, and thus it can be appreciated that the specific structural and functional details disclosed herein may be representative and illustrative. Variations and changes thereto may be made without departing from the scope of the claims.

In a typical nuclear reactor, such as a pressurized water reactor (PWR), heavy water reactor (e.g., a CANDU), or a boiling water reactor (BWR), the reactor core can include a large number of fuel assemblies, each of which includes a plurality of elongated fuel elements or fuel rods. For example,FIG.1illustrates a cross-sectional elevation view of a fuel assembly10, according to at least one non-limiting aspect of this disclosure. The fuel assembly10includes an organized array of elongated fuel rods22. The fuel rods22can house a plurality of fuel pellets26each comprising a fissile material capable of creating the reactive power of the reactor through fission reactions.

The fuel rods22may be supported by one or more transverse grids20which attach to guide thimbles18. The guide thimbles18extend longitudinally between top nozzle16and bottom nozzle12and are configured for control rods34to operably move therethrough. Opposite ends of the guide thimbles18can attach to the top nozzle16and bottom nozzle12, respectively. The bottom nozzle12can be configured to support the fuel assembly10on a reactor vessel lower core plate14in the core region of a reactor (not shown). A liquid coolant such as water, or water including a neutron absorbing material such as boron, may be pumped to the fuel assembly16upwardly through a plurality of flow openings in the lower core plate14. The bottom nozzle12of the fuel assembly10may pass the coolant flow to and along the fuel rods22of the assembly10in order to extract heat generated as a result of the fission reactions occurring therein.

FIG.2illustrates an enlarged cross-sectional view of a fuel rod22, according to at least one non-limiting aspect of this disclosure. Referring now toFIGS.1-2, as mentioned above, each of the fuel rods22may include a plurality of nuclear fuel pellets26. The fuel pellets26are housed within an elongated cladding38tube that is closed at opposite ends by an upper end plug28and a lower end plug30. The pellets26may be maintained in a stack by a plenum spring32disposed between the upper end plug28and the top of the pellet stack. However, in other aspects, the pellets26may be otherwise configured via alternate mechanisms.

In various aspects, the fuel pellets26may comprise a fissile material capable of creating the reactive power of the reactor through fission reactions. For example, the fissile material may include uranium dioxide (UO2), plutonium dioxide (PuO2), thorium dioxide (ThO2), uranium nitride (UN), uranium silicide (U3Si2), or mixtures thereof. The fuel pellets26may also include a neutron absorbing material such as boron or boron compounds, gadolinium or gadolinium compounds, erbium or erbium compounds, or a combination thereof. However, in other aspects, the pellets26can include a variety of suitable materials capable of generating and/or controlling reactive power.

In various aspects, the cladding38tube may comprise a material including zirconium (Zr), iron (Fe), or combinations thereof. For example, the cladding38tube may be constructed of a zirconium (Zr) alloy that includes other metals such as niobium (Nb), tin (Sn), iron (Fe), and/or chromium (Cr).

The cladding38of the fuel rods22operates in a harsh environment. For example, the cladding38can be exposed to temperatures up to 1200° C. under normal operating conditions and potentially even higher temperatures under accident conditions. Moreover, as fission reactions occur inside the fuel rods22, fission gasses are produced. These fission gasses can build up pressure inside the fuel rods22and cause a force to be exerted against the internal surface of the cladding38tube.

The external surface of the cladding38tube is also subject to harsh conditions. For example, external pressure is exerted against the cladding38as it is immersed in the liquid coolant. Additionally, reactions with oxygen and hydrogen atoms included in the chemistry of the liquid coolant can cause the cladding38material (e.g. zirconium alloy) to oxidize and deteriorate over time. As oxidation progresses, the structural integrity of the cladding38tube can weaken. Eventually, portions of the cladding38tube can oxidize and weaken to the point where rupture occurs.

Additional factors may drive the cladding38tube to rupture. For example, as mentioned above, fission gasses can build up pressure inside the fuel rods22. Under normal conditions, the external pressure exerted by the liquid coolant can help to counteract the internal fission gas pressure. However, if the external pressure is removed by a loss of coolant event, then the internal fission gasses may drive a deteriorated (e.g., from oxidation) cladding38tube to rupture. Moreover, increased temperatures and/or exposure to steam caused by the loss of coolant event can accelerate the oxidation process.

Rupture of the cladding38tube can lead to a variety of problems. For example, liquid coolant (e.g., water) may enter the cladding38tube at the rupture point. Exposure of the fuel pellets26(e.g., UO2) to water can cause the release of additional gasses, such as hydrogen, which can cause further degradation of the cladding38tubes. Moreover, extensive cleanup activities may be required if fuel pellet(s)26or portions thereof are released into the liquid coolant as a result of a rupture. Yet further, if the magnitude of a rupture and/or ruptures is severe, the structural integrity of the fuel rods22and/or the fuel assembly10may be weakened. Thus, there is a need for devices, systems, and methods for controlling oxidation of the fuel rod cladding and/or improving the structural integrity of the fuel rod cladding to help prevent ruptures from occurring and to minimize the damage caused when ruptures do occur.

FIG.3illustrates longitudinal cross-sectional view of a portion of a nuclear fuel rod cladding100including a base tube102and an oxidation-resistant coating110, according to at least one non-limiting aspect of this disclosure. The base tube102may be constructed from materials similar to those disclosed above with respect to cladding38. For example, the base tube102may include zirconium (Zr) and/or other metals such as niobium (Nb), tin (Sn), iron (Fe), and chromium (Cr). In various aspects, the base tube102can include a zirconium (Zr) alloy. The zirconium (Zr) alloy can include niobium (Nb), tin (Sn), iron (Fe), and/or chromium (Cr).

The base tube102can include an elongated tubular wall104having an inner surface108and an outer surface106. The oxidation-resistant coating110is formed on the outer surface106of the tubular wall104to protect the base tube102from oxidation that can occur as a result of exposure to the liquid coolant. Thus, the oxidation-resistant coating110can also help to maintain the structural integrity of the cladding100by preventing and/or slowing the deterioration of the tubular wall104of the base tube102.

The oxidation-resistant coating110may be constructed from any suitable oxidation-resistant material. For example, the oxidation-resistant coating110can include chromium (Cr), iron (Fe), yttrium (Y), and/or aluminum (Al) and/or alloys of any combination thereof. Further, the oxidation-resistant coating110may be applied to the base tube102using various surface treatment technologies such as, for example, cold spray, thermal spray, physical vapor deposition (PVD), slurry coating, etc.

The thickness Tcof the oxidation-resistant coating110may be optimized based on a variety of considerations. For example, various coating110materials such as, for example, chromium (Cr) can be a neutron absorber in addition to being an oxidation-resistant material. Thus, the coating110can impose a neutronic penalty that can negatively affect the efficiency of the reactor. Further, a coating110with a greater thickness Tcmay impose a greater neutronic penalty. Accordingly, it may be desirable to apply a very thin oxidation-resistant coating110(e.g., Tcno greater than 20 microns, no greater than 15 microns, or no greater than 10 microns) to limit the neutronic penalty imposed by the coating110. However, achieving a very thin oxidation-resistant coating110layer can be difficult depending on the treatment technology used to apply the coating110. Moreover, a very thin coating110may be less effective at preventing oxidation and ensuring the structural integrity of the base tube102compared to thicker coatings. Accordingly, there is a need for coatings and/or other surface treatments that can provide oxidative resistance and structural support to the base tube102while imposing less of a neutronic penalty.

FIG.4illustrates a longitudinal cross-sectional view of a portion of a nuclear fuel rod cladding200A including a base tube102and a mesh structure210, according to at least one non-limiting aspect of this disclosure. Similar to the oxidation-resistant coating110ofFIG.3, the mesh structure210is formed on the outer surface106of the tubular wall104. However, according to the non-limiting aspect ofFIG.4, and unlike the oxidation-resistant coating110ofFIG.3, the mesh structure210does not coat the entire outer surface106of the tubular wall104. Instead, the mesh structure210can include gaps formed therein (not shown inFIG.4) that selectively leave portions of the outer surface106of the tubular wall104uncovered by the mesh structure210.

For example,FIGS.8-10illustrate various examples of mesh structure210patterns having gaps216formed therein.FIG.8depicts a rectangular mesh pattern,FIG.9depicts a diamond mesh pattern, andFIG.10depicts a spiral mesh pattern. Each of the mesh structures210includes a plurality of mesh segments214forming the various patterns. The mesh segments214are configured such that gaps216are formed therebetween. Thus, referring again toFIG.4, and also toFIGS.8-10, the mesh segments214cover portions of the outer surface106of the tubular wall104while remaining portions of the outer surface106of the tubular wall104are exposed by the gaps216. Although rectangular, diamond, and spiral patterns are depicted inFIGS.8-10, the mesh structure210may be formed in any suitable pattern (e.g. triangular, pentagonal, hexagonal, non-structured, etc.).

Alternatively, a suitable mesh structure may include more than one type of gap pattern. For example, a mesh structure may include a first pattern and a second pattern different from the first pattern. Also, in some implementations, a mesh structure can include a random pattern. In at least one example, the mesh structure can define a porous layer with a predetermined porosity.

Still referring toFIG.4, and also toFIGS.8-10, in some aspects, the mesh structure210may be constructed from any suitable oxidation-resistant material. For example, the mesh structure210can be constructed from materials similar to the oxidation-resistant coating110ofFIG.3, such as chromium (Cr), iron (Fe), yttrium (Y), and/or aluminum (Al) and/or alloys of any combination thereof.

Still referring toFIG.4, and also toFIGS.8-10, the mesh structure210can have a thickness Tm. In some aspects, the thickness Tmof the mesh structure210can be in a range of 5 to 100 microns, such as, for example 5 microns, 10 microns, 15 microns, 20 microns, 25 microns, 30 microns, 35 microns, 40 microns, 45 microns, or 50 microns. In other aspects, the thickness Tmof the mesh structure210can be greater than 100 microns.

Still referring toFIG.4, and also toFIGS.8-10, the mesh segments214can have a width Wm. In some aspects, the width Wmof the mesh segments214can be in a range of 0.1 mm to 5 mm, such as a range of 0.5 mm to 3 mm. For example, the mesh segments214can have width Wmof 0.5 mm, 0.6 mm. 0.7 mm, 0.8 mm, 0.9 mm, 1.0 mm, 1.1 mm, 1.2 mm, 1.3 mm, 1.4 mm, 1.5 mm, 1.6 mm, 1.7 mm, 1.8 mm, 1.9 mm, 2.0 mm, 2.1 mm, 2.2 mm, 2.3 mm, 2.4 mm, 2.5 mm, 2.6 mm, 2.7 mm, 2.8 mm, 2.9 mm, or 3.0 mm. In some aspects, each of the mesh segments214can have the same or about the same width Wm. In other aspects, mesh segments214of the same mesh structure210can have different widths Wm. For example, perpendicular mesh segments may have different widths Wm, alternating rows and/or columns of mesh segments may have different widths Wm, different portions along the elongated length of the cladding200may have mesh segments with different widths Wm, etc.

The distance between the mesh segments214can be selected to control the size of the gaps216. For example, in the non-limiting aspects ofFIGS.8-9, rows of the mesh segments214can be spaced at a distance Drand columns of the mesh segments214distance Dc. As another example, in the non-liming aspect ofFIG.10, rows of the mesh segments214can be spaced at a distance Dr. In some aspects, the distances Dr, Dcbetween various rows and/or columns of the mesh structure210can be the same or about the same across the entire mesh structure210. In other aspects, the distances Dr, Dcbetween the various rows and/or columns of the mesh structure can be different.

As mentioned above, materials used to construct the oxidation-resistant coating110, such as chromium (Cr), can be neutron absorbers. Similar materials may be used to construct the mesh structure210. Thus, the mesh structure210can also have neutron absorbing properties. However, the mesh structure210can include gaps216that allow portions of the external surface106of the tubular wall104to remain uncovered by the mesh segments214. Neutrons emitted by nuclear fuel contained within the cladding200A can escape the cladding200A by passing through the tubular wall104of the base tube102and through gaps216in the mesh structure210. In other words, the gaps216provide a path for at least some neutrons to escape the cladding200A without needing to pass through the material of the mesh structure210. Accordingly, the widths Wmof the mesh segments214and/or the distances (e.g., Dr, Dc) between the mesh segments214may be optimized to control the neutronic penalty imposed by the mesh structure210. Moreover, because some neutrons escaping the base tube102can encounter the mesh segments214, the thickness Tmcan also be optimized to control the neutronic penalty imposed by the mesh structure210. A person skilled in the art will appreciate that the mesh structure210can be configured to impose a lower overall neutronic penalty compared to the oxidation-resistant coating110described above, even in some cases where the mesh structure210thickness Tmis greater than the coating110thickness Tc.

Furthermore, as explained above, exposure of the base tube102to liquid coolant can cause the tubular wall104to deteriorate overtime. This deterioration, along with the pressure of fission gasses exerting a force against the internal surface108of the tubular wall104, can cause the cladding base tube102to rupture. The mesh structure210can serve to protect the portions of the external surface106of the tubular wall104that are covered by the mesh segments214from oxidation. The mesh structure210can also help limit oxidation of the base tube102to the areas of the external surface106of the tubular wall104that are left uncovered by the gaps216. Thus, the mesh structure210can help to prevent the formation of large, rupture-prone oxidized areas on the tubular wall104. Moreover, where rupture does occur, the mesh structure210can provide additional strength to hold the base tube102together and help prevent larger rupture holes from forming. Accordingly, the mesh structure210thickness Tm, the widths Wmof the mesh segments214, and/or the distances (e.g., Dr, Dc) between the mesh segments214may be optimized to minimize the neutronic penalty imposed by the mesh structure210while also ensuring that the mesh structure210provides structural support and corrosion resistance to the base tube102.

In some aspects, the various parameters of the mesh structure210described above can be selected and/or optimized such that the portion of the outer surface106of the elongated tubular wall104that is left uncovered by the gaps216of the mesh structure210is in a range of 5% to 90% of the total surface area of the outer surface106of the elongated tubular wall104. For example, the portion of the outer surface106of the elongated tubular wall104that is left uncovered by the gaps216of the mesh structure210can be 5%, 10%, 15%, 20%, 25%, 30%, 35%, 40%, 45%, 50%, 55%, 60%, 65%, 70%, 75%, 80%, 85%, or 90% of the total surface area of the outer surface106of the elongated tubular wall104.

In various aspects, the nuclear fuel rod cladding200can include both an oxidation-resistant coating110and a mesh structure210. For example,FIG.5illustrates a longitudinal cross-sectional view of a portion of a nuclear fuel rod cladding200B including a base tube102, a mesh structure210formed on an outer surface106of the tubular wall104, and an oxidation-resistant coating110applied to the outer surface212of the mesh structure210. Although not shown in the cross-sectional view shown inFIG.5, the oxidation-resistant coating110is also applied to the portions of the outer surface106of the tubular wall104left uncovered by the gaps of the mesh structure. Thus, the oxidation-resistant coating covers the entire outside surface of the fuel rod cladding200B.

The various properties of the mesh structure210and oxidation-resistant coating110of cladding200B can be similar to those described above with respect toFIGS.3-4and8-10. Thus, the nuclear fuel rod cladding200B can retain the structural and neutronic-penalty-reducing benefits of having the mesh structure210while also retaining the oxidation-resistance benefits of having an oxidation-resistant coating110surrounding the entire outside surface of the cladding200B. Moreover, the thickness Tm, widths Ws, and/or distances Dr, Dcassociated with the mesh structure210as well as the thickness Tcof the coating110can be optimized to achieve these benefits. For example, the mesh structure210can be configured to minimize the size of potential oxidation patches and/or ruptures and provide structural support to the base tube102. Further, the oxidation-resistant coating110can be configured with a very small thickness Tc(e.g., about 5-10 microns) to provide corrosion protection to the entire outer surface of the cladding200B while imposing only a limited neutronic penalty.

The nuclear fuel rod cladding200B configuration illustrated inFIG.5can, in some aspects, have a smoother outer surface compared to the cladding configuration200A illustrated inFIG.4. For example, the coating110may help to smooth over bumps protruding from the cladding200B resulting from the mesh structure210. Thus, the cladding200B configuration illustrated inFIG.5may allow for a larger mesh structure210thickness Tmbecause the coating110may help to mitigate potential issues related to roughness and subcooled boiling as liquid coolant flows along the outer surface of the cladding200B.

The nuclear fuel rod cladding200B configuration illustrated inFIG.5can, in some aspects, employ a mesh structure210that does not have oxidation-resistant properties. As mentioned above, the mesh structure210of the fuel rod cladding200B is coated with an oxidation-resistant coating110. Thus, in some aspects, the mesh structure210material used for fuel rod cladding200B may be selected for structural properties. Any suitable mesh structure210material may be selected, such as, for example, the mesh structure210materials disclosed above, zirconium alloys, silicon carbide, and/or other ceramics or ceramic composites.

FIG.6illustrates a longitudinal cross-sectional view of a portion of a nuclear fuel rod cladding200C including a base tube102, an oxidation-resistant coating110applied to the outer surface106of the tubular wall104, and a mesh structure210formed on the outer surface112of the oxidation-resistant coating110. Although not shown in the cross-sectional view shown inFIG.6, a portion of the oxidation-resistant coating110is left uncovered by the gaps216of the mesh structure210.

Referring toFIG.6, and also toFIGS.8-10, in some aspects, the portion of the outer surface112of the oxidation-resistant coating110that is left uncovered by the gaps216of the mesh structure210is in a range of 5% to 90% of the total surface area of the outer surface112of the of the oxidation-resistant coating110. For example, the portion of the outer surface112of the oxidation-resistant coating110that is left uncovered by the gaps216of the mesh structure210can be 5%, 10%, 15%, 20%, 25%, 30%, 35%, 40%, 45%, 50%, 55%, 60%, 65%, 70%, 75%, 80%, 85%, or 90% of the total surface area of the outer surface112of the oxidation-resistant coating110.

The various properties of the mesh structure210and oxidation-resistant coating110of cladding200C can be similar to those described above with respect toFIGS.3-4and8-10. Thus, the nuclear fuel rod cladding200C can retain the structural and neutronic-penalty-reducing benefits of having the mesh structure210while also retaining the oxidation-resistance benefits of having an oxidation-resistant coating110surrounding the entire base tube102. Moreover, the thickness Tm, widths Wm, and/or distances Dr, Dcassociated with the mesh structure210, as well as the thickness Tcof the coating110can be optimized to achieve these benefits. For example, the mesh structure210can be configured to minimize the size of potential oxidation patches and/or ruptures and provide structural support to the base tube102. Further, the oxidation-resistant coating110can be configured with a very small thickness Tc(e.g., about 5-10 microns) to provide corrosion protection to the entire outer surface106of the base tube102while imposing only a limited neutronic penalty.

FIG.7illustrates a longitudinal cross-sectional view of a portion of a nuclear fuel rod cladding200D including a base tube102, an oxidation-resistant coating110applied to the outer surface106of the tubular wall104, and a mesh structure210formed on the inner surface108of the tubular wall104.

The various properties of the mesh structure210and oxidation-resistant coating110of cladding200D can be similar to those described above with respect toFIGS.3-4and8-10. Thus, the nuclear fuel rod cladding200C can retain the structural and neutronic-penalty-reducing benefits of having the mesh structure210while also retaining the oxidation-resistance benefits of having an oxidation-resistant coating110surrounding the entire base tube102. Moreover, the thickness Tm, widths Ws, and/or distances Dr, Dcassociated with the mesh structure210, as well as the thickness Tcof the coating110can be optimized to achieve these benefits. For example, the mesh structure210can be configured to provide structural support to the base tube102along the internal surface108of the tubular wall104. Further, the oxidation-resistant coating110can be configured with a very small thickness Tc(e.g., about 5-10 microns) to provide corrosion protection to the entire outer surface106of the base tube102while imposing only a limited neutronic penalty.

The nuclear fuel rod cladding200D configuration illustrated inFIG.7can, in some aspects, employ a mesh structure210that does not have oxidation-resistant properties. As mentioned above, the mesh structure210is formed on the internal surface108of the tubular wall104. Thus, in some aspects, the mesh structure210material used for fuel rod cladding200D may be selected for structural properties. Any suitable mesh structure210material may be selected, such as, for example, the mesh structure210materials disclosed above, zirconium alloys, silicon carbide, and/or other ceramics or ceramic composites.

Referring now toFIGS.4-10, the mesh structures210disclosed herein can be formed using any suitable technique. For example, various know deposition, additive manufacturing, coating, subtractive manufacturing, and/or reductive techniques can be used to form the mesh structure210.

In some aspects, cold spray techniques can be used to form the mesh structure210on the base tube102and/or on the oxidation-resistant coating110. For example, cold spray may be used to directly apply (e.g., print, spray) mesh segments214having a desired pattern to the surface of the base tube102and/or the surface of oxidation-resistant coating110. As another example, a masking material may be applied to the surface of the base tube102and/or the surface of the oxidation-resistant coating110. Cold spray can be used to apply the mesh structure material and the masking material can be removed to form the desired gaps216in the mesh structure.

In some aspects, deposition techniques such as physical vapor deposition (PVD) can be used to form the mesh structure on the base tube102and/or on the oxidation-resistant coating110. For example, a masking material may be applied to the surface of the base tube102and/or the surface of the oxidation-resistant coating110. PVD can be used to apply the mesh structure material and the masking material can be removed to form the desired gaps216in the mesh structure210.

In various other aspects, techniques such as chemical vapor deposition (CVD), selective laser melting (SLM), or electric discharge machine (EDM) can be used to form the mesh structure210. As needed, a masking material can be used to form the desired gaps216of the mesh structure210pattern. In yet other aspects, the mesh structure material can be deposited to the base tube102and a suitable etching technique can be used to form the desired gaps216in the mesh structure210.

Various methods can be employed to manufacture the nuclear fuel rod claddings100,200disclosed herein with respect toFIGS.3-10.FIG.11depicts a flow chart of a method1000for manufacturing a nuclear fuel rod cladding, according to at least one non-limiting aspect of this disclosure. Referring primarily toFIG.11, and alsoFIGS.3-10, the method1000includes providing1002a base tube102comprising an elongated tubular wall104, the elongated tubular wall104having an outer surface106, the base tube102configured to house nuclear fuel therein. Further, the method1000includes forming1004a mesh structure210on the outer surface106of the elongated tubular wall104, the mesh structure210configured to provide structural support to the base tube102.

In some aspects of the method1000, the base tube102includes zirconium, iron, or a combination thereof. In other aspects of the method1000, the cladding comprises chromium, yttrium, iron, or a combination thereof.

In some aspects of the method1000, forming1004the mesh structure comprises forming gaps216in the mesh structure, and wherein a portion of the outer surface106of the elongated tubular wall104is left uncovered by the gaps216of the mesh structure210. In other aspects of the method1000, the portion of the outer surface106of the elongated tubular wall104left uncovered by the gaps216of the mesh structure210is in a range of 5% to 90% of a surface area of the outer surface106of the elongated tubular wall104.

In some aspects, the method1000includes applying an oxidation-resistant coating110to an outer surface of the mesh structure210and a portion of the outer surface106of the base tube102left uncovered by the gaps216of the mesh structure210.

In some aspects of the method1000, forming1004the mesh structure210comprises forming a square pattern, a diamond pattern, a spiral pattern, or a combination thereof. In other aspects of the method1000, forming1004the mesh structure210comprises depositing the mesh structure210using physical vapor deposition, depositing the mesh structure210using cold spray deposition and a masking material, depositing the mesh structure210using chemical vapor deposition, or depositing a mesh material and forming gaps216in the mesh material using etching.

Various aspects of the devices, systems, and methods described herein are set out in the following examples.

Example 1: A nuclear fuel rod cladding, the nuclear fuel rod cladding comprising: a base tube comprising an elongated tubular wall, the base tube configured to house nuclear fuel therein; and a mesh structure comprising gaps therein, the mesh structure positioned along at least a portion of the elongated tubular wall; wherein the mesh structure is configured to provide structural support to the base tube; and wherein the gaps of the mesh structure are designed to permit neutrons emitted by the nuclear fuel to pass therethrough to escape the fuel rod cladding.

Example 2: The cladding of example 1, wherein the base tube comprises zirconium, iron, or a combination thereof.

Example 3: The cladding of any of examples 1-2, wherein the mesh structure comprises chromium, yttrium, iron, or a combination thereof.

Example 4: The cladding of any of examples 1-3, wherein the mesh structure is formed on an outer surface of the elongated tubular wall, and wherein a portion of the outer surface of the elongated tubular wall is left uncovered by the gaps of the mesh structure.

Example 5: The cladding of any of examples 1-4, wherein the portion of the outer surface of the elongated tubular wall left uncovered by the gaps of the mesh structure is in a range of 5% to 90% of a surface area of the outer surface of the elongated tubular wall.

Example 6: The cladding of any of examples 1-5, further comprising an oxidation-resistant coating applied to an outer surface of the mesh structure and the portion of the outer surface of the base tube left uncovered by the gaps of the mesh structure.

Example 7: The cladding of any of examples 1-6, further comprising an oxidation-resistant coating applied to an outer surface of the elongated tubular wall, wherein the mesh structure is formed on an outer surface of the oxidation resistant coating, and wherein a portion of the oxidation-resistant coating is left uncovered by the gaps of the mesh structure.

Example 8: The cladding of any of examples 1-7, wherein the mesh structure is formed on an inner surface of the elongated tubular wall, and wherein a portion of the inner surface of the elongated tubular wall is left uncovered by the gaps of the mesh structure.

Example 9: The cladding of any of examples 1-8, further comprising an oxidation-resistant coating applied to an outer surface of the elongated tubular wall.

Example 10: The cladding of any of examples 1-9, wherein the mesh structure is configured in a square pattern, a diamond pattern, a spiral pattern, or a combination thereof.

Example 11: The cladding of any of examples 1-10, wherein the mesh structure comprises a plurality of mesh segments, and wherein the mesh segments have a width in a range of 0.5 mm to 3 mm.

Example 12: The cladding of any of examples 1-11, wherein the mesh structure comprises a plurality of mesh segments, and wherein the mesh segments have a thickness in a range of 10 microns to 30 microns.

Example 13: A method for manufacturing a nuclear fuel rod cladding, the method comprising: providing a base tube comprising an elongated tubular wall, the elongated tubular wall having an outer surface, the base tube configured to house nuclear fuel therein; and forming a mesh structure on the outer surface of the elongated tubular wall, the mesh structure configured to provide structural support to the base tube.

Example 14: The method of example 13, wherein the base tube comprises zirconium, iron, or a combination thereof.

Example 15: The method of any of examples 13-14, wherein the cladding comprises chromium, yttrium, iron, or a combination thereof.

Example 16: The method of any of examples 13-15, wherein forming the mesh structure comprises selectively depositing a material in a predefined pattern, and wherein a portion of the outer surface of the elongated tubular wall is left uncovered by gaps of the mesh structure.

Example 17: The method of any of examples 13-16, wherein the portion of the outer surface of the elongated tubular wall left uncovered by the gaps of the mesh structure is in a range of 5% to 90% of a surface area of the outer surface of the elongated tubular wall.

Example 18: The method of any of examples 13-17, further comprising applying an oxidation-resistant coating to an outer surface of the mesh structure and a portion of the outer surface of the base tube left uncovered by the gaps of the mesh structure.

Example 19: The method of any of examples 13-18, wherein the predefined pattern is a square pattern, a diamond pattern, a spiral pattern, or a combination thereof.

Example 20: The method of any of examples 13-19, wherein forming the mesh structure comprises depositing the mesh structure using physical vapor deposition, depositing the mesh structure using cold spray deposition and a masking material, depositing the mesh structure using chemical vapor deposition, or depositing a mesh material and forming gaps in the mesh material using etching.

Example 21: A nuclear fuel rod cladding, the nuclear fuel rod cladding comprising: a base tube comprising an elongated tubular wall, the base tube configured to house nuclear fuel therein; and a porous layer comprising gaps therein, the porous layer positioned along at least a portion of the elongated tubular wall; wherein the porous layer is configured to provide structural support to the base tube; and wherein the gaps of the porous layer are designed to permit neutrons emitted by the nuclear fuel to pass therethrough to escape the fuel rod cladding.

Example 22: The cladding of example 21, wherein the porous layer comprises chromium, yttrium, iron, or a combination thereof.

Example 23: The cladding of any of examples 21-22, wherein the porous layer is formed on an outer surface of the elongated tubular wall, and wherein a portion of the outer surface of the elongated tubular wall is left uncovered by the gaps of the porous layer.

Example 24: The method of any of examples 21-23, wherein the portion of the outer surface of the elongated tubular wall left uncovered by the gaps of the porous layer is in a range of about 5% to about 90% of a surface area of the outer surface of the elongated tubular wall.

The term “substantially”, “about”, or “approximately” as used in the present disclosure, unless otherwise specified, means an acceptable error for a particular value as determined by one of ordinary skill in the art, which depends in part on how the value is measured or determined. In certain embodiments, the term “substantially”, “about”, or “approximately” means within 1, 2, 3, or 4 standard deviations. In certain embodiments, the term “substantially”, “about”, or “approximately” means within 50%, 20%, 15%, 10%, 9%, 8%, 7%, 6%, 5%, 4%, 3%, 2%, 1%, 0.5%, or 0.05% of a given value or range.