Patent ID: 8580350

Claim:
A method of forming a corrosion resistant neutron absorbing coating on a spent nuclear fuel support structure, comprising the steps of: producing a coating spray by providing amorphous metal, providing a neutron-absorbing material, and combining said amorphous metal and said neutron-absorbing material into a coating spray of combined amorphous metal and neutron-absorbing material; wherein said coating spray of combined amorphous metal and neutron-absorbing material contains undesirable particles with corrosion-prone bcc ferrite phase from boron-containing iron-based amorphous metal powders and further comprising the step of using a magnetic field for separating said undesirable particles with corrosion-prone bcc ferrite phase from said coating spray of combined amorphous metal and neutron-absorbing material; providing ceramic particles; wherein said step of combining said amorphous metal and said neutron-absorbing material into a coating spray of combined amorphous metal and neutron-absorbing material further comprises combining said amorphous metal, said neutron-absorbing material, and said ceramic particles into an amorphous metal/neutron-absorbing material/ceramic particles coating spray; positioning the spent nuclear fuel support structure and said coating spray of combined amorphous metal/neutron-absorbing material/ceramic particles in a position where said coating spray of combined amorphous metal neutron-absorbing material/ceramic particles is directed onto the spent nuclear fuel support structure; and spray processing the spent nuclear fuel support structure by spray processing the spent nuclear fuel support structure using said combined amorphous metal/neutron-absorbing material/ceramic particles coating spray of said combined amorphous metal/neutron-absorbing material/ceramic particles by cold spray deposition or thermal spray deposition of said combined amorphous metal/neutron-absorbing material/ceramic particles on the spent nuclear fuel support structure to form a composite material made of said combined amorphous metal/neutron-absorbing material/ceramic particles on the spent nuclear fuel support structure thereby producing homogenous metallic alloy that contains said combined amorphous metal neutron-absorbing material/ceramic particles on the spent nuclear fuel support structure.