Using additive manufacturing in creating a nuclear fuel structure with a shape corresponding to a mathematically-based periodic solid having a triply periodic minimal surface

Patent metadata

Field	Value
Publication number	US-12437891-B2
Application number	US-202318386031-A
Country	US
Kind code	B2
Filing date	Nov 1, 2023
Priority date	Apr 1, 2019
Publication date	Oct 7, 2025
Grant date	Oct 7, 2025

Abstract

A method of manufacturing a nuclear fuel segment includes varying a parameter of a lattice structure of a first mathematically-based periodic solid to form a second mathematically-based periodic solid. The second mathematically-based periodic solid comprises a triply periodic minimal surface (TPMS). The varying includes varying periodicity, thickness, or bias of the first mathematically-based periodic solid. The second mathematically-based periodic solid is embodied in a gridded mesh. The gridded mesh is sectioned into a plurality of layers. An additive manufacturing process is used to deposit a fissionable fuel composition in creating a body having a structure with a shape corresponding to the second mathematically-based periodic solid. The plurality of layers are used in controlling the additive manufacturing process.

First claim

What is claimed is:

1. A method of manufacturing a nuclear fuel segment, the method comprising:
varying a parameter of a lattice structure of a first mathematically-based periodic solid to form a second mathematically-based periodic solid, wherein the second mathematically-based periodic solid comprises a triply periodic minimal surface (TPMS) and wherein varying the parameter includes:
varying a periodicity of the first mathematically-based periodic solid,
varying a thickness of the first mathematically-based periodic solid, or
varying a bias of the first mathematically-based periodic solid,
where the bias relates to converging and diverging regions
within the second mathematically-based periodic solid;

embodying the second mathematically-based periodic solid in a gridded mesh;
sectioning the gridded mesh into a plurality of layers; and
using the plurality of layers to control an additive manufacturing process to deposit a fissionable fuel composition to manufacture a body having a structure with a shape corresponding to the second mathematically-based periodic solid.

2. The method of claim 1 , wherein the body having the structure with the shape corresponding to the second mathematically-based periodic solid includes a network of interconnected channels, and
wherein varying the parameter changes a flow rate of a medium flowing through the network of interconnected channels.

3. The method of claim 2 , wherein at least a portion of the interconnected channels of the network of interconnected channels extend from a first outer surface of the body to a second outer surface of the body,
wherein the structure has a volumetric density of 35% to 85%, and
wherein a composition of the structure includes a nuclear fissionable fuel having an enrichment of up to 20%.

4. The method according to claim 3 , wherein a specific enrichment of the structure (% enrichment per unit volume) is constant ±2%.

5. The method according to claim 2 , further comprising depositing a cladding layer on surfaces of the network of interconnected channels.

6. The method according to claim 5 , wherein depositing the cladding layer includes a vapor deposition technique, a chemical vapor deposition technique, electroplating or electroless plating.

7. The method according to claim 5 , wherein the cladding has a composition including molybdenum, tungsten, rhenium, tantalum, hafnium and alloys thereof, including carbides.

8. The method according to claim 5 , wherein the cladding layer has a composition including a steel alloy, a zirconium alloy, a molybdenum-containing metal alloy, a molybdenum-tungsten alloy, Zircaloy-4 or Hastelloy X.

9. The method of claim 1 , wherein varying the parameter changes a neutronic characteristic of a nuclear reactor incorporating a fuel element containing the nuclear fuel segment.

10. The method according to claim 9 , wherein the body having the structure with the shape corresponding to the second mathematically-based periodic solid includes a network of interconnected channels, and
wherein the method further comprises depositing a cladding layer on surfaces of the network of interconnected channels.

11. The method according to claim 10 , wherein depositing the cladding layer includes a vapor deposition technique, a chemical vapor deposition technique, electroplating or electroless plating.

12. The method according to claim 10 , wherein the cladding has a composition including molybdenum, tungsten, rhenium, tantalum, hafnium and alloys thereof, including carbides.

13. The method according to claim 10 , wherein the cladding layer has a composition including a steel alloy, a zirconium alloy, a molybdenum-containing metal alloy, a molybdenum-tungsten alloy, Zircaloy-4 or Hastelloy X.

14. The method of claim 1 , wherein varying the parameter changes a thermal hydraulics characteristic or a stress mechanics characteristic of a nuclear reactor incorporating a fuel element containing the nuclear fuel segment.

15. The method according to claim 14 , wherein the body having the structure with the shape corresponding to the second mathematically-based periodic solid includes a network of interconnected channels, and
wherein the method further comprises depositing a cladding layer on surfaces of the network of interconnected channels.

16. The method according to claim 15 , wherein depositing the cladding layer includes a vapor deposition technique, a chemical vapor deposition technique, electroplating or electroless plating.

17. The method according to claim 15 , wherein the cladding has a composition including molybdenum, tungsten, rhenium, tantalum, hafnium and alloys thereof, including carbides.

18. The method according to claim 15 , wherein the cladding layer has a composition including a steel alloy, a zirconium alloy, a molybdenum-containing metal alloy, a molybdenum-tungsten alloy, Zircaloy-4 or Hastelloy X.

19. The method according to claim 1 , wherein at least a portion of the interconnected channels of the network of interconnected channels extend from a first outer surface of the body to a second outer surface of the body,
wherein the structure has a volumetric density of 35% to 85%, and
wherein a composition of the structure includes a nuclear fissionable fuel having an enrichment of up to 20%.

20. The method according to claim 19 , wherein a specific enrichment of the structure (% enrichment per unit volume) is constant ±2%.

21. The method according to claim 19 , further comprising depositing a cladding layer on surfaces of the network of interconnected channels,
wherein depositing the cladding layer includes a vapor deposition technique, a chemical vapor deposition technique, electroplating or electroless plating.

22. The method according to claim 21 , wherein the cladding has a composition including molybdenum, tungsten, rhenium, tantalum, hafnium and alloys thereof, including carbides.

23. The method according to claim 21 , wherein the cladding layer has a composition including a steel alloy, a zirconium alloy, a molybdenum-containing metal alloy, a molybdenum-tungsten alloy, Zircaloy-4 or Hastelloy X.

24. The method according to claim 1 , wherein the additive manufacturing process includes photopolymerization.

25. The method according to claim 1 , wherein the body is disc-shaped and occupies a volume that includes a radial side surface corresponding to a thickness of the body between a first outer surface and a second outer surface, and wherein the method further comprises placing a side wall radially outward of the radial side surface of the body,
wherein the side wall has a composition including a neutron thermalizing material, and
wherein the neutron thermalizing material has a composition including a zirconium (Zr) alloy, a beryllium (Be) alloy, or graphite.

26. A method of manufacturing a nuclear fuel segment, the method comprising:
varying a parameter of a lattice structure of a first mathematically-based periodic solid to form a second mathematically-based periodic solid, wherein the second mathematically-based periodic solid comprises a triply periodic minimal surface (TPMS) and wherein the varying includes varying:
a periodicity of the first mathematically-based periodic solid,
a thickness of the first mathematically-based periodic solid, and
a bias of the first mathematically-based periodic solid, where the bias relates to converging and diverging regions;

e

Assignees

• Bwxt Advanced Tech Llc

Inventors

• Fisher Benjamin D
• Salasin John R
• Gramlich Craig D
• Witter Jonathan K

Classifications

• Y10S376/909

  Mobile reactors · CPC title

• Y10S376/901

  Fuel · CPC title

• G21C7/24

  Selection of substances for use as neutron-absorbing material · CPC title

• G21C3/64

  Ceramic dispersion fuel, e.g. cermet · CPC title

• G21C3/60

  Metallic fuel; Intermetallic dispersions · CPC title