Ut-battelle, Inc.

Kurt A Terrani

Michael P Trammell

Brian C Jolly

Christian M Petrie

Andrew T Nelson

Ryan Dehoff

Phillip C Chesser

Kevin G Field

Benjamin R Betzler

An improved method for embedding one or more sensors in SiC is provided. The method includes depositing a binder onto successive layers of a SiC powder feedstock to produce a dimensionally stable green body have a true-sized cavity. A sensor component is then press-fit into the true-sized cavity. Alternatively, the green body is printed around the sensor component. The assembly (the green body and the sensor component) is heated within a chemical vapor infiltration (CVI) chamber for debinding, and a precursor gas is introduced for densifying the SiC matrix material. During infiltration, the sensor component becomes bonded to the densified SiC matrix, the sensor component being selected to be thermodynamically compatible with CVI byproducts at elevated temperatures, including temperatures in excess of 1000° C.

Embedding sensors in 3D-printed silicon carbide

A nuclear fuel cladding with improved thermomechanical properties is provided. The nuclear fuel cladding includes a double-walled construction having inner and outer hexagonal sidewalls. The inner sidewall and the outer sidewall are spaced apart from each other to form a cooling channel therebetween, and the inner sidewall surrounds a nuclear fuel and is spaced apart from the nuclear fuel by a small gap. Helical fins extend into the cooling channel to interconnect the inner sidewall and the outer sidewall. Resilient fingers extend toward the nuclear fuel through the small gap to comply with variations in the size of the nuclear fuel due to fabrication tolerances as well as thermal expansion and swelling of the nuclear fuel, for example UO, when undergoing fission. The nuclear fuel cladding is formed according to an additive manufacturing process, for example laser powder bed fusion printing.

3D printed features on nuclear fuel cladding for optimized heat transfer

A method for the manufacture of a three-dimensional object using a refractory matrix material is provided. The method includes the additive manufacture of a green body from a powder-based refractory matrix material followed by densification via chemical vapor infiltration (CVI). The refractory matrix material can be a refractory ceramic (e.g., silicon carbide, zirconium carbide, or graphite) or a refractory metal (e.g., molybdenum or tungsten). In one embodiment, the matrix material is deposited according to a binder-jet printing process to produce a green body having a complex geometry. The CVI process increases its density, provides a hermetic seal, and yields an object with mechanical integrity. The residual binder content dissociates and is removed from the green body prior to the start of the CVI process as temperatures increase in the CVI reactor. The CVI process selective deposits a fully dense coating on all internal and external surfaces of the finished object.

Additive manufacturing of complex objects using refractory matrix materials

A method for manufacturing a nuclear fuel compact is provided. The method includes forming an additive structure, consolidating a fuel matrix around the additive structure, and thermally processing the fuel matrix to form a fuel compact in which the additive structure is encapsulated therein. The additive structure optionally includes a vertical segment and a plurality of arm segments that extend generally radially from the vertical segment for conducting heat outwardly toward an exterior of the fuel compact. In addition to improving heat transfer, the additive structure may function as burnable absorbers, and may provide fission product trapping.

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Knoxville, TN, United States of America

Kurt A Terrani