A nuclear fuel cladding element comprises a substrate made of a material containing zirconium and a protective coating covering the substrate on the outside. The protective coating is being made of a material containing chromium, and has a columnar microstructure composed of columnar grains and having on the outer surface thereof a microdroplet density of less than 100 per mm2.

Nuclear fuel assemblies include fuel elements that are sintered or cast into billets and co-extruded into a spiral, multi-lobed shape. The fuel kernel may be a metal alloy of metal fuel material and a metal-non-fuel material, or ceramic fuel in a metal non-fuel matrix. The fuel elements may use more highly enriched fissile material while maintaining safe operating temperatures. Such fuel elements according to one or more embodiments may provide more power at a safer, lower temperature than possible with conventional uranium oxide fuel rods. The fuel assembly may also include a plurality of conventional UO2 fuel rods, which may help the fuel assembly to conform to the space requirements of conventional nuclear reactors.

Nuclear fuel assemblies include fuel elements that are sintered or cast into billets and co-extruded into a spiral, multi-lobed shape. The fuel kernel may be a metal alloy of metal fuel material and a metal-non-fuel material, or ceramic fuel in a metal non-fuel matrix. The fuel elements may use more highly enriched fissile material while maintaining safe operating temperatures. Such fuel elements according to one or more embodiments may provide more power at a safer, lower temperature than possible with conventional uranium oxide fuel rods. The fuel assembly may also include a plurality of conventional UO2 fuel rods, which may help the fuel assembly to conform to the space requirements of conventional nuclear reactors.

A nuclear reactor is constructed in sub-modules and super modules which are manufactured, packaged, and shipped to a construction site. At least some of the modules are packaged in suitable shielding containers or portions of containers, which may be steel. The modules are assembled on-site, and some of the modules remain within their respective shipping containers after assembly. One or more of the shipping containers may be used as concrete forms to support the pouring of concrete in between selected modules. The concrete may be used for structural support, shielding, or both.

A nuclear reactor is constructed in sub-modules and super modules which are manufactured, packaged, and shipped to a construction site. At least some of the modules are packaged in suitable shielding containers or portions of containers, which may be steel. The modules are assembled on-site, and some of the modules remain within their respective shipping containers after assembly. One or more of the shipping containers may be used as concrete forms to support the pouring of concrete in between selected modules. The concrete may be used for structural support, shielding, or both.

A method of forming a water resistant boundary on a fissile material for use in a water cooled nuclear reactor is described. The method comprises mixing a powdered fissile material selected from the group consisting of UN and U.sub.3Si.sub.2 with an additive selected from oxidation resistant materials having a melting or softening point lower than the sintering temperature of the fissile material, pressing the mixed fissile and additive materials into a pellet, sintering the pellet to a temperature greater than the melting point of the additive. Alternatively, if the melting point of the oxidation resistant particles is greater than the sintering temperature of UN or U.sub.3Si.sub.2, then the oxidation resistant particles can have a particle size distribution less than that of the UN or U.sub.3Si.sub.2.

Multi-layered nuclear fuel cladding, according to the present inventive concept, comprises: an inner tube of zirconium alloy, of which both ends are open for providing an accommodation space into which a sintered nuclear fuel pellet is inserted; and an outer tube, disposed coaxially with the inner tube, having a greater diameter than the inner tube so as to surround the outer surface of the inner tube, wherein the outer tube and the inner tube are fixed to closely contact each other, and may be formed from metals different from each other.

Nuclear propulsion fission reactor structure has an active core region including fuel element structures, a reflector with rotatable neutron absorber structures (such as drum absorbers), and a core former conformal mating the outer surface of the fuel element structures to the reflector. Fuel element structures are arranged abutting nearest neighbor fuel element structures in a tri-pitch design. Cladding bodies defining coolant channels are inserted into and joined to lower and upper core plates to from a continuous structure that is a first portion of the containment structure. The body of the fuel element has a structure with a shape corresponding to a mathematically-based periodic solid, such as a triply periodic minimal surface (TPMS) in a gyroid structure. The nuclear propulsion fission reactor structure can be incorporated into a nuclear thermal propulsion engine for propulsion applications, such as space propulsion.

A method is for manufacturing a nuclear fuel assembly (2) comprising nuclear fuel rods (4) arranged in a bundle and a skeleton (6) supporting the fuel rods (4). The method comprise the steps of inserting fuel rods (4) into the skeleton (6) to obtain a fuel assembly (2) and packaging the fuel assembly (2) in view of transportation. The steps are being performed in a same nuclear fuel assembly manufacturing plant (20), preferably in a same nuclear fuel assembly manufacturing building (60).

A method is for manufacturing a nuclear fuel assembly (2) comprising nuclear fuel rods (4) arranged in a bundle and a skeleton (6) supporting the fuel rods (4). The method comprise the steps of inserting fuel rods (4) into the skeleton (6) to obtain a fuel assembly (2) and packaging the fuel assembly (2) in view of transportation. The steps are being performed in a same nuclear fuel assembly manufacturing plant (20), preferably in a same nuclear fuel assembly manufacturing building (60).