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.

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.

Carbide-based fuel assembly includes outer structural member of ceramic matrix composite material, the interior surface of which is lined in higher temperature regions with an insulation layer of porous refractory ceramic material. A continuous insulation layer extends the length of the fuel assembly or separate insulation layer sections have a thickness increasing step-wise along the length of the fuel assembly from upper (inlet) section towards bottom (outlet) section. A fuel element positioned inward of the insulation layer and between support meshes has a fuel composition including HALEU and has the form of a plurality of individual elongated fuel bodies or one or more fuel monolith bodies containing coolant flow channels. Fuel assemblies are distributively arranged in a moderator block, with upper end of the outer structural member attached to an inlet for propellant and lower end of the outer structural member operatively interfaced with a nozzle forming a NTP reactor.

A fuel core for a nuclear reactor in one embodiment includes an upper internals unit and a lower internals unit comprising nuclear fuel assemblies. The assembled fuel core includes an upper core plate, a lower core plate, and a plurality of channel boxes extending therebetween. Each channel box comprises a plurality of outer walls and inner walls collectively defining a longitudinally-extending interior channels or cells having a transverse cross sectional area configured for holding no more than a single nuclear fuel assembly in some embodiments. A cylindrical reflector circumferentially surrounds channel boxes and is engaged at opposing ends by the upper and lower core plates. Adjacent cells within each channel box are formed on opposite sides of inner walls such that the cells are separated from each other by the inner walls alone without any water gaps therebetween which benefits neutronics for some small modular reactor designs.

A zirconium alloy nuclear reactor cylindrical cladding has an inner Zr substrate surface, an outer volume of protective material, and an integrated middle volume of zirconium oxide, zirconium and protective material, where the protective material is applied by impaction at a velocity greater than 340 meters/second to provide the integrated middle volume resulting in structural integrity for the cladding.

A channel box has a hollow elongated portion and accommodates a plurality of nuclear reactor fuel rods inside the hollow elongated portion, wherein the hollow elongated portion is constituted by a plurality types of silicon carbide composite materials. The channel box has a shape that can be achieved by applying the silicon carbide composite material and can increase earthquake resistance and improve functions and performance as a fuel assembly.

A channel box has a hollow elongated portion and accommodates a plurality of nuclear reactor fuel rods inside the hollow elongated portion, wherein the hollow elongated portion is constituted by a plurality types of silicon carbide composite materials. The channel box has a shape that can be achieved by applying the silicon carbide composite material and can increase earthquake resistance and improve functions and performance as a fuel assembly.

An assembly to be inserted into a nuclear reactor, such as a liquid sodium-cooled fast neutron reactor, includes an assembly hollow body of elongate shape along a longitudinal axis X. The wall of the hollow body includes at least one through-opening. The assembly also includes an assembly element inserted into the hollow body. The assembly element includes at least one flexible blade of which the free end is shaped into a clip-fastening hook collaborating in clip-fastening fashion with the through-opening from inside the hollow body, so as to connect the assembly element to the hollow body. The assembly also includes at least one removable structure for locking the flexible blade clip-fastened into the through-opening. The removable locking structure makes it possible to prevent the flexible blade from flexing and thus the removable locking structure makes it possible to lock a connection between the assembly element and the hollow body.

An assembly to be inserted into a nuclear reactor, such as a liquid sodium-cooled fast neutron reactor, includes an assembly hollow body of elongate shape along a longitudinal axis X. The wall of the hollow body includes at least one through-opening. The assembly also includes an assembly element inserted into the hollow body. The assembly element includes at least one flexible blade of which the free end is shaped into a clip-fastening hook collaborating in clip-fastening fashion with the through-opening from inside the hollow body, so as to connect the assembly element to the hollow body. The assembly also includes at least one removable structure for locking the flexible blade clip-fastened into the through-opening. The removable locking structure makes it possible to prevent the flexible blade from flexing and thus the removable locking structure makes it possible to lock a connection between the assembly element and the hollow body.

A channel box in an embodiment includes a tubular portion. The tubular portion includes a first tubular layer, a second tubular layer, and an intermediate tubular layer. The first tubular layer contains silicon carbide as a major component. The second tubular layer is in parallel to and surrounds or is surrounded by the first tubular layer and contains silicon carbide fibers and silicon carbide complexed with the silicon carbide fibers. The intermediate tubular layer is disposed between the first tubular layer and the second tubular layer and contains a solid lubricant.