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.

The method includes assessing operational characteristics of the fuel assembly, the assessing including determining if the fuel assembly is to be placed in a controlled location in the reactor core, a controlled location being positioned adjacent to a control blade that is to be utilized, and configuring the sidewalls of the outer channel by making at least a first select sidewall of the outer channel a reinforced sidewall, the remaining sidewalls of the outer channel, other than the at least a first select sidewall, being non-reinforced sidewalls. The entirety of the reinforced sidewall as a whole is at least one of thicker and made from a material that is more resistant to radiation-induced deformation as compared to an entirety of the non-reinforced sidewalls.

The method includes assessing operational characteristics of the fuel assembly, the assessing including determining if the fuel assembly is to be placed in a controlled location in the reactor core, a controlled location being positioned adjacent to a control blade that is to be utilized, and configuring the sidewalls of the outer channel by making at least a first select sidewall of the outer channel a reinforced sidewall, the remaining sidewalls of the outer channel, other than the at least a first select sidewall, being non-reinforced sidewalls. The entirety of the reinforced sidewall as a whole is at least one of thicker and made from a material that is more resistant to radiation-induced deformation as compared to an entirety of the non-reinforced sidewalls.

A nuclear fuel assembly for a nuclear reactor core including at least one fuel cartridge having a lattice structure including an outer wall defining an interior volume, at least one flow channel extending through the interior volume of the lattice structure, at least one lattice site disposed in the interior of the lattice structure; and at least one fuel compact disposed within a corresponding one of the at least one lattice site. A cross-sectional shape of the at least one fuel compact is the same as a cross-sectional shape of the corresponding one of the at least one lattice site.

A method of making a fuel channel for a fuel assembly for a nuclear power boiling water reactor. The method includes providing at least one first sheet of a Zr-based material of a first thickness, and providing at least one second sheet of a Zr-based material of a second thickness which is less than said first thickness. It also includes assembling at least said at least one first sheet and said at least one second sheet, such that a fuel channel is formed and such that said at least one first sheet forms a lower part of the fuel channel. The at least one second sheet forms a higher part of the fuel channel and the lower part is joined with said higher part. The lower part constitutes 20-75% of the length of the fuel channel.

A method of making a fuel channel for a fuel assembly for a nuclear power boiling water reactor. The method includes providing at least one first sheet of a Zr-based material of a first thickness, and providing at least one second sheet of a Zr-based material of a second thickness which is less than said first thickness. It also includes assembling at least said at least one first sheet and said at least one second sheet, such that a fuel channel is formed and such that said at least one first sheet forms a lower part of the fuel channel. The at least one second sheet forms a higher part of the fuel channel and the lower part is joined with said higher part. The lower part constitutes 20-75% of the length of the fuel channel.

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.

Fuel assemblies include an outer channel having a physical configuration optimized for a position of the fuel assembly within a core of a nuclear reactor. The position of the fuel assembly with respect to an employed control blade in the nuclear reactor determines if the outer channel may be thickened, reinforced, and/or fabricated of Zircaloy-4 or similar distortion-resistant material, so as to reduce or prevent distortion of the channel against the control blade, or thinned so as to increase water volume and enhance reactivity in the assembly. Reactor cores having configured fuel assemblies include fuel assemblies having different outer channels. Methods include determining operational characteristics of the fuel assembly, including likelihood of being placed directly adjacent to an employed control blade, and physically selecting or modifying the outer channel of the fuel assembly based thereon.

Fuel assemblies include an outer channel having a physical configuration optimized for a position of the fuel assembly within a core of a nuclear reactor. The position of the fuel assembly with respect to an employed control blade in the nuclear reactor determines if the outer channel may be thickened, reinforced, and/or fabricated of Zircaloy-4 or similar distortion-resistant material, so as to reduce or prevent distortion of the channel against the control blade, or thinned so as to increase water volume and enhance reactivity in the assembly. Reactor cores having configured fuel assemblies include fuel assemblies having different outer channels. Methods include determining operational characteristics of the fuel assembly, including likelihood of being placed directly adjacent to an employed control blade, and physically selecting or modifying the outer channel of the fuel assembly based thereon.