A method of making a joint between parts is provided, wherein the surface of at least one of the parts comprises aluminum oxide such as alpha aluminum oxide in the form of sapphire. A layer of aluminum nitride is provided between the surfaces of the parts where these contact. The method comprises the steps of bringing the parts into contact whereby the aluminum nitride layer is sandwiched between the parts and is in contact with the aluminum oxide surface, and performing localized heating of the aluminum nitride. The aluminum nitride is heated to at least the melting temperature of the aluminum nitride aluminum oxide eutectic, such that the aluminum nitride and adjacent aluminum oxide mix and melt to form an aluminum oxy-nitride bond. On cooling, the aluminum oxynitride forms a solid joint between the parts.

A method of making a joint between parts is provided, wherein the surface of at least one of the parts comprises aluminum oxide such as alpha aluminum oxide in the form of sapphire. A layer of aluminum nitride is provided between the surfaces of the parts where these contact. The method comprises the steps of bringing the parts into contact whereby the aluminum nitride layer is sandwiched between the parts and is in contact with the aluminum oxide surface, and performing localized heating of the aluminum nitride. The aluminum nitride is heated to at least the melting temperature of the aluminum nitride aluminum oxide eutectic, such that the aluminum nitride and adjacent aluminum oxide mix and melt to form an aluminum oxy-nitride bond. On cooling, the aluminum oxynitride forms a solid joint between the parts.

A nuclear fuel assembly body with a lengthways axis includes first and second tubular segments made from a metal material forming the lengthways ends of the assembly body. A frame made from a metal material connects the first and second segments. The frame is openworked. A ceramic tubular internal structure is positioned between the first and second segments inside the frame.

A nuclear fuel assembly body with a lengthways axis includes first and second tubular segments made from a metal material forming the lengthways ends of the assembly body. A frame made from a metal material connects the first and second segments. The frame is openworked. A ceramic tubular internal structure is positioned between the first and second segments inside the frame.

Carbide-based fuel assembly includes outer structural member of ceramic matrix composite material (e.g., SiCSiC composite), insulation layer of porous refractory ceramic material (e.g., zirconium carbide with open-cell foam structure or fibrous zirconium carbide), and interior structural member of refractory ceramic-graphite composite material (e.g., zirconium carbide-graphite or niobium carbide-graphite). Spacer structures between various layers provide a defined and controlled spacing relationship. A fuel element bundle positioned between support meshes includes a plurality of distributively arranged fuel elements or a solid, unitary fuel element with coolant channels, each having a fuel composition including high assay, low enriched uranium (HALEU). Fuel assemblies are distributively arranged in a moderator block and the upper end of the outer structural member is attached to a metallic inlet tube for hydrogen propellant and the lower end of the outer structural member is interfaced with a support plate, forming a nuclear thermal propulsion reactor.

Insulated fuel assembly core with plurality of fuel monoliths, exhaust support plate, exhaust shield assembly, and insulation layer in which the plurality of fuel monoliths are located axially along a longitudinal axis and each of the plurality of fuel monoliths has a shape of an eccentric cylinder and a composition including a fissionable fuel component. Channels in the exhaust support plate are oriented so that propellant gas flow through the exhaust support plate does not impinge the exhaust shield assembly. The insulated fuel assembly core is manufactured by forming a tensioned fuel monolith stack mandrel assembly using mandrels spacers and internal tensioning components and forming an insulation layer on an outer surface of the tensioned fuel monolith stack mandrel assembly by mandrel winding. The insulated fuel assembly core can be incorporated into a fuel assembly of nuclear propulsion fission reactor structure of, for example, a nuclear thermal propulsion engine.

The fuel assembly includes a base material formed of a zirconium alloy and a coating layer, and the coating layer includes a chromium layer formed of chromium or a chromium alloy and a corrosion-resistant layer formed of zirconium alloy or a titanium alloy. The method for producing a fuel assembly includes a step of preparing the base material, a step of forming the chromium layer on a surface of the base material that would otherwise be in contact with cooling water, a step of forming the corrosion-resistant layer on a surface of the chromium layer, and a step of assembling the fuel assembly using the base material. The chromium layer and the corrosion-resistant layer are formed according to a thin plate cladding method, a physical vapor deposition method, a thermal spraying method, a cold spraying method, or a plating method before the assembling using the base material.

The fuel assembly includes a base material formed of a zirconium alloy and a coating layer, and the coating layer includes a chromium layer formed of chromium or a chromium alloy and a corrosion-resistant layer formed of zirconium alloy or a titanium alloy. The method for producing a fuel assembly includes a step of preparing the base material, a step of forming the chromium layer on a surface of the base material that would otherwise be in contact with cooling water, a step of forming the corrosion-resistant layer on a surface of the chromium layer, and a step of assembling the fuel assembly using the base material. The chromium layer and the corrosion-resistant layer are formed according to a thin plate cladding method, a physical vapor deposition method, a thermal spraying method, a cold spraying method, or a plating method before the assembling using the base material.

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. Fuel element positioned inward of the insulation layer and between support meshes has a fuel composition including HALEU and 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 nuclear thermal propulsion reactor.

Fuel bundle has plurality of twisted ribbon fuel rodlets arranged in hexagonal packing or circle packing arrangement in a reactor core encased in a multilayer casing. Arrangement of twisted ribbon fuel rodlets is facilitated by rodlet seating fixture with seating surface having a plurality of protrusions that form a receiving space for ends of the twisted ribbon fuel rodlets. Manufacture of the fuel bundle incorporates fiber manufacturing technologies and, optionally, infiltration of spaces in the reactor core by infiltrant. Twisted ribbon fuel rodlet manufacturing system has sub-systems that impart twist periodicity to extruded ribbons, inspect twisted extruded ribbons, and cut twisted extruded ribbons to length. Inspection sorts twisted ribbon fuel rodlets as well as provides feedback to adjust operation of sub-systems. The fuel bundle (and optional fuel bundle support) can be incorporated into a fuel assembly of nuclear propulsion fission reactor structure of, for example, a nuclear thermal propulsion engine.