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.

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. 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 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.

A fuel assembly for a nuclear reactor, a fuel rod of the fuel assembly, and a ceramic nuclear fuel pellet of the fuel rod are disclosed. The fuel pellet includes a first fissile material of UB.sub.2, The boron of the UB.sub.2 is enriched to have a concentration of the isotope .sup.11B that is higher than for natural B.

A fuel assembly for a nuclear reactor, a fuel rod of the fuel assembly, and a ceramic nuclear fuel pellet of the fuel rod are disclosed. The fuel pellet includes a first fissile material of UB.sub.2, The boron of the UB.sub.2 is enriched to have a concentration of the isotope .sup.11B that is higher than for natural B.

The present invention relates to a method for preparing a fully ceramic capsulated nuclear fuel material containing three-layer-structured isotropic nuclear fuel particles coated with a ceramic having a composition which has a higher shrinkage than a matrix in order to prevent cracking of ceramic nuclear fuel, wherein the three-layer-structured nuclear fuel particles before coating is included in the range of between 5 and 40 fractions by volume based on after sintering. More specifically, the present invention provides a composition for preparing a fully ceramic capsulated nuclear fuel containing three-layer-structured isotropic particles coated with the substance which includes, as a main ingredient, a silicon carbine derived from a precursor of the silicon carbide wherein a condition of ΔL.sub.c>ΔL.sub.m at normal pressure sintering is created, where the sintering shrinkage of the coating layer of the three-layer-structured isotropic nuclear fuel particles is ΔL.sub.c and the sintering shrinkage of the silicon carbide matrix is ΔL.sub.m; material produced therefrom; and a method for manufacturing the material. The residual porosity of the fully ceramic capsulated nuclear fuel material is 4% or less.

The present invention relates to a method for preparing a fully ceramic capsulated nuclear fuel material containing three-layer-structured isotropic nuclear fuel particles coated with a ceramic having a composition which has a higher shrinkage than a matrix in order to prevent cracking of ceramic nuclear fuel, wherein the three-layer-structured nuclear fuel particles before coating is included in the range of between 5 and 40 fractions by volume based on after sintering. More specifically, the present invention provides a composition for preparing a fully ceramic capsulated nuclear fuel containing three-layer-structured isotropic particles coated with the substance which includes, as a main ingredient, a silicon carbine derived from a precursor of the silicon carbide wherein a condition of ΔL.sub.c>ΔL.sub.m at normal pressure sintering is created, where the sintering shrinkage of the coating layer of the three-layer-structured isotropic nuclear fuel particles is ΔL.sub.c and the sintering shrinkage of the silicon carbide matrix is ΔL.sub.m; material produced therefrom; and a method for manufacturing the material. The residual porosity of the fully ceramic capsulated nuclear fuel material is 4% or less.

A metal or ceramic layer may be deposited on nuclear materials by chemical vapor deposition using a non-halogenated liquid organometallic metal precursor. The chemical vapor deposition is carried out by a method including steps of introducing nuclear fuel particles into a fluidized bed reactor, and heating the fluidized bed reactor to a desired operating temperature T.sub.1. A flow of a carrier- gas is initiated through a vaporizer, and the non-halogenated liquid organometallic metal precursor is injected into the vaporizer and vaporized. A first mixture of the carrier gas and the vaporized non-halogenated liquid organometallic metal precursor may be mixed with a gaseous carbon source, a gaseous nitrogen source, a gaseous oxygen source, or a mixture thereof to produce a second mixture; and the second mixture flows into the fluidized bed reactor at operating temperature T.sub.1, allowing deposition of a desired ceramic coating on the particles. The non-halogenated liquid organometallic metal precursor may be a compound of Zr, Hf, Nb, Ta, W, V, Ti, or a mixture thereof.

The known fully ceramic microencapsulated fuel (FCM) entrains fission products within a primary encapsulation that is the consolidated within a secondary ultra-high-temperature-ceramic of Silicon Carbide (SiC). In this way the potential for fission product release to the environment is significantly limited. In order to extend the performance of this fuel to higher temperature and more aggressive coolant environments, such as the hot-hydrogen of proposed nuclear rockets, a zirconium carbide matrix version of the FCM fuel has been invented. In addition to the novel nature to this very high temperature fuel, the ability to form these fragile TRISO microencapsulations within fully dense ZrC represent a significant achievement.

The known fully ceramic microencapsulated fuel (FCM) entrains fission products within a primary encapsulation that is the consolidated within a secondary ultra-high-temperature-ceramic of Silicon Carbide (SiC). In this way the potential for fission product release to the environment is significantly limited. In order to extend the performance of this fuel to higher temperature and more aggressive coolant environments, such as the hot-hydrogen of proposed nuclear rockets, a zirconium carbide matrix version of the FCM fuel has been invented. In addition to the novel nature to this very high temperature fuel, the ability to form these fragile TRISO microencapsulations within fully dense ZrC represent a significant achievement.

A method of forming a fuel rod for a nuclear reactor comprises disposing a powder comprising particles of a fuel material on a substrate, exposing the powder to energy from an energy source to form a first layer of a nuclear fuel, the first layer comprising inter-granular bonds between the particles of the fuel material, disposing additional powder comprising particles of the fuel material over the first layer of the nuclear fuel, and exposing the additional powder to energy from the energy source to form a second layer of the nuclear fuel and to form the nuclear fuel to have a void fraction greater than about 0.20, the second layer comprising inter-granular bonds between the additional powder and the first layer of the nuclear fuel. Related nuclear fuels comprising a porous structure, fuel rods, nuclear reactors, and methods are disclosed.