A method is described that includes the steps of making a thin walled Zr alloy tube, loading nuclear fuel pellets into the tube, compressing the tube onto the fuel pellets to substantially reduce free space around the fuel pellets, positioning end plugs at each of two ends of the tube, filling the tube with a heat transferring gas, and coating the compressed tube with a corrosion resistant material using a thermal deposition process, such as cold spray, before inserting the tube into a pre-formed SiC composite cover having at least one closed end.

A method is described that includes the steps of making a thin walled Zr alloy tube, loading nuclear fuel pellets into the tube, compressing the tube onto the fuel pellets to substantially reduce free space around the fuel pellets, positioning end plugs at each of two ends of the tube, filling the tube with a heat transferring gas, and coating the compressed tube with a corrosion resistant material using a thermal deposition process, such as cold spray, before inserting the tube into a pre-formed SiC composite cover having at least one closed end.

A nuclear reactor fuel rod is a fuel rod for a light-water reactor. The nuclear reactor fuel rod includes a fuel cladding tube and an end plug, both of which are formed of a silicon carbide material. A bonding portion between the fuel cladding tube and the end plug is formed by brazing with a predetermined metal bonding material interposed, and/or by diffusion bonding. The predetermined metal bonding material has a solidus temperature of 1200 C. or higher. An outer surface of the bonding portion, and a portion of an outer surface of the fuel cladding tube and the end plug, which is adjacent to the outer surface of the bonding portion are covered by bonding-portion coating formed of a predetermined coating metal. The predetermined metal bonding material and the predetermined coating metal have an average linear expansion coefficient which is less than 10 ppm/K.

A nuclear reactor fuel rod is a fuel rod for a light-water reactor. The nuclear reactor fuel rod includes a fuel cladding tube and an end plug, both of which are formed of a silicon carbide material. A bonding portion between the fuel cladding tube and the end plug is formed by brazing with a predetermined metal bonding material interposed, and/or by diffusion bonding. The predetermined metal bonding material has a solidus temperature of 1200 C. or higher. An outer surface of the bonding portion, and a portion of an outer surface of the fuel cladding tube and the end plug, which is adjacent to the outer surface of the bonding portion are covered by bonding-portion coating formed of a predetermined coating metal. The predetermined metal bonding material and the predetermined coating metal have an average linear expansion coefficient which is less than 10 ppm/K.

An improved retention system for retaining fuel rods in a fuel assembly is disclosed. The retention system includes a plurality of first engagement surfaces on the bottom nozzle of a fuel assembly. There is at least one engagement surface for each fuel rod. A second engagement surface is formed on the bottom end plug of each fuel rod. The first and second engagement surfaces are configured for engagement with each other for axially and laterally retaining each fuel rod within the fuel assembly. Debris deflectors may also be provided to deflect debris from coolant channels surrounding the fuel rods.

An improved retention system for retaining fuel rods in a fuel assembly is disclosed. The retention system includes a plurality of first engagement surfaces on the bottom nozzle of a fuel assembly. There is at least one engagement surface for each fuel rod. A second engagement surface is formed on the bottom end plug of each fuel rod. The first and second engagement surfaces are configured for engagement with each other for axially and laterally retaining each fuel rod within the fuel assembly. Debris deflectors may also be provided to deflect debris from coolant channels surrounding the fuel rods.

The invention relates to sealing a fuel rod composite cladding tube composed of silicon carbide regardless of the fuel rod cladding design architecture (e.g., monolithic, duplex with monolithic SiC on the inside and a composite made with SiC fibers and SiC matrix on the outside) preferably with sealed SiC end plug caps, additionally sealed with an interior braze and exterior SiC final coating, thus providing a double sealed end plug barrier effective at retaining gas tightness and providing mechanical strength for the sealed end joint while providing high chemical resistance.

The invention relates to sealing a fuel rod composite cladding tube composed of silicon carbide regardless of the fuel rod cladding design architecture (e.g., monolithic, duplex with monolithic SiC on the inside and a composite made with SiC fibers and SiC matrix on the outside) preferably with sealed SiC end plug caps, additionally sealed with an interior braze and exterior SiC final coating, thus providing a double sealed end plug barrier effective at retaining gas tightness and providing mechanical strength for the sealed end joint while providing high chemical resistance.

An improved retention system for retaining fuel rods in a fuel assembly is disclosed. The retention system includes a plurality of first engagement surfaces on the bottom nozzle of a fuel assembly. There is at least one engagement surface for each fuel rod. A second engagement surface is formed on the bottom end plug of each fuel rod. The first and second engagement surfaces are configured for engagement with each other for axially and laterally retaining each fuel rod within the fuel assembly. Debris deflectors may also be provided to deflect debris from coolant channels surrounding the fuel rods.

An improved retention system for retaining fuel rods in a fuel assembly is disclosed. The retention system includes a plurality of first engagement surfaces on the bottom nozzle of a fuel assembly. There is at least one engagement surface for each fuel rod. A second engagement surface is formed on the bottom end plug of each fuel rod. The first and second engagement surfaces are configured for engagement with each other for axially and laterally retaining each fuel rod within the fuel assembly. Debris deflectors may also be provided to deflect debris from coolant channels surrounding the fuel rods.