A method of forming one or more structures by additive manufacturing comprises introducing a first layer of a powder mixture comprising graphite and a fuel on a surface of a substrate. The first layer is at least partially compacted and then exposed to laser radiation to form a first layer of material comprising the fuel dispersed within a graphite matrix material. At least a second layer of the powder mixture is provided over the first layer of material and exposed to laser radiation to form inter-granular bonds between the second layer and the first layer. Related structures and methods of forming one or more structures are also disclosed.

A conversion process for converting uranium hexafluoride into uranium dioxide includes the steps of hydrolysis of UF6 to uranium oxyfluoride (UO.sub.2F.sub.2) in a hydrolysis reactor (4) by reaction between gaseous UF6 and dry water vapour injected into the reactor (4), pyrohydrolysis of UO.sub.2F.sub.2 to UO.sub.2 in a pyrohydrolysis furnace (6) by reacting UO.sub.2F.sub.2 with dry steam and gaseous hydrogen (H.sub.2) injected into the furnace (6), extracting excess gas in the reactor (4) via a collecting device (50) comprising several filters (52), periodically cleaning the filters (52) by injecting a neutral gas into the filters (52) from the outside to the inside of the reactor (4) to remove powder stuck on the filters (52), and measuring the relative pressure in the reactor (4). The conversion method further includes carrying out point cleaning of the filters (52) when the relative pressure in the reactor (4) exceeds a predetermined point cleaning threshold.

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.

Fuel bundle has plurality of twisted ribbon fuel rodlets arranged 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.

A nuclear fuel powder production plant comprises a conversion installation (2) for the conversion of uranium hexafluoride (UF.sub.6) into uranium dioxide (UO.sub.2) having a hydrolysis reactor (4) for the conversion of UF.sub.6 into uranium oxyfluoride powder (UO.sub.2F2) and a pyrohydrolysis furnace (6) for converting the UO.sub.2F2 powder into UO.sub.2 powder. The nuclear fuel powder production plant also includes a packaging unit (20) for the UO.sub.2 powder comprising a filling station (22) having a chamber (26) for receiving a container (24) to be filled, a filling duct (28) supplied from the furnace (6) and a suction system (32) comprising a suction ring (34) disposed at the outlet (30) of the filling duct (28) for sucking an annular air flow (A) around a stream (P) of UO.sub.2 powder falling from the outlet (30) from the filling duct (28) into the container (24).

A novel semi-batch process for deconverting high assay low enriched uranium (HALEU) from its uranium hexafluoride state to uranium dioxide and other chemical states useful as feeds for nuclear fuel in a nuclear reactor is provided. The semi-batch process enables the use of equipment that is small enough, and production rates that are low enough, to meet nuclear criticality safety restraints for HALEU, while enabling the safe, dependable, and economical production of HALEU feed for nuclear fuel at a nominal capacity of up to about 20 MTU (metric tons of uranium metal) per year per deconversion reactor.

A fuel structure includes an advanced technology fuel (ATF) composite body. The ATF composite body includes a first fissile material, such as uranium oxide (UO.sub.2), and a second fissile material, such as uranium diboride (UB.sub.2). The boron atoms of the second fissile material include an integrated burnable absorber (IBA). The ATF composite body further includes an ATF composition comprising the second fissile material combined with the first fissile material. The IBA of the second fissile material is distributed in a matrix of the first fissile material without a detectable amount of uranium tetraboride (UB.sub.4).

Fuel bundle has plurality of twisted ribbon fuel rodlets arranged 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.

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.