Nuclear fuel assemblies include fuel elements that are sintered or cast into billets and co-extruded into a spiral, multi-lobed shape. The fuel kernel may be a metal alloy of metal fuel material and a metal-non-fuel material, or ceramic fuel in a metal non-fuel matrix. The fuel elements may use more highly enriched fissile material while maintaining safe operating temperatures. Such fuel elements according to one or more embodiments may provide more power at a safer, lower temperature than possible with conventional uranium oxide fuel rods. The fuel assembly may also include a plurality of conventional UO2 fuel rods, which may help the fuel assembly to conform to the space requirements of conventional nuclear reactors.

Embodiments of the invention are directed to a method for production of a nuclear fuel pellet by spark plasma sintering (SPS), wherein a fuel pellet with more than 80% TD or more than 90% TD is formed. The SPS can be performed with the imposition of a controlled uniaxial pressure applied at the maximum temperature of the processing to achieve a very high density, in excess of 95% TD, at temperatures of 850 to 1600° C. The formation of a fuel pellet can be carried out in one hour or less. In an embodiment of the invention, a nuclear fuel pellet comprises UO.sub.2 and a highly thermally conductive material, such as SiC or diamond.

Embodiments of the invention are directed to a method for production of a nuclear fuel pellet by spark plasma sintering (SPS), wherein a fuel pellet with more than 80% TD or more than 90% TD is formed. The SPS can be performed with the imposition of a controlled uniaxial pressure applied at the maximum temperature of the processing to achieve a very high density, in excess of 95% TD, at temperatures of 850 to 1600° C. The formation of a fuel pellet can be carried out in one hour or less. In an embodiment of the invention, a nuclear fuel pellet comprises UO.sub.2 and a highly thermally conductive material, such as SiC or diamond.

Embodiments of the invention are directed to a method for production of a nuclear fuel pellet by spark plasma sintering (SPS), wherein a fuel pellet with more than 80% TD or more than 90% TD is formed. The SPS can be performed with the imposition of a controlled uniaxial pressure applied at the maximum temperature of the processing to achieve a very high density, in excess of 95% TD, at temperatures of 850 to 1600° C. The formation of a fuel pellet can be carried out in one hour or less. In an embodiment of the invention, a nuclear fuel pellet comprises UO.sub.2 and a highly thermally conductive material, such as SiC or diamond.

Embodiments of the invention are directed to a method for production of a nuclear fuel pellet by spark plasma sintering (SPS), wherein a fuel pellet with more than 80% TD or more than 90% TD is formed. The SPS can be performed with the imposition of a controlled uniaxial pressure applied at the maximum temperature of the processing to achieve a very high density, in excess of 95% TD, at temperatures of 850 to 1600° C. The formation of a fuel pellet can be carried out in one hour or less. In an embodiment of the invention, a nuclear fuel pellet comprises UO.sub.2 and a highly thermally conductive material, such as SiC or diamond.

Passive reactivity control technologies that enable reactivity control of a nuclear thermal propulsion (NTP) system with little to no active mechanical movement of circumferential control drums. By minimizing or eliminating the need for mechanical movement of the circumferential control drums during an NTP burn, the reactivity control technologies simplify controlling an NTP reactor and increase the overall performance of the NTP system. The reactivity control technologies mitigate and counteract the effects of xenon, the dominant fission product contributing to reactivity transients. Examples of reactivity control technologies include, employing burnable neutron poisons, tuning hydrogen pressure, adjusting wait time between burn cycles or merging burn cycles, and enhancement of temperature feedback mechanisms. The reactivity control technologies are applicable to low-enriched uranium NTP systems, including graphite composite fueled and tungsten ceramic and metal matrix (CERMET), or any moderated NTP system, such as highly-enriched uranium graphite composite NTP systems.

One embodiment provides a method of making an oxidation and corrosion resistant nuclear fuel. The method includes refining, by high energy ball milling (HEBM), a nuclear fuel powder comprising at least one nuclear fuel component and sintering the refined powder to form a nuclear fuel pellet. The method may further include adding a powdered dopant to the nuclear fuel powder. The refined powder includes the nuclear fuel powder and the powdered dopant.

One embodiment provides a method of making an oxidation and corrosion resistant nuclear fuel. The method includes refining, by high energy ball milling (HEBM), a nuclear fuel powder comprising at least one nuclear fuel component and sintering the refined powder to form a nuclear fuel pellet. The method may further include adding a powdered dopant to the nuclear fuel powder. The refined powder includes the nuclear fuel powder and the powdered dopant.

A customizable thin plate fuel form and reactor core therefor are disclosed. The thin plate fuel will comprise a fuel material embedded within a matrix material, with the entire unit having a coating. The thin plate fuel may be flat or curved and will have flow channels formed within at least the top surface of the fuel plate. The structure of the thin plate fuel will make it easier for coating with Tungsten or any other suitable material that will help contain any byproducts, prevent reactions with the working fluid, and potentially provide structural support to the thin plate fuel.

CERMET fuel element includes a fuel meat of consolidated ceramic fuel particles (preferably refractory-metal coated HALEU fuel kernels) and an array of axially-oriented coolant flow channels. Formation and lateral positions of coolant flow channels in the fuel meat are controlled during manufacturing by spacer structures that include ceramic fuel particles. In one embodiment, a coating on a sacrificial rod (the rod being subsequently removed) forms the coolant channel and the spacer structures are affixed to the coating; in a second embodiment, a metal tube forms the coolant channel and the spacer structures are affixed to the metal tube. The spacer structures laterally position the coolant channels in spaced-apart relation and are consolidated with the ceramic fuel particles to form CERMET fuel meat of a fuel element, which are subsequently incorporated into fuel assemblies that are distributively arranged in a moderator block within a nuclear fission reactor, in particular for propulsion.