The fuel element of the present invention includes a cladding tube and a metal fuel contained in the cladding tube, in which a gas plenum region is formed above the metal fuel and inside the cladding tube and has a small-diameter portion in the gas plenum region. Further, the fuel assembly of the present invention includes the fuel element of the present invention and a wrapper tube surrounding the fuel element, in which a coolant material passage is formed between the fuel element and the fuel element. Further, the core of the present invention includes an inner core fuel region loaded with the fuel assembly according to the present invention, and an outer core fuel region loaded with the fuel assembly of the present invention.

The disclosure relates to a high temperature gas-cooled reactor core including a plurality of elongate fuel elements arranged in the form of a multi-lobed prism. Each prismatic fuel element includes an elongate prismatic body and a plurality of elongate fuel channels located within the prismatic body, wherein the cross-sectional area of each prismatic fuel element in a plane parallel to the bases of the prismatic fuel element is no more than 800 cm.sup.2 and wherein a ratio of the height of the prismatic body to its greatest width is greater than or equal to 3.0.

Plurality of layers form a nuclear fission reactor structure, each layer having an inner segment body, an intermediate segment body, and an outer segment body (each segment body separated by an interface). The layers include a plurality of cladding arms having involute curve shapes that spirally radiate outward from a radially inner end to a radially outer end. Chambers in the involute curve shaped cladding arm contain fuel compositions (and/or other materials such as moderators and poisons). The design of the involute curve shaped cladding arms and the composition of the materials conform to neutronic and thermal management requirements for the nuclear fission reactor and are of sufficiently common design and/or have sufficiently few variations as to reduce manufacturing complexity and manufacturing variability.

The disclosure relates to a high temperature gas-cooled reactor core including a plurality of elongate fuel elements arranged in the form of a multi-lobed prism. Each prismatic fuel element includes an elongate prismatic body and a plurality of elongate fuel channels located within the prismatic body, wherein the cross-sectional area of each prismatic fuel element in a plane parallel to the bases of the prismatic fuel element is no more than 800 cm.sup.2 and wherein a ratio of the height of the prismatic body to its greatest width is greater than or equal to 3.0.

A method for the manufacture of a three-dimensional object using a refractory matrix material is provided. The method includes the additive manufacture of a green body from a powder-based refractory matrix material followed by densification via chemical vapor infiltration (CVI). The refractory matrix material can be a refractory ceramic (e.g., silicon carbide, zirconium carbide, or graphite) or a refractory metal (e.g., molybdenum or tungsten). In one embodiment, the matrix material is deposited according to a binder-jet printing process to produce a green body having a complex geometry. The CVI process increases its density, provides a hermetic seal, and yields an object with mechanical integrity. The residual binder content dissociates and is removed from the green body prior to the start of the CVI process as temperatures increase in the CVI reactor. The CVI process selective deposits a fully dense coating on all internal and external surfaces of the finished object.

A method for the manufacture of a three-dimensional object using a refractory matrix material is provided. The method includes the additive manufacture of a green body from a powder-based refractory matrix material followed by densification via chemical vapor infiltration (CVI). The refractory matrix material can be a refractory ceramic (e.g., silicon carbide, zirconium carbide, or graphite) or a refractory metal (e.g., molybdenum or tungsten). In one embodiment, the matrix material is deposited according to a binder-jet printing process to produce a green body having a complex geometry. The CVI process increases its density, provides a hermetic seal, and yields an object with mechanical integrity. The residual binder content dissociates and is removed from the green body prior to the start of the CVI process as temperatures increase in the CVI reactor. The CVI process selective deposits a fully dense coating on all internal and external surfaces of the finished object.

Plurality of layers form a nuclear fission reactor structure, each layer having an inner segment body, an intermediate segment body, and an outer segment body (each segment body separated by an interface). The layers include a plurality of cladding arms having involute curve shapes that spirally radiate outward from a radially inner end to a radially outer end. Chambers in the involute curve shaped cladding arm contain fuel compositions (and/or other materials such as moderators and poisons). The design of the involute curve shaped cladding arms and the composition of the materials conform to neutronic and thermal management requirements for the nuclear fission reactor and are of sufficiently common design and/or have sufficiently few variations as to reduce manufacturing complexity and manufacturing variability.

Plurality of layers form a nuclear fission reactor structure, each layer having an inner segment body, an intermediate segment body, and an outer segment body (each segment body separated by an interface). The layers include a plurality of cladding arms having involute curve shapes that spirally radiate outward from a radially inner end to a radially outer end. Chambers in the involute curve shaped cladding arm contain fuel compositions (and/or other materials such as moderators and poisons). The design of the involute curve shaped cladding arms and the composition of the materials conform to neutronic and thermal management requirements for the nuclear fission reactor and are of sufficiently common design and/or have sufficiently few variations as to reduce manufacturing complexity and manufacturing variability.

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.

The fuel element of the present invention includes a cladding tube and a metal fuel contained in the cladding tube, in which a gas plenum region is formed above the metal fuel and inside the cladding tube and has a small-diameter portion in the gas plenum region. Further, the fuel assembly of the present invention includes the fuel element of the present invention and a wrapper tube surrounding the fuel element, in which a coolant material passage is formed between the fuel element and the fuel element. Further, the core of the present invention includes an inner core fuel region loaded with the fuel assembly according to the present invention, and an outer core fuel region loaded with the fuel assembly of the present invention.