Methodologies and manufacturing processes to manufacture components by electron beam melting additive manufacturing, particularly components of molybdenum or a molybdenum-based alloy and particularly of complex nuclear component geometries. Input parameters are provided for controlling electron beam melting additive manufacturing equipment, such as electron beam melting machines. The input parameters relate to various process steps, including build set-up, initial thermal treatment, initial layering of powder, pre-consolidation thermal treatment, consolidation, post-consolidation thermal treatment, indexing of layers, and post-build thermal treatment. The methodologies and manufacturing processes allow manufacture of components of molybdenum having a purity of ≥99.0% and a density of ≥99.75%. Metallographic cross-sections of the manufactured molybdenum components were porosity-free and crack-free.

Nuclear fuel structures and methods for fabricating are disclosed herein. The nuclear fuel structure includes a plurality of fibers arranged in the structure and a multilayer fuel region within at least one fiber of the plurality of fibers. The multilayer fuel region includes an inner layer region made of a nuclear fuel material, and an outer layer region encasing the nuclear fuel material. A plurality of discrete multilayer fuel regions may be formed over a core region along the at least one fiber, the plurality of discrete multilayer fuel regions having a respective inner layer region of nuclear fuel material and a respective outer layer region encasing the nuclear fuel material. The plurality of fibers may be wrapped around an inner rod or tube structure or inside an outer tube structure of the nuclear fuel structure, providing both structural support and the nuclear fuel material of the nuclear fuel structure.

Process for manufacturing a nuclear component comprising i) a support containing a substrate based on a metal (1), the substrate (1) being coated or not coated with an interposed layer (3) positioned between the substrate (1) and at least one protective layer (2) and ii) the protective layer (2) composed of a protective material comprising chromium; the process comprising a step a) of vaporizing a mother solution followed by a step b) of depositing the protective layer (2) onto the support via a process of chemical vapor deposition of an organometallic compound by direct liquid injection (DLI-MOCVD).

Nuclear component comprising i) a support containing a substrate based on a metal, the substrate (1) being coated or not coated with an interposed layer (3) positioned between the substrate (1) and at least one protective layer (2) and ii) the protective layer (2) composed of a protective material comprising chromium. The composite nuclear component manufactured by the process of the invention has improved resistance to oxidation, hydriding and/or migration of undesired material.

The invention also relates to the use of the nuclear component for combating oxidation and/or hydriding.

Process for manufacturing a nuclear component comprising i) a support containing a substrate based on a metal (1), the substrate (1) being coated or not coated with an interposed layer (3) positioned between the substrate (1) and at least one protective layer (2) and ii) the protective layer (2) composed of a protective material comprising chromium; the process comprising a step a) of vaporizing a mother solution followed by a step b) of depositing the protective layer (2) onto the support via a process of chemical vapor deposition of an organometallic compound by direct liquid injection (DLI-MOCVD).

Nuclear component comprising i) a support containing a substrate based on a metal, the substrate (1) being coated or not coated with an interposed layer (3) positioned between the substrate (1) and at least one protective layer (2) and ii) the protective layer (2) composed of a protective material comprising chromium. The composite nuclear component manufactured by the process of the invention has improved resistance to oxidation, hydriding and/or migration of undesired material.

The invention also relates to the use of the nuclear component for combating oxidation and/or hydriding.

Nuclear fuel cladding for fast reactors, assemblies thereof, and methods of manufacture thereof are provided. The nuclear fuel cladding comprises a substrate, a first layer, and a second layer. The substrate a tubular shape. The first layer is deposited over an external surface of the substrate. The first layer comprises a corrosion resistant composition. The second layer is disposed over the first layer. The second layer comprises silicon carbide fibers infiltrated with silicon carbide. The second layer is configured to inhibit outward creep of the substrate.

Nuclear fuel cladding for fast reactors, assemblies thereof, and methods of manufacture thereof are provided. The nuclear fuel cladding comprises a substrate, a first layer, and a second layer. The substrate a tubular shape. The first layer is deposited over an external surface of the substrate. The first layer comprises a corrosion resistant composition. The second layer is disposed over the first layer. The second layer comprises silicon carbide fibers infiltrated with silicon carbide. The second layer is configured to inhibit outward creep of the substrate.

Plated metallic substrates and methods of manufacture are provided. The method comprises depositing a first layer onto at least a portion of the metallic substrate to create a coated substrate utilizing physical vapor deposition. The method comprises electroplating a second layer comprising chromium, a chromium alloy, or a combination thereof onto at least a portion of the first layer to create a plated substrate.

Plated metallic substrates and methods of manufacture are provided. The method comprises depositing a first layer onto at least a portion of the metallic substrate to create a coated substrate utilizing physical vapor deposition. The method comprises electroplating a second layer comprising chromium, a chromium alloy, or a combination thereof onto at least a portion of the first layer to create a plated substrate.

An article formed of a metal alloy is covered at least partially with a metal hydride and a shell metal to form an assembly. Load is applied to the assembly and the assembly is heated. The shell metal deforms around the article and the metal hydride and forms a gas proof seal. The metal hydride thermally decomposes to form hydrogen gas. At least a portion of the hydrogen gas dissociates and moves as monoatomic hydrogen into the article. The metal alloy can be a zirconium metal alloy, the metal hydride can be a zirconium metal hydride, and the shell metal can be substantially copper.

A composite nuclear reactor component comprises a support and a protective layer (2). The support contains a substrate (1) based on a metal. The substrate is coated with an interposed layer (3) positioned between the substrate (1) and the protective layer (2). The protective layer (2) is composed of a material which comprises amorphous chromium carbide. The nuclear reactor component provides for improved resistance to oxidation, hydriding, and/or migration of undesired material.