Ceramic reinforced zirconium alloy nuclear fuel cladding with intermediate oxidation resistant layer

1. A method of preparing a ceramic-containing composite nuclear fuel rod cladding for a nuclear water reactor, comprising:

providing a zirconium alloy tube, comprising:

a tubular wall having an interior surface and an exterior surface;

a cavity formed by the tubular wall;

a first end opening; and

a second end opening;

providing a first end plug having a first outer surface;

providing a second end plug having a second outer surface;

inserting the first end plug into the first end opening,

wherein the first outer surface forms a first exterior end of the cladding;

sealing the first end plug;

filling the fuel rod cladding with nuclear fuel and a hold down device;

inserting the second end plug into the second end opening,

wherein the second outer surface forms a second exterior end of the cladding;

sealing the second end plug;

pressurizing the cavity;

applying a first composition comprising an oxidation resistant material, to at least a portion of the exterior surface of the tubular wall of the zirconium alloy tube to form a first exterior coating;

following the sealing of the first and the second end plugs, applying a second composition to at least a portion of the first exterior coating to form a second exterior coating, the second exterior coating comprising:

SiC reinforced fibers having voids formed between at least a portion of the SiC reinforced fibers; and

a SiC material to at least partially fill the voids formed between at least a portion of the SiC reinforced fibers; and

applying the second composition to the first outer surface of the first end plug and the second outer surface of the second end plug,

wherein the second composition substantially encapsulates the exterior surface of the cladding including the first and second exterior ends.

2. The method of claim 1 , further comprising applying the first composition on the interior surface of the tubular wall of the zirconium alloy tube to form a first interior coating thereon.

3. The method of claim 2 , wherein applying of the first interior coating and applying of the first exterior coating is conducted by atomic layer deposition.

4. The method of claim 2 , wherein the first interior coating and the first exterior coating have a thickness in a range of 10 nanometers to 10 microns.

5. The method of claim 2 , wherein the applying of the first interior coating is conducted when only one of the first end plug and the second end plug is positioned within the first open end and the second open end, respectively, of the zirconium alloy tube.

6. The method of claim 1 , wherein the applying of the first exterior coating and the second exterior coating is conducted when the first and the second end plugs are positioned in each of the first and the second ends of the zirconium alloy tube.

7. The method of claim 1 , wherein the depositing of the SiC reinforced fibers is conducted by winding or braiding.

8. The method of claim 1 , wherein the SiC reinforced fibers form a layer having a thickness from about 10 mils to about 40 mils.

9. The method of claim 1 , wherein the second exterior coating has a density from about 2.5 and about 3.22 grams/cm 3 .

10. The method of claim 1 , wherein the oxidation resistant material selected from the group consisting of Al 2 O 3 , Cr 2 O 3 , and mixtures thereof.

11. The method of claim 1 , wherein the second composition substantially encapsulates the exterior surface of the cladding including the first and second exterior ends.

12. A ceramic-containing composite nuclear fuel rod cladding for a nuclear water reactor, comprising:

a zirconium alloy tube comprising a tubular wall having an interior surface and an exterior surface;

a cavity formed by the tubular wall, the cavity having nuclear fuel disposed therein;

a first end opening;

a second end opening;

a first end plug having a first outer surface inserted in the first end opening,

wherein the first outer surface forms a first exterior end of the cladding;

a second end plug having a second outer surface inserted in the second end opening,

wherein the second outer surface forms a second exterior end of the cladding;

a first composition deposited on at least a portion of the exterior surface of the tubular wall of the zirconium alloy tube to form a first exterior coating, said first composition comprising an oxidation resistant material;

a second composition deposited on at least a portion of the first exterior coating to form a second exterior coating, said second exterior coating comprising:

a plurality of SiC reinforced fibers deposited on said first exterior coating to form a fiber layer, said fibers having voids formed therebetween; and

a SiC material at least partially applied to the fiber layer to at least partially fill the voids; and

the second composition deposited on the first outer surface of the first end plug and the second outer surface of the second end plug.

13. The cladding of claim 12 , further comprising applying the first composition on the interior surface of the tubular wall of the zirconium alloy tube to form a first interior coating thereon.

14. The cladding of claim 12 , wherein the depositing of the first exterior coating and the second exterior coating is conducted when the first and the second end plugs are positioned in each of the first and the second ends of the zirconium alloy tube.

15. The cladding of claim 12 , wherein the first and the second end plugs are constructed of metal.

16. The cladding of claim 12 , wherein the oxidation resistant material does not comprise a material selected from the group consisting of SiC and a SiC-containing compound.