Zirconium-coated silicon carbide fuel cladding for accident tolerant fuel application
The invention relates to a multi-component cladding for a nuclear fuel rod that includes a combination of ceramic and metal components. More particularly, the invention is directed to a cladding that includes a ceramic composite having a zirconium composition deposited thereon to form a zirconium coated ceramic composite. The ceramic composite includes a ceramic matrix and a plurality of ceramic fibers. The cladding is effective to protect the contents of the cladding structure from exposure to high temperature environments during various load conditions of a nuclear reactor.
1. A method for preparing a nuclear fuel rod cladding, comprising:
preparing a ceramic composite, which comprises:
a ceramic matrix; and
a plurality of ceramic fibers;
forming the ceramic composite in a shape such that it has an interior surface, an exterior surface and an inner cavity; and
depositing on the exterior surface of the ceramic composite a metallic coating composition to form a coating thereon, the composition comprising a zirconium component composed of zirconium alloy, wherein the depositing comprises arc spray, liquid phase spray, cold spray, laser deposition, or a combination thereof, wherein the nuclear fuel rod cladding consists of the ceramic composite and the coating.
2. The method of claim 1 , wherein preparing the ceramic composite comprises:
obtaining the plurality of ceramic fibers in a form of fiber tows;
forming a woven ceramic fiber structure, wherein voids are formed therein; and
depositing the ceramic matrix over the woven ceramic fiber structure to at least partially fill the voids.
3. The method of claim 2 , wherein the forming a woven ceramic fiber structure employs a process selected from the group consisting of wrapping, winding and braiding.
4. The method of claim 3 , wherein the forming a woven ceramic fiber structure employs a winding process and the winding process comprises winding the ceramic fibers in the form of filaments over a mandrel.
5. The method of claim 4 , wherein the depositing a ceramic matrix comprises employing a process selected from chemical vapor deposition, chemical vapor infiltration and sol gel infiltration.
6. The method of claim 5 , wherein the depositing a coating composition comprises arc spray.
7. The method of claim 5 , wherein the depositing a coating composition comprises liquid phase spray.
8. The method of claim 5 , wherein the depositing a coating composition comprises plasma spray.
9. The method of claim 5 , wherein the depositing a coating composition comprises cold spray.
10. The method of claim 5 , wherein the depositing a coating composition comprises laser deposition.
11. The method of claim 5 , wherein the coating comprises a thickness in a range of 0.004 inch to 0.006 inch.
12. The method of claim 11 , wherein a thickness of the nuclear fuel rod cladding is in a range of 100 microns to 600 microns.