Photon propagation modified additive manufacturing compositions and methods of additive manufacturing using same
Additive manufacturing compositions include low-absorbing particles or non-absorbing particles that have an absorbance for wavelengths of 300 nm to 700 nm that is equal to or greater than 0 Au and is less 1.0 Au, such as 0.001 Au absorbance≤0.7 Au. Slurries including such particles and an uranium-containing particle and that are used in additive manufacturing processes have an increased penetration depth for curative radiation. Removal of low-absorbing particles or non-absorbing particles during post-processing of as-manufactured products results in pores that create porosity in the as-manufactured product that provide a volume accommodating fission gases and/or can enhance wicking of certain heat pipe coolant liquids. Low-absorbing particles or non-absorbing particles can be functionalized for improved properties, for example, with fissionable material for improved ceramic yields, with burnable poisons or stabilizers for increased homogeneity, with stabilizers for localized delivery of the stabilizer, or with combinations thereof.
1. A method for manufacturing a component of a nuclear reactor system, the method comprising:
using an additive manufacturing protocol with a nuclear fuel slurry to manufacture a green body of a component of a nuclear reactor system; and
sintering the green body to form the component of the nuclear reactor system,
wherein the nuclear fuel slurry has a composition including (in vol. % relative to total volume of the slurry):
a plurality of first particles
30 vol. % to 40 vol. %;
a plurality of second particles
10 vol. % to 20 vol. %;
at least one monomer resin
25 vol. % to <45 vol. %;
a dispersant
>0 vol. % to 5 vol. %;
a photoabsorber
greater than 0 vol. %; and
a photoinitiator
greater than 0 vol. %,
wherein a total amount of the plurality of first particles and the plurality of second particles is maximum 60 vol. %,
wherein the first particles have a composition including a uranium metal, a uranium metal alloy, a uranium ceramic, or a uranium-molybdenum alloy,
wherein the second particles have an absorbance for wavelengths of 300 nm to 700 nm that is equal to or greater than 0.001 Au and is less 0.7 Au, and
wherein the photoabsorber and photoinitiator operate within an incident wavelength of 300 nm to 700 nm.
2. A method for manufacturing a component of a nuclear reactor system, the method comprising:
using an additive manufacturing protocol with a nuclear fuel slurry to manufacture a green body of a component of a nuclear reactor system,
wherein the nuclear fuel slurry has a composition including (in vol. % relative to total volume of the slurry):
a plurality of first particles
30 vol. % to 40 vol. %;
a plurality of second particles
10 vol. % to 20 vol. %;
at least one monomer resin
25 vol. % to <45 vol. %;
a dispersant
>0 vol. % to 5 vol. %;
a photoabsorber
greater than 0 vol. %; and
a photoinitiator
greater than 0 vol. %,
wherein a total amount of the plurality of first particles and the plurality of second particles is maximum 60 vol. %,
wherein the first particles have a composition including a uranium oxide, a uranium dioxide, a uranium carbide, a uranium oxycarbide, a uranium nitride, a uranium silicide, a uranium fluoride, a uranium chloride, a cermet of uranium oxide and tungsten, a cermet of uranium dioxide and tungsten, a cermet of uranium oxide and molybdenum or a cermet of uranium dioxide and molybdenum,
wherein the second particles have an absorbance for wavelengths of 300 nm to 700 nm that is equal to or greater than 0.001 Au and is less 0.7 Au, and
wherein the photoabsorber and photoinitiator operate within an incident wavelength of 300 nm to 700 nm.
3. The method according to claim 2 , further comprising sintering the green body to form the component of the nuclear reactor system.
4. A method for manufacturing a component of a nuclear reactor system, the method comprising:
using an additive manufacturing protocol with a nuclear fuel slurry to manufacture a green body of a component of a nuclear reactor system,
wherein the nuclear fuel slurry has a composition including (in vol. % relative to total volume of the slurry):
a plurality of first particles
30 vol. % to 40 vol. %;
a plurality of second particles
10 vol. % to 20 vol. %;
at least one monomer resin
25 vol. % to <45 vol. %;
a dispersant
>0 vol. % to 5 vol. %;
a photoabsorber
greater than 0 vol. %; and
a photoinitiator
greater than 0 vol. %,
wherein a total amount of the plurality of first particles and the plurality of second particles is maximum 60 vol. %.
wherein the first particles have a composition including a uranium oxide or a uranium dioxide,
wherein the second particles have an absorbance for wavelengths of 300 nm to 700 nm that is equal to or greater 0.001 Au and is less 0.7 Au, and
wherein the photoabsorber, and photoinitiator operate within an incident wavelength of 300 nm to 700 nm.
5. The method according to claim 4 , further comprising sintering the green body to form the component of the nuclear reactor system.
6. A method for manufacturing a component of a nuclear reactor system, the method comprising:
using an additive manufacturing protocol with a nuclear fuel slurry to manufacture a green body of a component of a nuclear reactor system,
wherein the nuclear fuel slurry has a composition including (in vol. % relative to total volume of the slurry):
a plurality of first particles
30 vol. % to 40 vol. %;
a plurality of second particles
10 vol. % to 20 vol. %;
at least one monomer resin
25 vol. % to <45 vol. %;
a dispersant
>0 vol. % to 5 vol. %;
a photoabsorber
greater than 0 vol. %;
a photoinitiator
greater than 0 vol. %,
wherein a total amount of the plurality of first particles and the plurality of second particles is maximum 60 vol. %,
wherein the first particles have a composition including a uranium-containing material, where the uranium-containing material is U (C, O, N, Si, F, Cl),
wherein the second particles have an absorbance for wavelengths of 300 nm to 700 nm that is equal to or greater 0.001 Au and is less 0.7 Au, and
wherein the photoabsorber, and photoinitiator operate within an incident wavelength of 300 nm to 700 nm.
7. The method according to claim 6 , further comprising sintering the green body to form the component of the nuclear reactor system.