THREE-DIMENSIONAL ELECTROCHEMICAL MANUFACTURING AND SENSING SYSTEM AND RELATED METHODS
An electrochemical system includes at least one electrochemical cell with a receptacle containing an electrolytic bath in which is disposed a counter electrode. At least one nozzle opens from the receptacle toward and proximate a substrate configured as a working electrode. The at least one electrochemical cell is selectively configurable between a configuration for electrodeposition of a material onto the substrate and a configuration for electrodissolution of material from a structure on the substrate. In a method of using an electrochemical cell, a metal salt—of the electrolytic bath—is flowed through the nozzle in the presence of at least one of a voltage difference and a current flow between the working electrode and the counter electrode. The system may be configured for relative movement between the at least one nozzle and the substrate, and the electrochemical cell(s) may be usable for any of electrodeposition, electrodissolution, and electrochemical sensing.
This application is a national phase entry under 35 U.S.C. § 371 of International Patent Application PCT/US2019/065399, filed Dec. 10, 2019, designating the United States of America and published as International Patent Publication WO 2020/123461 A1 on Jun. 18, 2020, which claims the benefit under Article 8 of the Patent Cooperation Treaty to U.S. Provisional Patent Application Ser. No. 62/777,843, filed Dec. 11, 2018, for “Three-Dimensional Electrochemical Manufacturing and Sensing System and Related Methods.”
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENTThis invention was made with government support under Contract Number DE-AC07-05-ID14517 awarded by the United States Department of Energy. The government has certain rights in the invention.
TECHNICAL FIELDEmbodiments of the disclosure relate generally to systems and methods for performing electrochemical reactions and processes. More particularly, embodiments of the disclosure relate to systems for performing electrodeposition, electrodissolution, and electrochemical sensing of three-dimensional structures.
BACKGROUNDNuclear reactors are used to generate power (e.g., electrical power) using nuclear fuel materials. For example, heat generated by nuclear reactions carried out within the nuclear fuel materials may be used to boil water, and the steam resulting from the boiling water may be used to rotate a turbine. Rotation of the turbine may be used to operate a generator for generating electrical power.
Nuclear reactors generally include what is referred to as a “nuclear core,” which is the portion of the nuclear reactor that includes the nuclear fuel material and is used to generate heat from the nuclear reactions of the nuclear fuel material. The nuclear core may include a plurality of fuel rods, which include the nuclear fuel material.
Most nuclear fuel materials include one or more of the elements of uranium and plutonium (although other elements such as thorium are also being investigated). There are, however, different types or forms of nuclear fuel materials that include such elements. For example, nuclear fuel pellets may comprise ceramic nuclear fuel materials. Ceramic nuclear fuel materials include, among others, radioactive uranium oxide (e.g., uranium dioxide (UO2), which is often abbreviated as “UOX”), which is often used to form nuclear fuel pellets. Mixed oxide radioactive ceramic materials (which are often abbreviated as “MOX”) are also commonly used to form nuclear fuel pellets. Such mixed oxide radioactive ceramic materials may include, for example, a blend of plutonium oxide and uranium oxide. Such a mixed oxide may include, for example, UI-xPuxO2, wherein x is between about 0.2 and about 0.3. Transuranic (TRU) mixed oxide radioactive ceramic materials (which are often abbreviated as “TRU-MOX”) also may be used to form nuclear fuel pellets. Transuranic mixed oxide radioactive ceramic materials include relatively higher concentrations of minor actinides such as, for example, neptunium (Np), americium (Am), and curium (Cm). Carbide nuclear fuels and mixed carbide nuclear fuels having compositions similar to the oxides mentioned above, but wherein carbon is substituted for oxygen, are also being investigated for use in nuclear reactors.
In addition to ceramic nuclear fuel materials, there are also metallic nuclear fuel materials. Metallic nuclear fuels include, for example, metals based on one or more of uranium, plutonium, and thorium. Other elements such as hydrogen (H), zirconium (Zr), molybdenum (Mo), and others may be incorporated in uranium- and plutonium-based metals.
In nuclear reactors that employ metallic nuclear fuels, the metallic nuclear fuel is often formed into rods or pellets of predetermined size and shape (e.g., spherical, cubical, cylindrical, etc.) that at least substantially comprise the metallic nuclear fuel. The nuclear fuel material is contained within and at least partially surrounded by a cladding material, which may be in the form of, for example, an elongated tube. The cladding material is used to hold and contain the nuclear fuel. The cladding material typically comprises a metal or metallic alloy, such as stainless steel. During operation of the nuclear reactor, the cladding material may separate (e.g., isolate and hermetically seal) the nuclear fuel bodies from a liquid (e.g., water or molten salt) that is used to absorb and transport the heat generated by the nuclear reaction occurring within the nuclear fuel.
Traditional methods of manufacturing the foregoing nuclear fuel materials include the processing of nuclear fuel powders using so-called dry or wet processes and/or using high temperature (e.g., 1600° C. or greater) melting or laser-beam melting. Such traditional methods result in significant safety and environmental concerns. For example, such high temperature and laser-beam melting processes are associated with high energy expenditures. The dispersion of radioactive nuclear fuel powders to the atmosphere during manufacturing of the nuclear fuel materials also poses a significant safety risk. Traditional machining processes may also include one or more machining steps or leaching steps to remove material from the nuclear fuel materials, and the machining and/or leaching steps generate material waste. Thus, improved systems and methods of manufacturing nuclear fuels that reduce costs, waste, and safety risks are desirable.
BRIEF SUMMARYAn electrochemical system, according to embodiments of the disclosure, comprises at least one electrochemical cell. The at least one electrochemical cell comprises a receptacle containing an electrolytic bath. At least one nozzle opens from the receptacle toward and proximate a substrate configured as a working electrode of the at least one electrochemical cell. A counter electrode is disposed in the electrolytic bath. The at least one electrochemical cell is selectively configurable between a configuration for electrodeposition of material to form a structure on the substrate and a configuration for electrodissolution of material from the structure on the substrate.
A method of using an electrochemical cell, according to embodiments of the disclosure, comprises providing an electrolytic bath in a receptacle. The electrolytic bath comprises a metal salt. A counter electrode is disposed at least partially within the electrolytic bath. The counter electrode is coupled to a working electrode. In the presence of at least one of a voltage difference and a current flow between the working electrode and the counter electrode, the metal salt is flowed through a nozzle coupled to the receptacle.
According to embodiments of the disclosure, a method for manufacturing a metal structure comprises providing an electrochemical system. The electrochemical system comprises at least one electrochemical cell comprising a nozzle connected to a receptacle containing an electrolytic bath. The electrochemical system also includes at least one electrode at least partially within the electrolytic bath and coupled to a working electrode toward which the nozzle is directed. Metal material is removed from the working electrode or from a structure on the working electrode. The removing comprises applying an electric potential difference between the working electrode and the counter electrode to migrate metal salt ions from the working electrode or from the structure on the working electrode, through the nozzle into the electrolytic bath within the receptacle, to the counter electrode.
Systems and methods disclosed herein enable fabrication of three-dimensional structures, such as nuclear fuel elements, by additive manufacturing through electrodeposition using at least one electrochemical cell; etching of material from a structure through electrodissolution using at least one electrochemical cell; and/or sensing of a characteristic or composition of a material through electrochemical sensing using at least one electrochemical cell. The electrodeposition, electrodissolution, and/or electrochemical sensing of, e.g., nuclear material, may be accomplished at relatively low temperatures, with less risk of dispersion of radioactive nuclear fuel material into the atmosphere, with less material waste, with less energy expenditure, with less expense, and with increased safety.
The following description provides specific details, such as compositions, materials, processing conditions, equipment, and features thereof, in order to provide a thorough description of embodiments described herein. However, a person of ordinary skill in the art will understand that the embodiments disclosed herein may be practiced without employing these specific details. Indeed, the embodiments of the disclosure may be practiced in conjunction with conventional fabrication techniques employed in the industry. In addition, the description provided below does not form a complete process flow, apparatus, or system for forming a component of a nuclear reactor, another structure, or related methods. Only those process acts and structures necessary to understand the embodiments of the disclosure are described in detail below. Additional acts to form a component of a nuclear reactor core or another structure may be performed by conventional techniques. Further, any drawings accompanying the present application are for illustrative purposes only and, thus, are not necessarily drawn to scale.
The illustrations included herewith are not meant to be actual views of any particular systems or structures formed with the systems, but are merely idealized representations that are employed to describe embodiments herein. Elements and features common between figures may retain the same numerical designation.
As used herein, the terms “comprising,” “including,” “containing,” “characterized by,” and grammatical equivalents thereof are inclusive or open-ended terms that do not exclude additional, unrecited elements or method steps, but also include the more restrictive terms “consisting of” and “consisting essentially of” and grammatical equivalents thereof.
As used herein, the term “may” with respect to a material, structure, feature, or method act indicates that such is contemplated for use in implementation of an embodiment of the disclosure, and such term is used in preference to the more restrictive term “is” so as to avoid any implication that other compatible materials, structures, features and methods usable in combination therewith should or must be excluded.
As used herein, the term “configured” refers to a size, shape, material composition, and arrangement of one or more of at least one structure and at least one apparatus facilitating operation of one or more of the structure and the apparatus in a predetermined way.
As used herein, the term “substantially” in reference to a given parameter, property, or condition means and includes to a degree that one of ordinary skill in the art would understand that the given parameter, property, or condition is met with a degree of variance, such as within acceptable manufacturing tolerances. By way of example, depending on the particular parameter, property, or condition that is substantially met, the parameter, property, or condition may be at least 90.0% met, at least 95.0% met, at least 99.0% met, even at least 99.9% met, or even 100.0% met.
As used herein, “about” or “approximately” in reference to a numerical value for a particular parameter is inclusive of the numerical value and a degree of variance from the numerical value that one of ordinary skill in the art would understand is within acceptable tolerances for the particular parameter. For example, “about” or “approximately” in reference to a numerical value may include additional numerical values within a range of from 90.0% to 110.0% of the numerical value, such as within a range of from 95.0% to 105.0% of the numerical value, within a range of from 97.5% to 102.5% of the numerical value, within a range of from 99.0% to 101.0% of the numerical value, within a range of from 99.5% to 100.5% of the numerical value, or within a range of from 99.9% to 100.1% of the numerical value.
As used herein, “and/or” includes any and all combinations of one or more of the associated listed items.
Embodiments of the disclosure relate to systems and related methods for manufacturing (e.g., depositing, forming), machining (e.g., shaping, finishing), and analyzing composition of a structure (e.g., a three-dimensional structure).
The electrochemical cell 104 of the electrochemical processing unit 102 includes multiple electrodes. The substrate 106 of the electrochemical cell 104 serves as a working electrode. A counter electrode 114 is also included and, in some embodiments, also a reference electrode 116.
The electrochemical cell 104 of the electrochemical processing unit 102 further includes a container 118 (e.g., a receptacle), such as a crucible, in which an electrolytic bath 120 is retained. The reference electrode 116, if included, and the counter electrode 114 may be at least partially disposed in the electrolytic bath 120. At least one nozzle 122 may be coupled to the container 118. In some embodiments, a heater 124 (e.g., an induction heater or a heating block, either of which can be controlled by a temperature control unit) may be coupled to and disposed about the nozzle 122 and/or about the substrate 106 (e.g., the working electrode). In some embodiments, the heater 124 may comprise an induction heater that laterally surrounds each nozzle 122.
The substrate 106 (e.g., the working electrode) may be disposed proximate to the nozzle 122 such that one or more elements of the electrolytic bath 120 may be passed through the nozzle 122 (e.g., deposited from the nozzle 122 and onto a surface of the substrate 106; dissolved up into the nozzle 122 from the structure 108 on the substrate 106). Another container (not illustrated) may be included in the electrochemical processing unit 102 and may be proximate at least the surface of the substrate 106; the structure 108 during its formation, dissolution, or analyzing; and at least a lowest part of the nozzle 122. Such other container may be formed of steel, glass, plastic, or the like.
One or more of the substrate 106, the counter electrode 114, the reference electrode 116 (if included), and the nozzle 122 may be selected to comprise silver, titanium, gold, and/or a boron-containing material such as borosilicate glass, boron carbide, and high-boron steel. In some embodiments, the counter electrode 114 may be selected to comprise a metal substantially similar to a composition of a metal to be deposited to (or removed by dissolution from) the structure 108, using the system 100, as described further, below, with reference to
In a method for using the system 100, according to embodiments of the disclosure, a voltage differential is selected and is selectively applied by the controller 110 and an electrical current is selected and selectively flowed between the substrate 106 (e.g., the working electrode) and the counter electrode 114 such that the system 100 may be used for electrochemical manufacturing in a fashion that allows for material deposition (e.g., by electrodeposition), material dissolution (e.g., by electrodissolution), and/or analysis (e.g., by electrochemical sensing of the electrochemical state of the system) with additional electromechanical control of the position of the substrate 106, the counter electrode 114, and the nozzle 122 of the container 118. In some embodiments, a voltage differential is selected and applied by the controller 110 such that a proportional (e.g., corresponding) current flows between the substrate 106 (e.g., the working electrode) and the counter electrode 114. In other embodiments, a current is selected and is flowed by the controller 110 and a proportional voltage differential is applied between the substrate 106 (e.g., the working electrode) and the counter electrode 114.
With regard to the electromechanical control of the position of the substrate 106, the counter electrode 114, and the nozzle 122 of the container 118, one or both of the substrate 106 and the container 118 of the electrochemical cell 104 may be coupled to an electromechanical arm 126 such that the substrate 106 and the container 118 may be configured to move in the x-direction (i.e., left and right, along arrow X, in the view illustrated in
In some embodiments, the electromechanical arm 126 may also be configured to control movement of the substrate 106 (and therefore also the structure 108), such as by rotating the substrate 106. Accordingly, the electromechanical arm 126 of such embodiments may rotate the substrate 106 and/or the container 118 (and nozzle 122) about any or each axis of movement (e.g., the x-, y-, and z-directions) such that the electromechanical arm 126 may also be able to pitch, roll, etc. The electromechanical arm 126 may be configured to manipulate the movement of the substrate 106 (and therefore also the structure 108) and the container 118 (and therefore also the nozzle 122) either jointly (e.g., as the substrate 106 is moved in a certain direction, the container 118 is also moved in the same direction) or independently (e.g., enabling the substrate 106 to be moved in one directly while the container 118 is motionless or moved in a different direction).
In some embodiments, the electrochemical processing unit 102 of the system 100 also includes an XYZ platform 128 that may support the substrate 106 (and therefore also the structure 108). In such embodiments, the XYZ platform 128 may be configured to be manipulated to control the movement of the substrate 106 (and therefore also the structure 108), while the electromechanical arm 126 may be dedicated for controlled manipulation of the container 118 (and therefore also the nozzle 122).
At least one of the controllers of the at least one controller of the system 100, e.g., the controller 110 of
For example,
As another example,
In still other embodiments, one or more additional controllers may be included in the system to control additional system equipment, such as to control the heat applied (e.g., to the nozzle 122) by the heater 124. Alternatively, one or more of the aforementioned controllers (e.g., the controller 110 of the system 100 of
Any or all of the aforementioned controllers (e.g., the controller 110 of the system 100 of
In some embodiments, the substrate 106 may be supported on (e.g., directly on top of) the XYZ platform 128, as illustrated in
In some embodiments, the reaction chamber 112 may comprise a radioactive shield configured to contain radioactive materials that may be used to manufacture (e.g., by electrodeposition), machine (e.g., by electrodissolution), or analyze (e.g., by electrochemical sensing) the structure 108 therein. The reaction chamber 112 may also be configured to provide a controlled environment in which the nuclear fuel element 500 of
While the system 100 of
Each of the electrochemical cells 104 may comprise a respective container 118, nozzle 122, and, optionally, a heater 124 (
The composition of the electrolytic bath 120 may be tailored based upon a composition of the structure 108 to be manufactured (e.g., by electrodeposition), to be machined (e.g., by electrodissolution), or to be analyzed (e.g., by electrochemical sensing) using the system (e.g., the system 100 of
In some embodiments, the system (e.g., the system 100 of
With reference to
The nuclear fuel element 500 may comprise a nuclear fuel 502 surrounded by cladding 504. A sensor 506 may be embedded within the nuclear fuel 502. The nuclear fuel 502 of the nuclear fuel element 500 may be formed, using the systems and methods of embodiments of the disclosure, to exhibit composition, chemical, or morphological (e.g., microstructural) differences in different regions along a height (e.g., in the “Z” direction), and/or across a width (e.g., in the “X” direction) thereof. In some embodiments, the differences may be in the form of gradients along the height and/or cross the width, or portions thereof. For example, the nuclear fuel 502 may be formed, using the systems and embodiments of the disclosure, to form regions of varying microstructures along a length and/or across a width thereof. Thus, the nuclear fuel element 500 may include a nuclear material (e.g., a uranium-based nuclear material, such as a uranium-zirconium (UZr) material) with a porous microstructure in a porous zone 508, a less-porous/more-dense microstructure in a less-porous zone 510, and a dense microstructure in a dense zone 512.
In some embodiments, the electrochemical cell 104 is used for fabricating uranium-zirconium fuel elements, such as the nuclear fuel element 500 of
A nuclear fuel element such as the nuclear fuel element 500 may be additively manufactured, using any of the systems and methods described herein. For example, in some embodiments, the nuclear fuel element 500 may be additively formed, through electrodeposition of the material of the nuclear fuel element 500, in layer-by-layer fashion in the z-direction. In some such embodiments the nuclear material of the less-porous zone 510, the porous zone 508, and the dense zone 512 may be electrodeposited in conjunction with one another, either also in conjunction with the material of the sensor 506 or with the sensor 506 inserted into the nuclear fuel 502 after the nuclear fuel 502 has been fabricated. The burnable absorber 514 may be inserted after or while fabricating the nuclear fuel 502. In some embodiments, the barrier layer 516 may be electrodeposited, in layer-by-layer fashion, along with the electrodeposition, in layer-by-layer fashion, of the nuclear fuel 502. Alternatively, after forming the nuclear fuel 502, it may be inserted within a tube comprising the barrier layer 516 and the cladding 504.
The material of the nuclear fuel 502 may comprise aluminum-uranium alloys, uranium-zirconium alloys (e.g., U—Zr, U—Pu—Zr) and/or may comprise oxide fuels (e.g., UO2, U3O8, and PuO2—UO2). Accordingly, the electrolytic bath 120 may include, but is not limited to, salts of uranium, aluminum, zirconium, cesium, plutonium, chlorine, and/or oxygen dissolved therein, with the composition of the electrolytic bath 120 tailored according to the composition of the material to be electrodeposited. For example, in other embodiments, the electrolytic bath 120 may comprise radioactive elements for inclusion in the structure 108. In such embodiments, the electrolytic bath 120 may include hydrogen and/or carbon, as previously discussed.
Overall, by using an ionic bath for the electrolytic bath 120, the structure 108 (or structures 108), such as the structure of the nuclear fuel element 500 of
By way of example and not limitation,
Similarly, the potential (e.g., voltage) applied and/or current flowed by the controller (e.g., the controller 110 of
The fabrication (e.g., flow) rate, or rate at which material may flow from the electrolytic bath 120, through the nozzle 122, to the substrate 106 (or the structure 108 thereon), may be varied by tailoring the size (e.g., opening) of the nozzle 122 and by adjusting the kinetics of the reaction including, but not limited to, adjusting the temperature of the heater 124 and/or adjusting the potential or current applied by the controller 110 (
A method of forming a third-dimensional structure (e.g., structure 108), which may be, for example, the nuclear fuel element 500 of
In operation, an electric current flow and/or a voltage difference may be applied between the substrate 106 (e.g., the working electrode) and its corresponding counter electrode 114, resulting in the electrodeposition of a material (e.g., a metal) derived from one or more salts (e.g., metal salts) dissolved in the electrolytic bath 120. The voltage difference and/or current flow may be varied, e.g., for and/or during deposition, to selectively tailor at least one of a morphology (e.g., a microstructure, a density, a porosity) and/or a composition (e.g., relative concentration of one element of an alloy to another element of the alloy) of the deposited material (e.g., metal). In addition, the temperature of the heater 124 may be varied, e.g., for and/or during deposition, to selectively tailor a physiochemical property of the metal salt as the metal salt flows through the nozzle 122. As illustrated in
In embodiments in which the structure 108 to be formed (e.g., the nuclear fuel element 500 of
As described with reference to
The electromechanical arm 126 and/or the XYZ platform 128 (
Further, using multiple electrochemical cells 104 (e.g., one or more of which may be configured as the electrodeposition cell 700) and/or multiple nozzles 122 in the system, multiple different structures 108 and/or multiple different materials for the same structure 108 may be simultaneously or sequentially fabricated. Accordingly, the less-porous zone 510 of the nuclear fuel element 500 of
The electromechanical arm 126 and/or the XYZ platform 128 (
Further, using multiple electrochemical cells 104 (e.g., one or more of which may be configured as the electrodissolution cell 800) and/or multiple nozzles 122 in the system, multiple different structures 108 and/or multiple different materials from the same structure 108 may be simultaneously or sequentially machined (e.g., etched). In another embodiment, material from each of multiple regions of the structure 802 may be etched using the same electrolytic bath 120 and counter electrode 114 and through the same or different nozzles 122.
Accordingly the systems embodiments of the disclosure may be used for machining (e.g., etching) a structure by an electrodissolution process with selective removal of material from the structure. Such a system reduces waste compared to, for example, systems for conventional leaching process. Notably, the electrodissolution material-removal processes of embodiments of the disclosure may effectively recycle and collect previously-deposited material. That is, in some embodiments the system may have been used with the electrochemical cell 104 configured as the electrodeposition cell 700 of
For both the electrodeposition (
While the electrodeposition (e.g., of
The embodiments of the disclosure are not limited to electrochemical cells 104 of a shape and structure illustrated in the figures. In other embodiments, for example, one or more of the electrochemical cells 104 of a system may be configured as syringes, with the body of the syringe providing the container 118 of the electrochemical cell 104, and the liquid contents of the syringe being formulated as the electrolytic bath 120. The rate of dispensation of the electrolytic bath 120 from a syringe-type electrochemical cell 104, or the retraction of material back up into the syringe-type electrochemical cell 104, may be controlled by controlling the rate of engagement of a plunger of the syringe, which rate of engagement may be controlled by a controller of the system (e.g., any of the aforementioned controllers or another controller).
While the system (e.g., system 100 of
While embodiments of the disclosure may be susceptible to various modifications and alternative forms, specific have been described in detail herein. However, it should be understood that the disclosure is not limited to the particular forms disclosed. Rather, the disclosure encompasses all modifications, variations, combinations, and alternatives falling within the scope of the disclosure as defined by the following appended claims and their legal equivalents.
Claims
1. An electrochemical system comprising:
- at least one electrochemical cell comprising: a receptacle containing an electrolytic bath; at least one nozzle opening from the receptacle toward and proximate a substrate configured as a working electrode of the at least one electrochemical cell; and a counter electrode disposed in the electrolytic bath,
- the at least one electrochemical cell selectively configurable between a configuration for electrodeposition of material to form a structure on the substrate and a configuration for electrodissolution of material from the structure on the substrate.
2. The electrochemical system of claim 1, further comprising at least one of an electromechanical arm and an XYZ platform configured to control relative movement between the at least one nozzle and the substrate.
3. The electrochemical system of claim 1, further comprising at least one controller configured to apply a current or voltage to the counter electrode and the substrate configured as the working electrode.
4. The electrochemical system of claim 1, wherein the electrolytic bath comprises an ionic liquid and at least one a nuclear fuel material salt dissolved in the ionic liquid.
5. The electrochemical system of claim 1, wherein the electrolytic bath comprises an ionic liquid and at least one of a uranium salt and a zirconium salt dissolved in the ionic liquid.
6. The electrochemical system of claim 1, further comprising a heater disposed about the at least one nozzle, the substrate, or both.
7. The electrochemical system of claim 1, wherein each of the receptacle and the substrate are movable in three dimensions.
8. The electrochemical system of claim 1, wherein the electrochemical system comprises a plurality of the electrochemical cells, each electrolytic bath of the electrochemical cells having a different chemical composition.
9. The electrochemical system of claim 1, wherein the electrochemical system further comprises a plurality of controllers, the plurality of controllers comprising:
- at least one controller configured to control a voltage difference and a current flow between the counter electrode and the substrate configured as the working electrode; and
- at least one other controller configured to control movement of the at least one nozzle over the substrate.
10. The electrochemical system of claim 1, wherein the at least one nozzle is movable in three dimensions relative to the substrate.
11. A method of using an electrochemical cell, comprising:
- providing an electrolytic bath in a receptacle, the electrolytic bath comprising a metal salt;
- disposing a counter electrode at least partially within the electrolytic bath;
- coupling the counter electrode to a working electrode; and
- in the presence of at least one of a voltage difference and a current flow between the working electrode and the counter electrode, flowing the metal salt through a nozzle coupled to the receptacle.
12. The method of claim 11, wherein flowing the metal salt through the nozzle coupled to the receptacle comprises flowing the metal salt from the electrolytic bath, through the nozzle, and to the working electrode to form a structure comprising a metal of the metal salt, wherein the working electrode serves as a cathode, and wherein the counter electrode serves as an anode.
13. The method of claim 11, wherein flowing the metal salt through the nozzle coupled to the receptacle comprises flowing the metal salt from a structure on the working electrode, through the nozzle, through the electrolytic bath, and to the counter electrode, to form a recess in the structure on the working electrode, wherein the working electrode serves as an anode, and wherein the counter electrode serves as a cathode.
14. The method of claim 11, wherein flowing the metal salt through the nozzle comprises:
- flowing the metal salt through the nozzle toward the working electrode to electrodeposit a metal on the working electrode; and
- thereafter, flowing the metal salt from the metal on the working electrode through the nozzle to deposit the metal on the counter electrode within the receptacle.
15. The method of claim 11, further comprising measuring at least one of the voltage difference and the current flow to identify a composition of at least one of the counter electrode, the electrolytic bath, and a structure on the working electrode.
16. The method of claim 11, wherein the metal salt comprises uranium or plutonium.
17. A method for manufacturing a metal structure, comprising:
- providing an electrochemical system, the electrochemical system comprising: at least one electrochemical cell comprising a nozzle connected to a receptacle containing an electrolytic bath; and a counter electrode at least partially within the electrolytic bath and coupled to a working electrode toward which the nozzle is directed; and
- removing metal material from the working electrode or from a structure on the working electrode, the removing comprising applying an electric potential difference between the working electrode and the counter electrode to migrate metal salt ions from the working electrode or from the structure on the working electrode, through the nozzle into the electrolytic bath within the receptacle, to the counter electrode.
18. The method of claim 17, further comprising, while removing the metal material from the working electrode or from the structure on the working electrode, moving at least one of the nozzle and the working electrode relative to one another to form a recess in the working electrode or the structure on the working electrode.
19. The method of claim 18, wherein moving the at least one of the nozzle and the working electrode relative to one another comprises moving the at least one of the nozzle and the working electrode in more than one axial direction.
20. The method of claim 17, further comprising, electrodepositing the metal material on the working electrode or on the structure on the working electrode, the electrodepositing comprising reversing a direction of current flow between the working electrode and the counter electrode to migrate the metal salt ions away from the counter electrode, through the nozzle, toward the working electrode.
Type: Application
Filed: Dec 10, 2019
Publication Date: Jan 27, 2022
Inventors: Junhua Jiang (Idaho Falls, ID), Robert D. Mariani (Idaho Falls, ID)
Application Number: 17/309,577