Abstract: CERMET fuel element includes a fuel meat of consolidated ceramic fuel particles (preferably refractory-metal coated HALEU fuel kernels) and an array of axially-oriented coolant flow channels. Formation and lateral positions of coolant flow channels in the fuel meat are controlled during manufacturing by spacer structures that include ceramic fuel particles. In one embodiment, a coating on a sacrificial rod (the rod being subsequently removed) forms the coolant channel and the spacer structures are affixed to the coating; in a second embodiment, a metal tube forms the coolant channel and the spacer structures are affixed to the metal tube. The spacer structures laterally position the coolant channels in spaced-apart relation and are consolidated with the ceramic fuel particles to form CERMET fuel meat of a fuel element, which are subsequently incorporated into fuel assemblies that are distributively arranged in a moderator block within a nuclear fission reactor, in particular for propulsion.

Abstract: A nuclear fuel assembly for a nuclear reactor core, the fuel assembly having at least one fuel element including an elongated shell defining an interior volume, a lattice structure disposed within the interior volume, at least one flow channel extending through the lattice structure, at least one lattice site disposed in the lattice structure, and at least one fuel compact disposed within a corresponding one of the at least one lattice site, a first end cap including a boss having a first cross-sectional shape, the first end cap being affixed to a first end of the shell, and a second end cap including a first bore having a second cross-sectional shape, the second end cap being affixed to a second end of the shell, wherein the first cross-sectional shape of the boss is the same as the cross-sectional shape of the bore.

Abstract: CERMET fuel element includes a fuel meat of consolidated ceramic fuel particles (preferably refractory-metal coated HALEU fuel kernels) and an array of axially-oriented coolant flow channels. Formation and lateral positions of coolant flow channels in the fuel meat are controlled during manufacturing by spacer structures that include ceramic fuel particles. In one embodiment, a coating on a sacrificial rod (the rod being subsequently removed) forms the coolant channel and the spacer structures are affixed to the coating; in a second embodiment, a metal tube forms the coolant channel and the spacer structures are affixed to the metal tube. The spacer structures laterally position the coolant channels in spaced-apart relation and are consolidated with the ceramic fuel particles to form CERMET fuel meat of a fuel element, which are subsequently incorporated into fuel assemblies that are distributively arranged in a moderator block within a nuclear fission reactor, in particular for propulsion.

Abstract: Carbide-based fuel assembly includes outer structural member of ceramic matrix composite material, the interior surface of which is lined in higher temperature regions with an insulation layer of porous refractory ceramic material. A continuous insulation layer extends the length of the fuel assembly or separate insulation layer sections have a thickness increasing step-wise along the length of the fuel assembly from upper (inlet) section towards bottom (outlet) section. Fuel element positioned inward of the insulation layer and between support meshes has a fuel composition including HALEU and the form of a plurality of individual elongated fuel bodies or one or more fuel monolith bodies containing coolant flow channels. Fuel assemblies are distributively arranged in a moderator block, with upper end of the outer structural member attached to an inlet for propellant and lower end of the outer structural member operatively interfaced with a nozzle forming a nuclear thermal propulsion reactor.

Abstract: Carbide-based fuel assembly includes outer structural member of ceramic matrix composite material (e.g., SiC—SiC composite), insulation layer of porous refractory ceramic material (e.g., zirconium carbide with open-cell foam structure or fibrous zirconium carbide), and interior structural member of refractory ceramic-graphite composite material (e.g., zirconium carbide-graphite or niobium carbide-graphite). Spacer structures between various layers provide a defined and controlled spacing relationship. A fuel element bundle positioned between support meshes includes a plurality of distributively arranged fuel elements or a solid, unitary fuel element with coolant channels, each having a fuel composition including high assay, low enriched uranium (HALEU).

Abstract: Carbide-based fuel assembly includes outer structural member of ceramic matrix composite material, the interior surface of which is lined in higher temperature regions with an insulation layer of porous refractory ceramic material. Continuous insulation layer extends the length of the fuel assembly or separate insulation layer sections have a thickness increasing step-wise along the length of the fuel assembly from upper (inlet) section towards bottom (outlet) section. A fuel element positioned inward of the insulation layer and between support meshes has a fuel composition including HALEU and the form of a plurality of individual elongated fuel bodies or one or more fuel monolith bodies containing coolant flow channels. Fuel assemblies are distributively arranged in a moderator block, with upper end of the outer structural member attached to an inlet for propellant and lower end of the outer structural member operatively interfaced with a nozzle forming a nuclear thermal propulsion reactor.

Abstract: A nuclear reactor has first and second plenum plates disposed in a pressure vessel. Both plenum plates have a plurality of apertures. The second plenum plate is parallel to the first plenum plate. A fuel element includes a fuel element coolant flow tube which extends through aligned apertures of the parallel plenum plates. A fuel element standoff spool is disposed about a portion of the fuel element coolant flow tube which is located between the plenum plates. The nuclear reactor is also usable in nuclear thermal propulsion.

Abstract: Carbide-based fuel assembly includes outer structural member of ceramic matrix composite material (e.g., SiC—SiC composite), insulation layer of porous refractory ceramic material (e.g., zirconium carbide with open-cell foam structure or fibrous zirconium carbide), and interior structural member of refractory ceramic-graphite composite material (e.g., zirconium carbide-graphite or niobium carbide-graphite). Spacer structures between various layers provide a defined and controlled spacing relationship. A fuel element bundle positioned between support meshes includes a plurality of distributively arranged fuel elements or a solid, unitary fuel element with coolant channels, each having a fuel composition including high assay, low enriched uranium (HALEU).

Abstract: Fission reactor has a shell encompassing a reactor space within which are a central longitudinal channel, a plurality of axially extending rings with adjacent rings defining an annular cylindrical space in which a first plurality of primary axial tubes are circumferential located. Circumferentially adjacent primary axial tubes are separated by one of the plurality of secondary channels and a plurality of webbings connects at least a portion of the plurality of primary axial tubes to adjacent structure. A fissionable nuclear fuel composition is located in at least some of the plurality of secondary channels and a primary coolant passes thorough at least some of the primary axial tubes. Additive and/or subtractive manufacturing techniques produce an integral and unitary structure for the fuel loaded reactor space. During manufacturing and as-built, the reactor design can be analyzed using a computational platform that integrates and analyzes data from in-situ monitoring during manufacturing.

Abstract: 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.

Abstract: Fission reactor has a shell encompassing a reactor space within which are a central longitudinal channel, a plurality of axially extending rings with adjacent rings defining an annular cylindrical space in which a first plurality of primary axial tubes are circumferential located. Circumferentially adjacent primary axial tubes are separated by one of the plurality of secondary channels and a plurality of webbings connects at least a portion of the plurality of primary axial tubes to adjacent structure. A fissionable nuclear fuel composition is located in at least some of the plurality of secondary channels and a primary coolant passes thorough at least some of the primary axial tubes. Additive and/or subtractive manufacturing techniques produce an integral and unitary structure for the fuel loaded reactor space. During manufacturing and as-built, the reactor design can be analyzed using a computational platform that integrates and analyzes data from in-situ monitoring during manufacturing.

Abstract: A desuperheating spray chamber for use in a rocket exhaust recovery system for a nuclear thermal propulsion rocket, including a substantially-cylindrical outer tank with an upper end including an entrance port and two exhaust ports, a substantially-cylindrical shroud extending downwardly from an inner surface of the upper end of the tank, an annular inner spray ring that is both disposed within and concentric with the shroud; and an annular outer spray ring that is disposed between a side wall of the outer tank and the shroud, the annular outer ring being concentric with the shroud.

Abstract: Carbide-based fuel assembly includes outer structural member of ceramic matrix composite material (e.g., SiC—SiC composite), insulation layer of porous refractory ceramic material (e.g., zirconium carbide with open-cell foam structure or fibrous zirconium carbide), and interior structural member of refractory ceramic-graphite composite material (e.g., zirconium carbide-graphite or niobium carbide-graphite). Spacer structures between various layers provide a defined and controlled spacing relationship. A fuel element bundle positioned between support meshes includes a plurality of distributively arranged fuel elements or a solid, unitary fuel element with coolant channels, each having a fuel composition including high assay, low enriched uranium (HALEU).

Abstract: CERMET fuel element includes a fuel meat of consolidated ceramic fuel particles (preferably refractory-metal coated HALEU fuel kernels) and an array of axially-oriented coolant flow channels. Formation and lateral positions of coolant flow channels in the fuel meat are controlled during manufacturing by spacer structures that include ceramic fuel particles. In one embodiment, a coating on a sacrificial rod (the rod being subsequently removed) forms the coolant channel and the spacer structures are affixed to the coating; in a second embodiment, a metal tube forms the coolant channel and the spacer structures are affixed to the metal tube. The spacer structures laterally position the coolant channels in spaced-apart relation and are consolidated with the ceramic fuel particles to form CERMET fuel meat of a fuel element, which are subsequently incorporated into fuel assemblies that are distributively arranged in a moderator block within a nuclear fission reactor, in particular for propulsion.

Abstract: Carbide-based fuel assembly includes outer structural member of ceramic matrix composite material, the interior surface of which is lined in higher temperature regions with an insulation layer of porous refractory ceramic material. A continuous insulation layer extends the length of the fuel assembly or separate insulation layer sections have a thickness increasing step-wise along the length of the fuel assembly from upper (inlet) section towards bottom (outlet) section. A fuel element positioned inward of the insulation layer and between support meshes has a fuel composition including HALEU and has the form of a plurality of individual elongated fuel bodies or one or more fuel monolith bodies containing coolant flow channels. Fuel assemblies are distributively arranged in a moderator block, with upper end of the outer structural member attached to an inlet for propellant and lower end of the outer structural member operatively interfaced with a nozzle forming a NTP reactor.

Abstract: Fission reactor has a shell encompassing a reactor space within which are a central longitudinal channel, a plurality of axially extending rings with adjacent rings defining an annular cylindrical space in which a first plurality of primary axial tubes are circumferential located. Circumferentially adjacent primary axial tubes are separated by one of the plurality of secondary channels and a plurality of webbings connects at least a portion of the plurality of primary axial tubes to adjacent structure. A fissionable nuclear fuel composition is located in at least some of the plurality of secondary channels and a primary coolant passes thorough at least some of the primary axial tubes. Additive and/or subtractive manufacturing techniques produce an integral and unitary structure for the fuel loaded reactor space. During manufacturing and as-built, the reactor design can be analyzed using a computational platform that integrates and analyzes data from in-situ monitoring during manufacturing.

Abstract: An internal interface structure of a nuclear thermal propulsion nuclear reactor including a reactor vessel and a reactor head, including a substantially cylindrical body having a top end, a bottom end, an inner surface, and an outer surface, and an annular flange extending radially-outwardly from the outer surface of the body, wherein the annular flange of the interface structure is mounted between an upper flange of the reactor vessel and a bottom flange of the reactor head.

Abstract: A packing device for filling fuel elements with a powder through a fill aperture in an outer shell of the fuel element, including a stationary base, a clamp assembly including a body defining a bore therein, the bore being configured to slidably receive a fuel element therein, wherein the clamp assembly is movable along a vertical axis with respect to the stationary base, a cam assembly including a cam and a drive motor configured to rotate the cam, wherein rotation of the cam alternatingly raises the clamp assembly up along the vertical axis and subsequently drops the clamping assembly, and a powder reservoir assembly including a powder reservoir and a fill needle in fluid communication with the powder reservoir.

Abstract: Fission reactor has a shell encompassing a reactor space within which are a central longitudinal channel, a plurality of axially extending rings with adjacent rings defining an annular cylindrical space in which a first plurality of primary axial tubes are circumferential located. Circumferentially adjacent primary axial tubes are separated by one of the plurality of secondary channels and a plurality of webbings connects at least a portion of the plurality of primary axial tubes to adjacent structure. A fissionable nuclear fuel composition is located in at least some of the plurality of secondary channels and a primary coolant passes thorough at least some of the primary axial tubes. Additive and/or subtractive manufacturing techniques produce an integral and unitary structure for the fuel loaded reactor space. During manufacturing and as-built, the reactor design can be analyzed using a computational platform that integrates and analyzes data from in-situ monitoring during manufacturing.

Abstract: A sludge lancing system for use in a steam generator including a no tube lane disposed between a first bank of tubes and a second bank of tubes that are transverse to a horizontal reference plane, having a rail that extends through the no tube lane and includes a longitudinal center axis that lies in a first plane that is parallel to the reference plane, and a first lancing head, having a body portion a conduit, a nozzle assembly that is mounted to the body portion and is pivotable with respect to the body portion about an axis of rotation, the nozzle assembly including a manifold defining a conduit that is in fluid communication with the conduit of the body portion, at least a first nozzle that is mounted to the manifold and defines a conduit that generates a lancing fluid jet, wherein the conduit of the first nozzle lies in a first plane that is transverse to the longitudinal center axis of the rail so that the lancing fluid jet of the first nozzle is disposed in the first plane when the manifold is pivoted