Abstract: This disclosure describes systems and methods for synthesizing UCl3 from UCl4. These systems and methods may also be used to directly synthesize binary and ternary embodiments of uranium salts of chloride usable as nuclear fuel in certain molten salt reactor designs. The systems and methods described herein are capable of synthesizing any desired uranium chloride fuel salt that is a combination of UCl4, UCl3 and one or more non-fissile chloride compounds, such as NaCl. In particular, the systems and methods described herein are capable of synthesizing any UCl3—UCl4—NaCl or UCl3—NaCl fuel salt composition from UCl4—NaCl.

Abstract: Systems and methods are disclosed for manufacturing a three dimensional (3D) part. In one implementation a system in accordance with the present disclosure may make use of an additive manufacturing (AM) subsystem for performing an AM operation to form the 3D part. The 3D part may be formed using a plurality of distinct material layers layered one on top of another. The system may also involve at least one of a laser peening (LP) subsystem and a High Velocity Laser Accelerated Deposition (HVLAD) subsystem. The LP subsystem may be used for laser peening a selected subquantity of the layers, to impart improved hardness to the selected subquantity of the layers and/or to the overall 3D part. The HVLAD subsystem may be used to bond at least one of the material layers to a previously laid down one of the material layers.

Abstract: This disclosure describes systems and methods for synthesizing UCl3 from UCl4. These systems and methods may also be used to directly synthesize binary and ternary embodiments of uranium salts of chloride usable as nuclear fuel in certain molten salt reactor designs. The systems and methods described herein are capable of synthesizing any desired uranium chloride fuel salt that is a combination of UCl4, UCl3 and one or more non-fissile chloride compounds, such as NaCl. In particular, the systems and methods described herein are capable of synthesizing any UCl3—UCl4—NaCl or UCl3—NaCl fuel salt composition from UCl4—NaCl.

Abstract: A system is disclosed for performing an Additive Manufacturing (AM) fabrication process on a powdered material forming a substrate. The system may make use of a diode array for generating an optical signal sufficient to melt a powdered material of the substrate. A mask may be used for preventing a first predetermined portion of the optical signal from reaching the substrate, while allowing a second predetermined portion to reach the substrate. At least one processor may be used for controlling an output of the diode array.

Abstract: This disclosure describes nuclear fuel salts usable in certain molten salt reactor designs and related systems and methods. Binary, ternary and quaternary chloride fuel salts of uranium, as well as other fissionable elements, are described. In addition, fuel salts of UClxFy are disclosed as well as bromide fuel salts. This disclosure also presents methods and systems for manufacturing such fuel salts, for creating salts that reduce corrosion of the reactor components and for creating fuel salts that are not suitable for weapons applications.

Abstract: Configurations of molten fuel salt reactors are described that utilize neutron-reflecting coolants or a combination of primary salt coolants and secondary neutron-reflecting coolants. Further configurations are described that circulate liquid neutron-reflecting material around an reactor core to control the neutronics of the reactor. Furthermore, configurations which use the circulating neutron-reflecting material to actively cool the containment vessel are also described.

Abstract: An additive manufacturing system having a heat source for melting powder particles in a desired shape and pattern to produce a product. A secondary heat source is used for heat treating the product to achieve heat treatment. The secondary heat source is used to peen or anneal residual stresses caused by the additive manufacturing process.

Abstract: A system of 3D printing using a high temperature 3D print head that functions as a “modified ink jet” printer. The print head has the ability to print high temperature material such as metal, silicon carbide, and other high temperature material as opposed to inks or plastics. The print head is fabricated from a high temperature material to maintain structural integrity while operation at temperatures above the melting temperature for the material that is being printed.

Abstract: A system is disclosed for performing an Additive Manufacturing (AM) fabrication process on a powdered material forming a substrate. The system may make use of a diode array for generating an optical signal sufficient to melt a powdered material of the substrate. A mask may be used for preventing a first predetermined portion of the optical signal from reaching the substrate, while allowing a second predetermined portion to reach the substrate. At least one processor may be used for controlling an output of the diode array.

Abstract: This disclosure describes nuclear fuel salts usable in certain molten salt reactor designs and related systems and methods. Binary, ternary and quaternary chloride fuel salts of uranium, as well as other fissionable elements, are described. In addition, fuel salts of UClxFy are disclosed as well as bromide fuel salts. This disclosure also presents methods and systems for manufacturing such fuel salts, for creating salts that reduce corrosion of the reactor components and for creating fuel salts that are not suitable for weapons applications.

Abstract: A system is disclosed for performing an Additive Manufacturing (AM) fabrication process on a powdered material forming a substrate. The system may make use of a diode array for generating an optical signal sufficient to melt a powdered material of the substrate. A mask may be used for preventing a first predetermined portion of the optical signal from reaching the substrate, while allowing a second predetermined portion to reach the substrate. At least one processor may be used for controlling an output of the diode array.

Abstract: A system is disclosed for performing an Additive Manufacturing (AM) fabrication process on a powdered material forming a substrate. The system may make use of a diode array for generating an optical signal sufficient to melt a powdered material of the substrate. A mask may be used for preventing a first predetermined portion of the optical signal from reaching the substrate, while allowing a second predetermined portion to reach the substrate. At least one processor may be used for controlling an output of the diode array.

Abstract: A method is disclosed for manufacturing a part via an additive manufacturing process. A solution is used which has a volatile component within which is suspended particles of a powdered material. The solution is heated until it at least one of begins boiling or is about to begin boiling. The heated solution is then deposited at least at one location on a substrate to help form a layer of the part. The volatile component then evaporates, leaving only the particles of powdered material. The particles are then heated to the melting point. The deposition and heating operations are repeated to successively form a plurality of layers for the part. The evaporation of the volatile component helps to cool the part.

Abstract: Systems and methods are disclosed for manufacturing a three dimensional (3D) part. In one implementation a system in accordance with the present disclosure may make use of an additive manufacturing (AM) subsystem for performing an AM operation to form the 3D part. The 3D part may be formed using a plurality of distinct material layers layered one on top of another. The system may also involve at least one of a laser peening (LP) subsystem and a High Velocity Laser Accelerated Deposition (HVLAD) subsystem. The LP subsystem may be used for laser peening a selected subquantity of the layers, to impart improved hardness to the selected subquantity of the layers and/or to the overall 3D part. The HVLAD subsystem may be used to bond at least one of the material layers to a previously laid down one of the material layers.

Abstract: An apparatus for use in a friction stir operation, such as friction stir welding (FSW) or friction stir processing (FSP). The apparatus may have a rotating tool adapted to be plunged into a material, where the material is susceptible to being softened by heating. The rotating tool may further be adapted to be advanced along a surface of the material. An optical energy generating subsystem may be used to heat a portion of the material using optical energy as the tool is advanced along the material.

Abstract: A system is disclosed for performing an Additive Manufacturing (AM) fabrication process on a powdered material forming a substrate. The system may make use of a diode array for generating an optical signal sufficient to melt a powdered material of the substrate. A mask may be used for preventing a first predetermined portion of the optical signal from reaching the substrate, while allowing a second predetermined portion to reach the substrate. At least one processor may be used for controlling an output of the diode array.