Abstract: Nuclear fuel rods are disclosed. The nuclear fuel rods include a substrate and a chromium alloy coating layer applied to the substrate. The chromium alloy coating layer comprises chromium (Cr); a element or compound selected from the group consisting of yttrium (Y), lanthanum (La), thorium (Th), zirconium (Zr), titanium (Ti), hafnium (I-lf), molybdenum (Mo), tungsten (W), vanadium (V), rhenium (Re), ruthenium (Ru), cobalt (Co), aluminum (Al), carbides, borides, intermetallics, and combinations thereof; and interstitial elements up to 1500 ppm, wherein carbon (C), oxygen (O), and nitrogen (N) are each 500 ppm or less.

Abstract: In various aspects, a nuclear fuel rod cladding is disclosed. The cladding can include a base tube and a mesh structure including gaps therein. The base tube can include an elongated tubular wall and can be configured to house nuclear fuel therein. The mesh structure can be positioned along at least a portion of the elongated tubular wall and can be configured to provide structural support to the base tube. In one aspect, the gaps of the mesh structure are designed to permit neutrons emitted by the nuclear fuel to pass therethrough to escape the fuel rod cladding.

Abstract: Plated metallic substrates and methods of manufacture are provided. The method comprises depositing a first layer onto at least a portion of the metallic substrate to create a coated substrate utilizing physical vapor deposition. The method comprises electroplating a second layer comprising chromium, a chromium alloy, or a combination thereof onto at least a portion of the first layer to create a plated substrate.

Abstract: Disclosed is a method for manufacturing free-standing cladding tubes with multi-layer structures. According to the method, a cylindrical mandrel substrate defining a hollow cylindrical inner space is provided. A first cold spray powder metal is selected. The cylindrical mandrel substrate is rotated and the first cold spray powder metal is applied to an outer surface of the cylindrical mandrel substrate to form a first layer. The cylindrical mandrel substrate is removed.

Abstract: The present disclosure is generally related to methods, systems and devices for forming a randomized grain structure coating on a substrate of a component for use in a nuclear reactor to provide protection against corrosion and, more particularly, is directed to improved methods, systems and devices for forming a randomized grain structure coating on a zirconium alloy nuclear fuel cladding tube using a cathodic arc (CA) physical vapor deposition (PVD) process to provide protection against corrosion in both normal operation and in transient and accidents of the nuclear reactor.

Abstract: A nuclear fuel cladding tube is described herein that includes a zirconium alloy tube having an outer wear and oxidation resistant ceramic coating selected from the group consisting of CrN, Cr2N, CrWN, CrZrN, and combinations thereof. The cladding may have an intermediate layer formed between the tube and the outer ceramic coating. The intermediate layer may be selected from the group consisting of Ta, W, Mo, Nb, and combinations thereof. Both the intermediate layer and the outer ceramic coating may be deposited by physical vapor deposition.

Abstract: Disclosed is a method for manufacturing free-standing cladding tubes with multi-layer structures. According to the method, a cylindrical mandrel substrate defining a hollow cylindrical inner space is provided. A first cold spray powder metal is selected. The cylindrical mandrel substrate is rotated and the first cold spray powder metal is applied to an outer surface of the cylindrical mandrel substrate to form a first layer. The cylindrical mandrel substrate is removed.