Abstract: A process for making a cladding for a nuclear fuel rod is disclosed which includes the following steps. First, at least two layers of zirconium-based metals are spray deposited on a generally cylindrical substrate in a manner that provides a rough, cylindrically-shaped, porous billet. The zirconium-based metal for each layer is different from an adjacent layer and is selected to provide a desired combination of properties. Next, the substrate is removed from the spray deposited material, thereby providing an elongated tube hollow. The spray deposited material is then consolidated in a known manner to remove the porosity, densify the tube hollow to substantially full density, and reduce the cross-sectional dimension of the tube hollow to a desired size.

Abstract: A nuclear fuel channel has four corners and four elongated sidewalls disposed between the corners so as to provide a polygonal transverse cross-section. Each of the channel sidewalls has a longitudinal centerline that coincides with a line of maximum stress that is imposed on the sidewall during in-reactor service. The sidewalls have one or more longitudinal off-center lines that are located between the longitudinal centerline and one of the corners abutting the elongated sidewall. The longitudinal off-center line coincides with a line of minimum stress imposed on an elongated sidewall during in-reactor service. A weld is formed along the length of the off-center line on at least two of the sidewalls. At least one of the off-center line welds is also a seam weld. The disclosed arrangement provides improved resistance to bulging of the channel sidewalls during in-reactor service.