JP7197696B2 - 一体型核燃料要素及びその製造方法 - Google Patents
一体型核燃料要素及びその製造方法 Download PDFInfo
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- JP7197696B2 JP7197696B2 JP2021527963A JP2021527963A JP7197696B2 JP 7197696 B2 JP7197696 B2 JP 7197696B2 JP 2021527963 A JP2021527963 A JP 2021527963A JP 2021527963 A JP2021527963 A JP 2021527963A JP 7197696 B2 JP7197696 B2 JP 7197696B2
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01D—NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES
- F01D5/00—Blades; Blade-carrying members; Heating, heat-insulating, cooling or antivibration means on the blades or the members
- F01D5/12—Blades
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Description
本出願は、2018年7月31日に出願された米国仮出願第62/769,588号の利益を主張し、その開示は、その全体が基準により組み込まれる。
本発明は、米国エネルギー省により授与された契約番号DE-AC05-00OR22725に基づく政府支援によりなされた。米国政府は、本発明について特定の権利を有する。
本発明は、種々のエネルギー関連用途のための耐火性材料を使用する複雑な物体の付加的な製造に関する。
一つの実施形態に従う方法は、耐火性マトリックス材料を使用する三次元物体の製造を含む。図1を参照すると、この方法は、概して、(a)耐火性原料の選択、(b)耐火性原料を使用するグリーン体の付加的な製造、(c)CVIのための耐火性ガス前駆体の導入、(d)緻密化及びバインダ除去のためのグリーン体のCVI、及び(e)複雑な三次元形状を有する最終部品の完成を含む。このような各操作は、以下に別々に説明される。
ここで、不可欠な核燃料要素とその製造方法について説明する。以下に記載されるように、一体型核燃料要素は、概して、3Dプリントされた耐火性マトリックス材料から形成され、その中に均一に分散した燃料粒子、例えばTRISO核燃料粒子を含む、CVI高密度化燃料収容体を含み、燃料収容体は、任意に角柱状燃料ブロックとして成形される。
本発明に関連する発明の実施態様の一部を以下に示す。
[態様1]
下記を含む、物品の製造方法:
炭化ケイ素の粉末原料を提供すること;
前記粉末原料の連続層上にバインダを選択的に堆積させて、炭化ケイ素が30重量%を超える寸法安定性物体を製造すること;
前記物体を化学蒸気浸透(CVI)反応器内に配置し、その中の温度を上昇させ、それによって前記物体を脱バインダすること;及び
前記CVI反応器内に、ケイ素及び炭化水素を含む前駆体ガスを高温で導入し、それによって、前記高温での前駆体ガスの破壊によって、炭化ケイ素が前記物体に浸透し、前記物体を緻密化された外層で封止すること、ここで、前記物体は、炭化ケイ素の85重量%を超える密度と共に、実質的に純粋な炭化ケイ素微細構造及び高い耐熱性を有する。
[態様2]
前記前駆体ガスは、メチルトリクロロシラン(MTS)を含む、態様1に記載の方法。
[態様3]
前記粉末原料の連続層上にバインダを堆積させることが、周囲温度で行われる、態様1に記載の方法。
[態様4]
前記CVI反応器内の温度を上昇させることが、前記CVI反応器を850℃~1300℃に加熱することを含む、態様1に記載の方法。
[態様5]
前記物体が、アンダーカット、オーバーハング、又は内容積を有する三次元物体である、態様1に記載の方法。
[態様6]
前記物体が、核燃料要素、熱交換器、又はタービンブレードの一部分を形成する、態様1に記載の方法。
[態様7]
前記物体は、内容積を含み、前記CVI反応器内に前記物体を配置する前に、前記内容積に核燃料粒子を充填することをさらに含む、態様1に記載の方法。
[態様8]
隣接する核燃料粒子間で、前記物体の前記内容積に、炭化ケイ素粉末原料を導入することをさらに含む、態様7に記載の方法。
[態様9]
前記粉末原料の連続層上にバインダを選択的に堆積させることは、前記物体内に冷却チャネルを画定することを含み、前記冷却チャネルは、前記物体の下面から前記物体の上面まで延在する、態様7に記載の方法。
[態様10]
前記内容積内に、可燃性吸収体又は中性子減速材を配置することをさらに含む、態様7に記載の方法。
[態様11]
下記を含む、一体型核燃料要素:
実質的に純粋な炭化ケイ素微細構造を有する燃料収容体であって、少なくとも20ミクロンの厚さを有する炭化ケイ素の緻密化された外層を含み、内容積及びその下部から上部まで延在する少なくとも1つの冷却チャネルを画定する、前記燃料収容体、並びに
前記燃料収容体の内容積内に含まれる複数の燃料粒子であって、核分裂性材料を含み、炭化ケイ素粉末が、複数の燃料粒子のうちの隣接するもの間に配置され、前記複数の燃料粒子は、50%を超える充填率を達成する、前記燃料粒子。
[態様12]
前記炭化ケイ素の高密度化された外層は、両端の値を含んで00ミクロンと200ミクロンとの間の厚さを有する、態様11に記載の一体型核燃料要素。
[態様13]
前記燃料収容体は、前記下部と前記上部との間に延在する六角形の側壁を含む、態様11に記載の一体型核燃料要素。
[態様14]
前記少なくとも1つの冷却チャネルは、複数の曲線状通路を含む、態様11に記載の一体型核燃料要素。
[態様15]
前記少なくとも1つの冷却チャネルは、収束している第一の部分と発散している第二の部分とを含む、態様11に記載の一体型核燃料要素。
[態様16]
前記少なくとも1つの冷却チャネルは、垂直軸に対してゼロでない角度で冷却ガスを方向付けるように構成される、態様11に記載の一体型核燃料要素。
[態様17]
下記を含む、一体型核燃料要素の製造方法:
耐火性セラミック又は耐火性金属の粉末原料を提供すること;
前記粉末原料の連続層上にバインダを選択的に堆積させて、内容積を画定する寸法安定性燃料収容体を生成すること;
核分裂性物質を含有する複数の核燃料粒子を、前記燃料収容体の内容積内に堆積させること;
追加の粉末原料を、前記燃料収容体の前記内容積内に振動充填して、前記燃料収容体内に燃料コンパクトを得ること、及び
化学蒸気浸透を行って燃料収容体を高密度化し、前記燃料コンパクトをその中に封止すること、を含み、化学蒸気浸透は、第一の成分として耐火性セラミック又は耐火性金属の元素を有し、かつ第二の成分として炭化水素を有する、前駆体ガスを用いて行われ、高密度化された燃料収容体は、実質的に純粋な微細構造及び気密封止された外面を含む。
[態様18]
前記耐火性セラミックは、SiC、ZrC、及びCからなる群から選択される、態様17に記載の方法。
[態様19]
前記耐火性金属は、Mo及びWからなる群から選択される、態様17に記載の方法。
[態様20]
前記複数の燃料粒子は、核分裂性ウランを含むTRISO(三構造等方性)燃料粒子である、態様17に記載の方法。
[態様21]
前記複数の燃料粒子は、核分裂性ウランを含むBISO(双構造等方性)燃料粒子である、態様17に記載の方法。
[態様22]
前記複数の燃料粒子は、核分裂性ウランを含む裸のウラン含有球体である、態様17に記載の方法。
Claims (15)
- 下記を含む、一体型核燃料要素の製造方法:
炭化ケイ素の第一の粉末原料を提供すること;
前記第一の粉末原料の連続層上にバインダを選択的に堆積させることにより燃料収容体をバインダ-ジェット印刷すること、ここで、前記燃料収容体は、硬質であり、かつ、炭化ケイ素が30重量%を超えるものであり、前記燃料収容体は、外側側壁、1つ又は複数の内側側壁、基部及び頂部を有し、前記外側側壁、1つ又は複数の内側側壁、基部及び頂部はそれらの間に内部燃料空洞を画定しており、前記内部燃料空洞は、前記頂部の1つ又は複数の開口を通してアクセス可能であり、前記1つ又は複数の内側側壁は、前記基部と前記頂部とを相互接続する冷却チャネルを取り囲んでいる;
前記1つ又は複数の開口を通して核燃料粒子を導入し、次いで、前記1つ又は複数の開口を通して炭化ケイ素の第二の粉末原料を導入することにより前記内部燃料空洞を充填すること、ここで、炭化ケイ素の前記第二の粉末原料は、前記内部燃料空洞内の前記核燃料粒子の間に入れられる;
前記核燃料粒子と炭化ケイ素の前記第二の粉末原料が充填された内部燃料空洞を有する前記燃料収容体を化学蒸気浸透(CVI)反応器内に配置し、前記CVI反応器内に、ケイ素及び炭化水素を含む前駆体ガスを高温で導入し、それによって、85重量%を超える炭化ケイ素含有量まで前記燃料収容体を緻密化するとともに、緻密化された燃料収容体の前記内部燃料空洞内に核燃料粒子を密封して、25体積%未満の炭化ケイ素含有量を有する一体型核燃料要素を得ること。 - 前記前駆体ガスは、メチルトリクロロシラン(MTS)を含む、請求項1に記載の方法。
- 前記第一の粉末原料の連続層上にバインダを堆積させることが、周囲温度で行われる、請求項1に記載の方法。
- 前記CVI反応器内の温度を上昇させることが、前記CVI反応器を850℃~1300℃に加熱することを含む、請求項1に記載の方法。
- 前記1つ又は複数の開口を通して、前記核燃料粒子及び炭化ケイ素の前記第二の粉末原料とともに、可燃性吸収体又は中性子減速材を導入することをさらに含む、請求項1に記載の方法。
- 下記を含む、一体型核燃料要素:
実質的に純粋な炭化ケイ素微細構造を有する燃料収容体であって、前記燃料収容体は、外側側壁、1つ又は複数の内側側壁、基部及び頂部を有し、前記外側側壁、1つ又は複数の内側側壁、基部及び頂部はそれらの間に内部燃料容積を画定しており、前記内部燃料容積は、前記頂部の1つ又は複数の開口を通してアクセス可能であり、前記燃料収容体は、少なくとも20ミクロンの厚さを有する炭化ケイ素の緻密化された外層を含み、前記燃料収容体は、前記基部から前記頂部まで延在する少なくとも1つの冷却チャネルを画定する、前記燃料収容体、並びに
前記燃料収容体の内容積内に含まれる複数の燃料粒子であって、核分裂性材料を含み、炭化ケイ素粉末が、複数の燃料粒子のうちの隣接するもの間に配置され、前記複数の燃料粒子は、50%を超える充填率を達成する、前記燃料粒子。 - 前記炭化ケイ素の緻密化された外層は、両端の値を含んで20ミクロンと200ミクロンとの間の厚さを有する、請求項6に記載の一体型核燃料要素。
- 前記燃料収容体の外側側壁は、前記基部と前記頂部との間に延在する六角形の側壁を含む、請求項6に記載の一体型核燃料要素。
- 前記少なくとも1つの冷却チャネルは、複数の曲線状通路を含む、請求項6に記載の一体型核燃料要素。
- 前記少なくとも1つの冷却チャネルは、収束している第一の部分と発散している第二の部分とを含む、請求項6に記載の一体型核燃料要素。
- 前記少なくとも1つの冷却チャネルは、垂直軸に対してゼロでない角度で冷却ガスを方向付けるように構成される、請求項6に記載の一体型核燃料要素。
- 下記を含む、一体型核燃料要素の製造方法:
炭化ケイ素の第一の粉末原料を提供すること;
前記第一の粉末原料の連続層上にバインダを選択的に堆積させることにより燃料収容体をバインダ-ジェット印刷して、内容積を画定する寸法安定性燃料収容体を生成すること、ここで、前記燃料収容体は、外側側壁、1つ又は複数の内側側壁、基部及び頂部を有し、前記外側側壁、1つ又は複数の内側側壁、基部及び頂部はそれらの間に内部燃料空洞を画定しており、前記内部燃料空洞は、前記頂部の1つ又は複数の開口を通してアクセス可能であり、前記1つ又は複数の内側側壁は、前記基部と前記頂部とを相互接続する冷却チャネルを取り囲んでいる;
核分裂性物質を含有する複数の核燃料粒子を、前記燃料収容体の内容積内に堆積させること;
炭化ケイ素の第二の粉末原料を、前記燃料収容体の前記内容積内に振動充填して、前記燃料収容体内に燃料コンパクトを得ること、及び
化学蒸気浸透を行って燃料収容体を緻密化し、前記燃料コンパクトをその中に封止すること、ここで、前記化学蒸気浸透は、第一の成分としてケイ素前駆体を有し、かつ第二の成分として炭化水素前駆体を有し、前記燃料収容体は、85重量%を超える含有量の炭化ケイ素を含み、前記一体型核燃料要素は、25体積%未満の含有量の炭化ケイ素を含む。 - 前記複数の燃料粒子は、核分裂性ウランを含むTRISO(三構造等方性)燃料粒子である、請求項12に記載の方法。
- 前記複数の燃料粒子は、核分裂性ウランを含むBISO(双構造等方性)燃料粒子である、請求項12に記載の方法。
- 前記複数の燃料粒子は、核分裂性ウランを含む裸のウラン含有球体である、請求項12に記載の方法。
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US201862769588P | 2018-11-20 | 2018-11-20 | |
US62/769,588 | 2018-11-20 | ||
PCT/US2019/044276 WO2020106334A1 (en) | 2018-11-20 | 2019-07-31 | Additive manufacturing of complex objects using refractory matrix materials |
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JP2022509125A JP2022509125A (ja) | 2022-01-20 |
JP7197696B2 true JP7197696B2 (ja) | 2022-12-27 |
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