Steel-vanadium alloy cladding for fuel element

Abstract

This disclosure describes various configurations and components for bimetallic and trimetallic claddings for use as a wall element separating nuclear material from an external environment. The cladding materials are suitable for use as cladding for nuclear fuel elements, particularly for fuel elements that will be exposed to sodium or other coolants or environments with a propensity to react with the nuclear fuel.

1 . A wall element consisting of:
 a first layer of steel;   a second layer of at least 90% vanadium; and   a third layer of nickel, nickel alloy, chromium, chromium alloy, zirconium or zirconium alloy between the first layer and the second layer.   
     
     
         2 . The wall element of  claim 1 , wherein the second layer has a thickness that is from 0.1% to 50% of the thickness of the first layer and the third layer has a thickness that is from 0.1% to 50% of the thickness of the first layer. 
     
     
         3 . The wall element of  claim 1 , wherein the second layer has a thickness that is from 1% to 5% of the thickness of the first layer and the third layer has a thickness that is from 1% to 5% of the thickness of the first layer. 
     
     
         4 . The wall element of  claims 1 - 4 , wherein the second layer is selected from the vanadium alloys V-20Ti, V-10Cr-5Ti, V-15Cr-5Ti, V-4Cr-4Ti, V-4Cr-4Ti NIFS Heats 1 & 2, V-4Cr-4Ti US Heats 832665 & 8923864, and V-4Cr-4Ti Heat CEA-J57. 
     
     
         5 . The wall element of  claim 4 , wherein the second layer is V-4Cr-4Ti. 
     
     
         6 . The wall element of  claim 4 , wherein the second consists of:
 3.0-5.0 wt. % Cr;   3.0-5.0 wt. % Ti; and   no more than 0.02 wt. % C;   with the balance being V and other elements, wherein the vanadium alloy includes not greater than 0.1 wt. % of each of these other elements, and wherein the total of these other elements does not exceed 0.5 wt. %.   
     
     
         7 . The wall element of  claim 5 , wherein the second layer consists of:
 3.5-4.5 wt. % Cr;   3.5-4.5 wt. % Ti;   0.04-0.1 wt. % Si;   up to 0.02 wt. % O;   up to 0.02 wt. % N;   up to 0.02 wt. % C;   up to 0.02 wt. % Al;   up to 0.02 wt. % Fe;   up to 0.001 wt. % Cu;   up to 0.001 wt. % Mo;   up to 0.001 wt. % Nb;   up to 0.001 wt. % P;   up to 0.001 wt. % S; and   no more than 0.0002 wt. % Cl;   with the balance being V and other elements, wherein the vanadium alloy includes not greater than 0.001 wt. % of each of these other elements, and wherein the total of these other elements does not exceed 0.01 wt. %.   
     
     
         8 . The wall element of  claims 1 - 4 , wherein the second layer consists of:
 0.001-0.5 wt. % C;   the balance being V and other elements, wherein the second layer includes not greater than 0.1 wt. % of each of these other elements, and wherein the total of these other elements does not exceed 0.5 wt. %.   
     
     
         9 . The wall element of  claim 8 , wherein the second layer includes from 0.1 to 0.3 wt. % C addition to V. 
     
     
         10 . The wall element of any of  claims 1 - 9 , wherein the steel of the first layer is selected from a tempered martensitic steel, a ferritic steel, an austenitic steel, an oxide-dispersion strengthened steel, T91 steel, T92 steel, HT9 steel, 316 steel, and 304 steel. 
     
     
         11 . The wall element of any of  claims 1 - 10 , wherein the steel of the first layer consists of:
 9.0-12.0 wt. % Cr;   0.001-2.5 wt. % W;   0.001-2.0 wt. % Mo;   0.001-0.5 wt. % Si;   up to 0.5 wt. % Ti;   up to 0.5 wt. % Zr;   up to 0.5 wt. % V;   up to 0.5 wt. % Nb;   up to 0.3 wt. % Ta;   up to 0.1 wt. % N;   up to 0.3 wt. % C;   up to 0.01 wt. % B;   the balance being Fe and other elements, wherein the steel includes not greater than 0.15 wt. % of each of these other elements, and wherein the total of these other elements does not exceed 0.35 wt. %.   
     
     
         12 . The wall element of any of  claims 1 - 11 , wherein the steel includes one or more of carbide precipitates of Ti, Zr, Nb, Ta or B, nitride precipitates of Ti, Zr, V, Nb, or Ta, and/or carbo-nitride precipitates Ti, Zr, V, Nb, or Ta. 
     
     
         13 . The wall element of any of  claims 5 - 7 , wherein the vanadium alloy includes one or more carbide precipitates of Cr, Ti and/or other elements. 
     
     
         14 . The wall element of any of  claims 1 - 13 , wherein the first layer is at least 99% of the total thickness of the wall element and wherein with each of the third layer and second layer being from 0.0001% to 0.5% of the thickness of the first layer. 
     
     
         15 . The wall element of any of  claims 1 - 14 , wherein the wall element is in the form of a tube with an interior surface and an exterior surface, the first layer forming the interior surface of the tube and the second layer forming the exterior surface of the tube. 
     
     
         16 . The wall element of any of  claims 1 - 15 , wherein the third layer consists of:
 at least 99.9 wt.  5  Ni;   with the balance other elements, wherein the material includes not greater than 0.05 wt. % of each of these other elements, and wherein the total of these other elements does not exceed 0.1 wt. %.   
     
     
         17 . The wall element of any of  claims 1 - 15 , wherein the third layer consist of:
 at least 90.0 wt. % Ni;   with the balance other elements, wherein the material includes not greater than 1.0 wt. % of each of these other elements, and wherein the total of these other elements does not exceed 5.0 wt. %.   
     
     
         18 . The wall element of any of  claims 1 - 15 , wherein the third layer consists of:
 at least 99.9 wt. % Cr;   with the balance other elements, wherein the material includes not greater than 0.05 wt. % of each of these other elements, and wherein the total of these other elements does not exceed 0.1 wt. %.   
     
     
         19 . The wall element of any of  claims 1 - 15 , wherein the third layer consists of:
 at least 90.0 wt. % Cr;   with the balance other elements, wherein the material includes not greater than 1.0 wt. % of each of these other elements, and wherein the total of these other elements does not exceed 5.0 wt. %.   
     
     
         20 . The wall element of any of  claims 1 - 15 , wherein the third layer consists of:
 at least 99.9 wt. % Zr;   with the balance other elements, wherein the material includes not greater than 0.05 wt. % of each of these other elements, and wherein the total of these other elements does not exceed 0.1 wt. %.   
     
     
         21 . The wall element of any of  claims 1 - 15 , wherein the third layer consists of:
 at least 90.0 wt. % Zr;   with the balance other elements, wherein the material includes not greater than 1.0 wt. % of each of these other elements, and wherein the total of these other elements does not exceed 5.0 wt. %.   
     
     
         22 . A container made, at least in part, from wall elements of any of  claims 1 - 21 . 
     
     
         23 . A container for holding a nuclear fuel comprising:
 at least one wall element separating a fuel storage volume from an external environment;   the wall element having a first layer of steel separated from a second layer of at least 90% vanadium by a third layer between the first layer and the second layer;   the first layer of the wall contacting the external environment and the second layer contacting and the fuel storage volume; and   wherein the third layer consists of nickel, nickel alloy, chromium, chromium alloy, zirconium or zirconium alloy.   
     
     
         24 . The container of  claim 23 , wherein the container has a shape that is defined by one or more continuously connected wall elements to form a vessel. 
     
     
         25 . The container of  claim 23 , wherein the container is shaped as a cylindrical tube, at least one wall element forming a cylindrical wall of the tube and the fuel storage region being the inside of the tube. 
     
     
         26 . The container of any of  claims 23 - 25 , wherein the container includes a bottom wall and one or more sidewalls and at least one wall element forms a bottom wall or sidewall the container. 
     
     
         27 . An article, comprising:
 an amount of nuclear material;   a wall element disposed exterior to the nuclear fuel and separating at least some of the nuclear material from an exterior environment, the wall element consisting of:
 a first layer of steel in contact with the external environment; and 
 a second layer of at least 90% vanadium in contact with the nuclear material; and 
 a third layer between the first layer and the second layer, the first layer of nickel inhibiting the transfer of carbon from the steel into the vanadium alloy; 
   wherein the third layer consists of nickel, nickel alloy, chromium, chromium alloy, zirconium or zirconium alloy.   
     
     
         28 . The article of  claim 27 , wherein the nuclear material includes at least one of U, Th, Am, Np, and Pu. 
     
     
         29 . The article of  claim 27  or  28 , wherein the nuclear material includes at least one refractory material chosen from Nb, Mo, Ta, W, Re, Zr, V, Ti, Cr, Ru, Rh, Os, Ir, Nd, and Hf. 
     
     
         30 . The article of any of  claims 27 - 29 , wherein the first layer includes a steel, substantially all of which has at least one phase chosen from a tempered martensite phase, a ferrite phase, and an austenitic phase. 
     
     
         31 . The article of any of  claims 27 - 30 , wherein the cladding layer includes at least one steel chosen from a martensitic steel, a ferritic steel, an austenitic steel, an oxide-dispersed steel, T91 steel, T92 steel, HT9 steel, 346 steel, and 304 steel. 
     
     
         12 . The article of any of  claims 27 - 31 , wherein the nuclear fuel and the wall element are mechanically bonded. 
     
     
         33 . The article of any of  claims 27 - 32 , wherein the exterior environment includes molten sodium and the first layer of steel prevents contact between the sodium and the vanadium in the second layer. 
     
     
         34 . The article of any of  claims 27 - 33 , wherein the first layer and the second layer are mechanically bonded to opposite sides of the third layer. 
     
     
         35 . The article of any of  claims 27 - 34 , wherein the nuclear material includes at least 90 wt. % of U. 
     
     
         36 . The article of any of  claims 27 - 35 , wherein the nuclear material is a nuclear fuel and the article is a nuclear fuel element. 
     
     
         37 . The article of any of  claims 27 - 36 , wherein the third layer consists of:
 at least 99.9 wt. % Ni;   with the balance other elements, wherein the material includes not greater than 0.05 wt. % of each of these other elements, and wherein the total of these other elements does not exceed 0.1 wt. %.   
     
     
         38 . The article of any of  claims 27 - 36 , wherein the third layer consists of:
 at least 90.0 wt. % Ni;   with the balance other elements, wherein the material includes not greater than 5.0 wt. % of each of these other elements, and wherein the total of these other elements does not exceed 10.0 wt. %.   
     
     
         39 . The article of any of  claims 27 - 36 , wherein the third layer consists of:
 at least 99.9 wt. % Cr;   with the balance other elements, wherein the material includes not greater than 0.05 wt. % of each of these other elements, and wherein the total of these other elements does not exceed 0.1 wt. %.   
     
     
         40 . The article of any of  claims 27 - 36 , wherein the third layer consists of:
 at least 90.0 wt. % Cr;   with the balance other elements, wherein the material includes not greater than 5.0 wt. % of each of these other elements, and wherein the total of these other elements does not exceed 10.0 wt. %.   
     
     
         41 . The w article of any of  claims 27 - 36 , wherein the second layer consists of:
 0.001-0.5 wt. % C;   the balance being V and other elements, wherein the second layer includes not greater than 0.1 wt. % of each of these other elements, and wherein the total of these other elements does not exceed 0.5 wt. %.   
     
     
         42 . A wall element consisting of:
 a first layer of steel;   a second layer of vanadium doped with at least 0.001 wt. % carbon on the first layer of steel, the second layer having no more than 0.5 wt. % of other elements besides V and C.   
     
     
         43 . The wall element of  claim 42  comprising:
 a third layer between the first layer and the second layer, the third layer being made of nickel, nickel alloy, chromium, chromium alloy, zirconium or zirconium alloy. 
 
     
     
         44 . The wall element of  claim 42  or  43 , wherein the second layer consists of:
 0.001-0.5 wt. % C; 
 the balance being V and other elements, wherein the doped vanadium of the second layer includes not greater than 0.1 wt. % of each of these other elements, and wherein the total of these other elements does not exceed 0.5 wt. %. 
 
     
     
         45 . The wall element of any of  claims 42 - 44 , wherein the doped vanadium of the second layer includes from 0.1 to 0.3 wt. % C. 
     
     
         46 . The wall element of any of  claims 42 - 45 , wherein the steel of the first layer is selected from a tempered martensitic steel, a ferritic steel, an austenitic steel, an oxide-dispersion strengthened steel, T91 steel, T92 steel, HT9 steel, 316 steel, and 304 steel. 
     
     
         47 . The wall element of any of  claims 42 - 46 , wherein the steel of the first layer consists of:
 9.0-12.0 wt. % Cr;   0.001-2.5 wt. % W;   0.001-2.0 wt. % Mo;   0.001-0.5 wt. % Si;   up to 0.5 wt. % Ti;   up to 0.5 wt. % Zr;   up to 0.5 wt. % V;   up to 0.5wt. % Nb;   up to 0.3 wt. % Ta;   up to 0.1 wt. % N;   up to 0.3 wt. % C;   up to 0.01 wt. % B;   the balance being Fe and other elements, wherein the steel includes not greater than 0.15 wt. % of each of these other elements, and wherein the total of these other elements does not exceed 0.35 wt. %.   
     
     
         48 . The wall element of any of  claims 42 - 47 , wherein the steel includes one or more of carbide precipitates of Ti, Zr, V, Nb, Ta or B, nitride precipitates of Ti, Zr, V, Nb, or Ta, and/or carbo-nitride precipitates of Ti, Zr, V, Nb, or Ta and/or wherein the vanadium alloy includes one or more carbide precipitates of Cr, Ti and/or other elements. 
     
     
         49 . The wall element of  claim 42 , wherein the second layer has a thickness that is from 0.1% to 50% of the thickness of the first layer. 
     
     
         50 . The wall element of any of  claims 42 - 49 , wherein the second layer has a thickness that is from 1% to 5% of the thickness of the first layer. 
     
     
         51 . The wall element of any of  claims 42 - 50 , wherein the wall element is in the form of a tube with an interior surface and an exterior surface, the first layer forming the interior surface of the tube and the second layer forming the exterior surface of the tube. 
     
     
         52 . The wall element of  claim 51  further comprising:
 an amount of nuclear material within the tube. 
 
     
     
         53 . The article of  claim 52 , wherein the nuclear material includes one or more elements selected from U, Th, Am, Np, and Pu. 
     
     
         54 . The article of  claim 52  or  53 , wherein the nuclear material includes at least one refractory material chosen from Nb, Mo, Ta, W, Re, Zr, V, Ti, Cr, Ru, Rh, Os, Ir, Nd, and Hf. 
     
     
         55 . A container for holding a nuclear fuel comprising:
 at least one wall element separating a fuel storage region from an external environment;   the wall element having a first layer of steel attached to a second layer of vanadium doped with at least 0.001 wt. % carbon and having no more than 0.5 wt. % of other elements,   the first layer of the wall contacting the external environment and the second layer contacting the fuel storage region.   
     
     
         56 . The container of  claim 55 , wherein the container has a shape that is defined by one or more continuously connected wall elements to forma vessel. 
     
     
         57 . The container of  claim 55  or  56 , wherein the container is shaped as a cylindrical tube, at least one wall element forming a cylindrical wall of the tube and the fuel storage region being the inside of the tube. 
     
     
         58 . The container of any of  claims 55 - 57 , wherein the container includes a bottom wall and one or more sidewalls and at least one wall element forms a bottom wall of the container. 
     
     
         59 . The container of any of  claims 55 - 58 , wherein the container includes a bottom wall and one or more sidewalk and at least one wall demerit forms at least one of the one or more sidewalls of the container. 
     
     
         60 . A wall element consisting of:
 a first layer of steel;   a second layer of vanadium alloy on the first layer of steel, wherein the first layer of steel is from 0.1% to 50% of the thickness of the second layer.   
     
     
         61 . The wall element of  claim 60  comprising:
 a third layer between the first layer and the second layer, the third layer being made of nickel, nickel alloy, chromium, chromium alloy, zirconium or zirconium alloy. 
 
     
     
         62 . The wall element of  claim 60  or  61 , wherein the second layer is selected from the vanadium alloys V-20Ti, V-10Cr-5Ti, V-15Cr-5Ti, V-4Cr-4Ti, V-4Cr-4Ti NIFS Heats 1 & 2, V-4-Cr-4Ti US Heats 832665 & 8923864, and V-4Cr-4Ti Heat CEA-J57. 
     
     
         63 . The wall element of  claim 62 , wherein the second layer consists of:
 3.0-5.0 wt. % Cr;   3.0-5.0 wt. % Ti; and   no more than 0.02 wt. % Cr;   with the balance being V and other elements, wherein the vanadium alloy includes not greater than 0.1 wt. % of each of these other elements, and wherein the total of these other elements does not exceed 0.5 wt. %.   
     
     
         64 . The wall element of  claim 62 , wherein the second layer consists of:
 3.5-4.5 wt. % Cr;   3.5-4.5 wt. % Ti;   0.04-0.1 wt. % Si;   up to 0.02 wt. % O;   up to 0.02 wt. % N;   up to 0.02 wt. % C;   up to 0.02 wt. % Al;   up to 0.02 wt. % Fe;   up to 0.001 wt. % Cu;   up to 0.001 wt. % Mo;   up to 0.001 wt. % Nb;   up to 0.001 wt. % P;   up to 0.001 wt. % S; and   no more than 0.0002 wt. % Cl;   with the balance being V and other elements, wherein the vanadium alloy includes not greater than 0.001 wt. % of each of these other elements, and wherein the total of these other elements does not exceed 0.01 wt. %.   
     
     
         65 . The wall element of any of  claims 60 - 64 , wherein the steel of the first layer is selected from a tempered martensitic steel, a terrific steel, an austenitic steel, an oxide-dispersion strengthened steel, T91 steel, T92 steel, HT9 steel, 316 steel, and 304 steel. 
     
     
         66 . The wall element of  claims 60 - 64 , wherein the steel of the first layer consists of:
 9.0-12.0 wt. % Cr;   0.001-2.5 wt. % W;   0.001-2.0 wt. % Mo;   0.001-0.5 wt. % Si;   up to 0.5 wt. % Ti;   up to 0.5 wt. % Zr;   up to 0.5 wt. % V;   up to 0.5 wt. % Nb;   up to 0.3 wt. % Ta;   up to 0.1 wt. % N;   up to 0.3 wt. % C;   up to 0.01 wt. % B;   the balance being Fe and other elements, wherein the steel includes not greater than 0.15 wt. % of each of these other elements, and wherein the total of these other elements does not exceed 0.35 wt. %.   
     
     
         67 . The wall element of any of  claims 60 - 67 , wherein the steel includes one or more of carbide precipitates of Ti, Zr, V, Nb, Ta or B, nitride precipitates of Ti, Zr, V, Nb, Ta, and/or carbo-nitride precipitates of Ti, Zr, V, Nb, or Ta and/or wherein the vanadium alloy includes one or more carbide precipitates of Cr, Ti and/or other elements. 
     
     
         68 . The wall element of any preceding claim, wherein the first layer has a thickness that is from 1% to 5% of the thickness of the second layer. 
     
     
         69 . The wall element of any preceding claim, wherein the wall element is in the form of a tube with an interior surface and an exterior surface, the first layer forming the interior surface of the tube and the second layer forming the exterior surface of the tube. 
     
     
         70 . A container for holding a nuclear fuel comprising:
 at least one wall element separating a fuel storage region from an external environment;   the wall element having a first layer of steel attached to a second layer of vanadium alloy, wherein the first layer of steel is from 0.1% to 50% of the thickness of the second layer;   the first layer of the wall contacting the external environment and the second layer contacting the fuel storage region.   
     
     
         71 . The container of  claim 70 , wherein the container has a shape that is defined by one or more continuously connected wall elements to forma vessel. 
     
     
         72 . The container of  claim 70  or  71 , wherein the container is shaped as a cylindrical tube, at least one wall element forming a cylindrical wall of the tube and the fuel storage region being the inside of the tube. 
     
     
         73 . The container of any of  claims 70 - 72 , wherein the container includes a bottom wall and one or more sidewalls and at least one wall element forms a bottom wall of the container. 
     
     
         74 . The container of any of  claims 70 - 73 , wherein the container includes a bottom wall and one or more sidewalk and at least one wall element forms at least one of the one or more sidewalls of the container. 
     
     
         75 . An article, comprising:
 an amount of nuclear material;   a wall element disposed exterior to the nuclear fuel and separating at least some of the nuclear material from an exterior environment, the wall element consisting of:
 a first layer of steel; and 
 a second layer of vanadium alloy between the first layer and the nuclear material, wherein the first layer of steel is from 0.1% to 50% of the thickness of the second layer and the first layer of steel separates the second layer from the exterior environment. 
   
     
     
         76 . The article of  claim 75 , wherein the nuclear material includes at least one of U, Th, Am, Np and Pu. 
     
     
         77 . The article of  claim 75  or  76 , wherein the first layer includes at least one steel chosen from a martensitic steel, a ferritic steel, an austenitic steel, an oxide-dispersed steel, T91 steel, T92 steel, HT9 steel, 316 steel, and 304 steel. 
     
     
         78 . The article of any of  claims 75 - 77 , wherein the nuclear fuel and the wall element are mechanically bonded. 
     
     
         79 . The article of any of  claims 75 - 78 , wherein the exterior environment includes molten sodium and the first layer of steel prevents contact between the sodium and the vanadium alloy in the second layer. 
     
     
         80 . The article of any of  claims 75 - 79 , wherein the first layer and the second layer are mechanically bonded. 
     
     
         81 . The article of any of  claims 75 - 80 , wherein the nuclear material includes at least 90 wt. % of U. 
     
     
         82 . The article of any of  claims 75 - 81 , wherein the nuclear material is nuclear fuel and the article is a nuclear fuel element. 
     
     
         83 . A power-generating reactor including the article of any of  claim 75 - 82 . 
     
     
         84 . A method of manufacturing a wall element for separating a nuclear material from an external environment, the method comprising:
 manufacturing a first layer, the first layer including at least a steel layer; and   connecting the first layer to a second layer, the second layer including at least a vanadium alloy layer.   
     
     
         85 . The method of  claim 84  further comprising:
 manufacturing the second layer prior to connecting the second layer to the first layer. 
 
     
     
         86 . The method of  claims 84  or  85 , wherein connecting further comprises:
 connecting the steel layer to the vanadium alloy layer. 
 
     
     
         87 . The method of any of  claims 84 - 86 , wherein manufacturing the first layer includes manufacturing a first layer consisting of the steel layer connected to a chromium layer and connecting includes connecting the first layer to the second layer so that the chromium layer is between the steel layer and the vanadium alloy layer. 
     
     
         88 . The method of any of  claims 84 - 87 , wherein the second layer consists of the vanadium alloy layer connected to the chromium layer and connection includes the first layer to the second layer so that the chromium layer is between the steel layer and the vanadium alloy la