Topology optimization of fuel elements for additive manufacturing to enhance the fluid-thermal performance of nuclear fuel assemblies

The integration of additive manufacturing (AM) and topology optimization (TO) has revolutionized the design and production of advanced equipment, providing innovative approaches to solving complex engineering challenges. In the nuclear energy sector, achieving an optimal balance between the thermal and hydraulic performance of prismatic fuel elements has long been a key challenge. This study utilizes a coupled fluid-thermal TO method to design fuel elements with one, three, five, and seven inlets/outlets configurations suitable for AM. We systematically examine the impact of varying the number of inlets/outlets on the thermal-hydraulic performance of the elements. The results show that increasing the number of inlets/outlets can enhance the thermal performance of the fuel elements while sacrificing the hydraulic performance. Compared with the conventional design, the 5 inlets/outlets configuration achieved a coordinated improvement in both thermal and hydraulic performance, with a 2.38% enhancement in thermal performance and a 4.38% improvement in hydraulic performance. These findings highlight the significant potential of TO in improving the performance of fuel elements and strongly demonstrate the advantages of the collaborative application of AM and TO.