An Overview of Current and Past W-UO[2] CERMET Fuel Fabrication Technology

Studies dating back to the late 1940s performed by a number of different organizations and laboratories have established the major advantages of Nuclear Thermal Propulsion (NTP) systems, particularly for manned missions. A number of NTP projects have been initiated since this time; none have had any sustained fuel development work that appreciably contributed to fuel fabrication or performance data from this era. As interest in these missions returns and previous space nuclear power researchers begin to retire, fuel fabrication technologies must be revisited, so that established technologies can be transferred to young researchers seamlessly and updated, more advanced processes can be employed to develop successful NTP fuels. CERMET fuels, specifically W-UO2, are of particular interest to the next generation NTP plans since these fuels have shown significant advantages over other fuel types, such as relatively high burnup, no significant failures under severe transient conditions, capability of accommodating a large fission product inventory during irradiation and compatibility with flowing hot hydrogen. Examples of previous fabrication routes involved with CERMET fuels include hot isostatic pressing (HIPing) and press and sinter, whereas newer technologies, such as spark plasma sintering, combustion synthesis and microsphere fabrication might be well suited to produce high quality, effective fuel elements. These advanced technologies may address common issues with CERMET fuels, such as grain growth, ductile to brittle transition temperature and UO2 stoichiometry, more effectively than the commonly accepted ‘traditional’ fabrication routes. Bonding of fuel elements, especially if the fabrication process demands production of smaller element segments, must be investigated. Advanced brazing techniques and compounds are now available that could produce a higher quality bond segment with increased ease in joining. This paper will briefly address the history of CERMET fuel fabrication technology as related to the GE 710 and ANL Nuclear Rocket Programs, in addition to discussing future plans, viable alternatives and preliminary investigations for W-UO2 CERMET fuel fabrication. The intention of the talk is to provide the brief history and tie in an overview of current programs and investigations as related to NTP based W-UO2 CERMET fuel fabrication, and hopefully peak interest in advanced fuel fabrication technologies

Small-Scale Specimen Testing of Monolithic U-Mo Fuel Foils

The objective of this investigation is to develop a shear punch testing (SPT) procedure and standardize it to evaluate the mechanical properties of irradiated fuels in a hot-cell so that the tensile behavior can be predicted using small volumes of material and at greatly reduced irradiation costs. This is highly important in the development of low-enriched uranium fuels for nuclear research and test reactors. The load-displacement data obtained using SPT can be interpreted in terms of and correlated with uniaxial mechanical properties. In order to establish a correlation between SPT and tensile data, sub-size tensile and microhardness testing were performed on U-Mo alloys. In addition, efforts are ongoing to understand the effect of test parameters (such as specimen thickness, surface finish, punch-die clearance, crosshead velocity and carbon content) on the measured mechanical properties, in order to rationalize the technique, prior to employing it on a material of unknown strength

Modeling the Integrated Performance of Dispersion and Monolithic U-Mo Based Fuels

The evaluation and prediction of integrated fuel performance is a critical component of the Reduced Enrichment for Research and Test Reactors (RERTR) program. The PLATE code is the primary tool being developed and used to perform these functions. The code is being modified to incorporate the most recent fuel/matrix interaction correlations as they become available for both aluminum and aluminum/silicon matrices. The code is also being adapted to treat cylindrical and square pin geometries to enhance the validation database by including the results gathered from various international partners. Additional modeling work has been initiated to evaluate the thermal and mechanical performance requirements unique to monolithic fuels during irradiation

Monolithic Fuel Fabrication Process Development at the Idaho National Laboratory

Within the Reduced Enrichment for Research and Test Reactors (RERTR) program directed by the US Department of Energy (DOE), UMo fuel-foils are being developed in an effort to realize high density monolithic fuel plates for use in high-flux research and test reactors. Namely, targeted are reactors that are not amenable to Low Enriched Uranium (LEU) fuel conversion via utilization of high density dispersion-based fuels, i.e. 8-9 gU/cc. LEU conversion of reactors having a need for >8-9 gU/cc fuel density will only be possible by way of monolithic fuel forms. The UMo fuel foils under development afford fuel meat density of ~16 gU/cc and thus have the potential to facilitate LEU conversions without any significant reactor-performance penalty. Two primary challenges have been established with respect to UMo monolithic fuel development; namely, fuel element fabrication and in-reactor fuel element performance. Both issues are being addressed concurrently at the Idaho National Laboratory. An overview is provided of the ongoing monolithic UMo fuel development effort at the Idaho National Laboratory (INL); including development of complex/graded fuel foils. Fabrication processes to be discussed include: UMo alloying and casting, foil fabrication via hot rolling, fuel-clad interlayer application via co-rolling and thermal spray processes, clad bonding via Hot Isostatic Pressing (HIP) and Friction Bonding (FB), and fuel plate finishing

Determination of the degree of grain refinement in irradiated U-Mo fuels

A simple, repeatable method for determination of the degree of grain refinement in irradiated Uranium-Molybdenum fuels has been developed. This method involves mechanical potting and polishing of samples along with examination using a scanning electron microscope located outside of a hot cell. The commercially available software package Mathematica was used to determine the degree of grain refinement by way of a built-in iterative active contour method of image segmentation. Baseline methods for degree of grain refinement assessment are suggested for consideration and further development

Thermo-mechanical behavior simulation coupled with the hydrostatic-pressure-dependent grain-scale fission gas swelling calculation for a monolithic UMo fuel plate under heterogeneous neutron irradiation

Monolithic UMo fuels have a higher uranium density than previously developed fuels. They have become the most promising fuels to be used in high-flux research and test reactors after the US Office of Material Management and Minimization Reactor Conversion Program (formerly Reduced Enrichment Research and Test Reactor (RERTR) program). In this study, a computational method is established to couple the macro-scale irradiation-induced thermo-mechanical behavior simulation with the hydrostatic-pressure-dependent fission gas swelling calculation in the UMo grain. The stress update algorithms and consistent stiffness moduli are respectively presented for UMo fuel, in which both the hydrostatic-pressure-dependent irradiation swelling and deviatoric-stress-directed irradiation creep are taken into account. Accordingly, the user subroutines to define the thermo-mechanical non-homogeneous constitutive relations for the UMo fuel meat and Al cladding are developed and validated. The in-pile behavior in a monolithic UMo fuel plate under a location-dependent irradiation condition is calculated and discussed

Application of Self-Propagating High Temperature Synthesis to the Fabrication of Actinide Bearing Nitride and Other Ceramic Nuclear Fuels

The high vapor pressures of americium (Am) and americium nitride (AmN) are cause for concern in producing nitride ceramic nuclear fuel that contains Am. Along with the problem of Am retention during the sintering phases of current processing methods, are additional concerns of producing a consistent product of desirable homogeneity, density and porosity. Similar difficulties have been experienced during the laboratory scale process development stage of producing metal alloys containing Am wherein compact powder sintering methods had to be abandoned. Therefore, there is an urgent need to develop a low-temperature or low–heat fuel fabrication process for the synthesis of Am-containing ceramic fuels. Self-propagating high temperature synthesis (SHS), also called combustion synthesis, offers such an alternative process for the synthesis of Am nitride fuels. Although SHS takes thermodynamic advantage of the high combustion temperatures of these exothermic SHS reactions to synthesize the required compounds, the very fast heating, reaction and cooling rates can kinetically generate extremely fast reaction rates and facilitate the retention of volatile species within the rapidly propagating SHS reaction front. The initial objective of the research program is to use Mn as the surrogate for Am to synthesize a reproducible, dense, high quality Zr-Mn-N ceramic compound. Having determined the fundamental SHS reaction parameters and optimized SHS processing steps using Mn as the surrogate for Am, the technology will be transferred to Idaho National Laboratory to successfully synthesize a high quality Zr-Am-N ceramic fuel