Use of Friction Stir Welding and Friction Stir Processing for Advanced Nuclear Fuels and Materials Joining Applications

Application of the latest developments in materials technology may greatly aid in the successful pursuit of next generation reactor and transmutation technologies. One such area where significant progress is needed is joining of advanced fuels and materials. Rotary friction welding, also referred to as friction stir welding (FSW), has shown great promise as a method for joining traditionally difficult to join materials such as aluminum alloys. This relatively new technology, first developed in 1991, has more recently been applied to higher melting temperature alloys such as steels, nickel-based and titanium alloys. An overview of the FSW technology is provided and two specific nuclear fuels and materials applications where the technique may be used to overcome limitations of conventional joining technologies are highlighted

Interfacial adhesion and toughening mechanisms in an alloy of polycarbonate/polyethylene

Interfacial adhesion and toughening mechanisms in an alloy of polycarbonate/polyethylene (PC/PE) are investigated using transmission electron microscopy. In contrast to the general speculation, it is found that the PE particles strongly adhere to the PC matrix. The toughening mechanisms in the PC/PE blend are found to be debonding of the PC/PE interface, which relieves the triaxial tension in front of the crack tip, followed by shear banding of the PC matrix. Possible causes for such an unexpected strong interfacial adhesion between PC and PE are discussed. Also, the importance of the cavitational strength of the toughener phase in toughness optimization is addressed.Peer Reviewedhttp://deepblue.lib.umich.edu/bitstream/2027.42/30378/1/0000780.pd

Update on Mechanical Analysis of Monolithic Fuel Plates

Results on the relative bond strength of the fuel-clad interface in monolithic fuel plates have been presented at previous RRFM conferences. An understanding of mechanical properties of the fuel, cladding, and fuel / cladding interface has been identified as an important area of investigation and quantification for qualification of monolithic fuel forms. Significant progress has been made in the area of mechanical analysis of the monolithic fuel plates, including mechanical property determination of fuel foils, cladding processed by both hot isostatic pressing and friction bonding, and the fuel-clad composite. In addition, mechanical analysis of fabrication induced residual stress has been initiated, along with a study to address how such stress can be relieved prior to irradiation. Results of destructive examinations and mechanical tests are presented along with analysis and supporting conclusions. A brief discussion of alternative non-destructive evaluation techniques to quantify not only bond quality, but also bond integrity and strength, will also be provided. These are all necessary steps to link out-of-pile observations as a function of fabrication with in-pile behaviours

Characterization and Testing of Monolithic RERTR Fuel Plates

Monolithic fuel plates are being developed for application in research reactors throughout the world. These fuel plates are comprised of a U-Mo alloy foil encased in aluminum alloy cladding. Three different fabrication techniques have been looked at for producing monolithic fuel plates: hot isostatic pressing (HIP), transient liquid phase bonding (TLPB), and friction stir welding (FSW). Of these three techniques, HIP and FSW are currently being emphasized. As part of the development of these fabrication techniques, fuel plates are characterized and tested to determine properties like hardness and the bond strength at the interface between the fuel and cladding. Testing of HIPed samples indicates that the foil/cladding interaction behavior depends on the Mo content in the U-Mo foil, the measured hardness values are quite different for the fuel, cladding, and interaction zone phase and Ti, Zr and Nb are the most effective diffusion barriers. For FSW samples, there is a dependence of the bond strength at the foil/cladding interface on the type of tool that is employed for performing the actual FSW process

Fabrication of dual phase magnesia-zirconia ceramics doped with plutonia and erbia

Dual phase magnesia-zirconia ceramics doped with plutonia and erbia are being evaluated as an inert matrix fuel (IMF) for light water reactors (LWR). The motivation for this work is to develop an IMF with a thermal conductivity superior to that of the fuels based on single-phase yttria stabilized zirconia. The innovative fuel developed at INL is comprised of two major phases: pure MgO and quaternary solid solution consisting of MgO, ZrO{sub 2}, Er{sub 2}O{sub 3} and PuO{sub 2}. Pure MgO phase acts as an efficient heat conductor. It has been shown [1] that dual phase MgO-ZrO{sub 2} ceramics have the thermal conductivity superior to that of UO{sub 2} and have notable chemical resistance to water at the temperature of 573 K and pressure 8.6 MPa, which makes them attractive for use as an IMF matrix in LWRs

Role of A20 in cIAP-2 Protection against Tumor Necrosis Factor α (TNF-α)-Mediated Apoptosis in Endothelial Cells

Tumor necrosis factor α (TNF-α) influences endothelial cell viability by altering the regulatory molecules involved in induction or suppression of apoptosis. However, the underlying mechanisms are still not completely understood. In this study, we demonstrated that A20 (also known as TNFAIP3, tumor necrosis factor α-induced protein 3, and an anti-apoptotic protein) regulates the inhibitor of apoptosis protein-2 (cIAP-2) expression upon TNF-α induction in endothelial cells. Inhibition of A20 expression by its siRNA resulted in attenuating expression of TNF-α-induced cIAP-2, yet not cIAP-1 or XIAP. A20-induced cIAP-2 expression can be blocked by the inhibition of phosphatidyl inositol-3 kinase (PI3-K), but not nuclear factor (NF)-κB, while concomitantly increasing the number of endothelial apoptotic cells and caspase 3 activation. Moreover, TNF-α-mediated induction of apoptosis was enhanced by A20 inhibition, which could be rescued by cIAP-2. Taken together, these results identify A20 as a cytoprotective factor involved in cIAP-2 inhibitory pathway of TNF-α-induced apoptosis. This is consistent with the idea that endothelial cell viability is dependent on interactions between inducers and suppressors of apoptosis, susceptible to modulation by TNF-α

Fabrication and Characterization of Dual Phase Magnesia-Zirconia Ceramics Doped with Plutonia

Dual phase magnesia-zirconia ceramics doped with plutonia are being studied as an inert matrix fuel (IMF) for light water reactors. The motivation of this work is to develop an IMF with a thermal conductivity superior to that of the fuels based on yttria stabilized zirconia. The concept uses the MgO phase as an efficient heat conductor to increase thermal conductivity of the composite. In this paper ceramic fabrication and characterization by scanning electron microscopy, energy and wavelength dispersive xray spectroscopy is discussed. Characterization shows that the ceramics consist of the two-phase matrix and PuO2-rich inclusions. The matrix is comprised of pure MgO phase and MgO-ZrO2-PuO2 solid solution. The PuO2-rich inclusion contained dissolved MgO and ZrO2

Microstructural Characterization of Burnable Absorber Materials Being Evaluated for Application in LEU U-Mo Fuel Plates

The starting microstructure of a fuel plate will impact how it performs during irradiation. As a result, microstructural characterization has been performed on as-fabricated monolithic fuel plates to determine the changes in fuel plate microstructure that may result from changes in fabrication parameters. Particular focus has been given to the fuel plate U-10Mo/Zr and Zr/AA6061 cladding interfaces, since the integrity of these interfaces will play a big role in determining the overall performance of the fuel plate during irradiation. In addition, burnable absorber materials for potential incorporation into monolithic fuel plates have been characterized to identify their as-fabricated microstructures. This information will be important when trying to understand the PIE data from fuel plates with burnable absorbers that are irradiated in future irradiation experiments. This paper will focus on the microstructures observed using optical metallography, X-ray diffraction, and scanning and transmission electron microscopy for monolithic fuel plates exposed to different fabrication parameters and for as-fabricated burnable absorber materials

Monolithic Fuel Fabrication Process Development

The pursuit of a high uranium density research reactor fuel plate has led to monolithic fuel, which possesses the greatest possible uranium density in the fuel region. Process developments in fabrication development include friction stir welding tool geometry and cooling improvements and a reduction in the length of time required to complete the transient liquid phase bonding process. Annealing effects on the microstructures of the U-10Mo foil and friction stir welded aluminum 6061 cladding are also examined

Results of Recent Microstructural Characterization of Irradiated U-Mo Dispersion Fuels with Al Alloy Matrices that Contain Si

RERTR U-Mo dispersion fuel plates are being developed for application in research reactors throughout the world. As part of this development, reactor experiments are being conducted in the Advanced Test Reactor to determine the irradiation performance of different dispersion fuels that contain U-Mo alloys with different Mo contents and Al alloy matrices with different Si contents. Of particular interest is the performance of the dispersion fuels depending on the Si content of the Al alloy matrix, since the addition of Si is being looked to for improving the performance of these dispersion fuels. This paper will describe the results of recent microstructural examinations that have been performed using optical metallography and scanning electron microscopy on as-fabricated and as-irradiated dispersion fuels with different amounts of Si added to the Al matrix. Differences in the microstructural development during irradiation as a function of the Si content in the Al matrix will be discussed, and comments will be made about the development and stability of the fuel/matrix interaction layers that are commonly present in irradiated dispersion fuels