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At least 271 records · Page 15
All sourcesNASA NTRSDOE OSTI
DOE OSTI2016

Enrichment Penalty for Molybdenum Cladded Accident Tolerant Fuel

A tri-layered fuel cladding has been proposed as an enhanced accident tolerant fuel (EATF) design. The EATF cladding has an inner layer of zirconium alloy, a layer of molybdenum, and an outer layer of zirconium alloy. Due to its high melting point, high temperature creep resistance, and improved resistance to steam corrosion, the molybdenum layer will better tolerate a loss of active coolant accident than the standard single layer zircaloy cladding currently in use. The addition of the molybdenum layer to the cladding, however, has a deleterious effect on the fuel management due to the high thermal neutron capture cross section of Mo{sup 95}. This negative reactivity effect must be counterpoised by increasing the fuel enrichment in order to maintain a constant cycle length. This work presents a prima facie quantification of the enrichment increase required to maintain cycle length for a standard PWR 3 x 18 month cycle. The quantification of the required enrichment increase is necessary in order for a more thorough financial analysis to be performed for the prospective new fuel design. (author)

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2024

FUEL PERFORMANCE STUDIES AT IDAHO NATIONAL LABORATORY MAKING USE OF THE BYRON FUEL SHIPMENT

In December of 2023 a shipment of commercially irradiated fuel rods from the Byron Generating Station in Illinois was successfully shipped to the Materials and Fuels Complex (MFC) at Idaho National Laboratory (INL). The make-up of the rods includes a mix of cladding types from traditional ZirloTM, advanced zirconium alloys, and chrome coated ZirloTM. Burnups range from regular end of life values to over 70 GWd/MTU rod average. The R&D plan for the rods involves multiple projects from developing licensing data for new claddings to integral transient tests to support burnup extension efforts in the United States. The R&D began in early 2024 with the nondestructive examinations of the rods after which they will be sectioned for microscopy, mechanical testing, and analytical chemistry. Additionally, many rod segments will be refabricated into new test pins and inserted into a static water capsule for integral Reactivity Initiated Accident (RIA) and Loss of Coolant Accident (LOCA) testing at the TREAT reactor.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2024

Zirconium Sludge Criticality Calculations in Large Process Tanks

The Savannah River Site’s H-Canyon facility has been tasked with accelerating the disposition of used research reactor fuels. • Future missions will involve dissolution of “Non-Aluminum” clad fuels – not easily dissolved – Nitric acid is not capable of dissolving stainless steel, Zirconium, and Hastelloy, clad fuels by itself • The electrolytic dissolver has been (re) selected as a disposition path for these fuels. 2

Devine, Nathan P.↗
DOE OSTI2016

High temperature oxidation of PCD coated Zr alloy

Polycrystalline diamond (PCD) coating is a promising possibility for prevention, or reduction of high temperature oxidation of zirconium alloys and decrease corrosion rate of zirconium alloy during standard operation. Zirconium alloys are widely used as cladding and construction material in almost all types of nuclear reactors, where usually creates a barrier between nuclear fuel and cooling water in the primary circuit. Hydrogen and considerable amount of heat is released during steam oxidation that may occur in an eventual accident. In this paper zirconium alloy was covered by polycrystalline diamond layer using Plasma Enhanced Linear Antennas Microwave Chemical Vapor Deposition system reactor. X-Ray Diffraction and Raman spectroscopy measurements confirmed coverage of the surface area with crystalline and amorphous carbon layer. Characterizations (Raman spectroscopy) were done for zirconium alloy covered with polycrystalline diamond layer before and after high temperature steam exposure. Weight increase and hydrogen release were measured during steam exposure. The results show that the oxidation kinetics of PCD coated samples is similar to kinetics of uncoated samples at almost all temperatures, but with lower hydrogen production and lower weight gains. Most important difference is in later beginning of breakaway oxidation at 1000 Celsius degrees, when breakaway oxidation starts on PCD coated sample 15 minutes later. Raman spectroscopy revealed graphitization of the PCD layer and the diamond sp{sup 3} bounds are lost and the Raman signal consists only from the two graphite-related D bounds. It implies conversion of PCD layer to the homogeneous non-crystalline carbon layer with a large content of graphitic phase. Overall hydrogen production and weight gain values are generally lower then for uncoated samples.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2016

Helium-3 Production via Lithium-6 Activation in an Accelerator-Driven Reactor

In this paper, the possibility of using an accelerator-driven subcritical reactor to produce helium-3 is explored. Current supply of helium-3 in the United States is running low. Helium-3 has many applications in neutron detection, high-energy physics, and national security, and has a growing demand in the scientific community for its properties. The main source of helium-3 in the United States is from dismantling nuclear arms, where tritium is allowed to decay into helium-3. There are no current, significant future plans for increasing helium-3 production. However, the projected demand of this isotope is expected to increase dramatically, with greater research into aneutronic fusion, and allotments of helium for the Spallation Neutron Source, and ITER expected in years to come. Tritium, with a half-life of 12.3 years, will take time to decay to helium-3, which means production needs to start now to counter the future deficit. This helium-3 production system sets out to be an economical, and safe solution for this future deficit. A zirconium-lithium mixture is utilized as a target for breeding helium-3. Specifically, the target rods will consist of lithium aluminate pellets with diameters ranging from 100 to 500 microns, dispersed within a zirconium matrix. Lithium targets in pellet form were chosen over a solid rod, or annulus, in order to reduce self-shielding effects within the lithium, and to further facilitate tritium loading and containment within the zirconium. Additionally, a stainless steel 316 cladding surrounds the target rods, to further reduce outgassing of helium. The core is made up of 6480 fuel pins, enriched to 4.75% wt% U-235/U, and 3660 lithium pins in mixed assemblies arranged in hexagonal lattices, with the lithium enriched to 75% lithium-6, and a total lithium loading of approximately 70 kg. An accelerator is used as a neutron source, firing 800 MeV protons at a liquid lead target loop. Neutronics analysis and burnup calculation were performed with the aid of MCNP6. (authors)

07 ISOTOPE AND RADIATION SOURCES↗
DOE OSTI2020

An Investigation of Liquefaction in Irradiated TRIGA Fuel Exposed to Relatively High Temperatures

This report presents the findings of an investigation into high temperature fuel cladding chemical interactions (FCCI) in Training, Research, Isotopes, General Atomics (TRIGA) fuel rods. A TRIGA fuel-rod core or meat is principally composed of uranium (U) particles dispersed in a zirconium hydride (Zr H) matrix. The fuel is clad in sealed 304SS or Incoloy 800 tubes. At high temperatures, the fuel will interact with the cladding, resulting in FCCI. To investigate the FCCI (in this case, liquefaction), irradiated TRIGA fuel rods were exposed to relatively high temperatures in furnace tests. The tests were performed at different temperatures using segments from an irradiated TRIGA fuel rod at the Hot Fuel Examination Facility located at Idaho National Laboratory (INL). The data from this study is important for developing a better understanding of the performance of U-ZrH fuel type during transient events (e.g., a Loss of Coolant Accident (LOCA) event) that may result in high temperatures while operating a TRIGA reactor. Furnace tests were run for 6 hours at 730, 800, 900, 950, and 1,000°C. One test was run for 12 hours at 950°C. Post-test microstructural characterization was performed on the heat-treated samples using optical metallography to look for evidence of liquefaction. Additionally, microstructural characterization was performed using scanning electron microscopy to investigate the microstructure of the as-irradiated fuel before heat treatment and the microstructural changes that occurred after heat treating for the 730 and 950°C heat treatments for 6 hours. Results of the analysis were compared to those produced during diffusion studies performed using unirradiated TRIGA fuel meat and type 304 stainless steel. A gap is typically present in as-irradiated fuel that limits any possibility for chemical interaction between the fuel and cladding. Optical metallography (OM) was used to identify areas in the specimens heat treated at 950 and 1000°C where fuel and cladding contact was satisfactory for the FCCI to transpire. The bulk of the interaction zones that form due to FCCI developed in the fuel meat and not as much in the cladding. Even in the sample tested at 1,000°C, no evidence was found that gross fuel meat or cladding melting had occurred. Only limited porosity was found in the fuel meat that possibly could have been due to melting of a particular precipitate phase or phases that had formed during FCCI. These results agreed with those reported for the unirradiated diffusion couple studies.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2016

AREVA NP MR Cladding benefits for proposed US NRC RIA and LOCA requirements

M5 is the reference alloy of AREVA NP for PWR cladding applications. It is a zirconium-based alloy containing 1% niobium, no tin, and well-controlled oxygen, iron, and sulfur contents. It has a fully recrystallized microstructure. The absence of tin in M5 results in a very low corrosion rate and hydrogen pick-up during normal operation, even at high burn-up and in high duty irradiation conditions. Due to this low hydrogen pick-up under irradiation (typically less than 100 ppm, End of Life), M5 retains a very good strength and an exceptional residual ductility during and after the accident. This allows utilities implementing M5 to simplify the safety analysis and to demonstrate significant margins regarding fuel related criteria. Simplified methods are easier for plants to implement and maintain for future plant operations and core design management. This paper specifically presents 3 examples on the safety improvement brought by M5 cladding. First, during a reactivity-induced accident (RIA), the properties of M5 are such that bounding analyses for future cycles are significantly simplified, in particular by demonstrating that fuel dispersal will not occur. The major aspects of the AREVA NP RIA methodology are presented. A second focus is made on the low hydrogen embrittlement of M5 and on its high ductility after quenching during a loss-of-coolant accident (LOCA). In a third part, the breakaway oxidation testing program currently under development in Paimboeuf (France) is described, including details about the testing devices and qualification. The tests have demonstrated that M5 cladding does not have breakaway at least up to 5000 s oxidation duration at 1000 C. degrees, which is much higher than the LOCA duration.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2019

Elastic strain tensor of zirconium hydrides in Zr2.5%Nb pressure tubes by synchrotron X-ray diffraction

Zirconium alloys are used in fuel cladding and structural components of nuclear power plants. Hydrogen enters the Zr matrix during plant operation and precipitates as hydride particles that degrade the mechanical properties of the alloy, limiting service life. Knowledge of the stress state within hydride precipitates is important to understand stress-induced degradation mechanisms such as delayed hydride cracking, but no direct quantification has yet been reported in the literature. Here, measurements are reported of the average elastic strain tensor within δ zirconium hydride precipitates in Zr2.5%Nb pressure tube material from CANDU power plants. Complete intensity and strain pole figures for the hydride were obtained by synchrotron X-ray diffraction experiments on specimens with hydrogen contents ranging from ~100 wt p.p.m. hydrogen to nearly 100% δ-hydride. Zirconium hydride precipitates by a process involving a martensitic transformation, with two hydride variants possible from a single α-Zr grain. A synthetic model of the hydride crystallographic texture allowed the interpretation of the measured strain pole figures and quantification of the elastic strain tensor for both texture components. It was found that the two variants appear in nearly equal proportion but with different stress states, differing in the sign of the shear strain components (~±3000 µ$\epsilon$). This difference is possibly associated with the shear movement of Zr atoms during the phase transformation. This suggests that hydride clusters are composed of stacks of smaller hydrides in alternating hydride variants. Stresses were estimated from a set of rather uncertain hydride elastic constants. Overall, both variants showed compressive strains along the tube axial direction (~5000 µ$\epsilon$). For low hydrogen concentrations, the hydrides' stress tensor is dominated by compressive stresses of ~300 MPa along the axial direction, probably caused by the elongated morphology of hydride clusters along this direction, and variant-dependent shear stresses of ~±100 MPa, probably from the shear movement of the Zr atoms involved in the phase transformation.

36 MATERIALS SCIENCE↗
DOE OSTI2014

A Multi-Stage Wear Model for Grid-to-Rod Fretting of Nuclear Fuel Rods

The wear of fuel rod cladding against the supporting structures in the cores of pressurized water nuclear reactors (PWRs) is an important and potentially costly tribological issue. Grid-to-rod fretting (GTRF), as it is known, involves not only time-varying contact conditions, but also elevated temperatures, flowing hot water, aqueous tribo-corrosion, and the embrittling effects of neutron fluences. The multi-stage, closed-form analytical model described in this paper relies on published out-of-reactor wear and corrosion data and a set of simplifying assumptions to portray the conversion of frictional work into wear depth. The cladding material of interest is a zirconium-based alloy called Zircaloy-4, and the grid support is made of a harder and more wear-resistant material. Focus is on the wear of the cladding. The model involves an incubation stage, a surface oxide wear stage, and a base alloy wear stage. The wear coefficient, which is a measure of the efficiency of conversion of frictional work into wear damage, can change to reflect the evolving metallurgical condition of the alloy. Wear coefficients for Zircaloy-4 and for a polyphase zirconia layer were back-calculated for a range of times required to wear to a critical depth. Inputs for the model, like the friction coefficient, are taken from the tribology literature in lieu of in-reactor tribological data. Concepts of classical fretting were used as a basis, but are modified to enable the model to accommodate the complexities of the PWR environment. Factors like grid spring relaxation, pre-oxidation of the cladding, multiple oxide phases, gap formation, impact, and hydrogen embrittlement are part of the problem definition but uncertainties in their relative roles limits the ability to validate the model. Sample calculations of wear depth versus time in the cladding illustrate how GTRF wear might occur in a discontinuous fashion during months-long reactor operating cycles. A means to account for grid/rod gaps and repetitive impact effects on GTRF wear is proposed

fretting↗
DOE OSTI2016

Determination of the mechanical properties of blisters by nanoindentation

In light-water reactors, a zirconium oxide layer will be formed at the outer surface of the fuel cladding as a consequence of the chemical reaction which takes place between zirconium and the cooling water. This zirconium oxide layer is a good thermal insulator, but at some point, it may spall-out. As a consequence, a cold spot will be formed at the outer surface of the cladding. In this situation, the hydrogen will quickly migrate to this spot to form a highly-enriched hydride zone, known as blister. In this work, an experimental procedure has been devised to produce blisters with a similar shape to the ones reported in the literature for irradiated cladding with severe hydriding. Nano-indentation tests were performed on blisters prepared in laboratory. A numerical simulation by the finite element method was developed to fit the load versus penetration depth data from the aforementioned nano-indentation tests. By means of an inverse process which combines experimental data and numerical simulations, the constitutive equation of the blister was determined. The process has been used to calculate the plastic stress-strain curve of the blister under study at room temperature. The results show an almost perfect numerical fitting of the experimental data.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2017

Scanning electron microscopy examination of a Fast Flux Test Facility irradiated U-10Zr fuel cross section clad with HT-9

Observations from a scanning electron microscopy examination of irradiated U-10Zr fuel are presented. The sample studied had a local burnup of 5.7 atom percent and a local inner cladding temperature of 615°C. This examination by electron microscopy has concentrated on producing data relevant to facilitating a better understanding of Zr redistribution in irradiated U-10Zr fuel and on a better understanding of the complex microstructure present in fuel cladding chemical interaction (FCCI) layers. The presented zirconium redistribution data supplements the existing literature by providing a data set at these particular local conditions. In addition to FCCI layers that are readily visible in optical microscopy, this examination has revealed lanthanide degradation of the cladding by what appears to be a grain boundary facilitated pathway. Precipitates of fission produced Pd-lanthanide compounds were observed in the fuel. Furthermore, precipitated regions with elevated Mo and elevated W content were also observed in the HT-9 cladding of this sample.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2024

Enhanced Mechanical Properties and Wear Resistance of FeCrAl Alloys at ~ 300°C and Higher Temperatures

Abstract Worldwide, light water reactors (LWRs) have been using zirconium (Zr)-based alloys for the cladding of the uranium dioxide fuel for more than 6 decades. Zr alloys oxidize rapidly in the presence of water and steam at temperatures > 450°C; therefore, they do not respond well to scenarios of loss of coolant accidents. There is a global effort by nuclear materials technologists to find more robust or stronger cladding materials for LWRs. One option is to use an iron-chromium-aluminum (FeCrAl) alloy since they have excellent resistance to high temperature oxidation and superior mechanical properties at LWR operation temperatures. Results show that (1) FeCrAl alloys have better mechanical properties than Zr alloy and are orders of magnitude more resistant to creep at temperatures higher than LWR normal operation conditions. (2) FeCrAl alloys have better resistance to fretting wear than Zr alloys at the normal operation conditions of LWRs.

Materials Science↗
DOE OSTI2025

A critical review of the history of fabricating monolithic U-Mo fuel plates

The fabrication of monolithic uranium-molybdenum alloy fuels, specifically those developed for high-performance research and test reactors, began in the early 2000s. The primary fuel form consists of uranium alloyed with 10-wt% molybdenum in a thin foil coated with zirconium and encapsulated in aluminum-6061 cladding. Over the years, the process has evolved with different types of casting, heat treatments, rolling schedules, and cladding applications. This review examines the history of these fabrication processes and their impact on microstructure and fuel-swelling performance. Even though various fabrication methods were used, we found little correlation between fabrication variation and fuel swelling. This insensitive relationship between fabrication variation and fuel swelling is primarily due to inhomogeneous microstructures that formed during casting and grain refinement that occurred during rolling. We conclude that the fabrication processes we examined produced similar microstructures, indicating that the fuel microstructure is somewhat insensitive to the fabrication parameters evaluated. However, the relatively small amount of historic data, such as those for grain sizes, limited this analysis. More recently fabricated materials, such as those from ongoing irradiation experiment, Mini-Plate-1 and Mini-Plate-2, were also excluded from this analysis and are intended to be reviewed separately. The findings, that fuel microstructure is somewhat insensitive to the fabrication parameters, do not imply that any fabrication method is acceptable, given the uncertainties in data and fuel-swelling observations. For example, only arc melting and vacuum induction melting casting processes were previously explored in the historic fabrication efforts. In conclusion, the findings should not be extrapolated to other casting processes.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2022

FAST irradiations and initial post irradiation examinations – Part I

The Advanced Fuels Campaign Fission Accelerated Steady-state Test (FAST) at Idaho National Laboratory (INL) completed its first irradiation cycle within the Advanced Test Reactor (ATR). The test focused on the irradiation of alloy fuel forms for use in sodium fast reactors. Tests included the use of fuel additives (Sn, Sb, and Pd) for reducing the gettering of lanthanide fission products, zirconium liners to mitigate fuel-cladding chemical interaction, and annular fuel geometry for sodium-free fuel designs. The first cycle of FAST testing was completed and a series of rodlets were removed for the initial post irradiation examination (PIE) of FAST rodlets. The rodlet irradiation conditions was evaluated using Monte Carlo N-Particle (MCNP) for as-run power history and COMSOL for temperature analysis. These rodlets include a set of low burnups (~2.5 % heavy metal [%FIMA]) control rodlets and a helium bonded annular rodlet (4.7 %FIMA). Initial non-destructive PIE has been completed and includes, visual inspection, neutron radiography and gamma scanning of the FAST rodlets. Radiography confirmed the integrity of the experiments as well as showing the complete filling of the annulus in the annular fuel at a modest burnup (4.7 %FIMA) and potential slumping of the cooler rodlets at lower burnup. Precision gamma scanning indicated mostly usual fission product behavior with the exception of the ceasium in the He-bonded annular fuel. Future destructive PIE will be necessary in order to fully understand the effects of accelerated irradiation on U-Zr metallic fuel behavior.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2015

Effects of the shape of the foil corners on the irradiation performance of U10Mo alloy based monolithic mini-plates

Monolithic plate-type fuel is a fuel form being developed for high performance research and test reactors to minimize the use of enriched material. These fuel elements are comprised of a high density, low enrichment, U-Mo alloy based fuel foil, sandwiched between Zirconium liners and encapsulated in Aluminum cladding. The use of a high density fuel in a foil form presents a number of fabrication and operational concerns, such as: foil centering, flatness of the foil, fuel thickness variation, geometrical tilting, foil corner shape etc. To benchmark this new design, effects of various geometrical and operational variables on irradiation performance have been evaluated. As a part of these series of sensitivity studies, the shape of the foil corners were studied. To understand the effects of the corner shapes of the foil on thermo-mechanical performance of the plates, a behavioral model was developed for a selected plate from RERTR-12 experiments (Plate L1P785). Both fabrication and irradiation processes were simulated. Once the thermo-mechanical behavior the plate is understood for the nominal case, the simulations were repeated for two additional corner shapes to observe the changes in temperature, displacement and stress-strain fields. The results from the fabrication simulations indicated that the foil corners do not alter the post-fabrication stress-strain magnitudes. Furthermore, the irradiation simulations revealed that post-fabrication stresses of the foil would be relieved very quickly in operation. While, foils with chamfered and filleted corners yielded stresses with comparable magnitudes, they are slightly lower in magnitudes, and provided a more favorable mechanical response compared with the foil with sharp corners.

Finite Element Analysis↗
DOE OSTI2016

Is spent nuclear fuel immune from delayed hydride cracking during dry storage? An IAEA coordinated research project - 2016-0048

Delayed hydride cracking (DHC) has been responsible for cracking in zirconium alloy pressure tubes and fuel cladding and is a concern for spent fuel storage. For cracking to start, sufficient hydrogen must be present for hydride to form at a flaw tip and the local tensile stress must be sufficiently large to crack the hydride (a crack will not extend if the threshold in the stress intensity factor, K{sub IH}, is not exceeded. A high-temperature limit exists when the yield stress of the cladding alloy becomes too low to crack the hydride. In this paper we describe measurements of K{sub IH} and the crack growth rate, V, in unirradiated Zircaloy-4 fuel cladding containing approximately 130 ppm hydrogen in the cold-worked stress-relieved condition representing pressurized water reactors (PWRs) and pressurized heavy-water (PHWR) reactors. Four methods are used to evaluate K{sub IH}. The test specimen and fixture used in these methods was the pin-loading tension configuration. The test temperature ranged from 227 to 315 deg. C. The mean value of K{sub IH} below 280 deg. C had little temperature dependence; it was about 5.5 MPa√m in the PWR cladding and slightly higher at 7 MPa√m in the PHWR material. At higher test temperatures, K{sub IH} increased dramatically to more than 12 MPa√m, whereas the crack growth rate declined toward zero. This behavior suggests that unirradiated Zircaloy-4 fuel cladding is immune from DHC above about 320 deg. C; this temperature may be increased to 360 deg. C by irradiation. The implications for spent fuel storage are that during early storage when the temperatures are high, any flaw will not extend by DHC, whereas at low temperatures, after many years of storage, flaws would have to be very large, approaching through wall, before being extended by DHC. To date, spent nuclear fuel is not known to have failed by DHC during storage, confirming the inference. (authors)

36 MATERIALS SCIENCE↗
DOE OSTI2013

Enhanced Accident Tolerant LWR Fuels: Metrics Development

The Department of Energy (DOE) Fuel Cycle Research and Development (FCRD) Advanced Fuels Campaign (AFC) is conducting research and development on enhanced Accident Tolerant Fuels (ATF) for light water reactors (LWRs). This mission emphasizes the development of novel fuel and cladding concepts to replace the current zirconium alloy-uranium dioxide (UO2) fuel system. The overall mission of the ATF research is to develop advanced fuels/cladding with improved performance, reliability and safety characteristics during normal operations and accident conditions, while minimizing waste generation. The initial effort will focus on implementation in operating reactors or reactors with design certifications. To initiate the development of quantitative metrics for ATR, a LWR Enhanced Accident Tolerant Fuels Metrics Development Workshop was held in October 2012 in Germantown, MD. This paper summarizes the outcome of that workshop and the current status of metrics development for LWR ATF.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2017

ADVANCED TEST REACTOR (ATR) CONVERSION TO LOW ENRICHED URANIUM (LEU) FUEL

The United States Department of Energy (DOE), National Nuclear Security Administration (NNSA), Office of Material Management and Minimization (MMM) is working to convert research reactors globally from highly enriched uranium (HEU) fuel to low-enriched uranium (LEU) fuel. MMM and its predecessor programs have converted or verified the shutdown of 88 HEU research reactors and isotope production facilities, using LEU fuel developed in the 1980s. However, there is a small set of high performance research reactors which require a new high density LEU fuel for conversion, including six U.S. high performance research reactors (USHPRRs), which include the Advanced Test Reactor (ATR) and the ATR Critical (ATRC) Facility at the Idaho National Laboratory (INL) near Idaho Falls, ID; University of Missouri Research Reactor (MURR) at Columbia, MO; Massachusetts Institute of Technology Reactor (MITR) at MIT in Cambridge, MA; High Flux Isotope Reactor (HFIR) at Oak Ridge National Laboratory (ORNL) near Oak Ridge, TN; and National Bureau of Standards Reactor (NBSR) at the National Institute of Standards and Technology (NIST) Center for Neutron Research (NCNR) in Gaithersburg, MA. These reactors will share the same uranium-molybdenum (U-Mo) fuel plate design. The U-Mo fuel meat foil will have a zirconium (Zr) diffusion barrier with aluminum cladding. Three different application methods for the Zr diffusion barrier layer are being pursued – co-rolled, electroplating and plasma spraying. Fabrication of the higher density LEU U-Mo fuel has presented several challenges. Because the U-Mo fuel fabrication process uses the existing stockpile of 93% highly enriched uranium (HEU) to be blended with molybdenum and depleted uranium (DU) to form 19.75% LEU, cost benefits of enriching to 19.75% will not be realized. Homogeneity of the U-235 and molybdenum in the metal foil is a challenge due to U-Mo casting process results in variations between adjacent cast U-Mo plates. LEU will not require less U-235 as previously believed due to self-shielding properties of U-238 requiring additional U-235 to be loaded in each fuel element. Although the overall dimensions of the ATR fuel element remain unchanged, the weight of the LEU ATR fuel element is 72% greater than a HEU ATR fuel element. During waste recovery and recycling efforts, separation of aluminum cladding from the HEU fuel meat is a relatively simple chemical dissolution, however, separation of the Zr diffusion barrier from the U-Mo fuel meat is significantly more challenging.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗