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DOE OSTI2022

Fabrication of Polymer Membrane-Suspended Microstructures on Printed Circuit Boards

When microelectromechanical systems are manufactured in high densities, the necessary routing layer structures can become complex and thus expensive if executed in silicon technology. If, additionally, the microstructures are also to be fabricated suspended on membranes, complex thinning processes become necessary to form these often rather fragile membranes. Here, a novel fabrication concept is demonstrated that allows for the fabrication of membrane-suspended microstructures using standard microfabrication techniques directly integrated with printed circuit boards (PCB) by laminating polyimide (PI) films over cavities in the PCB. This results in cost-effective routing layer fabrication and direct compatibility with common electronic component standards such as SMT (surface-mount technology) and THT (through-hole technology). To illustrate the capabilities of the fabrication process, we fabricated an array of membrane suspended microheaters. Individual platinum microheater elements are suspended on PI membranes that are 25 μm thick and 500 μm in diameter. The fabricated PCB carries a 10x10 array of suspended microheaters on an area of 26,mm x 26,mm. Here, the characterization of the microheater array shows that a yield of 86% functional microheaters was achieved. An individual microheater shows an almost linear heating characteristic at least up to 200°C demonstrating the viability of the technique for creating functional membrane-suspended microstructures on a PCB. [2021-0226]

47 OTHER INSTRUMENTATION↗

DOE OSTI2012

Cu/Nb nano-composite wires processed by severe plastic deformation for applications in high pulsed magnets: effects of the multi-scale microstructure on the mechanical properties

Copper-based high strength and high electrical conductivity nano-composite wires reinforced by Nb nano-tubes are prepared by severe plastic deformation, applied with an Accumulative Drawing and Bundling process (ADB), for the windings of high pulsed magnets. The ADB process leads to a multi-scale Cu matrix containing up to N = 85{sub 4} (52.2.10{sup 6}) continuous parallel Nb tubes with diameter down to few tens nano-meters. After heavy strain, the Nb nano-tubes exhibit a homogeneous microstructure with grain size below 100 nm. The Cu matrix presents a multi-scale microstructure with multi-modal grain size distribution from the micrometer to the nano-meter range. The use of complementary characterization techniques at the microscopic and macroscopic level (in-situ tensile tests in the TEM, nano-indentation, in-situ tensile tests under high energy synchrotron beam) shed light on the interest of the multi-scale nature of the microstructure to achieve extreme mechanical properties, therefore allowing for design guidelines to further improve these properties. (authors)

36 MATERIALS SCIENCE↗

DOE OSTI2019

Correlation Between Microstructure and In-Field Performance of Zr-Added REBCO Coated Conductors Made by Advanced MOCVD

In this paper, we present correlation features between critical current density (J c ) and microstructural characteristics of Zr-added (0, 5, and 15 mol.%) REBa 2 Cu 3 O 7-x (REBCO and RE = rare earth) coated conductors fabricated by the novel advanced metal organic chemical vapor deposition technique. The J c along the tape normal (~ B || c-axis) measured by a vibrating sample magnetometer at 30 and 65 K and magnetic flux density range of 0-14 T was used for qualitative comparison of different Zr-added REBCO tapes. It is found that tapes with enhanced in-field J c exhibit a rise of critical current (plateau or fishtail effect) at magnetic flux density 1-8 T and temperatures 65 K. The TEM microstructure analysis indicates that the plateau effect is not the intrinsic property of REBCO matrix but depends on size distribution and density of BaZrO 3 (BZO) self-assembled nanocolumns. Two types of BZO microstructures have been identified: one with uniform BZO diameter 4-7 nm, whereas some films exhibit bottle-shaped BZO nanocolumns with alternating wide and narrow sections, 7-13 and 4-6 nm, respectively. The non-uniform shape and broad size distribution of BZO nanocolumns are correlated to more vortex pinning strength and matching field.

2G high-temperature superconductor (2GHTS)↗

DOE OSTI2018

Minimization of the Total Depth of Internal Saw-Tooth Reliefs of a Two-Layer Relief-Phase Diffraction Microstructure

Results of studying the possibility to decrease the total depth of reliefs of a two-layer microstructure having two internal saw-tooth microreliefs reducing the dependence of the diffraction efficiency of the microstructure on the radiation wavelength and angle of radiation incidence on the microstructure are presented. These results allow one to minimize the complexity of obtaining optimum microrelief depths depending on requirements applicable to the diffraction optical element in the framework of the electromagnetic-diffraction theory. Optimum depths provide in the specified spectral range and interval of angles of radiation incidence the maximum possible (for the chosen width of the narrowest zone of the saw-tooth microrelief) value of the diffraction efficiency at the point of its minimum.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗

DOE OSTI2013

Microstructure of bidisperse ferrofluids in a thin layer

In this work we present a characterization of the bidisperse ferrofluid microstructures that appear in thin layers of ferrofluid. These layers have been studied by a combination of Langevin dynamics simulations and density functional theory. Our results allow us to compare the microstructures that exist in quasi-two-dimensional ferrofluid nanolayers with the microstructures found in three-dimensional bidisperse ferrofluids. Furthermore, our results allow us to explain the influence of the geometry of the sample on the topology and size-distribution of the observed aggregates of magnetic nanoparticles.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗

DOE OSTI2016

Role of the heat accumulation effect in the multipulse modes of the femtosecond laser microstructuring of silicon

The results of quantitative evaluation of the heat accumulation effect during the femtosecond laser microstructuring of the surface of silicon are presented for discussion. In the calculations, the numerical–analytical method is used, in which the dynamics of electronic processes and lattice heating are simulated by the numerical method, and the cooling stage is described on the basis of an analytical solution. The effect of multipulse irradiation on the surface temperature is studied: in the electronic subsystem, as the dependence of the absorbance on the excited carrier density and the dependence of the absorbance on the electron-gas temperature; in the lattice subsystem, as the variation in the absorbance from pulse to pulse. It was shown that, in the low-frequency pulse-repetition mode characteristic of the femtosecond microstructuring of silicon, the heat accumulation effect is controlled not by the residual surface temperature by the time of the next pulse arrival, which corresponds to conventional concepts, but by an increase in the maximum temperature from pulse to pulse, from which cooling begins. The accumulation of the residual temperature of the surface can affect the microstructuring process during irradiation near the evaporation threshold or with increasing pulse-repetition rate.

36 MATERIALS SCIENCE↗

DOE OSTI2018

Parameters of a Microstructure of Erosion Regions during the Action of a Spark Discharge on a Copper Electrode Surface in Air

The parameters of a microstructure of regions of action of a spark discharge on a copper plane electrode surface in air at atmospheric pressure in the spike–plane gap both for positive and negative polarity of a spike have been studied using scanning electron microscopy. It has been found that regions of action have the appearance of rounded spots or groups of spots with an internal structure in the form of agglomeration of a large number of microcraters. It has been shown that the statistical distributions of microcrater diameters and intermicrocrater distances are characterized by several local maximums that determine the presence of several predominant values of these parameters in a spot. It has been revealed that the microstructure of a spot is characterized by the fractal behavior and the fractal dimensionalities of the microstructure have been determined.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗

DOE OSTI2022

Parametric Study of the Influence of Support Type, Presence of Platinum on Support, and Ionomer Content on the Microstructure of Polymer Electrolyte Fuel Cell Catalyst Layers

We report Ultra-small angle X-ray scattering (USAXS) was employed to investigate the effects of carbon support type, the presence of platinum on carbon, and ionomer loading on the microstructure of polymer electrolyte fuel cell (PEFC) catalyst layers (CLs). Particle size distributions (PSDs), obtained from fitting the measured scattering data were used to interpret the size of carbon aggregates (40–300 nm) and agglomerates (>400 nm) from two-component carbon/ionomer and three-component platinum/carbon/ionomer CLs. Two types of carbon supports were investigated: high surface area carbon (HSC) and Vulcan XC-72. CLs with a range of perfluorosulfonic acid (PFSA) ionomer to carbon (I/C) ratios (0.2–1.2) and also with perfluoroimide acid (PFIA) ionomer were studied to evaluate the effect of ionomer on CL microstructure. The carbon type, the presence of platinum, and ionomer loading were all found to significantly impact carbon agglomeration. The extent of Pt/C agglomeration in the CL was found to increase with increasing ionomer and platinum concentration and to decrease with increasing carbon surface area. Platinum electrochemically-active surface area (ECSA) and local oxygen transport resistance (R nF ) were correlated to the CL microstructure to yield relationships affecting electrode performance.

25 ENERGY STORAGE↗

DOE OSTI2022

ExaAM: Metal additive manufacturing simulation at the fidelity of the microstructure

Additive manufacturing (AM), or 3D printing, of metals is transforming the fabrication of components, in part by dramatically expanding the design space, allowing optimization of shape and topology. However, although the physical processes involved in AM are similar to those of welding, a field with decades of experimental, modeling, simulation, and characterization experience, qualification of AM parts remains a challenge. The availability of exascale computational systems, particularly when combined with data-driven approaches such as machine learning, enables topology and shape optimization as well as accelerated qualification by providing process-aware, locally accurate microstructure and mechanical property models. We describe the physics components comprising the Exascale Additive Manufacturing simulation environment and report progress using highly resolved melt pool simulations to inform part-scale finite element thermomechanics simulations, drive microstructure evolution, and determine constitutive mechanical property relationships based on those microstructures using polycrystal plasticity. We report on implementation of these components for exascale computing architectures, as well as the multi-stage simulation workflow that provides a unique high-fidelity model of process–structure–property relationships for AM parts. In addition, we discuss verification and validation through collaboration with efforts such as AM-Bench, a set of benchmark test problems under development by a team led by the National Institute of Standards and Technology.

3D printing↗

DOE OSTI2016

Microstructural evolution of Q12{sup TM} alloy irradiated in PWRs and comparison with other Zr base alloys - 2016-0061

Based on the M5{sup R}* alloy metallurgy, the Q12{sup TM} alloy (Zr-1Nb-0.5Sn-0.1Fe) was developed by AREVA NP for structural components, with ultra-low tin addition and slightly increased iron content. The behavior of this alloy was tested under irradiation in a pressurized water reactor (PWR) and has shown improvement in irradiation creep strength and similar free growth compared with M5. This paper provides results on dimensional stability and details the microstructural evolution of the Q12 alloy under neutron irradiation in PWRs. The Q12 microstructural evolution under irradiation was studied for fast neutron fluences up to 13 X 10{sup 25} n/m{sup 2} (E>1 MeV) with analytical transmission electron microscopy observations. We focused on radiation-enhanced needle-like particles, Laves phases, and the linear density of -component loops. These results are compared with other quaternary zirconium-niobium-tin-iron alloys and with M5. All these results allow a general discussion about microstructural evolution and behavior under irradiation of quaternary-type alloys compared to M5 alloy. This study, in agreement with previous works on Zr-1Nb and quaternary alloys, seems to show that increasing the iron content with the presence of niobium and tin will decrease the -component loop linear density and delay the growth breakaway. (authors)

36 MATERIALS SCIENCE↗

DOE OSTI2016

Investigating the effect of zirconium oxide microstructure on corrosion performance: a comparison between neutron, proton, and nonirradiated oxides - 2016-0069

Scanning precession electron diffraction in the transmission electron microscope has been used to simultaneously map the phase, orientation, and grain morphology of oxides formed on Zircaloy-2 after three and six cycles in a boiling water reactor in unprecedented detail. For comparison, a region of a preoxidized autoclave-formed oxide was also proton-irradiated at the Dalton Cumbrian Facility. The proton irradiation was observed to cause additional stabilization of the tetragonal phase that was attributed to the stabilizing effect of irradiation- induced defects in the oxide. In the reactor-formed oxides, no extra stabilization of the tetragonal grains was observed under neutron irradiation, as indicated by the similar tetragonal phase fraction and transformation twin-boundary distributions between the nonirradiated and reactor-formed oxides. It is suggested that the damage rate is too low in the newly formed oxide to cause significant stabilization of the tetragonal phase. This technique also reveals that the oxide formed under reactor conditions has a more heterogeneous microstructure, and the growth of well-oriented columnar monoclinic grains is significantly reduced compared with a nonirradiated oxide. High-angle annular dark-field scanning transmission electron microscopy also revealed the development of extensive networks of intergranular porosity and eventually grain de-cohesion in the reactor-formed oxides. These results suggest that the tetragonal-monoclinic transformation is not responsible for the accelerated corrosion exhibited under reactor conditions. It is proposed that the usual out-of-reactor oxide growth and nucleation processes are significantly modified under reactor conditions, resulting in a more heterogeneous and randomly oriented oxide microstructure with reduced columnar grain growth. It is suggested that this disordered oxide microstructure allows for the formation of extensive intergranular porosity that could lead to accelerated in-reactor corrosion. (authors)

36 MATERIALS SCIENCE↗

DOE OSTI2024

Microstructure development during rapid alloy solidification

Abstract Solidification processing of structural alloys can take place over an extremely wide range of solid–liquid interface velocities spanning six orders of magnitude, from the low-velocity constitutional supercooling limit of microns/s to the high-velocity absolute stability limit of m/s. In between these two limits, the solid–liquid interface is morphologically unstable and typically forms cellular-dendritic microstructures, but also other microstructures that remain elusive. Rapid developments in additive manufacturing have renewed the interest in modeling the high-velocity range, where approximate analytical theories provide limited predictions. In this article, we discuss recent advances in phase-field modeling of rapid solidification of metallic alloys, including a brief description of state-of-the-art experiments used for model validation. We describe how phase-field models can cope with the dual challenge of carrying out simulations on experimentally relevant length- and time scales and incorporating nonequilibrium effects at the solid–liquid interface that become dominant at rapid rates. We present selected results, illustrating how phase-field simulations have yielded unprecedented insights into high-velocity interface dynamics, shedding new light on both the absolute stability limit and the formation of banded microstructures that are a hallmark of rapid alloy solidification near this limit. We also discuss state-of-the-art experiments used to validate those insights. Graphical abstract

36 MATERIALS SCIENCE↗

DOE OSTI2019

Effect of α/β Forging on Microstructure and Texture Inhomogeneity in a Ti-1023 Forged Disk

The microstructure and texture distribution of a Ti-1023 forged disk were investigated by scanning electron microscopy and synchrotron-based high-energy X-ray diffraction. The finite element method was used to simulate temperature and strain distribution in order to investigate the relationship of the α/β forging process with microstructure and texture distribution. A bimodal microstructure and rolling textures with large inhomogeneity were observed in the disk. A plate-like and a necklace-like morphology and volume fraction variations of the primary α phase were observed in different regions with different forging conditions, such as temperature, deformation, position, and high density of flow lines. Texture sharpness distribution of the β phase was in good agreement with the strain distribution, which suggests deformation may play the most important part in the texture inhomogeneity. A weak cube texture was obtained near the center of the disk, and fiber textures were found near the rim of the disk. The primary a phase also exhibited a transverse texture, which is favored by large deformation.

36 MATERIALS SCIENCE↗

DOE OSTI2016

U-10Mo/Zr Interface Modeling using a Microstructure-Based FEM Approach

The U-10Mo in low enrichments (LEU) has been identified as the most promising alternative to the current highly enriched uranium (HEU) used in the United States’ fleet of high performance research reactors (USHPRRs). The nominal configuration of the new LEU U-10Mo plate fuel comprises a U-10Mo fuel foil enriched to slightly less than 20% U-235 (0.08” to 0.02” thick), a thin Zr interlayer/diffusion barrier (25 m thick) and a relatively thick outer can of 6061 aluminum. Currently, the Zr interlayer is clad by hot roll bonding. Previous studies and observations revealed a thinning of the zirconium (Zr) layer during this fuel fabrication process, which is not desirable from the fuel performance perspective. Coarse UMo grains, dendritic structures, Mo concentration segregation, carbides, and porosity are present in the as-cast material and can lead to a nonuniform UMo/Zr interface. The purpose of the current work is to investigate the effects of these microstructural parameters on the Zr coating variation. A microstructure-based finite-element method model was used in this work, and a study on the effect of homogenization on the interface between U-10Mo and Zr was conducted. The model uses actual backscattered electron–scanning electron microscopy microstructures, Mo concentrations, and mechanical properties to predict the behavior of a representative volume element under compressive loading during the rolling process. The model successfully predicted the experimentally observed thinning of the Zr layer in the as-cast material. The model also uses results from a homogenization model as an input, and a study on the effect of different levels of homogenization on the interface indicated that homogenization helps decrease this thinning. This model can be considered a predictive tool representing a first step for model integration and an input into a larger fuel fabrication performance model.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2014

Influence of Homogenization on the Mechanical Properties and Microstructure of the U-10Mo Alloy

In Phase 1 of this study, the mechanical properties of as-cast, depleted uranium alloyed with 10 weight percent molybdenum alloy (U-10Mo) samples were evaluated by high-temperature compression testing. Compression testing was conducted at three strain rates over a temperature range of 400 to 800°C. The results indicated that with increasing test temperature, the material flow stress decreases and the material becomes more sensitive to strain rate. In addition, above the eutectoid transformation temperature (~ 550°C), the drop in material flow stress is prominent and shows a strain-softening behavior, especially at lower strain rates. In the second part of this research, we studied the effect that homogenization heat treatment had on the high temperature mechanical properties and microstructure of the cast U-10Mo alloy. Various homogenization times and temperatures were studied ranging between 800 and 1000°C for 4 to 48 hours. Based on the microstructural response in this homogenization study, a heat treatment cycle of 800°C for 24 hours and another at 1000°C for 16 hours were selected as the times at temperature to achieve a fully homogenized sample. Samples from these conditions were then compression tested at a variety of temperatures ranging from 500 to 800°C. The microstructure of these samples were compared to the as-cast samples and to a baseline sample homogenized at 1000°C for 16 hours. The results indicate that below the eutectoid temperature (~ 550°C) all three samples showed strain hardening and followed similar trends. Above the eutectoid temperature, the yield strength of the material decreased linearly. For the as-cast sample and the sample homogenized at 800°C for 24 hours, the n-values were negative, whereas for the samples homogenized at 1000°C for 16 hours the material exhibited a perfectly plastic behavior. The as-cast sample, heat treated at 800°C for 24 hours, showed significant lamellar structure transformation that seems to have precipitated along the grain boundaries in the molybdenum-lean regions. In similar samples, homogenized at 800°C for 24 hours and tested at 650°C, the backscattered-electron scanning electron microscopy images revealed a composite structure of lamellar phase and nano-scale molybdenum-rich and -lean phases along the grain boundaries. These phases may have been responsible for the lowering of the flow stress in the material observed in the Phase 1 work. For comparison, the samples homogenized at 1000°C for 16 hours showed no such transformations.

36 MATERIALS SCIENCE↗

DOE OSTI2017

Graphite Microstructural Characterization Using Time-Domain and Correlation-Based Ultrasonics

Among techniques that have been used to determine elastic modulus in nuclear graphites, ultrasonic methods have enjoyed wide use and standards using contacting piezoelectric tranducers have been developed to ensure repeatability of these types of measurements. However, the use of couplants and the pressures used to effectively couple transducers to samples can bias measurements and produce results that are not wholly related to the properties of the graphite itself. In this work, we have investigated the use of laser ultrasonic methods for making elastic modulus measurements in nuclear graphites. These methods use laser-based transmitters and receivers to gather data and do not require use of ultrasonic couplants or mechanical contact with the sample. As a result, information directly related to the elastic responses of graphite can be gathered even if the graphite is porous, brittle and compliant. In particular, we have demonstrated the use of laser ultrasonics for the determination of both Young’s modulus and shear modulus in a range of nuclear graphites including those that are being considered for use in future nuclear reactors. These results have been analyzed to assess the contributions of porosity and microcracking to the elastic responses of these graphites. Laser-based methods have also been used to assess the moduli of NBG-18 and IG-110 where samples of each grade were oxidized to produce specific changes in porosity. These data were used to develop new models for the elastic responses of nuclear graphites and these models have been used to infer specific changes in graphite microstructure that occur during oxidation that affect elastic modulus. Specifically, we show how ultrasonic measurements in oxidized graphites are consistent with nano/microscale oxidation processes where basal plane edges react more readily than basal plane surfaces. We have also shown the use of laser-based methods to perform shear-wave birefringence measurements and have shown how these measurements can be used to assess elastic anisotropy in nuclear graphites. Using models developed in this program, ultrasonic data were interpreted to extract orientation distribution coefficients that could be used to represent anisotropy in these materials. This demonstration showed the use of ultrasonic methods to quantify anisotropy and how these methods provide more detailed information than do measurements of thermal expansion – a technique commonly used for assessing anisotropy in nuclear graphites. Finally, we have employed laser-based, ultrasonic-correlation techniques in attempts to quantify aspects of graphite microstructure such as pore size and distribution. Results of these measurements indicate that additional work must be performed to make this ultrasonic approach viable for quantitative microstructural characterization.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2020

Microstructure Experiments-Enabled MARMOT Simulations of SiC/SiC-based Accident Tolerant Nuclear Fuel System

We have undertaken an experimental-computational project that addresses a few key technology gaps associated with the use of SiC/SiC composites for light water reactor fuel cladding. Two principal endeavors in this project are to assess the irradiation-induced microstructural changes and swelling in SiC/SiC composites, and to characterize and model the porous oxide surface layer (when exposed to steam) along SiC recession that is detrimental to the clad integrity under accident conditions. The project tasks are: (i) ion irradiation and characterization (University of Tennessee, Knoxville), (ii) mechanical tests and analysis (University of South Carolina), (iii) steam exposure tests (Oak Ridge National Laboratory), (iv) electron microscopy and spectroscopic characterization (NC State University), (v) x-ray microscopy and reconstruction (University of South Carolina and NC State University), (vi) phase field modeling and simulations (NC State University and Idaho National Laboratory). The effects of 10 MeV Au ion irradiation at 350°C on the microstructure evolution in SiC/SiC composites are investigated at doses up to 400 displacements per atom (dpa) at the University of Tennessee, Knoxville. Atomic force microscopy and optical profilometry reveal irradiation induced axial and radial shrinkage of the fibers for doses greater than 10 dpa. Based on detailed electron microscopy characterization, the primary cause of the fiber shrinkage is attributed to irradiation-induced loss of carbon packets. Additionally, the multilayer PyC interface is observed to portray high resistance to irradiation damage. The mechanical response and failure mechanisms of un-irradiated samples is also assessed through loading tests and X-ray imaging at the University of South Carolina. Steam exposure tests are performed at the Oak Ridge National Laboratory in a facility that represents a reactor pressure vessel under a loss-of-coolant-accident scenario. The samples that are analyzed methodically in this report are tested for 32/31 hours at 1200°C with a velocity of 0.25 cm/s for the pressures: 0.1 MPa, 0.45 MPa, 0.92 MPa and 1.38 MPa. Scanning/transmission electron microscopy analysis conducted at the NC State University (NCSU) shows that the oxide layer thickness increases with the steam pressure. While the oxide layer is crystalline (α- cristobalite) for the pressures 0.45 MPa, 0.92 MPa and 1.38 MPa, the layer is amorphous at 0.1 MPa. Results from Raman spectroscopy have also confirmed the formation of α-cristobalite phase of SiO₂. The abrupt increase in the integrated Raman intensity ratio between steam pressures 0.1 and 0.45 MPa suggests the onset of accelerated crystallization. Non-destructive three dimensional X-ray microscopy/tomography (XCT) and computational image processing techniques are employed by the University of South Carolina to probe the porous oxidation features on SiC samples at varying pressures. Interestingly, most pores are observed to be located away from the surface as well as the oxide-SiC interface. The average oxide layer thickness assessed from the XCT analysis is seen to be in excellent agreement with the values determined through scanning electron microscopy analysis for the highest pressures where the oxide layer is relatively more uniform. A phase-field model developed by the NC State University and Idaho National Laboratory for simulating oxidation of SiC by steam captures the paralinear kinetics of SiC oxidation with a high degree of fidelity. Results from quasi-one-dimensional and two dimensional simulations show that the pores with oxidizing species lead to a higher volatilization rate. These simulations indicate that the enhanced apparent volatilization rates at higher pressures observed in experiments can be rationalized by the increased volatilization from the pores. The project team has also successfully developed the capability to import images from experiments for realistic evolution of the oxidizing microstructure.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2022

Microstructural Characterization of As-Cast MP-1 Experiment U-10Mo Alloy

The Mini-Plate-1 (MP-1) test is the first in a series of fuel testing campaigns with the purpose of achieving regulatory qualification for the U-10Mo monolithic plate-type fuel system. The objective of MP-1 is to assess fuel performance behavior of fuel plates fabricated by a commercial fuel fabricator (BWX Technologies, Inc.) and make sure that the fuel maintains mechanical integrity and geometric stability and behaves in a stable and predictable manner. As a part of MP1 fabrication campaign several castings were prepared. The castings were vacuum induction melted using HEU pieces mixed with a master alloy made up of DU and molybdenum pieces. The Master Alloy was poured by a commercial vendor. There was little mixing during melting. A three-plate mold was utilized to form three U-10Mo plates per melt pour. The work described here shows that the resulting microstructure varies greatly from one cast plate to another, and from the top to the bottom of each cast plate. The extent of variation in microstructural features such as grain size, second phase particle (SPP) distribution and morphology, microsegregation of constituents within the dendritic microstructure, porosity, and casting abnormalities are presented and discussed.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗