DOE OSTI2013
Based on data available in 2009, a decision was made to focus U–Mo monolithic fuel development and qualification efforts on a single fuel design. This fuel design consists of a U–10Mo (wt.%) monolithic fuel foil, a zirconium barrier layer applied to the faces of the foil, and 6061 aluminum cladding. This document updates the basis for the selection of that fuel system, drawing on additional fuel-performance data available as of May 2013. This update also applies recently developed GTRI (Global Threat Reduction Initiative) requirements for fuel qualification to the selection process. Because of its inherent gamma-phase stability and qualitatively better rolling behavior, U–10Mo was selected as the fuel alloy of choice, exhibiting reasonable uranium density and good irradiation performance. A zirconium barrier layer between the fuel and cladding was chosen to provide a predictable, well-bonded, fuel-cladding interface, greatly reducing fuel-cladding chemical interaction. The fuel plate testing conducted to inform this selection was based on the use of U–10Mo foils fabricated by hot- and cold co-rolling with a Zr foil. The foils were subsequently bonded to the Al–6061 cladding by hot isostatic pressing or friction stir welding. Since the original down-select decision was made, additional information has become available on fuel performance and on the cost of the fuel system. Preliminary cost estimates indicate that U–Mo-Zr waste generated during fabrication is difficult to recycle and adds substantially to the production cost. It is the purpose of this report to review fuel-performance data available as of May 2013, outline data and observations that are significant to informing the down-selection process, review the data against down-select requirements, and update the recommendation on a fuel system suitable for fuel qualification. In addition, this report assesses the potential of a fuel system without a zirconium barrier layer for use in USNRC-licensed research reactors. This revised report is issued as a working draft for discussion by the United States High Performance Research Reactor (USHPRR) program. The document will continue to be revised as additional information becomes available. This may include updates to information about normal and anticipated transient fuel operating conditions as conversion fuel-element designs evolve or additional information on fuel performance gained from U.S. or international testing programs. In particular, information from the RERTR–12 experiment will be included when available.
11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗