Crapps, J. | Search NASA

DOE OSTI2013

Separate effects identification via casting process modeling for experimental measurement of U–Pu–Zr alloys

Computational simulations of gravity casting processes for metallic U–Pu–Zr nuclear fuel rods have been performed using a design-of-experiments technique to determine the fluid flow, liquid heat transfer, and solid heat transfer parameters which most strongly influence the process solidification speed and fuel rod porosity. The results are used to make recommendations for the best investment of experimental time and effort to measure process parameters.

99 GENERAL AND MISCELLANEOUS↗

DOE OSTI2013

Metallic Fuel Casting Development and Parameter Optimization Simulations

One of the advantages of metallic fuel is the abilility to cast the fuel slugs to near net shape with little additional processing. However, the high aspect ratio of the fuel is not ideal for casting. EBR-II fuel was cast using counter gravity injection casting (CGIC) but, concerns have been raised concerning the feasibility of this process for americium bearing alloys. The Fuel Cycle Research and Development program has begun developing gravity casting techniques suitable for fuel production. Compared to CGIC gravity casting does not require a large heel that then is recycled, does not require application of a vacuum during melting, and is conducive to re-usable molds. Development has included fabrication of two separate benchscale, approximately 300 grams, systems. To shorten development time computer simulations have been used to ensure mold and crucible designs are feasible and to identify which fluid properties most affect casting behavior and therefore require more characterization.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗