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All sourcesNASA NTRSDOE OSTI
DOE OSTI2015

Report on results of current and future metal fuel casting

New modeling capabilities needed to simulate the casting of metallic fuels are added to Truchas code. In this report we summarize improvements we made in FY2015 in three areas; (1) Analysis of new casting experiments conducted with BCS and EFL designs, (2) the simulation of INL’s U-Zr casting experiments with Flow3D computer program, (3) the implementation of surface tension model into Truchas for unstructured mesh required to run U-Zr casting.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2015

Report on results of current and future metal casting

New modeling capabilities needed to simulate the casting of metallic fuels are added to Truchas code. In this report we summarize improvements we made in FY2015 in three areas; (1) Analysis of new casting experiments conducted with BCS and EFL designs, (2) the simulation of INL’s U-Zr casting experiments with Flow3D computer program, (3) the implementation of surface tension model into Truchas for unstructured mesh required to run U-Zr casting.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2015

Casting Process Modeling and Validation

Computational simulations of gravity casting for metallic U-Pu-Zr nuclear fuel rods were performed with the free surface flow solver Flow3d. Two different casting apparatus designs were explored for studying the effects on the final cast rod profiles. Experimental data for the casting problem obtained from Idaho National Laboratory (INL) was validated with numerical simulations on one of the designs considered. The volume of the rods cast, length of the rods, and temperature profiles were predicted through the transient casting process and were found to match closely with experimental data. A sensitivity analysis with vent locations, pressure, mesh refinement, and effects of surface tension at the interface were explored. This work serves as a validation benchmark for the casting problem and provides guidelines when performing simulation exercises for modeling casting. This paper also provides the mathematical framework to enabling modeling of the casting process.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2016

Overview of the U.S. DOE advanced fuels campaign

Advanced Fuel Campaign (AFC) has responsibility to develop advanced nuclear fuel technologies for the Fuel Cycle Research and Development (FCRD) program. AFC focus areas include 4 topics: advanced LWR fuels, actinide transmutation, research infrastructure development for the study of new nuclear fuels and advanced modeling and simulation. This paper reviews the latest technical advances in the 4 topics. Fuel and cladding materials under investigation include the following general classes of technologies: iron-based cladding, ceramic cladding, coated Zirconium alloy cladding, molybdenum-based cladding, high-density fuel, fully ceramic matrix fuel, and metallic alloy-based nuclear fuel. Concerning actinide transmutation fuel alloy additions to immobilize the lanthanide fission products, sodium-free annular fuel concepts, and cladding coatings and liners for mitigation of fuel-cladding chemical interaction have been investigated. Direct casting of metallic fuel into a zirconium liner was demonstrated. A Talos Transmission Electron Microscope was acquired for the study of advanced nuclear fuels and materials. The conceptual and preliminary designs for a static capsule, a flowing water loop, and a flowing sodium loop to support future transient testing needs have been completed. AFC interfaces with the Nuclear Energy Advanced Modeling and Simulation (NEAMS) program to develop multi-scale, multi-physics fuel performance codes.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2026

An Ab Initio Molecular Dynamics Study of Key Thermodynamic Input Parameters for Computer Simulation of U-6Nb Solidification

The key to metallic fuel development is the fabrication of uranium metal and alloys into fuel forms. U-Nb alloys are one of the best candidates for a metallic fuel alloy with high-temperature strength sufficient to support the core, acceptable nuclear properties, good fabricability, and compatibility with usable coolant media. Melt processing has been a key component of the metallic fuel cycle, and process models require thermophysical parameters at elevated temperatures, particularly above the melting temperatures, regarding which experimental data are scarce, for accurate simulations and process development. By means of ab initio density-functional theory (DFT) quantum molecular dynamics (QMD), we have calculated the main thermophysical parameters—the density, thermal expansion coefficient, specific heat, thermal conductivity, melting temperature, latent heat of fusion, and viscosity—used in the modeling of the U-6 wt.% Nb alloy casting. The melting temperature of the U-6 wt.% Nb alloy at ambient pressure is obtained by means of QMD simulations using the Z-method. The ambient volume change and latent heat of melting of U-6 wt.% Nb are also derived from QMD simulations in conjunction with analytical fitting for the energy and pressure. The thermal conductivity for the solid U-Nb alloy is calculated from the semi-classical Boltzmann transport equation combined with an estimate of the electron relaxation time obtained from DFT simulations.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2017

The characterization of microstructure and chemistry of transmutation fuels

The goal of the fast reactor development programs is fabrication and certification of a nuclear fuel system that performs all functions of a conventional fuel while destroying recycled actinides. Metal fuels, such as U-Pu-Zr fuels, are considered to be candidates for this application. The physical and mechanical properties, as well as behavior laws and correlations of metal alloy fuel, all of which define the behavior and performance of metal alloy fuels has been investigated in detail. The results indicated that the prospect for fueling a future fast spectrum reactor using metal fuels is excellent. There are several challenges associated with the fuel implementation in reactor environment. One of the limiting factors in lifetime and safety of thermal and fast reactor systems is fuel swelling and resulting fission product transport to cladding. Understanding diffusion kinetics and phases formed between metal fuel and cladding upon exposure to high temperatures typical in reactor environment is critical for ensuring integrity, safety, and performance of the material, advancement of this type of fuel in the future, and securing long-term success of the nuclear fleet. The first step to understanding fuel-cladding interaction is investigation of an as-cast fuel microstructure. Despite the importance of these fuels, detailed description of microstructures in these materials is extremely limited. The majority of published results are based on characterization of as-cast microstructures of these fuels in scanning electron microscopes (SEM). In this work, we present the results from microstructural characterization of metallic Pu-based fuels, which is essential in the validation of current and future atomistic and meso-scale modeling efforts. A firm understanding of microstructural evolution in reactor materials is imperative and will lead to deeper understanding of in-reactor degradation behavior, creating a new generation of radiation-resistant materials and fuels with the potential for significant increases in burn-up.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2022

Minimizing thickness variation in monolithic U-10Mo fuel foil and Zr interlayer during hot rolling: A microstructure-based finite element method analysis

Low-enriched uranium alloyed with 10 wt. % molybdenum (U-10Mo) has been identified as a promising alternative to highly enriched uranium fuel for the United States’ high performance research reactors. The monolithic U-10Mo fuel plate consists of a metallic U-10Mo fuel foil with a 25 µm Zr interlayer and a relatively thick cladding of aluminum alloy 6061. The Zr interlayer is typically applied during the hot co-rolling process, and this process dictates the uniformity of the Zr interlayer. Thickness variation observed in the U-10Mo and Zr interlayer has been attributed to several sources: the initial grain size of the U-10Mo castings, can materials, rolling temperature, inhomogeneous molybdenum content, and porosity in the cast U-10Mo. This thickness variation limits the ability to meet the dimensional specification; thus, a better understanding of the factors causing the nonuniform thickness is needed. In this work, we used a novel, microstructure-based finite element method to model the hot rolling process to address these concerns. Grain microstructures in U-10Mo were tessellated and explicitly considered in the finite element model. Each grain was assigned a random material property to mimic the grain strength variations induced by different grain orientations. Simulations were performed using six steel can thicknesses, four grain sizes, and with or without a Zr interlayer to investigate the influences of those variables on the thickness nonuniformity. The simulation results showed that a thinner steel can and finer U-10Mo grain size reduce thickness variations in both the U-10Mo fuel foil and Zr interlayer. The direct findings from the simulations and analysis can be used to optimize the hot rolling schedule, reduce fabrication defects, and meet the dimensional specifications. The proposed microstructure-based finite element model can be also coupled with experimental microstructure characterization data, images, and models to simulate multi-pass hot rolling.

36 MATERIALS SCIENCE↗
DOE OSTI2017

Development of Integrated Die Casting Process for Large Thin-Wall Magnesium Applications

The purpose of this project was to develop a process and product which would utilize magnesium die casting and result in energy savings when compared to the baseline steel product. The specific product chosen was a side door inner panel for a mid-size car. The scope of the project included: re-design of major structural parts of the door, design and build of the tooling required to make the parts, making of parts, assembly of doors, and testing (both physical and simulation) of doors. Additional work was done on alloy development, vacuum die casting, and overcasting, all in order to improve the performance of the doors and reduce cost. The project achieved the following objectives: 1. Demonstrated ability to design a large thin-wall magnesium die casting. 2. Demonstrated ability to manufacture a large thin-wall magnesium die casting in AM60 alloy. 3. Tested via simulations and/or physical tests the mechanical behavior and corrosion behavior of magnesium die castings and/or lightweight experimental automotive side doors which incorporate a large, thin-wall, powder coated, magnesium die casting. Under some load cases, the results revealed cracking of the casting, which can be addressed with re-design and better material models for CAE analysis. No corrosion of the magnesium panel was observed. 4. Using life cycle analysis models, compared the energy consumption and global warming potential of the lightweight door with those of a conventional steel door, both during manufacture and in service. Compared to a steel door, the lightweight door requires more energy to manufacture but less energy during operation (i.e., fuel consumption when driving vehicle). Similarly, compared to a steel door, the lightweight door has higher global warming potential (GWP) during manufacture, but lower GWP during operation. 5. Compared the conventional magnesium die casting process with the “super-vacuum” die casting process. Results achieved with cast tensile bars suggest some improvement in tensile properties with vacuum casting. Plant trials with large castings revealed cavity fill issues attributed to cooling and partial solidification of metal in the shot sleeve while waiting for vacuum to be established in the die cavity. 6. Developed age-hardenable Mg-based alloys as potential alternatives to the AM60 and AZ91 alloys typically used in automotive applications. Mg-7%Al-based alloys having Sn or Sn+Si additions exhibited significant age hardening, but more work is needed to demonstrate significant improvement in tensile properties. Corrosion behavior of these alloys is between those of AM60 and AZ91 alloys. 7. Evaluated the die casting of magnesium directly onto either steel or aluminum tubes as a potential process to make large lightweight subassemblies. Samples were free of gross defects, but additional work is needed to increase the interfacial shear strength. Overall, the project demonstrated that an automotive door-in-white design incorporating a die cast magnesium inner panel and a stamped aluminum outer panel can achieve approximately 50% mass reduction compared to the stamped steel baseline door-in-white. This leads to reduced energy consumption when driving the vehicle, which should more than offset the increased embedded energy of manufacture associated with the lighter metals. However, additional design work would be needed in order to meet the mechanical performance required of a door. Development of high-strength, high-ductility magnesium alloy castings would help make this technology more attractive for potential use in the side doors on automobiles. Also, increased use of recycled magnesium and aluminum would reduce the embedded energy and greenhouse gas emissions associated with the manufacture of this type of lightweight door. Commercialization planning of the type of lightweight door technology addressed in this project would be contingent upon the doors meeting all technical performance requirements of the car maker. The specific lightweight door developed in this project didn’t meet some of those requirements, but a preliminary business case study was conducted anyhow. This study considered the ratio of cost increase to mass decrease when the lightweight door is compared to a baseline steel door. The ratio was found to be in an acceptable range for some vehicle programs, especially if the number of such vehicles to be produced is equal to or slightly less than the estimated 250,000-shot life of the die set. This would allow for the investment in the dies to be spread across many parts and thereby help minimize the cost increase.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2017

Robust metal-ceramic coaxial cable sensors for distributed temperature monitoring in fossil energy power systems

The project aims to develop a new type of low cost, robust metal-ceramic coaxial cable (MCCC) Fabry-Pérot interferometer (FPI) sensor and demonstrate the capability of cascading a series of FPI sensing points in a single MCCC for real-time distributed monitoring of temperature up to 1000°C. The technical accomplishments of this project include: (i) development of metal and ceramic materials for fabricating the MCCC suitable for use in high temperature (up to 1000oC) fossil fuel, (ii) design, construction and test of single point MCCC-FPI sensors for high temperature measurement at deviation within ±2.7%, (iv) demonstration of the MCCC-FPI sensors for real-time distributed temperature measurement with desired sensitivity, spatial resolution, stability, and response speed that are important to practical applications, and (v) development of a novel MCCC-FPI sensor platform for measuring high frequency dielectric constants for solids and liquids as function of temperature. Single point MCCC-FPI sensors are fabricated based on the FPI parameters, including the relationship between reflector width and reflectance as well as the inter-reflector distance for a FPI, estimated by model calculations. MCCC-FPI sensors have been made using insulators of packed ceramic powders, ceramic tubes, and air or inert gases; outer conductors of various metal tubes; inner conductors of wires of the same metal materials as the tubes used; and reflectors of dense ceramic discs, casted ceramic discs and air gaps. The insulator, conductor and reflector materials are investigated for their thermal, chemical, and structural stabilities under temperatures up to 1000°C in simulated coal-derived syngas. Based on the experimental findings, alumina tube and discs, and stainless steel tube and wire are selected for reflector, insulator and outer and inner conductors, respectively. Air or inert gases are found to be useful for reflectors (in the form of narrow groves) or insulators (in the form of empty chamber cavity between ceramic discs) in construction of MCCC-FPI sensors. Single point MCCC-FPI sensors have been fabricated using stainless steel as conductors, dense α-alumina tubes as dielectric insulators, and two air gaps in the insulator as reflectors. The MCCC-FPI sensor with air gap reflectors has been demonstrated for measuring temperature between 200 and 500°C using microwave as sensing signal in a frequency range of 2 – 8 GHz. The temperature measurement is achieved by monitoring the frequency shift (Δƒ) of a selected resonant peak of the microwave interferogram reflected from the pair of air gap reflectors. The MCCC-FPI sensor exhibited excellent linear temperature-dependence for Δƒ, good accuracy (deviation ±2.7%), and reasonable response speed (<180 s for stabilization). Thermal drifting of the sensing signal was also rather minimal for the MCCC-FPI sensors after operating for more than one week at around 500oC. MCCC-FPI sensors with each containing 2 or 3 pairs of reflectors (i.e. 2 or 3 FPIs in a single cable) have been fabricated and demonstrated for distributed temperature measurement between 250 and 550°C in a microwave frequency range of 3-6 GHz. The measurement is achieved by monitoring the frequency shift of a selected resonant peak of the reflected microwave interferogram, which is obtained by the join-time-domain signal processing method. The results demonstrate that the FPI sensing points in both the three-point and two-point MCCC sensors can measure distributed high temperature with good reproducibility and consistency in multiple runs of measurement tests. The sensor signal displays excellent linear dependence between temperature and the corresponding frequency shift. The 2-point and 3-point MCCC-FPI sensors also exhibit fast response to environmental temperature changes. A three-point MCCC-FPI sensor has been further examined for temperature measurement up to 1000°C for multiple heating-cooling cycles and the results prove that the sensor is suitable for distributed temperature measurement up to 1000°C. MCCC-FPI sensors with more than 4 FPIs point in a single line are made in two structures: the first uses alumina tube as insulation and air gaps as reflectors; and the second uses air chamber as insulation and complete circular alumina discs (2 mm-thick) as reflectors. MCCC-FPIs in neither of the two structures are able to exceed four FPIs in a cable because the reflections from the FPIs are too strong for the microwave to transmit through >4 FPIs over a long distance. Specially shaped alumina discs made by removing parts of the circular discs are found to decrease the microwave reflectance because of reduced reflection areas. However, the smallest reflectance (in terms of percentage of the incident signal) obtained in this work is as high as 7.5%, which is still too large to construct more than 10 FPIs in a single MCCC. Nevertheless, the feasibility of the proposed multipoint MCCC-FPI has been demonstrated using air insulation and 2 mm-thick low-ε r Teflon discs as reflectors on a 2 m-long cable containing 10 FPIs (with reflectance <5% on each FPI). These results indicate that the contrast of dielectric constant between the insulation and reflector has a more significant impact on the reflectance. Thus, future research efforts should also be directed to developing ceramic materials (dense or porous) with low dielectric constant values which, when used as insulation or reflector, can realize large numbers of FPIs in a single cable over a long distance. To assist the development of high temperature dielectric materials, a novel MCCC-FPI sensor platform is developed and successfully demonstrated for measuring high frequency dielectric constants for fluids, packed dielectric solids, and ceramic tube materials and determining ε r dependencies on temperature and chemical composition, etc..

36 MATERIALS SCIENCE↗
DOE OSTI2019

Natural and Engineered Features Supporting Environmental Performance of Idaho National Laboratory's Remote-Handled Low-Level Waste Disposal Facility - 19436

The Idaho National Laboratory's (INL's) Remote-Handled Low-Level Waste (RH LLW) Disposal Facility has been designed and constructed to receive waste generated at the INL site in support of the US DOE Office of Nuclear Energy (NE) and Naval Reactors (NR) missions. The facility has been designed to receive legacy RH LLW currently in storage at INL facilities and new waste generated by nuclear research programs. RH LLW to be received at the facility is solid waste consisting of surface contaminated materials; ion exchange resins used to purify cooling and canal water; and activated metal components generated during reactor core change outs and Naval spent fuel management; and nuclear R and D. Disposal of INL's RH LLW poses unique disposal challenges due to high radiation levels (contact rates up to 600 Sv/hr [60,000 Rem/hr]) that require remote handling and adequate shielding for transportation and disposal. The facility has been designed to meet the requirements of DOE Order 435.1, Radioactive Waste Management, including the all-pathways dose, air pathway dose, inadvertent intruder doses, and radon emissions limits. This paper presents an overview of natural and engineered design features that support the safety case and enhance the environmental performance of the facility. These features include location selection, use of reinforced pre-cast concrete vaults; a robust hydraulic drainage system; use of steel waste canisters for waste disposal; the facility monitoring system; facility layout; and crediting waste forms. The facility performance assessment (PA) developed to meet the requirements of DOE Order 435.1, credits each of these protective features. Releases from waste forms disposed of at this facility are limited by corrosion of the steel waste canisters which will ultimately allow contact with infiltrating water followed by transport of radionuclides from the vault system. The steel waste canisters were credited for their ability to limit water contact with the waste based on the demonstrated ability of the reinforced pre-caste concrete vaults to provide long-term structural protection of the steel waste canisters. Verification of hydraulic and concrete performance was conducted through laboratory data, field infiltration tests supported by a robust monitoring system, and numerical modeling. Releases into the vault system from activated metals are based on site-specific corrosion data. Radionuclide transport from the vault system from all waste forms is based on site-specific climatological, hydrologic, and stratigraphic data. At INL, the groundwater pathway historically and appropriately has received the most attention. By crediting aspects of the natural system, the engineered vault system, and the waste, estimated radiologic doses via the groundwater pathway are minimal. Air pathway doses were reduced by differentially crediting corrosion of aluminum and stainless steel activated metals resulting in the pathway being screened out of the PA. Groundwater and inadvertent intruder doses were reduced through selective facility layout. This paper provides an overview of the system-wide protective features incorporated into the facility design along with an extensive reference list to supporting technical papers and analyses that provide data and interpretation. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2023

Dual-Purpose Canister Filling Demonstration Project Progress Report at ORNL, 2023

The US DOE Office of Nuclear Energy is investigating the feasibility of direct disposal of dual-purpose canisters (DPCs) in a hypothetical geological repository to offset the potential requirement to repackage spent nuclear fuel (SNF) from existing DPCs into smaller, disposal-ready canisters. Oak Ridge National Laboratory (ORNL) is currently evaluating the feasibility of filling void space in loaded DPCs with an engineered material to prevent a criticality event caused by groundwater/moderator intrusion. Metal alloys are being investigated as a filler material because of their relatively low viscosities when molten, which may facilitate their injection via an existing drainpipe that runs almost the full length of the DPC. ORNL’s strategy for evaluating filler viability includes simulations and physical demonstrations of filling and casting behavior, as well as evaluations of materials for compatibility in the repository environment. Filling of DPCs in this manner is expected to mitigate the risk associated with a post-closure criticality event during the repository performance assessment time frame (10,000 years or greater). Efforts in this fiscal year focused on (1) destructive analysis of experimental filler castings made in FY 2022, (2) a report outlining a conceptual design of a DPC filling facility (Fortner et al., 2023, M3SF 23OR010305044/ ORNL/SPR-2023/2921, May 31, 2023), (3) a report on affected features, events, and processes (FEPs) due to DPC filling (Price et al., 2023, M3SF-23SN010305093, issuance pending), (4) developing and testing a more practical alloy filler based upon a Sn-Al eutectic, and (5) modeling the heating and cooling dynamics of a DPC subjected to molten metal filling. The preliminary results from each of these tasks support the feasibility of filling DPCs with metal as a strategy against the possibility of criticality in the repository. The FY 2022 casting was found to penetrate even very small orifices in the mold and internal structures. Preliminary testing of the Sn-Al eutectic indicate little interaction of the melt with Zircaloy cladding. Thermal modelling shows that a filled DPC will cool to manageable temperatures within 2-3 days, which is likely manageable in a facility.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2017

Triple Plate Mold Final Report: Optimization of the Mold Design and Casting Parameters for a Thin U-10mo Fuel Casting

This work describes the experiments and modeling that have been performed to improve and try to optimize the simultaneous casting of three plates of U-10wt%Mo in a single coil vacuum induction melting (VIM) furnace. The plates of interest are 280 mm wide by 203 mm tall by 5 mm thick (11" x 8" x 0.2"). The initial mold design and processing parameters were supplied by Y-12. The mold and casting cavity were instrumented with a number of thermocouples, and the casting performed to determine the thermal history of the mold and casting. The resulting cast plates were radiographed and numerous defects identified. Metallography was performed to help identify the nature of the radiographically observed defects. This information was then used to validate a mold filling and solidification model of that casting. Based on the initial casting, good casting design practice, and process simulation of several design alternatives, a revised design was developed with the goal of minimizing casting defects such as porosity. The redesigned mold had a larger hot-top and had its long axis along the horizontal direction. These changes were to try to develop a strong thermal gradient conducive to good feeding and minimization of micro- and macroporosity in the cast plates. An instrumented casting was then performed with the revised mold design and a linear distributor. This design yielded cast plates with significantly less radiographically identified defects. Unfortunately, there was significant variation in plate weight and metal content in their hot-tops. Fluid flow simulations were then performed on this mold/distributor design. This helped identify the issue with this linear distributor design. Additional simulations were then performed on candidate distributor redesigns and a preferred distributor annular design was identified. This improved annular design was used to produce a third instrumented casting with favorable results. These refined designs and their radiographic characterization are compared to the initial design.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Accelerated fission rate irradiation design, pre-irradiation characterization, and adaptation of conventional PIE methods for U-10Mo and U-17Mo

Metallic U alloys have high U density and thermal conductivity and thus have been explored since the beginning of nuclear power research. Alloys of U with modest amounts of Mo, such as U-10 wt % Mo (U-10Mo), are of particular interest because the γ-U crystal structure in this alloying addition shows prolonged stability in reactor service. Historically, radiation data on U-10Mo fuels were collected in Na fast reactors or lower temperature research reactor conditions, but little is known about irradiation behavior, particularly swelling and creep, at irradiation temperatures between 250 and 500°C. This work discusses the methodology and pre-irradiation characterization results from a U-Mo irradiation campaign performed in the High Flux Isotope Reactor at Oak Ridge National Laboratory. U-10Mo and U-17Mo samples irradiations are being completed at temperatures ranging from 250 to 500°C to three targeted fission densities between 2 × 10 20 and 1.5 × 10 21 fissions per cubic centimeter. Swelling measurement of the specimen sizes studied here required development and assessment of new methods for volume determination before and after irradiation. Laser profilometry and X-ray computation tomography (XCT) were used to provide preirradiation characterization of samples to determine the error and applicability of each to determine swelling following irradiation. These outcomes are contextualized through use of BISON simulations performed to assess the predicted expansion of U-Mo fuels subjected to the irradiation conditions of this work. Use of existing BISON fuel performance models predicted a maximum of 7% swelling under the irradiation conditions of this study. Pre-irradiation characterization revealed the as-cast U-Mo fuel samples were uniformly large-grained fully cubic U crystals with small U-C/N bearing precipitates and pores distributed throughout. Samples were found to contain a bulk porosity between .4 and 3% because of the casting process. Local porosity in areas far from large, interconnected pores was found by Slice-and-View to be under .2%. Nanometer-sized precipitates rich in C and N were identified in all samples, likely because of impurities during the fabrication process. Dendritic bands were also observed throughout the samples. These bands were characterized by variable Mo content that deviated from the overall Mo content by 2–3 wt %. No other microstructural features were correlated to these bands. Mechanical properties were found to be slightly strengthened compared to literature reports of bulk U-Mo fuels due to the nano-scale precipitates throughout the sample.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2016

The Effect of Rolling As-Cast and Homogenized U-10Mo Samples on the Microstructure Development and Recovery Curves

Over the past several years Pacific Northwest National Laboratory (PNNL) has been actively involved in supporting the U.S. Department of Energy National Nuclear Security Administration Office of Material Management and Minimization (formerly Global Threat Reduction Initiative). The U.S. High- Power Research Reactor (USHPRR) project is developing alternatives to existing highly enriched uranium alloy fuel to reduce the proliferation threat. One option for a high-density metal fuel is uranium alloyed with 10 wt% molybdenum (U-10Mo). Forming the U-10Mo fuel plates/foils via rolling is an effective technique and is actively being pursued as part of the baseline manufacturing process. The processing of these fuel plates requires systematic investigation/understanding of the pre- and post-rolling microstructure, end-state mechanical properties, residual stresses, and defects, their effect on the mill during processing, and eventually, their in-reactor performance. In the work documented herein, studies were conducted to determine the effect of cold and hot rolling the as-cast and homogenized U-10Mo on its microstructure and hardness. The samples were homogenized at 900°C for 48 h, then later annealed for several durations and temperatures to investigate the effect on the material’s microstructure and hardness. The rolling of the as-cast plate, both hot and cold, was observed to form a molybdenum-rich and -lean banded structure. The cold rolling was ineffective, and in some cases exacerbated the as-cast defects. The grains elongated along the rolling direction and formed a pancake shape, while the carbides fractured perpendicularly to the rolling direction and left porosity between fractured particles of UC. The subsequent annealing of these samples at sub-eutectoid temperatures led to rapid precipitation of the ' lamellar phase, mainly in the molybdenum-lean regions. Annealing the samples above the eutectoid temperature did not refine the grain size or the banded microstructure. However, annealing the samples led to quick recovery in hardness as evidenced by a drop in Vickers hardness of 20%. Hot rolling was performed at 650 and 800°C. The hot-rolling mill loads (load separation force) were approximately 40 to 50% less than the cold-rolling for the same reduction and thickness. It was observed that hot rolling the samples with 50% or more reduction in thickness were responsible for dynamic recrystallization in the hot-rolled samples and led to grain refinement. Unlike the cold-rolled samples, the hot-rolled samples did not fracture the carbides and appeared to heal the casting defects. The recovery phenomenon was similar to the cold-rolled samples above the eutectoid temperatures, but owing to the refined grain size, the precipitation of the lamellar phase was far more rapid in these samples and the hardness increased more rapidly than in the cold rolled sample when heated below the eutectoid temperature. The data generated from these rolling efforts has been used to make the process modeling efforts more robust and applicable to all USHPRR partner rolling mills. The flow stress for cold rolling the samples was determined to be between 170-190 ksi, with frictional forces between 0.2 and 0.4 for the PNNL mill. The measured roll separation forces and those simulated using finite element methods for hot and cold rolling for the PNNL rolling mill were in good agreement.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2016

The Effect of Rolling As-Cast and Homogenized U-10Mo Samples on the Microstructure Development and Recovery Curves

Over the past several years Pacific Northwest National Laboratory (PNNL) has been actively involved in supporting the U.S. Department of Energy National Nuclear Security Administration Office of Material Management and Minimization (formerly Global Threat Reduction Initiative). The U.S. High-Power Research Reactor (USHPRR) project is developing alternatives to existing highly enriched uranium alloy fuel to reduce the proliferation threat. One option for a high-density metal fuel is uranium alloyed with 10 wt% molybdenum (U-10Mo). Forming the U-10Mo fuel plates/foils via rolling is an effective technique and is actively being pursued as part of the baseline manufacturing process. The processing of these fuel plates requires systematic investigation/understanding of the pre- and post-rolling microstructure, end-state mechanical properties, residual stresses, and defects, their effect on the mill during processing, and eventually, their in-reactor performance. In the work documented herein, studies were conducted to determine the effect of cold and hot rolling the as-cast and homogenized U-10Mo on its microstructure and hardness. The samples were homogenized at 900°C for 48 h, then later annealed for several durations and temperatures to investigate the effect on the material’s microstructure and hardness. The rolling of the as-cast plate, both hot and cold, was observed to form a molybdenum-rich and -lean banded structure. The cold rolling was ineffective, and in some cases exacerbated the as-cast defects. The grains elongated along the rolling direction and formed a pancake shape, while the carbides fractured perpendicularly to the rolling direction and left porosity between fractured particles of UC. The subsequent annealing of these samples at sub-eutectoid temperatures led to rapid precipitation of the α + γ ' lamellar phase, mainly in the molybdenum-lean regions. Annealing the samples above the eutectoid temperature did not refine the grain size or the banded microstructure. However, annealing the samples led to quick recovery in hardness as evidenced by a drop in Vickers hardness of 20%. Hot rolling was performed at 650 and 800°C. The hot-rolling mill loads (load separation force) were approximately 40 to 50% less than the cold-rolling for the same reduction and thickness. It was observed that hot rolling the samples with 50% or more reduction in thickness were responsible for dynamic recrystallization in the hot-rolled samples and led to grain refinement. Unlike the cold-rolled samples, the hot-rolled samples did not fracture the carbides and appeared to heal the casting defects. The recovery phenomenon was similar to the cold-rolled samples above the eutectoid temperatures, but owing to the refined grain size, the precipitation of the lamellar phase was far more rapid in these samples and the hardness increased more rapidly than in the cold rolled sample when heated below the eutectoid temperature. The data generated from these rolling efforts has been used to make the process modeling efforts more robust and applicable to all USHPRR partner rolling mills. The flow stress for cold rolling the samples was determined to be between 170-190 ksi, with frictional forces between 0.2 and 0.4 for the PNNL mill. The measured roll separation forces and those simulated using finite element methods for hot and cold rolling for the PNNL rolling mill were in good agreement.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗