DOE OSTI2026
Refractory carbide nuclear fuel has been one of the most promising fuel candidates for space nuclear propulsion due to its high melting point, temperature stability, and compatibility in a hot hydrogen environment. In this study, U x Zr 1-x C y fuel was produced by means of a carbothermic reduction process in different UC compositions including 5,10, 20, and 30 at.% UC in the fuel compound. The powder feedstock was consolidated via direct current sintering with densities up to 97% of the theoretical density. The samples with different U x Zr 1-x C y compositions were exposed to hot hydrogen at 2600 K for a cumulative time of 300 min. The samples were characterized by SEM, XRD, density, and measured for mass losses. The high-density samples displayed improved performance in hot hydrogen by minimizing porous sites and reducing areas of direct contact with hydrogen gas, leading to reduced mass losses. Variations in sample density proved to induce large changes in mass loss rates, increasing them up to 90%. The compositions with higher UC content reported the largest mass losses in the study. The loss of uranium occurred primarily at the surfaces exposed to the hot hydrogen where changes in the lattice constant confirmed losses exceeding 50% of the initial UC content in higher compositions, specifically to U 0.3 Zr 0.7 C y . XRD analyses revealed the presence of UH 3 in U 0.3 Zr 0.7 C y suggesting that metallic uranium formed inside the sample as a product of carbon losses. High-density U x Zr x-1 C y fuel with UC concentrations at or below 20 at.% UC exhibited stability and negligible density changes in a high temperature hydrogen environment.
11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗