Powder Injection Molding Processes for Manufacture of Fast Reactor Nuclear Fuels

Current methods of manufacturing sodium fast reactor (SFR) fuels are constrained to small window of manufacturability. Powder forming processes could provide unique material advantages over traditional casting and extrusion techniques; however, fuel materials in powder form are highly reactive with oxygen and represent a pyrophoric hazard. U and Pu alloys and ceramics are easily dispersible in powder form and require significant radiological protection for the safety of fuel workers. General statement of how this problem is being addressed: A powder injection molding (PIM) process could provide a viable economic alternative to traditional manufacturing methods for SFR fuels. PIM is capable of complex geometries that could unlock new performance potential in SFR fuels relative to currently achievable designs. Furthermore, PIM enables the use of powder in fuel manufacturing through polymer encapsulation which protects the fuel from oxidation and mitigates facility contamination. The encapsulated feedstock can then be molded as an SFR fuel slug or integrated fuel-clad system through a novel two-component PIM (2C-PIM) process. The molded parts can then undergo debinding and sintering to achieve high density fuel materials. JFoster & Associates, LLC (JFA) will develop PIM processes as an alternative solution for the manufacture of fast reactor nuclear fuels. This will entail determination of processing parameters to manufacture fuel slugs, fuel-clad integrated materials, and related methods to form a diffusion barrier at the fuel-clad interface. JFA will demonstrate these techniques using surrogate metallic alloys to simulate typical SFR fuel and cladding materials based on solidus temperature. These results will lay the foundation for Phase II work with uranium-bearing materials as well as further development of JFA feedstock processes and capabilities for SFR fuels. JFA anticipates benefit to the nuclear industry through simplified fuel fabrication that enhances the economic viability of SFR deployment. This would provide benefit to the general public through establishing a closed fuel cycle thus ensuring the sustainability of nuclear energy well into the future. JFA aims to deliver these solutions in the form of fuel technologies and related services.