A high-temperature, short-duration method of fabricating surrogate fuel microkernels for carbide-based TRISO nuclear fuels

High-temperature gas-cooled reactor technology is a frontrunner among generation IV nuclear reactor designs. Among the advanced nuclear fuel forms proposed for these reactors, dispersion-type fuel consisting of microencapsulated uranium di-oxide kernels, popularly known as tri-structural isotropic (TRISO) fuel, has emerged as the fuel form of choice. Generation IV gas-cooled fast reactors offer the benefit of recycling nuclear waste with increased burn-ups in addition to producing the required power and hydrogen. Uranium carbide has shown great potential to replace uranium di-oxide for use in these fast spectrum reactors. Uranium carbide microkernels for fast reactor TRISO fuel have traditionally been fabricated by long-duration carbothermic reduction and sintering of precursor uranium dioxide microkernels produced using sol-gel techniques. These long-duration conversion processes are often plagued by issues such as final product purity and process parameters that are detrimental to minor actinide retention. In this context a relatively simple, high-temperature but relatively quick-rotating electrode arc melting method to fabricate microkernels directly from a feedstock electrode was investigated. The process was demonstrated using surrogate tungsten carbide on account of its easy availability, accessibility and the similarity of its melting point relative to uranium carbide and uranium di-oxide.