Initial Microstructure Evaluation of a U₃Si₂ + W Fuel Pin Fabricated Via Arc Melt Gravity Drop Casting

Injection casting has historically been used to fabricate metallic nuclear fuel on a large scale. Casting of intermetallic fuel forms, such as U₃Si₂, may be an alternative pathway for fabrication of fuel pins to powder metallurgy. To investigate casting on a small scale, arc melt gravity drop casting was employed to cast a one-off pin of U₃Si₂ for evaluation as a fabrication method for U₃Si₂ as a light water reactor fuel. The pin was sectioned and examined via optical microscopy and scanning electron microscopy equipped with energy dispersive x-ray spectroscopy (EDS). Image analysis was used to estimate the volume fraction of phase impurities as well as porosity. The primary phase determined by EDS was U₃Si₂ with U-O and U-Si-W phase impurities. Unusually high levels of tungsten were observed because of accidental tungsten introduction during arc melting. No significant changes in microstructure were observed after annealing a section of the pin at 800°C for 72 h. The average density of the sectioned specimens was 12.4 g/cm³ measured via Archimedes principle immersion density and He gas displacement.