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A new type of high density fuel is needed for the conversion of research and test reactors from high to lower enriched uranium. The most promising one is a dispersion of atomized uranium-molybdenum (U–Mo) particles in an Al matrix. However, during in-pile irradiation the growth of an interaction layer between the U–Mo and the Al matrix strongly limits the fuel’s performance. To improve the in-pile behaviour, the U–Mo particles can be coated with protective layers. The SELENIUM (Surface Engineering of Low ENrIched Uranium–Molybdenum) fuel development project consists of the production, irradiation and post-irradiation examination of 2 flat, full-size dispersion fuel plates containing respectively Si and ZrN coated U–Mo atomized powder dispersed in a pure Al matrix. In this paper X-ray diffraction analyses of the Si and ZrN layers after deposition, fuel plate manufacturing and thermal annealing are reported. It was found for the U–Mo particles coated with ZrN (thickness 1 μm), that the layer is crystalline, and exhibits lower density than the theoretical one. Fuel plate manufacturing does not strongly influence these crystallographic features. For the U–Mo particles coated with Si (thickness 0.6 μm), the measurements of the as received material suggest an amorphous state of the deposited layer. Fuel plate manufacturing strongly modifies its composition: Si reacts with the U–Mo particles and the Al matrix to grow U(Al, Si) 3 and U 3 Si 5 phases. Finally both coatings have shown excellent performances under thermal treatment by limiting drastically the U–Mo/Al interdiffusion.

Several irradiation experiments have confirmed the positive effect of adding Si to the matrix of an U(Mo) dispersion fuel plate on its in-pile irradiation behavior. E-FUTURE, the first experiment of the LEONIDAS program, was performed to select an optimum Si concentration and fuel plate heat treatment parameters for further qualification. It consisted of the irradiation of 4 distinct (regarding Si content and heat treatments), full size flat fuel plates in the BR2 reactor under bounding conditions (470 W/cm 2 peak BOL power, ∼70% peak burn-up). After the irradiation, the E-FUTURE plates were examined non-destructively and found to have pillowed in the highest burn-up positions. The destructive post-irradiation examination confirmed that the fuel evolves in a stable way up to a burn-up of 60% 235 U. Even in the deformed area (pillow) the U(Mo) fuel itself shows stable behavior and remaining matrix material was present. From the calculation of the volume fractions, the positive effect of a higher Si amount added to the matrix and the higher annealing temperature can be derived.

In the framework of the elimination of High-Enriched Uranium (HEU) from the civil circuit, the search for an appropriate fuel to replace the high-enriched research reactor fuel in those reactors that currently still require it for their operation has led to the development of a U–7 wt.%Mo alloy based dispersion fuel with an Al–Si matrix. The European LEONIDAS program, joining SCK•CEN, ILL, CEA and AREVA-CERCA, is aimed at the qualification of such a fuel for the use in high power conditions. The first experiment of the program, designated E-FUTURE, was performed to select the appropriate matrix Si concentration and fuel plate post-production heat treatment parameters for further qualification. It consisted of the irradiation of four distinct (4% and 6% Si, 3 different heat treatments) full size, flat fuel plates in the BR2 reactor. The irradiation conditions were relatively severe: 470 W/cm 2 peak BOL power, with a ∼70% 235 U peak burnup.

In the framework of the IRIS-TUM irradiation program, several full size, flat dispersion fuel plates containing ground U(Mo) fuel kernels in an aluminum matrix, with and without addition of silicon (2.1 wt.%), have been irradiated in the OSIRIS reactor. The highest irradiated fuel plate (with an Al–Si matrix) reached a local maximum burnup of 88.3% 235 U LEU-equivalent and showed a maximum thickness increase of 323 μm (66%) but remained intact. This paper reports the post irradiation examination results obtained on four IRIS-TUM plates. The evolution of the fission gas behavior in this fuel type from homogeneously dispersed nanobubbles to the eventual formation of large but apparently stable fission gas bubbles at the interface of the interaction layer and the fuel kernel is illustrated. It is also shown that the observed moderate, but positive effect of Si as inhibitor for the U(Mo)–Al interaction is related to the dispersion of this element in the interaction layer, although its concentration is very inhomogeneous and appears to be too low to fully inhibit interaction layer growth.

Advanced nuclear power reactor designs such as (Very) High Temperature Reactors (V/HTR) employ TRISO fuel particles that typically have a sub-millimetre U-based fuel kernel coated with three isotropic ceramic layers-a layer of silicon carbide sandwiched between pyrocarbon layers of different density. Evaluation of the ceramic layer thickness and of the degree of sphericity of these typical nuclear fuel particles is required at each step of the fabrication, in order to estimate future fuel performance under irradiation conditions. This study is based on the image processing of polished cross-sections, realized near the equatorial plane. From these 2D images, some measurements are carried out, giving an estimation of the diameter values for a sample of particles at each step of the coating process. These values are then statistically extended to the third dimension in order to obtain the thickness of each layer and the degree of sphericity of each particle. A representation of diameter and layer thickness in polar coordinates enables one to identify steps for which the coating process is defective or deviating from nominal objectives.

International audience; Si addition to Al is considered as a promising route to reduce (U,Mo)-Al interaction kinetics, due to its accumulation in the interaction layer, yielding the formation of silicide phases. The (U,Mo) alloy microstructure, and especially its homogenization state, could play a role on this accumulation process. The addition of a third element in γ(U,Mo) could also influence diffusion mechanisms of Al and Si. These two parameters were studied by means of diffusion couple experiments by joining γU based alloys with Al and (Al,Si) alloy. Chemical elements X added into γ(U,Mo) were thoroughly chosen on the following criteria: (i) the potential solubility of the alloying element into the γ(U,Mo) matrix, (ii) its capability to form the ternary aluminides based on the CeCr2Al20 and Ho6Mo4Al43 - types, and (iii) the feasibility to control the microstructure of the alloys. On this basis, a test matrix is defined. It concerns γ(U80,Mo15,X5) alloys (in at.%) with X = Y, Cu, Zr, Ti or Cr. These alloys were homogenized and coupled with Al or (Al,Si) alloy. Results evidenced, first, the importance of the state of homogenization of the γ(U,Mo) binary alloy on interaction processes with (Al,Si) alloy, and the benefit on the diffusion of Si through the interaction layer, as observed on the elementary concentration profiles, when the third element X has some solubility into γ(U,Mo) alloy.

International audience; Within the framework of the development of low enriched nuclear fuels for research reactors, U-Mo/Al is the most promising option that has however to be optimised. Indeed at the U-Mo/Al interfaces between U-Mo particles and the Al matrix, an interaction layer grows under irradiation inducing an unacceptable fuel swelling. Adding silicon in limited content into the Al matrix has clearly improved the in-pile fuel behaviour. This breakthrough is attributed to an U-Mo/Al-Si protective layer around U-Mo particles appeared during fuel manufacturing. In this work, the evolution of the microstructure and composition of this protective layer with increasing Si concentrations in the Al matrix has been investigated. Conclusions are based on the characterization at the micrometer scale (X-ray diffraction and energy dispersive spectroscopy) of U-Mo7/Al-Si diffusion couples obtained by thermal annealing at 450 °C. Two types of interaction layers have been evidenced depending on the Si content in the Al-Si alloy: the threshold value is found at about 5 wt.% but obviously evolves with temperature. It has been shown that for Si concentrations ranging from 2 to 10 wt.%, the U-Mo7/Al-Si interaction is bi-layered and the Si-rich part is located close to the Al-Si for low Si concentrations (below 5 wt.%) and close to the U-Mo for higher Si concentrations. For Si weight fraction in the Al alloy lower than 5 wt.%, the Si-rich sub-layer (close to Al-Si) consists of U(Al, Si)3 + UMo2Al20, when the other sub-layer (close to U-Mo) is silicon free and made of UAl3 and U6Mo4Al43. For Si weight concentrations above 5 wt.%, the Si-rich part becomes U3(Si, Al)5 + U(Al, Si)3 (close to U-Mo) and the other sub-layer (close to Al-Si) consists of U(Al, Si)3 + UMo2Al20. On the basis of these results and of a literature survey, a scheme is proposed to explain the formation of different types of ILs between U-Mo and Al-Si alloys (i.e. different protective layers).