Metallic Fuel Fabrication Optimization

Metallic fuel casting batches were examined for mass balance and to determine necessary
improvements. The mass balance showed that approximately 95% of the fuel alloy is used. The
remaining 5% of material is in the form of fine-fine and dust and glass which will require further
processing to recover the usable material. There is also a large amount of quartz mold waste
produced for every casting batch which will require disposal. To improve the efficiency of the fuel
fabrication, process the single use quartz molds need to be eliminated, and the recycle streams
reduced by reducing or eliminating the casting heels and slug fines. Several fabrication processes
including centrifugal casting, gravity casting, microwave casting, additive manufacturing, and
extrusion were examined to improve efficiency of the current casting process. Development of
centrifugal and microwave is not recommended because the advantages can be realized with other
systems without the associated disadvantages. Inductively heated permanent mold casting and
extrusion have many of the same advantages with the benefit of possible higher production rates.
Continuous casting is the least developed and may require a higher level of automation and
complexity, but carries significant advantages such as the ability to cast more complex geometries,
is a near net shape process, has a higher melt utilization. The advantages outweighs the
disadvantages of lack of laboratory experience and complex systems, and it is recommended for
further development..