Pressureless sintering of large sized fully ceramic microencapsulated fuel pellets

Abstract

Large-sized fully ceramic microencapsulated (FCM) nuclear fuel pellets were fabricated by a novel tape casting process in this study. The process involved producing a single layer of FCM fuel green tapes embracing TRISO particles by tape casting with silicon carbide ceramic as the matrix. The resulting tapes were stacked vertically and made into green bodies through cold isostatic pressing. Large-sized FCM fuel pellet with diameters over 86 mm was then successfully prepared by pressure-less sintering with AlN-Y2O3-Sc2O3−MgO as sintering additives. The FCM fuel pellets obtained through this method exhibited a dense structure, flat surface, and no cracks. Thus, the integrated formation of the fuel-free zone and fuel-filled zone could be realized by precisely controlling the fuel-free zone thickness. The TRISO particles were regularly and uniformly distributed in a triangular shape and remained structurally intact. By adjusting the spacing of the TRISO particles in the FCM fuel pellets to a range of 500 to 1500 μm, the volume fraction of fuel particles in the FCM fuels was controlled between 12.8 and 31.7 vol.%.