Ceramics fail by brittle fracture due to flaws and affect process yield. The starting material is usually in powder form. UO2 pellets are obtained by pressing powder, sintering and finish grinding. Large powder blends are usually accepted for pressing and sintering after evaluating a small representative powder sample by conducting a sinterability test under regular process conditions. On the other hand, this paper recommends activated sintering conditions, such as those achieved with additives or sintering atmosphere control. Many defects in ceramics have origins in the powder. For example, large hard agglomerates in the powder can cause packing difficulties in pressing. Defects that are not detected in normal sintering may be noticed more readily in activated sintering due to defect amplification. In sintering, open porosity ceases after reaching a density of ∼93 % TD. The residual closed porosity tends to shrink on further sintering. The temperature at which open porosity or permeability is lost shifts to a lower temperature in activated sintering. Yet, activated sintering is to be carried out at conventional high sintering temperature, to be able to amplify and expose pellet defects due to powder. Desintering is a result of large sized packing defects in the green body and premature loss of open porosity in the course of sintering. A descriptive model of desintering is suggested that takes into account powder specific surface area, sintering additive and atmosphere. There is no desintering when green microstructure is homogeneous with no density gradients and with uniformly distributed fine voids that shrink and close during sintering. A high-quality powder sample is one that results in high pelleting yield both in conventional and activated sintering. The low temperature sintering process for UO2 manufacture that did not progress due to thermal stability concerns in nuclear reactor, may be revived to lower nuclear fuel costs.
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