Summary: Stainless steel clad nuclear fuel cycle costs can be reduced to those associated with Zircaloy clad fuel or potentially lower by reducing the thickness of the clad tube wall until performance penalties offset the savings associated with the reduction in parasitic neutron absorption. To demonstrate the feasibility and investigate performance capabilities of thin clad fuel rods for power reactor application an assembly was fabricated with 0.0127 cm (5 mil) thick stainless steel cladding tubes for irradiation testing in the Vallecitos Boiling Water Reactor (VBWR). The fuel bundle was placed in the VBWR and irradiation was begun in November, 1961. The irradiation is scheduled to continue until the target exposure of 2.74 x 10(20) fissions/cc (10,000 MWD/T of uranium) average burnup is reached. Destructive examinations of fuel rods will be performed at regular intervals throughout life to determine fuel rod performance.

Technical report describing that as part of the AEC Fuel Cycle Program, tests are being conducted to evaluate the significance of current fuel design limitations that do not permit the maximum fuel temperature to exceed the melting point of UO2. The reliability of prediction of the fuel rod operating conditions that will cause melting of the UO2 was evaluated by means of a calibration test conducted in the Vallecitos Boiling Water Reactor. Conclusions: (a) The central portion of the 3.15-cm diameter uranium dioxide fuel column melted. It appears that the UO2 was molten to a radius of 1.22 cm in the peak power region. The maximum extent of melting probably occurred during the peak power run when the kdT in this region of the rod reached 171 watts cm. The estimated radius of melting from metallographic examination indicates the kdT for sintered UO2 is 89 watts/cm. This supports a calculated estimate for sintered UO2 thermal conductivity published by D. R. deHalas and G. R. Horn. The results of the previous calibration run and subsequent experimental data by Lyons are also consistent with the value. This conclusion is contingent on the interpretation of the post-irradiation crystal structure of the UO2. Insufficient …

Quarterly progress report discussing activities related to the Vallecitos Boiling Water Reactor (VBWR) and related facilities.

Abstract: Continued irradiation experience under the AEC - Euratom, UO2 High Performance Program provided five separate and distinct sets of data on UO2 thermal conductivity. Four of these results are expressed in terms of the value of the thermal conductivity. The first two of these measurements were applicable -- strictly -- to poly crystalline UO2. Recently, three additional sets of measurements have been obtained -- all pertinent to UO2 after the formation of large columnar grains. The extent of melting in the experiments on which the results are based ranges from slight, to greater than 70 percent of the fuel cross section. The conclusions from all of these thermal conductivity measurements considered together are: (1) The true value of the UO2 conductivity integral form 0 degrees C to melting (2805 - 15 degrees C) lies in the range from 90 to 96 W/cm. The most probable value is closer to 90 W/cm. To ensure no central melting and the associated clad swelling the maximum thermal performance level for solid pellet, UO2 fuel rods should not exceed 90 W/cm. (2) Any improvement in thermal conductivity due to the formation of large, columnar UO2 grains is small and not detectable within the …

The extrusion forming of ceramic powders may be economically interesting in the field of nuclear fuel fabrication. When applied to the forming of rod-type uranium dioxide fuel, extrusion processes have been able to produce cylindrical bodies with length-to-diameter ratios much greater than those of the conventional die-pressed pellets. Furthermore, after being sintered, the extrusions have exhibited densities at least as high as those of sintered pellets. Thus, extrusion forming may offer reductions in handling during fabrication and, at the same time, provide a fuel with improved performance characteristics by decreasing the number of discontinuities in the fuel column. This report reviews the production of these extrusions, sets forth some of their characteristics, describes the materials and processes employed in cladding them, and records the pre-irradiation data pertaining to the finished fuel rods and fuel assembly. Irradiation of the fuel assembly in the VBWR was initiated on July 17, 1962.

Work performed during the quarter is summarized by direct measurement of fission gas pressure, loop operations, performance of UO2 fuel.