Optimization of a thin U-10Mo fuel plate casting by modeling and experiment

LEU U-10%Mo fuel fabrication begins with a molten metal casting process which is feedstock for fuel foil fabrication by rolling. This work describes the experiments and modeling that have been performed to optimize the casting of long thin (28 cm x 20 cm x 0.5 cm) plates of U-10%Mo using vacuum induction melting (VIM). Three casting trials where used to evaluate a preliminary design and two revised designs. The mold and casting cavity were instrumented with a number of thermocouples to determine the thermal history of the mold and casting. The resulting cast plates were analyzed for filling and solidification defects using radiography. The goal was to develop a refined mold design and casting process parameters that maximized casting yield and minimized casting defects such as porosity and Mo segregation. (author)