Pelletization and encapsulation of general purpose heat source (GPHS) fueled clads for future space missions

Because of the significant costs of space exploration, it can more effectively be accomplished through an international team effort. This unified effort must include the design, planning, and execution phases of future space missions, extending down to such activities as the processing, pelletization, and encapsulation of the fuel that will be used to support the spacecraft electrical power generation systems. Over the last 30 years, radioisotopes have provided heat from which electrical power is generated. For space missions, the isotope of choice has generally been 238PuO2, its long half-life making it ideal for supplying power to remote satellites and spacecraft like the Voyager, Pioneer, and Viking missions, as well as the recently launched Galileo and Ulysses missions, and the presently planned Cassini mission. Electric power for future space missions will be provided by either radioisotopic thermoelectric generators (RTG), radioisotope thermophotovoltaic systems (RTPV), radioisotope Stirling systems or a combination of these. However, all of the aforementioned systems will be thermally driven by General-Purpose Heat Source (GPHS) fueled clads in some configuration. Each GPHS fueled clad contains a 150-gram pellet of 238PuO2, and each pellet is encapsulated within an iridium-alloy shell. Historically, the fabrication of the iridium-alloy shells has been performed at EG ampersand G Mound, and Oak Ridge National Laboratory, and the girth welding of the GPHS capsules has been performed at Westinghouse Savannah River Corporation, and Los Alamos National Laboratory. This paper describes a cost effective alternative method for the production of GPHS capsules. Fundamental considerations such as the potential production options, the associated support activities, and the methodology to transport the welded fueled clads are discussed. (Abstract Truncated)