Fabrication and microstructural analysis of UN-U₃Si₂ composites for accident tolerant fuel applications

In this study, U₃Si₂ was synthesized via the use of arc-melting and mixed with UN powders, which together were sintered using the SPS method. The study revealed a number of interesting conclusions regarding the stability of the system – namely the formation of a probable but as yet unidentified ternary phase coupled with the reduction of the stoichiometry in the nitride phase – as well as some insights into the mechanics of the sintering process itself. By milling the silicide powders and reducing its particle size ratio compared to UN, it was possible to form a high density UN-U₃Si₂ composite, with desirable microstructural characteristics for accident tolerant fuel applications. - Highlights: • U₃Si₂ fabricated from elemental uranium and silicon through arc melting. • Homogeneity of the silicides assessed through densitometry, XRD, SEM and EDS, chemical etching and optical microscopy. • UN powder fabricated using hydriding-nitriding method. • No phase transformations detected when sintering using silicide particle sizes less than UN particle size. • High density composite (98%TD) fabricated with silicide grain coating using spark plasma sintering at 1450 °C.