Completed 
          (Aug 2001-Aug 2004) 
          Continued under task22

 

Title  Design and Evaluation of Processes for Fuel Fabrication	Researchers G.Mauer Collaborators Mitchell K. Meyer, Group Leader, Fabrication Development Group, Nuclear Technology Division, Argonne National Laboratory
Background  The safe and effective manufacturing of actinide-bearing fuels for any transmutation strategy requires that the entire manufacturing process be contained within a shielded hot cell environment.  To ensure that the fabrication process is feasible, the entire process must be designed for remote operation.  The equipment must be reliable enough to perform over several decades, and also easy to maintain or repair remotely.  The facility must also be designed to facilitate its own decontamination and decommissioning.  In addition to these design factors, the potential viability of any fuel fabrication process will also be impacted by a number of variables, such as the current state of technology, potential problem areas, deployment scaling, facility safety, and cost.	Research Objectives and Methods The goal of this research project was to provide technical support to process designers working on the development of the fuel cycles for transmutation applications.  Detailed process models were developed to better define the impact of fuel choice on the transmuter fuel cycle, including relative process losses, waste generation, and plant capital cost.  These process models provide insight regarding required plant size and number of plants needed to mesh with the fuel recycling line.  They also determine requirements for automation.   Manufacturing models for large-scale production in a hot cell environment were also developed.  Combined, these two models allow the assessment of plant layout, and provide the framework for estimation of plant capital and operating cost estimates, and for feasibility in general.  The need for development in the areas of robotic and sensor technology was assessed.  The manufacturing technology developed for hot cell applications was also applicable to other, more general uses, where occupational hazards prevent human presence near processes. The research work was divided into several tasks and subtasks:  Methods and Processes – A literature survey and detailed analysis of the research and development pertaining to candidate processes for transmuter fuel manufacture was performed.  Industry standards were used to refine equipment, instrumentation, and control specifications, and assessed the reliability and safety of operations.   Simulations – This task modeled manufacturing processes to generate a realistic assessment of plant layout, size, feasibility, and technology development required for large-scale remote fabrication of fuel.  Modeling of the candidate fuel manufacturing processes was conducted using the MSC.visualNastran and ProEngineer simulation software tools.  The modeling of powder-processed fuels was completed, and the modeling of other fuel types (metallic, TRISO etc.) was initiated.  Process and Equipment for Autonomous Manufacturing – This task developed an understanding of the cost and capability of current generation remotely operated equipment suitable for use in radiation environments.  Monitoring of the market for equipment and components with regard to suitability for automated manufacturing under hot cell conditions was conducted.  Sensors, Controls, and Operational Safety – This task determined the adequacy of current technology and the need for suitable sensor technology development for deployment in hard radiation environments.  A means to identify the precise location and spatial orientation of all parts in the robot’s work envelope were implemented.  The ability to position and handle materials along with trouble shooting techniques were evaluated.  Radiation hardened vision systems appear to be promising technologies.    The Wäelischmiller robot inserts the fuel pins in the cladding tube. Friction Force (N) between Second Pin and Cladding Tube vs. Time (sec) during Insertion.
Students  Jae-Kyu Lee, G Richard Silva G Jamil Renno, G	Department Mechanical Engineering
Final Report   Final Report 09/01/01-08/31/04	Annual Report  Task 9 Year 1 Academic Year 2001
Proposal Final 08/12/01 Task 9 Year 2 Task 9 Year 3	Quarterly Reports  09/01/01-11/30/01    12/01/01-02/28/02 03/01/02-05/31/02  07/01/02-08/31/02    09/01/02-11/30/02 12/01/02-02/28/03 03/01/03-05/31/03  06/01/03-08/31/03  09/01/03-11/30/03  12/01/03-02/29/04  03/01/04-05/31/04
Papers 3D Simulation of Manufacturing Processes For Transmuter Fuel Fabrication-ANS 4/2-5/03	Researchers R. Silvia

 Thesis
Ph.D Mechanical Engineering, Jae-Kyu Lee, "Three Dimensional Pattern Recognition Using Feature-Based Indexing and Rule-Based Search" Dec 2003 (TRP Task 9) 
M.S. Mechanical engineering, Jamil Mohamad Renno, “Virtual Design and Modeling of Various Manufacturing Processes for Remote Fabrication of Transmuter Fuel” May 2005 (TRP Task 9)

  Posters
  AFCI Semi-Annual Review Meeting Poster: Design and Evalution of Processes for 
  Transmuter Fuel Fabrication-Jan 2003

 Abstract
 2003 ANS/ENS International Winter Meeting, Nov. 16-20 , 2003 , New Orleans, LA