Abstracts and Available Papers Presented at the
1997 International RERTR Meeting

Study of Diffusion Bonding in 6061 Aluminum and Development of Future
High-Density Fuels Fabrication

I. G. Prokofiev, T. C. Wiencek, and D. J. McGann

Energy Technology Division
Argonne National Laboratory
Argonne, IL 60439, U.S.A.

ABSTRACT

Powder metallurgy dispersions of uranium alloys and silicides in an aluminum matrix have been developed by the RERTR program as a new generation of proliferation-resistant fuels. Testing uses fuel miniplates to simulate standard fuel with cladding and matrix in plate-type configurations. In order to seal the dispersion fuel plates, a diffusion bond must be established between the aluminum cover plates that surround the fuel meat. Four different variations of the standard method for roll-bonding 6061 aluminum were studied: mechanical cleaning, addition of a getter material, modifications to the standard chemical etching, and modifications to welding. Aluminum test pieces were subjected to a bend test after each rolling pass. Results, based on 400 samples, indicate that a reduction in thickness of at least 70% is required to produce a diffusion bond with the standard roll-bonding method, versus a 60% reduction when using a method in which the assembly was 100% welded and contained empty 9 mm holes near the frame corners.