Green strength of zirconium sponge and uranium dioxide powder compacts

Zirconium metal sponge is compacted into rectangular or cylindrical shapes using hydraulic presses. These shapes are stacked and electron beam welded to form a long electrode suitable for vacuum arc melting and casting into solid ingots. The compact electrodes should be sufficiently strong to prevent breakage in handling as well as during vacuum arc melting. Usually, the welds are strong and the electrode strength is limited by the green strength of the compacts, which constitute the electrode. Green strength is also required in uranium dioxide (UO2) powder compacts, to withstand stresses during de-tensioning after compaction as well as during ejection from the die and for subsequent handling by man and machine. The strengths of zirconium sponge and UO2 powder compacts have been determined by bending and crushing respectively, and Weibul moduli evaluated. The green density of coarse sponge compact was found to be larger than that from finer sponge. The green density of compacts from lightly attrited UO2 powder was higher than that from unattrited category, accompanied by an improvement in UO2 green crushing strength. The factors governing green strength have been examined in the light of published literature and experimental evidence. The methodology and results provide a basis for quality control in metal sponge and ceramic powder compaction in the manufacture of nuclear fuel.