Unparalleled leadership in next-generation nuclear fuels, extreme temperature ceramics, and radioisotope sorbents to enable reliable, high-performance nuclear energy systems.
Advanced nuclear reactors will rely on specialized fuels designed to operate reliably under extreme conditions. Developing and fabricating these fuels requires deep understanding and precise control of materials’ microstructure and behavior.
ORNL’s Advanced Fuel Fabrication (AFF) Group addresses this challenge by creating new processes, equipment, and tools to accelerate advanced nuclear fuel development and qualification. The group is driven by innovation and a dedication to producing advanced nuclear fuels with exceptional reliability and performance.
Innovating in nuclear fuel fabrication
Innovating in nuclear fuel fabrication
The AFF group represents a unique capability in the DOE complex, leveraging specialized knowledge and infrastructure to fabricate coated particle fuel and fuel elements using state-of-the-art techniques, including:
- Solid-state chemistry for precise control of fuel composition and properties.
- Sol-gel processing, enabling finely controlled microstructures and consistent fuel performance.
- Chemical vapor deposition to produce uniform, high-quality protective fuel coatings essential for safe high-temperature operations.
- Advanced manufacturing to allow the fabrication and characterization of novel nuclear fuel forms.
- Data analysis and modeling to accelerate fuel fabrication, streamline material characterization, and optimize the fuel qualification process.
Bridging research and real-world nuclear applications
The group collaborates closely with partners to support fuel development efforts for advanced energy systems and specialized nuclear deployments.
- Leading advanced coated particle fuel development and plutonium adsorbent research within Department of Energy’s Advanced Gas Reactor Fuel Development and Qualification program, and Pu-238 supply program.
- Using computational fluid dynamics and experimental validation to improve coated particle fuel fabrication processes alongside BWXT through the Department of Energy’s Advanced Reactor Demonstration Program.
- Supporting specialized development of nuclear thermal propulsion fuels, coatings, and structural materials in support of NASA’s Space Nuclear Propulsion Office.
- Partnering with Westinghouse Electric Company on the development of advanced coated particle fuel technologies through the Advanced Fuel Campaign
- Collaborating with fusion energy company Type One Energy to demonstrate coated particle lithium-breeding materials for future fusion reactors through a strategic partnership project.
The AFF group also explores the integration of taggants within nuclear fuels to enhance nuclear forensic capabilities and improve traceability and develops specialized plutonium adsorbents to support safer nuclear fuel cycles.
Recent advances in fuel fabrication
- Successful fabrication of uranium nitride coated fuel particles tailored specifically for nuclear thermal propulsion applications, offering enhanced fuel reliability and enabling ambitious future space missions.
- New sintering additives for uranium nitride fuels, significantly improving densification and microstructure control, which are critical to achieving reliable and efficient fuel performance in advanced reactors.
- Accelerated chemical vapor deposition component design, creating an innovative process that rapidly prototypes, tests, and selects improved components used in coated particle fuel production, enhancing fuel quality and production efficiency.
- Record-setting uranium nitride TRISO fuel burnup performance, achieving the highest reported burnup levels for this advanced nuclear fuel. This milestone demonstrates the fuel's exceptional durability, paving the way for higher-efficiency reactor operations and extended fuel service life.
Toward an advanced nuclear fuel future
The AFF group has set the pace for advancing next-generation nuclear fuel fabrication and qualification. With a focus on supporting advanced reactor deployment, space exploration, and developing predictive tools to speed up how fuels are made and tested, the Group’s research and collaborations are pivotal to shaping the future of advanced nuclear fuel.