This application is a National Stage of International patent application PCT/EP2013/059438, filed on May 7, 2013, which claims priority to foreign French patent application No. FR 1254327, filed on May 11, 2012, the disclosures of which are incorporated by reference in their entirety.
The field of the invention is that of compositions based on actinide powder, and which have the advantage of being injectable since they allow a rheology that is compatible with injection systems. One of the main fields of application may concern (but not exclusively) the manufacture of nuclear fuels (or more generally of actinide-based components/materials).
More generally, the present invention relates to the production of components with more or less complex shapes containing actinides, whether in metallic, oxide, carbide or even nitride form. The standard and industrial production of fuel currently and mainly proceeds via exploitation of powder metallurgy (based on the pressing of the constituent powders of components/fuels to be formed and the sintering of the compacts obtained after pressing).
However, the use of powder metallurgy induces a certain number of drawbacks and obstacles when it is desired to make components of complex shapes or when it is desired to have very good control of the size of the components (and all the more so when these components are of complex shapes) to be produced, without the need for a rectification step.
Currently, the manufacture of nuclear fuels (actinide compounds) is typically performed via standard processes based on the metallurgy of powders. Two major steps are exploited to do so:
This type of process is proven and industrial, but induces at least four types of drawbacks:
To act on all of these drawbacks, the Applicant proposes filled compositions that make it possible to use a process known as powder injection molding (PIM).
However, in order for this type of process to be operative for the use of actinide powders, it is necessary to have available an organic matrix consisting of organic components, generally based on polymers that allow good (in the sense of homogeneous distribution) incorporation of the powder into said organic matrix. This organic matrix must satisfy all of the objective functions and constraints imposed by this type of process in the light of the specificities of the nuclear materials to be used and of the specifications of the targeted fuels.
At the present time, no formulation of organic matrix for preparing actinide components is mentioned in the technical and scientific literature. This may notably be explained by the number of constraints/criteria weighing on a filled organic matrix. These are to be taken into account for the use of actinide powders which have specific properties, and under satisfactory conditions (i.e. conditions making it possible to obtain components whose characteristics are at least equivalent to those obtained by powder metallurgy).
Thus, to satisfy this general problem of manufacturing actinide fuels/components via the PIM process in a satisfactory manner, it is necessary for the envisioned filled matrix to concomitantly satisfy the following criteria:
Specifically, when the PIM process is applied to actinide powders whose purpose is to result in objects whose characteristics are similar to those obtained by powder metallurgy, it is necessary after the step of debinding of the formed polymers to result in granular stacks that need to be cohesive, i.e. to keep their shape, and whose density is equivalent to that obtained by uniaxial powder pressing (powder metallurgy). A powder may be considered as cohesive if it notably satisfies the definition of Geldard (class C) or has a Hausner coefficient of greater than 1.4, “Techniques de l'ingenieur mise en forme des poudres, J 3 380-1”. To achieve this minimum filler content value, it is necessary for the powder, especially if it is cohesive, as is conventionally the case for actinide powders (and notably the oxides thereof), to be deagglomerated during the blending/preparation of the filler. This prerequisite is not trivial per se for the following reasons:
Given that actinides are moreover compounds that are reputed to promote the decomposition of the constituent carbon-based compounds of the filled matrix (cf. “The activity and mechanism of uranium oxide catalysts for the oxidative destruction of volatile organic compounds”, S. H. Taylor, C. S. Heneghana, G. J. Hutchingsa et al., Catalysis Today, 59:249-259, 2000; A study of uranium oxide based catalysts for the oxidative destruction of short chain alkanes, Applied Catalysis B: environmental, 25:137-149, 2000, S. H. Taylor et al.), this stability criterion of the properties is not trivial to achieve with, notably, either a risk of modification of the degree of oxidation of the actinides in contact with the constituent compounds of the matrix, or a risk of formation of non-debindable carbon-based residues (which may thus be disadvantageous at the end of the manufacture depending on the residual content) during the implementation of the PIM process;
These acceptability criteria for the filled matrix are to be respected concomitantly given, moreover, the targeted actinide fuels/components must have characteristics at least equivalent to those that may be achieved by powder metallurgy, i.e., notably:
All the criteria weighing directly on the filled matrix and those expected on the object that may be achieved by PIM of this same filler define a specific nontrivial problem that the present invention proposes to solve.
This is why one subject of the present invention is a set of filled compositions, which, despite the very specific and penalizing characteristics of the abovementioned actinide powders, allows a satisfactory implementation (in the sense of the abovementioned particular problem) of these powders in the PIM process.
One subject of the present invention is thus compositions filled with actinide which allow use in a standard process of injection molding type in order to obtain, after injection, debinding and sintering, components of complex, controlled geometries containing actinide compounds, having a microstructural quality equivalent to that which would have been obtained by standard powder metallurgy. Such formulations moreover allow the use of actinide powders currently used for the industrial manufacture of nuclear fuels, without particular preparation of the latter.
More specifically, one subject of the present invention is a composition filled with actinide powder comprising an organic matrix and an actinide powder or a mixture of actinide powders, characterized in that it comprises at least:
According to one variant of the invention, the polyolefinic polymer has a mean molar mass of at least 10 000 g/mol.
According to one variant of the invention, the polyolefinic polymer is polyethylene.
According to one variant of the invention, the polyolefinic polymer is polypropylene.
According to one variant of the invention, the polyolefinic polymer is polypropylene with a molar mass of greater than about 100 000 g/mol.
According to one variant of the invention, the plasticizer comprises paraffin. According to one variant of the invention, the plasticizer comprises polypropylene.
According to one variant of the invention, the plasticizer comprises polypropylene with a molar mass of about 10 000 g/mol.
According to one variant of the invention, the specific surface area of the grains of said actinide powder is between about 1 m2/g and 15 m2/g.
According to one variant of the invention, the tapped density of said actinide powder is between about 10% and 70% of the theoretical density of the powder compound(s).
According to one variant of the invention, the theoretical density of the constituent materials of the powder is between 2 and 20.
According to one variant of the invention, the theoretical density of the constituent materials of the powder is between 7 and 10.
According to one variant of the invention, the carboxylic acid or salts thereof have a molar mass at least equal to 100 g/mol.
According to one variant of the invention, the mass proportion of said carboxylic acid or salts thereof relative to the mass of actinide powders is between about 0.01% and 1% by mass.
The invention will be understood more clearly and other advantages will emerge more clearly on reading the description that follows, which is given without any limitation, and by means of the attached figures, among which:
In general, the filled compositions of the present invention are intended to provide actinide fillers that have satisfactory properties and that allow implementation according to the PIM process described below and illustrated by the steps summarized in
In a first step 1, corresponding to the mixing and blending of the starting materials, all of the starting materials are mixed together, namely, in the present invention: the organic matrix Morg comprising the plasticizer, the binder, the dispersant, and the filler based on actinide powder Pi. As regards the procedure, the powder is generally added gradually to the mixture of the other heated starting materials using a blender, which may be equipped with paddles making it possible to obtain high shear rates, thus ensuring homogeneity of the whole.
In a second step 2, the step of injection molding may be performed as follows: the fluid filled matrix obtained previously is placed in an injection press. The injection cycle then proceeds in the following manner: the material placed in the injection press hopper arrives in the sheath which is heated to a suitable temperature and is then conveyed via an endless screw to the injection nozzle connected to the mold having the desired shape. Once the material has been metered out (volume linked to that of the component to be injected), the screw stops turning and the mold is filled under pressure (the screw acts as a piston). The mixture is then compacted in the print during the maintenance under pressure. The component is then ejected when the mixture has sufficiently cooled (sufficient rigidity). The main parameters that govern this step are: the temperature of the starting materials, the temperature of the mold, the injection pressure and the injection speed.
The third step 3 corresponds to the debinding operation. Debinding is a key operation of the process, which consists in removing the organic materials from the filled matrix, once the component has been injected. The quality of this operation is fundamental so as not to cause any physical damage (cracks) or chemical damage (carbidation) in the component. A very large proportion of the defects that appear after sintering is generated by inadequate debinding.
The fourth step 4 corresponds to the sintering operation. Once the debinding step has been completed, the component must be consolidated by a sintering step. Sintering is a thermal process which makes it possible, by heating compacted powders, generally below their melting point, to give them cohesion after cooling and to obtain the desired microstructure of the final material. The principle of sintering is based on atomic scattering: particles in contact weld via atomic transport phenomena via scattering if they are subjected to temperatures higher than half of their absolute melting point so as to obtain a finished object OF.
Examples of Filled Compositions Used in the Present Invention:
In order to demonstrate the possibility of using the compositions of the present invention in a satisfactory manner, in the sense of the abovementioned problem, several filled compositions comprising a plasticizer, a binder and a dispersant as described in the present invention with an actinide powder reputed to be cohesive were prepared, with industrial uranium oxide powders.
Since one of the main difficulties induced by the use of actinide powders in the PIM process is linked to the cohesive nature of this type of powder, the example of powder used for the illustration of the present invention is representative of this characteristic. To do this, uranium oxide powder was used, the crystallites of which (constituent elemental objects of the powder) are grouped into aggregates, which are themselves lumped into agglomerates.
The main characteristics of the powder mainly used for the illustration of the present invention are given below:
Various filled composite compositions according to the invention collated in Table 1 below were studied:
Table 2 above gives examples of operating conditions under which the compositions of the present invention were prepared.
The present description gives below the elements for illustrating the achievement of the numerous acceptability criteria for the filled compositions described, notably with regard to the problem of the present invention.
Injectability and Filler Content in Filled Compositions According to the Invention:
In the light of the shear viscosity values for these formulations, it is possible to indicate that these filled compositions are indeed acceptable with respect to the rheology criterion, despite a relatively large filler content, since it is between 50 and 10 000 Pa·s.
It should be noted that these formulations also make it possible to deagglomerate cohesive powders, as shown by
CR15: ground alumina powder with a specific surface area of 15 m2/g;
CR30: ground alumina powder with a specific surface area of 30 m2/g;
GE15: non-ground alumina powder with a specific surface area of 15 m2/g.
Stability of the Properties of the Filled Compositions According to the Invention:
The preceding three filled compositions were moreover evaluated during a debinding operation and these results were compared with theoretical results.
This target stability is also confirmed by the comparison of the melting points of the various constituents when they are taken individually or as a mixture as represented in Table 3 below.
An example of a thermal cycle that may be used under an atmosphere of argon and hydrogen in the debinding process is illustrated in
Differential thermal analysis (DTA) is a method used for determining the temperatures corresponding to changes in the material as a function of the thermal treatment. It consists in measuring the temperature difference between a sample (Te) and a reference (Tr) (thermally inert material) as a function of time or temperature, when they are subjected to a programmed temperature variation, under a controlled atmosphere.
In general, the phase transitions and the evaporation of solvents are reflected by endothermic peaks. On the other hand, crystallization, oxidation and certain decomposition reactions are characterized by exothermic peaks. DTA is generally associated with a thermogravimetric analysis (TGA) which makes it possible to measure the variation of a mass of a sample as a function of the thermal treatment temperature. This mass variation may be a loss of mass such as the emission of vapors or a gain of mass during the fixing of a gas, for example.
The curves of these figures do not show any exothermicity peaks or any notable event other than phenomena of melting and of degradation/volatilization of the filled matrix constituents, which confirms the stability of these formulations.
These measurements are reinforced in their conclusion by the XRD measurements, which were taken at the end of the process for producing the powders and thus after the sintering operation.
Debinding Capacity of the Filled Compositions According to the Invention:
As regards the debinding capacity criterion, it is necessary for the debinding operation to be able to be performed while conserving the integrity of the component once the forming polymers have been debonded and without an excessive proportion of carbon-based residues that would not be removable during sintering and that might moreover modify the microstructure of the sintered actinide material.
To demonstrate the acceptability of the examples of filled compositions Fa, Fb and Fc with respect to this criterion, Table 4 below gives the percentages of carbon-based residues in the components obtained from sintering with an illustration of the shape of the TGA signal for the Fa formulation sintered under oxidation:
After sintering, the components moreover have controlled geometry and microstructure as illustrated in
Number | Date | Country | Kind |
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12 54327 | May 2012 | FR | national |
Filing Document | Filing Date | Country | Kind |
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PCT/EP2013/059438 | 5/7/2013 | WO | 00 |
Publishing Document | Publishing Date | Country | Kind |
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WO2013/167563 | 11/14/2013 | WO | A |
Number | Name | Date | Kind |
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4056584 | Miertschin et al. | Nov 1977 | A |
20070053785 | Hetz | Mar 2007 | A1 |
Number | Date | Country |
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1757896 | Feb 2007 | EP |
2286476 | Apr 1976 | FR |
881883 | Nov 1961 | GB |
2000328103 | Nov 2000 | JP |
Entry |
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Copending U.S. Appl. No. 14/399,959, filed Nov. 9, 2014. |
Stuart H. Taylor, et al., “The Activity of Mechanism of Uranium Oxide Catalysts for the Oxidative Destruction of Volatile Organic Compounds”, Catalysis Today, 2000, pp. 249-259, Elsevier Science B.V. |
Stuart H. Taylor, et al., “A Study of Uranium Oxide Based Catalysts for the Oxidative Destruction of Short Chain Alkanes”, Applied Catalysis B: Environmental, 2000, pp. 137-149, vol. 25, Elsevier Science B.V. |
Number | Date | Country | |
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20150126660 A1 | May 2015 | US |