Fabrication Technology of Metallic Nuclear Fuel Rods under Extreme Conditions: Research Progress in Material Innovation and Process Optimization

WANG Yan; ZHOU Yisong; XIE Xufeng; HU Hongjun; ZHONG Tao

doi:10.3969/j.issn.1674-6457.2026.06.021

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Journal of Netshape Forming Engineering ›› 2026, Vol. 18 ›› Issue (6) : 228-259. DOI: 10.3969/j.issn.1674-6457.2026.06.021

Refractory Metal Forming

Fabrication Technology of Metallic Nuclear Fuel Rods under Extreme Conditions: Research Progress in Material Innovation and Process Optimization

WANG Yan¹, ZHOU Yisong¹, XIE Xufeng¹, HU Hongjun^1,*, ZHONG Tao^2,*

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Abstract

As the global energy structure transitions toward low-carbonization, nuclear energy has emerged as a critical energy source owing to its high energy density and low-carbon emission characteristics. As the core component of nuclear reactors, nuclear fuel directly affects reactor efficiency and reliability in terms of its performance and safety. This paper systematically reviews the research status and challenges of fabrication and processing technologies for metallic nuclear fuel rods, and introduces the development and application of nuclear fuel pellets and cladding materials, pellet-cladding interaction, as well as advanced fabrication processes. Studies indicate that metallic fuels are generally uranium-based, in which alloying elements exert significant effects on microstructural evolution and phase stability. Tight coupling between pellets and cladding may influence their mutual interaction. In terms of fabrication processes, casting is commonly adopted in preliminary stages; co-extrusion enables efficient forming of multilayer structures yet requires further optimization of process parameters and improvement of interfacial bonding performance; rolling technology is widely applied to fabricate high-quality metallic fuel components. For cladding materials, zirconium alloys remain the dominant choice due to their low neutron absorption cross section and excellent corrosion resistance, whereas issues such as high-temperature hydrogen embrittlement and oxidation need urgent solutions. Innovative cladding materials including silicon carbide (SiC) exhibit accident-tolerant potential, yet their radiation resistance requires further enhancement. Within the pellet-cladding interaction mechanism, chemical diffusion and thermal stress mismatch are the primary causes of interfacial failure, which requires process optimization via diffusion barrier design and material matching. Current research on surface modification is continuously advancing, and additive manufacturing technologies provide new approaches for fabricating fuels with complex structures.

Key words

nuclear fuel / metallic fuel / cladding material / co-extrusion / irradiation effects

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WANG Yan, ZHOU Yisong, XIE Xufeng, HU Hongjun, ZHONG Tao. Fabrication Technology of Metallic Nuclear Fuel Rods under Extreme Conditions: Research Progress in Material Innovation and Process Optimization[J]. Journal of Netshape Forming Engineering. 2026, 18(6): 228-259 https://doi.org/10.3969/j.issn.1674-6457.2026.06.021

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Funding

Major Project of Science and Technology Research Project of Chongqing Municipal Education Commission (KJZD-M202501105); Project of Enhancing the Basic Ability of Scientific Research of Young and Middle-aged Teachers in Guangxi Colleges and Universities (2025KY1333); Graduate Innovation Project of Chongqing University of Technology (gzlcx20253112, gzlcx20253100)