A-1 APPENDIX 0-Physical and Chemical Characterization Results for the Cladding. B-1 APPENDIX C-Characterization Results for Graphite Coating. . C-1 APPENDIX D-Physical and Chemical Characterization,Results for the Fuel D-1 APPENDIX E-Physical and Chemical Characterization Results for the Alumina 1nsula.tor Pellets .

LEGAL DISCLAIMER This report was prepared as an account of work sponsored by an agency of theUmted States Government. Nmtherthe Um_ed States Government nor any agency mereof, nor any of the+r employees, nor any of the+r contractors, subcontractors or their employees, makes any warranty, express or implied, or assumes any legal liability or respons_b_l+tyfor me accuracy, completeness, or any third party's use or the results of such use of any _nformation, apparatus, _roduct, or process disclosed, or represents that its use would not _nfringe privately ownedrtghts. Reference hereunto anyspec_fic commercial product, _rocess, c, serwce by trade name, trademark, manufacturer, or otherwtse, does not necessar=ly const,tute or =reply =tsendorsement, recommenc!at=on, or favoring 0y the United Sta_es Government or any agency thereof orqtscontractorso_ sut_contractots. Thewews and opinions of authors expressec here_n do not necessarily state or reflect those of the Untted Slates Government or any agency thereof. Thts report has been reproclucecl from the best avatlable copy. Avadable in paper copy and mLcroficne.

Viii D. 10 Typical Annular Pellet with Enrichment Symbol D-35 D.11 Axial Section of an Annular Pellet D-36 D. 12 Microstructure of a Polished FPIP-001, Revision 0 Annular Pellet D-36 D. 13 Microstructure of an Etched FPIP-001, Revision 0 Annular Pellet D-38 D.14 Microstructure of a Polished FPIP-001, Revision 1 Annular Pellet D-39 D. 15 Microstructure of an Etched FPIP-001, Revision 1 Annular Pellet D-40 D.16 Microstructure of a Polished FPIP-001, Revision 2 Annular Pellet D-41 D.17 Microstructure of an Etched FPIP-001 Revision 2 Annular Pellet D-42

The Exxon Nuclear Company, Inc. acting as a Subcontractor to EG &G Idaho Inc., Idaho National Engineering Laboratory, Idaho Falls, Idaho, has developed a welding process to attach titanium sheathed thermocouples to the outside of the zircaloy clad fuel rods.The fuel rods and thermocouples are used to test simulated loss -of-coolant-accident (LOCA) conditions in a pressurized water reactor (LOFT Reactor, Idaho National Laboratory).The design goals were to (1) reliably attach thermocouples to the zircaloy fuel rods, (2) achieve or exceed a life expectancy of 6,000 hours of reactor operation in a borated water environment of 316 °C at 2240 psi, (3) provide and sustain repeatable physical and metallurgical properties in the instrumented rods subjected to transient temperatures up to 1538 °C with blowdown, shock, loading, and fast quench.A laser beam was selected as the optimum welding process because of the extremely high energy input per unit volume that can be achieved allowing local fusion of a small area irrespective of the difference in material thickness to be joined.A commercial pulsed laser and energy control system was installed along with specialized welding fixtures.Laser room facility requirements and tolerances were established. Performance qualifications and detailed welding procedures were also developed. Product performance tests were conducted to assure that engineering design requirements could be met on a production basis.Irradiation tests showed no degradation of thermocouples or weld structure. Fast thermal cycle and heater rod blowdown reflood tests were made to subject the weldments to high temperatures, high pressure steam, and fast water quench cycles.From the behavior of these tests, it was concluded that the attachment welds would survive a series of reactor safety tests.

Pacifrc Northwest Laboratory fiiSTWUmw Of im; mwm fs mim9 N O I I C L this report was prepared as an account of work sponsored by thn i nirea iiaies Government Neither the United States nor the Department of Energy nor any of their employees, nor any of their contractors, subcontractors, or their employees, makes any warranty , express or implied, or assumes any legal liability or responsibility for the accuracy, completeness or usefulness of anv information apparatus product or process disclosed or represents that its use would not infringe privately owned ri ' The vl('v^s opinion^ and conclusions conlainr u in uus report ari.M i "-e oi me conn actor ana ao not ncttss iriiy lepresenl