Resistance Welding – Preferred Technique for Appendage Welding in PHWR Fuel Manufacturing

Abstract

Nuclear Fuel Complex (NFC) at Hyderabad is the sole supplier of nuclear fuel bundles for all the PHWRs and BWRs currently operating in India and is the world’s largest producer of PHWR fuel bundles. Empty tube resistance welding technique is used extensively for welding tiny Zircaloy-4 appendages and fuel tubes. On an average, about two lakh tubes per month are being appendage resistance welded successfully at NFC. A comprehensive study on the robustness of this welding process has been carried out in this paper and the findings demonstrate the process as a highly reliable technique with consistent product quality.