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Zirconolite‐rich full ceramic wasteforms designed to immobilize Pu‐bearing wastes were produced via hot isostatic pressing (HIP) using stainless steel (SS) and nickel (Ni) HIP canisters. A detailed profiling of the elemental compositions of the major and minor phases over the canister–wasteform interaction zone was performed using scanning electron microscopy combined with energy‐dispersive X‐ray spectroscopy (SEM‐EDS) characterization. Bulk sample analyses from regions near the center of the HIP canister were also conducted for both samples using X‐ray diffraction and SEM‐EDS. The sample with the Ni HIP canister showed almost no interaction zone with only minor diffusion of Ni from the inner wall of the canister into the near‐surface region of the wasteform. The sample with the SS HIP canister showed ∼100–120 μm of interaction zone dominated by high‐temperature Cr diffusion from canister materials to the wasteform with the Cr predominantly incorporated into the durable zirconolite phase. We also examined, for the first time, changes to the HIP canister wall thickness caused by HIPing and demonstrated that no canister wall thinning occurred. Instead, in the areas examined, the canister wall thickness was observed to increase (up to ∼20%) due to the compression occurring during the HIP cycle. Further, only sparse formation of (Cr, Mn)‐rich oxide particles were noted within the HIP canister inner wall area immediately adjacent to the ceramic material, with no evidence for reverse diffusion of ceramic materials. Though the HIP canister–wasteform interaction extends to ∼120 μm when using an SS HIP canister for the system investigated, this translates to <<1 vol.% for an industrial scale HIPed wasteform. Importantly, the HIP canister–wasteform interactions did not produce any obviously less durable phases in the wasteform or had any detrimental impact on the HIP canister properties. [ABSTRACT FROM AUTHOR]

As potential waste forms for immobilizing actinide‐rich radioactive wastes, Eu2Ti2O7 (Eu as a surrogate for minor actinides) pyrochlore glass‐ceramics were fabricated via hot isostatic pressing (HIPing) at 1200°C. The structure and microstructure at the reaction interface between the glass‐ceramic waste form and the stainless steel (SS) canister under HIPing conditions were carefully investigated with scanning electron microscopy (SEM), transmission electron microscopy (TEM), and synchrotron single crystal X‐ray diffraction (SC‐XRD). The interactions at the reaction interface led to the formations of a ~10‐µm‐thick Cr2O3 layer as the oxidation front of the SS and a layer of a mixed oxide phase (Eu1.25SiCr0.8Ti1.2O7.5) on the glass‐ceramic side of the reaction interface. The crystal structure of such a unique mixed oxide phase was revealed indubitably with a combination of synchrotron SC‐XRD and TEM assisted with a focused ion beam (FIB) SEM system. The improved structural understanding of the reaction interface will help to support the utilization of HIPing as a versatile hot consolidation process for the treatment of radioactive wastes. [ABSTRACT FROM AUTHOR]

Since the end of the 1970s, Synroc at the Australian Nuclear Science and Technology Organisation (ANSTO) has evolved from a focus on titanate ceramics directed at PUREX waste to a platform waste treatment technology to fabricate tailored glass-ceramic and ceramic waste forms for different types of actinide, highand intermediate level wastes. The particular emphasis for Synroc is on wastes which are problematic for glass matrices or existing vitrification process technologies. In particular, nuclear wastes containing actinides, notably plutonium, pose a unique set of requirements for a waste form, which Synroc ceramic and glass-ceramic waste forms can be tailored to meet. Key aspects to waste form design include maximising the waste loading, producing a chemically durable product, maintaining flexibility to accommodate waste variations, a proliferation resistance to prevent theft and diversion, and appropriate process technology to produce waste forms that meet requirements for actinide waste streams. Synroc waste forms incorporate the actinides within mineral phases, producing products which are much more durable in water than baseline borosilicate glasses. Further, Synroc waste forms can incorporate neutron absorbers and 238U which provide criticality control both during processing and whilst within the repository. Synroc waste forms offer proliferation resistance advantages over baseline borosilicate glasses as it is much more difficult to retrieve the actinide and they can reduce the radiation dose to workers compared to borosilicate glasses. Major research and development into Synroc at ANSTO over the past 40 years has included the development of waste forms for excess weapons plutonium immobilization in collaboration with the US and for impure plutonium residues in collaboration with the UK, as examples. With a waste loading of 40-50 wt.%, Synroc would also be considered a strong candidate as an engineered waste form for used nuclear fuel and highly enriched uranium-rich wastes. [ABSTRACT FROM AUTHOR]

Graphical abstract Both Y 2 Ti 2 O 7 and Gd 2 Ti 2 O 7 pyrochlore glass-ceramics have been prepared with a typical oxide route and consolidated via hot isostatic pressing, and characterized as potential waste forms for the immobilization of actinide-rich radioactive wastes. Abstract Both Y 2 Ti 2 O 7 and Gd 2 Ti 2 O 7 pyrochlore glass-ceramics (GCs) have been prepared with an oxide route and consolidated via hot isostatic pressing (HIPing) as waste forms for actinide immobilization. The crystallization of Y 2 Ti 2 O 7 /Gd 2 Ti 2 O 7 pyrochlore as the major actinide host phase in the residue glass has been confirmed with XRD, SEM-EDS and Raman spectroscopy. The static leaching tests confirmed that both GCs are chemically durable with normalized Y/Gd and Ti leach rates ∼10−4–10-5 g m-2 d-1 after 28 days. In addition, the interactions between the 316L stainless steel (SS) HIP-can and the GCs have been investigated. Interactions occur at the interface with a layer of mixed Cr/Ti oxide and CrTi 2 O 5 crystals observed for the Y 2 Ti 2 O 7 GC and a layer (∼10 μm) of Cr 2 O 3 observed for the Gd 2 Ti 2 O 7 GC as the reaction fronts from the SS cans. Furthermore, a layer (∼10 μm) of Gd-(Si/Ti)-oxide phase formed on the GC side of the interface. [ABSTRACT FROM AUTHOR]