The nonfissile uranium-238 can be converted to fissile plutonium-239 by the following nuclear reactions:

In this equation, uranium-238, through the absorption of a neutron (n) and the emission of a quantum of energy known as a gamma ray (γ), becomes the isotope uranium-239 (the higher mass number reflecting the presence of one more neutron in the nucleus). Over a certain period of time (23.5 minutes), this radioactive isotope loses a negatively charged electron, or beta particle (β^-); this loss of a negative charge raises the positive charge of the atom by one proton, so that it is effectively transformed into the element neptunium (Np; with an atomic number of 93, one more than uranium). Neptunium-239 in turn undergoes beta decay, being transformed into plutonium-239 (atomic number 94).

Uranium and plutonium are recovered from irradiated nuclear fuel through the widely practiced plutonium-uranium extraction, or Purex, process. In this solvent-extraction process, the fuel cladding encasing nuclear fuel elements (typically made of aluminum, magnesium, or zirconium alloys) is removed either chemically or mechanically, and the metal or oxide fuel is dissolved in nitric acid. Plutonium and uranium are then coextracted into a tributyl phosphate solution, while practically all the fission products and nonradioactive components are left in the aqueous raffinate. The loaded organic extract is contacted with an aqueous phase containing any of several possible reductants to separate the plutonium from the uranium, and uranium is stripped from the tributyl phosphate solution into a dilute nitric acid solution. Additional extraction-strip cycles are performed as needed with the separated uranium and plutonium streams in order to complete purification from each other and from traces of coextracted fission-product zirconium and ruthenium.

Purified uranium nitrate is calcined to an oxide (either UO₃ or U₃O₈) for subsequent conversion to UF₆ and enrichment of the uranium-235 content, as described above. Purified plutonium nitrate is converted to plutonium dioxide (PuO₂) either for conversion to plutonium metal (weapons-grade plutonium) or for recycling into nuclear reactor fuel. Like uranium, metallic plutonium is usually obtained by high-temperature reduction of a halide salt (plutonium tetrafluoride or plutonium trifluoride) with calcium metal. Much use is also made of the so-called direct oxidation-reduction process, whereby PuO₂ is reduced with calcium metal to plutonium metal and a calcium oxide slag:

Reactor-grade uranium

Uranium metal intended for use in production reactors to produce plutonium-239 is rolled into round billets typically 23 centimetres (9 inches) in diameter and 51 centimetres long. Metallic uranium fuel elements for power reactors are prepared by hot extrusion of the uranium into tubing made of Zircaloy, a corrosion-resistant alloy of zirconium and tin. Uranium fuel elements can also be clad in alloys of magnesium and aluminum.

Uranium reacts with a large variety of other metals to form intermetallic compounds, solid solutions, or (in a few instances) true alloys. Many of these systems have been exploited to prepare reactor fuels that possess increased resistance to in-reactor corrosion and radiation damage as well as greater mechanical strength than pure uranium metal. Examples include low-enrichment uranium-molybdenum and uranium-aluminum alloys.

Even though uranium and plutonium are completely miscible, the plutonium-uranium system is not suitable for nuclear applications. As described above, uranium exists in three crystal structures between ambient temperature and its melting point of 1,132° C (2,070° F). Plutonium metal undergoes five phase transformations below its melting temperature of 640° C (1,183° F). Transformation from one phase to the next occurs no matter what the concentration of either element, thereby preventing use of plutonium-uranium alloys over a major temperature range. However, the addition of zirconium—for example, in a fuel containing 20 percent plutonium, 10 percent zirconium, and 70 percent uranium—can yield a metallic system completely adaptable to reactor use.

Depleted uranium

Uranium fuel elements can be sheathed in a metallic blanket containing, for example, 10 percent zirconium and 90 percent uranium depleted of its uranium-235 content. The depleted uranium, consisting almost completely of uranium-238, captures neutrons that are emitted in the fission of the fuel elements, thus producing (or “breeding”) plutonium-239 simultaneous with the generation of nuclear power.

Certain alloys of depleted uranium are also used in armour for tanks and other military vehicles. Because of its very high density, uranium metal is well suited for this purpose as well as for armour-piercing projectiles.

Oxide fuels

Pellets made of low-enrichment UO₂ are universally employed as fuel in commercial light-water reactors that produce electrical energy. The pellets are made by blending appropriate quantities of enriched and natural or depleted UO₂ powders, mechanically compacting them, adding an organic binder, pressing into pellets, heating to burn off the binder, and finally sintering at high temperature to 95 percent theoretical density. Fuel pins are fabricated by loading the pellets into a Zircaloy tube.

Similar procedures are employed to fabricate mixed uranium-plutonium dioxide (MOX) pellets for use in fast-neutron breeder reactors. Unirradiated MOX fuel typically contains 20 to 35 percent plutonium dioxide.

Carbide fuels

Various uranium and plutonium carbides are known, including the monocarbides (UC, PuC), the sesquicarbides (U₂C₃, Pu₂C₃), and the dicarbides (UC₂, PuC₂). Because they are highly refractory, these compounds have been much investigated for use as fuels for nuclear reactors. For example, the fuel in the high-temperature gas-cooled reactor (HTGR) consists of highly enriched uranium, together with thorium as a fertile material; each is in the form of carbide pellets embedded in a dense form of graphite.

Nitride fuels

Uranium forms a mononitride (UN) and two higher nitride phases (alpha- and beta-sesquinitrides; α = U₂N₃ and β = U₂N₃), whereas plutonium forms only a mononitride. Both uranium and plutonium nitrides are brittle, refractory compounds that melt at temperatures generally above 2,000° C (3,600° F). This latter property makes the mononitrides attractive as possible high-performance nuclear reactor fuels.