Methods of fabricating metallic fuel from surplus plutonium

A method of fabricating metallic fuel from surplus plutonium may include combining (102) plutonium oxide powder and uranium oxide powder to obtain a mixed powder with reduced proliferation potential. The mixed powder may be electroreduced (104) in a bath of molten salt so as to convert the mixed powder to a first alloy. The first alloy may be pressed (110) to remove a majority of the molten salt adhered to the first alloy to form a pressed alloy-salt mixture. The first alloy may be isolated (112) from the salt by melting the pressed alloy-salt mixture. The first alloy may be further processed to fabricate a fuel rod. Accordingly, the metallic fuel produced may be used in a fast reactor system, such as a Power Reactor Innovative Small Module (PRISM).