Abstract: The process includes hot-forming a large diameter Zircaloy ingot to a flat plate having longitudinal, transverse and depth dimensions and forming blanks in a transverse direction from the flat plate for ultimately forming the end plugs of a nuclear fuel rod. The axis of the end plugs is generally transverse to the longitudinal dimensions of the flat plate whereby centerline defects in the blank are reduced or eliminated. To the extent centerline defects occur, they lie generally transverse to the axis of the end plug whereby the defects are rendered ineffective to form leakage paths through the end plugs.