Sting33 said:
In a nuclear reaction, it is my understanding that mass is converted to energy.
This is not the same as matter being converted to light. There are many nuclear reactions that have matter particles as both reactants and reaction products, but still convert mass to energy (the energy shows up as the kinetic energy of the reaction products). See further comments below.
Sting33 said:
It is also my understanding that as matter approaches the speed of light it's mass approaches infinity. If that is so, why is the mass of light itself zero?
You're confusing two different concepts that go by the name "mass".
One is "rest mass" or "invariant mass" (the latter is a better name for reasons which will appear in a moment). Ordinary objects, and matter particles like electrons, have nonzero invariant mass; light has zero invariant mass. (The case of light illustrates why "rest mass" is not a good name: light always moves at the speed of light, so it's never at rest, but it still has a well-defined invariant mass of zero.)
The other is "relativistic mass", which is really just total energy. This is the "mass" that increases without bound as an ordinary object, or a matter particle like an electron, approaches the speed of light. The term "relativistic mass" is out of favor now among physicists because, first, it causes confusion, and second, we don't need it because we already have a perfectly good word, "energy", for the same concept. (Note that light itself also has energy, but the concept of "relativistic mass" is never applied to light; we just talk about its energy.)
Sting33 said:
I suppose what I am trying to figure out is what physical process takes place at the instant mass is converted to energy?
When people talk about this happening, as in the nuclear reactions you referred to, what they mean is that the sum of the invariant masses of the reactants is greater than the sum of the invariant masses of the reaction products. The difference shows up as energy in the reaction products; this energy can appear as kinetic energy of matter particles in the reaction products, or it can appear as electromagnetic radiation such as gamma rays, or both. The physical process involved is just whatever nuclear reaction is taking place: particles interact with each other to form other particles.