SEARCH · Search NASA

Results for “nuclear cladding”

Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

SourceResearch connectionFrom yearThrough year

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 343 records · Page 19

All sources NASA NTRS DOE OSTI

DOE OSTI2019

Characterization of PVD Cr, CrN, and TiN coatings on SiC

SiC ceramic matrix composites are a potential replacement for current light water nuclear reactor fuel cladding material. However, loss of fission gas via micro-cracks and corrosion remain an issue. Cathodic arc Cr, CrN, and TiN coatings were deposited on SiC tubes and plates to provide hermeticity and corrosion resistance. These coatings were characterized to determine as-deposited quality. Cross-sectional microscopy, X-ray diffraction, glow discharge optical emission spectroscopy, and scratch tests were performed to evaluate the purity, structure, and mechanical performance of the coatings. Nitride coatings had stable interfaces, but larger defects in the coatings as compared to the Cr coatings which showed cracking at the interface, but less deposition-induced defects. Despite the local state of the interface, the mechanical properties of the metallic coatings versus ceramic coatings enabled the Cr coatings to resist loads three times that of the nitride coatings during scratch tests. Finally, glow-discharge optical emission spectroscopy showed that improvement in elemental purity is needed for future coatings.

36 MATERIALS SCIENCE↗

DOE OSTI2018

Completion of a Chlorination Test Using 250 grams of High-Burnup Used Fuel Cladding from a North Anna Pressurized Water Reactor

A second large -scale chlorination test was completed in February 2017 by chlorinating 250 g of used nuclear fuel (UNF) cladding from a North Anna pressurized water reactor (PWR). Analytical results and a Zr mass balance from this test are described and compared with previous results obtained by the Zirconium Recovery and Recycle Project.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2016

Capture of Tritium Released from Cladding in the Zirconium Recycle Process

Zirconium may be recovered from the Zircaloy® cladding of used nuclear fuel (UNF) for recycle or to reduce the quantities of high-level waste destined for a geologic repository. Recovery of zirconium using a chlorination process is currently under development at the Oak Ridge National Laboratory. The approach is to treat the cladding with chlorine gas to convert the zirconium in the alloy (~98 wt % of the alloy mass) to zirconium tetrachloride. A significant fraction of the tritium (0–96%) produced in nuclear fuel during irradiation may be found in zirconium-based cladding and could be released from the cladding when the solid matrix is destroyed by the chlorination reaction. To prevent uncontrolled release of radioactive tritium to other parts of the plant or to the environment, a method to recover the tritium may be required. The focus of this effort was to (1) identify potential methods for the recovery of tritium from the off-gas of the zirconium recycle process, (2) perform scoping tests on selected recovery methods using nonradioactive gas simulants, and (3) select a process design appropriate for testing on radioactive gas streams generated by the engineering-scale zirconium recycle demonstrations on radioactive used cladding.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2016

Capture of Tritium Released from Cladding in the Zirconium Recycle Process

This report is issued as the first revision to FCRD-MRWFD-2016-000297. Zirconium may be recovered from the Zircaloy® cladding of used nuclear fuel (UNF) for recycle or to reduce the quantities of high-level waste destined for a geologic repository. Recovery of zirconium using a chlorination process is currently under development at the Oak Ridge National Laboratory. The approach is to treat the cladding with chlorine gas to convert the zirconium in the alloy (~98 wt % of the alloy mass) to zirconium tetrachloride. A significant fraction of the tritium (0–96%) produced in nuclear fuel during irradiation may be found in zirconium-based cladding and could be released from the cladding when the solid matrix is destroyed by the chlorination reaction. To prevent uncontrolled release of radioactive tritium to other parts of the plant or to the environment, a method to recover the tritium may be required. The focus of this effort was to (1) identify potential methods for the recovery of tritium from the off-gas of the zirconium recycle process, (2) perform scoping tests on selected recovery methods using non-radioactive gas simulants, and (3) select a process design appropriate for testing on radioactive gas streams generated by the engineering-scale zirconium recycle demonstrations on radioactive used cladding.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2025

INL_intern_poster_RashedA

Advanced nuclear reactors often operate at elevated temperatures, novel fuel with different chemical and thermal properties that may interact differently with cladding, new coolants (e.g., molten salt, liquid metal, or sodium) that are chemically aggressive, requires cladding materials with superior oxidation, corrosion, and creep resistance. Developing fuel cladding for advanced reactors is essential, as the cladding plays a critical role in reactor safety, performance, and longevity. In this study, innovative Non-Concentrated Alloys (NCAs) were developed as novel fuel cladding materials for advanced nuclear reactors. Multiple elements were chosen for the alloys. NCAs were manufactured and tested mechanically, showing promise with the arc-melting method, and setting a clear path for the next step of NCAs' development as a fuel cladding for advanced nuclear reactors.

36 - MATERIALS SCIENCE↗

DOE OSTI2016

R&D Progress on Recovery/Recycle of Zirconium from Used Fuel Cladding

There has been significant progress accomplished at Oak Ridge National Laboratory (ORNL) on the development of a dry chlorination process for recovery and purification of zirconium from used nuclear fuel (UNF) cladding by conversion to zirconium tetrachloride, which sublimes to a vapor and is then condensed as a dry salt product, essentially free of fuel and alloy components (impurities). We have accomplished significant progress on developing a chlorination process for removing the zirconium in UNF cladding and purifying the product salt for re-use—possibly in manufacture of new cladding, or at a minimum to meet specifications for disposal as low level waste.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2022

Report summarizing demonstration of thermal conductivity measurement methods for coated zirconium cladding

Thermal diffusivity measurements on Zirconium-based cladding materials have historically been a challenge due to the difficulty to measure on specimens with curved geometries, including nuclear grade Zircaloy cladding materials. In this work, we first used Laser Flash Analysis methods to measure the thermal diffusivity of Zircaloy tubes, which show good agreement with Zircaloy plates in this work, as well as previously published data. The consistent results proved the applicability of the Laser Flash Analysis setup for investigating thermal diffusivity of Zircaloy tubes. We further investigate the hydrogen effect on thermal diffusivity of Zircaloy tubes. Hydrogen plays significant roles in temperature dependent thermal diffusivity trends of Zircaloy tube. For low hydrogen concentration, where hydride dissolved into single phase α-Zr at higher temperature, thermal diffusivity is relatively unchanged at low temperature at two phase regions (α-Zr and δ-hydride), and it increases as a function of temperature at single phase α-Zr region. For high hydrogen concentration, where phase transformation (α-Zr + δ-hydride → α-Zr + β-Zr) occurs at 567 °C, thermal diffusivity decreases as a function of temperature below 567 °C before the transformation (α-Zr and δ-hydride), while increase at higher temperature after the transformation (α-Zr and β-Zr).

36 MATERIALS SCIENCE↗

DOE OSTI2014

Ferritic Alloys as Accident Tolerant Fuel Cladding Material for Light Water Reactors

The objective of the GE project is to demonstrate that advanced steels such as iron-chromium-aluminum (FeCrAl) alloys could be used as accident tolerant fuel cladding material in commercial light water reactors. The GE project does not include fuel development. Current findings support the concept that a FeCrAl alloy could be used for the cladding of commercial nuclear fuel. The use of this alloy will benefit the public since it is going to make the power generating light water reactors safer. In the Phase 1A of this cost shared project, GE (GRC + GNF) teamed with the University of Michigan, Los Alamos National Laboratory, Brookhaven National Laboratory, Idaho National Laboratory, and Oak Ridge National Laboratory to study the environmental and mechanical behavior of more than eight candidate cladding materials both under normal operation conditions of commercial nuclear reactors and under accident conditions in superheated steam (loss of coolant condition). The main findings are as follows: (1) Under normal operation conditions the candidate alloys (e.g. APMT, Alloy 33) showed excellent resistance to general corrosion, shadow corrosion and to environmentally assisted cracking. APMT also showed resistance to proton irradiation up to 5 dpa. (2) Under accident conditions the selected candidate materials showed several orders of magnitude improvement in the reaction with superheated steam as compared with the current zirconium based alloys. (3) Tube fabrication feasibility studies of FeCrAl alloys are underway. The aim is to obtain a wall thickness that is below 400 µm. (4) A strategy is outlined for the regulatory path approval and for the insertion of a lead fuel assembly in a commercial reactor by 2022. (5) The GE team worked closely with INL to have four rodlets tested in the ATR. GE provided the raw stock for the alloys, the fuel for the rodlets and the cost for fabrication/welding of the rodlets. INL fabricated the rodlets and the caps and welded them to provide hermetic seal. The replacement of a zirconium alloy using a ferritic material containing chromium and aluminum appears to be the most near term implementation for accident tolerant nuclear fuels.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2022

Analysis of inconel 600 oxidized under loss-of-coolant accident conditions: A multi-modal approach

Understanding the performance of cladding materials during a loss-of-coolant accident scenario is crucial for developing next-generation accident tolerant nuclear fuel rod claddings. We describe a multi-modal approach combining synchrotron-based diffraction, and Raman spectroscopy with nano-scale electron microscopy techniques for investigating oxidation of Inconel 600 (A600) in steam and air environments at 1200 °C for 2 h. We report that A600 exposed to steam develops a Cr 2 O 3 -enriched surface layer while a mixed phase oxide layer containing NiFe 2 O 4 , Cr 2 O 3 , Fe 3 O 4 and Fe (3–x) CrxO 4 is formed in air. Mechanism of oxidation for A600 in air and steam environments is discussed.

36 MATERIALS SCIENCE↗

DOE OSTI2022

Hydrogen effects on thermal diffusivity and electrical resistivity of zircaloy cladding

Thermal diffusivity measurements on Zirconium-based cladding materials have historically been a challenge due to the difficulty to measure on specimens with curved geometries, including nuclear grade Zircaloy cladding materials. Here, in this work, we first used laser flash analysis method and four-probe configuration method to measure the thermal diffusivity and electrical resistivity of Zircaloy tubes respectively, which show good agreement with Zircaloy plates in this work, as well as previously published data. The consistent results proved the applicability of the laser flash analysis setup and four-probe configuration method for investigating thermal diffusivity and electrical resistivity of Zircaloy tubes. We further investigated the hydrogen effect on thermal diffusivity and electrical resistivity of Zircaloy. Hydrogen plays significant roles in the thermal diffusivity of Zircaloy, which depends on the hydrogen concentration. For higher hydrogen contents (1130 and 1820 wppm in this work), where phase transformation (α-Zr + δ-hydride → α-Zr + β-Zr) occurs at 567 °C, thermal diffusivity decreases as a function of temperature at the α-Zr + δ-hydride phase regime, while increase at higher temperature at the α-Zr + β-Zr phase regime. For low hydrogen concentration, where hydride dissolved into α-Zr matrix phase at higher temperature, the thermal diffusivity is lower than non-hydrided Zircaloy-4 with similar temperature-dependent trends. Such observation demonstrates the hydrogen effects on reducing thermal diffusivity of α-Zr phase. Hydrogen increases the electrical resistivity of Zircaloy. Similar to thermal diffusivity results, the phase transformation causes a reversal of temperature-dependent trends in electrical resistivity results in Zircaloy-4 with higher hydrogen contents.

36 MATERIALS SCIENCE↗

DOE OSTI2016

R&D Plan for RISMC Industry Application #1: ECCS/LOCA Cladding Acceptance Criteria

The Nuclear Regulatory Commission (NRC) is finalizing a rulemaking change that would revise the requirements in 10 CFR 50.46. In the proposed new rulemaking, designated as 10 CFR 50.46c, the NRC proposes a fuel performance-based equivalent cladding reacted (ECR) criterion as a function of cladding hydrogen content before the accident (pre-transient) in order to include the effects of higher burnup on cladding performance as well as to address other technical issues. A loss of operational margin may result due to the more restrictive cladding embrittlement criteria. Initial and future compliance with the rule may significantly increase vendor workload and licensee costs as a spectrum of fuel rod initial burnup states may need to be analyzed to demonstrate compliance. The Idaho National Laboratory (INL) has initiated a project, as part of the DOE Light Water Reactor Sustainability Program (LWRS), to develop analytical capabilities to support the industry in the transition to the new rule. This project is called the Industry Application 1 (IA1) within the Risk-Informed Safety Margin Characterization (RISMC) Pathway of LWRS. The general idea behind the initiative is the development of an Integrated Evaluation Model (IEM). The motivation is to develop a multiphysics framework to analyze how uncertainties are propagated across the stream of physical disciplines and data involved, as well as how risks are evaluated in a LOCA safety analysis as regulated under 10 CFR 50.46c. This IEM is called LOTUS which stands for LOCA Toolkit for US, and it represents the LWRS Program’s response to the proposed new rule making. The focus of this report is to complete an R&D plan to describe the demonstration of the LOCA/ECCS RISMC Industry Application # 1 using the advanced RISMC Toolkit and methodologies. This report includes the description and development plan for a RISMC LOCA tool that fully couples advanced MOOSE tools already in development in order to characterize and optimize plant safety and operational margins. Advanced MOOSE tools that are needed to complete this integrated evaluation model are: RAVEN, RELAP-7, BISON, and MAMMOTH.

10CFR50.46C↗

DOE OSTI2012

Pre-irradiation testing and analysis to support the LWRS Hybrid SiC-CMC-Zircaloy-04 unfueled rodlet irradiation

Nuclear fuel performance is a significant driver of nuclear power plant operational performance, safety, economics and waste disposal requirements. The Advanced Light Water Reactor (LWR) Nuclear Fuel Development Pathway focuses on improving the scientific knowledge basis to enable the development of high-performance, high burn-up fuels with improved safety and cladding integrity and improved nuclear fuel cycle economics. To achieve significant improvements, fundamental changes are required in the areas of nuclear fuel composition, cladding integrity, and fuel/cladding interaction.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2013

Pre-Irradiation Testing and Analysis to Support the LWRS Hybrid SiC-CMC-Zircaloy-4 Unfueled Rodlet Irradiation

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2017

Use of multiscale zirconium alloy deformation models in nuclear fuel behavior analysis

Accurate prediction of cladding mechanical behavior is a key aspect of modeling nuclear fuel behavior, especially for conditions of pellet-cladding interaction (PCI), reactivity-initiated accidents (RIA), and loss of coolant accidents (LOCA). Current approaches to fuel performance modeling rely on empirical constitutive models for cladding creep, growth and plastic deformation, which are limited to the materials and conditions for which the models were developed. To improve upon this approach, a microstructurally-based zirconium alloy mechanical deformation analysis capability is being developed within the United States Department of Energy Consortium for Advanced Simulation of Light Water Reactors (CASL). Specifically, the viscoplastic self-consistent (VPSC) polycrystal plasticity modeling approach, developed by Lebensohn and Tomé [1], has been coupled with the BISON engineering scale fuel performance code to represent the mechanistic material processes controlling the deformation behavior of light water reactor (LWR) cladding. A critical component of VPSC is the representation of the crystallographic nature (defect and dislocation movement) and orientation of the grains within the matrix material and the ability to account for the role of texture on deformation. A future goal is for VPSC to obtain information on reaction rate kinetics from atomistic calculations to inform the defect and dislocation behavior models described in VPSC. The multiscale modeling of cladding deformation mechanisms allowed by VPSC far exceed the functionality of typical semi-empirical constitutive models employed in nuclear fuel behavior codes to model irradiation growth and creep, thermal creep, or plasticity. This paper describes the implementation of an interface between VPSC and BISON and provides initial results utilizing the coupled functionality.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗

DOE OSTI2022

Cold spray chromium coating for nuclear fuel rods

A zirconium alloy cladding tube for use in a water cooled nuclear reactor under normal operating conditions and under high temperature oxidation conditions is described. The cladding tube has a coating uniformly deposited thereon. The coating, which may be up to 300 microns thick, is selected from the group consisting of chromium, a chromium-based alloy, and combinations thereof.

36 MATERIALS SCIENCE↗

DOE OSTI2022

Investigation of γ - ( U , Z r ) structural properties and its interfacial properties with liquid sodium using ab initio molecular dynamics

In this study, the elastic properties, structural parameters, sound velocity, and Debye temperature of γ–(U,Zr) were computed using ab initio molecular dynamics (AIMD) at temperatures between 1000 K and 1400 K and for Zr content between 0 at. % and 100 at. %. UZr is used as a metallic fuel for Sodium Fast Reactors (SFRs). The study of the mechanical and thermal behavior of these alloys leads to a better data-informed fuel design. The bulk modulus, shear modulus, Young's modulus, and Poisson's ratio were calculated from the elastic constants and their dependence on Zr content and temperature was investigated, comparing the results with previous computational work and the available experimental data in the literature. Interfacial properties between UZr (up to 32 at. % which typically exists in nuclear fuel) and liquid sodium are also of interest due to the presence of a sodium bond between the fuel and the cladding in metallic nuclear fuel. The interfacial energy between γ–(U,Zr) and liquid sodium, the surface tension of liquid sodium, and the work of adhesion were computed at different temperatures and Zr concentrations. It was demonstrated that γ–(U,Zr) is completely wetted by liquid sodium at all the investigated temperatures and Zr concentrations. Finally, this work provides the basis for the determination of interfacial resistances in SFRs and their implementation into heat transfer fuel performance simulations, which will be the subject of future work.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2020

BWR Spent Nuclear Fuel Acquisition and Testing to Support DOE-NE High Burnup Spent Fuel Data Project

The Office of Spent Fuel and Waste Disposition (SFWD) within the US Department of Energy (DOE) Office of Nuclear Energy (NE) established the Spent Fuel and Waste Science and Technology (SFWST) campaign to conduct research and development (R&D) activities related to the storage, transportation, and disposal of spent nuclear fuel (SNF) and high-level radioactive waste. The SFWST program was created within SFWD to address issues of extended or long-term SNF storage and transportation. Some near-term objectives of SFWST are to use a science-based, engineering-driven approach to: Support the enhancement of the technical bases to support the continued safe and secure dry storage of SNF for extended periods; Support the enhancement of the technical bases for retrieving SNF after extended dry storage; Support the enhancement of the technical bases for transporting high burnup (HBU) fuel and transporting low burnup fuel and HBU fuel after dry storage DOE-NE, in partnership with the Electric Power Research Institute, developed the High Burnup Spent Fuel Data Project to perform a large-scale demonstration and laboratory-scale testing of HBU pressurized water reactor (PWR) fuels (exceeding 45 gigawatt-days per metric ton of uranium [GWd/MTU]). Under this project, 25 sister rods—which are rods that have the same design, power histories, and other characteristics—were removed from assemblies at the North Anna Nuclear Power Station and sent to Oak Ridge National Laboratory (ORNL) in January 2016. ORNL performed detailed nondestructive examination (NDE) on all 25 rods. The NDE consisted of visual examinations, gamma and neutron scanning, profilometry and rod length measurements, and eddy current examinations. After completing the NDE, 10 of the sister rods were delivered to Pacific Northwest National Laboratory (PNNL) in a NAC International, Inc. legal-weight truck cask in September 2018 for destructive examination (DE). To date, SFWD work has focused on the PWR fuel that is part of the Sister Rod Test program. No boiling water reactor (BWR) fuel has been tested in the program, and the data needs that were identified for the PWR fuel have not been collected for BWR fuel. The goal to obtain six to nine BWR rods and test them at ORNL will support closing this important data gap. BWR fuel comprises approximately 56% of the total fuel assemblies currently in storage at nuclear power plants in the United States. BWR nuclear fuel and cladding designs and manufacturing are significantly different from PWRs. Differences include the following: BWR fuel pellets are larger than PWR pellets; Variations of Zircaloy-2 (including liners) are used instead of the Zircaloy-4 cladding materials used in PWRs; Clad manufacturing and stress-relief processes are different between PWRs and BWRs; The fuel rod dimensions are different because larger rod diameters and thicker cladding are used in BWRs; BWR fuel typically has lower internal rod pressures and sees vastly different operating conditions than PWR fuel (i.e., two-phase flow); BWR assemblies are “canned,” meaning each assembly is surrounded by a metal fuel channel; BWR cladding is often composed of an inner pure Zr liner that has widely different mechanical properties than the Zircaloy-2 alloy and exhibits a stronger affinity for hydrogen; The BWR SNF generally has more total hydrogen in the cladding/liner than typical PWR fuel; The construction of the PWR and BWR assemblies is vastly different; BWR rods are solidly attached to the assembly nozzles and experience a much different vibration and shock load than PWR rods, which are “floating” within a grid system attached to guide tubes, and the rods sit loosely on the bottom end plates. These numerous differences will affect the way the BWR SNF responds under dry storage preparation processes (e.g., vacuum drying) and during transportation. The results collected in the PWR experimental program must be compared with a subset of similar data collected on BWR SNF to establish a technical basis for whether the larger PWR database is sufficient to bound the BWR SNF end-of-life conditions as is currently assumed for several fuel/clad properties. Changes that occur in both fuel types at HBU could exacerbate any mechanical property differences. As the fuel burnup increases, several changes occur that might affect the performance of the fuel, cladding, and assembly hardware in storage and transportation. These changes include increased cladding corrosion layer thickness, increased cladding hydrogen content, increased cladding creep strains, increased fission gas release, and the formation of the HBU structure at the surface of the fuel pellets. The Nuclear Regulatory Commission (NRC) limits the current maximum rod-averaged burnup to 62 GWd/MTU due to these changes and the lack of data at higher burnups.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2013

Irradiation of SiC Clad Fuel Rods in the HFIR

During 2009 and- 2010, new test capability for the High Flux Isotope Reactor (HFIR) at Oak Ridge National Laboratory (ORNL) was developed that allows testing of advanced nuclear fuels and cladding under prototypic light-water-reactor (LWR) operating conditions (i.e., cladding and fuel temperatures, fuel average linear heat generation rates, and cladding fluence). For the initial experiments for this test program, ORNL teamed with commercial fuel/cladding vendors who have developed an advanced composite-wound SiC cladding material for possible use in LWRs. The first experiment, containing SiC-clad UN fuel, was inserted in HFIR in June 2010, and the second experiment, containing SiC-clad UO2 fuel, was inserted in October 2010. Two capsules (one containing UN fuel and the other UO2) were withdrawn from their respective assemblies in November 2011 at an estimated fuel burnup of approximately 10 GWd/MTHM; and two capsules (one containing UN fuel and the other UO2) were withdrawn from their respective assemblies in February 2013 at an estimated fuel burnup of approximately 20 GWd/MTHM. These capsules are currently awaiting PIE. This paper will describe the experiment, as-run operating conditions for these capsules, and current PIE plans and status.

Irradiation SiC fuel rods HFIR↗