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DOE OSTI2017

Modeling copper precipitation hardening and embrittlement in a dilute Fe-0.3at.%Cu alloy under neutron irradiation

The neutron irradiation in light water reactors can induce precipitation of nanometer sized Cu clusters in reactor pressure vessel steels. The Cu precipitates impede dislocation gliding, leading to increase of yield strength (hardening) and upward shift of ductile-to-brittle transition temperature (embrittlement). In this work, cluster dynamics modeling is used to model the entire Cu precipitation process (nucleation, growth, and coarsening) in a Fe-0.3at.%Cu alloy under neutron irradiation at 300 °C. The evolution of the Cu cluster number density and mean radius predicted by the modeling agrees well with experimental data reported in literature for the same alloy under the same irradiation conditions. The predicted precipitation kinetics are used as input for a dispersed barrier hardening model to correlate the microstructural evolution with the radiation hardening and embrittlement in this alloy. The predicted radiation hardening agrees well with the mechanical test results in literature. In conclusion, the limitation of the model and future improvement directions are also discussed in this work.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2016

Reactor lifetime extension by limiting the RPV fluence increase

Lifetime extension of Pressurized Water Reactors must consider the embrittlement of the reactor pressure vessel. AREVA NP has a long history in developing and implementing problem oriented shielding measures. The main goal of these measures is the reduction of the fast flux at the original core periphery. Dependent on the size of the problem, the measures can be characterized as optimization of core design, insertion of neutron absorber material in regular fuel assemblies at the core periphery, partly inert assemblies, and fully inert assemblies. The first two solutions can in principal be handled with standard tools. Special measures had to be developed for the neutronic description of the other two options. These newly developed methodologies are based on the Equivalence Theory that was developed at AREVA NP in the late 1970's and early 1980's and is applied for the description of inert fuel assemblies as well as for reflectors in its code systems. The implemented solutions were accompanied by measurement programs for qualification of the design methods and for confirmation of the predicted shielding effect. The design shielding ratios of the developed measures cover a range of approximately 1.5 to 10 with the shielding ratio being defined as the ratio of vessel fluence per time interval of a core without shielding to a core with shielding provision. The comparisons of calculation and measurement verify the projected behavior of the shielding measures. (authors)

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2016

Remote Dismantling and Packaging of the RPV and Thermal Shield at the Obrigheim NPP - 16073

The Obrigheim Nuclear Power Plant (KWO) is located in the Federal State of Baden- Wuerttemberg in Germany and was operated by the EnKK-KWO. The Nuclear Power Plant - a light water pressurized water reactor with 357 MW of electrical power - was operated from 1968 to 2005. In June 2009 the Energiewerke Nord GmbH (EWN) was charged with the dismantling planning and dismantling of the reactor. According to the German nuclear and radiation protection law, several licenses will be required for the realisation of this task. This also applies to the disposal of the waste produced by dismantling, which must finally be stored in the German final repository for low and medium-radioactive waste (underground repository 'Konrad'). In spring 2010 EWN completed all application documents for the dismantling of the reactor pressure vessel (RPV) and the RPV internals and EnKK-KWO delivered them to the responsible Environmental Ministry of Baden-Wuerttemberg. Since then it has been worked intensively on the design, construction and manufacturing of the facilities for dismantling. With a separate notification of amendment, it was applied for the license to install and commission the facilities for the dismantling of the RPV and the RPV internals at the Environmental Ministry of Baden-Wuerttemberg in October 2010. This notification of amendment was confirmed in summer 2012. In September 2011 the work process and test plan and the technical information about the campaign for the removal of the radioactive waste resulting from the RPV with internals, peripheral components and secondary waste with the aim of final disposal in the Federal Repository 'Konrad' was submitted to the Federal Office for Radiation Protection. The evaluation and assessment of the work process and test plan was concluded in August 2013, when it was audited by TUV Nord EnSys without any further measures and indications. On September 10 the work process and test plan was released by the Federal Office for radiation protection. The dismantling of the RPV internals upper core and lower core structure started in September 2013 in the wet cutting area in room 01.106/306 and were finished in October 2014. In the presentation 'Dismantling of the Obrigheim NPP Reactor and Waste Management' held on the WM Symposia in Phoenix, 2014, an overview about the remote cutting and packaging of the upper and lower core structure was given. In today's presentation the subsequent dismantling activities will be outlined and evaluated. The presentation will start with the short description of the basic frame conditions for the nuclear licensing procedure, important procedural principles, and necessary plant-specific conditions. After the remote cutting and packing of the reactor internals of the upper and lower core structure was completed, the wet cutting area 'reactor room 01.106/306' was cleaned and the reactor room rebuilt into a cutting area for peripheral components. After the peripheral components were dismantled, all preconditions were set to lift the RPV from its mounting position and to arrange it in the upper reactor room 01.306. After these activities were completed, the lifting of the RPV was prepared and the cutting area 'Dismantling of the RPV insulation in the reactor room 01.106/306' was set up. To carry out this task, a strand jack unit with connection block was installed on the bridge of the reactor building crane. The opening created by the dismantling of the pool plate was closed with a flap door. The manipulators used for the wet cutting of the RPV internals were also used for the remote dismantling of the RPV insulation and mounted in the cutting area. The remote facilities were handled from a control centre and/or control stand. The air-technical housing which has already been used for the remote dismantling of the RPV internals was designed for the dismantling of the RPV insulation and was extended for this dismantling scope with appropriate ventilation systems. A special feature is the fixation of the RPV insulation at the RPV corpus. The RPV insulation consists of insulation wool, wire mesh and metal-sheet insulation. This 'Sandwich Construction' is detached with a steel corset at the RPV corpus and partly tightened. The insulation of the RPV bottom dome is tightened at the supporting frame. Due to the activation of the material in the core area and the resulting high ambient dose rate the RPV insulation can only be dismantled remotely. Additionally, as asbestos fibers are expected to be found in the insulation the dismantling has to be performed according to the Technical Rules for hazardous substances. The demolition, restoration or maintenance works have to be performed remotely according to the Technical Rules for hazardous substances when the RPV is located in the cutting area. But in case of dismantling of a power reactor no such experience can be found. Beginning with the explanation of the technical, radiological and substantial boundary conditions this presentation will not only impart knowledge about the dismantling of the RPV insulation but also about the remote controlled packaging of the metal sheet insulation and the manual conditioning of the RPV insulation. Subsequently, reports on the remotely controlled cutting and packaging of the RDB are given. Here is particularly interesting that cutting methods have been used and how the activity determination of the segments was carried out. On the basis of the evaluation of the realisation the subsequent dismantling activities will be lined out. In parallel to the dismantling tasks, the waste package documentation for the final repository was issued, checked and confirmed for the containers loaded with parts of the RDB internals. The most important stages are exemplified in this presentation. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2016

Physics-Based Modeling of Precipitation in Nuclear Structural Materials

One form of materials degradation in nuclear structural materials, including both core austenitic stainless steels (SS) and reactor pressure vessels (RPVSs), is formation of second phase precipitates. These precipitates increase the materials hardness and consequently make them brittle. Predicting the level of embrittlement stemming from precipitated phases is a critical question in extending the lives of current light water reactors (LWR) to 80 or even 100 years. We have developed physics-based models which combine CALPHAD (Calculation of Phase Diagram), Cluster Dynamics (for both precipitation kinetics and defect evolution) and classical nucleation theory (using the MatCalc code for precipitation kinetics in complex alloys) to predict the evolution of second phase precipitation in nuclear structural materials under LWR extended life conditions. (authors)

36 MATERIALS SCIENCE↗

DOE OSTI2024

ASME Design Code Rule Changes for Nuclear Graphite

The American Society of Mechanical Engineers Boiler Pressure and Vessel Code (ASME BPVC) Section III, Division 5, Article HHA-3000 outlines graphite core component and graphite core assembly design guidelines. Graphite core components are defined as ?components manufactured from graphite that are installed to form a graphite core assembly within the reactor pressure vessel of a high temperature, graphite moderated fission reactor.? (p. 413) Graphites? inherent defect distributions do not allow for deterministic material reliability. Rather, graphite has variable strength distributions which change by grade. Article HHA-3000 outlines two semi-probabilistic methods, the full and simplified assessments, which set design load limit targets for each of three component structural reliability classes. The Design Task Group was officially recognized as a specialized task group within ASME November of 2023, though we?ve been collaborating since 2022. The purpose of the Design Task Group is to correct, clarify, and make HHA-3000 function as intended. The Design Task Group will sunset once we?ve achieved our objectives. The Design Task Group was specifically told to not write new Code. While there may be more precise and more accurate methods to determine reliability targets, the current methods are conservative, relatively simple to implement, and have thus far been considered satisfactory for setting design reliability targets. Much of the ground-work to write proposal files and background documents for records to make the changes needed to achieve our objective have been completed. The Design Task Group has documented much of their work through papers, presentations, and memorandums. Three memorandums in which INL team members had substantial contributions are found in the Appendices: FEA Modeling for the Baseline Program, Evaluating the Effects on Margin of Updating the Threshold and Shape Parameters in the Full Assessment, and Interpretations of the Full and Simplified Assessments in ASME BPVC. Most of the on-going work to achieve the Design Task Group?s objective will be addressing comments on existing records and moving records through the balloting process. The Design Task Group met bi-weekly mostly through the end of FY2023. Since February 2024, the Design Task Group has mostly been completed with solving and documenting the technical issues associated with the assessments. Unless new tasks are identified, the remaining work of the Design Task Group will be political and editorial.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2016

Simulations of a Helical Tube Bundle in Cross-Flow for Application to Flow-Induced Vibration

Helical tubes have been used in a number of systems, including the energy and chemical processing industries. Helical-Coil Steam Generators (HCSGs) in particular have special application in systems for which spatial constraints are important. Variants of these designs are notably included in a number of integral-vessel small modular reactor (SMR) designs which are currently in development by multiple companies. These designs typically have the primary side located within the vessel, with the secondary side flowing upward through the helical tubes. One complexity in implementing an HCSG within the reactor pressure vessel is that any potential flow-induced vibration (FIV) can impact reactor safety. In a typical power plant, heat exchanger tube failures caused by FIV can be costly, but generally do not have immediate impact on the core safety due to their relative isolation from the core area. In an integral-vessel design, a tube rupture could eject material from the secondary side into the primary flow, potentially damaging the core itself or other crucial components. Thus a higher degree of confidence in predicting and/or preventing FIV should be attained for implementing the helical tubes in these designs. A significant campaign is currently underway to address the topic of FIV in helical tube arrays. The U.S. Department of Energy, under the Nuclear Energy Advanced Modeling and Simulation (NEAMS) initiative, has deemed this a 'high-impact problem'. This will include both experimental and computational contributions from a consortium consisting of multiple universities, industry partners, and national laboratories, including Argonne National Laboratory. The primary industrial partner is NuScale, which will see direct benefits from this initiative to the development of their SMR and its component design. The primary focus of this paper is to establish some of the computational efforts that have been made to this stage and the initial benchmarking of computational tools. (authors)

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2018

High-resolution time-resolved experiments on mixing and entrainment of buoyant jets in stratified environments

Fluid jets interacting with a stratified layer play an important role in the safety of several reactor designs. In the containment of nuclear power plants, fluid jets dominate the transport and mixing of gaseous species and consequent hydrogen distribution in case of a severe accident. The mixing phenomena in the containment are driven by buoyant high-momentum injections (jets) and low momentum injection plumes. Mixing near the postulated break is initially dominated by high flow velocities. Plumes with moderate flow velocities are instead relevant in the break compartment during the long-term pressurization phase, or in any of the apertures between two connected compartments if the mass flows are sufficiently high and the density differences between efflux and ambient are sufficiently low. Phenomena of interest include free plumes (as produced by the efflux from the break compartment in a larger room or directly from a break flow), wall plumes (such those produced by low mass flows through inter-compartment apertures), and propagating stratification fronts in the ambient (for any stably stratified conditions). These phenomena have been highly ranked about nuclear reactor design, especially regarding of safety protocols. During a Pressurized Thermal Shock (PTS) scenario, the interaction between the cold ECCS injection plume and the stratified fluid present in the cold (or hot) leg is important in order to determine the temperature at the time-dependent temperature at the inlet of the reactor pressure vessel (RPV) and the potential to cause a thermal shock on the RPV wall. In sodium-cooled fast reactors (SFRs), core channels are typically hydro-dynamically isolated so that there exists a considerable temperature variation at the exit of adjacent fuel assemblies. All the above phenomena are characterized by the interaction of buoyant jets with the stratified flow. In stratified layers baroclinic forces create significant redistribution of turbulent kinetic energy and scales, which leads to anisotropy. This important physical phenomenon is highly three dimensional and is challenging to capture even with high-fidelity CFD simulations, due in part to lack of sufficiently resolved validation data. Furthermore, the experimental data available in the open literature do not feature the level of fidelity needed for an extensive validation of turbulence models in lower order CFD. To shed new lights into the crucial phenomena object of the present research project, it was proposed to conduct coordinated experiments and simulations at the University of Michigan and the George Washington University. The project has resulted in an experimental database of high-resolution time-resolved measurements of jets in uniform and stratified environments. The novel experimental data will be used to validate computational fluid dynamic (CFD) codes, including both Large Eddy Simulations (LES) and unsteady Reynolds-averaged Navier-Stokes equations (URANS) methodologies. In the Experimental and Multiphase flow (ECMF) laboratory at Univerisity of Michigan, we built two experimental facilities to investigate also the effect of scaling. The first facility, DESTROJER (DEnsity Stratified Turbulent ROund free Jet ExpeRiment), featuring a contoured jet nozzle with a diameter of D=12.7mm and a 1m×1m×1m cubic tank, which is made of acrylic glass for optical access. The ratio between the tank width and the nozzle diameter is equal to 78, which ensures that there is no direct interaction between the jet and the side walls. A second, modular experimental facility, features three different tank sizes of size 10×10×30, 20×20×30, 30×30×30 cm3 respectively (all tanks have the same height of 30 cm), and a jet diameter of 2mm. For the modular facility, tank-to-nozzle ratio of 50, 100, and 150 are obtained respectively. Experiments with different-density jet impactions and sharp interface with a density difference of 3.16% In the Laboratory at George Washington University, complementary experiments have been carried out at a facility featuring the same dimensions as DESTROYER. Experiments with different jet diameters have been carried out as well. High-resolution time-resolved measurements have been performed at all facilities using high-speed particle image velocimetry (PIV) and planar laser-induced fluorescence (PLIF). In this way, simultaneous measurements of velocity and density fields have been carried out. At the University of Michigan, wire-mesh sensors have been designed and built to gather high-resolution, time-dependent data of the stratified front in the tank. These measurements are important to provide accurate initial conditions for the CFD simulations. An important outcome of the project has been the development of novel techniques to achieve refractive index matching (RIM) of acqueous solutions with high density differences. RIM is crucial if optical techniques such as PIV are used to measure velocity fields. Previous to this project, experiments up to 3% density difference had been reported in the literature. With the methodology developed in this project, we have been able to push the envelop to density differences up to 9%. The experiments have been used to validate Reynolds Averaged Navier-Stokes (RANS) turbulence models and Large Eddy Simulations (LES) models. Both NEK5000 and the commercial CFD code STAR-CCM+ have been used. The experimental data will be made available to the community through the NE-KAMS databasehave been successfully conducted in the scaled facility.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2019

Out-of-pile performance of High Temperature Irradiation Resistant and Cladding Thermocouples

The High Temperature Irradiation Resistant thermocouple (HTIR-TCs) has proven to be the nuclear temperature sensor. It outlast and outperforms all other commercially available thermocouples above 1100 °C inside reactor pressure vessels; also, recent calibration methods have pushed the HTIR-TC to accurately read temperatures through thermal transients during reactor shutdowns and restarts. The new temperature range of HTIR-TCs is from 0 °C to 1650 °C. The main objective of this study is to address manufacturing a more robust TC for handling and inserting into reactor experiments; to also apply the TC to a wider application. The TC has shown to be mainly susceptible to oxygen levels inside the heat treatment and calibration process and it is recommended that O2 levels be brought to as low as possible. However, through modeling efforts the O2 has been found to intercalate only within the first few layers of niobium on the outer sheath. Lastly, multiple materials were used for the sheath and insulators; all with similar outcomes when testing occurred over a long period of time.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

DOE OSTI2023

On High-Fluence Irradiation Hardening of Nine RPV Surveillance Steels in the UCSB ATR-2 Experiment: Implications for Extended-Life Embrittlement Predictions

Nine archival reactor pressure vessel (RPV) surveillance steels from commercial nuclear power plants were irradiated in the University of California, Santa Barbara Advanced Test Reactor 2 (ATR-2) experiment to evaluate irradiation embrittlement under low-flux surveillance capsule versus higher flux test reactor (ATR-2) conditions. The postirradiation measurements of irradiation hardening, measured as increases in yield stress (Δσy), and corresponding conversions of Δσy to Charpy V-notch 41-J transition temperature shifts (ΔTc) are compared with various embrittlement trend curve (ETC) model predictions for the nine steels. Tensile and converted shear punch and microhardness measurements of Δσy generally show a continuing increase between intermediate and high ATR-2 fluences. The Eason-Odette-Nanstad-Yamamoto and ASTM E900 ETC models underpredict embrittlement at the ATR-2 irradiation condition: irradiation temperature (Ti) of 292°C, neutron fluence (ϕt) of 1.4 × 1020 n/cm2 (E > 1 MeV), and neutron flux (ϕ) of 3.68 × 1012 n/cm2-s. On average, the French FIS and Japanese JAEC ETCs slightly overpredict the ATR-2 data. The increase in Δσy with higher fluence is primarily due to Ni-Mn-Si precipitates, which slowly evolve in both nearly copper-free and copper-bearing steels. Finally, a new Odette-Wells-Almirall-Yamamoto embrittlement model is shown that yields good predictions for the nine steels at high fluences (ϕt > 5.5 × 1019 n/cm2).

Nanstad, Randy K.↗

DOE OSTI2023

On High-Fluence Irradiation Hardening of Nine RPV Surveillance Steels in the UCSB ATR-2 Experiment: Implications for Extended-Life Embrittlement Predictions

Nanstad, Randy↗

DOE OSTI2017

Irradiation Response of the Ferrite Phase in CF3 Cast Stainless Steel

Extending service of Light Water Reactors (LWRs) to beyond 60 years will demand a high integrity of materials and components in reactors. The accurate evaluation and prediction of materials performance under anticipated operation conditions are of particular importance for ensuring the safe operation of nuclear power plants over their extended lifetime. The duplex structure stainless steels including cast austenitic stainless steels (CASS) and welds of austenitic stainless steels are widely used in LWRs. The CASS alloys are mainly used in LWRs primary pressure boundary and for some limited core structural components. The type 308/309 welds are used for welding the reactor components made of 304 and 316 stainless steels and as a cladding layer on the inner surface of reactor pressure vessel. The core support columns made of CF8 CASS in a B and W design PWR are expected to be exposed to a fluence of between 1x10{sup 21} and 1x10{sup 22} n/cm{sup 2}, E>1.0 MeV, and the austenitic stainless steel welds can potentially receive a fluence up to 5x10{sup 22} n/cm{sup 2}, E>1.0 MeV. In addition to the thermal aging effect, the radiation induced fracture toughness in those duplex structure stainless steel components located in the high neutron fluence regions in LWRs hasn't be fully evaluated. Previous studies showed that the spinodal decomposition in the delta ferrite phase in CASS or type 308/309 welds is the primary embrittlement mechanism, and the G-phase precipitates were also identified but with less impact on the reduction of fracture toughness. It is generally agreed that the irradiation induced fracture toughness decrease in CASS and weld steels saturates after 10 dpa (∼1x10{sup 22} n/cm{sup 2}, E>1.0 MeV). Nevertheless, there are not enough high dose data points to confirm the lower bound in measured fracture toughness as the reported doses are limited to 15 dpa. The work in this paper is to present a more comprehensive study on the microstructural evolution in the ferrite phase in a CF3 CASS, and the results provide a scientific basis for extrapolating the change of fracture toughness to a high dose range.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2018

Neutron and Thermal Embrittlement of RPV Steels: An Overview

Because the reactor pressure vessel (RPV) represents the first structural line of defense against the release of radiation to the public, the design and fabrication of the RPV for any nuclear reactor facility is performed at very high standards in accordance with consensus codes that are based on mechanical and physical properties of the steels used to construct the vessel. Nuclear RPVs may weigh up to 800 tons with wall thicknesses up to approximately 330 mm and are clad on the inside with stainless-steel weld metal and given a final post-weld heat treatment. The RPV is a unique structural component in that it operates under high pressures and temperatures and is exposed to relatively high neutron radiation. Although typical RPV steels and welds have excellent fracture toughness at room temperature and above when put into service, the degrading effects of high-energy neutron irradiation can cause levels of irradiation-induced embrittlement in radiation-sensitive materials of concern for the structural integrity of the RPV. In recent decades, remarkable progress has been made in developing a mechanistic understanding of irradiation embrittlement. This progress includes developing physically based and statistically calibrated models of Charpy V-notch-indexed transition temperature shifts based on results from RPV surveillance programs complemented by significant results from comprehensive research experiments performed in test reactors. In addition, advances in elastic-plastic fracture mechanics allow for a relatively small number of relatively small specimens to characterize the fracture toughness of RPV steels with statistical confidence. This paper presents a review of the primary mechanical properties, test procedures, examples of applicable codes and standards, and specimen types used to characterize RPV steels and welds, the effects of neutron irradiation on those most relevant mechanical properties, and a brief review of the effects of thermal aging on RPV materials. The paper closes with a summary.

Nanstad, Randy K.↗

DOE OSTI2016

Statistical Study of Primary Knock-on Atoms under Neutron Irradiation in RMC Code

Materials in high flux neutron condition will suffer from an evolution of damage which ultimately restricts the lifetime of the fuel clad and reactor pressure vessel. Atoms in irradiated material transform to primary knock-on atoms (PKAs) by absorbing the kinetic energy transferred from neutrons, and the energy released from nuclear reactions. The secondary collision cascades which are induced by PKAs create point defects within the material, with residual vacancies and interstitials eventually causing swelling and embrittlement that degrades mechanical behavior. For a long time, Displacements per Atom (DPA) index has been identified as a measure of radiation damage in material. Nowadays, several advanced methods, such as Molecular Dynamics (MD) and Kinetic Monte Carlo (KMC) simulations, have been developed for more accurately simulating the evolution of the damage. However, all of these techniques need more comprehensive information of PKA, such as the type, energy, direction and spatial distribution. The limitations of DPA emerge and a method should be provided to simulate the generative process of PKAs. Recently, a deterministic analysis code SPECTRA-PKA has been developed by Gilbert to calculate the energy spectra of almost all types PKAs by solving the group-to-group cross-section matrices equation which includes neutron scattering, light charged particles, and recoils of the residual nuclei. But this deterministic analysis code could not give the direction, spatial and time distribution of PKAs. Based on the Geant4 program, Cui Zhenguo has simulated the irradiation by neutrons with 1 MeV energy in zirconium, while only the two adjacent elastic collisions between injected neutron and target atoms are taken into consideration. In this paper, Monte Carlo method to calculate PKAs information during neutron transport in RMC code is introduced. RMC is a continuous-energy Reactor Monte Carlo neutron and photon transport code being developed by Department of Engineering Physics at Tsinghua University, Beijing. PKAs in zirconium are calculated in fixed neutron source mode. Statistical information of PKAs in PWR fuel cell and SFR fuel cell is shown and compared. The results show that Monte Carlo method can provide more comprehensive information of PKAs. (authors)

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗

DOE OSTI2017

A New Graphical Dismantling Process Simulation Technology for Flexible Planning of Nuclear Facility

The dismantling of highly radioactive components of the nuclear facility is one of the most difficult activities in decommissioning. In the planning stage, the dismantling scenario including dismantling equipment and processes has a significant effect on the cost and safety of the whole decommissioning. High level radiation of the dismantling object such as a reactor pressure vessel (RPV) and its internals restricts access by human workers, and makes an accident during the dismantling process more difficult to deal with. Decommissioning of nuclear facilities demand a large scale of budget and high level of safety, and therefore the preliminary verification of dismantling scenarios by graphical simulation has special importance at planning stage. In recent years, the manufacturing industry has aggressively adopted the virtual manufacturing technology to verify the facilities and processes with high efficiency. The virtual manufacturing technology was beginning to be adopted in the area of the nuclear facility decommissioning. The dismantling process of the Rotary Specimen Rack (RSR) in the Korea Research Reactor-1 and 2 was established and it was also applied to replace the steam generators on time and on budget in San Onofre Nuclear Generating Station. Current virtual manufacturing technologies are not sufficient for the area of nuclear facility decommissioning because the object segmenting function absolutely required for graphical simulations over various dismantling scenarios is unavailable. This paper proposes a new technology for graphical decommissioning simulator which is able to simulate various dismantling scenarios over nuclear facilities including repetitive object cuttings of heavy and complex structures by applying flexible cutting algorithm.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2016

Thermal-Mechanical Stress Analysis of PWR Pressure Vessel and Nozzles under Grid Load-Following Mode: Interim Report on the Effect of Cyclic Hardening Material Properties and Pre-existing Cracks on Stress Analysis Results

This report provides an update on an assessment of environmentally assisted fatigue for light water reactor components under extended service conditions. This report is a deliverable under the work package for environmentally assisted fatigue as part of DOE’s Light Water Reactor Sustainability Program. In a previous report (September 2015), we presented tensile and fatigue test data and related hardening material properties for 508 low-alloys steel base metal and other reactor metals. In this report, we present thermal-mechanical stress analysis of the reactor pressure vessel and its hot-leg and cold-leg nozzles based on estimated material properties. We also present results from thermal and thermal-mechanical stress analysis under reactor heat-up, cool-down, and grid load-following conditions. Analysis results are given with and without the presence of preexisting cracks in the reactor nozzles (axial or circumferential crack). In addition, results from validation stress analysis based on tensile and fatigue experiments are reported.

42 ENGINEERING↗

DOE OSTI2021

Effect of thermal aging and irradiation on microstructure and crack growth response of Alloy 690

Nickel-base Alloy 690 and the associated weld Alloys 52 and 152 are typically used for nozzle penetrations in replacement heads for pressurized water reactor (PWR) vessels, because of their excellent overall resistance to general corrosion and environmental degradation, primarily stress corrosion cracking (SCC). However, many of the existing PWRs reactors are expected to operate for 40-80 years. Likewise, advanced water-cooled small modular reactors (SMRs) will use Ni-Cr alloys and are expected to receive initial operating licenses for 60 years. Hence, the thermal stability of Ni-Cr alloys is a potential concern for the long-term performance of both existing and advanced nuclear plants, and possibly spent fuel storage containers. The objective of this research is to understand the microstructural changes occurring in high-Cr, Ni-based Alloy 690 during long time exposure to the reactor operating temperatures, and the effect of these changes on the service performance. One area of particular concern is the potential for long range ordering (LRO), i.e. formation of the intermetallic Ni 2 Cr phase under prolonged exposure to reactor temperatures and/or irradiation, which can increase strength, decrease ductility, and cause dimensional changes or lead to in-service embrittlement of components made with these alloys. Hence, this research focused on the microstructural evolution and the SCC response of Alloy 690 under accelerated thermal aging and irradiation conditions. The materials studied involved Alloy 690 from two sources: (i) Alloy 690 plate from an Alloy 152 dissimilar metal weld (DMW) joining the Alloy 690 plate to Alloy 533 LAS, aged at three different temperatures (370°C, 400°C and 450°C) for up to 75,000h (equivalent to 60 years of service), and (ii) specimens neutron-irradiated in the BOR-60 reactor up to 40 dpa. For aged Alloy 690 specimens, hardness was found to increase with aging time, however, the microstructural characterization by means of synchrotron X-ray did not find evidence of LRO. The microstructural characterization of neutron-irradiated specimens by TEM found no evidence of LRO either. Testing in a primary water environment of Alloy 690 specimens aged to a 60-year service equivalent revealed a fatigue and corrosion fatigue crack growth responses similar to those measured on the un-aged alloy. The SCC CGR response was also low. Overall, the two Alloy 690 heats investigated in this work, aged up to 60-year service equivalents or exposed to neutron irradiation up to 40 dpa, did not exhibit a deterioration in microstructure or performance.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2024

Fitness-for-Service Analysis of Reactor Components under Flexible Load-Following Operating Conditions

Conventional power-generation plants, including nuclear plants, have been traditionally designed to provide a steady baseload energy capacity, optimizing output efficiency while minimizing variable costs. However, the growing adoption of large-scale renewable energy-generation systems, which rely on intermittent sources such as solar and wind, has introduced more variability into the energy supply in interconnected electricity grids. As a result, the next generation of power plants needs to operate in what is known as the load-following mode, requiring flexible adjustments in electricity production to align with the energy demand on the grid. This transition from the steady baseload operation to load-following operating conditions can significantly increase the number of times various plant components are exposed to transient stresses. This increased thermo-mechanical cycling can lead to accelerated material degradation, thereby elevating the risk of premature failure of a component. It becomes imperative to conduct a comprehensive analysis of fatigue, creep-fatigue, and stress corrosion cracking life, to assess the resilience of the various engineering components under these flexible load-following operating conditions. This study aims to develop a comprehensive numerical model of a light-water reactor pressure vessel (RPV) to investigate its degradation under various operating scenarios. This coupled thermo-mechanical finite element analysis evaluated the stress response of the RPV caused by considering fluctuations in thermal and mechanical loads caused by the varying pressure and temperature occurring during the load-following operation. Critical locations on the RPV are subsequently identified based on the stress response. The stress intensity factors for the postulated flaws at those locations are then calculated, followed by an evaluation of the reactor's life in accordance with the ASME Boiler and Pressure Vessel Code Section XI. This comprehensive life assessment covers a number of transients expected during the flexible load-following operation, providing invaluable insights into the RPV's structural integrity. Moreover, the development methodology can be adapted to other reactor components, as well as components of conventional power stations that are affected by varying operating conditions.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2025

Experimental Methods for the Performance Test of Environment-Assisted Cracking (EAC) in Nuclear Industry and Examples through NSUF

Environmentally assisted cracking (EAC) is a critical failure mode in nuclear reactor environments, where materials are exposed to high temperatures, radiation, and corrosive media. Specific EAC studies in nuclear environments include stress corrosion cracking in primary water chemistry, irradiation-assisted stress corrosion cracking (IASCC) under neutron exposure, and hydrogen induced cracking (HIC) in reactor pressure vessels. The experimental methodologies of EAC include slow strain rate testing (SSRT), constant load, and cyclic loading techniques, conducted in autoclaves designed to simulate the reactor’s operational environments. This paper highlights several experimental case studies, especially on IASCC, conducted within the Nuclear Science User Facilities (NSUF).

36 - MATERIALS SCIENCE↗