Fracture Mechanics Analysis of Isotope Fuel Impact Tester, Milli-Watt, Multi-Hundred Watt and GPHS Outer Catch-Tube Subassembly Design
The Isotope Fuel Impact Tester (IFIT) at PF-4 is a specialized set of equipment designed for simulating high-speed impact of experimental parts. The IFIT is an inert gas launcher designed to impact 238 PuO 2 heat source assemblies, fuel encapsulation materials, structural materials, and subassemblies of radioisotope thermoelectric generators (RTGs). TA-55 management desires to re-use outer catch tube (OCT) of the milli-watt (MW), multi-hundred watt (MHW) and general purpose heat source (GPHS) designs and thus requires a technical evaluation of potential life cycles to failure. This report provides a fitness-for-service (FFS) assessment using fracture mechanics techniques based on the state-of-stress developed with the aid of a computational finite element model (FEM) of the IFIT. Importantly, the report describes the different material options for the OCT; H-11 vacuum-arc re-melted (VAR) and H-13 VAR for a given heat treatment resulting in a Rockwell-C hardness of 42, and an additional option of 4340 alloy steel with a range of heat treatment resulting in Rockwell-C hardness of 40 to 44.