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DOE OSTI2017

Influence of Alloying Elements and Effect of Stress on Anisotropic Hydrogen Diffusion in Zr-Based Alloys Predicted by Accelerated Kinetic Monte Carlo Simulations

The formation of hydrides degrades the toughness of Zr-based claddings, and thus is one of the primary concerns regarding cladding integrity during fuel operation and used fuel storage. However, the formation mechanism of hydrides, particularly the nucleation mechanism, is yet to be fully understood. To explore the nucleation process, atomic scale studies including density functional theory, molecular dynamics and kinetic Monte Carlo have been used to investigate H diffusion, segregation, and the possible nucleation paths of hydrides. Here, density functional theory calculations are used to parameterize a kinetic Monte Carlo model, which can accurately predict the effective H diffusivity in various Zr-based claddings including Zircaloy, Zirlo and Zr-2.5Nb. Assisted by density functional theory calculations, a recently developed charge-optimized-many-body potential is further improved and used to investigate the possible nucleation paths of hydrides. It’s shown that the formation of face-centered hydrides starts with coherent zeta-phase, shearing of which in the basal plane changes the hcp stacking into fcc and leads to the formation of gamma-hydride nuclei. The shearing involves a negligible barrier and negligible strain accumulation in the matrix by adopting three equivalent shear partials. The results obtained at the atomic scale are consistent with previous theory and experiments, and improves the current understanding on how and how fast hydride forms in Zr based cladding.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2012

An analysis of the sliding pressure start-up of SCWR

In this paper, the preliminary sliding pressure start-up system and scheme of supercritical water-cooled reactor in CGNPC (CGN-SCWR) were proposed. Thermal-hydraulic behavior in start-up procedures was analyzed in detail by employing advanced reactor subchannel analysis software ATHAS. The maximum cladding temperature (MCT for short) and core power of fuel assembly during the whole start-up process were investigated comparatively. The results show that the recommended start-up scheme meets the design requirements from the perspective of thermal-hydraulic. (authors)

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2023

BISON validation to in situ cladding burst test and high-burnup LOCA experiments

The process for developing and qualifying nuclear fuels for commercial nuclear application requires fundamental material development, characterization, and design; out-of-pile testing on unirradiated materials; integral fuel rod irradiations, testing, and postirradiation examinations; and transient analyses. The historical approach depends on the generation of large empirical datasets and series of integral fuel rod irradiations, and this approach ultimately takes ~20 years—or sometimes longer—to acquire data through extensive sequential testing. Thus, the qualification and eventual deployment of new fuel systems constitute a long process. However, recent technological advancements have provided researchers the opportunity to perform out-of-cell, in situ measurements to assess material performance for the duration of the experiment. One such example of this capability is the use of digital image coordination and thermal imaging to assess Zircaloy cladding performance under a simulated loss-of-coolant accident (LOCA) transient condition. In situ measurements generally provide high-fidelity strain, strain rates, and temperature surface maps. This is critical for the US nuclear industry, which is actively developing a technical basis to support extending the peak rod average burnup from 62 to ~75 GWd/tU and the deployment of accident-tolerant fuel. However, the US Nuclear Regulatory Commission (NRC) outlined in its research information letter several technical issues that the industry must address before extending burnup. One topic of specific interest is understanding the cladding balloon and rupture geometry during the LOCA heat-up phase. By leveraging these advanced in situ capabilities, this work used in situ data generated from a simulated LOCA to better understand high-temperature creep and its effect on Zircaloy balloon and rupture performance. Here, this work used the BISON fuel performance code to assess the high-temperature creep model predictions with in situ data.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2022

Carburization Kinetics of Zircalloy-4 and Its Implication for Small Modular Reactor Performance

Carburization of cladding materials has long been a concern for the nuclear industry and has led to the restricted use of high-thermal conductivity fuels such as uranium carbides. With the rise of small modular reactors (SMRs) that frequently implement a graphite core-block, carburization of reactor components is once more in the foreground as a potential failure mechanism. To ensure commercial viability for SMRs, neutron-friendly cladding materials such as Zr-based alloys are required. In this work, the carburization kinetics of Zircaloy-4 (Zry-4), for the temperature range 1073–1673 K (covering typical operating temperatures and off-normal scenarios) are established. The following Arrhenius relationship for the parabolic constant describing ZrC growth is derived: Kp (in μm2/s) = 609.35 exp(−1.505 × 105/RT)). Overall, the ZrC growth is sluggish below 1473 K which is within the operational temperature range of SMRs. In all cases the ZrC that forms from solid state reaction is hypo-stoichiometric, as confirmed through XRD. The hardness and elastic modulus of carburized Zry-4 are also examined and it is shown that despite the formation of a ZrC layer, C ingress in the Zry-4 bulk does not impact the mechanical response after carburization at 1073 K and 1473 K for 96 h.

36 MATERIALS SCIENCE↗

DOE OSTI2016

Molybdenum Disilicide Oxidation Kinetics in High Temperature Steam

The Fuel Cycle Research and Development program’s Advanced Fuels Campaign is currently supporting a range of experimental efforts aimed at the development and qualification of ‘accident tolerant’ nuclear fuel forms. One route to enhance the accident tolerance of nuclear fuel is to replace the zirconium alloy cladding, which is prone to rapid oxidation in steam at elevated temperatures, with a more oxidation-resistant cladding. Several cladding replacement solutions have been envisaged. The cladding can be completely replaced with a more oxidation resistant alloy, a layered approach can be used to optimize the strength, creep resistance, and oxidation tolerance of various materials, or the existing zirconium alloy cladding can be coated with a more oxidation-resistant material. Molybdenum is one candidate cladding material favored due to its high temperature creep resistance. However, it performs poorly under autoclave testing and suffers degradation under high temperature steam oxidation exposure. Development of composite cladding architectures consisting of a molybdenum core shielded by a molybdenum disilicide (MoSi 2 ) coating is hypothesized to improve the performance of a Mo-based cladding system. MoSi 2 was identified based on its high temperature oxidation resistance in O 2 atmospheres (e.g. air and “wet air”). However, its behavior in H 2 O is less known. This report presents thermogravimetric analysis (TGA), scanning electron microscopy (SEM), and x-ray diffraction (XRD) results for MoSi 2 exposed to 670-1498 K water vapor. Synthetic air (80-20%, Ar-O 2 ) exposures were also performed, and those results are presented here for a comparative analysis. It was determined that MoSi 2 displays drastically different oxidation behavior in water vapor than in dry air. In the 670-1498 K temperature range, four distinct behaviors are observed. Parabolic oxidation is exhibited in only 670-773 K water vapor, a temperature range in which the material pests in dry O 2 environments. From 877-1084 K in water vapor, MoSi 2 undergoes rapid mass gain resulting in oxidation throughout the bulk of the sample at 980 K and 1084 K. The resulting material displays swelling and warping after the 980-1084 K exposures. A pre-passivation heat treatment performed at 1395 K was found capable of producing a coarse SiO 2 layer that limited pesting at lower temperatures in water vapor over the time periods investigated.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2016

Accelerated Corrosion Tests to Evaluate Long-Term Performance of BORAL{sup R} in Spent Fuel Pools

Neutron absorber materials are used to increase storage capacity in spent fuel pools (SFPs) while maintaining criticality safety margins. BORAL{sup R} - a neutron absorber material commonly used in SFPs - is a metal matrix composite containing boron carbide (B{sub 4}C) and Al-1100 mixture. The aluminum (Al) cladding, which is on both sides of the core, serves as a protective barrier. Al cladding is susceptible to corrosion, which can lead to blisters between the core material and the cladding over time. Based on operational experience to date, pits also have been observed via visual examination and microscopy. EPRI has maintained a database containing coupon data spanning more than 25 years, and to date no loss of BORAL{sup R} efficacy has been observed. In the United States, about 50% of the plants use BORAL{sup R} as neutron absorber material in SFPs. BORAL{sup R} is also used in nuclear plants in Mexico, Korea, Taiwan, and other countries. Given that the plant lifetime is increasing-and, hence, the SFP lifetime-EPRI initiated a five-year accelerated corrosion test in 2013 to evaluate and determine the long-term performance of BORAL{sup R} in SFPs. This paper presents an overview of the accelerated corrosion test project. Results from the Year 1 and Year 2 test results are also presented. (authors)

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2017

Rod Internal Pressure Distribution and Uncertainty Analysis Using FRAPCON

The discharge rod internal pressure (RIP) and cladding hoop stress (CHS) distributions are quantified for Watts Bar Nuclear Unit 1 (WBN1) fuel rods by modeling core cycle design data, operation data, and as-built fuel enrichments and densities of each fuel rod in FRAPCON-3.5. A methodology is developed that tracks intercycle assembly movements and assembly batch fabrication information to build individual FRAPCON inputs for each evaluated WBN1 fuel rod. An alternate model for the amount of helium released from the zirconium diboride (ZrB 2 ) integral fuel burnable absorber (IFBA) layer is derived and applied to FRAPCON output data to quantify the RIP and CHS for these types of fuel rods. SCALE/Polaris is used to quantify fuel rod–specific spectral quantities and the amount of gaseous fission products produced in the fuel for use in FRAPCON inputs. Fuel rods with ZrB 2 IFBA layers (i.e., IFBA rods) are determined to have RIP predictions that are elevated when compared to fuel rods without IFBA layers (i.e., standard rods) despite the fact that IFBA rods often have reduced fill pressures and annular fuel pellets. The primary contributor to elevated RIP predictions at burnups less than and greater than 30 GWd/tonne U is determined to be the total fuel rod void volume and the amount of released fission gas in the fuel rod, respectively. Cumulative distribution functions (CDFs) are prepared from the distribution of RIP and CHS predictions for all standard and IFBA rods. The provided CDFs allow for the determination of the portion of WBN1 fuel rods that exceeds a specified RIP or CHS limit. Results are separated into IFBA and standard rods so that the two groups may be analyzed individually. FRAPCON results are provided in sufficient detail to enable the recalculation of the RIP while considering any desired plenum gas temperature, total void volume, or total amount of gas present in the void volume. A method to predict the CHS from a determined or assumed RIP is also proposed that is based on the approximately linear relationship between the CHS and the RIP. Finally, improvements to the computational methodology of FRAPCON are proposed.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2020

Performance of U 3 Si 2 in an LWR following a cladding breach during normal operation

High-density fuels have been proposed as a possible replacement for uranium-dioxide as a fuel for light water reactors (LWRs) due to their increased loading of fissionable material. The objectives of this proposal are (1) to increase reactor cycle length and reactor power, and (2) to offset any neutronic penalty associated with advanced cladding systems. Of the high-density fuels under consideration, there is particular interest in triuranium disilicide (U 3 Si 2 ) due to its increased metal density and favorable thermal properties as compared to UO 2 . However, there are concerns regarding the chemical compatibility of U 3 Si 2 with water and steam as used for LWR coolant.This paper summarizes research on fuel-coolant chemical compatibility for UO 2 LWR fuel during a cladding breach and highlights that generally, because of its chemical inertness, UO 2 -coolant reactions are of little consequence to reactor operation. However, the volumetric expansion associated with the reaction of UO 2 and oxygen is a concern for possible conditions encountered during air ingress of dry storage. These same concerns arise for U 3 Si 2 , which exhibits greater volumetric expansion than UO 2 when exposed to water or steam. These reactions ultimately result in increased fuel volume that the cladding must accommodate, as well as additional heat generated as the fuel reacts.The BISON fuel performance code was used to perform a comparative analysis on the behavior of UO 2 and U 3 Si 2 under normal operation. Silicide fuel simulations were then extended to demonstrate how varying thermodynamic and chemical kinetics influence fuel expansion and subsequent cladding performance during a cladding breach. These simulations were further extended to a 3D subsection of a fuel rod to demonstrate the characteristics of the resulting cladding crack.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2016

Small-Angle Neutron Scattering Measurements of the δ Deuteride Phase in Zircaloy 4

Hydrogen pickup by Zr-based LWR fuel cladding during service leads to the formation of circumferential hydride platelet particles embedded within the Zr matrix. The precipitation of the hydride phase occurs preferentially on the water-side due to the temperature gradient within the clad wall. The non-uniform hydride morphology is known as a rim structure. Significant tensile hoop stresses within the clad wall develop during the fuel lifetime due to fission gas release and pellet-clad mechanical interaction. One potential post-service cladding failure mechanism is delayed hydride cracking (DHC) initiated by hydride reorientation under this tensile hoop stress. As a consequence, hydride reorientation and DHC have been extensively studied over the last few decades to understand the interdependencies of tensile stress, temperature, hydride morphology, and hydrogen concentration. Much of the most recent work in this area has taken advantage of 3. generation synchrotron X-ray sources to perform in situ measurements of hydride phase stability. Neutron scattering based techniques offer unique advantages in the study of hydrogen in metals (typically with deuterium substituted for hydrogen) but are under utilized in the study of hydrides in Zr. We present small-angle neutron scattering (SANS) measurements of the deuteride phase in Zircaloy 4 (Zy4) here. The SANS measurements presented here demonstrate the sensitivity of the technique to deuteride phase particles embedded in a Zy4 matrix. Quantifiable net scattering at 50 wppm effective hydrogen concentration is derived from a subtraction of a reference sample. This demonstrates that the strong χ phase Porod scattering can be effectively eliminated, revealing the response from the deuteride phase. A similar experimental protocol using small-angle X-ray scattering (SAXS) would likely fail due to poor contrast between the hydride phase and the Zr matrix. Stated in different terms, the SAXS response would be dominated by SPP Porod scattering with unresolvable net scattering from hydride particles. (authors)

36 MATERIALS SCIENCE↗

DOE OSTI2018

Conformal core cooling and containment structure

A nuclear reactor includes a pressure vessel and a nuclear reactor core comprising fissile material disposed inside the pressure vessel at the bottom of the pressure vessel. A secondary core containment structure includes a containment basket comprising insulation with a maximum stable temperature of at least 2200K cladded by steel. The bottom of the pressure vessel and the nuclear reactor core are disposed inside the containment basket with the containment basket spaced apart from the bottom of the pressure vessel by a clearance gap. The containment basket may comprise zirconia insulation cladded by steel. In some embodiments the clearance gap between the containment basket and the bottom of the pressure vessel is no larger than one meter. The secondary core containment structure may further comprise conduits arranged to inject water into the clearance gap between the containment basket and the bottom of the pressure vessel.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2018

Conformal core cooling and containment structure

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2017

Steam Corrosion Investigation of Single Silicon Carbide Nanostructures

Silicon carbide (SiC) has been advanced as an alternative to zircaloy for use as an accident-tolerant fuel cladding material in next-generation water-cooled reactors. This is due, in large part, to the predicted superior corrosion resistance of SiC, as compared to zircaloy, particularly at the high temperatures that are obtained in a nuclear reactor under accident conditions. The other favorable performance metrics of SiC include its enhanced mechanical stability, low neutron absorption, low chemical reactivity, and high radiation stability. Past reports, which include theoretical and isolated experimental activities, have studied the corrosion of bulk-scale SiC in reactor-like conditions. This report will present high-temperature steam corrosion results from single SiC nanofiber-based constructs. The changes in microstructure, and the evolution of oxide thickness and SiC recession with progressive corrosion will be characterized at the atomic-to-nanoscale using transmission electron microscopy (TEM). Furthermore, the corrosion-induced degradation in mechanical properties of the SiC nanofibers will be characterized using three-point bending tests involving an atomic-force microscope (AFM) in the contact mode.

36 MATERIALS SCIENCE↗

DOE OSTI2022

A layered 2D computational framework: Theory and applications to nuclear fuel behavior

Nuclear fuel performance computer codes have been developed over the last 50 years to analyze fuel behavior under various operating conditions. Traditionally, these codes used quasi-two-dimensional (also commonly known as 1.5D) representations of the fuel rod, which model the rod using a set of one-dimensional axisymmetric models that represent the behavior at specific axial positions on the rod. Modern fuel performance codes have the ability to investigate full three-dimensional (3D) effects and couple to other physics-based codes for true multiphysics simulations. However, with increasing complexity comes increasing computational costs. Many phenomena of interest involve azimuthally-varying behavior that cannot be represented using the aforementioned quasi-two-dimensional approach, but do not require the use of a full 3D model. To efficiently address these problems, there is a need for a computational framework that provides a compromise between the quasi-two-dimensional and full 3D models. In this paper, we present a new quasi-three-dimensional approach that represents the fuel as a set of 2D planar models that represent the behavior of the fuel cross-section at various axial positions. Presented here are the theory behind the methodology, test cases to illustrate proper implementation, and practical applications of its use in the BISON fuel performance code for a variety of cases in nuclear fuel analysis, such as fuel fracture, axial fuel relocation, and cladding distension and oxidation.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2023

Ductility of Zircaloy-4 Sibling Pin Cladding

This report summarizes the FY2022-23 work performed by Argonne National Laboratory (ANL) on sibling pins that are part of the High Burnup (HBU) Spent Fuel Data Project. The project is funded by the US Department of Energy’s Spent Fuel & Waste Science and Technology (SFWST) Office, which is part of the Office of Nuclear Energy’s Spent Fuel and Waste Disposition Office.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2022

BISON Validation to In-Situ Cladding Burst Test and High Burnup LOCA Experiments

The process to develop and qualify nuclear fuels for commercial nuclear application requires fundamental material development, characterization, and design; out-of-pile testing on unirradiated materials; integral fuel rod irradiations, testing, and post irradiation examinations (PIEs); and transient analyses. The historical approach depends on the generation of large empirical datasets and series of integral fuel rod irradiations, and this approach ultimately takes approximately 20 years—or sometimes longer—to acquire data through extensive sequential testing. Thus, the qualification and eventual deployment of new fuel systems constitute a long and drawn-out process. However, recent technological advancements have provided researchers the opportunity to perform out-of-cell, in-situ measurements to assess material performance for the duration of the experiment. One such example of this capability is the use of digital image coordination and thermal imaging to assess Zircaloy cladding performance under a simulated loss-of-coolant accident (LOCA) transient condition. In general, the in-situ measurements provide high-fidelity strain, strain rates, and temperature surface maps. This is critical for the United States nuclear industry, which is actively developing a technical basis to support extending the peak rod average burnup from 62 to ~75 GWd/tU and the deployment of accident-tolerant fuel. However, the Nuclear Regulatory Commission, through their research information letter, outlined a number of technical issues for the industry to address before extending burnup. One topic of specific interest is understanding the cladding balloon and rupture geometry during the LOCA heatup phase. Leveraging these advanced in-situ capabilities, this work intends to use insitu data generated from a simulated LOCA in the Severe Accident Test Station at Oak Ridge National Laboratory to better understand high-temperature creep and its impact on Zircaloy balloon and rupture performance. This work used the BISON fuel performance code to compare BISON’s high-temperature creep model predictions to in-situ data and identify limitations and gaps within the model. Additionally, BISON will subsequently be used to simulate relevant high-burnup LOCA tests. The results will be analyzed and compared to the available post-test data in a manner consistent with the approach outlined in the Nuclear Regulatory Commission research information letter.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2016

Utilization of the Halden reactor for supporting development of fuel with enhanced accident tolerance

This paper gives an overview of the facilities and capabilities of the Halden Boiling Water Reactor (HBWR) for supporting the development and validation of nuclear fuels. The pressurized water loops, the auxiliary in-reactor experimental systems, the instrumented test fuel assemblies and the post-irradiation facilities are succinctly described. The HBWR is contributing to the validation of new fuel types proposed as candidates for enhanced accident tolerance fuel (EATF) concepts, including uranium nitride compounds and microcell UO{sub 2}. Another point is the validation of new cladding materials for EATF. A new experiment is to be carried out to study the corrosion and irradiation creep and growth behaviour of several candidate claddings compared against a reference of Zircaloy-4. The candidate claddings include coated and surface modified Zr-based alloys, optimized FeCrAl and a Mo-based cladding.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2015

Hydride precipitation kinetics in Zircaloy-4 studied using synchrotron X-ray diffraction

Not Available

Courty, Olivier F.↗

DOE OSTI2017

Evaluating the irradiation effects on the elastic properties of miniature monolithic SiC tubular specimens

The initial results of a post-irradiation examination study conducted on CVD SiC tubular specimens irradiated under a high radial heat flux are presented herein. The elastic moduli were found to decrease more than that estimated based on previous studies. The significant decreases in modulus are attributed to the cracks present in the specimens. The stresses in the specimens, calculated through finite element analyses, were found to be greater than the expected strength of irradiated specimens, indicating that the irradiation-induced stresses caused these cracks. In conclusion, the optical microscopy images and predicted stress distributions indicate that the cracks initiated at the inner surface and propagated outward.

36 MATERIALS SCIENCE↗