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At least 109 records · Page 6

Dynamic data-driven multiscale modeling for predicting the degradation of a 316L stainless steel nuclear cladding material

Here, we have developed a long short-term memory stacked ensemble (LSTM-SE) surrogate modeling approach that can provide rapid predictions of microstructural evolution and the resultant mechanical properties of American Iron and Steel Institute (AISI) 316L series stainless steel (316LSS) fuel cladding under conditions of varying temperature and radiation dose rate. To acquire training data, we developed and implemented a kinetic Monte Carlo (KMC) model to simulate precipitation kinetics of M 23 C 6 , γ', and G phases within SS316L cladding. Experimentally reported precipitation kinetics of SS316L in literature were linked to the kinetic parameters of the simulated precipitation in our KMC model. The model was then used to simulate microstructure evolution under synthetically generated treatments of varying temperature and radiation dose rate, for periods of up to 3000 hours. Changes in volume fraction, number density, and particle size of precipitates were recorded, and particle area fractions were correlated using statistical methods to develop the surrogate model. Simultaneously, the mechanical properties of the simulated microstructures were evaluated using microstructure-based finite element method (FEM) analysis to determine the elastic modulus, yield stress, ultimate tensile strength, and elongation to failure of the aged microstructures. Using this approach, our surrogate model can predict precipitation behavior within 0.25% volume fraction and mechanical properties within 6% relative error from the values predicted by the KMC and FEM models using 50 training simulations as input. The trained recurrent neural network-based model can return estimations of precipitation kinetics and mechanical properties ~1000 times faster than the physics-based codes. This work demonstrates, as a proof of concept, that reactor material service lifetimes under variable service conditions can be predicted for a statistics-based model from a practicably obtainable dataset.

36 MATERIALS SCIENCE

A comparison of wrought and powder metallurgical FeCrAl claddings under simulated LWR accident transients

Iron-chromium-aluminum (FeCrAl) alloys are potential accident tolerant fuel (ATF) cladding candidates for light-water reactors but are difficult to fabricate as thin-walled tubes via conventional cast-and-wrought routes. Powder metallurgy (PM) offers a manufacturing alternative with improved compositional control, but its transient accident performance has not been directly benchmarked against wrought variants. This study evaluates the burst behavior of commercially developed PM-processed FeCrAl alloys, PM-C26M (Fe-12Cr-6Al-2Mo) and the high precipitate density FA-SMT (Fe-22Cr-5Al-3Mo), under simulated light-water reactor accident transient conditions. Burst testing was conducted using the Severe Accident Test Station with heating rates of 5 °C/s and 50 °C/s and internal pressures ranging from 25 MPa to 100 MPa. PM-C26M reproduced wrought C26M burst behavior within 7–37 °C across the stress range, indicating that PM processing does not compromise transient strength. FA-SMT exhibited markedly higher burst temperatures and reduced heating-rate sensitivity, consistent with its engineered precipitate strengthening. FA-SMT rupture exhibited axial "unzipping" rather than the lateral tearing characteristic of PM- and wrought C26M. Post-test EBSD and fractography indicate that this behavior is strongly correlated with strain-gated intergranular void nucleation associated with the dense precipitate architecture of FA-SMT, a response absent in the comparatively clean PM-C26M matrix and consistent with rupture morphologies reported for oxide-dispersion strengthened (ODS) FeCrAl of similar base-matrix chemistry to PM-C26M. These findings highlight the potential of powder metallurgy as a viable fabrication route for ATF claddings from an accident performance standpoint.

Bell, Sam [ORNL] (ORCID:0000000251905657)

Crack mitigation and wear performance of high-strength steel coatings deposited by high-speed laser cladding

This article investigates the fabrication of defect-free Rockit® 606, a high‑carbon, vanadium- and chromium-enriched precipitation-hardening martensitic steel coating, using high-speed laser cladding (HSLC). Compared to conventional laser cladding, HSLC offers higher deposition efficiency, improved coating quality, minimal thermal distortion, and a reduced heat-affected zone. Various HSLC parameters—including laser power, travel speed, powder feed rate, and overlap distance—were optimized to achieve superior coating properties. Microstructural analysis revealed solidification cracks in coatings deposited on carburized steel, regardless of processing parameters. However, preheating the substrate to 250 °C effectively eliminated cracking by reducing thermal gradients. The coatings exhibited a columnar dendritic microstructure, with coarser dendrites near the substrate and finer dendrites towards the surface. Hardness measurements confirmed that all coatings significantly exceeded the industry-specified threshold of 60 HRC, with preheating having minimal effect on overall hardness distribution. Reciprocating sliding wear tests demonstrated a substantial improvement in wear resistance for the defect-free HSLC coatings compared to baseline carburized steel. These findings underscore the potential of HSLC for producing high-performance, wear-resistant coatings suitable for industrial applications.

36 MATERIALS SCIENCE

Mechanical response of HFIR-irradiated M5FRAMATOME cladding under simple and complex loading conditions

This study investigates the mechanical behavior of High Flux Isotope Reactor (HFIR) irradiated M5FRAMATOME cladding under simple and complex loading conditions through axial tensile and reversible cyclic bending. Axial tension specimens were pre-machined prior to HFIR irradiation while cyclic bend specimens were inserted as intact tubes. Tests articles were neutron-irradiated to 4 and 16 dpa, and specimens were tested at ORNL's hotcell facilities. The axial tension tests were conducted under constant displacement control, and the reversible cyclic bend tests were performed using ORNL's Cyclic Integrated Reversible-Bending Fatigue Tester (CIRFT) apparatus. Results showed that mechanical response of Cr-coated and uncoated M5FRAMATOME cladding were similar and independent of irradiation dose for axial tension tests, while Cr-coated specimens’ reversible cyclic bend behavior differed from uncoated counterparts. For all tests, irradiation temperature showed a significant impact on the mechanical behavior. Below 280°C, all axial tensile specimens whether coated or not behaved similarly. Above 280°C, YS and UTS showed decrease with increasing irradiation temperature. A similar behavior was also observed in cyclic bend tests as well. The mechanical damage during cyclic bend tests was linked to damage accumulation in unirradiated Cr-coated zircaloy-4 specimens, and the effect of irradiation temperature was related to changing characteristics of defect mobility during high temperature irradiation.

Cinbiz, Nedim [ORNL] (ORCID:0000000346268515)

Irradiation Vehicles for Evaluating SiC/SiC Cladding Bowing Under Neutron Flux Gradients

Silicon carbide fiber–reinforced silicon carbide matrix (SiC/SiC) composites are among the most promising candidates for long term accident-tolerant nuclear fuel cladding. A key challenge related to their deployment is lateral bowing caused by differential radiation-induced swelling under dose or temperature gradients, which could obstruct coolant flow or interfere with control rod/blade movements. Although previous modeling efforts have predicted bowing behavior in light-water reactor (LWR) environments, experimental validation remains limited, especially at prototypic LWR temperatures. This study addresses that gap by irradiating six reduced-length SiC/SiC cladding tubes (~600 mm) in the High Flux Isotope Reactor (HFIR) at ~300°C, which is representative of LWR conditions. The tubes will be housed in a sealed vessel with an inert gas gap to maintain target temperatures and prevent direct coolant contact. Arranged in three pairs, each set will receive a different radiation dose (low, medium, high), with the central pair receiving ~0.1 displacements per atom (dpa)—the expected dose for peak bowing. The experiment will determine the dose-dependent bowing behavior and validate predictive finite element models. In this work, the tubes are freely suspended from pins to allow for unconstrained bowing; however, we present a concept for introducing localized constraints to represent grid spacer effects. Post-irradiation examination will include swelling measurements and profilometry to assess bowing and compare the results with model predictions. This work aims to confirm the conditions under which maximum bowing occurs so as to improve the reliability of SiC/SiC performance models in nuclear applications.

Russell, Nick [ORNL] (ORCID:0000000296099820)

Brittle failure analysis and modeling of high-burnup PWR fuel cladding alloys

The aim of this research is the development of methods for predicting mechanical behavior and identification of limiting conditions to prevent brittle failure of high-burnup (HBU) pressure water reactor (PWR) fuel cladding alloys. A finite element (FE) model of the ring compression test (RCT) was created to analyze the failure behavior of zirconium-based alloys with radial hydrides during the RCT. An elastic-plastic material model describes the zirconium alloy. The stress-strain curve needed for the elastic-plastic material model was derived by inverse finite element analyses. Cohesive zone modeling is used to reproduce sudden load drops during RCT loading. Based on the failure mechanism in non-irradiated ZIRLO (R) claddings, a micro-mechanical model was developed that distinguishes between brittle failure along hydrides and ductile failure of the zirconium matrix. Two different cohesive laws representing these types of failure are present in the same cohesive interface. The key differences between these constitutive laws are the cohesive strength, the stress at which damage initiates, and the cohesive energy, which is the damage energy dissipated by the cohesive zone. Statistically generated matrix-hydride distributions were mapped onto the cohesive elements and simulations with focus on the first load drop were performed. Computational results are in good agreement with the RCT results conducted on high-burnup M5 (R) samples. It could be shown that crack initiation and propagation strongly depend on the specific configuration of hydrides and matrix material in the fracture area.

Simbruner, Kai

Investigation of Degradation Mechanisms of Cr-coated Zirconium Alloy Cladding in Reactivity-Initiated Accident

Reactivity-initiated accident testing has been performed on two baseline fuel rodlets which were fabricated from Zr-4 cladding and utilized fresh UO 2 fuel pellets. These experiments are part of a larger series of transient irradiations to explore Cr-coated zirconium alloy cladding under Reactivity-initiated accident conditions to evaluate ballooning and burst and sever oxidation characteristic of late-stage failure. The first two irradiations have been completed and post-transient examinations have been performed. In one rod, ballooning and burst occurred, along with oxidation. The second rod leaked and as a result did not balloon as much during the transient. This second rod also experienced increased oxidation compared to the first due to higher temperatures.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS

High-Temperature SiC Cladding Bowing Irradiation Design and HFIR Readiness

Silicon carbide fiber–reinforced silicon carbide (SiC/SiC) matrix composites are candidate materials for long-term accident-tolerant fuel cladding for use in light water reactors (LWRs). This report documents the design of a dry SiC/SiC composite cladding bowing experiment intended for irradiation in the High Flux Isotope Reactor. The dry experiment allows for testing at representative LWR temperatures for comparison to previous experimental results. This report describes detailed neutronics, thermal, and bowing analyses supporting the irradiation. The design leverages calculations from previous irradiation experiments and production targets for reduced design complexity. The thermal analysis provides a map of SiC thermometer temperatures for comparison during post-irradiation examination to determine the experiment’s irradiation temperatures. Finally, two concepts for introducing localized constraints representative of pressurized water reactor grid spacers are presented.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS

Applied Research and Development to Support Open Water Testing at PacWave – Task 5: Development of additively manufactured, functionally graded, corrosion resistant clads for wave energy applications

In this task, we focused on developing corrosion-resistant claddings for wave energy applications. Wave energy systems are exposed to saline conditions, which are corrosive to many metallic structural materials (e.g., carbon steel). Corrosion-resistant (stainless) steels are typically alloyed with >18% chromium (Cr) and >8% nickel (Ni), which dramatically raises material costs and can hinder the development of wave energy systems; thus, coatings are a necessary corrosion protection method for most. Non-metallic coatings (paint, epoxy) have shorter service lives, limited resistance to mechanical stress and wear, plus additional costs of inspection and eventual replacement. Therefore, overlay stainless steel (SS) claddings have a cost-effective use case for protecting components from corrosion, particularly for those that may be subject to mechanical stress / wear and with long service lives.

16 TIDAL AND WAVE POWER

Development and Evaluation of Embrittlement Resistant Alloys for Advanced LWR Cladding

The primary challenge preventing the deployment of reactor designs that leverage wrought FeCrAl as an advanced light-water reactor (LWR) cladding is irradiation hardening and embrittlement. Wrought FeCrAl alloys experience a loss of post-irradiation ductility and fracture toughness under low-temperature neutron irradiation (< 350°C) resulting from the combined effects of dislocation loop formation and the irradiation-enhanced precipitation of Cr-rich alpha-prime precipitates throughout the microstructure. Over the past decade, significant improvements in our understanding regarding the effect of Cr and Al content have been enabled through neutron irradiations, but even optimized wrought alloys such as C26M remain vulnerable to brittle failure during storage, transportation, and handling following irradiation. This report summarizes multiple irradiation campaigns initiated over the past 7 years and provides recent insights into the effect of (1) minor alloying composition, (2) alloy processing strategy, (3) crystal structure, and (4) the use of advanced oxide dispersion strengthened (ODS) alloys. The first irradiation campaign irradiated body-centered cubic FeCrAl alloy C26M with and without elements such as Mo and Y. It also included face-centered cubic alumina-forming austenitic (AFA) alloys that have a steeper neutronic penalty but that have far superior high-temperature strength than wrought FeCrAl. Finally, this campaign compared conventional wrought C26M with the same material produced using modern powder metallurgical hotisostatic pressing (PM-HIP). The second irradiation campaign, initiated in 2018, irradiated wrought and FeCrAl-ODS materials up to 50 dpa to assess their irradiation resistance to high-doses. The results of this work indicate that wrought C26M suffers significant degradation following neutron irradiation at LWR-relevant temperatures regardless of Mo and Y content. The PM-HIP variant appears to be more resilient to irradiation-induced ductility loss in comparison with wrought variants but still loses almost all ductility by 8 dpa. Notably, the AFAs retained at least 5% total elongation after irradiation at the same dose and temperature condition, although additional deterioration may be expected at higher fluence levels. FeCrAl-ODS materials show the greatest promise as a transformative longer-term accident-tolerant fuel (LT-ATF) cladding material. The extruded 106ZY10C alloy retained 10% total elongation after 16 dpa irradiation and retained 8% total elongation after 50 dpa. Additional challenges with FeCrAl-ODS alloys also remain, including optimization of end cap joining methodologies, enhancement of fracture toughness, scaling production to prove economic viability, and optimizing post-pilger heat treatments to maximize ductility and irradiation resistance. This series of irradiations demonstrates the efficacy of the LWR testbed available within the United States for the rapid irradiation and down-selection of LT-ATF candidates. As the country rapidly accelerates its timeline for the deployment of advanced reactor concepts, the effective utilization of the High Flux Isotope Reactor for separate-effects style irradiations should continue to be prioritized to answer the final questions pertaining to LT-ATF candidates necessary for the deployment of advanced boiling water reactors and small modular reactors.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS

Extension of Clad Damage Propagation Model for Fission Gas Dispersal and Two-Phase Flow Effects in MOOSE SubChannel Module

This report presents an extension of the Clad Damage Propagation (CDAP) model implemented in the MOOSE SubChannel Module (SCM) to capture post-failure fission-gas dispersal and two-phase flow effects in sodium-cooled fast reactor assemblies. The extended model tracks discharged gas axially and radially, computes channel-averaged flow quality and void fraction using a Lockhart–Martinelli framework, evaluates two-phase frictional pressure-drop multipliers, determines inlet mass-flow degradation under fixed core pressures, and applies an intensified-void-based heat-transfer degradation to affected fuel pins. Radial plume expansion is parameterized using mineral-oil jet experiments mapped to sodium conditions via Reynolds–Weber similarity. Implementation details are documented, along with the new methods and user inputs needed to control plume mapping and two-phase behavior. Demonstration simulations for 19- and 37-pin bundles show that breach size and inlet velocity strongly influence propagation potential: small breaches (≤0.5 mm) produce limited degradation while larger breaches (~1 mm) can drive oscillatory temperature spikes and enhanced failure propagation, especially at higher velocities. These results demonstrate that the extended CDAP model provides a more complete framework for quantifying cladding damage propagation and evaluating propagation potential in transient scenarios. The approach remains computationally efficient, consistent with subchannel-level analysis, yet incorporates sufficient physics to bridge localized post-failure effects with bundle- and assembly-scale degradation.

22 GENERAL STUDIES OF NUCLEAR REACTORS

Material development for thermionic fuel-cladding systems.

Fuel-cladding systems capable of maintaining stable dimension and electron emission characteristics at high temperatures under irradiation are essential to the successful operation of nuclear thermionic power sources. Studies regarding two possible systems, involving tungsten clad uranium carbide and uranium oxide, are considered. Out-of-pile developmental efforts and the in-pile evaluation results for the two systems are described. Prototypical emitters have been tested for 8000 hours for the carbide system and 4000 hours for the oxide system.

Yang, L.

Irradiation test of tungsten clad uranium carbide-zirconium carbide ((U,Zr)C) specimens for thermionic reactor application at conditions conductive to long-term performance

Uranium carbide fueled, thermionic emitter configurations were encapsulated and irradiated. One capsule contained a specimen clad with fluoride derived chemically vapor deposited (CVD) tungsten. The other capsule used a duplex clad specimen consisting of chloride derived on floride derived CVD tungsten. Both fuel pins were 16 millimeters in diameter and contained a 45.7-millimeter length of fuel.

Creagh, J. W. R.

Development of a metal-clad advanced composite shear web design concept

An advanced composite web concept was developed for potential application to the Space Shuttle Orbiter main engine thrust structure. The program consisted of design synthesis, analysis, detail design, element testing, and large scale component testing. A concept was sought that offered significant weight saving by the use of Boron/Epoxy (B/E) reinforced titanium plate structure. The desired concept was one that was practical and that utilized metal to efficiently improve structural reliability. The resulting development of a unique titanium-clad B/E shear web design concept is described. Three large scale components were fabricated and tested to demonstrate the performance of the concept: a titanium-clad plus or minus 45 deg B/E web laminate stiffened with vertical B/E reinforced aluminum stiffeners.

Laakso, J. H.

Apollo experience report: Detection and minimization of ignition hazards from water/glycol contamination of silver-clad electrical circuitry

The potential flammability hazard when a water/glycol solution contacts defectively insulated silver-clad copper circuitry or electrical components carrying a direct current is described. The chemical reactions and means for detecting them are explained. Methods for detecting and cleaning contaminated areas and the use of inhibitors to arrest chemical reactivity are also explained. Preventive measures to minimize hazards are given. Photomicrographs of the chemical reactions occurring on silver clad wires are also included.

Downs, W. R.

Measurement and analysis of periodic coupling in silicon-clad planar waveguides

Computer modeling studies indicate that planar dielectric waveguides clad with silicon exhibit a damped periodic oscillation in their attenuation and phase characteristics. The effect is due to a periodic coupling between the lossy, guided modes in the silicon film and the TE0 mode of the dielectric waveguide. Experimental confirmation of the periodic coupling for a wavelength of 632.8 nm is presented. Propagation characteristics for a wavelength of 1150 nm were investigated for application in integrated optical modulators. Frequency filtering properties of silicon-clad waveguides are also examined and it is shown that the silicon thickness controls the filter response curve.

Mcwright, G. M.

Cladding for transverse-pumped solid-state laser

In a transverse pumped, solid state laser, a nonabsorptive cladding surrounds a gain medium. A single tranverse mode, namely the Transverse Electromagnetic (TEM) sub 00 mode, is provided. The TEM sub 00 model has a cross sectional diameter greater than a transverse dimension of the gain medium but less than a transverse dimension of the cladding. The required size of the gain medium is minimized while a threshold for laser output is lowered.

Byer, Robert L.

Process for the manufacture of seamless metal-clad fiber-reinforced organic matrix composite structures

A process for producing seamless metal-clad composite structures includes providing a hollow, metallic inner member and an outer sleeve to surround the inner member and define an inner space therebetween. A plurality of continuous reinforcing fibers is attached to the distal end of the outside diameter of the inner member, and the inner member is then introduced, distal end first, into one end of the outer sleeve. The inner member is then moved, distal end first, into the outer sleeve until the inner member is completely enveloped by the outer sleeve. A liquid matrix material is then injected into the space containing the reinforcing fibers between the inner member and the outer sleeve. Next a pressurized heat transfer medium is passed through the inner member to cure the liquid matrix material. Finally, the wall thickness of both the inner member and the outer sleeve are reduced to desired dimensions by chemical etching, which adjusts the thermal expansion coefficient of the metal-clad composite structure to a desired value.

Bluck, Raymond M.