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At least 109 records · Page 6
All sourcesNASA NTRSDOE OSTI
DOE OSTI2011

Comparison of Calculated and Measured Neutron Fluence in Fuel/Cladding Irradiation Experiments in HFIR

A recently-designed thermal neutron irradiation facility has been used for a first series of irradiations of PWR fuel pellets in the high flux isotope reactor (HFIR) at Oak Ridge National Laboratory. Since June 2010, irradiations of PWR fuel pellets made of UN or UO{sub 2}, clad in SiC, have been ongoing in the outer small VXF sites in the beryllium reflector region of the HFIR, as seen in Fig. 1. HFIR is a versatile, 85 MW isotope production and test reactor with the capability and facilities for performing a wide variety of irradiation experiments. HFIR is a beryllium-reflected, light-water-cooled and -moderated, flux-trap type reactor that uses highly enriched (in {sup 235}U) uranium (HEU) as the fuel. The reactor core consists of a series of concentric annular regions, each about 2 ft (0.61 m) high. A 5-in. (12.70-cm)-diam hole, referred to as the flux trap, forms the center of the core. The fuel region is composed of two concentric fuel elements made up of many involute-shaped fuel plates: an inner element that contains 171 fuel plates, and an outer element that contains 369 fuel plates. The fuel plates are curved in the shape of an involute, which provides constant coolant channel width between plates. The fuel (U{sub 3}O{sub 8}-Al cermet) is nonuniformly distributed along the arc of the involute to minimize the radial peak-to-average power density ratio. A burnable poison (B{sub 4}C) is included in the inner fuel element primarily to reduce the negative reactivity requirements of the reactor control plates. A typical HEU core loading in HFIR is 9.4 kg of {sup 235}U and 2.8 g of {sup 10}B. The thermal neutron flux in the flux trap region can exceed 2.5 x 10{sup 15} n/cm{sup 2} {center_dot} s while the fast flux in this region exceeds 1 x 10{sup 15} n/cm{sup 2} {center_dot} s. The inner and outer fuel elements are in turn surrounded by a concentric ring of beryllium reflector approximately 1 ft (0.30 m) thick. The beryllium reflector consists of three regions: the removable reflector, the semi-permanent reflector, and the permanent reflector. It is surrounded by a water reflector of effectively infinite thickness. In the axial direction, the reactor is reflected by water above and below the reactor. The irradiation facilities, one for UN and the other for UO{sub 2} pellets, utilize a thin cylindrical hafnium shield approximately 4 cm in diameter surrounding the facility basket to reduce the thermal neutron flux sufficiently such that the linear power rating in the irradiated fuel pins will be similar to PWR operating conditions. The facilities each contain nine fuel pins, each comprising 10 fuel pellets, arranged as if three fuel rods.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2017

Parametric Evaluation of SiC/SiC Composite Cladding with UO 2 Fuel for LWR Applications: Fuel Rod Interactions and Impact of Nonuniform Power Profile in Fuel Rod

SiC/SiC composites are candidates for accident tolerant fuel cladding in light water reactors. In the extreme nuclear reactor environment, SiC-based fuel cladding will be exposed to neutron damage, significant heat flux, and a corrosive environment. Here, to ensure reliable and safe operation of accident tolerant fuel cladding concepts such as SiC-based materials, it is important to assess thermo-mechanical performance under in-reactor conditions including irradiation and realistic temperature distributions. The effect of non-uniform dimensional changes caused by neutron irradiation with spatially varying temperatures, along with the closing of the fuel–cladding gap, on the stress development in the cladding over the course of irradiation were evaluated. The effect of non-uniform circumferential power profile in the fuel rod on the mechanical performance of the cladding is also evaluated. These analyses have been performed using the BISON fuel performance modeling code and the commercial finite element analysis code Abaqus. A constitutive model is constructed and solved numerically to predict the stress distribution in the cladding under normal operating conditions. The dependence of dimensions and thermophysical properties on irradiation dose and temperature has been incorporated into the models. Initial scoping results from parametric analyses provide time varying stress distributions in the cladding as well as the interaction of fuel rod with the cladding under different conditions of initial fuel rod-cladding gap and linear heat rate. It is found that a non-uniform circumferential power profile in the fuel rod may cause significant lateral bowing in the cladding, and motivates further analysis and evaluation.

Accident tolerant fuel↗
DOE OSTI2013

Scoping assessments of ATF impact on late–stage accident progression including molten core-concrete interaction

Simple scoping models that can be used to evaluate ATF performance under severe accident conditions have been developed. The methodology provides a fundamental technical basis (a.k.a. metric) based on the thermodynamic boundary for evaluating performance relative to that of traditional Zr-based claddings. The initial focus in this study was on UO 2 fuel with the advanced claddings 310 SS, D9, FeCrAl, and SiC. The evaluation considered only energy release with concurrent combustible gas production from fuel–cladding–coolant interactions and, separately, molten core–concrete interactions at high temperatures. Other important phenomenological effects that can influence the rate and extent of cladding decomposition (e.g., eutectic interactions, degradation of other core constituents) were not addressed. For the cladding types addressed, potential combustible gas production under both in-vessel and ex-vessel conditions was similar to that for Zr. However, exothermic energy release from cladding oxidation was substantially less for iron-based alloys (by at least a factor of 4), and modestly less (by ~20%) for SiC. Data on SiC-clad UO 2 fuel performance under severe accident conditions are sparse in the literature; thus, assumptions on the nature of the cladding decomposition process were made in order to perform this initial screening evaluation. Furthermore, experimental data for this system under severe accident conditions is needed for a proper evaluation and comparison to iron-based claddings.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2022

Stress rupture of SiC/SiC composite tubes under high-temperature steam

SiC-fiber–reinforced SiC matrix composite cladding for light water reactor fuel elements must withstand high-temperature steam oxidation in a loss-of-coolant accident scenario (LOCA). Current composite designs include an outer monolithic SiC layer, in part, to increase steam oxidation resistance. However, it is not clear how such a structure would behave under high-temperature steam in the case when the monolithic layer cracks and carbon interphases and SiC fibers are exposed to the environment. To fill this knowledge gap, stress-rupture tests of prototypic SiC composite cladding at 1000°C under steam and inert environments were conducted. The applied stress was ~120 MPa, which was beyond the initial cracking stress. The failure lifetime under steam was 400–1300 s, while 75% of the composite specimens did not fail after 3 h of total exposure under inert gases. Microstructural observations suggest that steam oxidation activated slow crack growth in the fibers, which led to failure of the composite. The results from this study suggest that stress rupture in steam environments could be a limiting factor of the cladding under reactor LOCA conditions.

36 MATERIALS SCIENCE↗
DOE OSTI2016

Fuel cycle impacts of accident tolerant fuels

This paper discusses the impact of several accident-tolerant fuel (ATF) options on the fuel cycle performance of once-through LWRs compared to current uranium oxide-Zircaloy fueled commercial LWRs. Desirable characteristics of proposed ATF concepts include higher thermal conductivity, enhanced fission product retention, and reduced reaction kinetics and hydrogen generation in loss of coolant conditions. ATF concepts that have been proposed target changes to the fuel and/or cladding. Broadly speaking, the options can be summarized as follows: -) UO{sub 2} pellet fuels with increased thermal conductivity to lower temperatures, -) high-density pellet fuels (e.g., nitrides and/or silicides), -) fully ceramic microencapsulated (FCM) fuels, -) metallic fuel with high fissile density and high thermal conductivity, -) coatings on Zircaloy cladding, -) total elimination of the Zircaloy as cladding and replacement with a ceramic, and -) composite cladding including for instance layered Zircaloy and SiC and molybdenum. We can draw 4 conclusions. First, other than SiC, the other cladding options will result in a reactivity penalty requiring either thinner cladding or increased fissile loading. Secondly, silicide fuels have a higher density than UO{sub 2} and can allow longer cycle lengths for the same enrichment or a reduction in the enrichment for a given cycle length. Thirdly, while the pellet fuels yield very similar results, the FCM fuel is dramatically different due to the low fuel loading. Fourthly, we have to note that in order to achieve the maximum benefit from a particular fuel-clad combination, it requires consideration of the characteristics of each. For example, a cladding with a relatively high absorption (e.g., FeCrAl) would benefit from a high density fuel such as U{sub 3}Si{sub 2}.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
NASA NTRS1989

Chemical vapor deposition for silicon cladding on advanced ceramics

Polycrystalline Si was used to clad several advanced ceramic materials such as SiC, Si3N4, sapphire Al2O3, pyrolytic BN, and Si by a CVD process. The thickness of Si cladding ranged from 0.025 to 3.0 mm. CVD Si adhered quite well to all the above materials except Al3O, where the Si cladding was highly stressed and cracked or delaminated. A detailed material characterization of Si-clad SiC samples showed that Si adherence to SiC does not depend much on the substrate surface preparation; that the thermal cycling and polishing of the samples do not cause delamination; and that, in four-point bend tests, the Si-SiC bond remains intact, with the failure occurring in the Si.

Goela, Jitendra S.↗
DOE OSTI2021

Grid-to-rod fretting wear study of SiC/SiC composite accident-tolerant fuel claddings using an autoclave fretting bench test

Grid-to-rod-fretting (GTRF) in pressurized water reactors (PWRs) is known to cause wear and surface damage on the fuel claddings, potentially leading to radioactive leakage. One of the accident-tolerant fuel (ATF) concepts is to use advanced cladding materials that could withstand higher temperatures. Here, we investigated the wear behavior of candidate silicon carbide (SiC)-based composite claddings with different levels of surface finish in fretting against a commercial ZIRLO alloy grid using a unique bench-scale autoclave GTRF rig. The experiments mimicked the environment in an industrial full-assembly PWR simulator. Fretting tests were conducted with a realistic load (~0.5 N) in deionized water under a pressure of 20–23 bar at 204 °C for 100 h. While the SiC/SiC composite claddings showed significantly higher wear resistance than the commercial ZIRLO alloy cladding as expected, the smoother versions experienced surprisingly higher wear than the much softer counterface, ZIRLO grid. The wear mechanism of the SiC/SiC cladding was attributed to the SiC wear debris that was trapped at the fretting interface causing both 3-body and 2-body (embedded into the grid surface) abrasion of the cladding. Rougher SiC/SiC claddings had less material loss but caused more wear on the ZIRLO grid. Finally, pre-oxidized ZIRLO grid showed better compatibility with the SiC/SiC cladding to protect both the cladding and grid as a result of reduced wear debris trapping.

36 MATERIALS SCIENCE↗
DOE OSTI2015

Report on status of execution of SiC step document

Advanced fuel claddings made entirely or mainly of silicon carbide (SiC) ceramics and/or composites are considered very attractive elements of the accident-tolerant fuels for the light water reactors. In order to translate the promise of SiC composite materials into a reliable fuel cladding, a coordinated program of component level design and materials development must be carried out with many key feasibility issues addressed a-priori to inform the process. With the primary objective of developing a draft blueprint of a technical program that addresses the critical feasibility issues; assesses design and performance issues related with manufacturing, operating, and off-normal events; and advances the technological readiness levels in essential technology elements, a draft plan for the Systematic Technology Evaluation Program for SiC/SiC Composite Accident-Tolerant LWR Fuel Cladding and Core Structures was developed in the FY-14 Advanced Fuels Campaign of the U.S. Department of Energy’s Fuel Cycles Research and Development Program. This document summarizes the status of execution of the technical plan within the activities at the Oak Ridge National Laboratory.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Effects of elevated temperature exposure on the residual stress state and microstructure of PVD Cr coatings on SiC investigated via in situ X-ray diffraction and transmission electron microscopy

Pure Cr coatings are being considered as corrosion-resistant layers for SiC-SiC f composite fuel cladding in light water reactors. The residual stress state and interdiffusion behavior of Cr coatings deposited on SiC substrates using bipolar high-power impulse magnetron sputtering (B-HiPIMS) and direct current impulse magnetron sputtering (DCMS) were studied using in situ X-ray diffraction experiments at 300 °C, 700 °C, and 1200 °C. After elevated temperature exposure, evolution of the coating microstructure and coating/substrate interdiffusion was characterized by transmission electron microscopy. The compressive residual stress of the dense B-HiPIMS coating at room temperature was gradually relieved at 300 °C, while the stress transitioned to a tensile state at 700 °C. Grain growth of the Cr coating and a Cr–SiC interdiffusion layer consisting of newly formed Cr–C and Cr–Si phases were observed in the B-HiPIMS coating after exposure at 700 °C. The phases in the interdiffusion layer were identified to be Cr 7 C 3 , Cr 3 Si, and Cr 5 Si 3 C x experimentally and by thermodynamic predictions. For the DCMS coating, however, changes in residual stress and microstructure at the elevated temperatures were limited by the inherent porosity and inhomogeneous structure of the as-deposited coating. At 1200 °C, both coating types interacted rapidly with the underlying SiC substrate in the early stages of the experiment. The results from this study suggest that the characteristics of the Cr coatings do not significantly change at the reactor operating temperature of 300 °C, while changes in microstructure and stress state are expected in off-normal conditions of 700 °C and 1200 °C. Finally the results from this study suggest the B-HiPIMS coating is best-suited as a protective coating for SiC fuel cladding.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Damage progression and failure of SiC/SiC composite tubes under hard-contact radial expansion

The response of silicon carbide (SiC) fiber-reinforced SiC matrix (SiC/SiC) composite cladding to mechanical interaction with fissile fuel is a knowledge gap that must be overcome to design and assess SiC-based cladding systems for advanced nuclear applications. This study developed the relevant mechanical testing capability and identified the failure behavior and the critical microstructural features and processing defects. Sections of SiC composite tube were subjected to a modified expansion-due-to-compression (EDC) test in an X-ray computed tomography microscope: a polyurethane plug pressed surrogate Al 2 O 3 into the inner walls of the SiC/SiC composite tubes to achieve hard contact. A pure EDC test with just a polyurethane plug was also performed as a reference. Through the use of displacement fields, digital volume correlation revealed inhomogeneous deformation fields in the tubes, even for pure EDC, which was related to the inherent defects in the structure. Deep learning–aided segmentation and systematic data analysis revealed that the presence of inhomogeneous deformation applied by the hard contact was exaggerated by the presence of inner surface imperfections left behind from the matrix densification process. In conclusion, the findings provide insights into the applications, highlighting the necessity for improvements in inner surface roughness and the incorporation of localized contacts in pellet–cladding mechanical interaction computational models.

Composites↗
DOE OSTI2017

Experimental design and analysis for irradiation of SiC/SiC composite tubes under a prototypic high heat flux

The purpose of this work is to design an irradiation vehicle for testing silicon carbide (SiC) fiber-reinforced SiC matrix composite cladding materials under conditions representative of a light water reactor in order to validate thermo-mechanical models of stress states in these materials due to irradiation swelling and differential thermal expansion. The design allows for a constant tube outer surface temperature in the range of 300–350 °C under a representative high heat flux (~0.66 MW/m 2 ) during one cycle of irradiation in an un-instrumented “rabbit” capsule in the High Flux Isotope Reactor. An engineered aluminum foil was developed to absorb the expansion of the cladding tubes, due to irradiation swelling, without changing the thermal resistance of the gap between the cladding and irradiation capsule. Finite-element analyses of the capsule were performed, and the models used to calculate thermal contact resistance were validated by out-of-pile testing and post-irradiation examination of the foils and passive SiC thermometry. Six irradiated cladding tubes (both monoliths and composites) were irradiated and subsequently disassembled in a hot cell. The calculated temperatures of passive SiC thermometry inside the capsules showed good agreement with temperatures measured post-irradiation, with two calculated temperatures falling within 10 °C of experimental measurements. Furthermore, the success of this design could lead to new opportunities for irradiation applications with materials that suffer from irradiation swelling, creep, or other dimensional changes that can affect the specimen temperature during irradiation.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2020

Dynamic PRA-Based Estimation of PWR Coping Time Using a Surrogate Model for Accident Tolerant Fuel

In this study, we propose an interpolation-based response surface surrogate methodology to manage a large number of scenarios in dynamic probabilistic risk assessment. It adopts the shape Dynamic Time Warping algorithm to cluster the interpolation neighborhood from time series sample data. The interpolation method was adapted from Taylor Kriging to allow a reduced-order model of the Taylor series. In order to demonstrate its applicability to complex issues in risk assessment for nuclear engineering, an example risk response surface to estimate emergency core cooling system (ECCS) criteria for triplex silicon carbide (SiC) accident-tolerant fuel was constructed. The response surface was exploited to estimate the cumulative failure probability of the fuel cladding structure due to the uncertainties in operator actions and safety systems. The functional failures were assessed based on a combination of individual layer failures computed by coupling Risk Analysis Virtual Environment software with a pressurized water reactor 1000-MW(electric) RELAP5 model and the in-house fuel performance assessment module. Results showed that SiC cladding failure probability spiked less than 1 min after a large-break loss-of- coolant accident whenever the current ECCS criteria for Zircaloy-4 (Zr-4) cladding was used. However, it still provides an increased safety margin of three orders of magnitude compared to Zr-4. This positive margin could be utilized to relax active ECCS requirements by allowing deviations of up to 450 s in its actuation time. The proposed surrogate methodology generated a response surface of SiC cladding failure probability reasonably well, with a significant savings of computation time. This methodology is expected to be useful in the analysis of system response with complex uncertainty sources.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2013

Laser Cladding Applied to the Construction of PFC's with Integral Tritium Diffusion Barriers (Final Report)

This report summarizes progress during the performance period of 02 February 2013 through 02 December 2013 for contract number DE-SC0009685. During this period Nanohmics Inc., in partnership with Dr. Y. C. Shin of Purdue Universities’ Mechanical Engineering Department, have successfully developed a design and a process for constructing PFC tiles suitable for incorporation in fusion reactors. The tiles consist of an ODS steel substrate with tungsten cladding, an integral SiC tritium diffusion barrier layer and a top cap of tungsten. The close match of the coefficient of linear expansion (CTE) between the tungsten and the SiC layer allow high temperature operation without layer delamination of cracking. Furthermore, similar samples constructed by Nanohmics were tested at MIT’s Plasma Science Fusion Center and demonstrated the SiC layer to be an excellent barrier for hydrogen isotope diffusion. The cladding process for applying tungsten to the ODS substrate is unique and provides a quick means of joining complex ODS structures to tungsten layers.

Laser Cladding Applied to the Construction of PFC'↗
DOE OSTI2022

Post-irradiation Examination Status for the BSU-269 Project

High-density uranium inter-metallic uranium silicide (U 3 Si 2 ) was initially considered as a potential advanced nuclear fuel for light water reactor (LWR) systems due to several advantages it demonstrated in thermophysical properties, chemical, and irradiation stability. In addition to understanding the basic thermophysical and mechanical properties of U 3 Si 2 under LWR irradiation conditions, it is important to assess its performance with advanced claddings such as FeCrAl, SiC, or conventional Zr-based claddings. Several aspects of the fuel cycle and fuel performance are being evaluated for U 3 Si 2 coupled with different types of claddings. To thoroughly characterize the U 3 Si 2 -cladding system, their chemical compatibilities and the potential for fuel-cladding chemical interaction (FCCI) must be addressed. Interdiffusion studies have been performed between U 3 Si 2 /Zry-4 and U 3 Si 2 /FeCrAl using diffusion couples. For the U 3 Si 2 /Zry-4 system, ZrSi 2 was the primary interdiffusion product observed at 800°C in addition to other secondary phases from the Zr alloying elements such as Fe and Cr. Low melting point U 6 Fe was also observed at 1000°C. For the U 3 Si 2 /FeCrAl system, at temperatures above 500°C, chemical diffusion Fe-U and Fe-U-Si was observed, increasing with rising temperatures. Although information from these non-irradiated tests is a fundamental first assessment, follow-up with focused irradiation tests is necessary. Irradiation can significantly alter the structure and evolution of the FCCI layers compared to the non-irradiated conditions.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2014

Neutronics and Fuel Performance Evaluation of Accident Tolerant Fuel under Normal Operation Conditions

This report details the analysis of neutronics and fuel performance analysis for enhanced accident tolerance fuel, with Monte Carlo reactor physics code Serpent and INL’s fuel performance code BISON, respectively. The purpose is to evaluate two of the most promising candidate materials, FeCrAl and Silicon Carbide (SiC), as the fuel cladding under normal operating conditions. Substantial neutron penalty is identified when FeCrAl is used as monolithic cladding for current oxide fuel. From the reactor physics standpoint, application of the FeCrAl alloy as coating layer on surface of zircaloy cladding is possible without increasing fuel enrichment. Meanwhile, SiC brings extra reactivity and the neutron penalty is of no concern. Application of either FeCrAl or SiC could be favorable from the fuel performance standpoint. Detailed comparison between monolithic cladding and hybrid cladding (cladding + coating) is discussed. Hybrid cladding is more practical based on the economics evaluation during the transition from current UO 2 /zircaloy to Accident Tolerant Fuel (ATF) system. However, a few issues remain to be resolved, such as the creep behavior of FeCrAl, coating spallation, inter diffusion with zirconium, etc. For SiC, its high thermal conductivity, excellent creep resistance, low thermal neutron absorption cross section, irradiation stability (minimal swelling) make it an excellent candidate materials for future nuclear fuel/cladding system.

99 GENERAL AND MISCELLANEOUS↗
DOE OSTI2018

Fuel performance of chromium-coated zirconium alloy and silicon carbide accident tolerant fuel claddings

The U.S. Department of Energy’s Accident Tolerant Fuel program is focused on extending the time for fuel failure during postulated severe accidents compared to the standard UO2-Zr alloy fuel system. This research investigates the feasibility of two different chromium-coated cladding concepts, one of which is zirconium-alloy based and the other is composite-SiC based. Both claddings had 50µm coatings, deducted from the base layer thicknesses. The claddings were reported on, using the multi- physics fuel performance tool BISON, under steady-state PWR operating conditions as well as two transients: power ramp and a loss-of-coolant accident (LOCA). The chromium-coated claddings showed comparable thermo-mechanical performance to the reference Zircaloy-4 cladding. As chromium is reported to provide an order of magnitude improvement in oxidation resistance, it is expected to be a better alternative in accident scenarios. Simulation results for both concepts call for further experimental investigation as well as modeling of beyond design-basis accidents.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2023

Multi-Scale Characterization of Porosity and Cracks in Silicon Carbide Cladding after Transient Reactor Test Facility Irradiation

Silicon carbide (SiC) ceramic matrix composite (CMC) cladding is currently being pursued as one of the leading candidates for accident-tolerant fuel (ATF) cladding for light water reactor applications. The morphology of fabrication defects, including the size and shape of voids, is one of the key challenges that impacts cladding performance and guarantees reactor safety. Therefore, quantification of defects’ size, location, distribution, and leak paths is critical to determining SiC CMC in-core performance. This research aims to provide quantitative insight into the defect’s distribution under multi-scale characterization at different length scales before and after different Transient Reactor Test Facility (TREAT) irradiation tests. A non-destructive multi-scale evaluation of irradiated SiC will help to assess critical microstructural defects from production and/or experimental testing to better understand and predict overall cladding performance. X-ray computed tomography (XCT), a non-destructive, data-rich characterization technique, is combined with lower length scale electronic microscopic characterization, which provides microscale morphology and structural characterization. This paper discusses a fully automatic workflow to detect and analyze SiC-SiC defects using image processing techniques on 3D X-ray images. Following the XCT data analysis, advanced characterizations from focused ion beam (FIB) and transmission electron microscopy (TEM) were conducted to verify the findings from the XCT data, especially quantitative results from local nano-scale TEM 3D tomography data, which were utilized to complement the 3D XCT results. In this work, three SiC samples (two irradiated and one unirradiated) provided by General Atomics are investigated. The irradiated samples were irradiated in a way that was expected to induce cracking, and indeed, the automated workflow developed in this work was able to successfully identify and characterize the defects formation in the irradiated samples while detecting no observed cracking in the unirradiated sample. These results demonstrate the value of automated XCT tools to better understand the damage and damage propagation in SiC-SiC structures for nuclear applications.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗