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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 109 records · Page 6
All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

Investigation of the temperature-dependent failure processes in PVD Cr-coated ZIRLO nuclear fuel cladding using in situ X-ray micro-tomography imaging

In this work, an accident tolerant fuel cladding system with Cr coating deposited using physical vapour deposition (PVD) method onto commercial Optimized ZIRLO™ was studied. The cladding tubes were machined into C-rings and loaded to failure under compression with real-time synchrotron micro-X-ray computed tomography (XCT) imaging at room temperature (RT), 345 °C, 650 °C and 950 °C in argon (Ar) atmosphere. The mechanical behaviour and failure processes were found strongly temperature-dependent where the Cr coating showed brittle fracture at RT and 345 °C, ductile fracture at 650 °C and a reversion to brittle fracture at 950 °C. Nanoindentation measurements and scanning electron microscopy (SEM) imaging were conducted on the materials after high temperature testing. It was found that recrystallisation of the Cr coating occurred at elevated temperatures, which significantly affected its local properties hence the failure behaviour at different temperatures. This work represents the first in situ 3D XCT observation of progressive failure processes in PVD Cr-coated ZIRLO claddings up to 950 °C providing critical insights into its brittle-to-ductile transition (BDTT) behaviour and subsequent ductile-to-brittle reversion with the increase in temperature. Moreover, results are compared with other PVD Cr-coated Zircaloy materials from open literature; the influences of the coating microstructure and local properties on the failure stress/strain and fracture processes are discussed.

Yuan, Guanjie↗
DOE OSTI2023

Effect of surface oxides on tritium entrance and permeation in FeCrAl alloys for nuclear fuel cladding: a review

Abstract Iron-chromium-aluminum (FeCrAl) alloys are being considered for the cladding of uranium dioxide fuel in light water reactors (LWRs). FeCrAl alloys have good mechanical properties at temperatures of 300 °C and higher, and have superlative resistance to attack by steam at temperatures of up to 1000 °C and higher. A concern has been raised that the use of FeCrAl for cladding would result in a higher content of tritium in the reactor coolant as compared with the current system where the cladding is a zirconium based alloy. This review shows that the flux of tritium from the fuel rod cavities to the coolant across the fuel cladding wall will be greatly reduced by the presence of oxides on the surface of the cladding. The review of current literature and permeation data show that (a) protective oxides are expected to be present on both sides of the FeCrAl cladding, and (b) depending on the characteristics of these oxide layers it is reasonable to expect about two–three orders of magnitude reduction in tritium permeation, relative to the permeation response in clean, unoxidized condition for FeCrAl steels of interest, around 277 °C–377 °C temperatures.

Electrochemistry↗
DOE OSTI2021

Technical Basis for Extended Dry Storage of Aluminum-Clad Spent Nuclear Fuel

This report addresses previously identified technical knowledge and technology gaps and presents the key findings of the multiyear, EMTD-funded research efforts with the goal of evaluating whether ASNF can be safely stored dry for many decades and whether changes to existing ASNF management practices are appropriate. The findings formulate the technical basis for the extended dry storage of ASNF, leading to the main conclusion: All completed work to close the identified knowledge gaps on extended (>50 years) ASNF dry storage supports the conclusion that extended ASNF dry storage is both safe and viable.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2018

Development of Transient Coupled Chemical-Thermal-Fluid Multiphysics Simulation for Unsealed, Vented Aluminum-clad Spent Nuclear Fuel Storage Canister

As the second step towards modeling three-dimensional (3D) multi-physics computational fluid dynamics (CFD) of the unsealed containers in the IFSF facility, the previous methodology used for developing the sealed DOE standard canister model was utilized here. This 3D CFD model considers unsealed canister with small mass exchange with surrounding air as time evolves in the simulation and contains a larger network of chemical reactions to consider due to several of the side reactions occurring in the presence of water vapor, nitrogen, oxygen and carbon dioxide rather than a helium backfilled canister. Similar to the sealed system, the set of full radiolytic chemical reactions of bulk moist air were established, and then reduced to a more manageable set of equations for the computational efficiency of the 3D CFD simulation. Due to the similar size of the unsealed canisters to the sealed DOE canisters, it is assumed that the chemical and thermal response times to changes in the conditions remains similar such that the same time-stepping algorithm can be utilized. This report documents the theory of the model, workflow to establish radiolysis reaction network, and initial simulations of the evolutions of thermal fields, hydrogen gas and nitric acid concentrations within unsealed canisters in conditions relevant to INL INTEC CPP-603 over a long period of time.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2020

Transient Coupled Chemical-Thermal-Fluid Field Simulation for Sealed Aluminum-clad Spent Nuclear Fuel Storage Canister

As the first step toward developing three-dimensional (3D) multi-physics computational fluid dynamics (CFD) model for unsealed and vented canister storage system, a 3D CFD model coupled with bulk gas radiolysis reactions was developed first for sealed DOE standard canisters filled with inert gas and trace amount of air and water. The workflow for constructing canister-scale 3D CFD models and coupling with gas phase radiolysis reactions were established, which can be readily extended to unsealed, vented canister storage system. This interim milestone report documents the theory of the model, workflow to establish radiolysis reaction network, and initial simulations of the evolutions of thermal fields and hydrogen gas concentrations within sealed DOE standard canisters over long period of time. In addition, a mesh refinement test was done to show that increasing the models mesh refinement had negligible impact upon the temperature profiles.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2018

Accelerated Irradiation Testing of Miniature Nuclear Fuel and Cladding Specimens

Qualification of advanced nuclear fuels and materials requires irradiation testing to provide input to predictive models for licensing. Oak Ridge National Laboratory has a long history of performing accelerated irradiation testing and post-irradiation examination (PIE) of miniature material specimens to determine the evolution of microstructure and thermophysical properties, leveraging the High Flux Isotope Reactor, dedicated hot cells, and instruments for handling small, low-level radioactive samples. This work gives a brief overview of irradiation testing of miniature samples to support qualification of advanced fuel cladding materials such as FeCrAl alloys and SiC ceramic matrix composites. More recent work has enabled separate effects irradiation testing of miniature fuel specimens. The small fuel size essentially decouples fuel temperature from fission rate, allowing for highly accelerated testing without large temperature gradients. This paper briefly highlights the new mini fuel irradiation facility and its first set of experiments.

Petrie, Christian↗
DOE OSTI2018

Oxyhydroxides on aluminum spent nuclear fuel: formation studies and removal practices to prevent radiolytic gas production

Aluminum-clad nuclear fuel has been at the forefront in research and commercial reactors. After being removed from the reactor, the spent nuclear fuel is placed in large-volume water basins (wet storage) that are constantly monitored for water quality to minimize corrosion/deterioration. The water provides both radiation shielding and cooling for the freshly removed fuel. It is highly desired to have a pathway for fuel to be transitioned to dry storage in sealed casks, so that spent nuclear fuel can be safely transported and dispositioned in a permanent repository, and basin capacity can be made available for temporary wet storage of fresher spent fuel. A challenge for safe, road-ready dry storage is the hydrated aluminum oxides (oxyhydroxides) that are prevalent on aluminum spent nuclear fuel that has been stored under water for years. If water is released from the oxyhydroxides during dry storage, it can create corrosion within the storage canister, and hydrogen can be generated through radiolysis of the oxyhydroxides, causing pressurization and flammability risks. The focus of this project is to develop knowledge of the oxyhydroxide growth and production of gases through radiolysis and to apply empirical models for predicting these phenomena. The expertise developed will be used to formulate conditions and parameters for oxyhydroxide removal/dehydration from fuel cladding through vacuum or forced-air gas drying, to prevent problems during permanent dry storage.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2021

Fracture toughness evaluations for spent nuclear fuel dry storage canister welds and spent nuclear fuel clad-pellet structures

Integrity of spent nuclear fuel (SNF) interim storage canisters is very important to the safety of the back-end nuclear fuel cycle. Stress corrosion cracking (SCC) potential of interim storage canister has been considered as a high priority. Because no post-weld heat treatment was required for forming these canisters, the high tensile residual stress existed within these canister welds. This can change the fracture resistance capacity significantly as well as increase SCC potential. Due to relative thin shell thickness of a canister weldment, the spiral notch torsion test (SNTT) method was used to estimate the canister weldment fracture toughness. SNTT was developed to measure the intrinsic fracture toughness of structural materials using small specimens. The SNTT method has been applied to a wide variety of structural materials, such as low-alloy steels, stainless steel, aluminum alloy, ceramics, concrete, and composites. The SNTT system operates by applying pure torsion to cylindrical specimens with a notch line that spirals around the specimen at a 45° pitch. In order to carry out pure torsion load mode, biaxial tension/torsion tester was developed accordingly to perform SNTT protocol. Moreover, applying fracture mechanics approach to SNF system reliability investigation is warranted due to the inherent flaws and hydride structures existed in a SNF system after nuclear reactor operation. However, none of the existing fracture toughness data deal with fuel cladding specific geometry or spent fuel material conditions, such as cladding structure with the pellet-inserts and the associated pellet clad mechanical interactions induced mixed-mode damage mechanisms. Thus, the development of an intrinsic fracture mechanics approach that is suitable for SNF materials is needed. Furthermore, due to thin wall and small dimension of clad tubing structure, the SNTT method was used to estimate the clad tubing structure fracture toughness. Fracture testing were performed on the received stainless steel canister weldment, most SNTT weld samples fracture initiation sites are at heat-affected zone (HAZ) regions. The estimated fracture toughness J Q ’ for the baseline SS304 steel is at 283 kJ/m². The estimated JQ’ for the SS304/308 weld and baseline metals are 148 kJ/m 2 and 459 kJ/m 2 , respectively. Out of cell fracture testing for spent fuel structure were carried out on the surrogate rods made of Zr-4 clad and alumina inserts, the estimated fracture toughness values for baseline Zr-4 cladding with alumina-pellet inserts are: (1) For SNTT samples with a short or medium crack length, between 5.4-mm and 8-mm, the estimate J IQ upon fracture initiation for the baseline Zr-4 cladding is at 50 kJ/m 2 with 2-sigma uncertainty of 3.26 kJ/m 2 , and the associated K IQ is at 67.46 MPa$\sqrt{m}$; and (2) For SNTT samples with a long crack length, around 13-mm, the crack initialization is deviated from that of the Mode-I tensile fracture and appears to be a mixed-mode fracture of Mode I - tensile stress and Mode III - out of plane shear stress; the estimated J MQ is at 18.9 kJ/m 2 , the associated K MQ is at 41.4 MPa$\sqrt{m}$.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2018

Finite element analysis of compliant cladding and base metal systems

This report describes a roadmap towards a design method for high temperature nuclear cladded components that does not require long term testing of clad materials. Molten Salt Reactors (MSRs) will operate using corrosive fuel or coolant salts. The existing Class A metallic materials qualified for ASME Boiler and Pressure Vessel Code Section III, Division 5 design are not optimal for corrosion resistance when exposed to MSR salts. Corrosion could then severely limit the service life of MSRs. One option to alleviate this could be to Code qualify new corrosion resistant materials. However, this is a lengthy and expensive process and MSR developers have a near term need for a design solution that enables reactor designs with long service lives. An alternative would be to use cladded components – overlay some existing Class A material with a thin layer of some corrosion resistant material. This report describes the outlines of a design strategy that would enable this approach. The strategy relies on approximate design analysis methods for certain types of clad/base systems that avoids requiring long-term mechanical properties for the clad materials. This would allow the use of cladded components in the near term, without requiring long testing programs. However, it will limit the types of clad materials that can be used. This report describes the design framework, demonstrates the effectiveness of the approximate analysis methods, and confirms the approach using full scale finite element analysis of prototypical cladded high temperature components. It also describes a roadmap towards a complete design method and surveys available clad materials and bonding methods for suitably, considering only mechanical and not environmental effects.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗