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At least 1,117 records · Page 62
All sourcesNASA NTRSDOE OSTI
DOE OSTI2017

Status Report on Pressure Resistance Weld Development for FeCrAl Thin-Wall Cladding

This report summarizes the recent development on the weld techniques of joining the thin walled FeCrAl cladding to the endplug as a part of accident tolerant fuels (ATF) program for advanced light water reactor (LWR) systems. The FeCrAl alloy has been considered as the top candidate cladding materials for ATF fuels largely due to its high oxidation resistance in high temperature steam relevant to the loss of coolant accident (LOCA) conditions. The two primary techniques for the thin-walled cladding weld development are laser beam weld (fusion based) and pressure resistance weld (solid state without melting). This report focuses on the progress made on the pressure resistance weld (PRW) development for a commercial FeCrAl alloy.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2019

Initial Application of TSUNAMI for Validation of Advanced Fuel Systems

A number of advanced reactor concepts and accident-tolerant fuels (ATFs) are under development or in the initial stages of deployment and testing in the nuclear power industry. Many of these concepts incorporate chemical or material forms that have not traditionally been used in the nuclear industry and may present challenges for nuclear criticality safety validation. Sensitivity/uncertainty methods are ideally suited for assessing the applicability of existing critical experiments to these potentially challenging applications. This paper presents two case studies recently completed at Oak Ridge National Laboratory (ORNL) which investigated the use of the TSUNAMI tools within the SCALE code system to perform such assessments.Many advanced reactor concepts include uranium enrichments above 5 wt% 235U but below the 20 wt% limit of low-enriched uranium (LEU). This material, referred to as high assay LEU (HA-LEU), poses difficulties across the entire infrastructure of nuclear power, including enrichment, transportation, fabrication, and storage. A potentially representative transportation package was selected to perform a criticality safety validation assessment for UF6 containing HA-LEU. Sensitivity data were generated using the TSUNAMI-3D sequence, and an assessment of the applicability of a range of critical experiments was performed using the TSUNAMI-IP tool. The critical experiments were drawn from the set of available sensitivity data files distributed with the International Criticality Safety Benchmark Evaluation Project (ICSBEP) Handbook. The results indicate that a sufficient number of available experiments may be available to perform validations for these systems.Many different cladding materials and fuel dopants are included in ATFs to mitigate the consequences of a loss of coolant accident. Some of these systems have already been fabricated and introduced as lead test assemblies in commercial reactors, while others are still being developed. Several concepts were considered for pressurized-water reactors (PWRs) and boiling-water reactors (BWRs) in comparison to the current Zircaloy and UO2 fuel system. In most of these cases, the ATF materials did not significantly impact the number of applicable experiments for validation. Some fuel and cladding materials were identified, however, which may reduce the number of available experiments and which will increase the nuclear data–induced uncertainty in neutron multiplication.

Marshall, William (B.J.)↗
DOE OSTI2024

Multi-principal element alloys for fast reactor cladding applications

Given the extensive list of multi-principal element alloys (MPEAs) within literature and the overwhelming number of alloys that can be made from only a handful of elements, this article proposes a methodology for prioritizing alloys for use as cladding within advanced reactors. This paper applies neutronic, mechanical, and chemical assessments to a collection of MPEAs available within literature for use as advanced reactor cladding. The results are compared to a reference design of HT9, a ferritic/martensitic steel, for employed in sodium-cooled fast reactor. Mechanical assessments determined pressure limits for a thin-walled tube pressure boundary, thus relating the material's mechanical properties to a minimum acceptable wall thickness. Neutronic analyses reveal a maximum allowable wall thickness that a given material must meet to provide a level of neutronic economy that is equivalent to than that of HT9. Lastly, each alloying element is compared to typical fission products found in a fast reactor fuels to mitigate deleterious phenomena such as fuel-cladding chemical interactions (FCCI). These analyses indicate that Mo-Nb-Ti-V-based alloys are likely to be advantageous and that the inclusion of elements with a high neutronic penalty (e.g., Hf) could be considered with minimal consequences.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2014

Microstructural Characteristics of HIP-bonded Monolithic Nuclear Fuels with a Diffusion Barrier

Due to the limitation of maximum uranium load achievable by dispersion fuel type, the Global Threat Reduction Initiative (GTRI) is developing an advanced monolithic fuel to convert US high performance research reactors to low-enriched uranium. Hot-isostatic-press bonding was the single process down-selected to bond monolithic U-Mo fuel meat to aluminum alloy cladding. A diffusion barrier was applied to the U–Mo fuel meat by roll-bonding process to prevent extensive interaction between fuel meat and aluminum-alloy cladding. Microstructural characterization was performed on fresh fuel plates fabricated at Idaho National Laboratory. Interfaces between fuel meat, cladding, and diffusion barrier, as well as U–10Mo fuel meat and Al–6061 cladding were characterized by scanning electron microscopy. Preliminary results indicate that the interfaces contain many different phases while decomposition, second phases, and chemical banding were also observed in the fuel meat. The important attributes of the HIP-bonded monolithic fuel are • A typical Zr diffusion barrier of thickness 25 µm • Transverse cross section that exhibits relatively equiaxed grains with an average grain diameter of 10 µm • Chemical banding, in some areas more than 100 µm in length, that is very pronounced in longitudinal (i.e., rolling) direction with Mo concentration varying from 7–13 wt% • Decomposed areas containing plate-shaped low-Mo phase • A typical Zr/cladding interaction layer of thickness 1-2 µm • A visible UZr2 bearing layer of thickness 1-2 µm • Mo-rich precipitates (mainly Mo2Zr, forming a layer in some areas) followed by a Mo-depleted sub-layer between the visible UZr2-bearing layer and the U–Mo matrix • No excessive interaction between cladding and the uncoated fuel edge • Cladding-to-cladding bonding that exhibits no cracks or porosity with second phases high in Mg, Si, and O decorating the bond line. • Some of these attributes might be critical to the irradiation performance of monolithic U-10Mo nuclear fuel. There are several issues or concerns that warrant more detailed study, such as precipitation along cladding-to-cladding bond line, chemical banding, uncovered fuel-zone edge, and interaction layer between U–Mo fuel meat and zirconium. Future post-irradiation examination results will focus, among other things, on identifying in-reactor failure mechanisms and, eventually, directing further fresh fuel characterization efforts.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2012

Uncertainty quantification for accident management using ACE surrogates

The alternating conditional expectation (ACE) regression method is used to generate RELAP5 surrogates which are then used to determine the distribution of the peak clad temperature (PCT) during the loss of feedwater accident coupled with a subsequent initiation of the feed and bleed (F and B) operation in the Zion-1 nuclear power plant. The construction of the surrogates assumes conditional independence relations among key reactor parameters. The choice of parameters to model is based on the macroscopic balance statements governing the behavior of the reactor. The peak clad temperature is calculated based on the independent variables that are known to be important in determining the success of the F and B operation. The relationship between these independent variables and the plant parameters such as coolant pressure and temperature is represented by surrogates that are constructed based on 45 RELAP5 cases. The time-dependent PCT for different values of F and B parameters is calculated by sampling the independent variables from their probability distributions and propagating the information through two layers of surrogates. The results of our analysis show that the ACE surrogates are able to satisfactorily reproduce the behavior of the plant parameters even though a quasi-static assumption is primarily used in their construction. The PCT is found to be lower in cases where the F and B operation is initiated, compared to the case without F and B, regardless of the F and B parameters used. (authors)

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2016

Determination of water equivalent content in fuel rods

In water-cooled reactors, hydriding failure of zircaloy cladding tubes can be easily caused by high content of total water in fuel rods. WEC, which is the water equivalent content within the cold space of a fuel rod, directly reflects the total water content of the fuel rod. A device measuring WEC has been designed, manufactured and tested. This extraction device is a hermetically sealed system consisting of six parts: the break-off part, the heating unit, the reduction unit, the sample storage part, the collecting unit and the gas flow system. Each part is connected to another one using a special connection, and the device's end part is connected to a gas chromatograph. The determination procedure can be briefly summarized as follows: first, a test fuel rod should be put into the sealed device after lathing two circular grooves on both ends, so that it can be easily broken at these points in the break-off part. Driven by carrier gas, water and hydrogen both contained in helium gas and absorbed on the rod in-wall pass over the hot uranium filament where water is converted into hydrogen. After being concentrated by the collecting unit, hydrogen flows into the gas chromatograph for measurement and data are calculated as total water content A. UO{sub 2} pellets in the test rod should be taken out from the sample storage part and the total hydrogen content of these pellets is determined according to ASTM C1457 standard, followed by its conversion into total water content B. Finally, the sum of A and B being divided by the free volume of the cold space within the test rod, gives the value of WEC.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2013

Post-Irradiation Examination of Zircaloy-4 Samples in Target Capsules and Initiation of Bending Fatigue Testing for Used Nuclear Fuel Vibration Integrity Investigations (FY 2013 Summary Report)

This report documents ongoing work performed at Oak Ridge National Laboratory (ORNL) for the Department of Energy, Office of Fuel Cycle Technology Used Fuel Disposition Campaign (UFDC), and satisfies the deliverable for milestone M2FT-13OR0805041, “Data Report on Hydrogen Doping and Irradiation in HFIR.” This work is conducted under WBS 1.02.08.05, Work Package FT-13OR080504 ST “Storage and Transportation-Experiments – ORNL.” The objectives of work packages that make up the S&T Experiments Control Account are to conduct the separate effects tests (SET) and small-scale tests that have been identified in the Used Nuclear Fuel Storage and Transportation Data Gap Prioritization (FCRD-USED-2012-000109). In FY 2013, the R&D focused on cladding and container issues and small-scale tests as identified in Sections A-2.9 and A-2.12 of the prioritization report.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2023

Unraveling the Mechanics: Computational Modeling of Residual Stresses in U10Mo Fuel with Aluminum Cladding

LEU (Low Enriched Uranium) plate-type fuel elements consist of a high-density, low-enrichment U–Mo alloy-based fuel foil encapsulated in an aluminum cladding and is fabricated through the Hot Isostatic Pressing (HIP) technique. Understanding the mechanism of possible failure modes of nuclear fuel is critical to mitigate potential consequences. One of the major contributing factors in various failure modes is stress and it greatly affects the integrity under temperature, pressure, and irradiation. These stresses could originate from various sources, including manufacturing, and operation, and can lead to deformation, cracking, or even complete failure of fuel elements. This study focuses on the development of a computational model that accurately predicts the residual stresses generated in the U10Mo fuel during fabrication. It has been observed that cladding creep has a substantial impact on the residual stresses in the U10Mo fuel post the HIP fabrication process. Furthermore, during the HIP bonding process the fuel plate system is heated to a temperature of 560 oC and as a result, the aluminum cladding transitions from (Al 6061-T6 to -O). This presents a challenge in capturing the change in material properties accurately. Therefore, a temperature dependent creep model such as hyperbolic sine creep model is considered to estimate the creep properties of the Aluminum cladding. The proposed calibrated creep model accurately predicts the residual stresses in the U10Mo fuel foil and agrees well with the experiments.

42 ENGINEERING↗
DOE OSTI2012

Operational Challenges of Extended Dry Storage of Spent Nuclear Fuel - 12550

As a result of the termination of the Yucca Mountain used fuel repository program and a continuing climate of uncertainty in the national policy for nuclear fuel disposition, the likelihood has increased that extended storage, defined as more than 60 years, and subsequent transportation of used nuclear fuel after periods of extended storage may become necessary. Whether at the nation's 104 nuclear energy facilities, or at one or more consolidated interim storage facilities, the operational challenges of extended storage and transportation will depend upon the future US policy for Used Fuel Management and the future Regulatory Framework for EST, both of which should be developed with consideration of their operational impacts. Risk insights into the regulatory framework may conclude that dry storage and transportation operations should focus primarily on ensuring canister integrity. Assurance of cladding integrity may not be beneficial from an overall risk perspective. If assurance of canister integrity becomes more important, then mitigation techniques for potential canister degradation mechanisms will be the primary source of operational focus. If cladding integrity remains as an important focus, then operational challenges to assure it would require much more effort. Fundamental shifts in the approach to design a repository and optimize the back-end of the fuel cycle will need to occur in order to address the realities of the changes that have taken place over the last 30 years. Direct disposal of existing dual purpose storage and transportation casks will be essential to optimizing the back end of the fuel cycle. The federal used fuel management should focus on siting and designing a repository that meets this objective along with the development of CIS, and possibly recycling. An integrated approach to developing US policy and the regulatory framework must consider the potential operational challenges that they would create. Therefore, it should be integral to these efforts to redefine retrievability to apply to the dual purpose cask, and not to apply to individual assemblies. (authors)

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

Consequence Analysis of Residual Water in a Storage Canister - 20484

Recent observations from projects sponsored under the DOE-Nuclear Energy Spent Fuel and Waste Disposition campaign show that residual free water, well above the 0.4 gm-moles that correspond to a 3 torr rebound pressure after a 30-minute hold following prototypic drying, may remain within SNF canisters used for long-term dry storage. Specifically, experimental observations in an Integrated Research Project showed subzero temperatures and a local pocket of frozen water in a mockup fuel assembly subjected to an industry practiced drying process. In gas sampling and analysis from the High Burnup (HBU) Demonstration project, using a fully loaded and dried SNF canister, indicated presence of 100 g of residual water had remained in the canister. The effects of residual water in terms of potential adverse impacts on the condition of the SNF and the canister internals during long-term dry storage has been rigorously evaluated to address inadvertent residual water contents. The impact of residual water on the fuel and canister internals, with a focus on the oxidation of the cladding and of postulated exposed (breached-clad) fuel, were evaluated using an integrated set of time-dependent environmental conditions with semi-empirical materials oxidation models. An 'integration model,' with coupled sub-models, developed and previously used by the Center for Nuclear Waste Regulatory Analysis (CNWRA), was applied and expanded with improved sub-models for water radiolysis, and for cladding and fuel oxidations. Cladding oxidation models for various alloys were developed using the rate constants for various cladding alloys in the dry storage temperature range. A burnup-dependent fuel oxidation model was developed; it accounted for inhibition effect of fission products on fuel oxidation rates. The potential for extension of the initial breach flaw (1 mm hole) was evaluated by two separate mechanics criteria. In the first case, a critical cladding strain criterion was used. In the second case, a critical stress intensity was used to evaluate stability of a planar axial flaw postulate. A failure condition exists when a sufficient amount of fuel oxidation (at the postulated breached-clad location) causes fuel pellet swelling to load the cladding to meet a mechanics criterion for flaw extension. The integration model's results provide the following insights. The radiolysis-generated oxygen is consumed with a partitioning between the cladding and the fuel. The extent of cladding oxidation is no more than 2 μm additional consumption of the cladding metal even with 10 moles of residual water, indicating that changes in cladding conditions due to water are expected to be negligible. The conditions for cladding failure (breach opening size extension) directly correlates with the extent of fuel oxidation. Fuel oxidation significant to extend the breach could occur even with 5.5 moles of residual water. The results indicate that fuel oxidation vis-a-vis cladding oxidation is more likely under a higher radiation field, i.e., when radiolytic decomposition of the residual water occurs in few years compared to several decades, and that the conditions to cause failure are increased with fuel and cladding temperatures approaching the peak storage temperature limit of 400 deg. C. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2017

Weld Development of FeCrAl Thin-Wall Cladding for LWR Accident Tolerant Fuel

The development of new cladding materials to replace Zr-based cladding for light water reactors (LWRs) has been actively pursued with improved high-temperature oxidation resistance to significantly suppress hydrogen production from an accident such as a loss of coolant event. FeCrAl alloy with a typical composition of approximately Fe-15Cr-5Al has been selected as a candidate material because of its improved high-temperature oxidation resistance over the present LWR zircaloy cladding. As a result of higher thermal neutron absorption for FeCrAl alloy, the cladding wall thickness needs to be reduced by approximately half compared to that of Zircaloy cladding to be comparable to the current LWR fuel performance under the normal operating condition. New weld techniques for joining the endplug to thin-walled cladding need to be developed. Both laser beam weld and pressure resistance weld were employed. This paper summarizes the recent progress on the laser weld development for FeCrAl cladding with 350 µm wall thickness. The results of microstructural characterization and mechanical property testing of the weld for the cladding-endplug set are discussed.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2015

Vacuum drying of spent fuel storage canisters/casks - 'just how much water could be left in there, anyway?' - 15233

The process of moving spent fuel assemblies from wet storage in the spent fuel pool to dry storage in an inert gas environment within a canister or cask typically involves two main stages. In the first stage, the bulk of the water is removed by a draining or siphoning operation, conducted with pressure inside the canister maintained at 1.3 to 2 atm. This process removes most of the water in the cask cavity, but residual water can be left behind, in three main regions. The largest region, typically, is the bottom of the cavity below the end of the siphon tube. A second general class of locations, also located at the bottom of the cask cavity, consists of the 'dashpots' at the ends of the various non-fuel tubular structures within the fuel assemblies. For PWR assemblies, these are the control rod guide sleeve tubes and instrumentation thimbles. For BWR assemblies, these are the water rods of various designs and control blade ends in some configurations. A third class of locations consists of porous material within the cavity that can absorb water, such as thin ceramic neutron poison plates, and ostensibly intact fuel rods that nevertheless might have pinholes or fine cracks in the cladding that could allow pool water to creep inside the fuel rod. To remove residual water from these locations, the second stage of drying operations utilizes vacuum drying, by reducing the pressure sufficiently to convert the water to vapor that can then be pumped out of the canister cavity. In this operation, the cask cavity pressure is slowly reduced from the nominal condition of (1.3-2.0 atm (1000-1520 torr), to a final target pressure below 3 torr (0.004 atm). This is typically accomplished in three to five stages, with prescribed 'hold' points defined in procedures or in the Technical Specifications, to preclude sudden pressure spikes due to flashing of water to steam, or development of large local temperature gradients in the fuel rods or other cask internal components. This paper discusses the various locations in the system where residual water may 'hang up' in the cask, and presents a discussion of the physical basis for the effectiveness of vacuum drying for removing it. Results and conclusions based on realistic qualitative and quantitative evaluations of the transient heat transfer behavior of the system are presented, based on detailed modeling of a range of spent fuel canister designs and decay heat loads, most notably the 24P Dry Shielded Canisters (DSCs) stored at the Rancho Seco Independent Spent Fuel Storage Installation (ISFSI), the NAC-MPC modules at Maine Yankee, the 24P DSCs stored at Calvert Cliffs, and the Holtec HI-STORM modules at Hope Creek. The evaluations presented here show that ice formation within a spent fuel canister is highly unlikely, due to the availability of a large thermal source term in the form of the decay heat load of the spent fuel. The formation of ice is an operational concern, since it mainly affects operation of equipment external to the canister (i.e., the hoses, valves, and fittings of the vacuum drying equipment.) Evaluations are presented for quantifying the amount of residual water that could remain in the cask cavity, even after successful drying operations, since vacuum drying is a limit process, and by definition, cannot remove all of the water from the cavity, no matter how long the operation goes on, even if all of it is in vapor form. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2025

Reference Fuel Development for Non-Aluminum Spent Nuclear Fuel Management

The Savannah River Site (SRS) L Area Facility provides for the safe receipt, storage, handling, and shipping of spent nuclear fuel (SNF) and has received more than 47,000 SNF assemblies since 1964. In order to consolidate receipt and storage analysis, L Area criticality safety has historically used several aluminum-clad “reference fuels” to establish bounding storage, handling, and cask loading limits and then applied a reactivity comparison approach to demonstrate that candidate fuels may be processed under the reference fuel limits. Currently, only aluminum-clad SNF from off-site research reactors are transferred on-site. The Accelerated Basin De-Inventory (ABD) program will begin the removal of bundled Non-Aluminum Spent Nuclear Fuel (NASNF) from the L Area disassembly basin for dissolution and disposition, which has driven the need for a non-aluminum reference fuel. This paper discusses the process and results of creating a new fictional homogenous NASNF highly enriched uranium reference fuel, “MITZ,” to be used in nuclear criticality safety evaluations for upcoming SNF disposition operations. Data demonstrating the relationship between neutron multiplication behavior and fuel spacing is generated for the new reference fuel MITZ as well as existing reference fuels representing several types of SNF assemblies.

Reference Fuel↗