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DOE OSTI2022

Sister Rod Destructive Examinations (FY2021) Appendix F: Cyclic Integrated Reversible-Bending Fatigue Tests

As a part of DOE NE High Burnup Spent Fuel Data Project, Oak Ridge National Laboratory (ORNL) is performing destructive examinations (DEs) of high burnup (HBU) (>45 GWd/MTU) spent nuclear fuel (SNF) rods from the North Anna Nuclear Power Station operated by Dominion Energy. The SNF rods, called sister rods or sibling rods, are all HBU and include four different kinds of fuel rod cladding: standard Zircaloy-4 (Zirc-4), low-tin (LT) Zirc-4, ZIRLO, and M5. This appendix documents the status of the ORNL Phase 1 DE activities related to tests of the sister rods using the Cyclic Integrated Reversible-Bending Fatigue Tester (CIRFT) in Phase 1 of the sister rod test program.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2012

Density Functional Theory Calculations of Mass Transport in UO2

In this talk we present results of density functional theory (DFT) calculations of U, O and fission gas diffusion in UO{sub 2}. These processes all impact nuclear fuel performance. For example, the formation and retention of fission gas bubbles induce fuel swelling, which leads to mechanical interaction with the clad thereby increasing the probability for clad breach. Alternatively, fission gas can be released from the fuel to the plenum, which increases the pressure on the clad walls and decreases the gap thermal conductivity. The evolution of fuel microstructure features is strongly coupled to diffusion of U vacancies. Since both U and fission gas transport rates vary strongly with the O stoichiometry, it is also important to understand O diffusion. In order to better understand bulk Xe behavior in UO{sub 2{+-}x} we first calculate the relevant activation energies using DFT techniques. By analyzing a combination of Xe solution thermodynamics, migration barriers and the interaction of dissolved Xe atoms with U, we demonstrate that Xe diffusion predominantly occurs via a vacancy-mediated mechanism. Since Xe transport is closely related to diffusion of U vacancies, we have also studied the activation energy for this process. In order to explain the low value of 2.4 eV found for U migration from independent damage experiments (not thermal equilibrium) the presence of vacancy clusters must be included in the analysis. Next we investigate species transport on the (111) UO{sub 2} surface, which is motivated by the formation of small voids partially filled with fission gas atoms (bubbles) in UO{sub 2} under irradiation. Surface diffusion could be the rate-limiting step for diffusion of such bubbles, which is an alternative mechanism for mass transport in these materials. As expected, the activation energy for surface diffusion is significantly lower than for bulk transport. These results are further discussed in terms of engineering-scale fission gas release models. Finally, oxidation of UO{sub 2} and the importance of cluster formation for understanding thermodynamic and kinetic properties of UO{sub 2+x} are investigated.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2014

Using Finite Model Analysis and Out of Hot Cell Surrogate Rod Testing to Analyze High Burnup Used Nuclear Fuel Mechanical Properties

Based on a series of FEA simulations, the discussions and the conclusions concerning the impact of the interface bonding efficiency to SNF vibration integrity are provided in this report; this includes the moment carrying capacity distribution between pellets and clad, and the impact of cohesion bonding on the flexural rigidity of the surrogate rod system. As progressive de-bonding occurs at the pellet-pellet interfaces and at the pellet-clad interface, the load ratio of the bending moment carrying capacity gradually shifts from the pellets to the clad; the clad starts to carry a significant portion of the bending moment resistance until reaching the full de-bonding state at the pellet-pellet interface regions. This results in localized plastic deformation of the clad at the pellet-pellet-clad interface region; the associated plastic deformations of SS clad leads to a significant degradation in the stiffness of the surrogate rod. For instance, the flexural rigidity was reduced by 39% from the perfect bond state to the de-bonded state at the pellet-pellet interfaces.

fuel-pellet interface↗
DOE OSTI2022

Testing fast reactor fuels in a thermal reactor: Comparison of transmutation metallic fuel alloys behavior by scanning electron microscopy

To optimize nuclear waste repository performance, the destruction of minor actinide elements, particularly Np and Am, in a neutron fast spectrum reactor is possible by incorporating these elements into nuclear fuel. Evaluating the performance of minor actinide containing fuel is of paramount importance to enabling this technology. However, such a task is challenging without an available domestic fast spectrum test reactor. A comparison of fuel performance tested in an available domestic thermal reactor at the Idaho National Laboratory, the Advanced Test Reactor, and in a fast spectrum reactor in France (Phénix) is presented here in this study. This study evaluates the capability of using a cadmium shrouded test position to mimic the power profile along the fuel radius present in fast spectrum reactors so that thermally driven phenomenon (e.g., constituent redistribution) can be evaluated in a thermal reactor and determined to be prototypical of a fast reactor. Thus, optical microscopy and scanning electron microscopy has been performed on irradiated 35U-29Pu-4Am-2Np-30Zr fuel samples (where the number preceding the element is the weight percent concentration) from the two mentioned reactors that present similar irradiation temperatures and power conditions. The results indicate that fuel performance phenomena are reproducible in the two irradiation conditions. The redistribution of Zr occurred in the same manner for the two samples. Similar partitioning of U-Pu-Zr phases was observed, and the behavior of Am was similar in the analyzed specimens. Finally, the overall microstructure evolution seems not to be affected by minor actinides addition compared to expected behavior of conventional U-19Pu-10Zr ternary metal fuels for both specimens. Slight differences in fuel cladding chemical interaction were, however, observed. This difference is likely driven by difference in cladding composition rather than irradiation conditions.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2013

The JRC-ITU approach to the safety of advanced nuclear fuel cycles

The JRC-ITU safety studies of advanced fuels and cycles adopt two main axes. First the full exploitation of still available and highly relevant knowledge and samples from past fuel preparation and irradiation campaigns (complementing the limited number of ongoing programmes). Secondly, the shift of focus from simple property measurement towards the understanding of basic mechanisms determining property evolution and behaviour of fuel compounds during normal, off-normal and accident conditions. The final objective of the second axis is the determination of predictive tools applicable to systems and conditions different from those from which they were derived. State of the art experimental facilities, extensive networks of partnerships and collaboration with other organizations worldwide, and a developing programme for training and education are essential in this approach. This strategy has been implemented through various programs and projects. The SUPERFACT programme constitutes the main body of existing knowledge on the behavior in-pile of MOX fuel containing minor actinides. It encompassed all steps of a closed fuel cycle. Another international project investigating the safety of a closed cycle is METAPHIX. In this case a U-Pu19-Zr10 metal alloy containing Np, Am and Cm constitutes the fuel. 9 test pins have been prepared and irradiated. In addition to the PIE (Post Irradiation Examination), pyrometallurgical separation of the irradiated fuel has been performed, to demonstrate all the steps of a multiple recycling closed cycle and characterize their safety relevant aspects. Basic studies like thermodynamic fuel properties, fuel-cladding-coolant interactions have also been carried out at JRC-ITU.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2021

Sockeye: A One-Dimensional, Two-Phase, Compressible Flow Heat Pipe Application

Sockeye is a heat pipe analysis application based on the Multiphysics Object-Oriented Simulation Environment (MOOSE) finite element framework. The primary purpose of Sockeye is to provide a transient heat pipe simulation tool to be used in the analysis of nuclear microreactor designs. Sockeye provides the capability to perform one-dimensional, two-phase, compressible flow simulation of a heat pipe working fluid and two-dimensional, axisymmetric heat conduction for the heat pipe cladding and its surroundings. Sockeye is demonstrated against analytical solutions and experimental data from the SAFE-30 heat pipe module test.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2015

Lanthana-bearing nanostructured ferritic steels via spark plasma sintering

Here, a lanthana-containing nanostructured ferritic steel (NFS) was processed via mechanical alloying (MA) of Fe-14Cr-1Ti-0.3Mo-0.5La 2 O 3 (wt.%) and consolidated via spark plasma sintering (SPS). In order to study the consolidation behavior via SPS, sintering temperature and dwell time were correlated with microstructure, density, microhardness and shear yield strength of the sintered specimens. A bimodal grain size distribution including both micron-sized and nano-sized grains was observed in the microstructure of specimens sintered at 850, 950 and1050 °C for 45 min. Significant densification occurred at temperatures greater than 950 °C with a relative density higher than 98%. A variety of nanoparticles, some enriched in Fe and Cr oxides and copious nanoparticles smaller than 10 nm with faceted morphology and enriched in La and Ti oxides were observed. After SPS at 950 °C, the number density of Cr–Ti–La–O-enriched nanoclusters with an average radius of 1.5 nm was estimated to be 1.2 × 10 24 m –3 . The La + Ti:O ratio was close to 1 after SPS at 950 and 1050 °C; however, the number density of nanoclusters decreased at 1050 °C. With SPS above 950 °C, the density improved but the microhardness and shear yield strength decreased due to partial coarsening of the grains and nanoparticles.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2023

Fuel performance uncertainty quantification and sensitivity analysis in the presence of epistemic and aleatoric sources of uncertainties

Fuel performance modeling and simulation includes many uncertain parameters from models to boundary conditions, manufacturing parameters and material properties. These parameters exhibit large uncertainties and can have an epistemic or aleatoric nature, something that renders fuel performance code-to-code and code-to-measurements comparisons for complex phenomena such as the pellet cladding mechanical interaction (PCMI) very challenging. Additionally, PCMI and other complex phenomena found in fuel performance modeling and simulation induce strong discontinuities and non-linearities that can render difficult to extract meaningful conclusions form uncertainty quantification (UQ) and sensitivity analysis (SA) studies. In this work, we develop and apply a consistent treatment of epistemic and aleatoric uncertainties for both UQ and SA in fuel performance calculations and use historical benchmark-quality measurement data to demonstrate it. More specifically, the developed methodology is applied to the OECD/NEA Multi-physics Pellet Cladding Mechanical Interaction Validation benchmark. A cold ramp test leading to PCMI is modeled. Two measured quantities of interest are considered: the cladding axial elongation during the irradiations and the cladding outer diameter after the cold ramp. The fuel performance code used to perform the simulation is FAST. The developed methodology involves various steps including a Morris screening to decrease the number of uncertain inputs, a nested loop approach for propagating the epistemic and aleatoric sources of uncertainties, and a global SA using Sobol indices. The obtained results indicate that the fuel and cladding thermal conductivities as well as the cladding outer diameter uncertainties are the three inputs having the largest impact on the measured quantities. More importantly, it was found that the epistemic uncertainties can have a significant impact on the measured quantities and can affect the outcome of the global sensitivity analysis.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2020

Pitch Variation Experiments in Water-Moderated Square-Pitched U(6.90)O 2 Fuel Rod Lattices with Fuel to Water Volume Ratios Spanning 0.08 to 0.67

The US Department of Energy (DOE) Nuclear Energy Research Initiative funded the design and construction of the Seven Percent Critical Experiment (7uPCX) at Sandia National Laboratories. The start-up of the experiment facility and the execution of the experiments described here were funded by the DOE Nuclear Criticality Safety Program. The 7uPCX is designed to investigate critical systems with fuel for light water reactors in the enrichment range above 5 % 235 U. The 7uPCX assembly is a water-moderated and -reflected array of aluminum-clad square-pitched U(6.90 %)O 2 fuel rods. Other critical experiments performed in the 7uPCX assembly are documented in LEU-COMP-THERM-078, LEU-COMP-THERM-080, LEU-COMPTHERM- 096, LEU-COMP-THERM-097, and LEU-COMP-THERM-101. The fuel used in these experiments was fabricated using unirradiated 6.90 % enriched UO 2 fuel pellets from fuel elements designed to be used in the internal nuclear superheater section of the Pathfinder boiling water reactor operated in South Dakota by the Northern States Power Company in the 1960s. The fuel elements were obtained from The Pennsylvania State University where they had been stored for many years. The fuel pellets in those fuel elements were removed from the original Incoloy cladding and reclad in 3003 aluminum tubes and end caps for use in the experiments reported here. The purpose of these experiments was to measure the effects of decreasing the fuel-to-water volume ratio on the critical array size. This was accomplished by removing fuel rods from fully fueled configurations, effectively increasing the pitch of the fuel arrays in the assembly. The fuel rod pitch variations provided assembly configurations that ranged from strongly undermoderated to slightly overmoderated.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2018

Post-Irradiation Examinations of High Burnup PWR Fuel Rods - Initial Results

The High Burnup Spent Fuel Data Project (herein referred to as the “project”), sponsored by the US Department of Energy (DOE) Office of Nuclear Energy (NE), is focused on experimentally evaluating the effects of long-term storage and transportation on high burnup (HBU) (defined as >45 gigawatt days per metric ton uranium) pressurized water reactor (PWR) spent nuclear fuel (SNF) [1]. To support this project, in the fall of 2017, an instrumented bolted-lid cask (project cask) at the North Anna reactor site was loaded with intact, HBU PWR fuel assemblies (project assemblies) having four different kinds of cladding and will be reopened in approximately 10-years for inspection. To support pre- and post-storage SNF rod characterization, 25 “sister rods” that are similar to the rods being stored in the project cask were extracted from seven different fuel assemblies at the North Anna nuclear power plant for post-irradiation examination (PIE).

Bevard, Bruce Balkcom↗
DOE OSTI2016

Mechanical Properties and Characterization of Coated SiC Fuel Cladding

SiC fiber-reinforced SiC matrix (SiC{sub f}-SiC) composites continue to undergo process modifications to address remaining concerns for Light Water Reactor (LWR) fuel cladding. The critical concerns include the radiolysis-assisted hydrothermal corrosion and the loss of hermeticity during normal operation. Coating technologies are being developed to provide a solution to both problems with no or minimum modification to the SiC{sub f}-SiC clad structures. Several barrier coating options have been considered and examined for these purposes. A comprehensive screening program is being developed to determine their feasibility in LWR environments before the coated fuel claddings are further advanced toward the ideal 'drop-in' replacements for the aging LWR fleet. There have been several coating technologies proposed. All are based on chromium and zirconium interacting with the coolant because they have a proven performance history. However, it is difficult to deposit these elements in reduced form (Zr{sup 0}, Cr{sup 0}) due to the high enthalpy associated with the stable oxide. The Cr chemical deposition techniques use electrochemical 'hard chrome' reduction of Cr{sup 3+/6+} protected by chelating ligands in solution. The collaborative partner for this endeavor is NEO Knoxville, LLC, and two types of hard chrome systems (trivalent and hard chrome) are being investigated. There are also two feasible vapor techniques previously demonstrated: commercial physical vapor deposition (PVD) methods and an experimental, proprietary vacuum plasma spray (VPS) by Plasma Processes, LLC. Both of these use Zr{sup 0} and Cr{sup 0} in high vacuum systems. In total, eight coatings and four bond coats are being evaluated. In mid-2016, these were inserted into a reactor and a characterization program is underway. (authors)

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2022

Sister Rod Destructive Examinations (FY2021) Appendix C: Rod Internal Pressure, Void Volume, and Gas Transmission Tests

As a part of the DOE NE High Burnup Spent Fuel Data Project, Oak Ridge National Laboratory (ORNL) is performing destructive examinations (DEs) of high burnup (HBU) (>45 GWD/MTU) spent nuclear fuel (SNF) rods from the North Anna Nuclear Power Station operated by Dominion Energy. The SNF rods, called the sister rods or sibling rods, are all HBU and include four different kinds of fuel rod cladding: standard Zircaloy-4 (Zirc-4), low-tin (LT) Zirc-4, ZIRLO, and M5. This Appendix C documents the status of the ORNL Phase 1 DE activities [C-2, C-3] related to rod internal pressure and void volume measurement techniques, fission gas stack flow measurements applied to selected sister rods, and fission gas release calculations in Phase 1 of the sister rod test program.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2015

Modeling and Simulation of Used Nuclear Fuel During Transportation with Consideration of Hydride Effects and Cyclic Fatigue

The objective of this work is to understand the integrity of Used Nuclear Fuel (UNF) during transportation. Previous analysis work has been performed to look at the integrity of UNF during transportation but these analyses have neglected to analyze the effect of hydrides and flaws (fracture mechanics models to capture radial cracking in the cladding). In this study, the clad regions of interest are near the pellet-pellet interfaces. These regions can experience more complex stress-states than the rest of the clad during cooling and have a greater possibility to develop radially reoriented hydrides during vacuum drying.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2018

Assessment of Te as a U-Zr fuel additive to mitigate fuel-cladding chemical interactions

Tellurium was investigated as a potential additive to metallic fuel (e.g. U-10Zr) to mitigate fuel-cladding chemical interaction (FCCI). A primary cause of FCCI is the lanthanide fission products migrating to the fuel periphery and interacting with cladding, Te therefore was used to bind the lanthanides into stable compounds in the U-10Zr. The present work investigates the microstructures of as-cast and annealed U-10Zr-4Te and U-10Zr-4Te-4Ce alloys (weight percent) with scanning electron microscope and transmission electron microscopy. In conclusion, tellurium was found to bind Ce and form CeTe compound, which will mitigate lanthanides migration to the cladding.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2023

IER 296 Experiment- Thermal Feasibility Analysis [Slides]

This set of slides summarizes progress, highlights, and issues related to the LANL design engineering effort for the IER 296 critical experiment. The experiment configuration described in Section 5.1.1 of CED-1 IRSN Preliminary Design for Thermal/Epithermal Experiments with MOX FUEL (TEX-MOX) is re-examined in a finite element analysis model using design geometry utilized in the Chlorine Worth Study (CWS) Experiments. Preliminary results and design considerations are presented. Additional analysis has been performed based on comments from the collaborative virtual meeting on 12JAN2023. Specifically, the fuel cladding and gas gap have been included in the thermal analysis.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2015

Incorporate MPACT into TIAMAT and Demonstrate Pellet-Clad Interactions (PCI) Calculations

CASL (the Consortium for Advanced Simulation of LWRs) is investing in the development of the multi-dimensional Bison fuel performance code for both transient and nominal performance analysis. The MPACT whole-core neutronics capability has been integrated with the Cobra-TF sub-channel solver to provide a neutron-transport based core-simulator with substantially improved fidelity over traditional diffusion-based core simulators. The Tiamat code is being developed to provide an integrated tool for predicting pellet-clad interaction and improving the high-fidelity core simulator.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2016

Development of SiC-based Cladding for Accident Tolerant Fuels

Fuels and core structures in current light water reactors (LWR's) are vulnerable to catastrophic failure in severe accidents. This vulnerability is attributed primarily to the rapid oxidation kinetics of zirconium alloys in a water vapor environment at very high temperatures. Alternative materials to zirconium alloys with reduced oxidation kinetics are sought to enable enhanced accident-tolerant fuels and cores. Among the candidate alternatives, silicon carbide (SiC) - based materials, in particular continuous SiC fiber-reinforced SiC matrix ceramic composites (SiC/SiC composites), are considered to offer outstanding safety benefits. The primary objective of this work is to provide with updated overviews of the concepts, development status, and future prospect for the SiC-based accident-tolerant fuel (ATF) claddings. A systematic technology evaluation program plan was developed and updated to review the technologies needed, to identify and analyze critical gaps, and to lay out a road-map toward establishing key technologies. The technology review and the gap analysis in this exercise were based on an early study and community workshops. Many of the technical gaps identified are related with the three key feasibility issues: hydrothermal corrosion, mechanical failure, and fuel compatibility. Additional performance issues including accident-tolerance features and fission product retention during the normal operation have also been identified. The program plan was designed to systematically address the key gap issues and is formulated in a work breakdown structure. Simultaneously, the plan is being established to set a technical program for advancing the technological readiness levels of concept non-specific essential technologies in three top-level categories of Design and Failure, Environmental Effects, and Off-normal Behavior. The execution of the program plan is in progress across the U.S. Department of Energy laboratories, industries, universities, and international collaborators. The critical issues for SiC composite-based fuel cladding concepts were found to be related to the performance in the normal operation. In particular, radiation-assisted hydrothermal corrosion and the gaseous fission product (FP) retention are identified to be the most critical issues. The primary ORNL concept pursues the use of dual-purpose coating on the SiC composite cladding wall to mitigate the corrosion and the gas permeation issues at the same time, whereas the alternative approaches such as the dense monolithic SiC protective layer combined with the water chemistry control may be feasible. Surface metallization through variations of physical vapor deposition and electroplating are being demonstrated. The FP gas retention is an issue associated with the cracking for the ceramic matrix composite cladding. To establish the probabilistic failure behavior, the relevant test methods were developed in ASTM Committee C28 on Advanced Ceramics. Toward the end-plugging technology development, various methods for joining SiC to SiC had been developed and tested for mechanical properties, irradiation effects, and environmental effects. Multiple methods including the pressureless transient eutectic SiC joining and CVD-based SiC joining were identified particularly promising. In addition, a multi-physics, three-dimensional finite element-based modeling is in progress toward an integrated simulation of the SiC composite-cladded fuel evolutions. (authors)

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2016

(Project 13-5292) Correlating thermal and mechanical coupling based multiphysics behavior of nuclear materials through in-situ measurements

Irradiations and post characterization experiments were performed first on Zr samples. This step will help understand the effect of the 2.5% alloying elements on the behavior of Zircaloy-4 (PWR cladding material) when compared to pure Zr. Irradiation flux measurements and sample temperature calibrations were performed at different energies prior to the irradiation experiments. Irradiations were performed with two different energy regimes1: non-displacment energies and displacement energies. Time was also dedicated to optimize transmission electron microscopy (TEM) sample preparation conditions via electropolishing technique. This step is crucial to prepare TEM samples for the in-situ TEM/irradiation experiments (Year 2). In addition, Zircaloy-4 samples are being prepared for irradiation, and a setup is built by one of our collaborators (Dr. Mert Efe) to prepare ultrafine (UF) and nanocrystalline (NC) Zircaloy-4 samples for comparison with the commercial Zircaloy-4 samples.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗