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At least 145 records · Page 8
All sourcesNASA NTRSDOE OSTI
DOE OSTI2020

Degradation and Failure Phenomena of Accident Tolerant Fuel Concepts: FeCrAl Alloy Cladding

The U.S. Nuclear Regulatory Commission (NRC) is anticipating licensing applications and commercial use of accident tolerant fuel (ATF) in United States commercial nuclear power reactors. Pacific Northwest National Laboratory is providing technical assistance to the NRC related to the newly proposed nuclear fuel and cladding designs. This report focuses specifically on the iron-chromium-aluminum (FeCrAl) alloys being investigated to replace zirconium-based alloys for fuel cladding and provides current state-of-the-industry information on material properties and fuel performance considerations under reactor operating conditions and design basis accident conditions. Currently, Global Nuclear Fuels (GNF) is the only U.S.-based fuel vendor considering FeCrAl cladding as a near-term ATF design. GNF has tested several different FeCrAl alloys including Kanthal APMT, C26M, and MA956; fueled C26M rods and unfueled Kanthal APMT, C26M, and MA956 rods have been inserted in lead test assemblies at Plants Hatch and Clinton. This report will focus on those three alloys specifically, with broader information given regarding in-reactor and ex-reactor testing of FeCrAl alloys. To support the NRC’s readiness efforts, this report will identify and discuss degradation and failure modes of FeCrAl cladding concepts, including fuel performance characteristics that may not be addressed within existing regulatory documents.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2023

The Complex, Unique, and Powerful Imaging Instrument for Dynamics (CUPI 2 D) at the Spallation Neutron Source (invited)

The Oak Ridge National Laboratory is planning to build the Second Target Station (STS) at the Spallation Neutron Source (SNS). STS will host a suite of novel instruments that complement the First Target Station’s beamline capabilities by offering an increased flux for cold neutrons and a broader wavelength bandwidth. A novel neutron imaging beamline, named the Complex, Unique, and Powerful Imaging Instrument for Dynamics (CUPI 2 D), is among the first eight instruments that will be commissioned at STS as part of the construction project. CUPI 2 D is designed for a broad range of neutron imaging scientific applications, such as energy storage and conversion (batteries and fuel cells), materials science and engineering (additive manufacturing, superalloys, and archaeometry), nuclear materials (novel cladding materials, nuclear fuel, and moderators), cementitious materials, biology/medical/dental applications (regenerative medicine and cancer), and life sciences (plant–soil interactions and nutrient dynamics). The innovation of this instrument lies in the utilization of a high flux of wavelength-separated cold neutrons to perform real time in situ neutron grating interferometry and Bragg edge imaging—with a wavelength resolution of δλ/λ ≈ 0.3%—simultaneously when required, across a broad range of length and time scales. This manuscript briefly describes the science enabled at CUPI 2 D based on its unique capabilities. The preliminary beamline performance, a design concept, and future development requirements are also presented.

47 OTHER INSTRUMENTATION↗
DOE OSTI2017

The Mechanical Response of Advanced Claddings during Proposed Reactivity Initiated Accident Conditions

This study investigates the failure mechanisms of advanced nuclear fuel cladding of FeCrAl at high-strain rates, similar to design basis reactivity initiated accidents (RIA). During RIA, the nuclear fuel cladding was subjected to the plane-strain to equibiaxial tension strain states. To achieve those accident conditions, the samples were deformed by the expansion of high strength Inconel alloy tube under pre-specified pressure pulses as occurring RIA. The mechanical response of the advanced claddings was compared to that of hydrided zirconium-based nuclear fuel cladding alloy. The hoop strain evolution during pressure pulses were collected in situ; the permanent diametral strains of both accident tolerant fuel (ATF) claddings and the current nuclear fuel alloys were determined after rupture.

Accident tolerant fuel↗
DOE OSTI2016

Effect of Alloying Additions on Wrought FeCrAl Alloys for Accident-Tolerant Fuel Cladding

Nuclear-grade wrought Fe-Cr-Al alloys are under development as one of the candidate materials for accident-tolerant fuel (ATF) cladding for light water reactors (LWRs) because of their superior oxidation and corrosion resistance in high-temperature steam environment compared to Zr-based alloys that are currently in service. Numerous efforts have been made for the development of the FeCrAl alloys with the ATF concept. The current researches focused on optimizing the balance between the improved environmental compatibility and sufficient mechanical properties in both normal service condition and under accident scenario, as well as fabricability of seamless tube product for fuel cladding applications. Alloying addition is one of the key factors to control the various properties. The effect of Cr and Al additions on the properties in model Fe-Cr-Al-Y alloys were systematically examined by the authors, and the candidate base alloy composition with 13 wt.% Cr and 5 wt.% Al was proposed for further development. The modified FeCrAl alloys with Mo and Nb additions were also investigated in order to achieve improved strength. It was revealed that the microstructure control together with the thermal stability to retain desired microstructure were also the dominant factors for successful development of ATF FeCrAl alloys, especially when the fabricability of seamless tube production was also considered. This paper summarizes further investigation of alloying effects with a wide composition range of Cr and Al additions in the model alloys, as well as the effect of minor alloying additions of Mo, Nb, and Zr, through evaluation of the tensile properties. The combined effect of microstructure control is also discussed. Effect of alloying additions on tensile properties of wrought FeCrAl alloys was investigated. Minor alloying additions such as Al, Mo, Nb, and Zr were found to improve room-temperature tensile strength of the wrought FeCrAl alloys significantly. It was also found that stabilized deformed microstructure consisting of subgrains was also effective to improve the properties compared to the recrystallized grain structure. Optimization to balance the properties and the seamless FeCrAl tube fabricability is currently in progress. (authors)

36 MATERIALS SCIENCE↗
DOE OSTI2012

TiN-based coatings on fuel cladding tubes for advanced nuclear reactors

Titanium nitride (TiN) thin films are coated on HT-9 and MA957 fuel cladding tubes and bars to explore their mechanical strength, thermal stability, diffusion barrier properties, and thermal conductivity properties. The ultimate goal is to implement TiN as an effective diffusion barrier to prevent the inter-diffusion between the nuclear fuel and the cladding material, and thus lead to a longer life time of the cladding tubes. Mechanical tests including hardness and scratch tests for the samples before and after thermal cycle tests show that the films have a high hardness of 28 GPa and excellent adhesion properties despite the thermal treatment. Thermal conductivity measurements demonstrate that the thin TiN films have very minimal impact on the overall thermal conductivity of the MA957 and HT9 substrates, i.e., the thermal conductivity of the uncoated HT-9 and MA957 substrates was 26.25 and 28.44 W m-1K-1 , and that of the coated ones was 26.21 and 28.38 W m-1K-1, respectively. A preliminary Ce diffusion test on the couple of Ce/TiN/HT-9 suggests that TiN has excellent material compatibility and good diffusion barrier properties.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2016

Oxidation behavior of Zry-4 in steam-air mixtures at high temperature

This study dealt with the oxidation behavior of Zry-4 nuclear fuel cladding under a severe nuclear reactor accident scenario occurring in a light-water reactor. Influence of the reaction extent on cladding mechanical properties was also treated. Zry-4 fuel cladding segments were exposed to steam atmosphere containing different amount of air in composition ranging from 0 to 100 vol. %. Exposure times covered both pre- and post-breakaway regimes. Metallographic observations along with microhardness testing were carried out to study the effect of air fraction on the material microstructure. Hydrogen pick-up was measured and residual mechanical properties were assessed employing Ring Compression Tests. The results show that the addition of air in steam can lead to more than 300 % increase of weight gain in case of ∼50 % or higher air fraction after the exposure of 60 min., namely, 'late post-breakaway regime'. Approximately three times thicker oxide scales were observed in such cases, indicating that most of the weight gain was due to the oxide layer increase. Nitride phase was preferentially observed close to the interface between oxide and metal layers. The α-Zr(O) sublayer thickness decreases with the increasing fraction of air in steam. Microhardness, measured within the prior β-phase region, slightly depends on the air fraction. Hydrogen uptake, on the other hand, depends strongly on the air fraction in steam. In the case of shorter exposure times, the effect of air addition in steam was suppressed. Eventually, specimen plastic strains drastically reduced in the late post-breakaway regime. (authors)

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2020

Investigation of Process Emissions during Thermal Cutting of Clad Metals from the Nuclear Sector - 20183

Typically, reactor pressure vessels as well as steam generators comprising low alloyed steel with a cladding of stainless steel. Recently the permissible values for Cr (VI) in the air of the working areas have been reduced in Germany from 100 μg/m{sup 3} to 1 μg/m{sup 3} air. This results in the danger that even with low-alloy steel with claddings these limit values would be exceeded when using flame cutting technologies. In order to ensure compliance with the permissible limit values, exhaust gas systems with gas cleaning measures are provided. The process emission test shall replace the assumptions required for the design of these systems with measured values. NUKEM Technologies Engineering Services GmbH (NUKEM) has chosen autogenous flame cutting as an example of a thermal cutting system for process emission testing, as there are no proven values in the literature for the Cr (VI) and NiOx emissions produced. The autogenous flame cutting can be used for a variety of cutting tasks within decommissioning projects. In order to simulate the material to be cut, mock ups were generated and cut from information about the material specification for the reactor pressure vessel from existing nuclear power plants including possible claddings. The cutting length needed for analysis in the test will be maximum 100 mm. The airborne emissions from the thermal cutting process will be captured and analyzed as follows: - Dust emission: The generated particles will be collected by a hood equipped with strong suction device and suitable filter elements. The resulting filter is gravimetrically measured before and after the tests. - Particle Size Distribution: The airborne particle size distribution measurement will result in figures for the size and number of particles arising from the thermal cutting process. - Gas Analysis: The gas analysis enables the determination of e.g. CO{sub 2}, CO, O{sub 3}, NO, NO{sub 2}. - Cr (VI) and NiOx Analysis: For the Cr (VI) and NiOx analysis, samples of the filter residue will be taken. As a result Cr (VI) in relation to total Cr as well as the Ni content will be determined by ICP-optically emission spectroscopy and put in relation to the total dust amount. The process emissions test itself as well as the necessary gas analyses and spectroscopic analyses were carried out at the Institute of Materials Science (IW) of Leibniz Universitaet Hannover (LUH). The results of the process emission tests are used to confirm the design of the gas cleaning systems. (authors)

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

Mechanical failure of fresh nuclear grade iron–chromium–aluminum (FeCrAl) cladding under simulated hot zero power reactivity initiated accident conditions

The reactivity initiated accident (RIA) is a postulated accident in light water reactors initiated by a rapid increase in reactivity which causes an increase in fission rate and fuel temperature. One potential mode of fuel system failure during RIA is pellet cladding mechanical interaction (PCMI) due to the rapid thermal expansion of the fuel pellet. Simulated PCMI experiments were performed by rapidly pressurizing iron-chromium-aluminum (FeCrAl) cladding tube samples using a hydraulic modified burst test system, causing the specimens to burst under a biaxial loading path. Deformation and rupture of the specimens were tracked with a telecentric lens and high-speed camera system. Outer surface strains were calculated using digital image correlation (DIC) on speckle patterns painted on the specimens’ outer surfaces. Experiments were conducted at approximately 275 °C, representative of hot zero power RIA conditions. The failure hoop strain was DIC-calculated between approximately 1.8–3.4%, corresponding to quasi-static energy depositions of approximately 110–260 calories per gram UO 2 assuming initial pellet-cladding contact. These conditions are very similar to the proposed energy deposition limit of 150 calories per gram UO 2 for unirradiated zirconium-based cladding in US Nuclear Regulatory Commission (NRC) Draft Regulatory Guide 1327. A very small strain rate dependence was observed in the data, with the magnitude of the failure hoop strain decreasing slightly with increasing strain rate. This observed dependence may be relevant because the FeCrAl cladding strain rate will be approximately 20% higher than in zirconium-based cladding due to the harder neutron spectrum and resultant shorter neutron generation time.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2018

Measuring the elastic tensor of a monolithic SiC hollow cylinder with resonant ultrasound spectroscopy

Resonant Ultrasound Spectroscopy (RUS) has become a standard tool in material science to measure nondestructively the elastic properties of materials. The widespread adoption of this tool for applications related to nondestructive testing and structural health monitoring in the industry and other places has been restricted thus far by some requirements imposed by RUS on the sample to be tested, in particular the fact that the sample geometry should be relatively simple (e.g., cuboid, cylinder, or sphere). Here, we use RUS to determine the baseline material properties of a hollow cylinder made of monolithic SiC, a surrogate material and geometry representing nuclear fuel cladding for this study. Typically, elastic properties of the nuclear fuel cladding samples are inspected destructively (e.g., indentation) or with acoustic techniquesrequiring multiple and cumbersome measurements. Here, a relatively new RUS approach specifically developed to measure the elastic tensor of samples with arbitrary geometries is used. The results obtained from this RUS approach are compared to values reported in the literature. As a second verification step, vibrational mode shapes computed numerically with the elastic constants are compared to those measured on the sample using a 3D laser Doppler vibrometer, showing an excellent agreement.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Recent Advances in Cladding Material Extraction from Fuels in Nuclear Fuel Cycles

An improved recycling and recovery process for the cladding material from spent nuclear fuels is very important toward confirming nuclear energy to support ongoing sustainable development of nuclear management by reducing waste and conserving resources. Nuclear spent fuel cladding materials such as zirconium alloys have economic values and can be recovered, and their recovery eliminates problems in waste disposal and conserves valuable resources. Over 110 published reports and journal articles are reviewed and summarized herein, with a main focus on documenting recovery techniques used to recover cladding materials from spent nuclear fuel and recent developments. Several recovery techniques which are used at present times, such as mechanical separation, chemical dissolution, and hydrometallurgical processes have been covered with examples and discussions. Difficulties within the recovery process are also discussed, and most probable areas for future research in improving efficiency and sustainability of recovering cladding material are identified and discussed at the end. Here, this review could be an important document to the field of spent nuclear fuel reprocessing, recovering valuables and thereby offering guidance on how to effectively manage, safely handle, and reduce nuclear waste. In addition to reducing the volume and radiotoxicity of high-level waste, this review also highlights the potential economic benefit of recovering zirconium from spent fuel cladding by relating typical zirconium metal prices to the mass of cladding per tonne of spent fuel, illustrating that the recoverable material value is non-negligible compared with back-end fuel-cycle costs.

Mondal, Kunal [Oak Ridge National Laboratory (ORNL↗
DOE OSTI2016

TEM Study of Zircaloy 2 with FeCrAl Layer under Simulated BWR Environment

Zircaloy 2 is widely used as nuclear fuel cladding in light-water nuclear reactors, which is resistive to corrosion, creep, and swelling. Due to water chemical reactivity and high-temperature steam exposure, oxidation in zirconium cladding is possible during transients. To mitigate the zirconium oxidation and the hydrogen generation at elevated temperature, we have coated Zircaloy 2 with oxide resistant FeCrAl thin film layers using magnetron sputtering. Transmission electron microscopy (TEM), scanning transmission electron microscopy (STEM), and electron energy-dispersive X-ray spectroscopy (EDX) are used to understand the behavior of the protective FeCrAl layer under typical BWR operation conditions. (authors)

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2013

Features of temperature control of fuel element cladding for pressurized water nuclear reactor “WWER-1000” while simulating reactor accidents

During the experiments simulating NPR (nuclear power reactor) accidents with a coolant loss fuel elements behavior in a steam-hydrogen medium was studied at the temperature changed with the rate from 1 to 100K/s within the range of 300÷1500 °C. Indications of the thermocouples fixed on the cladding notably differ from real values of the cladding temperatures in the area of measuring junction due to thermal resistance influence of the transition zones “cladding-junction” and “junction-coolant”. The estimating method of a measurement error was considered which can provide adequate accounting of the influence factors. The method is based on thermal probing of a thermocouple by electric current flashing through thermoelements under the coolant presence or absence, a response time registration and processing, calculation of thermal inertia value for a thermocouple junction. A formula was derived for calculation of methodical error under stationary mode and within the stage of linear increase in temperature, which will determine the conditions for the cladding depressurization. Some variants of the formula application were considered, and the values of methodical errors were established which reached ∼5% of maximum value by the final moment of the stage of linear increase in the temperature.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2015

Development and property evaluation of nuclear grade wrought FeCrAl fuel cladding for light water reactors

Development of nuclear grade, iron-based wrought FeCrAl alloys has been initiated for light water reactor (LWR) fuel cladding to serve as a substitute for zirconium-based alloys with enhanced accident tolerance. Ferritic alloys with sufficient chromium and aluminum additions can exhibit significantly improved oxidation kinetics in high-temperature steam environments when compared to zirconium-based alloys. In the first phase, a set of model FeCrAl alloys containing 10–20Cr, 3–5Al, and 0–0.12Y in weight percent, were prepared by conventional arc-melting and hot-working processes to explore the effect of composition on the properties of FeCrAlY alloys. It was found that the tensile properties were insensitive to the alloy compositions studied; however, the steam oxidation resistance strongly depended on both the chromium and the aluminum contents. The second phase development focused on strengthening Fe-13Cr-5Al with minor alloying additions of molybdenum, niobium, and silicon. Combined with an optimized thermo-mechanical treatment, a thermally stable microstructure was produced with improved tensile properties at temperatures up to 741°C.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2022

Silicon carbide reinforced zirconium based cladding

A method for making an improved nuclear fuel cladding tube includes reinforcing a Zr alloy tube by first winding or braiding ceramic yarn directly around the tube to form a ceramic covering, then physically bonding the ceramic covering to the tube by applying a first coating selected from the group consisting of Nb, Nb alloy, Nb oxide, Cr, Cr oxide, Cr alloy, or combinations thereof, by one of a thermal deposition process or a physical deposition process to provide structural support member for the Zr tube, and optionally applying a second coating and optionally applying a third coating by one of a thermal deposition process or a physical deposition process. If the tube softens at 800° C.-1000° C., the structural support tube will reinforce the Zr alloy tube against ballooning and bursting, thereby preventing the release of fission products to the reactor coolant.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗