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EVALUATION OF U10MO FUEL PLATE IRRADIATION BEHAVIOR VIA NUMERICAL AND EXPERIMENTAL BENCHMARKING

This article analyzes dimensional changes due to irradiation of monolithic plate-type nuclear fuel and compares results with finite element analysis of the plates during fabrication and irradiation. Monolithic fuel plates tested in the Advanced Test Reactor (ATR) at Idaho National Lab (INL) are being used to benchmark proposed fuel performance for several high power research reactors. Post-irradiation metallographic images of plates sectioned at the midpoint were analyzed to determine dimensional changes of the fuel and the cladding response. A constitutive model of the fabrication process and irradiation behavior of the tested plates was developed using the general purpose commercial finite element analysis package, Abaqus. Using calculated burn-up profiles of irradiated plates to model the power distribution and including irradiation behaviors such as swelling and irradiation enhanced creep, model simulations allow analysis of plate parameters that are either impossible or infeasible in an experimental setting. The development and progression of fabrication induced stress concentrations at the plate edges was of primary interest, as these locations have a unique stress profile during irradiation. Additionally, comparison between 2D and 3D models was performed to optimize analysis methodology. In particular, the ability of 2D and 3D models account for out of plane stresses which result in 3-dimensional creep behavior that is a product of these components. Results show that assumptions made in 2D models for the out-of-plane stresses and strains cannot capture the 3-dimensional physics accurately and thus 2D approximations are not computationally accurate. Stress-strain fields are dependent on plate geometry and irradiation conditions, thus, if stress based criteria is used to predict plate behavior (as opposed to material impurities, fine micro-structural defects, or sharp power gradients), unique 3D finite element formulation for each plate is required.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Dual-Purpose Canister Filling Demonstration Project Progress Report at ORNL, 2023

The US DOE Office of Nuclear Energy is investigating the feasibility of direct disposal of dual-purpose canisters (DPCs) in a hypothetical geological repository to offset the potential requirement to repackage spent nuclear fuel (SNF) from existing DPCs into smaller, disposal-ready canisters. Oak Ridge National Laboratory (ORNL) is currently evaluating the feasibility of filling void space in loaded DPCs with an engineered material to prevent a criticality event caused by groundwater/moderator intrusion. Metal alloys are being investigated as a filler material because of their relatively low viscosities when molten, which may facilitate their injection via an existing drainpipe that runs almost the full length of the DPC. ORNL’s strategy for evaluating filler viability includes simulations and physical demonstrations of filling and casting behavior, as well as evaluations of materials for compatibility in the repository environment. Filling of DPCs in this manner is expected to mitigate the risk associated with a post-closure criticality event during the repository performance assessment time frame (10,000 years or greater). Efforts in this fiscal year focused on (1) destructive analysis of experimental filler castings made in FY 2022, (2) a report outlining a conceptual design of a DPC filling facility (Fortner et al., 2023, M3SF 23OR010305044/ ORNL/SPR-2023/2921, May 31, 2023), (3) a report on affected features, events, and processes (FEPs) due to DPC filling (Price et al., 2023, M3SF-23SN010305093, issuance pending), (4) developing and testing a more practical alloy filler based upon a Sn-Al eutectic, and (5) modeling the heating and cooling dynamics of a DPC subjected to molten metal filling. The preliminary results from each of these tasks support the feasibility of filling DPCs with metal as a strategy against the possibility of criticality in the repository. The FY 2022 casting was found to penetrate even very small orifices in the mold and internal structures. Preliminary testing of the Sn-Al eutectic indicate little interaction of the melt with Zircaloy cladding. Thermal modelling shows that a filled DPC will cool to manageable temperatures within 2-3 days, which is likely manageable in a facility.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

Computational Modeling of Multi-Pass Rolling Parameters Effect on Resulting Fuel Foil Shape

A focus of the U.S. Department of Energy is to improve production yield and reduce the cost of Low Enriched Uranium (LEU)-molybdenum alloy (U-10Mo) monolithic fuel plates that will be replacing High Enriched Uranium (HEU) oxide dispersion fuels used currently in the United States High Performance Research Reactors (USHPRR). One area of improvement is lowering the high transverse waviness and longitudinal waviness currently present within rolled foils prior to cladding to produce fuel plates. Traditional rolling manufacturing techniques for other metal foils use winders to pull and straighten the foil as it is rolled back and forth to the final thickness. This approach cannot be used to roll thin U-10Mo foils (0.008-0.025” thick) because only small castings can be rolled due to nuclear criticality safety concerns. As a result, the fuel foils are too short (1 m in length) to use traditional winders. Therefore, it is crucial to identify other rolling parameters (i.e., roller friction, axial tension load, roller diameter, and roll pass reduction percent) that might reduce transverse waviness and longitudinal waviness in the rolled fuel foil and develop a high-yield, low-cost multi-pass rolling manufacturing process. This report documents a systematic finite element modeling study to investigate the effects of numerous rolling parameters to reduce resulting transverse waviness and longitudinal waviness in the fuel foil during multi-pass rolling of U-10Mo foils. The rolling of a U-10Mo plate with initial dimensions of 1”x1”x 0.048” is modeled using Abaqus CAE. This rolling is modeled to undergo eight 20% reduction roll passes to a final fuel foil thickness of 0.01”. The elastic-plastic constitutive model of the U-10Mo alloy was input to the fuel foil rolling model. The rollers were modeled as rigid bodies. A comparison of rolling friction coefficients of 0.3 and 0.7 over a wide range of applied axial tension loads were investigated in order to evaluate the effect of using a lubricant during rolling. The effect of roller diameter on the resulting transverse waviness and longitudinal waviness of the fuel foil over a wide range of axial tension loads were also investigated by modeling rollers 7/8” and 3.75” in diameter. The results of this systematic finite element method study will aid manufacturers in producing low transverse waviness and reduced longitudinal waviness in U-10Mo fuel foils.

U-10Mo, FEA, Rolling, Residual Stress, Fuel Foil↗

Fully Distributed Acoustic and Magnetic Field Monitoring Via a Single Fiber Line for Optimized Production of Unconventional Resource Plays

This is the final technical report for the Virginia Tech Center for Photonics Technology (VT-CPT) research project entitled “Fully Distributed Acoustic and Magnetic Field Monitoring Via a Single Fiber Line for Optimized Production of Unconventional Resource Plays”. In the the four-year effort, VT-CPT collaborated with the Departments of Mathmatics at VT and Sentek Instrument, LLC (Sentek) to develop a fiber-optic sensing system capable of real-time simultaneous distributed measurement of multiple subsurface, drilling, and production parameters. The ultra-sensitive fiber optic distributed acoustic sensing technology, picoDAS, developed by Sentek was integrated with a novel multi-material optical sensing fiber fabricated by CPT-VT to obtain distributed acoustic and magnetic field measurements with ultrahigh sensitivity and high spatial resolution. The sensing technology successfully developed and demonstrated under this research program is truly unique has application beyond subsurface imaging to include carbon storage and electrical grid monitoring, as well as healthcare and nuclear fusion. The project, sponsored by the Advanced Technology Program, began in 2019 and had the original goal of developing the next generation of harsh environment sensing systems. Exhaustive theoretical modeling was performed to optimize the multi-material optical fiber design. VT developed the processing techniques employed to successfully fabricate single mode fibers with metal cladding wires. Sensing fibers with nickel and Metglas cladding wires were fully characterized, inscribed with sensors, and fully integrated with the picoDAS system. Laboratory scale testing was performed to demonstrate performance upon exposure to lateral and transverse magnetic fields. Preliminary field trials were performed for prototype magnetic and acoustic sensing systems upon near surface deployment at VT. The distributed acoustic and magnetic field sensing system was advanced from a (Technology Readiness Level) TRL=2 to a TRL=5 via laboratory scale system validation in relevant environments. The truly one-of-its kind distributed magnetic and acoustic sensing system is expected to find immediate applications that require subsurface monitoring, to include carbon storage site monitoring, and has the potential to be a distributive technology in healthcare and electric grid markets. The technologies developed by Virginia Tech’s Center for Photonics Technology will support the mission of the National Energy Technology Laboratory (NETL) to drive innovation and deliver solutions for an environmentally sustainable and prosperous energy future by ensuring affordable, abundant, and reliable energy that drives a robust economy and national security. Technical accomplishments during the program are summarized briefly here and described in detail in the remainder of the report.

02 PETROLEUM↗

Q-value (MeV/fission) Determination for the Advanced Test Reactor

This report documents a step-by-step procedure that can be used to calculate a Q-value for the Advanced Test Reactor (ATR) at Idaho National Laboratory (INL). The Q-value calculation here is an estimate of the total energy released per fission event in the ATR driver fuel in units of MeV/fission and is recognized as a reactor-specific Q-value for the ATR. Such a Q-value is needed INL ATR reactor physicists to normalize calculated fluxes and reaction rates to measured ATR total core and lobe powers. The calculated ATR Q-value and the procedure used to calculate this value are presented in a detailed manner so as to establish a credible basis, such that this single Q-value can be used consistently among all ATR reactor physicists. A Q-value is essentially the summation of all the kinetic energy from all radiation components released from a single fission event that ends up as heat in the reactor coolant. Estimation of a Q-value for a given reactor can theoretically be very complex because it is dependent on several variables, which include (1) the materials in the reactor core, (2) the neutron energy spectrum, and (3) the mix of actinide isotopes that are being simultaneously fissioned. Since these three variables can potentially change over time or with reactor burnup, this potentially makes the Q-value a time-dependent quantity. However, for ATR, we will invoke some simplifying assumptions, based on the unique features of the ATR core and supported by neutronic calculations, which will reduce the complexity of the problem and lead to a single time-independent Q-value. Of the three variables, the materials in the core have the greatest impact on the ATR Q-value. Since the materials in the core are most important, an array of components (materials) have been carefully selected to compose a typical ATR core configuration. It should be noted that the step-by-step procedure here for calculating a reactor-specific Q-value can be applied to any nuclear reactor. In a more general procedure, if one needed to include time-dependent spectral and actinide composition changes as a function of burnup for a specific reactor, this procedure can still be used, but at discrete time steps throughout the burnup. The result will be a set of discrete Q-values as a function of burnup. However, here we will apply the procedure to the ATR, as an example, and obtain a single Q-value that is valid for the ATR reactor as a function of burnup. In the evaluated nuclear data file (ENDF), Q-values for specific actinides are known for a reasonably high degree of accuracy, especially the major uranium and plutonium isotopes. The isotopic Q-values are composed of the kinetic energy of the fission fragments and the energies of the various radiation components emitted from the fission event. One complication is the fact that some of these energy components are dependent on the incident neutron energy (EINC) that induces the fission event (neutron energy spectrum dependence). For ATR, we will estimate an average neutron energy based on the neutron energy flux weighted by the fission cross sections and use this average neutron energy value in the ENDF formulas. This neutron energy dependence is one of two dependencies that make the final ATR Q-value a reactor-specific value. The second dependency, and the most important variable for ATR, involves the materials in the core and the de-excitation radiations produced from neutron radiative capture radiation; radiation energy that becomes heat in the reactor coolant. This important dependency is discussed in detail below. The third dependency, or the mix of fissioning actinides as a function of ATR burnup, is ignored because the bulk of the fissions over a cycle are always due to U-235 in the high-enriched ATR core. In a fission event, the fission energy is partitioned between the fission fragments and the radiation components that include neutrons, gamma rays, and beta particles. The main variable that makes the calculated Q-value reactor-specific is the amount of radiative capture energy produced in the core due to prompt and delayed neutron capture in the reactor core materials and the subsequent release of nuclear binding energy in the form of de-excitation gamma radiation energy in the reactor core. This energy component, neutron radiative capture energy, is not in the ENDF, because it depends on the reactor and its core materials. The radiative capture gamma energy release can be significant, or approximately 3–12 MeV/fission depending on the materials in the reactor core (fuel materials, cladding, structural components, coolant, targets, reflector, etc.). For the ATR, the energy released from radiative capture gamma radiation is calculated to be near the middle of the 3–12 MeV range. This makes the radiative capture radiation component an important and significant contribution to the total ATR Q-value. The ATR has unique reactor features that will allow us to simplify the complex procedure for determining an ATR reactor-specific Q-value. For example, the ATR is a thermal reactor and contains high-enriched fuel (93.15 wt% U-235). Consequently, the bulk of the fissions in the ATR core from beginning-of-cycle (BOC) to end-of-cycle are from U-235. Even though U-238 makes up approximately 7% of the uranium atoms in the fuel, the number of fissions relative to U-235 is insignificant, since U-238 is fertile and ATR is a thermal reactor. The same is true for U-234 and U-236 (both fertile). The ATR’s high-enriched uranium fuel also inhibits the buildup of large quantities of plutonium isotopes. So, even though there is some buildup of U-236, Np-237, and Pu-239 in the ATR driver fuel, the impact or contribution of these isotopes fissions on the ATR Q-value is minor compared to U-235. Nonetheless, we will include fission contributions from all the major uranium isotopes (U-234, U-235, U-236, and U-238) in the determination of an average isotopic Q-value that is used in the ATR Q-value determination. Although the ATR Q-value calculated here is based on BOC conditions (fresh fuel with no higher order actinide buildup), it is believed that the ATR Q-value is relatively constant with burnup or during any given ATR power cycle (14–60 days). The reason is that the vast majority of the core driver fuel fissions are always from U-235 during the cycle. Also, since we effectively assume instantaneous energy release for the fission product gammas and beta particles and delayed neutrons from a fission event, this corresponds to equilibrium conditions for all fission product concentrations in the ATR driver fuel too. The goal of this effort was to determine a specific numerical and core-average Q-value for the recoverable energy released by a single fission event (MeV/fission) for the ATR. This calculated value has the potential to help standardize and add credibility to not only the Monte Carlo tally normalization process used by many ATR core physics analysts, but also to the normalization process for all reactor physics calculation methods involving ATR analyses. Currently, the ATR core physics analysts use slightly different Q-values. Some values are known to be conservative for specific applications. However, sometimes a more accurate Q-value is needed for the calculation in which ATR test specimens require non-conservative and as-accurate-as-possible Q-values to estimate burnups, heat rates, neutron fluxes, nuclear reaction rates, etc., where corresponding measured post-irradiation examination data provides the ultimate validation for the calculated results. A detailed Q-value procedure was developed and is outlined in this document along with numerical values calculated specifically for the determination of the ATR Q-value. This report attempts to document in some detail the calculation methodology, nuclear data, computer code, computer model, code calculated results, hand calculations, assumptions, and logic that went into the determination of the ATR Q-value.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Thermal-Hydraulic Simulations of Single Pin and Assembly Sector for IVG- 1M Reactor

Thermal-hydraulic simulations have been performed using computational fluid dynamics (CFD) for the highly-enriched uranium (HEU) design of the IVG.1M reactor at the Institute of Atomic Energy (IAE) at the National Nuclear Center (NNC) in the Republic of Kazakhstan. Steady-state simulations were performed for both types of fuel assembly (FA), i.e. the FA in rows 1 & 2 and the FA in row 3, as well as for single pins in those FA (600 mm and 800 mm pins). Both single pin calculations and bundle sectors have been simulated for the most conservative operating conditions corresponding to the 10 MW output power, which corresponds to a pin unit cell Reynolds number of only about 7500. Simulations were performed using the commercial code STAR-CCM+ for the actual twisted pin geometry as well as a straight-pin approximation. Various Reynolds-Averaged Navier-Stokes (RANS) turbulence models gave different results, and so some validation runs with a higher-fidelity Large Eddy Simulation (LES) code were performed given the lack of experimental data. These singled out the Realizable Two-Layer k-ε as the most accurate turbulence model for estimating surface temperature. Single-pin results for the twisted case, based on the average flow rate per pin and peak pin power, were conservative for peak clad surface temperature compared to the bundle results. Also the straight-pin calculations were conservative as compared to the twisted pin simulations, as expected, but the single-pin straight case was not always conservative with regard to the straight-pin bundle. This was due to the straight-pin temperature distribution being strongly influenced by the pin orientation, particularly near the outer boundary. The straight-pin case also predicted the peak temperature to be in a different location than the twisted-pin case. This is a limitation of the straight-pin approach. The peak temperature pin was in a different location from the peak power pin in every case simulated, and occurred at an inner pin just before the enrichment change. The 600 mm case demonstrated a peak clad surface temperature of 370.4 K, while the 800 mm case had a temperature of 391.6 K. These temperatures are well below the necessary temperatures for boiling to occur at the rated pressure. Fuel temperatures are also well below the melting point. Future bundle work will include simulations of the proposed low-enriched uranium (LEU) design. Two transient scenarios were also investigated for the single-pin geometries. Both were “model” problems that were focused on pure thermal-hydraulic behavior, and as such were simple power changes that did not incorporate neutron kinetics modeling. The first scenario was a high-power, ramp increase, while the second scenario was a low-power, step increase. A cylindrical RELAP model was also constructed to investigate its accuracy as compared to the higher-fidelity CFD. Comparisons between the two codes showed good agreement for peak temperatures in the fuel and at the cladding surface for both cases. In the step transient, temperatures at four axial levels were also computed. These showed greater but reasonable discrepancy, with RELAP outputting higher temperatures. These results provide some evidence that RELAP can be used with confidence in modeling transients for IVG.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

Strategies for Fabricating Molybdenum Structures Using Laser Powder Bed Fusion

Advances in manufacturing techniques are viewed as enabling technologies for development of high performance nuclear fuel forms that couple high uranium density with improvements to key properties such as thermal conductivity unattainable through conventional fabrication routes. Additive manufacturing (AM) enables the fabrication of complex fuel geometries that are difficult or impossible to achieve using conventional manufacturing methods. Melting-based AM processes, such as laser powder bed fusion (LPBF), provide high geometric resolution (>200 µm depending on the feature) across a variety of metal alloys, including those suitable for high-temperature fuel cladding applications, such as Nb, W, and Mo. Molybdenum is particularly attractive due to its high thermal conductivity, low thermal expansion, and excellent mechanical stability at elevated temperatures. However, its high melting temperature and brittle nature at low temperatures pose significant challenges during LPBF processing. Rapid solidification inherent to LPBF induces high residual stresses, often leading to post-solidification cracking, which limits the manufacturability of Mo components via this method.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Advanced Retrieval and Disposition Techniques for Remote Handled Mixed Low-Level Waste - 20319

Legacy waste generated by the sodium-cooled fast reactor, EBR-II, program at the Idaho National Laboratory (INL) (owned by the U.S. Department of Energy and managed and operated by Battelle Energy Alliance, LLC) is challenging to treat and disposition using conventional methods. As a result, Veolia Nuclear Solutions is under contract with the Idaho National Laboratory to demonstrate an integrated retrieval and disposition solution for Remote-Handled Mixed Low-Level Waste currently stored in underground liners at INL. Delivery of the integrated solution builds on the expertise and successes of Veolia Nuclear Solutions under its Problematic Waste Treatment Initiative with INL. This initiative focuses solely on the treatment of problematic (reactive metal containing) waste streams using the Veolia Nuclear Solutions GeoMelt{sup R} In-Container Vitrification (ICV{sup TM}) technology. Under the contract, Veolia Nuclear Solutions will provide a fully commissioned prototype remote retrieval system to semi-remotely retrieve and size-reduce problematic waste liners into a safe and consolidated package for transport. The consolidated package will be shipped to Richland, Washington for demonstration treatment using the robust GeoMelt Richland system at Perma-Fix Northwest. The treated waste will ultimately be disposed of as a vitrified Low-Level Waste glass monolith. Veolia Nuclear Solutions has delivered countless remotely operated systems globally to solve some of the industry's most challenging problems. To ensure risk is mitigated in the best possible manner, a methodical phased approach is being utilized to validate the integrated solution. This contract focuses on the delivery and deployment of the prototype retrieval system onsite and the treatment of a single liner. Following successful demonstration treatment using GeoMelt ICV, the project is planning to make prototype enhancements before retrieving and treating another liner. Establishing a new integrated approach for retrieval and disposition of waste offers many benefits to INL and the U.S. Department of Energy. It is anticipated that the integrated solution will provide significant cost and schedule savings by increasing the number of liners dispositioned per year. In addition, the complexity of the overall waste disposition process will be reduced. Remotely retrieving and size-reducing waste in the field will provide additional safety to operational personnel and allow critical resources, such as hot cells, to focus on the primary missions at hand. Vitrification (using the GeoMelt ICV technology) allows for the direct processing of metal clad waste thereby significantly reducing pretreatment steps while providing a robust waste form for long-term disposal. The results from this ongoing contract are presented in this paper. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

Radiation Effects in Next Generation Used Nuclear Fuel Reprocessing Strategies

With the global community committed to significantly expanding nuclear energy capacity, the development of efficient used nuclear fuel (UNF) management strategies has become more critical than ever. These strategies are vital to fostering the widespread adoption of closed fuel cycles, which are essential for sustainable nuclear energy production and security. Achieving this ambitious goal necessitates a comprehensive understanding of radiation effects on next-generation technologies, as radiolysis can often limit the longevity and performance of these systems. This seminar will provide an overview of next-generation UNF reprocessing strategies, highlighting the latest advancements and innovative approaches in the field. Particular attention will be given to two key areas of recent research: 1. Radiation robustness and performance of advanced sulfur chloride-based chlorination technologies. We will explore the efficacy of sulfur chloride-based chlorination processes in the presence of surrogate cladding materials, specifically aluminum. These processes have shown promise in the dissolution, decontamination, and recovery of cladding materials for reuse. Detailed findings on how the composition and performance of these sulfur chloride solvents respond to radiation exposure will be discussed. 2. Impacts of metal ion complexation and direct dissolution conditions on monoamide-based reprocessing strategies. We will delve into the time-resolved and dose accumulation effects of irradiation on the direct dissolution of voloxidized uranium and rhenium using N,N-di-(2-ethylhexyl) butyramide (DEHBA) or N,N-di-(2-ethylhexyl)isobutyramide (DEHiBA) in pre-equilibrated n-dodecane solvent. The implications of these interactions on dissolution efficiency, radiolytic stability, and overall process performance will be examined. These studies aim to underscore the importance of understanding radiation effects in the development of next-generation UNF reprocessing technologies and the global transition towards more sustainable and efficient nuclear energy systems.

38 - RADIATION CHEMISTRY, RADIOCHEMISTRY, AND NUCL↗

2nd Gen FeCrAl ODS Alloy Development For Accident-Tolerant Fuel Cladding

Extensive research at ORNL aims at developing advanced low-Cr high strength FeCrAl alloys for accident tolerant fuel cladding. One task focuses on the fabrication of new low Cr oxide dispersion strengthened (ODS) FeCrAl alloys. The first Fe-12Cr-5Al+Y 2 O 3 (+ ZrO 2 or TiO 2 ) ODS alloys exhibited excellent tensile strength up to 800 C and good oxidation resistance in steam up to 1400 C, but very limited plastic deformation at temperature ranging from room to 800 C. To improve alloy ductility, several fabrication parameters were considered. New Fe-10-12Cr-6Al gas-atomized powders containing 0.15 to 0.5wt% Zr were procured and ball milled for 10h, 20h or 40h with Y2O3. The resulting powder was then extruded at temperature ranging from 900 to 1050 C. Decreasing the ball milling time or increasing the extrusion temperature changed the alloy grain size leading to lower strength but enhanced ductility. Small variations of the Cr, Zr, O and N content did not seem to significantly impact the alloy tensile properties, and, overall, the 2nd gen ODS FeCrAl alloys showed significantly better ductility than the 1st gen alloys. Tube fabrication needed for fuel cladding will require cold or warm working associated with softening heat treatments, work was therefore initiated to assess the effect of these fabrications steps on the alloy microstructure and properties. This report has been submitted as fulfillment of milestone M3FT 16OR020202091 titled, Report on 2nd Gen FeCrAl ODS Alloy Development for the Department of Energy Office of Nuclear Energy, Advanced Fuel Campaign of the Fuel Cycle R&D program.

36 MATERIALS SCIENCE↗

BISON Fuel Performance Analysis of IFA-796 Rod 3 & 4 and Investigation of the Impact of Fuel Creep

In order to improve the accident tolerance of light water reactor (LWR) fuel, alternative cladding materials have been proposed to replace the currently used zirconium (Zr)-based alloys. Of these materials, there is a particular focus on iron-chromiumaluminum (FeCrAl) alloys because they exhibit slower oxidation kinetics in high-temperature steam than Zr-alloys. This should decrease the energy release due to oxidation and slow cladding consumption in the presence of high temperature steam. These alloys should also exhibit increased “coping time” in the event of an accident scenario by improving the mechanical performance at high temperatures, allowing greater flexibility to achieve core cooling. As a continuation of the development of these alloys, in-reactor irradiation testing of FeCrAl cladded fuel rods has started. In order to provide insight on the possible behavior of these fuel rods as they undergo irradiation in the Halden Boiling Water Reactor, engineering analysis has been performed using FeCrAl material models implemented into the BISON fuel performance code. This milestone report provides an update on the ongoing development of modeling capability to predict FeCrAl cladding fuel performance and to provide an early look at the possible behavior of planned in-reactor FeCrAl cladding experiments. In particular, this report consists of two separate analyses. The first analysis consists of fuel performance simulations of IFA-796 rod 4 and two segments of rod 3. These simulations utilize previously implemented material models for the C35M FeCrAl alloy and UO2 to provide a bounding behavior analysis corresponding to variation of the initial fuel cladding gap thickness within the fuel rod. The second analysis is an assessment of the fuel and cladding stress states after modification of the fuel creep model that is currently implemented in the BISON fuel performance code. Effects from modifying the fuel creep model were identified for the BISON simulations of the IFA-796 rod 4 experiment, but show that varying the creep model (within the range investigated here) only provide a minimal increase in the fuel radius and maximum cladding hoop stress. Continued investigation of fuel behavioral models will include benchmarking the modified fuel creep model against available experimental data, as well as an investigation of the role that fuel cracking will play in the compliance of the fuel. Correctly calculating stress evolution in the fuel is key to assessing fuel behavior up to gap closure and the subsequent deformation of the cladding due to PCMI. The inclusion of frictional contact should also be investigated to determine the axial elongation of the fuel rods for comparison with data from this experiment.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Overview of the Water-Based RIA Testing in TREAT

A series of reactivity-initiated accident (RIA) commissioning tests have been completed with the static water capsule in the Transient Reactor Test (TREAT) Facility. The test campaign included a calibration test followed by five tests in the Static Environment Rodlet Transient Test Apparatus (SERTTA) capsule. The conditions varied from room temperature and pressure up to 200°C and 2.5 MPa with energy depositions varying between ~500-1100 J/gUO2. The series of tests allowed for a number of instrumentation qualifications and demonstrations including cladding thermometry, rodlet plenum pressure, cladding elongation, and an electro-impedance boiling detector. This paper documents the design of the capsule and highlight the results from the commissioning tests.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Overview of the Water-Based RIA Testing in TREAT

We have completed a series of reactivity-initiated accident commissioning tests with the static water capsule in the Transient Reactor Test Facility. The test campaign included a calibration test followed by five tests in the Static Environment Rodlet Transient Test Apparatus capsule. The conditions varied from room temperature and pressure up to 200°C and 2.5 MPa, with energy depositions varying between ~500–1100 J/gUO2. The series of tests allowed for a number of instrumentation qualifications and demonstrations, including cladding thermometry, rodlet plenum pressure, cladding elongation, and an electro-impedance boiling detector. This paper documents the design of the capsule and highlights the results from the commissioning tests.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Risk-Informed Safety Analysis for Accident Tolerant Fuels

Accident Tolerant Fuels (ATF) are being tested by different nuclear vendors and research organizations and their introduction in the US light water reactors fleet is planned for the second half of the 2020`s. In the framework of the US-DOE Light-Water Reactor Sustainability program, Risk-Informed Systems Analysis pathway, researches are being conducted at the Idaho National Laboratory for developing tools and methods that can help the industry quantifying the benefits from the adoption of ATF technology. In this paper we describe the developed risk-informed methodology including the safety analysis codes improvements, and we present some results for selected accident scenarios. The developed methodology combines INL state-of-the-art deterministic Best Estimate code RELAP5-3D, and Probabilistic Risk Analysis tools RAVEN and SAPHIRE. The analyses are performed on a three-loops pressurized water reactor, simulating Station Blackout and LB-LOCA accidents and considering near-term ATFs, or FeCrAl and Chromium-coated clads. Finally, we show how, applying our methodology, the new Core Damage Frequency can be assessed. The results indicated that the main benefits in introducing near-term ATFs concern a significant reduction in the hydrogen production during accident conditions. No significant Core Damage Frequency reduction was found.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

A Brief Review of Past INL Work Assessing Radionuclide Content in TMI-2 Melted Fuel Debris: The Use of 144 Ce as a Surrogate for Pu Accountancy

This report serves as a literature review of prior work performed at Idaho National Laboratory, and its predecessor organizations Idaho National Engineering Laboratory (INEL) and Idaho National Engineering and Environmental Laboratory (INEEL), studying radionuclide partitioning within the melted fuel debris of the reactor of the Three Mile Island 2 (TMI-2) nuclear power plant. The purpose of this review is to document prior published work that provides supporting evidence of the utility of using 144 Ce as a surrogate for plutonium within melted fuel debris. When the TMI-2 accident occurred no quantitative nondestructive analysis (NDA) techniques existed that could assay plutonium in the unconventional wastes from the reactor. However, unpublished work performed at INL by D. W. Akers in the late 1980s through the 1990s demonstrated that passive gamma-ray spectrometry of 144 Ce could potentially be used to develop a semi-quantitative correlation for estimating plutonium content in these materials. The fate and transport of radioisotopes in fuel from different regions of the core, including uranium, fission products, and actinides, appear to be well characterized based on the maximum temperature reached by fuel in different parts of the core and the melting point, boiling point, and volatility of those radioisotopes. Also, the chemical interactions between fuel, fuel cladding, control elements, and core structural components appears to have played a large role in determining when and how fuel relocation occurred in the core; perhaps the most important of these reaction appears to be related to the formation of mixed-material alloys, eutectics, in the fuel cladding. Because of its high melting point, low volatility, and similar chemical behavior to plutonium, the element cerium appears to have behaved similarly to plutonium during the evolution of the TMI-2 accident. Anecdotal evidence extrapolated from open-source literature strengthens this logical feasibility for using cerium, which is rather easy to analyze using passive nondestructive analysis gamma-ray spectrometry, as a surrogate for plutonium in the final analysis of TMI-2 melted fuel debris. The generation of this report is motivated by the need to perform nuclear material accountancy measurements on the melted fuel debris that will be excavated from the damaged nuclear reactors at the Fukushima Daiichi nuclear power plant in Japan, which were destroyed by the Tohoku earthquake and tsunami on March 11, 2011. Lessons may be taken from prior U.S. work related to the study of the TMI-2 core debris to support the development of new assay methods for use at Fukushima Daiichi. While significant differences exist between the two reactor systems (pressurized water reactor (TMI-2) versus boiling water reactor (FD), fresh water post-accident cooing (TMI-2) versus salt water (FD), maintained containment (TMI-2) versus loss of containment (FD)) there remain sufficient similarities to motivate these comparisons.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

Update: structural uncertainty of used nuclear fuel in dry storage canisters

The Structural Uncertainty research task uses numerical modeling to help close knowledge gaps associated with extended dry storage of used nuclear fuel. Modeling helps to predict the expected range of mechanical loading on used nuclear fuel and dry storage system components, which is needed to help guide materials research. Knowledge of expected loads helps the materials researchers prioritize their research and focus only on the relevant material degradation phenomena that can have an effect on the ability of dry storage systems to function. The loads considered in this task are DSC tip-over, handling drops of the multipurpose fuel canister, and seismic loading of DSC systems while situated on the concrete pad of a storage facility. This document is a progress report that describes the work that was performed in fiscal year 2015. The work is a broad task that considers a number of physical phenomena and uses sophisticated LS-DYNA finite element models to predict used fuel and DSC system response to dynamic loads. Due to the broad list of topics and limited budgets, the topics of this task are prioritized at the beginning of the year and the priorities are subject to revision throughout the year as the Pacific Northwest National Laboratory team collaborates with other members of the Used Fuel Disposition Campaign. This year, three topics were investigated: options for modeling cladding in LS-DYNA, the effect of cladding thinning in the tip-over load case, and stress corrosion cracking in multipurpose canister welds. In each of these cases, significant progress was made. This report details the work that was done and identifies areas where more work is needed.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Assessment of Pre-Irradiation SiC CMC Joint Performance in Representative Cladding Geometries

Silicon carbide fiber reinforced, silicon carbide matrix composites (SiC-SiC) offer strength at high temperatures, corrosion resistance, and stability during irradiation, and are being developed by General Atomics as cladding for accident tolerant fuel (ATF) applications and advanced reactor concepts. Advanced joining techniques capable of withstanding harsh reactor environments are key to enable GA’s SiGAtm SiC-SiC composite. The objective of this work is to obtain joint-specific material properties for assemblies in representative planar and cladding geometries that will allow for the generation of a material properties database and more accurate simulation of SiC joint behavior across arange of temperatures and irradiation conditions. To support this, three different joint formulations are being assessed for mechanical and thermal performance pre and post irradiation in the High Flux Isotope Reactor (HIFR) at ORNL. GA has previously identified its hybrid SiC (HSiC) joint as the most promising and best suited joining approach for cladding applications [1]. Additionally, oxide and transeutectic phase (TEP) joints are being investigated to make the material property database more comprehensive as these joints have previously shown strength resilience under irradiation in planar geometries [2]. The thermal and mechanical data obtained in this work will address vital knowledge gaps, enabling more accurate modeling of joints in SiC-based components for accelerated material qualification.The scope of work presented here focuses on the mechanical and thermal performance of the joint material prior to irradiation in HFIR. Endplug push-out (EPPO) testing to determine joint strength in tube geometries, and shear strength testing for planar geometries have provided a benchmark for pre-irradiation mechanical performance. These results show that all three selected joint methodologies result in cladding joints capable of withstanding the expected joint stresses in a LWR reactor environment [3]. This has been accompanied by He leak testing of the joint regions on tube specimens to assess the suitability of each joint methodology for cladding applications. Here, only the HSiC formulation consistently met critical leak rate requirements suggesting that other joining strategies require additional development. Finally, pre-irradiation thermal testing has been completed to establish a baseline for comparison after irradiation. Subsequent irradiation of these joints types in HFIR will provide further detail on joint material properties and their appropriateness for nuclear applications.

Gonderman, Sean↗