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DOE OSTI2014

The Development of Reversible Bending Fatigue Tester and Its Application to High Burnup Spent Nuclear Fuel Vibration Integrity Investigation under Normal Transportation

For high burn-up spent nuclear fuel (SNF), it is expected that the spent fuel cladding will have a high population of microcracks and hydrides, including macro-hydrides and micro-hydrides. This will reduce the stress intensity required to advance the crack growth. The linking of these microcracks during vibration loading also reduces the fatigue threshold/incubation period significantly, accelerating fatigue failure. In addition to the damages in cladding, the microstructure of comprising fuel pellets and interfaces of fuel rod have changed dramatically after the high burn-up process. These modifications have a direct impact on the structural integrity and vibration response of SNF rods in transportation.

Fuel Transport↗

DOE OSTI2014

Surrogate Spent Nuclear Fuel Vibration Integrity Investigation

bending fatigue↗

DOE OSTI2013

Progress Letter Report on Bending Fatigue Test System Development for Spent Nuclear Fuel Vibration Integrity Study (Out-of-cell fatigue testing development - Task 2.4)

Vibration integrity of high burn-up spent nuclear fuel in transportation remains to be a critical component of US nuclear waste management system. The structural evaluation of package for spent fuel transportation eventually will need to see if the content or spent fuel is in a subcritical condition. However, a system for testing and characterizing such spent fuel is still lacking mainly due to the complication involved with dealing radioactive specimens in a hot cell environment. Apparently, the current state-of-the-art in spent fuel research and development is quite far away from the delivery of reliable mechanical property data for the assessment of spent fuels in the transport package evaluation.

Spent Nuclear Fuel Vibration Integrity↗

DOE OSTI2014

POTENTIAL IMPACT OF INTERFACIAL BONDING EFFICIENCY ON USED NUCLEAR FUEL VIBRATION INTEGRITY DURING NORMAL TRANSPORTATION

Finite element analysis (FEA) was used to investigate the impacts of interfacial bonding efficiency at pellet pellet and pellet clad interfaces on surrogate of used nuclear fuel (UNF) vibration integrity. The FEA simulation results were also validated and benchmarked with reversible bending fatigue test results on surrogate rods consisting of stainless steel (SS) tubes with alumina-pellet inserts. Bending moments (M) are applied to the FEA models to evaluate the system responses of the surrogate rods. From the induced curvature, , the flexural rigidity EI can be estimated as EI=M/ . The impacts of interfacial bonding efficiency include the moment carrying capacity distribution between pellets and clad and cohesion influence on the flexural rigidity of the surrogate rod system. The result also indicates that the immediate consequences of interfacial de-bonding are a load carrying capacity shift from the fuel pellets to the clad and a reduction of the composite rod flexural rigidity. Therefore, the flexural rigidity of the surrogate rod and the bending moment bearing capacity between the clad and fuel pellets are strongly dependent on the efficiency of interfacial bonding at the pellet pellet and pellet clad interfaces. FEA models will be further used to study UNF vibration integrity.

finite element method↗

DOE OSTI2014

Potential Impact of Interfacial Bonding Efficiency on High-Burnup Spent Nuclear Fuel Vibration Integrity during Normal Transportation

Finite element analysis (FEA) was used to investigate the impacts of interfacial bonding efficiency at pellet pellet and pellet clad interfaces on spent nuclear fuel (SNF) vibration integrity. The FEA simulation results were also validated and benchmarked with reverse bending fatigue test results on surrogate rods consisting of stainless steel (SS) tubes with alumina-pellet inserts. Bending moments (M) are applied to the FEA models to evaluate the system responses of the surrogate rods. From the induced curvature, , the flexural rigidity EI can be estimated as EI=M/ . The impacts of interfacial bonding efficiency on SNF vibration integrity include the moment carrying capacity distribution between pellets and clad and the impact of cohesion on the flexural rigidity of the surrogate rod system. The result also indicates that the immediate consequences of interfacial de-bonding are a load carrying capacity shift from the fuel pellets to the clad and a reduction of the composite rod flexural rigidity. Therefore, the flexural rigidity of the surrogate rod and the bending moment bearing capacity between the clad and fuel pellets are strongly dependent on the efficiency of interfacial bonding at the pellet pellet and pellet clad interfaces. The above-noted phenomenon was calibrated and validated by reverse bending fatigue testing using a surrogate rod system.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2013

The Impact of Interface Bonding Efficiency on High Burn-up Spent Fuel Vibration Integrity during Normal Transportation

Finite element analysis (FEA) was used to investigate the impacts of interfacial bonding efficiency at pellet-pellet and pellet-clad interfaces on spent nuclear fuel (SNF) vibration integrity. The FEA simulation results were validated and benchmarked with ORNL reversal bending fatigue test results on surrogate rods consisting of stainless steel (SS) tubes with alumina-pellet inserts.

interface bonding↗

DOE OSTI2016

Spent Nuclear Fuel Vibration Integrity Study

The objective of this research is to collect dynamic experimental data on spent nuclear fuel (SNF) under simulated transportation environments using the Cyclic Integrated Reversible-Bending Fatigue Tester (CIRFT), the hot-cell testing technology developed at Oak Ridge National Laboratory (ORNL). The collected CIRFT data will be utilized to support ongoing spent fuel modeling activities, and support SNF transportation related licensing issues. Recent testing to understand the effects of hydride reorientation on SNF vibration integrity is also being evaluated. CIRFT results have provided insight into the fuel/clad system response to transportation related loads. The major findings of CIRFT on the HBU SNF are as follows: SNF system interface bonding plays an important role in SNF vibration performance, Fuel structure contributes to the SNF system stiffness, There are significant variations in stress and curvature of SNF systems during vibration cycles resulting from segment pellets and clad interaction, and SNF failure initiates at the pellet-pellet interface region and appears to be spontaneous. Because of the non-homogeneous composite structure of the SNF system, finite element analyses (FEA) are needed to translate the global moment-curvature measurement into local stress-strain profiles. The detailed mechanisms of the pellet-pellet and pellet-clad interactions and the stress concentration effects at the pellet-pellet interface cannot be readily obtained directly from a CIRFT system measurement. Therefore, detailed FEA is used to understand the global test response, and that data will also be presented.

bending fatigue↗

DOE OSTI2015

High burn-up spent nuclear fuel vibration integrity study - 15134

The Oak Ridge National Laboratory (ORNL) has developed the cyclic integrated reversible-bending fatigue tester (CIRFT) approach to successfully demonstrate the controllable fatigue fracture of high burnup (HBU) spent nuclear fuel (SNF) in a normal vibration mode. CIRFT enables examination of the underlying mechanisms of SNF system dynamic performance. Due to the inhomogeneous composite structure of the SNF system, the detailed mechanisms of pellet-pellet and pellet-clad interactions and the stress concentration effects at the pellet-pellet interface cannot be readily obtained from a CIRFT system measurement. Therefore, finite element analyses (FEAs) are being used to complement the experimental work by estimating values of local stresses and strains from the measured global moment-curvature. These results and their implications will be used for further investigation. Major findings of CIRFT on the HBU SNF are as follows: - The degree of bonding between pellets, as well as the bonding between pellets and clad in the SNF system plays an important role in the vibration performance of SNF. - Fuel structure contributes to SNF system stiffness. - There are significant variations in stress and curvature of SNF systems during vibration cycles resulting from segment pellet and clad interactions. - SNF failure initiates at the pellet-pellet interface region and appears to be spontaneous. (authors)

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2016

Spent Nuclear Fuel Vibration Integrity Study - 16332

The objective of this research is to collect dynamic experimental data on spent nuclear fuel (SNF) under simulated transportation environments using the Cyclic Integrated Reversible-Bending Fatigue Tester (CIRFT), the hot-cell testing technology developed at Oak Ridge National Laboratory (ORNL). The collected CIRFT data will be utilized to support ongoing spent fuel modeling activities, and support SNF transportation related licensing issues. Recent testing to understand the effects of hydride reorientation on SNF vibration integrity is also being evaluated. CIRFT results have provided insight into the fuel/clad system response to transportation related loads. The major findings of CIRFT on the HBU SNF are as follows: - SNF system interface bonding plays an important role in SNF vibration performance, - Fuel structure contributes to the SNF system stiffness, - There are significant variations in stress and curvature of SNF systems during vibration cycles resulting from segment pellets and clad interaction, and - SNF failure initiates at the pellet-pellet interface region and appears to be spontaneous. Because of the non-homogeneous composite structure of the SNF system, finite element analyses (FEA) are needed to translate the global moment-curvature measurement into local stress-strain profiles. The detailed mechanisms of the pellet-pellet and pellet-clad interactions and the stress concentration effects at the pellet-pellet interface cannot be readily obtained directly from a CIRFT system measurement. Therefore, detailed FEA is used to understand the global test response, and that data will also be presented. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2015

High Burn-Up Spent Nuclear Fuel Vibration Integrity Study

The Oak Ridge National Laboratory (ORNL) has developed the cyclic integrated reversible-bending fatigue tester (CIRFT) approach to successfully demonstrate the controllable fatigue fracture on high burnup (HBU) spent nuclear fuel (SNF) in a normal vibration mode. CIRFT enables examination of the underlying mechanisms of SNF system dynamic performance. Due to the inhomogeneous composite structure of the SNF system, the detailed mechanisms of the pellet-pellet and pellet-clad interactions and the stress concentration effects at the pellet-pellet interface cannot be readily obtained from a CIRFT system measurement. Therefore, finite element analyses (FEAs) are used to translate the global moment-curvature measurement into local stress-strain profiles for further investigation. The major findings of CIRFT on the HBU SNF are as follows: SNF system interface bonding plays an important role in SNF vibration performance. Fuel structure contributes to SNF system stiffness. There are significant variations in stress and curvature of SNF systems during vibration cycles resulting from segment pellets and clad interactions. SNF failure initiates at the pellet-pellet interface region and appears to be spontaneous.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2013

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

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

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2021

Drop impact tester development for spent nuclear fuel vibration integrity study

The accumulated damage of SNF rod is defined as the integrated damage induced by the SNF assembly harmonic vibrations and SNF assembly & cask system contact interactions induced transient shocks, experienced by SNF rods during normal conditions of transportation (NCT). The CIRFT technology has provided means to resolve/understand the SNF rod harmonic vibration reliability issues associated with maximum axial clad tubing stress induced by SNF inertia related dynamic bending loading. However, the SNF rod integrity in association with the transient shock loads during NCT through dynamic contact interactions among SNF assembly cannot be investigated systematically through CIRFT technology alone. Thus, the proposed drop impact tester development become a viable tool for SNF system transient shock effect investigation. Furthermore, the transient shocks induced loading mode is normally perpendicular to the SNF rod axial orientation, i.e., in a transverse orientation to the SNF rod. To proceed with such loading mode investigation, a new device, “SNF Drop Impact Tester” that provides the transverse impact shock load onto a SNF rod through a free-drop projectile was developed in FY20 for SNF System Vibration Reliability Investigation; where the SNF system contact impact intensity can be calibrated accordingly with projectile weight and projectile head geometry. This newly developed research tool can further provide a detailed understanding about the effect of dynamic contact-interaction loadings; and combined harmonic vibration and transient shock loading modes on the fatigue damage evolution of the HBU SNF under NCT.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2014

REVERSIBLE BENDING F ATIGUE TESTING SYSTEM DESIGN CONCEPTS FO R SPENT FUEL VIBRATION INTEGRITY STUDY

Explore the source record for details and available documents.

Jiang, Hao↗

DOE OSTI2015

An Innovative Testing Protocol to Study Spent Nuclear Fuel Vibration Integrity under Normal Condition of Transportation

Explore the source record for details and available documents.

Wang, Jy-An John↗

DOE OSTI2013

Development of U-Frame Bending System for Studying the Vibration Integrity of Spent Nuclear Fuel

A bending fatigue system developed to evaluate the response of spent nuclear fuel rods to vibration loads is presented. Design and analysis, fabrication, modification, calibration, and instrumentation are described. The system is composed of a U-frame testing setup for imposing bending loads on the spent fuel rod test specimen and a method for measuring the curvature of the rod during bending. The U-frame setup consists of two rigid arms, linking members, and linkages to a universal testing machine. The test specimen s curvature of bending is obtained through a three-point deflection measurement method consisting of three LVDTs mounted to the side connecting plates of the U-frame to capture the deformation of the test specimen. The system has some unique features: 1) The test specimen is installed by simple insertion using linear bearings incorporated with rigid sleeves. 2) Reverse cyclic bending tests can be carried out effectively and efficiently by push and pull at the loading point of the setup. Any test machine with a linear motion function can be used to drive the setup. 3) The embedded and preloaded linear roller bearings eliminate the backlash that exists in the conventional reverse bend tests. 4) The number of linkages between the U-frame and the universal machine is minimized. Namely, there are only two linkages needed at the two loading points of a U-frame setup, whereas a conventional four/three-point bend test frame requires four linkages. 5) The curvature measurement is immune to the effects arising from compliant layers and the rigid body motion of the machine. The compliant layers are used at the holding areas of the specimen to prevent contact damage. The tests using surrogate specimens composed of SS cladding/tube revealed several important phenomena that may cast light on the expected response of a spent fuel rod: 1) Cyclic quasi-static load (10 N/s under force control) in compressive mode (with respect to that at the loading point of the U-frame) produced increased irreversible or plastic curvature and also increased flexural rigidity of the surrogate rod. 2) Dynamic cyclic load (at least 1 Hz) in compressive mode resulted in increased flexural rigidity of the surrogate rod prior to SS cladding fracture. 3) Pellets and epoxy bonding exhibited various effects on the response of surrogate rods during the loading process as validated from static tests. 4) Dynamic cyclic load (2 Hz) in reverse mode demonstrated a substantial cyclic softening before the fracture of the surrogate rod. The degree of decrease in flexural rigidity was consistent in both measurement and on-line monitoring. The developed U-frame system is thus verified and demonstrated to be ready for further pursuit in hot-cell tests.

fuel transporation↗

DOE OSTI2013

Reversible Bending Fatigue Test System for Investigating Vibration Integrity of Spent Nuclear Fuel during Transportation

Transportation packages for spent nuclear fuel (SNF) must meet safety requirements under normal and accident conditions as specified by federal regulations. During transportation, SNF experiences unique conditions and challenges to cladding integrity due to the vibrational and impact loading during road or rail shipment. Oak Ridge National Laboratory (ORNL) has been developing testing capabilities that can be used to improve the understanding of the impacts on SNF integrity due to vibration loading, especially for high burn-up SNF in normal transportation operation conditions. This information can be used to meet the nuclear industry and U.S. Nuclear Regulatory Commission needs in the area of safety and security of spent nuclear fuel storage and transport operations. The ORNL developed test system can perform reversible-bending fatigue testing to evaluate both the static and dynamic mechanical response of SNF rods under simulated loads. The testing apparatus is also designed to meet the challenges of hot-cell operation, including remote installation and detachment of the SNF test specimen, in-situ test specimen deformation measurement, and implementation of a driving system suitable for use in a hot cell. The system contains a U-frame set-up equipped with uniquely designed grip rigs, to protect SNF rod and to ensure valid test results, and use of 3 specially designed LVDTs to obtain the in-situ curvature measurement. A variety of surrogate test rods have been used to develop and calibrate the test system as well as in performing a series of systematic cyclic fatigue tests. The surrogate rods include stainless steel (SS) cladding, SS cladding with cast epoxy, and SS cladding with alumina pellets inserts simulating fuel pellets. Testing to date has shown that the interface bonding between the SS cladding and the alumina pellets has a significant impact on the bending response of the test rods as well as their fatigue strength. The failure behaviors observed from tested surrogate rods provides a fundamental understanding of the underlying failure mechanisms of the SNF surrogate rod under vibration which has not been achieved previously. The newly developed device is scheduled to be installed in the hot-cell in summer 2013 to test high burnup SNF.

high burn-up spent fuel↗

DOE OSTI2016

Spent Nuclear Fuel Transport Reliability Study

This conference paper was orignated and shorten from the following publisehd PTS documents: 1. Jy-An Wang, Hao Jiang, and Hong Wang, Dynamic Deformation Simulation of Spent Nuclear Fuel Assembly and CIRFT Deformation Sensor Stability Investigation, ORNL/SPR-2015/662, November 2015. 2. Jy-An Wang, Hong Wang, Mechanical Fatigue Testing of High-Burnup Fuel for Transportation Applications, NUREG/CR-7198, ORNL/TM-2014/214, May 2015. 3. Jy-An Wang, Hong Wang, Hao Jiang, Yong Yan, Bruce Bevard, Spent Nuclear Fuel Vibration Integrity Study 16332, WM2016 Conference, March 6 10, 2016, Phoenix, Arizona.

bending fatigue tester↗

DOE OSTI2013

TEST SYSTEM FOR EVALUATING SPENT NUCLEAR FUEL BENDING STIFFNESS AND VIBRATION INTEGRITY

Transportation packages for spent nuclear fuel (SNF) must meet safety requirements specified by federal regulations. For normal conditions of transport, vibration loads incident to transport must be considered. This is particularly relevant for high-burnup fuel (>45 GWd/MTU). As the burnup of the fuel increases, a number of changes occur that may affect the performance of the fuel and cladding in storage and during transportation. The mechanical properties of high-burnup de-fueled cladding have been previously studied by subjecting defueled cladding tubes to longitudinal (axial) tensile tests, ring-stretch tests, ring-compression tests, and biaxial tube burst tests. The objective of this study is to investigate the mechanical properties and behavior of both the cladding and the fuel in it under vibration/cyclic loads similar to the sustained vibration loads experienced during normal transport. The vibration loads to SNF rods during transportation can be characterized by dynamic, cyclic, bending loads. The transient vibration signals in a specified transport environment can be analyzed, and frequency, amplitude and phase components can be identified. The methodology being implemented is a novel approach to study the vibration integrity of actual SNF rod segments through testing and evaluating the fatigue performance of SNF rods at defined frequencies. Oak Ridge National Laboratory (ORNL) has developed a bending fatigue system to evaluate the response of the SNF rods to vibration loads. A three-point deflection measurement technique using linear variable differential transformers is used to characterize the bending rod curvature, and electromagnetic force linear motors are used as the driving system for mechanical loading. ORNL plans to use the test system in a hot cell for SNF vibration testing on high burnup, irradiated fuel to evaluate the pellet-clad interaction and bonding on the effective lifetime of fuel-clad structure bending fatigue performance. Technical challenges include pure bending implementation, remote installation and detachment of the SNF test specimen, test specimen deformation measurement, and identification of a driving system suitable for use in a hot cell. Surrogate test specimens have been used to calibrate the test setup and conduct systematic cyclic tests. The calibration and systematic cyclic tests have been used to identify test protocol issues prior to implementation in the hot cell. In addition, cyclic hardening in unidirectional bending and softening in reverse bending were observed in the surrogate test specimens. The interface bonding between the surrogate clad and pellets was found to impact the bending response of the surrogate rods; confirming this behavior in the actual spent fuel segments will be an important aspect of the hot cell test implementation,

reversal bending fatigue tester↗