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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 19 records
All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

A mortar thermomechanical contact computational framework for nuclear fuel performance simulation

Nuclear fuel performance simulations involve the modeling of complex physical phenomena, ranging from fission gas release to fuel swelling and other temperature-induced effects. For light-water reactors (LWRs), swelling of the fuel and the pressure it imposes on the clad when they come into contact causes permanent clad deformation. Accurately characterizing the fuel-cladding interaction, which involves multiple physics, is essential to accurately simulate the fuel/cladding system. Thermomechanical modeling of this problem using a variationally consistent enforcement (e.g., a mortar approach) has been shown to improve the quality of results and facilitate convergence. Here, we present a general multiphysics computational framework for solving nuclear fuel problems using a mortar approach in BISON, a nuclear fuel performance code. In this study analyses show that using the mortar approach, which enables variationally consistent constraint enforcement, improves the quality of results as compared to the more commonly used node-on-face enforcement for representative LWR nuclear fuel simulations.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗
DOE OSTI2022

Phase-field simulations to inform nuclear fuel performance modeling

Software tools to simulate nuclear fuel performance at the engineering scale, such as Idaho National Laboratory (INL)’s BISON code, are increasingly relied upon in regulatory and economic decision-making. However, accurate results from these tools depends on the availability of materials parameters that are used as input. In recent years, atomistic and mesoscale simulation methods have emerged as a cost-effective, expedient means to obtain such input parameters. Phase-field simulations using INL’s Marmot application have been used to obtain microstructure-level parameters and to improve material models for fuel performance modeling using BISON. In this talk, recent examples of this process are given, including applications in UO2, U3Si2, and UZr fuel.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2025

BISON: A Finite Element-Based Nuclear Fuel Performance Code

BISON is a finite element-based nuclear fuel performance code applicable to a variety of fuel forms including light water reactor fuel rods, TRISO particle fuel, and metallic rod and plate fuel. It is a multiphysics fuel analysis tool that solves fully-coupled thermomechanical problems. BISON is based on MOOSE and can efficiently solve problems using standard workstations or very large high-performance computers in a variety of different dimensions, including full 3D, 2D-RZ axisymmetric, layered axisymmetric 1D, and spherically symmetric 1D systems. It is developed by a team of scientists and engineers at Idaho National Laboratory and by collaborators. The development of BISON is supported by various funding agencies, principally the United States Department of Energy.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2023

Interface Problem Formulation Improvements with Application to Nuclear Fuel Performance Analysis

The U.S. Department of Energy’s Nuclear Energy Advanced Modeling and Simulation Program aims to develop predictive capabilities by applying computational methods to the analysis and design of advanced reactor and fuel cycle systems. This program has been providing engineering scale support for the development of BISON, a high-fidelity and high-resolution fuel performance tool. This report documents new developments and robustness improvements in mechanical and thermal (gap heat transfer) contact formulations. The improvements range from the migration of industrial level (“assessment”) nuclear fuel model setups to the usage of mortar formulations, the addition of frictional contact to one-dimensional layered representations of fuel and cladding components, and the addition of the Petrov-Galerkin approach to dual mortar, which improves performance on curved, relatively coarse meshes. In addition, the Lagrange-multiplier enforcement of mechanical mortar contact constraints has been extended to two additional types of enforcement: penalty and augmented Lagrange-Uzawa. We show that the latter approach yields the same interface results as dual mortar in the Multiphysics Object-Oriented Simulation Environment, with the advantage of not worsening the condition number of the system matrix—thereby enabling the use of some general implementations of iterative preconditioners, at the expense of additional system evaluations (i.e., augmentations).

42 ENGINEERING↗
DOE OSTI2025

Mechanistic nuclear fuel performance modeling of uranium nitride

Uranium mononitride (UN) is a nuclear fuel candidate for advanced reactor designs and an alternative being considered for light water reactors due to its higher thermal conductivity and uranium density than UO 2 . As with any nuclear fuel, swelling and fission gas release are important factors for safety, while also being some of the hardest phenomena to predict with a high degree of confidence. Getting a grasp on the gas swelling behavior and release is crucial to lower the barrier for UN utilization. An accelerated swelling rate at high temperatures observed experimentally, sometimes referred to as “breakaway swelling,” further complicates the prediction of fuel performance of UN. A mechanistic model has been developed using a multiscale approach to describe the intragranular and intergranular fission gas behavior. Lower-length-scale calculations have been employed to inform models of the gas and self-diffusion behavior, resolution rate, and bubble shape. Leveraging previous work on high burnup UO 2 , two populations of intragranular bubbles are considered; small bulk bubbles and larger bubbles located along dislocations. The dislocation bubbles were found to be crucial to the overall swelling behavior, and the breakaway swelling transition was associated with the transition in the gas atom diffusion mechanism from an irradiation-induced athermal diffusion regime at lower temperatures to an intrinsic thermal equilibrium regime at higher temperatures, accelerating the growth of the dislocation bubbles. Similarly, the threshold for fission gas release was associated with the grain boundary vacancy diffusivity surpassing the gas atom diffusivity at sufficiently high temperatures, allowing the over-pressurized grain boundary bubble to grow in size and interconnect. Using thermo-mechanical models with the fission gas model, two integral fuel pin assessment cases were simulated. Finally, this work demonstrates the ability of a multiscale approach to accelerate the understanding of advanced fuel forms when experimental data is limited.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2025

Enabling BWR fuel rod analysis in the BISON fuel performance code

Nuclear fuel vendors around the world are pursuing approaches to sustain the existing nuclear reactor fleet consisting primarily of pressurized-water reactors (PWRs) and boiling-water reactors (BWRs). To support the industry's efforts, advanced modeling and simulation tools need to be capable of analyzing both legacy reactor concepts. BWR fuel rods are significantly different than those used in PWRs, which can affect fuel performance analysis. BWR fuel rods include: (1) an extensive use of gadolinia dopant as a burnable absorber, (2) an axial variation in fuel enrichment and gadolinia content, (3) the inclusion of a liner on the inner cladding surface to mitigate the impact of pellet-clad mechanical interaction (which impacts hydrogen and hydride distribution), (4) a lower initial fill gas pressure, (5) bottom-entry control rods, and (6) a lower coolant pressure that results in the two-phase flow boiling phenomenon. Although the primary focus of BISON has been in the area of PWR and advanced reactor fuel analyses, this paper presents the developments in BISON to support BWR fuel performance analysis. An overview of the models that account for the effects of gadolinia is highlighted. Internal mesh generation capabilities to include a liner is presented. Normal operating and transient (reactivity insertion accident) demonstration problems are presented to illustrate the impact of gadolinia, the hydrogen and hydride evolution due to the presence of the liner, and BISON's ability to simulate axially varying enrichments and dopant concentration. Bottom-entry control effects are captured by the axial power peaking factors present in the demonstration cases. Comparisons to integral experiments from the Halden IFA-681 experiments are discussed as initial validation. Reasonable comparisons are obtained for fuel centerline temperature and rod internal pressure as a function of time. In conclusion, simulations of additional experiments containing Gd 2 O 3 -bearing fuel are necessary to completely validate the code for BWR applications.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2023

An approach to grid-to-rod fretting wear modeling using dynamic mortar contact

This article presents the development of a grid-to-rod fretting (GTRF) modeling methodology that utilizes dynamic mortar contact. Here, we leverage a recently developed computational framework for modeling thermomechanical contact in dynamic simulations from the nuclear fuel performance code Bison. Usage of mortar contact ensures a smooth distribution of normal and frictional contact forces, displacements, and velocities on the contact interface, thus facilitating an accurate computation of wear. The integration within an advanced nuclear fuel performance code enables analysis of complex interactions between the fuel, cladding, and spacer grid. Such interactions include swelling, creep, fuel fragmentation, burnup, plenum pressure, and fission gas release. Our methodology is demonstrated via the modeling of two spacer grid geometries and the influence of fuel-cladding mechanical contact on the generation of fretting wear.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2022

Comparison of Fission Product Release Predictions using PARFUME and BISON with Results from the AGR-3/4 Irradiation Experiment

The PARFUME (PARticle Fuel ModEl) fuel performance modeling code and the BISON nuclear fuel performance application built on the Multiphysics Object-Oriented Simulation Environment (MOOSE) finite element library were used to predict the fission product release from tristructural isotropic (TRISO) coated fuel particles and compacts during the third and fourth irradiation experiment of the Advanced Gas Reactor (AGR-3/4) Fuel Development and Qualification Program. The fuel performance modeling codes PARFUME and BISON modeled the AGR-3/4 irradiation experiment using the fuel compact time-averaged volume averaged (TAVA) daily temperatures for a total irradiation duration of 369.1 effective full power days (EFPD) to predict the release fraction of the fission product silver (Ag-110m) from a representative TRISO-coated fuel particle from AGR-3/4 compacts. Post-irradiation examination (PIE) measurements provided data on the release of these fission products in the compacts outside of the silicon carbide (SIC) layer. The PARFUME and BISON results were then compared to the silver release measured from compact gamma scanning. The results showed good agreement between PARFUME and BISON but both codes under-predicted the silver release fraction for all the compacts. In addition, BISON was used to model and predict the fission product concentration radial profile outside of the compacts in capsules’ inner and outer rings. These rings were either comprised of matrix and/or structural graphite. To obtain the concentration profiles of silver, cesium, and strontium, a sorption isotherm model was developed in BISON to capture the effects of fission product transport across the gaps between the concentric rings. The general shape of the concentration radial profiles as calculated by BISON were similar in the inner ring (IR) but varied in the outer ring (OR) depending on the fission product of interest or capsule temperature. Using this methodology and model, BISON now has the capability to aid in developing new fission product diffusion coefficients for matrix or structural graphite materials.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2022

A layered 2D computational framework: Theory and applications to nuclear fuel behavior

Nuclear fuel performance computer codes have been developed over the last 50 years to analyze fuel behavior under various operating conditions. Traditionally, these codes used quasi-two-dimensional (also commonly known as 1.5D) representations of the fuel rod, which model the rod using a set of one-dimensional axisymmetric models that represent the behavior at specific axial positions on the rod. Modern fuel performance codes have the ability to investigate full three-dimensional (3D) effects and couple to other physics-based codes for true multiphysics simulations. However, with increasing complexity comes increasing computational costs. Many phenomena of interest involve azimuthally-varying behavior that cannot be represented using the aforementioned quasi-two-dimensional approach, but do not require the use of a full 3D model. To efficiently address these problems, there is a need for a computational framework that provides a compromise between the quasi-two-dimensional and full 3D models. In this paper, we present a new quasi-three-dimensional approach that represents the fuel as a set of 2D planar models that represent the behavior of the fuel cross-section at various axial positions. Presented here are the theory behind the methodology, test cases to illustrate proper implementation, and practical applications of its use in the BISON fuel performance code for a variety of cases in nuclear fuel analysis, such as fuel fracture, axial fuel relocation, and cladding distension and oxidation.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2023

MST e-News Summer 2023

David Andersson (Materials Science in Radiation and Dynamic Extremes, MST-8) is the recipient of the 2023 American Nuclear Society (ANS) Mishima Award. The award recognizes outstanding contributions of an individual in research and development work on nuclear fuels and materials. Andersson is a staff scientist on MST-8’s Modeling of Radiation Effects team. An expert in atomistic modeling of nuclear fuels—both traditional UO 2 light water reactor fuel and advanced accident tolerant fuel concepts—he has been involved in numerous international and national multiscale simulation efforts to develop models for use in nuclear fuel performance simulations.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2022

FAST-1.1: Integral Assessment

An integral assessment has been performed to quantify the predictive capabilities of FAST, a thermal-mechanical nuclear fuel performance code designed to analyze fuel behavior from beginning of life to burnup levels allowed by the U.S. Nuclear Regulatory Commission (NRC). FAST code calculations are shown to compare satisfactorily to a preselected set of experimental data with both steady-state and anticipated operating occurrence (AOO) conditions and design basis accident (DBA) transient operating conditions. This document describes the assessment of FAST-1.1, the latest version of FAST, released April 2022. Abstract

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2023

FAST-1.2: Integral Assessment

An integral assessment has been performed to quantify the predictive capabilities of FAST, a thermal-mechanical nuclear fuel performance code designed to analyze fuel behavior from beginning of life to burnup levels allowed by the U.S. Nuclear Regulatory Commission (NRC). FAST code calculations are shown to compare satisfactorily to a preselected set of experimental data with both steady-state and anticipated operating occurrence (AOO) conditions and design basis accident (DBA) transient operating conditions. This document describes the assessment of FAST-1.2, the latest version of FAST, released March 2023.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2024

Multidimensional modeling of fuel-cladding friction in an LWR fuel rod

Solving finite element problems with friction often increases the level of difficulty to obtain properly converged solutions. This type of challenge becomes more salient when advanced, possibly multiscale, material models are employed to capture the thermomechanical behavior of fuel and cladding materials. Here the present work details our recent developments in a nuclear fuel performance finite element code for the systematic consideration of friction in nuclear reactor finite element simulations. We show the application of friction and its effects on the mechanics of light-water reactor rods accounting for various fuel constitutive modeling techniques, model dimensionalities, pellet assumed geometries, and power conditions. In particular, we focus on the fuel rod mechanical behavior as it relates to fuel constitutive models, sensitivity to the coefficient of friction, pellet states of stress, and rod elongation. We discuss the trade-offs between the various multidimensional modeling options and highlight the relevance of frictional effects in the prediction of the fuel rod deformation and interfacial stresses. To relate our modeling results with actual reactor operation, simulations including frictional effects are compared with fuel rod elongation experimental data and some challenges for carrying out a full validation of the axial mechanics are discussed.

42 ENGINEERING↗
DOE OSTI2022

Advanced Autonomous Welding for Refabrication and Follow-On Testing of Previously Irradiated Nuclear Fuel

The performance of follow-on experiments using irradiated nuclear fuel at any point in its lifecycle is a critical step in understanding phenomena and behavior. Transient experiments with high-burnup fuel can deepen the understanding of fuel fragmentation, relocations, and dispersal under loss-of-coolant accidents. An advanced autonomous welding process to refabricate commercial fuel rods inside a hot cell was created and tested to enable flexible experiment approaches on fuels irradiated in commercial and test reactors. Irradiated light water reactor fuel test pins from experiments performed at the Advanced Test Reactor (ATR) at Idaho National Laboratory were used to demonstrate the refabrication process. The welding process was found to be sensitive to welding parameters but flexible such that multiple passes could be performed on the same location until a hermetic weld was obtained. The refabrication of rodlets and successful welds was also found to be sensitive to the preparation of the irradiated cladding and endcaps. Thorough defueling of the fuel at the weld location and proper sizing of the endcaps and backing material mitigated these issues. The use of strategically located heat sinks in contact with the cladding and endcap materials also increased welding and refabrication success. For this work, the test pins were sectioned to remove the original endcaps and fuel was removed from both ends of each rodlet. The reassembly of the rodlets was then completed in four steps, which included the press fitting of new endcaps, the circumferential welding of rodlet endcaps to the cladding, rodlet pressurization in a pressure chamber, and seal welding the rodlet under pressure. The integrity of the refabricated rodlets was then verified via helium leak checking inside a vacuum chamber. The advanced welding system is capable of refabricating rodlets up to 380 mm in length, and repressurizing them up to 15 500 kPa. The refabricated lengths of the rodlets used in this work ranged from 149 to 165 mm and the refabricated fuel stack heights ranged from 70.4 to 79.8 mm. Here, the rodlets were pressurized with argon to an average pressure of 3617 kPa, and the average leak rate after refabrication was 6.7 • 10 -8 cm 3 • s -1 .

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2023

Equibiaxial flexural strength determination of UO 2 using a ball-on-ring test

To increase nuclear fuel performance and reliability, their mechanical properties require an accurate and statistically relevant assessment. Biaxial flexural strength tests provide an alternative to bend bar techniques for assessing mechanical behavior; namely, the transverse rupture strength (TRS) of ceramic samples. Biaxial test samples require simple geometries and minimal surface preparation, reducing fabrication costs and handling hazards. This study investigated the TRS of polycrystalline UO 2 fuel forms at room temperature using a ball-on-ring test fixture. Here, pellets were fabricated from UO 2 powder using conventional powder processing and sintering techniques. The TRS and Weibull parameters were obtained through Weibull statistics on over 60 UO 2 samples tested under equibiaxial flexure. The larger sample size in this study enabled a more robust Weibull statistical analysis than alternative test methods, which may not capture the stochastic failure of typical ceramics. Furthermore, two different loading ball diameters were employed to assess the impact of contact damage on fracture strength. While Hertzian contact damage was observed with the smaller loading ball, the fracture strength remained unaffected. A fracture analysis of the tested UO 2 samples indicated a mixture of intergranular and transgranular fracture that transitions to transgranular fracture with increasing distance from the fracture origin. The characteristic strength of the combined data sets was determined to be 148 MPa, and the Weibull modulus was determined to be 9.1. The TRS values and Weibull parameters were close to values found in the literature for alternative testing techniques using samples with similar microstructure and density. The findings in this study validate the ball-on-ring method used to obtain the TRS of UO 2 with a sample geometry more representative of nuclear fuels. Additionally, experimental TRS results from this study can be implemented in modeling codes to predict fuel performance, which is critical to fuel burnup extension and advanced nuclear fuel technologies.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2025

Implications of point defect accumulation on UO 2 thermal conductivity and fission gas release under accelerated fuel irradiation

Evaluation of thermal properties is a crucial factor for nuclear fuel performance. During reactor operation, the accumulation of fission products and irradiation-induced lattice defects are responsible for degradation in thermal conductivity. Consequently, it affects fuel temperature and fission gas release (FGR) among other Multiphysics processes important for economics and safety analysis. We analyze the implications of point defects (PD) accumulation described using a rate theory (RT) Model on lattice thermal conductivity of UO 2 . Here, we demonstrate that fission rate-dependent point defect concentrations have the largest impact on in-pile thermal conductivity in the periphery of light water reactor fuels below a temperature threshold governed by the migration barrier of defects. Our analysis provides a mechanistic description of this phenomena which current fuel performance codes treat empirically. The reduction of thermal conductivity in the low -temperature rim region acts as additional thermal resistance and leads to a temperature notably larger than suggested by Lucuta thermal conductivity correlation. These effects are anticipated to have notable impacts when fuels are exposed to accelerated radiation. The impact of such point defect-informed treatment of thermal conductivity on fuel performance is evaluated by a detailed analysis of fission gas behavior and its release. We consider several models capturing different stages of fission gas bubble evolution and fission gas release (FGR). Finally, a new fission rate-dependent correction to the Lucuta correlation is proposed. The results show a significant reduction in thermal conductivity at the fuels’ periphery and an increase in fuel centerline temperature specifically at low burnups. Ultimately a modified LC shows a higher FGR compared to the original LC, while the acceleration process results in a reduction in overall FGR.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗