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At least 19 records

Pellet cladding mechanical interaction as a potential failure mechanism during a control rod drop accident in a boiling water reactor

Boiling water reactors (BWRs) represent approximately one-third of the operating fleet in the United States, contributing significantly towards the global effort in reducing carbon emissions. Even though most of the operating fleet has been in operation for quite some time, continued advancements in new nuclear fuel (such as accident tolerant fuel) or operating regimes (such as power up-rates and higher burnup operation) necessitates similar advancements in modeling and simulation capabilities. Bison, a component of the Virtual Environment for Reactor Applications (VERA), is a high-fidelity fuel performance code able to explore the fuel performance of a wide variety of fuel types in one-, two-, and three-dimensions. Until recently, the code had not been used for analyses of BWRs. Modeling capabilities have been added for Gd-bearing UO{sub 2} and pure zirconium liners. New models have been added based upon the U.S. Nuclear Regulatory Commission (NRC) guide-lines for hydrogen pickup in Zircaloy-2 claddings and pellet-clad mechanical interaction (PCMI) failure during a reactivity insertion accident (RIA), known as a rod drop accident (CRDA) in BWRs. Implementing and/or improving Bison modeling capabilities extended its analytical reach to areas beyond its original intended purpose. This paper demonstrates one of these capabilities as a proof of concept. Recently developed models enable Bison to provide an alternate approach for cladding integrity determination in CRDA evaluations, which currently use bounding conservative estimates. As part of this demonstration, NRC guidance on hydrogen-pickup and PCMI failure models were utilized in this research. Even though more research is needed in establishing right inputs and process in this area, this paper demonstrates Bison's ability to determine cladding integrity in a CRDA evaluation. This first of a kind demonstration is a proof of concept in this area, which could potentially be extended to a number of other areas where a more accurate cladding integrity determination would be needed. (authors)

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

Pellet-clad mechanical interaction screening using VERA applied to Watts Bar Unit 1, Cycles 1–3

The Consortium for Advanced Simulation of Light Water Reactors (CASL) aims to provide high-fidelity multiphysics simulations of light water nuclear reactors. To accomplish this, CASL is developing the Virtual Environment for Reactor Applications (VERA), which is a suite of code packages for thermal hydraulics, neutron transport, fuel performance, and coolant chemistry. As VERA continues to grow and expand, there has been an increased focus on incorporating fuel performance analysis methods. One of the primary goals of CASL is to estimate local cladding failure probability through pellet-clad interaction, which consists of both pellet-clad mechanical interaction (PCMI) and stress corrosion cracking. Estimating clad failure is important to preventing release of fission products to the primary system and accurate estimates could prove useful in establishing less conservative power ramp rates or when considering load-follow operations.While this capability is being pursued through several different approaches, the procedure presented in this article focuses on running independent fuel performance calculations with BISON using a file-based one-way coupling based on multicycle output data from high fidelity, pin-resolved coupled neutron transport–thermal hydraulics simulations. This type of approach is consistent with traditional fuel performance analysis methods, which are typically separate from core simulation analyses. A more tightly coupled approach is currently being developed, which is the ultimate target application in CASL.Recent work simulating 12 cycles of Watts Bar Unit 1 with VERA core simulator are capitalized upon, and quarter-core BISON results for parameters of interest to PCMI (maximum centerline fuel temperature, maximum clad hoop stress, and minimum gap size) are presented for Cycles 1–3. In conclusion, based on these results, this capability demonstrates its value and how it could be used as a screening tool for gathering insight into PCMI, singling out limiting rods for further, more detailed analysis.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

Failure behavior of SiC/SiC composite tubes under strain rates similar to the pellet-cladding mechanical interaction phase of reactivity-initiated accidents

The mechanical response of a nuclear-grade silicon carbide fiber-reinforced silicon carbide matrix (SiC/SiC) composite was investigated under mechanical loading conditions mimicking the pellet-cladding mechanical interaction (PCMI) phase of a reactivity-initiated accident (RIA). In a RIA, cladding deformation and failure can be induced by the rapid thermal expansion of the nuclear fuel. A pulse-controlled modified-burst test was used to investigate RIA-like PCMI scenarios on SiC/SiC composite samples at pulse widths from 12 to 100 ms.The strain-driven nature of the cladding sample deformation was due to the rapid internal pressurization and subsequent expansion of a secondary tube. A digital-image correlation technique was used to measure strains from the speckle-painted outer surface of the tubes. The failure strains of samples tested at slower rates, such as RIA event durations of 52 and 100 ms, showed good agreement with the literature-reported values for similar composites tested at slow strain rates. Additionally, the failure strain showed good agreement with reference expansion-due-to-compression tests at slow strain rate. However, a decrease in the failure strain was determined for the fast-rate (12 ms) tests. This indicated that the failure strain of these composites might be influenced by the strain rate during RIA-like events. In conclusion, the failure strains observed in the tests corresponded to local energy depositions of approximately 50 cal/g UO 2 from hot zero power, with an initial condition of pellet–cladding gap closure prior to the event. In-pile transient testing of these concepts that would result in hoop strain due to PCMI in the range of 0.5–1.0% is recommended.

36 MATERIALS SCIENCE↗

Pellet Cladding Mechanical Interaction Modeling Using the Extended Finite Element Method

As a brittle material, the ceramic UO2 used as light water reactor fuel experiences significant fracturing throughout its life, beginning with the first rise to power of fresh fuel. This has multiple effects on the thermal and mechanical response of the fuel/cladding system. One such effect that is particularly important is that when there is mechanical contact between the fuel and cladding, cracks that extending from the outer surface of the fuel into the volume of the fuel cause elevated stresses in the adjacent cladding, which can potentially lead to cladding failure. Modeling the thermal and mechanical response of the cladding in the vicinity of these surface-breaking cracks in the fuel can provide important insights into this behavior to help avoid operating conditions that could lead to cladding failure. Such modeling has traditionally been done in the context of finite-element-based fuel performance analysis by modifying the fuel mesh to introduce discrete cracks. While this approach is effective in capturing the important behavior at the fuel/cladding interface, there are multiple drawbacks to explicitly incorporating the cracks in the finite element mesh. Because the cracks are incorporated in the original mesh, the mesh must be modified for cracks of specified location and depth, so it is difficult to account for crack propagation and the formation of new cracks at other locations. The extended finite element method (XFEM) has emerged in recent years as a powerful method to represent arbitrary, evolving, discrete discontinuities within the context of the finite element method. Development work is underway by the authors to implement XFEM in the BISON fuel performance code, and this capability has previously been demonstrated in simulations of fracture propagation in ceramic nuclear fuel. These preliminary demonstrations have included only the fuel, and excluded the cladding for simplicity. This paper presents initial results of efforts to apply XFEM to model stress concentrations induced by fuel fractures at the fuel/cladding interface during pellet cladding mechanical interaction (PCMI). This is accomplished by enhancing the thermal and mechanical contact enforcement algorithms employed by BISON to permit their use in conjunction with XFEM. The results from this methodology are demonstrated to be equivalent to those from using meshed discrete cracks. While the results of the two methods are equivalent for the case of a stationary crack, it is demonstrated that XFEM provides the additional flexibility of allowing arbitrary crack initiation and propagation during the analysis, and minimizes model setup effort for cases with stationary cracks.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

BISON Contact Algorithm Improvements in Support of Pellet Cladding Mechanical Interaction Modeling

The thermal and mechanical behavior of the gap between the fuel and cladding plays an extremely important role in determining the response of light water reactor (LWR) fuel under irradiation. This is especially true during situations when pellet-cladding mechanical interactions (PCMI) have a significant effect on the behavior of the fuel/cladding system. The BISON code, which is being used as the fuel performance simulation tool for the CASL program, employs contact detection and enforcement algorithms to realistically simulate the thermal and mechanical interactions across the fuel/cladding interaction in LWR fuel. These contact algorithms permit accurate representation of these interactions even when there is significant relative movement between the two surfaces, which is typically the case in many regions of an LWR fuel rod. This report summarizes work done during the 2017 fiscal year to further improve the accuracy and robustness of the contact enforcement algorithms in BISON. This work will benefit all BISON simulations, but will particularly benefit simulations scenarios where PCMI is of interest.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Demonstrate new plasticity models for doped UO 2 that capture dislocation mechanisms

In light water reactors, fuel vendors are investigating the use of dopants to modify the properties of UO 2 pellets, with the goal of improving pellet-cladding mechanical interactions during operation. Dopants are expected to ‘soften’ the pellets; that is, the doped pellets have higher plastic deformation than conventional UO 2 . This leads to a reduction in the severity of mechanical pellet-cladding interactions, helping to reduce the hoop strain on the cladding. By minimizing the strain exerted by the pellet on the cladding, it is anticipated that cladding performance under accident conditions can be enhanced (i.e., lowering the risk of burst during a LOCA). Dopants such as chromium (Cr) promote grain growth during pellet fabrication, leading to larger grains; therefore, understanding the link between chemistry, microstructure and mechanical deformation (enhanced creep rates) behavior of UO 2 is critical to helping operators further substantiate the benefits of doping UO 2 . Historically, the nuclear energy industry has relied on empirical models to make assessments of performance. Compared to empirical models, mechanistic physics-based models provide benefits, such as, fewer data points for validation and better extrapolation where experimental data is scarce or non-existent. In this report, Bayesian inference techniques have been applied to a previously developed lower length-scale-informed diffusional creep model. The objective is to i) infer lower-length-scale parameter distributions from available experiment and then ii) determine the uncertainties in the measurable quantity (in this case creep rates) after propagating the inferred lower length scale parameter uncertainties. The approach requires many evaluations of the model, which becomes computationally insurmountable; therefore, a neural-network model is trained to data obtained by sampling the full model over the most important parameters. This neural-network is then used in the Bayesian inference approach to determine probability distributions in the parameter values that represent the uncertainty in the model given what is known from the experiments (posterior). A significant reduction compared to conservative initial (prior) uncertainties is achieved through inference against the experimental data, demonstrating the efficacy of this approach. Furthermore, by accounting for uncertainties in the experimental conditions and sample non-stoichiometry, it is possible to resolve apparent discrepancies in experimental measurements within a self-consistent grain boundary (Coble) creep model that is sensitive to chemistry. This work has been written up and submitted to Nuclear Technology for a special issue on accelerated fuel qualification (AFQ). This uncertainty quantification (UQ) work not only improves the diffusional model, while accounting for uncertainty, but also establishes a framework which can readily be applied to the mechanistic models of dislocation deformation developed in this study. The most likely values from the Bayesian analysis are incorporated into our UO 2 diffusional creep model and a lower length scale-informed irradiation UO 2 creep mechanistic model to generate a dataset. This dataset has been provided to our INL collaborators for training an artificial neural network surrogate model, which will be implemented in the BISON fuel performance code to assess how the results differ from those currently obtained using a fully empirical model and that of using the nominal (uncalibrated) atomic scale parameters in our mechanistic model. Plastic deformation (creep and glide) in UO 2 is a complex phenomenon, governed by multiple underlying processes such as local defect concentrations, applied stresses, and microstructural characteristics. Consequently, there is a need for a meso-scale model with polycrystalline resolution capable of extrapolating to large grain sizes applicable to doped UO 2 , where data is limited and the model can help bridge the knowledge gap. By integrating atomistic data into the polycrystal LApx code, it becomes possible to predict dislocation climb and glide plasticity that simple analytical models cannot accurately represent. The application of atomic-scale data within LApx demonstrated the importance of climb and glide mechanisms in reproducing high-stress UO 2 behavior. Behaviors such as this are crucial to capture and implement in BISON, as parts of the fuel pellet can reach temperatures where glide can occur before pellet cracking. This model which captures dislocation based mechanisms for UO 2 is then used to stand up the doped model accounting for larger grain sizes. It was found that larger grain sizes can lead to enhanced deformation rates in the glide regime, and therefore can help with the pellet cladding mechanical interaction. Therefore if the fuel pellet reaches conditions (stress/temperature) where glide is active, the enhanced creep rates for larger grains in the glide regime (doped UO 2 ) can help with pellet cladding mechanical interactions. Plastic deformation in UO 2 involves multiple mechanisms, including diffusional creep, dislocation climb, and glide. This milestone contains two parts: (1) UQ of a pre-existing lower length scale informed mechanistic diffusional creep model, and (2) development of a new LApx based model for dislocation-mediated creep mechanisms in UO 2 , with application to large-grain doped UO 2 .

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

High-burnup Experiments in Reactivity Initiated Accidents (HERA)

HERA is a joint experimental program (JEEP) operating within the Nuclear Energy Agency’s (NEA’s) framework for irradiation experiments (FIDES). HERA is dedicated to the understanding of light water reactor (LWR) fuel performance at high burnup under reactivity-initiated accidents (RIA). During RIAs the fuel cladding can be breached by one of two mechanisms; pellet-cladding mechanical interaction or high temperature balloon and rupture. Pellet-cladding mechanical interaction (PCMI) failure occurs in the early phase of an RIA transient where the fuel pellet expands rapidly into the cladding prior to any meaningful heat transfer from the pellet to the cladding. This results in high stresses in the cladding resulting in crack propagation through the base Zircaloy metal and axially along the cladding tube. Failure by PCMI is a brittle failure mode and occurs at low cladding strains, approximately 2% hoop strain. If the cladding survives the PCMI phase of the transient, it may still fail due to ballooning and rupture induced by extended exposure to high temperature. Thermal transport from the fuel pin to the coolant is significantly reduced if a transition to film boiling on the cladding surface occurs. This result in both a rapid increase in fuel temperature, which drives fission gas release, and a spike in cladding temperature, which results in loss of mechanical strength. If the internal pressure of the fuel rod is greater than the system pressure the cladding can inelastically deform and eventually rupture. Failure by swelling and rupture occurs at larger strains, generally greater than 5% hoop strain. While PCMI failures are generally seen as more limiting, the dominance of one failure mode over the other can be affected by both the cladding material conditions, and the transient evolution.

(HERA)↗

High-burnup Experiments in Reactivity Initiated Accidents (HERA)

HERA is a joint experimental program (JEEP) operating within the Nuclear Energy Agency’s (NEA’s) framework for irradiation experiments (FIDES). HERA is dedicated to the understanding of light water reactor (LWR) fuel performance at high burnup under reactivity-initiated accidents (RIA). During RIAs the fuel cladding can be breached by one of two mechanisms; pellet-cladding mechanical interaction or high temperature balloon and rupture. Pellet-cladding mechanical interaction (PCMI) failure occurs in the early phase of an RIA transient where the fuel pellet expands rapidly into the cladding prior to any meaningful heat transfer from the pellet to the cladding. This results in high stresses in the cladding resulting in crack propagation through the base Zircaloy metal and axially along the cladding tube. Failure by PCMI is a brittle failure mode and occurs at low cladding strains, approximately 2% hoop strain. If the cladding survives the PCMI phase of the transient, it may still fail due to ballooning and rupture induced by extended exposure to high temperature. Thermal transport from the fuel pin to the coolant is significantly reduced if a transition to film boiling on the cladding surface occurs. This result in both a rapid increase in fuel temperature, which drives fission gas release, and a spike in cladding temperature, which results in loss of mechanical strength. If the internal pressure of the fuel rod is greater than the system pressure the cladding can inelastically deform and eventually rupture. Failure by swelling and rupture occurs at larger strains, generally greater than 5% hoop strain. While PCMI failures are generally seen as more limiting, the dominance of one failure mode over the other can be affected by both the cladding material conditions, and the transient evolution.

(HERA)↗

Testing Accident Tolerant Fuels in Reactivity Initiated Accident Conditions

The Transient Reactor Test Facility (TREAT) at Idaho National Laboratory (INL) has been successfully restarted. A principal goal of restarting the reactor was to perform transient testing of Accident Tolerant Fuels (ATF), supporting their safe adoption by the commercial Light Water Reactor (LWR) fleet. This paper will describe the efforts underway at INL to conduct testing of ATF under Reactivity Initiated Accident (RIA) conditions in an inert helium atmosphere. Tests in an inert helium atmosphere capsule provide valuable information about initial deposition and distribution of energy in the nuclear fuel. Tests in an inert helium atmosphere are especially suited for ATF concepts where the thermophysical properties of the new fuel material differ from UO2 such as the U3Si2 fuel concept and other non-oxide materials. These tests are also useful for exploring the thermal mechanical interaction of pellets with cladding where the cladding mechanical properties do not change much with temperature such as Silicon Carbide Cladding. Tests with nominal dimensions will be used to determine how fresh fuel failure and core coolability limits of ATF pellet and cladding materials compare with that of standard LWR fuel made up of UO2 pellets and Zircaloy cladding. Tests with a reduced pellet cladding gap will be used as a preliminary indicator of any pellet cladding mechanical interaction (PCMI) vulnerabilities of the new fuel concepts. The materials, methods, and schedule for the ATF RIA tests will be discussed in the paper.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

(Project 14-6770) An Investigation to Establish Multiphysical Property Dataset of Nuclear Materials Based on in-situ Observations and Measurements

In-core nuclear materials including fuel pins and cladding materials fail due to issues including corrosion, mechanical wear, and pellet cladding interaction. In most such scenario microstructure dependent and corrosioninduced chemistry dependent property changes significantly affect performance of cladding, pellet, and housing. Emphasis of this work was on replace conventional pellet-cladding material models with a new straingradient viscoplasticity model that is informed by transmission electron microscopy (TEM) based measurements and by nanomechanical Raman spectroscopy (NMRS) based measurements. The TEM measurements are quantitative in nature and therefore reveal stress-strain relations with simultaneous insights into mechanisms of deformation at nanoscale. The NMRS measurements reveal the similar information at mesoscale along with additional information on relating local microstructural stresses with applied stresses. The resulting information is used to fit constants in the strain gradient viscoplasticity model as well as to validate one. During TEM measurements, a micro-electro-mechanical system based setup was developed with mechanical actuation, sensing, heating, and electrical loading. Contrary to post-mortem analysis or qualitative visualization, this setup combines direct visualization of the mechanisms behind deformation with measurement of stress, strain, thermal and electrical properties. The unique research philosophy of visualizing the microstructure at high resolution while measuring the properties led to fundamental understanding in grain size and temperature effects on measured mechanical properties such as fracture toughness. A key contribution is the role of mechanical loading boundary conditions to deconvolute the insitu TEM based nanoscale and NMRS based mesoscale data to bulk behavior. First the literature based pellet cladding mechanical interaction model based on the work of Retel’s and Williamson’s in literature work to predict tempurature and stress distribution in cladding and pellet at normal operating condition was analyzed. Later the data was fitted to find constants for a viscoplastic strain gradient model. The developed model still needs to be refined and calibrated using various experimental results. That remains the focus of future work. Overall, a major thrust of the work was therefore on active control of the microstructure (grain size, defect density and types) exploiting the multi-physics coupling in materials. In particular, using experiments the synergy of current density, mechanical stress and temperature were studied to annihilate defects and recrystallize grains. The developed model is being examined for implementation in BISON. Multiple invited talks, international journal publications, and conference publications were performed by students supported on this work. Another output is support multiple PhD and masters thesis students who will be an important asset for future basic nuclear research. Future Work Recommendations: A nuclear reactor operates under significant variations of thermal loads due to energy cycling and mechanical loads due to constraint effects. Significant thermal and chemical diffusion takes place at the pallet-cladding level. While the proposed work established new experimental approach and new dataset for Zircaloy-4, the irradiation level was in the range of 1-2 dpa. Samples with higher dpa need to be examined. Therefore, a continual of support of the performed work is essential. Currently, these are the only experiments that can measure the produced data. The work also needs to be extended to different fuel types and cladding types such as SiC and FeCrAl based claddings. A combination of datasets for these materials can then be used to analyze accurately predict behavior of critical pellet cladding systems in accident scenario with high heat flux and high thermal loads. This is a BIG unknown as if now.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

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

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

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

BISON validation of FeCrAl cladding mechanical failure during simulated reactivity-initiated accident conditions*

Here, a reactivity-initiated accident (RIA) is a postulated design basis accident in light water reactors (LWRs) in which a rapid reactivity insertion induces a fission rate increase and a fuel pellet temperature rise. During RIA, the fuel pellet thermally expands and may cause pellet-cladding mechanical interaction (PCMI). Separate effects PCMI tests were performed on C26M FeCrAl cladding tube samples, introducing biaxial stress via a well understood modified burst test (MBT) system. A high-speed camera in the MBT system captured the projections, covering a 360° view of the cladding deformation and enabling a digital image correlation (DIC) method to quantify the surface strains with high fidelity. Representative hot zero-power RIA mechanical loading conditions were applied to the sample, and the test duration ranged from 20 to 500 ms at an average temperature of 573 K. BISON finite element–based fuel performance code modeling was performed against the high-fidelity DIC data produced from the MBTs. Validation calculations were conducted with 2D models and systematically compared with test data of the burst time, burst pressure, burst hoop strains, and hoop strain rates. Based on the behaviors from the separate effects test, BISON calculations satisfactorily predicted the cladding deformation behaviors. Sensitivity analysis was conducted to identify highly influential mechanical properties responsible for the cladding failure behavior during the MBT experiments. The results highlight the significance of the cladding's mechanical strength in governing cladding strain, followed by the significance of the mechanical interactions between the pellet and the cladding.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

A pulse-controlled modified-burst test instrument for accident-tolerant fuel cladding

Pellet-cladding mechanical interaction due to thermal expansion of nuclear fuel pellets during a reactivity-initiated accident (RIA) is a potential mechanism for failure of nuclear fuel cladding. To investigate the mechanical behavior of cladding during an RIA, we developed a mechanical pulse-controlled modified burst test instrument that simulates transient events with a pulse width from 10 to 300 ms. This paper includes validation tests of unirradiated and prehydrided ZIRLO cladding tubes. A ZIRLO cladding sample with a hydrogen content of 168 wt. ppm showed ductile behavior and failed at the maximum limits of the test setup with hoop strain to failure greater than 9.2%. ZIRLO samples showed high resistance to failure even at very high hydrogen contents (1,466 wt. ppm). When the hydrogen content was increased to 1,554 wt. ppm, brittle-like behavior was observed at a hoop strain of 2.5%. Preliminary scoping tests at room temperature with FeCrAl tubes were conducted to imitate the pulse behavior of transient test reactors during integral tests. The preliminary FeCrAl tests are informative from the perspective of characterizing the test rig and supporting the design of integral tests for current and potentially accident tolerant cladding materials.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

OECD/NEA MPCMIV Benchmark - Preliminary fuel performance results

The on-going OECD/NEA Multi-physics Pellet Cladding Mechanical Interaction Validation (MPCMIV) benchmark aims to provide guidance on multi-physics validation through the modelling of two cold ramps. In this paper, the first results for the base irradiation of the father rod and fuel rodlet (refabricated from the father rod), and the first cold ramp are presented. The base irradiation consists of 3 years of irradiation in the Forsmark-2 reactor. The cold ramp encompasses a steady-state pre-ramp period of less than one hour at a low constant linear heat rate (LHR) followed by a ramp test (< 1 min) with a much higher maximal LHR. The base irradiation is modelled using the fuel performance codes FRAPCON and FAST, while the cold ramp modeling is using the fuel performance code FRAPTRAN. Several missing parameters for FRAPCON/FAST base irradiation models have been selected using multiple references such as the OECD/NEA light water reactor Uncertainty Analysis in Modelling (UAM) benchmark specifications and the FRAPCON Integral Assessment report. The obtained results for the base irradiation such as the cladding outer diameter show reasonable agreement with the experimental measurements. The results for the cold ramp show larger differences with the experimental measurements (e.g., cladding axial elongation). However, such differences have been observed as well in other studies involving pellet cladding mechanical interaction analyses and are attributed to the fuel performance modelling assumptions and to the tuned modelling parameters that were not covered by the specifications. Uncertainty and sensitivity analysis might allow a better quantification of these missing parameters. (authors)

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

Temperature-Dependent Mechanical Anisotropy in Textured Zircaloy Cladding

This work evaluates deformation activity in textured zircaloy-4 cladding with the aim of elucidating the mechanisms that govern mechanical behavior across a temperature range anticipated in reactor service. In particular, the dependence of mechanical anisotropy on temperature and stress state (ratio of applied stresses) is examined via uniaxial and biaxial tensile experiments at room temperature and 400 °C. The mechanical behavior was interpreted based on micro-texture and dominant slip system activity. Thermal activation of basal systems is found as a key mechanism affecting mechanical behavior across the temperature range. The biaxial stress states produce resolved shear stresses contrasting to uniaxial stress states. As a result, mechanical testing and implications for reactor pellet-cladding mechanical interaction stress conditions are discussed.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Fracture Toughness Evaluation for Spent Nuclear Fuel Clad Systems Using Spiral Notch Torsion Fracture Toughness Test

Many radioactive materials within the nuclear fuel cycle present a significant hazard. Such materials include spent nuclear fuel, high-level waste, legacy waste and other nuclear materials. These materials are often held in long-term storage as an interim stage within their lifecycle, including reuse or disposal. Safety and security of spent nuclear fuel (SNF) interim storage installations and follow-on SNF transportations to its final repository sites are very important, due to a great concentration of fission products, actinides and activation products. Fracture mechanics approach in applying to SNF system reliability investigation, especially for the high burn up (HBU) SNF, during SNF long term dry storage or SNF transportation is necessary due to the inherited flaws and inhomogeneity structures existed in a SNF system from the reactor operation. For instance, such as hydride and oxide formation, surface flaw induced by SNF assembly contact interactions, or internal flaws induced by pellet-clad mechanical interaction (PCMI). However, none of the existing fracture toughness data deal with fuel cladding specific geometry or SNF material conditions, such as cladding structure with the segment fuel pellets configuration and the PCMI mechanism. Consequently, the application of existing fracture toughness data to SNF system reliability investigation can be error prone; thus, the development of an industry-wide consensus fracture mechanics approach is needed. The objective of this research is to develop an in-situ fracture mechanics testing protocol, including the associated analytical procedure, that is suitable for evaluating the SNF fracture toughness. Fracture toughness data was obtained under quasi-static fracture loading using Oak Ridge National Laboratory (ORNL) developed Spiral Notch Torsion Test (SNTT) technology carried out on a biaxial tension/torsion tester. These data will be used to support SNF reliability investigation during long-tern SNF dry storage stage or in the follow-on SNF system transport to the final repository sites. SNTT has been a recent breakthrough in measuring fracture toughness for different materials, including metals, ceramics, concrete and polymers composites. Due to its high geometry constraint and unique loading condition, SNTT can be used to measure the fracture toughness with smaller specimens without concern of size effects. The application of SNTT to brittle materials has been proved to be successful. The micro-cracks induced by original notches in brittle materials could ensure crack growth in SNTT samples. Therefore, no fatigue pre cracks are needed for brittle materials specimens. The application of SNTT to the ductile material to generate valid toughness data will require a test sample with sufficient pre-crack length to increase the sample localized constraint at crack front. Fatigue pre-crack growth techniques with the associated compliance function estimated was developed for estimating the crack penetration depth to monitor the fatigue crack growth evolution. In order to extend SNTT approach to a thin shell cladding structure material, a new testing protocol and the associated analytical procedure for estimating the SNF fracture toughness was developed. The detailed SNTT approach and its estimated fracture toughness for the Zr-4 cladding structure with segment alumina inserts are presented in this report. The SNTT test results indicate that SNTT method is a reliable test approach with good repeatability in applying to Zr-4 cladding material. For the medium and the short crack length, the estimate J Q upon fracture for the baseline Zr-4 cladding is at 285.7 lb/in with 2-sigma uncertainty of 18.59 lb/in., and the associated K Q is at 61.4 Ksi√in. For a long crack length, the crack initialization orientation is apparently deviated from the principle tensile stress contour – 45° spiral crack front (i.e., Mode I + Mode III failure mechanism); and the estimated J Q is at 108 lb/in., the associated K Q is at 37.7 Ksi√in. The estimate Mode I J Q (along the 45° pitch principle tensile stress contour) is at 200 lb/in.; which indicate a significant reduction in the fracture toughness in a tubing structure under mixed mode loading condition, Mode I + Mode III, compared to that of Mode I (tensile stress dominated) alone.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

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

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

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Transverse Rupture Strength of Uranium Dioxide

Uranium dioxide (UO 2 ) fuel is used as fuel in light water reactors (LWRs). While the fuel pellet is technically the first engineering barrier for radionuclide release, pellet fracturing at intermediate- to high-burnup values releases fission gases into the fuel rod plenum [1, 2]. Therefore, the true engineering barrier is the fuel cladding, which performs very well in LWR environments [3]. The extreme temperature gradients generated by fission energy and the low thermal conductivity of UO 2 quickly induce radial cracking in UO 2 during operation [4]. Cracks in the fuel provide opportunities for fuel relocation, increased fission gas release, and pellet-cladding mechanical interaction (PCMI) [5]. The ability to predict and engineer the fracture of UO 2 fuel pellets using modern computational tools is therefore a key engineering goal that has been the focus of ongoing experimental and computational efforts [6, 7]. Accurate predictions of fuel pellet cracking during operation requires knowledge of more complex phenomena, but improved understanding of the fundamental fracture behavior of unirradiated UO 2 is first necessary.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗