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At least 19 records
All sourcesNASA NTRSDOE OSTI
DOE OSTI2012

PWR cores with silicon carbide cladding

The feasibility of using silicon carbide rather than Zircaloy cladding, to reach higher power levels and higher discharge burnups in PWRs has been evaluated. A preliminary fuel design using fuel rods with the same dimensions as in the Westinghouse Robust Fuel Assembly but with fuel pellets having 10 vol% central void has been adopted to mitigate the higher fuel temperatures that occur due to the lower thermal conductivity of the silicon carbide and to the persistence of the open clad-pellet gap over most of the fuel life. With this modified fuel design, it is possible to achieve 18 month cycles that meet present-day operating constraints on peaking factor, boron concentration, reactivity coefficients and shutdown margin, while allowing batch average discharge burnups up to 80 MWD/kgU and peak rod burnups up to 100 MWD/kgU. Power uprates of 10% and possibly 20% also appear feasible. For non-uprated cores, the silicon carbide-clad fuel has a clear advantage that increases with increasing discharge burnup. Even for comparable discharge burnups, there is a savings in enriched uranium. Control rod configuration modifications may be required to meet the shutdown margin criterion for the 20% up-rate. Silicon carbide's ability to sustain higher burnups than Zircaloy also allows the design of a licensable two year cycle with only 96 fresh assemblies, avoiding the enriched uranium penalty incurred with use of larger batch sizes due to their excessive leakage. (authors)

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2023

Multi-Scale Characterization of Porosity and Cracks in Silicon Carbide Cladding after Transient Reactor Test Facility Irradiation

Silicon carbide (SiC) ceramic matrix composite (CMC) cladding is currently being pursued as one of the leading candidates for accident-tolerant fuel (ATF) cladding for light water reactor applications. The morphology of fabrication defects, including the size and shape of voids, is one of the key challenges that impacts cladding performance and guarantees reactor safety. Therefore, quantification of defects’ size, location, distribution, and leak paths is critical to determining SiC CMC in-core performance. This research aims to provide quantitative insight into the defect’s distribution under multi-scale characterization at different length scales before and after different Transient Reactor Test Facility (TREAT) irradiation tests. A non-destructive multi-scale evaluation of irradiated SiC will help to assess critical microstructural defects from production and/or experimental testing to better understand and predict overall cladding performance. X-ray computed tomography (XCT), a non-destructive, data-rich characterization technique, is combined with lower length scale electronic microscopic characterization, which provides microscale morphology and structural characterization. This paper discusses a fully automatic workflow to detect and analyze SiC-SiC defects using image processing techniques on 3D X-ray images. Following the XCT data analysis, advanced characterizations from focused ion beam (FIB) and transmission electron microscopy (TEM) were conducted to verify the findings from the XCT data, especially quantitative results from local nano-scale TEM 3D tomography data, which were utilized to complement the 3D XCT results. In this work, three SiC samples (two irradiated and one unirradiated) provided by General Atomics are investigated. The irradiated samples were irradiated in a way that was expected to induce cracking, and indeed, the automated workflow developed in this work was able to successfully identify and characterize the defects formation in the irradiated samples while detecting no observed cracking in the unirradiated sample. These results demonstrate the value of automated XCT tools to better understand the damage and damage propagation in SiC-SiC structures for nuclear applications.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2018

Completion of the Irradiation of Silicon Carbide Cladding Tube Specimens in the High Flux Isotope Reactor

This document outlines the irradiation of silicon carbide cladding tube specimens in the High Flux Isotope Reactor at Oak Ridge National Laboratory. The cladding tube specimens consisted of monolithic, composite, and coated SiC specimens in order to test the effect of these various materials on the overall cladding performance during irradiation. A total of 18 specimens were irradiated for one cycle, with 9 specimens irradiated at low heat flux conditions and 9 specimens at high heat flux conditions. The specimens were inserted in cycle 475 in September 2017 and reached an average irradiation dose of approximately 2.6 dpa.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2025

Integral Heat Transfer Test Method for Determining Thermal Resistance of Silicon Carbide Cladding and Liquid Tin System at Elevated Temperatures - Master's Thesis Presentation University of Idaho

Presentation for master's work at University of Idaho discussing Integral Heat Transfer Test Method for Determining Thermal Resistance of Silicon Carbide Cladding and Liquid Tin System at Elevated Temperatures. Presentation covers slight literature review results/previous work, discussions on system design and approach for thermal property measurement of SiC composite and Tin system, modeling efforts, and results.

36 - MATERIALS SCIENCE↗
DOE OSTI2017

Assembly and Delivery of Rabbit Capsules for Irradiation of Silicon Carbide Cladding Tube Specimens in the High Flux Isotope Reactor

Neutron irradiation of silicon carbide (SiC)-based fuel cladding under a high radial heat flux presents a critical challenge for SiC cladding concepts in light water reactors (LWRs). Fission heating in the fuel provides a high heat flux through the cladding, which, combined with the degraded thermal conductivity of SiC under irradiation, results in a large temperature gradient through the thickness of the cladding. The strong temperature dependence of swelling in SiC creates a complex stress profile in SiCbased cladding tubes as a result of differential swelling. The Nuclear Science User Facilities (NSUF) Program within the US Department of Energy Office of Nuclear Energy is supporting research efforts to improve the scientific understanding of the effects of irradiation on SiC cladding tubes. Ultimately, the results of this project will provide experimental validation of multi-physics models for SiC-based fuel cladding during LWR operation. The first objective of this project is to irradiate tube specimens using a previously developed design that allows for irradiation testing of miniature SiC tube specimens subjected to a high radial heat flux. The previous “rabbit” capsule design uses the gamma heating in the core of the High Flux Isotope Reactor (HFIR) to drive a high heat flux through the cladding tube specimens. A compressible aluminum foil allows for a constant thermal contact conductance between the cladding tubes and the rabbit housing despite swelling of the SiC tubes. To allow separation of the effects of irradiation from those due to differential swelling under a high heat flux, a new design was developed under the NSUF program. This design allows for irradiation of similar SiC cladding tube specimens without a high radial heat flux. This report briefly describes the irradiation experiment design concepts, summarizes the irradiation test matrix, and reports on the successful delivery of six rabbit capsules to the HFIR. Rabbits of both low and high heat flux configurations have been assembled, welded, evaluated, and delivered to the HFIR along with a complete quality assurance fabrication package. These rabbits contain a wide variety of specimens including monolith tubes, SiC fiber SiC matrix (SiC/SiC) composites, duplex specimens (inner composite, outer monolith), and specimens with a variety of metallic or ceramic coatings on the outer surface. The rabbits are targeted for insertion during HFIR cycle 475, which is scheduled for September 2017.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2024

Multiscale Modeling of Silicon Carbide Cladding for Nuclear Applications: Thermal Performance Modeling

The complex multiscale and anisotropic nature of silicon carbide (SiC) ceramic matrix composite (CMC) makes it difficult to accurately model its performance in nuclear applications. The existing models for nuclear grade composite SiC do not account for the microstructural features and how these features can affect the thermal and structural behavior of the cladding and its anisotropic properties. In addition to the microstructural features, the properties of individual constituents of the composites and fiber tow architecture determine the bulk properties. Models for determining the relationship between the individual constituents’ properties and the bulk properties of SiC composites for nuclear applications are absent, although empirical relationships exist in the literature. Here, a hierarchical multiscale modeling approach was presented to address this challenge. This modular approach addressed this difficulty by dividing the various aspects of the composite material into separate models at different length scales, with the evaluated property from the lower-length-scale model serving as an input to the higher-length-scale model. The multiscale model considered the properties of various individual constituents of the composite material (fiber, matrix, and interphase), the porosity in the matrix, the fiber volume fraction, the composite architecture, the tow thickness, etc. By considering inhomogeneous and anisotropic contributions intrinsically, our bottom-up multiscale modeling strategy is naturally physics-informed, bridging constitutive law from micromechanics to meso-mechanics and structural mechanics. The effects that these various physical attributes and thermo-physical properties have on the composite’s bulk thermal properties were easily evaluated and demonstrated through the various analyses presented herein. Since silicon carbide fiber-reinforced SiC CMCs are also promising thermal–structural materials with a broad range of high-end technology applications beyond nuclear applications, we envision that the multiscale modeling method we present here may prove helpful in future efforts to develop and construct reinforced CMCs and other advanced composite nuclear materials, such as MAX phase materials, that can service under harsh environments of ultrahigh temperatures, oxidation, corrosion, and/or irradiation.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2021

Transient testing of uranium silicide fuel in zircaloy and silicon carbide cladding

Using the newly restarted Transient Reactor Test (TREAT) facility at Idaho National Laboratories, fresh (unirradiated) U 3 Si 2 fuel pellets were tested under reactivity-initiated accident conditions in dry helium capsules. These tests were performed with total energy depositions sufficient to induce melting of the U 3 Si 2 fuel pellets based on available thermophysical property data. The instrumented experiments utilized in-pile thermocouples and infrared pyrometers to measure the cladding temperature during the transient, which are in reasonable agreement with predicted peak cladding temperatures using a simple BISON fuel performance model. This same model is then used to predict expected cladding stresses during the transients in areas where pellet cladding interaction is expected. It was shown that for transient energy depositions up to 528J/g rod like geometry of the test articles was maintained. While it is acknowledged that more confirmatory testing is required in more prototypic environments, these first of their kind experiments have demonstrated that unirradiated U 3 Si 2 fuel and unirradiated SiC-SiC claddings can likely retain a “rod like” geometry for transient energy depositions up to 528J/g.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2020

Evaluation of Constitutive Relationship for Silicon Carbide Cladding Material

A curved representative volume element (RVE) was employed to analyze SiC/SiC tubular composites. By imposing periodicity on the tubular model through appropriate boundary conditions, the elastic constants of the composite was evaluated. It was found that as the radius of the tubular composite increases, the more the flat RVE model and curved RVE model disagreed.

Thandaga Nagaraju, Hemanth↗
DOE OSTI2016

Radiation tolerant joining for silicon carbide-based accident tolerant fuel cladding

Silicon carbide (SiC) and silicon carbide fiber reinforced, silicon carbide matrix (SiC-SiC) composites are candidate materials for nuclear fuel cladding in accident tolerant light water reactors and advanced high temperature reactors due to their chemical stability and retention of strength at elevated temperature and neutron flux. A reliable means to join silicon carbide components is imperative to the successful implementation of SiC-based structural nuclear materials as fuel cladding as well as more complex core internal structures. A comprehensive approach has been taken to address several of the significant challenges associated with SiC joining and fabrication of complex SiC structures. This work focuses on low activation joining materials that are expected to behave well under a variety of different reactor operating conditions. Pre- and post-irradiation mechanical testing and microstructural evaluation will be presented for specimens subjected to fast flux irradiation to 4.5 dpa at 730 C. degrees, as well as 8.7 dpa at 270 C. degrees. Joints did not exhibit any strength degradation under either irradiation condition. Additionally, the performance of joined cylindrical SiC-SiC composite specimens was evaluated following irradiation in pressurized water reactor (PWR) coolant chemistry to 0.5 dpa. Lastly, out-of-pile characterization of permeability has been conducted on joined cylindrical SiC-SiC specimens to assess performance of this joint material under additional conditions relevant to reactor operation. Details of the experimental set-up and relationships between microstructure and performance will be discussed. (authors)

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2019

Emergency core cooling system performance criteria for Multi-Layered Silicon Carbide nuclear fuel cladding

Multi-layered Silicon Carbide (SiC) cladding has been proposed to replace the current Zircaloy (Zr) cladding in existing nuclear power plants. Due to its ceramic property, SiC may have a different failure mechanism from that of metallic Zr clad. This characteristic should be considered in designing the plant’s safety system performance, such that the fuel’s integrity is reasonably assured during accident scenarios. This paper aims at optimizing the Emergency Core Cooling System (ECCS) performance criteria in mitigating LBLOCA accidents at a Pressurized Water Reactor (PWR) using the uranium dioxide fuel and duplex or triplex SiC cladding structures. Clad failures by brittle fractures and thermal degradation were modeled in a fuel analysis code. This fuel model was coupled with the RELAP5 plant model by adapting the fuel’s mesh configuration and formulating the effective heat transfer coefficients. A model to quantify the likelihood of clad functional failure as a combination of individual layer fractures at various axial positions was proposed. Updated SiC material properties were gathered from recent reference studies. Clad reliability estimates using the proposed model were compared with the estimates obtained using other models. The results were used to relax the criterion of required actuation timing of ECCS, such that the risk of the new plant design is less or equal to that of the initial plant configuration. Triplex clad was more reliable than duplex clad and Zr, reducing the conditional core damage probability by three orders of magnitude in the reference LBLOCA scenario. Compressive stresses due to irradiation swelling played the determining role in the vulnerabilities of each clad design. The duplex clad was vulnerable to pressure-loading stresses while triplex clad was prone to fail due to thermal shocks experienced during the LOCA reflood phase. Additionally, it was concluded that the most vulnerable axial fuel rod location in the reference LBLOCA scenario was located at the highest axial power peaking location. A sensitivity study on the ECCS timing density was conducted. The results showed that ECCS actuation timing could be extended from the initial technical specification, without increasing the fuel damage likelihood. The time extension was distributed in the order of several hundreds of seconds, which was comparable with time extensions offered by FeCrAl and Cr-coated-Zr clad designs in LBLOCA scenarios. This time extension may potentially reduce the failure probabilities of EDGs and pumps, hence improving the plant safety further.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2024

Silicon Carbide Composite Cladding Qualification

This report examines the process to qualify a new fuel-cladding type focusing on the data requirements and types of irradiation testing necessary to meet the regulatory burden and related guidance applicable to fuel qualification of accident-tolerant fuel. The report considers the use of accelerated fuel qualification techniques and lead-test specimen programs that may shorten the timeline for qualifying fuel for use in a nuclear reactor at the desired burnup. The assessment framework particularly emphasizes the identification of key fuel manufacturing parameters, the specification of a fuel performance envelope to inform testing requirements, the use of evaluation models in the fuel qualification process, and the assessment of the experimental data used to develop and validate the empirical models and empirical safety criteria.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2016

Development of joining technology using local heating for SiC fuel cladding

Silicon carbide (SiC) is an attractive material for an accident-tolerant fuel in light water reactors because of its lower hydrogen-generation rate and lower heat of reaction than conventional Zircaloy. On the other hand, practical application of SiC fuel cladding faces a lot of critical issues, one of which is end-plug joining. The objective of this study is to clarify the feasibility of end-plug joining by silicon brazing using local heating by evaluating the shear strength of joint specimens and producing a circumferential joint experimentally. Silicon is thought to be a compatible joining material with SiC because as well as being a constituent of SiC, its thermal-expansion coefficient is close to that of SiC. Local heating using processes such as laser irradiation and a resistance-heating element needs to be applied for end-plug joining. Brazing is expected to seal a cladding with an end plug by using brief heating without a strong compression force. Shear strength was evaluated using specimens with silicon-brazing joints processed using laser irradiation. The joint sections without defects showed shear strengths higher than or equal to 59 MPa at temperatures from normal room temperature to 1473 K. The average shear strength of the joint (99 MPa) is comparable to that of a diffusion-bonding joint using titanium or molybdenum foil. A tube and a plug were circumferentially joined with silicon brazing using laser irradiation or a graphite heating element. A defocused laser beam was effective for joining without cracking during laser irradiation. Although local heating using a resistance-heating element can more easily control the temperature of the joint, it took longer processing time than that using laser irradiation due to limited temperature-increase rate in order to avoid thermal shock damage. (authors)

36 MATERIALS SCIENCE↗
DOE OSTI2022

Mechanistic modeling of lifetime distribution of SiC/SiC composite claddings

Silicon carbide (SiC) fiber-reinforced SiC matrix (SiC/SiC) composites have emerged as a new material candidate for fuel claddings in light water reactors. Recent studies showed that the load capacity of SiC/SiC materials exhibits a considerable statistical variation. Therefore, reliability analysis plays a critical role in design of SiC/SiC composite claddings. Here, this paper presents a probabilistic model for the lifetime distribution of SiC/SiC composites. The model is anchored by a multiaxial stress-based failure criterion and subcritical damage accumulation mechanism. Based on the kinetics of subcritical damage growth, the lifetime distribution of a laboratory test specimen for any given loading history can be calculated. A finite weakest-link model is used to extrapolate the lifetime distribution of test specimens to full-length claddings. It is shown that the damage accumulation mechanism has a strong influence on the lifetime distribution of the cladding. This finding highlights the importance of understanding the static fatigue behavior of SiC/SiC composites. The present analysis also demonstrates an intricate length effect on the failure probability of the cladding, which is expected to play a crucial role in design extrapolation.

36 MATERIALS SCIENCE↗