The Mechanical Response of Advanced Claddings during Proposed Reactivity Initiated Accident Conditions

DOE Office of Scientific and Technical Information (OSTI.GOV)

Cinbiz, Mahmut N; Brown, Nicholas R; Terrani, Kurt A

2017-01-01

This study investigates the failure mechanisms of advanced nuclear fuel cladding of FeCrAl at high-strain rates, similar to design basis reactivity initiated accidents (RIA). During RIA, the nuclear fuel cladding was subjected to the plane-strain to equibiaxial tension strain states. To achieve those accident conditions, the samples were deformed by the expansion of high strength Inconel alloy tube under pre-specified pressure pulses as occurring RIA. The mechanical response of the advanced claddings was compared to that of hydrided zirconium-based nuclear fuel cladding alloy. The hoop strain evolution during pressure pulses were collected in situ; the permanent diametral strains of bothmore » accident tolerant fuel (ATF) claddings and the current nuclear fuel alloys were determined after rupture.« less

Container for reprocessing and permanent storage of spent nuclear fuel assemblies

DOEpatents

Forsberg, C.W.

1992-03-24

A single canister process container is described for reprocessing and permanent storage of spent nuclear fuel assemblies comprising zirconium-based cladding and fuel, which process container comprises a collapsible container, having side walls that are made of a high temperature alloy and an array of collapsible support means wherein the container is capable of withstanding temperature necessary to oxidize the zirconium-based cladding and having sufficient ductility to maintain integrity when collapsed under pressure. The support means is also capable of maintaining its integrity at a temperature necessary to oxidize the zirconium-based cladding. The process container also has means to introduce and remove fluids to and from the container. 10 figs.

Iron-chrome-aluminum alloy cladding for increasing safety in nuclear power plants

NASA Astrophysics Data System (ADS)

Rebak, Raul B.

2017-12-01

After a tsunami caused plant black out at Fukushima, followed by hydrogen explosions, the US Department of Energy partnered with fuel vendors to study safer alternatives to the current UO2-zirconium alloy system. This accident tolerant fuel alternative should better tolerate loss of cooling in the core for a considerably longer time while maintaining or improving the fuel performance during normal operation conditions. General electric, Oak ridge national laboratory, and their partners are proposing to replace zirconium alloy cladding in current commercial light water power reactors with an iron-chromium-aluminum (FeCrAl) cladding such as APMT or C26M. Extensive testing and evaluation is being conducted to determine the suitability of FeCrAl under normal operation conditions and under severe accident conditions. Results show that FeCrAl has excellent corrosion resistance under normal operation conditions and FeCrAl is several orders of magnitude more resistant than zirconium alloys to degradation by superheated steam under accident conditions, generating less heat of oxidation and lower amount of combustible hydrogen gas. Higher neutron absorption and tritium release effects can be minimized by design changes. The implementation of FeCrAl cladding is a near term solution to enhance the safety of the current fleet of commercial light water power reactors.

Hydrogen permeation in FeCrAl alloys for LWR cladding application

NASA Astrophysics Data System (ADS)

Hu, Xunxiang; Terrani, Kurt A.; Wirth, Brian D.; Snead, Lance L.

2015-06-01

FeCrAl, an advanced oxidation-resistant iron-based alloy class, is a highly prevalent candidate as an accident-tolerant fuel cladding material. Compared with traditional zirconium alloy fuel cladding, increased tritium permeation through FeCrAl fuel cladding to the primary coolant is expected, raising potential safety concerns. In this study, the hydrogen permeability of several FeCrAl alloys was obtained using a static permeation test station, which was calibrated and validated using 304 stainless steel. The high hydrogen permeability of FeCrAl alloys leads to concerns with respect to potentially significant tritium release when used for fuel cladding in LWRs. The total tritium inventory inside the primary coolant of a light water reactor was quantified by applying a 1-dimensional steady state tritium diffusion model to demonstrate the dependence of tritium inventory on fuel cladding type. Furthermore, potential mitigation strategies for tritium release from FeCrAl fuel cladding were discussed and indicate the potential for application of an alumina layer on the inner clad surface to serve as a tritium barrier. More effort is required to develop a robust, economical mitigation strategy for tritium permeation in reactors using FeCrAl clad fuel assemblies.

Zirconium-based alloys, nuclear fuel rods and nuclear reactors including such alloys, and related methods

DOEpatents

Mariani, Robert Dominick

2014-09-09

Zirconium-based metal alloy compositions comprise zirconium, a first additive in which the permeability of hydrogen decreases with increasing temperatures at least over a temperature range extending from 350.degree. C. to 750.degree. C., and a second additive having a solubility in zirconium over the temperature range extending from 350.degree. C. to 750.degree. C. At least one of a solubility of the first additive in the second additive over the temperature range extending from 350.degree. C. to 750.degree. C. and a solubility of the second additive in the first additive over the temperature range extending from 350.degree. C. to 750.degree. C. is higher than the solubility of the second additive in zirconium over the temperature range extending from 350.degree. C. to 750.degree. C. Nuclear fuel rods include a cladding material comprising such metal alloy compositions, and nuclear reactors include such fuel rods. Methods are used to fabricate such zirconium-based metal alloy compositions.

Hydrogen permeation in FeCrAl alloys for LWR cladding application

DOE PAGES

Hu, Xunxiang; Terrani, Kurt A.; Wirth, Brian D.; ...

2015-03-19

FeCrAl is an advanced oxidation-resistant iron-based alloy class, is a highly prevalent candidate as an accident-tolerant fuel cladding material. Compared with traditional zirconium alloy fuel cladding, increased tritium permeation through FeCrAl fuel cladding to the primary coolant is expected, raising potential safety concerns. In our study, the hydrogen permeability of several FeCrAl alloys was obtained using a static permeation test station, which was calibrated and validated using 304 stainless steel. The high hydrogen permeability of FeCrAl alloys leads to concerns with respect to potentially significant tritium release when used for fuel cladding in LWRs. Also, the total tritium inventory insidemore » the primary coolant of a light water reactor was quantified by applying a 1-dimensional steady state tritium diffusion model to demonstrate the dependence of tritium inventory on fuel cladding type. Furthermore, potential mitigation strategies for tritium release from FeCrAl fuel cladding were discussed and indicate the potential for application of an alumina layer on the inner clad surface to serve as a tritium barrier. More effort is required to develop a robust, economical mitigation strategy for tritium permeation in reactors using FeCrAl clad fuel assemblies.« less

Nuclear fuel elements having a composite cladding

DOEpatents

Gordon, Gerald M.; Cowan, II, Robert L.; Davies, John H.

1983-09-20

An improved nuclear fuel element is disclosed for use in the core of nuclear reactors. The improved nuclear fuel element has a composite cladding of an outer portion forming a substrate having on the inside surface a metal layer selected from the group consisting of copper, nickel, iron and alloys of the foregoing with a gap between the composite cladding and the core of nuclear fuel. The nuclear fuel element comprises a container of the elongated composite cladding, a central core of a body of nuclear fuel material disposed in and partially filling the container and forming an internal cavity in the container, an enclosure integrally secured and sealed at each end of said container and a nuclear fuel material retaining means positioned in the cavity. The metal layer of the composite cladding prevents perforations or failures in the cladding substrate from stress corrosion cracking or from fuel pellet-cladding interaction or both. The substrate of the composite cladding is selected from conventional cladding materials and preferably is a zirconium alloy.

Recycle of Zirconium from Used Nuclear Fuel Cladding: A Major Element of Waste Reduction

DOE Office of Scientific and Technical Information (OSTI.GOV)

Collins, Emory D; DelCul, Guillermo D; Terekhov, Dmitri

2011-01-01

Feasibility tests were initiated to determine if the zirconium in commercial used nuclear fuel (UNF) cladding can be recovered in sufficient purity to permit re-use, and if the recovery process can be operated economically. Initial tests are being performed with unirradiated, non-radioactive samples of various types of Zircaloy materials that are used in UNF cladding to develop the recovery process and determine the degree of purification that can be obtained. Early results indicate that quantitative recovery can be accomplished and product contamination with alloy constituents can be controlled sufficiently to meet purification requirements. Future tests with actual radioactive UNF claddingmore » are planned. The objective of current research is to determine the feasibility of recovery and recycle of zirconium from used fuel cladding wastes. Zircaloy cladding, which contains 98+% of hafnium-free zirconium, is the second largest mass, on average {approx}25 wt %, of the components in used U.S. light-water-reactor fuel assemblies. Therefore, recovery and recycle of the zirconium would enable a large reduction in geologic waste disposal for advanced fuel cycles. Current practice is to compact or grout the cladding waste and store it for subsequent disposal in a geologic repository. This paper describes results of initial tests being performed with unirradiated, non-radioactive samples of various types of Zircaloy materials that are used in UNF cladding to develop the recovery process and determine the degree of purification that can be obtained. Future tests with actual radioactive UNF cladding are planned.« less

Nuclear fuel element

DOEpatents

Armijo, Joseph S.; Coffin, Jr., Louis F.

1983-01-01

A nuclear fuel element for use in the core of a nuclear reactor is disclosed and has a composite cladding having a substrate and a metal barrier metallurgically bonded on the inside surface of the substrate so that the metal barrier forms a shield between the substrate and the nuclear fuel material held within the cladding. The metal barrier forms about 1 to about 30 percent of the thickness of the cladding and is comprised of a low neutron absorption metal of substantially pure zirconium. The metal barrier serves as a preferential reaction site for gaseous impurities and fission products and protects the substrate from contact and reaction with such impurities and fission products. The substrate of the composite cladding is selected from conventional cladding materials and preferably is a zirconium alloy. Methods of manufacturing the composite cladding are also disclosed.

Advanced Steels for Accident Tolerant Fuel Cladding in Current Light Water Reactors

NASA Astrophysics Data System (ADS)

Rebak, Raul B.

After the March 2011 Fukushima events, the U.S. Congress directed the Department of Energy (DOE) to focus efforts on the development of fuel cladding materials with enhanced accident tolerance. In comparison with the stand-ard UO2-Zirconium based system, the new fuels need to tolerate loss of active cooling in the core for a considerably longer time period while maintaining or improving the fuel performance during normal operation conditions. Advanced steels such as iron-chromium-aluminum (FeCrAl) alloys are being investigated for degradation behavior both under normal operation conditions in high temperature water (e.g. 288°C) and under accident conditions for reaction with steam up to 1400°C. Commercial and experimental alloys were tested for several periods of time in 100% superheated steam from 800°C to 1475°C. Results show that FeCrAl alloys significantly outperform the resistance in steam of the current zirconium alloys.

Systematic technology evaluation program for SiC/SiC composite-based accident-tolerant LWR fuel cladding and core structures: Revision 2015

DOE Office of Scientific and Technical Information (OSTI.GOV)

Katoh, Yutai; Terrani, Kurt A.

2015-08-01

Fuels and core structures in current light water reactors (LWR’s) are vulnerable to catastrophic failure in severe accidents as unfortunately evidenced by the March 2011 Fukushima Dai-ichi Nuclear Power Plant Accident. This vulnerability is attributed primarily to the rapid oxidation kinetics of zirconium alloys in a water vapor environment at very high temperatures. Zr alloys are the primary material in LWR cores except for the fuel itself. Therefore, alternative materials with reduced oxidation kinetics as compared to zirconium alloys are sought to enable enhanced accident-tolerant fuels and cores.

White Paper Summary of 2nd ASTM International Workshop on Hydrides in Zirconium Alloy Cladding

DOE Office of Scientific and Technical Information (OSTI.GOV)

Sindelar, R.; Louthan, M.; PNNL, B.

2015-05-29

This white paper recommends that ASTM International develop standards to address the potential impact of hydrides on the long term performance of irradiated zirconium alloys. The need for such standards was apparent during the 2nd ASTM International Workshop on Hydrides in Zirconium Alloy Cladding and Assembly Components, sponsored by ASTM International Committee C26.13 and held on June 10-12, 2014, in Jackson, Wyoming. The potentially adverse impacts of hydrogen and hydrides on the long term performance of irradiated zirconium-alloy cladding on used fuel were shown to depend on multiple factors such as alloy chemistry and processing, irradiation and post irradiation history,more » residual and applied stresses and stress states, and the service environment. These factors determine the hydrogen content and hydride morphology in the alloy, which, in turn, influence the response of the alloy to the thermo-mechanical conditions imposed (and anticipated) during storage, transport and disposal of used nuclear fuel. Workshop presentations and discussions showed that although hydrogen/hydride induced degradation of zirconium alloys may be of concern, the potential for occurrence and the extent of anticipated degradation vary throughout the nuclear industry because of the variations in hydrogen content, hydride morphology, alloy chemistry and irradiation conditions. The tools and techniques used to characterize hydrides and hydride morphologies and their impacts on material performance also vary. Such variations make site-to-site comparisons of test results and observations difficult. There is no consensus that a single material or system characteristic (e.g., reactor type, burnup, hydrogen content, end-of life stress, alloy type, drying temperature, etc.) is an effective predictor of material response during long term storage or of performance after long term storage. Multi-variable correlations made for one alloy may not represent the behavior of another alloy exposed to identical conditions and the material responses to thermo-mechanical exposures will be different depending on the materials and systems used. The discussions at the workshop showed several gaps in the standardization of processes and techniques necessary to assess the long term performance of irradiated zirconium alloy cladding during dry storage and transport. The development of, and adherence to, standards to help bridge these gaps will strengthen the technical basis for long term storage and post-storage operations, provide consistency across the nuclear industry, maximize the value of most observations, and enhance the understanding of behavioral differences among alloys. The need for, and potential benefits of, developing the recommended standards are illustrated in the various sections of this report.« less

Protected Nuclear Fuel Element

DOEpatents

Kittel, J. H.; Schumar, J. F.

1962-12-01

A stainless steel-clad actinide metal fuel rod for use in fast reactors is reported. In order to prevert cladding failures due to alloy formation between the actinide metal and the stainless steel, a mesh-like sleeve of expanded metal is interposed between them, the sleeve metal being of niobium, tantalum, molybdenum, tungsten, zirconium, or vanadium. Liquid alkali metal is added as a heat transfer agent. (AEC)

Use of multiscale zirconium alloy deformation models in nuclear fuel behavior analysis

DOE Office of Scientific and Technical Information (OSTI.GOV)

Montgomery, Robert; Tomé, Carlos; Liu, Wenfeng

Accurate prediction of cladding mechanical behavior is a key aspect of modeling nuclear fuel behavior, especially for conditions of pellet-cladding interaction (PCI), reactivity-initiated accidents (RIA), and loss of coolant accidents (LOCA). Current approaches to fuel performance modeling rely on empirical models for cladding creep, growth and plastic deformation, which are limited to the materials and conditions for which the models were developed. CASL has endeavored to improve upon this approach by incorporating a microstructurally-based, atomistically-informed, zirconium alloy mechanical deformation analysis capability into the BISON-CASL engineering scale fuel performance code. Specifically, the viscoplastic self-consistent (VPSC) polycrystal plasticity modeling approach, developed bymore » Lebensohn and Tome´ [2], has been coupled with BISON-CASL to represent the mechanistic material processes controlling the deformation behavior of the cladding. A critical component of VPSC is the representation of the crystallographic orientation of the grains within the matrix material and the ability to account for the role of texture on deformation. The multiscale modeling of cladding deformation mechanisms allowed by VPSC far exceed the functionality of typical semi-empirical constitutive models employed in nuclear fuel behavior codes to model irradiation growth and creep, thermal creep, or plasticity. This paper describes the implementation of an interface between VPSC and BISON-CASL and provides initial results utilizing the coupled functionality.« less

Ceramic Coatings for Clad (The C 3 Project): Advanced Accident-Tolerant Ceramic Coatings for Zr-Alloy Cladding

DOE Office of Scientific and Technical Information (OSTI.GOV)

Sickafus, Kurt E.; Wirth, Brian; Miller, Larry

The goal of this NEUP-IRP project is to develop a fuel concept based on an advanced ceramic coating for Zr-alloy cladding. The coated cladding must exhibit demonstrably improved performance compared to conventional Zr-alloy clad in the following respects: During normal service, the ceramic coating should decrease cladding oxidation and hydrogen pickup (the latter leads to hydriding and embrittlement). During a reactor transient (e.g., a loss of coolant accident), the ceramic coating must minimize or at least significantly delay oxidation of the Zr-alloy cladding, thus reducing the amount of hydrogen generated and the oxygen ingress into the cladding. The specific objectivesmore » of this project are as follows: To produce durable ceramic coatings on Zr-alloy clad using two possible routes: (i) MAX phase ceramic coatings or similar nitride or carbide coatings; and (ii) graded interface architecture (multilayer) ceramic coatings, using, for instance, an oxide such as yttria-stabilized zirconia (YSZ) as the outer protective layer. To characterize the structural and physical properties of the coated clad samples produced in 1. above, especially the corrosion properties under simulated normal and transient reactor operating conditions. To perform computational analyses to assess the effects of such coatings on fuel performance and reactor neutronics, and to perform fuel cycle analyses to assess the economic viability of modifying conventional Zr-alloy cladding with ceramic coatings. This project meets a number of the goals outlined in the NEUP-IRP call for proposals, including: Improve the fuel/cladding system through innovative designs (e.g. coatings/liners for zirconium-based cladding) Reduce or eliminate hydrogen generation Increase resistance to bulk steam oxidation Achievement of our goals and objectives, as defined above, will lead to safer light-water reactor (LWR) nuclear fuel assemblies, due to improved cladding properties and built-in accident resistance, as well as the possibilities for enhanced fuel/clad system performance and longevity.« less

METHOD OF DISSOLVING REFRACTORY ALLOYS

DOEpatents

Helton, D.M.; Savolainen, J.K.

1963-04-23

This patent relates to the dissolution of alloys of uranium with zirconium, thorium, molybdenum, or niobium. The alloy is contacted with an anhydrous solution of mercuric chloride in a low-molecular-weight monohydric alcohol to produce a mercury-containing alcohol slurry. The slurry is then converted to an aqueous system by adding water and driving off the alcohol. The resulting aqueous slurry is electrolyzed in the presence of a mercury cathode to remove the mercury and produce a uranium-bearing aqueous solution. This process is useful for dissolving irradiated nuclear reactor fuels for radiochemical reprocessing by solvent extraction. In addition, zirconium-alloy cladding is selectively removed from uranium dioxide fuel compacts by this means. (AEC)

Electrochemical Study of Corrosion Phenomena in Zirconium Alloys

DTIC Science & Technology

2005-06-01

required reaction rates [1.1]. Based predominantly on this fact, zirconium alloys were chosen to sheath, or clad, the fuel. With the increasing demand...cathode or anode. As the oxidation and reduction reactions occur, a galvanic cell is developed. The electrons on the anode are released from the metallic...matrix as the ions are released into the aqueous solution in the initial half-cell reaction . The second half-cell reaction , taking place on the

Development and property evaluation of nuclear grade wrought FeCrAl fuel cladding for light water reactors

DOE PAGES

Yamamoto, Yukinori; Pint, Bruce A.; Terrani, Kurt A.; ...

2015-10-19

Development of nuclear grade, iron-based wrought FeCrAl alloys has been initiated for light water reactor (LWR) fuel cladding to serve as a substitute for zirconium-based alloys with enhanced accident tolerance. Ferritic alloys with sufficient chromium and aluminum additions can exhibit significantly improved oxidation kinetics in high-temperature steam environments when compared to zirconium-based alloys. In the first phase, a set of model FeCrAl alloys containing 10–20Cr, 3–5Al, and 0–0.12Y in weight percent, were prepared by conventional arc-melting and hot-working processes to explore the effect of composition on the properties of FeCrAlY alloys. It was found that the tensile properties were insensitivemore » to the alloy compositions studied; however, the steam oxidation resistance strongly depended on both the chromium and the aluminum contents. The second phase development focused on strengthening Fe-13Cr-5Al with minor alloying additions of molybdenum, niobium, and silicon. Combined with an optimized thermo-mechanical treatment, a thermally stable microstructure was produced with improved tensile properties at temperatures up to 741°C.« less

Overview of the multifaceted activities towards development and deployment of nuclear-grade FeCrAl Alloys

DOE Office of Scientific and Technical Information (OSTI.GOV)

Field, Kevin G; Yamamoto, Yukinori; Pint, Bruce A

2016-01-01

A large effort is underway under the leadership of US DOE Fuel Cycle R&D program to develop advanced FeCrAl alloys as accident tolerant fuel (ATF) cladding to replace Zr-based alloys in light water reactors. The primary motivation is the excellent oxidation resistance of these alloys in high-temperature steam environments right up to their melting point (roughly three orders of magnitude slower oxidation kinetics than zirconium). A multifaceted effort is ongoing to rapidly advance FeCrAl alloys as a mature ATF concept. The activities span the broad spectrum of alloy development, environmental testing (high-temperature high-pressure water and elevated temperature steam), detailed mechanicalmore » characterization, material property database development, neutron irradiation, thin tube production, and multiple integral fuel test campaigns. Instead of off-the-shelf commercial alloys that might not prove optimal for the LWR fuel cladding application, a large amount of effort has been placed on the alloy development to identify the most optimum composition and microstructure for this application. The development program is targeting a cladding that offers performance comparable to or better than modern Zr-based alloys under normal operating and off-normal conditions. This paper provides a comprehensive overview of the systematic effort to advance nuclear-grade FeCrAl alloys as an ATF cladding in commercial LWRs.« less

Surface modification techniques for increased corrosion tolerance of zirconium fuel cladding

NASA Astrophysics Data System (ADS)

Carr, James Patrick, IV

Corrosion is a major issue in applications involving materials in normal and severe environments, especially when it involves corrosive fluids, high temperatures, and radiation. Left unaddressed, corrosion can lead to catastrophic failures, resulting in economic and environmental liabilities. In nuclear applications, where metals and alloys, such as steel and zirconium, are extensively employed inside and outside of the nuclear reactor, corrosion accelerated by high temperatures, neutron radiation, and corrosive atmospheres, corrosion becomes even more concerning. The objectives of this research are to study and develop surface modification techniques to protect zirconium cladding by the incorporation of a specific barrier coating, and to understand the issues related to the compatibility of the coatings examined in this work. The final goal of this study is to recommend a coating and process that can be scaled-up for the consideration of manufacturing and economic limits. This dissertation study builds on previous accident tolerant fuel cladding research, but is unique in that advanced corrosion methods are tested and considerations for implementation by industry are practiced and discussed. This work will introduce unique studies involving the materials and methods for accident tolerant fuel cladding research by developing, demonstrating, and considering materials and processes for modifying the surface of zircaloy fuel cladding. This innovative research suggests that improvements in the technique to modify the surface of zirconium fuel cladding are likely. Three elements selected for the investigation of their compatibility on zircaloy fuel cladding are aluminum, silicon, and chromium. These materials are also currently being investigated at other labs as alternate alloys and coatings for accident tolerant fuel cladding. This dissertation also investigates the compatibility of these three elements as surface modifiers, by comparing their microstructural and mechanical properties. To test their application for use in corrosive atmospheres, the corrosion behaviors are also compared in steam, water, and boric-acid environments. Various methods of surface modification were attempted in this investigation, including dip coating, diffusion bonding, casting, sputtering, and evaporation. The benefits and drawbacks of each method are discussed with respect to manufacturing and economic limits. Characterization techniques utilized in this work include optical microscopy, scanning electron microscopy, energy-dispersive spectroscopy, X-ray diffraction, nanoindentation, adhesion testing, and atomic force microscopy. The composition, microstructure, hardness, modulus, and coating adhesion were studied to provide encompassing properties to determine suitable comparisons and to choose an ideal method to scale to industrial applications. The experiments, results, and detailed discussions are presented in the following chapters of this dissertation research.

Reactivity Initiated Accident Simulation to Inform Transient Testing of Candidate Advanced Cladding

DOE Office of Scientific and Technical Information (OSTI.GOV)

Brown, Nicholas R; Wysocki, Aaron J; Terrani, Kurt A

2016-01-01

Abstract. Advanced cladding materials with potentially enhanced accident tolerance will yield different light water reactor performance and safety characteristics than the present zirconium-based cladding alloys. These differences are due to different cladding material properties and responses to the transient, and to some extent, reactor physics, thermal, and hydraulic characteristics. Some of the differences in reactors physics characteristics will be driven by the fundamental properties (e.g., absorption in iron for an iron-based cladding) and others will be driven by design modifications necessitated by the candidate cladding materials (e.g., a larger fuel pellet to compensate for parasitic absorption). Potential changes in thermalmore » hydraulic limits after transition from the current zirconium-based cladding to the advanced materials will also affect the transient response of the integral fuel. This paper leverages three-dimensional reactor core simulation capabilities to inform on appropriate experimental test conditions for candidate advanced cladding materials in a control rod ejection event. These test conditions are using three-dimensional nodal kinetics simulations of a reactivity initiated accident (RIA) in a representative state-of-the-art pressurized water reactor with both nuclear-grade iron-chromium-aluminum (FeCrAl) and silicon carbide based (SiC-SiC) cladding materials. The effort yields boundary conditions for experimental mechanical tests, specifically peak cladding strain during the power pulse following the rod ejection. The impact of candidate cladding materials on the reactor kinetics behavior of RIA progression versus reference zirconium cladding is predominantly due to differences in: (1) fuel mass/volume/specific power density, (2) spectral effects due to parasitic neutron absorption, (3) control rod worth due to hardened (or softened) spectrum, and (4) initial conditions due to power peaking and neutron transport cross sections in the equilibrium cycle cores due to hardened (or softened) spectrum. This study shows minimal impact of SiC-based cladding configurations on the transient response versus reference zirconium-based cladding. However, the FeCrAl cladding response indicates similar energy deposition, but with significantly shorter pulses of higher magnitude. Therefore the FeCrAl-based cases have a more rapid fuel thermal expansion rate and the resultant pellet-cladding interaction occurs more rapidly.« less

BISON Fuel Performance Analysis of FeCrAl cladding with updated properties

DOE Office of Scientific and Technical Information (OSTI.GOV)

Sweet, Ryan; George, Nathan M.; Terrani, Kurt A.

2016-08-30

In order to improve the accident tolerance of light water reactor (LWR) fuel, alternative cladding materials have been proposed to replace zirconium (Zr)-based alloys. Of these materials, there is a particular focus on iron-chromium-aluminum (FeCrAl) alloys due to much slower oxidation kinetics in high-temperature steam than Zr-alloys. This should decrease the energy release due to oxidation and allow the cladding to remain integral longer in the presence of high temperature steam, making accident mitigation more likely. As a continuation of the development for these alloys, suitability for normal operation must also be demonstrated. This research is focused on modeling themore » integral thermo-mechanical performance of FeCrAl-cladded fuel during normal reactor operation. Preliminary analysis has been performed to assess FeCrAl alloys (namely Alkrothal 720 and APMT) as a suitable fuel cladding replacement for Zr-alloys, using the MOOSE-based, finite-element fuel performance code BISON and the best available thermal-mechanical and irradiation-induced constitutive properties. These simulations identify the effects of the mechanical-stress and irradiation response of FeCrAl, and provide a comparison with Zr-alloys. In comparing these clad materials, fuel rods have been simulated for normal reactor operation and simple steady-state operation. Normal reactor operating conditions target the cladding performance over the rod lifetime (~4 cycles) for the highest-power rod in the highest-power fuel assembly under reactor power maneuvering. The power histories and axial temperature profiles input into BISON were generated from a neutronics study on full-core reactivity equivalence for FeCrAl using the 3D full core simulator NESTLE. Evolution of the FeCrAl cladding behavior over time is evaluated by using steady-state operating conditions such as a simple axial power profile, a constant cladding surface temperature, and a constant fuel power history. The fuel rod designs and operating conditions used are based off the Peach Bottom BWR and design consideration was given to minimize the neutronic penalty of the FeCrAl cladding by changing fuel enrichment and cladding thickness. As this study progressed, systematic parametric analysis of the fuel and cladding creep responses were also performed.« less

Use of multiscale zirconium alloy deformation models in nuclear fuel behavior analysis

NASA Astrophysics Data System (ADS)

Montgomery, Robert; Tomé, Carlos; Liu, Wenfeng; Alankar, Alankar; Subramanian, Gopinath; Stanek, Christopher

2017-01-01

Accurate prediction of cladding mechanical behavior is a key aspect of modeling nuclear fuel behavior, especially for conditions of pellet-cladding interaction (PCI), reactivity-initiated accidents (RIA), and loss of coolant accidents (LOCA). Current approaches to fuel performance modeling rely on empirical constitutive models for cladding creep, growth and plastic deformation, which are limited to the materials and conditions for which the models were developed. To improve upon this approach, a microstructurally-based zirconium alloy mechanical deformation analysis capability is being developed within the United States Department of Energy Consortium for Advanced Simulation of Light Water Reactors (CASL). Specifically, the viscoplastic self-consistent (VPSC) polycrystal plasticity modeling approach, developed by Lebensohn and Tomé [1], has been coupled with the BISON engineering scale fuel performance code to represent the mechanistic material processes controlling the deformation behavior of light water reactor (LWR) cladding. A critical component of VPSC is the representation of the crystallographic nature (defect and dislocation movement) and orientation of the grains within the matrix material and the ability to account for the role of texture on deformation. A future goal is for VPSC to obtain information on reaction rate kinetics from atomistic calculations to inform the defect and dislocation behavior models described in VPSC. The multiscale modeling of cladding deformation mechanisms allowed by VPSC far exceed the functionality of typical semi-empirical constitutive models employed in nuclear fuel behavior codes to model irradiation growth and creep, thermal creep, or plasticity. This paper describes the implementation of an interface between VPSC and BISON and provides initial results utilizing the coupled functionality.

ZIRCONIUM-CLADDING OF THORIUM

DOEpatents

Beaver, R.J.

1961-11-21

A method of cladding thorium with zirconium is described. The quality of the bond achieved between thorium and zirconium by hot-rolling is improved by inserting and melting a thorium-zirconium alloy foil between the two materials prior to rolling. (AEC)

Continuum model for hydrogen pickup in zirconium alloys of LWR fuel cladding

NASA Astrophysics Data System (ADS)

Wang, Xing; Zheng, Ming-Jie; Szlufarska, Izabela; Morgan, Dane

2017-04-01

A continuum model for calculating the time-dependent hydrogen pickup fractions in various Zirconium alloys under steam and pressured water oxidation has been developed in this study. Using only one fitting parameter, the effective hydrogen gas partial pressure at the oxide surface, a qualitative agreement is obtained between the predicted and previously measured hydrogen pickup fractions. The calculation results therefore demonstrate that H diffusion through the dense oxide layer plays an important role in the hydrogen pickup process. The limitations and possible improvement of the model are also discussed.

Structure and Thermodynamical Properties of Zirconium Hydrides from First-Principle

NASA Astrophysics Data System (ADS)

Blomqvist, Jakob; Olofsson, Johan; Alvarez, Anna-Maria; Bjerkén, Christina

Zirconium alloys are used as nuclear fuel cladding material due to their mechanical and corrosion resistant properties together with their favorable cross-section for neutron scattering. At running conditions, however, there will be an increase of hydrogen in the vicinity of the cladding surface at the water side of the fuel. The hydrogen will diffuse into the cladding material and at certain conditions, such as lower temperatures and external load, hydrides will precipitate out in the material and cause well known embrittlement, blistering and other unwanted effects. Using phase-field methods it is now possible to model precipitation buildup in metals, for example as a function of hydrogen concentration, temperature and external load, but the technique relies on input of parameters, such as the formation energy of the hydrides and matrix. To that end, we have computed, using the density functional theory (DFT) code GPAW, the latent heat of fusion as well as solved the crystal structure for three zirconium hydride polymorphs: δ-ZrH1.6, γ-ZrH, and Є-ZrH2.

Mechanical behavior of aluminum-bearing ferritic alloys for accident-tolerant fuel cladding applications

NASA Astrophysics Data System (ADS)

Guria, Ankan

Nuclear power currently provides about 13% of electrical power worldwide. Nuclear reactors generating this power traditionally use Zirconium (Zr) based alloys as the fuel cladding material. Exothermic reaction of Zr with steam under accident conditions may lead to production of hydrogen with the possibility of catastrophic consequences. Following the Fukushima-Daiichi incident, the exploration of accident-tolerant fuel cladding materials accelerated. Aluminum-rich (around 5 wt. %) ferritic steels such as Fecralloy, APMT(TM) and APM(TM) are considered as potential materials for accident-tolerant fuel cladding applications. These materials create an aluminum-based oxide scale protecting the alloy at elevated temperatures. Tensile deformation behavior of the above alloys was studied at different temperatures (25-500 °C) at a strain rate of 10-3 s-1 and correlated with microstructural characteristics. Higher strength and decent ductility of APMT(TM) led to further investigation of the alloy at various combination of strain rates and temperatures followed by fractography and detailed microscopic analyses. Serrations appeared in the stress-strain curves of APMT(TM) and Fecralloy steel tested in a limited temperature range (250-400 °C). The appearance of serrations is explained on the basis of dynamic strain aging (DSA) effect due to solute-dislocation interactions. The research in this study is being performed using the funds received from the US DOE Office of Nuclear Energy's Nuclear Energy University Programs (NEUP).

Use of multiscale zirconium alloy deformation models in nuclear fuel behavior analysis

DOE Office of Scientific and Technical Information (OSTI.GOV)

Montgomery, Robert, E-mail: robert.montgomery@pnnl.gov; Tomé, Carlos, E-mail: tome@lanl.gov; Liu, Wenfeng, E-mail: wenfeng.liu@anatech.com

Accurate prediction of cladding mechanical behavior is a key aspect of modeling nuclear fuel behavior, especially for conditions of pellet-cladding interaction (PCI), reactivity-initiated accidents (RIA), and loss of coolant accidents (LOCA). Current approaches to fuel performance modeling rely on empirical constitutive models for cladding creep, growth and plastic deformation, which are limited to the materials and conditions for which the models were developed. To improve upon this approach, a microstructurally-based zirconium alloy mechanical deformation analysis capability is being developed within the United States Department of Energy Consortium for Advanced Simulation of Light Water Reactors (CASL). Specifically, the viscoplastic self-consistent (VPSC)more » polycrystal plasticity modeling approach, developed by Lebensohn and Tomé [1], has been coupled with the BISON engineering scale fuel performance code to represent the mechanistic material processes controlling the deformation behavior of light water reactor (LWR) cladding. A critical component of VPSC is the representation of the crystallographic nature (defect and dislocation movement) and orientation of the grains within the matrix material and the ability to account for the role of texture on deformation. A future goal is for VPSC to obtain information on reaction rate kinetics from atomistic calculations to inform the defect and dislocation behavior models described in VPSC. The multiscale modeling of cladding deformation mechanisms allowed by VPSC far exceed the functionality of typical semi-empirical constitutive models employed in nuclear fuel behavior codes to model irradiation growth and creep, thermal creep, or plasticity. This paper describes the implementation of an interface between VPSC and BISON and provides initial results utilizing the coupled functionality.« less

The influence of cladding on fission gas release from irradiated U-Mo monolithic fuel

NASA Astrophysics Data System (ADS)

Burkes, Douglas E.; Casella, Amanda J.; Casella, Andrew M.

2017-04-01

The monolithic uranium-molybdenum (U-Mo) alloy has been proposed as a fuel design capable of converting the world's highest power research reactors from use of high enriched uranium to low enriched uranium. However, a zirconium (Zr) diffusion barrier must be used to eliminate interactions that form between the U-Mo monolith and aluminum alloy 6061 (AA6061) cladding during fabrication and are enhanced during irradiation. One aspect of fuel development and qualification is to demonstrate an appropriate understanding of the extent of fission product release from the fuel under anticipated service environments. An exothermic reaction has previously been observed between the AA6061 cladding and Zr diffusion layer. In this paper, two fuel segments with different irradiation history were subjected to specified thermal profiles under a controlled atmosphere using a thermogravimetric/differential thermal analyzer coupled with a mass spectrometer inside a hot cell. Samples from each segment were tested with cladding and without cladding to investigate the effect, if any, that the exothermic reaction has on fission gas release mechanisms. Measurements revealed there is an instantaneous effect of the cladding/Zr exothermic reaction, but not necessarily a cumulative effect above approximately 973 K (700 °C). The mechanisms responsible for fission gas release events are discussed.

The influence of cladding on fission gas release from irradiated U-Mo monolithic fuel

DOE Office of Scientific and Technical Information (OSTI.GOV)

Burkes, Douglas E.; Casella, Amanda J.; Casella, Andrew M.

2017-04-01

The monolithic uranium-molybdenum (U-Mo) alloy has been proposed as a fuel design capable of converting the world’s highest power research reactors from use of high enriched uranium to low enriched uranium. However, a zirconium (Zr) diffusion barrier must be used to eliminate interactions that form during fabrication and are enhanced during irradiation between the U-Mo monolith and aluminum alloy 6061 (AA6061) cladding. One aspect of fuel development and qualification is to demonstrate appropriate understanding of the extent of fission product release from the fuel under anticipated service environments. An exothermic reaction has previously been observed between the AA6061 cladding andmore » Zr diffusion layer. In this paper, two fuel segments with different irradiation history were subjected to specified thermal profiles under a controlled atmosphere using a thermogravimetric/differential thermal analyzer coupled with a mass spectrometer inside a hot cell. Samples from each segment were tested with cladding and without cladding to investigate the effect, if any, that the exothermic reaction has on fission gas release mechanisms. Measurements revealed there is an instantaneous effect of the cladding/Zr exothermic reaction, but not necessarily a cumulative effect above approximately 973 K (700 oC). The mechanisms responsible for fission gas release events are discussed.« less

Nanocrystalline diamond protects Zr cladding surface against oxygen and hydrogen uptake: Nuclear fuel durability enhancement.

PubMed

Škarohlíd, Jan; Ashcheulov, Petr; Škoda, Radek; Taylor, Andrew; Čtvrtlík, Radim; Tomáštík, Jan; Fendrych, František; Kopeček, Jaromír; Cháb, Vladimír; Cichoň, Stanislav; Sajdl, Petr; Macák, Jan; Xu, Peng; Partezana, Jonna M; Lorinčík, Jan; Prehradná, Jana; Steinbrück, Martin; Kratochvílová, Irena

2017-07-25

In this work, we demonstrate and describe an effective method of protecting zirconium fuel cladding against oxygen and hydrogen uptake at both accident and working temperatures in water-cooled nuclear reactor environments. Zr alloy samples were coated with nanocrystalline diamond (NCD) layers of different thicknesses, grown in a microwave plasma chemical vapor deposition apparatus. In addition to showing that such an NCD layer prevents the Zr alloy from directly interacting with water, we show that carbon released from the NCD film enters the underlying Zr material and changes its properties, such that uptake of oxygen and hydrogen is significantly decreased. After 100-170 days of exposure to hot water at 360 °C, the oxidation of the NCD-coated Zr plates was typically decreased by 40%. Protective NCD layers may prolong the lifetime of nuclear cladding and consequently enhance nuclear fuel burnup. NCD may also serve as a passive element for nuclear safety. NCD-coated ZIRLO claddings have been selected as a candidate for Accident Tolerant Fuel in commercially operated reactors in 2020.

Irradiation effects on thermal properties of LWR hydride fuel

NASA Astrophysics Data System (ADS)

Terrani, Kurt; Balooch, Mehdi; Carpenter, David; Kohse, Gordon; Keiser, Dennis; Meyer, Mitchell; Olander, Donald

2017-04-01

Three hydride mini-fuel rods were fabricated and irradiated at the MIT nuclear reactor with a maximum burnup of 0.31% FIMA or ∼5 MWd/kgU equivalent oxide fuel burnup. Fuel rods consisted of uranium-zirconium hydride (U (30 wt%)ZrH1.6) pellets clad inside a LWR Zircaloy-2 tubing. The gap between the fuel and the cladding was filled with lead-bismuth eutectic alloy to eliminate the gas gap and the large temperature drop across it. Each mini-fuel rod was instrumented with two thermocouples with tips that are axially located halfway through the fuel centerline and cladding surface. In-pile temperature measurements enabled calculation of thermal conductivity in this fuel as a function of temperature and burnup. In-pile thermal conductivity at the beginning of test agreed well with out-of-pile measurements on unirradiated fuel and decreased rapidly with burnup.

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

DOE Office of Scientific and Technical Information (OSTI.GOV)

Wirth, Brian; Terrani, Kurt A.; Sweet, Ryan T.

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

Nuclear fuel alloys or mixtures and method of making thereof

DOEpatents

Mariani, Robert Dominick; Porter, Douglas Lloyd

2016-04-05

Nuclear fuel alloys or mixtures and methods of making nuclear fuel mixtures are provided. Pseudo-binary actinide-M fuel mixtures form alloys and exhibit: body-centered cubic solid phases at low temperatures; high solidus temperatures; and/or minimal or no reaction or inter-diffusion with steel and other cladding materials. Methods described herein through metallurgical and thermodynamics advancements guide the selection of amounts of fuel mixture components by use of phase diagrams. Weight percentages for components of a metallic additive to an actinide fuel are selected in a solid phase region of an isothermal phase diagram taken at a temperature below an upper temperature limit for the resulting fuel mixture in reactor use. Fuel mixtures include uranium-molybdenum-tungsten, uranium-molybdenum-tantalum, molybdenum-titanium-zirconium, and uranium-molybdenum-titanium systems.

DOE Office of Scientific and Technical Information (OSTI.GOV)

Wood, Elizabeth Sooby; Parker, Stephen Scott; Nelson, Andrew Thomas

The Fuel Cycle Research and Development program’s Advanced Fuels Campaign is currently supporting a range of experimental efforts aimed at the development and qualification of ‘accident tolerant’ nuclear fuel forms. One route to enhance the accident tolerance of nuclear fuel is to replace the zirconium alloy cladding, which is prone to rapid oxidation in steam at elevated temperatures, with a more oxidation-resistant cladding. Several cladding replacement solutions have been envisaged. The cladding can be completely replaced with a more oxidation resistant alloy, a layered approach can be used to optimize the strength, creep resistance, and oxidation tolerance of various materials,more » or the existing zirconium alloy cladding can be coated with a more oxidation-resistant material. Molybdenum is one candidate cladding material favored due to its high temperature creep resistance. However, it performs poorly under autoclave testing and suffers degradation under high temperature steam oxidation exposure. Development of composite cladding architectures consisting of a molybdenum core shielded by a molybdenum disilicide (MoSi 2) coating is hypothesized to improve the performance of a Mo-based cladding system. MoSi 2 was identified based on its high temperature oxidation resistance in O 2 atmospheres (e.g. air and “wet air”). However, its behavior in H 2O is less known. This report presents thermogravimetric analysis (TGA), scanning electron microscopy (SEM), and x-ray diffraction (XRD) results for MoSi 2 exposed to 670-1498 K water vapor. Synthetic air (80-20%, Ar-O 2) exposures were also performed, and those results are presented here for a comparative analysis. It was determined that MoSi 2 displays drastically different oxidation behavior in water vapor than in dry air. In the 670-1498 K temperature range, four distinct behaviors are observed. Parabolic oxidation is exhibited in only 670-773 K water vapor, a temperature range in which the material pests in dry O 2 environments. From 877-1084 K in water vapor, MoSi 2 undergoes rapid mass gain resulting in oxidation throughout the bulk of the sample at 980 K and 1084 K. The resulting material displays swelling and warping after the 980-1084 K exposures. A pre-passivation heat treatment performed at 1395 K was found capable of producing a coarse SiO 2 layer that limited pesting at lower temperatures in water vapor over the time periods investigated.« less

Alloy Selection for Accident Tolerant Fuel Cladding in Commercial Light Water Reactors

NASA Astrophysics Data System (ADS)

Rebak, Raul B.

2015-12-01

As a consequence of the March 2011 events at the Fukushima site, the U.S. congress asked the Department of Energy (DOE) to concentrate efforts on the development of nuclear fuels with enhanced accident tolerance. The new fuels had to maintain or improve the performance of current UO2-zirconium alloy rods during normal operation conditions and tolerate the loss of active cooling in the core for a considerably longer time period than the current system. DOE is funding cost-shared research to investigate the behavior of advanced steels both under normal operation conditions in high-temperature water [ e.g., 561 K (288 °C)] and under accident conditions for reaction with superheated steam. Current results show that, under accident conditions, the advanced ferritic steels (1) have orders of magnitude lower reactivity with steam, (2) would generate less hydrogen and heat than the current zirconium alloys, (3) are resistant to stress corrosion cracking under normal operation conditions, and (4) have low general corrosion in water at 561 K (288 °C).

Layer Protecting the Surface of Zirconium Used in Nuclear Reactors.

PubMed

Ashcheulov, Petr; Skoda, Radek; Skarohlíd, Jan; Taylor, Andrew; Fendrych, Frantisek; Kratochvílová, Irena

2016-01-01

Zirconium alloys have very useful properties for nuclear facilities applications having low absorption cross-section of thermal electrons, high ductility, hardness and corrosion resistance. However, there is also a significant disadvantage: it reacts with water steam and during this (oxidative) reaction it releases hydrogen gas, which partly diffuses into the alloy forming zirconium hydrides. A new strategy for surface protection of zirconium alloys against undesirable oxidation in nuclear reactors by polycrystalline diamond film has been patented- Czech patent 305059: Layer protecting the surface of zirconium alloys used in nuclear reactors and PCT patent: Layer for protecting surface of zirconium alloys (Patent Number: WO2015039636-A1). The zirconium alloy surface was covered by polycrystalline diamond layer grown in plasma enhanced chemical vapor deposition apparatus with linear antenna delivery system. Substantial progress in the description and understanding of the polycrystalline diamond/ zirconium alloys interface and material properties under standard and nuclear reactors conditions (irradiation, hot steam oxidation experiments and heating-quenching cycles) was made. In addition, process technology for the deposition of protective polycrystalline diamond films onto the surface of zirconium alloys was optimized. Zircaloy2 nuclear fuel pins were covered by 300 nm thick protective polycrystalline diamond layer (PCD) using plasma enhanced chemical vapor deposition apparatus with linear antenna delivery system. The polycrystalline diamond layer protects the zirconium alloy surface against undesirable oxidation and consolidates its chemical stability while preserving its functionality. PCD covered Zircaloy2 and standard Zircaloy2 pins were for 30 min. oxidized in 1100°C hot steam. Under these conditions α phase of zirconium changes to β phase (more opened for oxygen/hydrogen diffusion). PCD anticorrosion protection of Zircaloy nuclear fuel assemblies can significantly prolong lifetime of Zirconium alloy in nuclear reactors even above Zirconium phase transition temperatures. Even after ion beam irradiation (10 dpa, 3 MeV Fe(2+)) the diamond film still shows satisfactory structural integrity with both sp(3) and sp(2) carbon phases. Zircaloy2 under the carbon-based protective layer after hot steam oxidation test differed from the original Zircaloy2 material composition only very slightly, proving that the diamond coating increases the material resistance to high temperature oxidation. Zirconium alloys nuclear fuel pins' surfaces were covered by compact and homogeneous polycrystalline diamond layers consisting of sp(3) and sp(2) carbon phases with a high crystalline diamond content and low roughness. Diamond withstands very high temperatures, has excellent thermal conductivity and low chemical reactivity, it does not degrade over time and (important for the nuclear fuel cladding) being pure carbon, it has perfect neutron cross-section properties. Moreover, polycrystalline diamond layers consisting of crystalline (sp(3)) and amorphous (sp(2)) carbon phases could have suitable thermal expansion. Zirconium alloys coated with polycrystalline diamond film are protected against undesirable changes and processes. Further, the polycrystalline diamond layer prevents the reaction between the alloy surface and water vapor. During such reaction, water molecules dissociate and initiate formation of zirconium dioxide and hydrogen, accompanied by the release of large amount of heat. Thus the protective layer prevents the formation of hydrogen and the release of reaction heat. Few relevant patents to the topic have been reviewed and cited.

A study into the impact of interface roughness development on mechanical degradation of oxides formed on zirconium alloys

NASA Astrophysics Data System (ADS)

Platt, P.; Wedge, S.; Frankel, P.; Gass, M.; Howells, R.; Preuss, M.

2015-04-01

As a cladding material used to encapsulate nuclear fuel pellets, zirconium alloys are the primary barrier separating the fuel and a pressurised steam or lithiated water environment. Degradation mechanisms such as oxidation can be the limiting factor in the life-time of the fuel assembly. Key to controlling oxidation, and therefore allowing increased burn-up of fuel, is the development of a mechanistic understanding of the corrosion process. In an autoclave, the oxidation kinetics for zirconium alloys are typically cyclical, with periods of accelerated kinetics being observed in steps of ∼2 μm oxide growth. These periods of accelerated oxidation are immediately preceded by the development of a layer of lateral cracks near the metal-oxide interface, which may be associated with the development of interface roughness. The present work uses scanning electron microscopy to carry out a statistical analysis of changes in the metal-oxide interface roughness between three different alloys at different stages of autoclave oxidation. The first two alloys are Zircaloy-4 and ZIRLO™ for which analysis is carried out at stages before, during and after first transition. The third alloy is an experimental low tin alloy, which under the same oxidation conditions and during the same time period does not appear to go through transition. Assessment of the metal-oxide interface roughness is primarily carried out based on the root mean square of the interface slope known as the Rdq parameter. Results show clear trends with relation to transition points in the corrosion kinetics. Discussion is given to how this relates to the existing mechanistic understanding of the corrosion process, and the components required for possible future modelling approaches.

Results of NDE Technique Evaluation of Clad Hydrides

DOE Office of Scientific and Technical Information (OSTI.GOV)

Kunerth, Dennis C.

2014-09-01

This report fulfills the M4 milestone, M4FT-14IN0805023, Results of NDE Technique Evaluation of Clad Hydrides, under Work Package Number FT-14IN080502. During service, zirconium alloy fuel cladding will degrade via corrosion/oxidation. Hydrogen, a byproduct of the oxidation process, will be absorbed into the cladding and eventually form hydrides due to low hydrogen solubility limits. The hydride phase is detrimental to the mechanical properties of the cladding and therefore it is important to be able to detect and characterize the presence of this constituent within the cladding. Presently, hydrides are evaluated using destructive examination. If nondestructive evaluation techniques can be used tomore » detect and characterize the hydrides, the potential exists to significantly increase test sample coverage while reducing evaluation time and cost. To demonstrate the viability this approach, an initial evaluation of eddy current and ultrasonic techniques were performed to demonstrate the basic ability to these techniques to detect hydrides or their effects on the microstructure. Conventional continuous wave eddy current techniques were applied to zirconium based cladding test samples thermally processed with hydrogen gas to promote the absorption of hydrogen and subsequent formation of hydrides. The results of the evaluation demonstrate that eddy current inspection approaches have the potential to detect both the physical damage induced by hydrides, e.g. blisters and cracking, as well as the combined effects of absorbed hydrogen and hydride precipitates on the electrical properties of the zirconium alloy. Similarly, measurements of ultrasonic wave velocities indicate changes in the elastic properties resulting from the combined effects of absorbed hydrogen and hydride precipitates as well as changes in geometry in regions of severe degradation. However, for both approaches, the signal responses intended to make the desired measurement incorporate a number of contributing parameters. These contributing factors need to be recognized and a means to control them or separate their contributions will be required to obtain the desired information.« less

Plasma electrolytic oxidation treatment mode influence on corrosion properties of coatings obtained on Zr-1Nb alloy in silicate-phosphate electrolyte

NASA Astrophysics Data System (ADS)

Farrakhov, R. G.; Mukaeva, V. R.; Fatkullin, A. R.; Gorbatkov, M. V.; Tarasov, P. V.; Lazarev, D. M.; Babu, N. Ramesh; Parfenov, E. V.

2018-01-01

This research is aimed at improvement of corrosion properties for Zr-1Nb alloy via plasma electrolytic oxidation (PEO). The coatings obtained in DC, pulsed unipolar and pulsed bipolar modes were assessed using SEM, XRD, PDP and EIS techniques. It was shown that pulsed unipolar mode provides the PEO coatings having promising combination of the coating thickness, surface roughness, porosity, corrosion potential and current density, and charge transfer resistance, all contributing to corrosion protection of the zirconium alloy for advanced fuel cladding applications.

Evaluation of a Zirconium Recycle Scrubber System

DOE Office of Scientific and Technical Information (OSTI.GOV)

Spencer, Barry B.; Bruffey, Stephanie H.

2017-04-01

A hot-cell demonstration of the zirconium recycle process is planned as part of the Materials Recovery and Waste Forms Development (MRWFD) campaign. The process treats Zircaloy® cladding recovered from used nuclear fuel with chlorine gas to recover the zirconium as volatile ZrCl4. This releases radioactive tritium trapped in the alloy, converting it to volatile tritium chloride (TCl). To meet regulatory requirements governing radioactive emissions from nuclear fuel treatment operations, the capture and retention of a portion of this TCl may be required prior to discharge of the off-gas stream to the environment. In addition to demonstrating tritium removal from amore » synthetic zirconium recycle off-gas stream, the recovery and quantification of tritium may refine estimates of the amount of tritium present in the Zircaloy cladding of used nuclear fuel. To support these objectives, a bubbler-type scrubber was fabricated to remove the TCl from the zirconium recycle off-gas stream. The scrubber was fabricated from glass and polymer components that are resistant to chlorine and hydrochloric acid solutions. Because of concerns that the scrubber efficiency is not quantitative, tests were performed using DCl as a stand-in to experimentally measure the scrubbing efficiency of this unit. Scrubbing efficiency was ~108% ± 3% with water as the scrubber solution. Variations were noted when 1 M NaOH scrub solution was used, values ranged from 64% to 130%. The reason for the variations is not known. It is recommended that the equipment be operated with water as the scrubbing solution. Scrubbing efficiency is estimated at 100%.« less

Parametric and experimentally informed BWR Severe Accident Analysis Utilizing FeCrAl - M3FT-17OR020205041

DOE Office of Scientific and Technical Information (OSTI.GOV)

Ott, Larry J.; Howell, Michael; Robb, Kevin R.

Iron-chromium-aluminum (FeCrAl) alloys are being considered as advanced fuel cladding concepts with enhanced accident tolerance. At high temperatures, FeCrAl alloys have slower oxidation kinetics and higher strength compared with zirconium-based alloys. FeCrAl could be used for fuel cladding and spacer or mixing vane grids in light water reactors and/or as channel box material in boiling water reactors (BWRs). There is a need to assess the potential gains afforded by the FeCrAl accident-tolerant-fuel (ATF) concept over the existing zirconium-based materials employed today. To accurately assess the response of FeCrAl alloys under severe accident conditions, a number of FeCrAl properties and characteristicsmore » are required. These include thermophysical properties as well as burst characteristics, oxidation kinetics, possible eutectic interactions, and failure temperatures. These properties can vary among different FeCrAl alloys. Oak Ridge National Laboratory has pursued refined values for the oxidation kinetics of the B136Y FeCrAl alloy (Fe-13Cr-6Al wt %). This investigation included oxidation tests with varying heating rates and end-point temperatures in a steam environment. The rate constant for the low-temperature oxidation kinetics was found to be higher than that for the commercial APMT FeCrAl alloy (Fe-21Cr-5Al-3Mo wt %). Compared with APMT, a 5 times higher rate constant best predicted the entire dataset (root mean square deviation). Based on tests following heating rates comparable with those the cladding would experience during a station blackout, the transition to higher oxidation kinetics occurs at approximately 1,500°C. A parametric study varying the low-temperature FeCrAl oxidation kinetics was conducted for a BWR plant using FeCrAl fuel cladding and channel boxes using the MELCOR code. A range of station blackout severe accident scenarios were simulated for a BWR/4 reactor with Mark I containment. Increasing the FeCrAl low-temperature oxidation rate constant (3 times and 10 times that of the rate constant for APMT) had a negligible impact on the early stages of the accident and minor impacts on the accident progression after the first relocation of the fuel. At temperatures below 1,500°C, increasing the rate constant for APMT by a factor of 10 still resulted in only minor FeCrAl oxidation. In general, the gains afforded by the FeCrAl enhanced ATF concept with respect to accident sequence timing and combustible gas generation are consistent with previous efforts. Compared with the traditional Zircaloy-based cladding and channel box system, the FeCrAl concept could provide a few extra hours of time for operators to take mitigating actions and/or for evacuations to take place. A coolable core geometry is retained longer, enhancing the ability to stabilize an accident. For example, a station blackout was simulated in which cooling water injection was lost 36 hours after shutdown. The timing to first fuel relocation was delayed by approximately 5 h for the FeCrAl ATF concept compared with that of the traditional Zircaloy-based cladding and channel box system.« less

Effects of thermal treatment on the co-rolled U-Mo fuel foils

DOE Office of Scientific and Technical Information (OSTI.GOV)

Dennis D. Keiser, Jr.; Tammy L. Trowbridge; Cynthia R. Breckenridge

2014-11-01

A monolithic fuel type is being developed to convert US high performance research and test reactors such as Advanced Test Reactor (ATR) at Idaho National Laboratory from highly enriched uranium (HEU) to low-enriched uranium (LEU). The interaction between the cladding and the U-Mo fuel meat during fuel fabrication and irradiation is known to have negative impacts on fuel performance, such as mechanical integrity and dimensional stability. In order to eliminate/minimize the direct interaction between cladding and fuel meat, a thin zirconium diffusion barrier was introduced between the cladding and U-Mo fuel meat through a co-rolling process. A complex interface betweenmore » the zirconium and U-Mo was developed during the co-rolling process. A predictable interface between zirconium and U-Mo is critical to achieve good fuel performance since the interfaces can be the weakest link in the monolithic fuel system. A post co-rolling annealing treatment is expected to create a well-controlled interface between zirconium and U-Mo. A systematic study utilizing post co-rolling annealing treatment has been carried out. Based on microscopy results, the impacts of the annealing treatment on the interface between zirconium and U-Mo will be presented and an optima annealing treatment schedule will be suggested. The effects of the annealing treatment on the fuel performance will also be discussed.« less

On the control of the crystallographic texture in cladding tubes from Zr-based alloys for nuclear reactor

NASA Astrophysics Data System (ADS)

Isaenkova, M.; Perlovich, Yu.; Fesenko, V.

2016-10-01

This paper summarizes researches of authors, directed to the development of the methodological basis of X-ray studies as applied to zirconium alloys and on the systematization of new experimental results obtained using developed methods. The paper describes regularities of crystallographic texture formation in cladding tubes from zirconium alloys and their substructure inhomogeneity at various stages of manufacture, i.e. at hot and cold deformation, recrystallization, phase transformations and interaction of the above processes. The special attention is payed to possibilities of control the crystallographic texture of tubes at successive stages of their technological treatment.

The Deformation Mechanism of Fatigue Behaviour in a N36 Zirconium Alloy

NASA Astrophysics Data System (ADS)

Wang, Yingzhu

2018-05-01

Zirconium alloys are widely used as claddings in nuclear reactor. A N36 zirconium alloy has been deformed into a sheet with highly texture according to the result of electron back scatter diffraction test. Then this N36 zirconium alloy sheet has been cut into small beam samples with 12 x 3 x 3 mm3 in size. In this experiment, a three-point bending test was carried out to investigate the fatigue behaviour of N36 zirconium alloy. Cyclic loadings were applied on the top middle of the beam samples. The region of interest (ROI) is located at the middle bottom of the front face of the beam sample where slip band was observed in deformed beam sample due to strain concentration by using scanning electron microscopy. Twinning also plays an important role to accommodate the plastic deformation of N36 zirconium alloy in fatigue, which displays competition with slip.

Screening of advanced cladding materials and UN-U3Si5 fuel

NASA Astrophysics Data System (ADS)

Brown, Nicholas R.; Todosow, Michael; Cuadra, Arantxa

2015-07-01

In the aftermath of Fukushima, a focus of the DOE-NE Advanced Fuels Campaign has been the development of advanced nuclear fuel and cladding options with the potential for improved performance in an accident. Uranium dioxide (UO2) fuels with various advanced cladding materials were analyzed to provide a reference for cladding performance impacts. For advanced cladding options with UO2 fuel, most of the cladding materials have some reactivity and discharge burn-up penalty (in GWd/t). Silicon carbide is one exception in that the reactor physics performance is predicted to be very similar to zirconium alloy cladding. Most candidate claddings performed similar to UO2-Zr fuel-cladding in terms of safety coefficients. The clear exception is that Mo-based materials were identified as potentially challenging from a reactor physics perspective due to high resonance absorption. This paper also includes evaluation of UN-U3Si5 fuels with Kanthal AF or APMT cladding. The objective of the U3Si5 phase in the UN-U3Si5 fuel concept is to shield the nitride phase from water. It was shown that UN-U3Si5 fuels with Kanthal AF or APMT cladding have similar reactor physics and fuel management performance over a wide parameter space of phase fractions when compared to UO2-Zr fuel-cladding. There will be a marginal penalty in discharge burn-up (in GWd/t) and the sensitivity to 14N content in UN ceramic composites is high. Analysis of the rim effect due to self-shielding in the fuel shows that the UN-based ceramic fuels are not expected to have significantly different relative burn-up distributions at discharge relative to the UO2 reference fuel. However, the overall harder spectrum in the UN ceramic composite fuels increases transuranic build-up, which will increase long-term activity in a once-thru fuel cycle but is expected to be a significant advantage in a fuel cycle with continuous recycling of transuranic material. It is recognized that the fuel and cladding properties assumed in these assessments are preliminary, and that additional data are necessary for these materials, most significantly under irradiation.

DISSOLUTION OF ZIRCONIUM-CONTAINING FUEL ELEMENTS

DOEpatents

Horn, F.L.

1961-12-12

Uranium is recovered from spent uranium fuel elements containing or clad with zirconium. These fuel elements are placed in an anhydrous solution of hydrogen fluoride and nitrogen dioxide. Within this system uranium forms a soluble complex and zirconium forms an insoluble complex. The uranium can then be separated, treated, and removed from solution as uranium hexafluoride. (AEC)

Microstructural characteristics of HIP-bonded monolithic nuclear fuels with a diffusion barrier

NASA Astrophysics Data System (ADS)

Jue, Jan-Fong; Keiser, Dennis D.; Breckenridge, Cynthia R.; Moore, Glenn A.; Meyer, Mitchell K.

2014-05-01

Due to the limitation of maximum uranium load achievable by dispersion fuel type, the Global Threat Reduction Initiative is developing an advanced monolithic fuel to convert US high-performance research reactors to low-enriched uranium. Hot-isostatic-press (HIP) bonding was the single process down-selected to bond monolithic U-Mo fuel meat to aluminum alloy cladding. A diffusion barrier was applied to the U-Mo fuel meat by roll-bonding process to prevent extensive interaction between fuel meat and aluminum-alloy cladding. Microstructural characterization was performed on fresh fuel plates fabricated at Idaho National Laboratory. Interfaces between the fuel meat, the cladding, and the diffusion barrier, as well as between the U-10Mo fuel meat and the Al-6061 cladding, were characterized by scanning electron microscopy. Preliminary results indicate that the interfaces contain many different phases while decomposition, second phases, and chemical banding were also observed in the fuel meat. The important attributes of the HIP-bonded monolithic fuel are:

Microstructural Characteristics of HIP-bonded Monolithic Nuclear Fuels with a Diffusion Barrier

DOE Office of Scientific and Technical Information (OSTI.GOV)

Jan-Fong Jue; Dennis D. Keiser, Jr.; Cynthia R. Breckenridge

Due to the limitation of maximum uranium load achievable by dispersion fuel type, the Global Threat Reduction Initiative (GTRI) is developing an advanced monolithic fuel to convert US high performance research reactors to low-enriched uranium. Hot-isostatic-press bonding was the single process down-selected to bond monolithic U-Mo fuel meat to aluminum alloy cladding. A diffusion barrier was applied to the U–Mo fuel meat by roll-bonding process to prevent extensive interaction between fuel meat and aluminum-alloy cladding. Microstructural characterization was performed on fresh fuel plates fabricated at Idaho National Laboratory. Interfaces between fuel meat, cladding, and diffusion barrier, as well as U–10Momore » fuel meat and Al–6061 cladding were characterized by scanning electron microscopy. Preliminary results indicate that the interfaces contain many different phases while decomposition, second phases, and chemical banding were also observed in the fuel meat. The important attributes of the HIP-bonded monolithic fuel are • A typical Zr diffusion barrier of thickness 25 µm • Transverse cross section that exhibits relatively equiaxed grains with an average grain diameter of 10 µm • Chemical banding, in some areas more than 100 µm in length, that is very pronounced in longitudinal (i.e., rolling) direction with Mo concentration varying from 7–13 wt% • Decomposed areas containing plate-shaped low-Mo phase • A typical Zr/cladding interaction layer of thickness 1-2 µm • A visible UZr2 bearing layer of thickness 1-2 µm • Mo-rich precipitates (mainly Mo2Zr, forming a layer in some areas) followed by a Mo-depleted sub-layer between the visible UZr2-bearing layer and the U–Mo matrix • No excessive interaction between cladding and the uncoated fuel edge • Cladding-to-cladding bonding that exhibits no cracks or porosity with second phases high in Mg, Si, and O decorating the bond line. • Some of these attributes might be critical to the irradiation performance of monolithic U-10Mo nuclear fuel. There are several issues or concerns that warrant more detailed study, such as precipitation along cladding-to-cladding bond line, chemical banding, uncovered fuel-zone edge, and interaction layer between U–Mo fuel meat and zirconium. Future post-irradiation examination results will focus, among other things, on identifying in-reactor failure mechanisms and, eventually, directing further fresh fuel characterization efforts.« less

Initial results of metal waste form development activities at ANL-West

DOE Office of Scientific and Technical Information (OSTI.GOV)

Keiser, D.D. Jr.; Westphal, B.R.; Hersbt, R.S.

1997-10-01

Argonne National Laboratory is developing a metal alloy to contain metallic waste constituents from the electrometallurgical treatment of spent nuclear fuel. This alloy will contain stainless steel (from stainless steel-clad fuel elements), {approximately}15 wt.% zirconium (from alloy fuel), fission products noble to the process (e.g., Ru, Pd, Tc, etc.), and minor amounts of actinides. The alloy will serve as a final waste form for these components and will be disposed of in a geologic repository. The alloy ingot is produced in an induction furnace situated in a hot cell using Ar cover gas. This paper discusses results from the meltingmore » campaigns that have been initiated at ANL-West to generate the metal waste form using actual process materials. In addition, metal waste form samples have been doped with Tc and selected actinides and are described in the context of how elements of interest partition between various phases in the alloy and how this distribution of elements in the alloy may affect the leaching behavior of the components in an aqueous environment. 3 refs.« less

Initial results of metal waste-form development activities at ANL-West

DOE Office of Scientific and Technical Information (OSTI.GOV)

Keiser, D.D. Jr.; Westphal, B.R.; Herbst, R.S.

1997-12-01

Argonne National Laboratory (ANL) is developing a metal alloy to contain metallic waste constituent residual from the electrometallurgical treatment of spent nuclear fuel. This alloy will contain stainless steel (from stainless steel-clad fuel elements), {approximately} 15 wt% zirconium (from alloy fuel), fission products noble to the process (e.g., ruthenium, palladium, technetium, etc.), and minor amounts of actinides. The alloy will serve as a final waste form for these components and will be disposed of in a geologic repository. The alloy ingot is produced in an induction furnace situated in a hot cell using argon cover gas. This paper discusses resultsmore » from the melting campaigns that have been initiated at ANL-West to generate the metal waste form using actual process materials. In addition, metal waste form samples have been doped with technetium and selected actinides and are described in the context of how elements of interest partition between various phases in the alloy and how this distribution of elements in the alloy may affect the leaching behavior of the components in an aqueous environment.« less

Development of LWR Fuels with Enhanced Accident Tolerance

DOE Office of Scientific and Technical Information (OSTI.GOV)

Lahoda, Edward J.; Boylan, Frank A.

2015-10-30

Significant progress was made on the technical, licensing, and business aspects of the Westinghouse Electric Company’s Enhanced Accident Tolerant Fuel (ATF) by the Westinghouse ATF team. The fuel pellet options included waterproofed U 15N and U 3Si 2 and the cladding options SiC composites and zirconium alloys with surface treatments. Technology was developed that resulted in U 3Si 2 pellets with densities of >94% being achieved at the Idaho National Laboratory (INL). The use of U 3Si 2 will represent a 15% increase in U235 loadings over those in UO₂ fuel pellets. This technology was then applied to manufacture pelletsmore » for 6 test rodlets which were inserted in the Advanced Test Reactor (ATR) in early 2015 in zirconium alloy cladding. The first of these rodlets are expected to be removed in about 2017. Key characteristics to be determined include verification of the centerline temperature calculations, thermal conductivity, fission gas release, swelling and degree of amorphization. Waterproofed UN pellets have achieved >94% density for a 32% U 3Si 2/68% UN composite pellet at Texas A&M University. This represents a U235 increase of about 31% over current UO 2 pellets. Pellets and powders of UO 2, UN, and U 3Si 2the were tested by Westinghouse and Los Alamos National Laboratory (LANL) using differential scanning calorimetry to determine what their steam and 20% oxygen corrosion temperatures were as compared to UO 2. Cold spray application of either the amorphous steel or the Ti 2AlC was successful in forming an adherent ~20 micron coating that remained after testing at 420°C in a steam autoclave. Tests at 1200°C in 100% steam on coatings for Zr alloy have not been successful, possibly due to the low density of the coatings which allowed steam transport to the base zirconium metal. Significant modeling and testing has been carried out for the SiC/SiC composite/SiC monolith structures. A structure with the monolith on the outside and composite on the inside was developed which is the current baseline structure and a SiC to SiC tube closure approach. Permeability tests and mechanical tests were developed to verify the operation of the SiC cladding. Steam autoclave (420°C), high temperature (1200°C) flowing steam tests and quench tests were carried out with minimal corrosion, mechanical or hermeticity degradation effect on the SiC cladding or end plug closure. However, in-reactor loop tests carried out in the MIT reactor indicated an unacceptable degree of corrosion, likely due to the corrosive effect of radiolysis products which attacked the SiC.« less

Characterization of Hydrogen Embrittled Zircaloy-4 by Using a Van de Graaff Particle Accelerator

NASA Astrophysics Data System (ADS)

Budd, John

2013-04-01

On-site, dry cask storage was originally by the intended to be a short-term solution for holding spent nuclear fuel. Due to the lack of a permanent storage facility, the nuclear power industry seeks to assess the effective lifetime of the casks. One issue which could compromise cask integrity is Hydrogen embrittlement. This phenomenon occurs in the Zircaloy-4 fuel-rod cladding and is caused by the formation of Zirconium hydrides. Over time, thermal stresses caused by the heat from reactions of the stored nuclear fuel could result in significant breaches of the cladding. Our group at Texas A&M University- Kingsville is conducting experiments to aid in determining when such breaches will occur. We will irradiate samples of the alloy with protons of energies up to 400 keV using a Van de Graaff particle accelerator. Once irradiated, their properties will be characterized using scanning electron microscopy and Vickers hardness tests.

DOE Office of Scientific and Technical Information (OSTI.GOV)

Kohnert, Aaron A.; Dasgupta, Dwaipayan; Wirth, Brian

In order to improve the accident tolerance of light water reactor (LWR) fuel, alternative cladding materials have been proposed to replace zirconium (Zr)-based alloys. Of these materials, there is a particular focus on iron-chromium-aluminum (FeCrAl) alloys due to much slower oxidation kinetics in high-temperature steam than Zr-alloys. This should decrease the energy release due to oxidation and allow the cladding to remain integral longer in the presence of high temperature steam, making accident mitigation more likely. As a continuation of the development for these alloys, the material response must be demonstrated to provide suitable radiation stability, in order to ensuremore » that there will not be significant dimensional changes (e.g., swelling), as well as quantifying the radiation hardening and radiation creep behavior. In this report, we describe the use of cluster dynamics modeling to evaluate the defect physics and damage accumulation behavior of FeCrAl alloys subjected to neutron irradiation, with a particular focus on irradiation-induced swelling and defect fluxes to dislocations that are required to model irradiation creep behavior.« less

Theoretical analysis of swelling characteristics of cylindrical uranium dioxide fuel pins with a niobium - 1-percent-zirconium clad

NASA Technical Reports Server (NTRS)

Saltsman, J. F.

1973-01-01

The relations between clad creep strain and fuel volume swelling are shown for cylindrical UO2 fuel pins with a Nb-1Zr clad. These relations were obtained by using the computer code CYGRO-2. These clad-strain - fuel-volume-swelling relations may be used with any fuel-volume-swelling model, provided the fuel volume swelling is isotropic and independent of the clad restraints. The effects of clad temperature (over a range from 118 to 1642 K (2010 to 2960 R)), pin diameter, clad thickness and central hole size in the fuel have been investigated. In all calculations the irradiation time was 500 hours. The burnup rate was varied.

Establishment of the roadmap for chlorination process development for zirconium recovery and recycle

DOE Office of Scientific and Technical Information (OSTI.GOV)

Collins, E.D.; Del Cul, G.D.; Spencer, B.B.

Process development studies are being conducted to recover, purify, and reuse the zirconium (about 98.5% by mass) in used nuclear fuel (UNF) zirconium alloy cladding. Feasibility studies began in FY 2010 using empty cladding hulls that were left after fuel dissolution or after oxidation to a finely divided oxide powder (voloxidation). In FY 2012, two industrial teams (AREVA and Shaw-Westinghouse) were contracted by the Department of Energy Office of Nuclear Energy (NE) to provide technical assistance to the project. In FY 2013, the NE Fuel Cycle Research and Development Program requested development of a technology development roadmap to guide futuremore » work. The first step in the roadmap development was to assess the starting point, that is, the current state of the technology and the end goal. Based on previous test results, future work is to be focused on first using chlorine as the chlorinating agent and secondly on the use of a process design that utilizes a chlorination reactor and dual ZrCl{sub 4} product salt condensers. The likely need for a secondary purification step was recognized. Completion of feasibility testing required an experiment on the chemical decladding flowsheet option. This was done during April 2013. The roadmap for process development will continue through process chemistry optimization studies, the chlorinated reactor design configuration, product salt condensers, and the off-gas trapping of tritium or other volatile fission products from the off-gas stream. (authors)« less

A model for recovery of scrap monolithic uranium molybdenum fuel by electrorefining

NASA Astrophysics Data System (ADS)

Van Kleeck, Melissa A.

The goal of the Reduced Enrichment for Research and Test Reactors program (RERTR) is toreduce enrichment at research and test reactors, thereby decreasing proliferation risk at these facilities. A new fuel to accomplish this goal is being manufactured experimentally at the Y12 National Security Complex. This new fuel will require its own waste management procedure,namely for the recovery of scrap from its manufacture. The new fuel is a monolithic uraniummolybdenum alloy clad in zirconium. Feasibility tests were conducted in the Planar Electrode Electrorefiner using scrap U-8Mo fuel alloy. These tests proved that a uranium product could be recovered free of molybdenum from this scrap fuel by electrorefining. Tests were also conducted using U-10Mo Zr clad fuel, which confirmed that product could be recovered from a clad version of this scrap fuel at an engineering scale, though analytical results are pending for the behavior of Zr in the electrorefiner. A model was constructed for the simulation of electrorefining the scrap material produced in the manufacture of this fuel. The model was implemented on two platforms, Microsoft Excel and MatLab. Correlations, used in the model, were developed experimentally, describing area specific resistance behavior at each electrode. Experiments validating the model were conducted using scrap of U-10Mo Zr clad fuel in the Planar Electrode Electrorefiner. The results of model simulations on both platforms were compared to experimental results for the same fuel, salt and electrorefiner compositions and dimensions for two trials. In general, the model demonstrated behavior similar to experimental data but additional refinements are needed to improve its accuracy. These refinements consist of a function for surface area at anode and cathode based on charge passed. Several approximations were made in the model concerning areas of electrodes which should be replaced by a more accurate function describing these areas.

Irradiation performance of U-Mo monolithic fuel

DOE PAGES

Meyer, M. K.; Gan, J.; Jue, J. F.; ...

2014-04-01

High-performance research reactors require fuel that operates at high specific power to high fission density, but at relatively low temperatures. Research reactor fuels are designed for efficient heat rejection, and are composed of assemblies of thin-plates clad in aluminum alloy. The development of low-enriched fuels to replace high-enriched fuels for these reactors requires a substantially increased uranium density in the fuel to offset the decrease in enrichment. Very few fuel phases have been identified that have the required combination of very-high uranium density and stable fuel behavior at high burnup. U-Mo alloys represent the best known tradeoff in these properties.more » Testing of aluminum matrix U-Mo aluminum matrix dispersion fuel revealed a pattern of breakaway swelling behavior at intermediate burnup, related to the formation of a molybdenum stabilized high aluminum intermetallic phase that forms during irradiation. In the case of monolithic fuel, this issue was addressed by eliminating, as much as possible, the interfacial area between U-Mo and aluminum. Based on scoping irradiation test data, a fuel plate system composed of solid U-10Mo fuel meat, a zirconium diffusion barrier, and Al6061 cladding was selected for development. Developmental testing of this fuel system indicates that it meets core criteria for fuel qualification, including stable and predictable swelling behavior, mechanical integrity to high burnup, and geometric stability. In addition, the fuel exhibits robust behavior during power-cooling mismatch events under irradiation at high power.« less

IRRADIATION PERFORMANCE OF U-Mo MONOLITHIC FUEL

DOE Office of Scientific and Technical Information (OSTI.GOV)

M.K. Meyer; J. Gan; J.-F. Jue

2014-04-01

High-performance research reactors require fuel that operates at high specific power to high fission density, but at relatively low temperatures. Research reactor fuels are designed for efficient heat rejection, and are composed of assemblies of thin-plates clad in aluminum alloy. The development of low-enriched fuels to replace high-enriched fuels for these reactors requires a substantially increased uranium density in the fuel to offset the decrease in enrichment. Very few fuel phases have been identified that have the required combination of very-high uranium density and stable fuel behavior at high burnup. UMo alloys represent the best known tradeoff in these properties.more » Testing of aluminum matrix U-Mo aluminum matrix dispersion fuel revealed a pattern of breakaway swelling behavior at intermediate burnup, related to the formation of a molybdenum stabilized high aluminum intermetallic phase that forms during irradiation. In the case of monolithic fuel, this issue was addressed by eliminating, as much as possible, the interfacial area between U-Mo and aluminum. Based on scoping irradiation test data, a fuel plate system composed of solid U-10Mo fuel meat, a zirconium diffusion barrier, and Al6061 cladding was selected for development. Developmental testing of this fuel system indicates that it meets core criteria for fuel qualification, including stable and predictable swelling behavior, mechanical integrity to high burnup, and geometric stability. In addition, the fuel exhibits robust behavior during power-cooling mismatch events under irradiation at high power.« less

Some observations on uranium carbide alloy/tungsten compatibility

NASA Technical Reports Server (NTRS)

Phillips, W. M.

1972-01-01

Chemical compatibility between both pure and thoriated tungsten and uranium carbide alloys was studied at 1800 C for up to 3300 hours. Alloying with zirconium carbide appeared to widen the homogeneity range of uranium carbide, making additional carbon available for reaction with the tungsten. Reaction layers were formed both by vapor phase reaction and by physical contact, producing either or both UWC2 and W2C, dependent upon the phases present in the starting fuel alloy. Formation of UWC2 results in slow growth of the reaction layer with time, while W2C reaction layers grow rapidly, allowing equilibrium to be reached in less than 2500 hours at 1800 C. The presence of a thermal gradient had no effect on the reactions observed nor did the presence of thoria in the tungsten clad.

Some observations on uranium carbide alloy/tungsten compatibility.

NASA Technical Reports Server (NTRS)

Phillips, W. M.

1972-01-01

Results of chemical compatibility tests between both pure tungsten and thoriated tungsten run at 1800 C for up to 3300 hours with uranium carbide alloys. Alloying with zirconium carbide appeared to widen the homogeneity range of uranium carbide, making additional carbon available for reaction with the tungsten. Reaction layers were formed both by vapor phase reaction and by physical contact, producing either or both UWC2 and W2C, depending upon the phases present in the starting fuel alloy. Formation of UWC2 results in slow growth of the reaction layer with time, while W2C reaction layers grow rapidly, allowing equilibrium to be reached in less than 2500 hours at 1800 C. Neither the presence of a thermal gradient nor the presence of thoria in the tungsten clad affect the reactions observed.

PRELIMINARY EVALUATION OF FeCrAl CLADDING AND U-Si FUEL FOR ACCIDENT TOLERANT FUEL CONCEPTS

DOE Office of Scientific and Technical Information (OSTI.GOV)

Hales, J. D.; Gamble, K. A.

2015-09-01

Since the accident at the Fukushima Daiichi Nuclear Power Station, enhancing the accident tolerance of light water reactors (LWRs) has become an important research topic. In particular, the community is actively developing enhanced fuels and cladding for LWRs to improve safety in the event of accidents in the reactor or spent fuel pools. Fuels with enhanced accident tolerance are those that, in comparison with the standard UO2-zirconium alloy system, can tolerate loss of active cooling in the reactor core for a considerably longer time period during design-basis and beyond design-basis events while maintaining or improving the fuel performance during normalmore » operations and operational transients. This paper presents early work in developing thermal and mechanical models for two materials that may have promise: U-Si for fuel, and FeCrAl for cladding. These materials would not necessarily be used together in the same fuel system, but individually have promising characteristics. BISON, the finite element-based fuel performance code in development at Idaho National Laboratory, was used to compare results from normal operation conditions with Zr-4/UO2 behavior. In addition, sensitivity studies are presented for evaluating the relative importance of material parameters such as ductility and thermal conductivity in FeCrAl and U-Si in order to provide guidance on future experiments for these materials.« less

Electroless deposition process for zirconium and zirconium alloys

DOEpatents

Donaghy, R. E.; Sherman, A. H.

1981-08-18

A method is disclosed for preventing stress corrosion cracking or metal embrittlement of a zirconium or zirconium alloy container that is to be coated on the inside surface with a layer of a metal such as copper, a copper alloy, nickel, or iron and used for holding nuclear fuel material as a nuclear fuel element. The zirconium material is etched in an etchant solution, desmutted mechanically or ultrasonically, oxidized to form an oxide coating on the zirconium, cleaned in an aqueous alkaline cleaning solution, activated for electroless deposition of a metal layer and contacted with an electroless metal plating solution. This method provides a boundary layer of zirconium oxide between the zirconium container and the metal layer. 1 fig.

Electroless deposition process for zirconium and zirconium alloys

DOEpatents

Donaghy, Robert E.; Sherman, Anna H.

1981-01-01

A method is disclosed for preventing stress corrosion cracking or metal embrittlement of a zirconium or zirconium alloy container that is to be coated on the inside surface with a layer of a metal such as copper, a copper alloy, nickel, or iron and used for holding nuclear fuel material as a nuclear fuel element. The zirconium material is etched in an etchant solution, desmutted mechanically or ultrasonically, oxidized to form an oxide coating on the zirconium, cleaned in an aqueous alkaline cleaning solution, activated for electroless deposition of a metal layer and contacted with an electroless metal plating solution. This method provides a boundary layer of zirconium oxide between the zirconium container and the metal layer.

Nanophase Nickel-Zirconium Alloys for Fuel Cells

NASA Technical Reports Server (NTRS)

Narayanan, Sekharipuram; Whitacre, jay; Valdez, Thomas

2008-01-01

Nanophase nickel-zirconium alloys have been investigated for use as electrically conductive coatings and catalyst supports in fuel cells. Heretofore, noble metals have been used because they resist corrosion in the harsh, acidic fuel cell interior environments. However, the high cost of noble metals has prompted a search for less-costly substitutes. Nickel-zirconium alloys belong to a class of base metal alloys formed from transition elements of widely different d-electron configurations. These alloys generally exhibit unique physical, chemical, and metallurgical properties that can include corrosion resistance. Inasmuch as corrosion is accelerated by free-energy differences between bulk material and grain boundaries, it was conjectured that amorphous (glassy) and nanophase forms of these alloys could offer the desired corrosion resistance. For experiments to test the conjecture, thin alloy films containing various proportions of nickel and zirconium were deposited by magnetron and radiofrequency co-sputtering of nickel and zirconium. The results of x-ray diffraction studies of the deposited films suggested that the films had a nanophase and nearly amorphous character.

Irradiation test of tungsten clad uranium carbide-zirconium carbide ((U,Zr)C) specimens for thermionic reactor application at conditions conductive to long-term performance

NASA Technical Reports Server (NTRS)

Creagh, J. W. R.; Smith, J. R.

1973-01-01

Uranium carbide fueled, thermionic emitter configurations were encapsulated and irradiated. One capsule contained a specimen clad with fluoride derived chemically vapor deposited (CVD) tungsten. The other capsule used a duplex clad specimen consisting of chloride derived on floride derived CVD tungsten. Both fuel pins were 16 millimeters in diameter and contained a 45.7-millimeter length of fuel.

Influence of chemical composition of zirconium alloy E110 on embrittlement under LOCA conditions - Part 1: Oxidation kinetics and macrocharacteristics of structure and fracture

NASA Astrophysics Data System (ADS)

Nikulin, S. A.; Rozhnov, A. B.; Belov, V. A.; Li, E. V.; Glazkina, V. S.

2011-11-01

Exploratory investigations of the influence of alloying and impurity content in the E110 alloy cladding tubes on the behavior under conditions of Loss of Coolant Accidents (LOCA) has been performed. Three alloys of E110 type have been tested: E110 alloy of nominal composition Zr-1%Nb (E110), E110 alloy of modified composition Zr-1%Nb-0.12%Fe-0.13%O (E110M), E110 alloy of nominal composition Zr-1%Nb with reduced impurity content (E110G). Alloys E110 and E110M were manufactured on the electrolytic basis and alloy E110G was manufactured on the basis of zirconium sponge. The high temperature oxidation tests in steam ( T = 1100 °C, 18% of equivalent cladding reacted (ECR)) have been conducted, kinetics of oxidation was investigated. Quantitative research of structure and fracture macrocharacteristics was performed by means of optical and electron microscopy. The results received were compared with the residual ductility of specimens. The results of the investigation showed the existence of "breakaway oxidation" kinetics and white spalling oxide in E110 and E110M alloys while the specimen oxidation kinetics in E110G alloy was characterized by a parabolic law and specimens had a dense black oxide. Oxygen and iron alloying in the E110 alloy positively changed the macrocharacteristics of structure and fracture. However, in general, it did not improve the resistance to embrittlement in LOCA conditions apparently because of a strong impurity influence caused by electrolytic process of zirconium production.

PLUTONIUM-ZIRCONIUM ALLOYS

DOEpatents

Schonfeld, F.W.; Waber, J.T.

1960-08-30

A series of nuclear reactor fuel alloys consisting of from about 5 to about 50 at.% zirconium (or higher zirconium alloys such as Zircaloy), balance plutonium, and having the structural composition of a plutonium are described. Zirconium is a satisfactory diluent because it alloys readily with plutonium and has desirable nuclear properties. Additional advantages are corrosion resistance, excellent fabrication propenties, an isotropie structure, and initial softness.

Analysis of Operating Strategies Using Different Target Designs For 238Pu Production

DOE Office of Scientific and Technical Information (OSTI.GOV)

Thomas, Tomcy; Sherman, Steven R; Sawhney, Dr. Rapinder

2017-01-01

An engineering effort is underway to re-establish capability to produce 238Pu oxide at the kilogram scale in the United States. A multi-step batch process is being developed to produce this important material. Recently, a portion of this process was studied using discrete-event simulation tools to determine whether the conceptual process might achieve its yearly production goal. The study showed the conceptual process can meet the yearly production goal under some circumstances, but process improvements would be needed to ensure greater likelihood of success. This study extends the work performed previously by examining the effects of changing the reactor target designmore » on the yearly process output. Two new reactor target configurations are considered an aluminum-clad reactor target containing 50% greater 237Np oxide content than the original target, and a zirconium alloy-clad target using no aluminum. The results indicate that use of the new aluminum-clad target configuration may allow the process to achieve the same yearly production goal in less time using fewer targets. If the zirconium alloy-clad target is used, then even fewer targets would be needed to reach the production goal, but some process changes would be required to handle the zirconium cladding. The number of days needed to process a target batch to completion, and the steady state 238Pu oxide production rate, for each configuration are compared to the results from the initial simulation study.« less

METHOD OF MAKING WIRE FUEL ELEMENTS

DOEpatents

Zambrow, J.L.

1960-08-01

A method is given for making a nuclear reactor fuel element in the form of a uranium-bearing wire clad with zirconium. A uranium bar is enclosed in a zirconium sheath which is coated with an oxide of magnesium, beryllium, or zirconium. The sheathed bar is then placed in a steel tube and reduced to the desired diameter by swaging at 800 to 900 deg C, after which the steel and oxide are removed.

Solid-phase zirconium and fluoride species in alkaline zircaloy cladding waste at Hanford.

PubMed

Reynolds, Jacob G; Huber, Heinz J; Cooke, Gary A; Pestovich, John A

2014-08-15

The United States Department of Energy Hanford Site, near Richland, Washington, USA, processed plutonium between 1944 and 1987. Fifty-six million gallons of waste of various origins remain, including waste from removing zircaloy fuel cladding using the so-called Zirflex process. The speciation of zirconium and fluoride in this waste is important because of the corrosivity and reactivity of fluoride as well as the (potentially) high density of Zr-phases. This study evaluates the solid-phase speciation of zirconium and fluoride using X-ray diffraction (XRD) and scanning electron microscopy with energy dispersive spectroscopy (SEM-EDS). Two waste samples were analyzed: one waste sample that is relatively pure zirconium cladding waste from tank 241-AW-105 and another that is a blend of zirconium cladding wastes and other high-level wastes from tank 241-C-104. Villiaumite (NaF) was found to be the dominant fluoride species in the cladding waste and natrophosphate (Na7F[PO4]2 · 19H2O) was the dominant species in the blended waste. Most zirconium was present as a sub-micron amorphous Na-Zr-O phase in the cladding waste and a Na-Al-Zr-O phase in the blended waste. Some zirconium was present in both tanks as either rounded or elongated crystalline needles of Na-bearing ZrO2 that are up to 200 μm in length. These results provide waste process planners the speciation data needed to develop disposal processes for this waste. Copyright © 2014 Elsevier B.V. All rights reserved.

NEUTRONIC REACTOR CONTROL ROD AND METHOD OF FABRICATION

DOEpatents

Porembka, S.W. Jr.

1961-06-27

A reactor control rod formed from a compacted powder dispersion is patented. The rod consists of titanium sheathed with a cladding alloy. The cladding alloy contains 1.3% to 1.6% by weight of tin, 0.07% to 0.12% by weight of chromium, 0.04% to 0.08% by weight of nickel, 0.09% to 0.16% by weight of iron, carbon not exceeding 0.05%, less than 0.5% by weight of incidental impurities, and the balance zirconium.

LIGHT WATER REACTOR ACCIDENT TOLERANT FUELS IRRADIATION TESTING

DOE Office of Scientific and Technical Information (OSTI.GOV)

Carmack, William Jonathan; Barrett, Kristine Eloise; Chichester, Heather Jean MacLean

2015-09-01

The purpose of Accident Tolerant Fuels (ATF) experiments is to test novel fuel and cladding concepts designed to replace the current zirconium alloy uranium dioxide (UO2) fuel system. The objective of this Research and Development (R&D) is to develop novel ATF concepts that will be able to withstand loss of active cooling in the reactor core for a considerably longer time period than the current fuel system while maintaining or improving the fuel performance during normal operations, operational transients, design basis, and beyond design basis events. It was necessary to design, analyze, and fabricate drop-in capsules to meet the requirementsmore » for testing under prototypic LWR temperatures in Idaho National Laboratory's Advanced Test Reactor (ATR). Three industry led teams and one DOE team from Oak Ridge National Laboratory provided fuel rodlet samples for their new concepts for ATR insertion in 2015. As-built projected temperature calculations were performed on the ATF capsules using the BISON fuel performance code. BISON is an application of INL’s Multi-physics Object Oriented Simulation Environment (MOOSE), which is a massively parallel finite element based framework used to solve systems of fully coupled nonlinear partial differential equations. Both 2D and 3D models were set up to examine cladding and fuel performance.« less

Modeling of complex wear behavior associated with grid-to-rod fretting in light water nuclear reactors

DOE Office of Scientific and Technical Information (OSTI.GOV)

Blau, P. J.; Qu, J.; Lu, R.

One significant concern in the operation of light water nuclear reactors is the fretting wear damage to fuel cladding from flow-induced vibrations. For years, research on the grid-to-rod fretting (GTRF) phenomena has been underway in countries where nuclear power production is a significant industry. Under the auspices of the U.S. Department of Energy Consortium for Advanced Simulation of Light Water Reactors, an effort has been underway to develop and test an engineering wear model for zirconium alloy fuel rod cladding against a supporting grid. Furthermore, the multi-stage model accounts for oxide layers and wear rate transitions. Our paper describes themore » basis for a GTRF engineering wear model, the physical significance of the wear factor it contains, and recent progress toward model validation based on a fretting wear testing apparatus that accounts for coolant temperature, pressure, and the presence of periodic impacts (gaps) in grid/rod contact.« less

HRTEM and chemical study of an ion-irradiated chromium/zircaloy-4 interface

NASA Astrophysics Data System (ADS)

Wu, A.; Ribis, J.; Brachet, J.-C.; Clouet, E.; Leprêtre, F.; Bordas, E.; Arnal, B.

2018-06-01

Chromium-coated zirconium alloys are being studied as Enhanced Accident Tolerant Fuel Cladding for Light Water Reactors (LWRs). Those materials are especially studied to improve the oxidation resistance of LWRs current fuel claddings in nominal and at High Temperature (HT) for hypothetical accidental conditions such as LOss of Coolant Accident. Beyond their HT behavior, it is essential to assess the materials behavior under irradiation. A first generation chromium/Zircaloy-4 interface was thus irradiated with 20 MeV Kr8+ ions at 400 °C up to 10 dpa. High-Resolution Transmission Electron Microscopy and chemical analysis (EDS) were conducted at the Cr/Zr interface. The atomic structure of the interface reveals the presence of Zr(Fe, Cr)2 Laves phase, displaying both C14 and C15 structure. After irradiation, only the C14 structure was observed and atomic row matching was preserved across the different interfaces, thus ensuring a good adhesion of the coating after irradiation.

Modeling of complex wear behavior associated with grid-to-rod fretting in light water nuclear reactors

DOE PAGES

Blau, P. J.; Qu, J.; Lu, R.

2016-09-21

One significant concern in the operation of light water nuclear reactors is the fretting wear damage to fuel cladding from flow-induced vibrations. For years, research on the grid-to-rod fretting (GTRF) phenomena has been underway in countries where nuclear power production is a significant industry. Under the auspices of the U.S. Department of Energy Consortium for Advanced Simulation of Light Water Reactors, an effort has been underway to develop and test an engineering wear model for zirconium alloy fuel rod cladding against a supporting grid. Furthermore, the multi-stage model accounts for oxide layers and wear rate transitions. Our paper describes themore » basis for a GTRF engineering wear model, the physical significance of the wear factor it contains, and recent progress toward model validation based on a fretting wear testing apparatus that accounts for coolant temperature, pressure, and the presence of periodic impacts (gaps) in grid/rod contact.« less

Extending FEAST-METAL for analysis of low content minor actinide bearing and zirconium rich metallic fuels for sodium fast reactors

NASA Astrophysics Data System (ADS)

Karahan, Aydın

2011-07-01

Computational models in FEAST-METAL fuel behaviour code have been upgraded to simulate minor actinide bearing zirconium rich metallic fuels for use in sodium fast reactors. Increasing the zirconium content to 20-40 wt.% causes significant changes in fuel slug microstructure affecting thermal, mechanical, chemical, and fission gas behaviour. Inclusion of zirconium rich phase reduces the fission gas swelling rate significantly in early irradiation. Above the threshold fission gas swelling, formation of micro-cracks, and open pores increase material compliancy enhance diffusivity, leading to rapid fuel gas swelling, interconnected porosity development and release of the fission gases and helium. Production and release of helium was modelled empirically as a function of americium content and fission gas production, consistent with previous Idaho National Laboratory studies. Predicted fuel constituent redistribution is much smaller compared to typical U-Pu-10Zr fuel operated at EBR-II. Material properties such as fuel thermal conductivity, modulus of elasticity, and thermal expansion coefficient have been approximated using the available database. Creep rate and fission gas diffusivity of high zirconium fuel is lowered by an order of magnitude with respect to the reference low zirconium fuel based on limited database and in order to match experimental observations. The new code is benchmarked against the AFC-1F fuel assembly post irradiation examination results. Satisfactory match was obtained for fission gas release and swelling behaviour. Finally, the study considers a comparison of fuel behaviour between high zirconium content minor actinide bearing fuel and typical U-15Pu-6Zr fuel pins with 75% smear density. The new fuel has much higher fissile content, allowing for operating at lower neutron flux level compared to fuel with lower fissile density. This feature allows the designer to reach a much higher burnup before reaching the cladding dose limit. On the other hand, in order to accommodate solid fission product swelling and to control fuel clad mechanical interaction of the stiffer fuel, the fuel smear density is reduced to 70%. In addition, plenum height is increased to accommodate for fission gases.

Thermochemical Compatibility and Oxidation Resistance of Advanced LWR Fuel Cladding

DOE PAGES

Besmann, T. M.; Yamamoto, Y.; Unocic, K. A.

2016-06-21

We assessed the thermochemical compatibility of potential replacement cladding materials for zirconium alloys in light water reactors. Considered were FeCrAl steel (similar to Kanthal APMT), Nb-1%Zr (similar to PWC-11), and a hybrid SiC-composite with a metallic barrier layer. The niobium alloy was also seen as requiring an oxidation protective layer, and a diffusion silicide was investigated. Metallic barrier layers for the SiC-composite reviewed included a FeCrAl alloy, Nb-1%Zr, and chromium. Thermochemical calculations were performed to determine oxidation behavior of the materials in steam, and for hybrid SiC-composites possible interactions between the metallic layer and SiC. Additionally, experimental exposures of SiC-alloymore » reaction couples at 673K, 1073K, and 1273K for 168 h in an inert atmosphere were made and microanalysis performed. Whereas all materials were determined to oxidize under higher oxygen partial pressures in the steam environment, these varied by material with expected protective oxides forming. Finally, the computed and experimental results indicate the formation of liquid phase eutectic in the FeCrAl-SiC system at the higher temperatures.« less

Perform Tests and Document Results and Analysis of Oxide Layer Effects and Comparisons

DOE Office of Scientific and Technical Information (OSTI.GOV)

Collins, E. D.; DelCul, G. D.; Spencer, B. B.

2014-08-30

During the initial feasibility test using actual used nuclear fuel (UNF) cladding in FY 2012, an incubation period of 30–45 minutes was observed in the initial dry chlorination. The cladding hull used in the test had been previously oxidized in a dry air oxidation pretreatment prior to removal of the fuel. The cause of this incubation period was attributed to the resistance to chlorination of an oxide layer imparted by the dry oxidation pretreatment on the cladding. Subsequently in 2013, researchers at the Korea Atomic Energy Institute (KAERI) reported on their chlorination study [R1] on ~9-gram samples of unirradiated ZirloTMmore » cladding tubes that had been previously oxidized in air at 500oC for various time periods to impart oxide layers of varying thickness. In early 2014, discussions with Indefinite Delivery, Indefinite Quantity (IDIQ) contracted technical consultants from Westinghouse described their previous development (and patents) [R2] on methods of chemical washing to remove some or all of the hydrous oxide layer imparted on UNF cladding during irradiation in light water reactors (LWRs) . Thus, the Oak Ridge National Laboratory (ORNL) study, described herein, was planned to extend the KAERI study on the effects of anhydrous oxide layers, but on larger ~100-gram samples of unirradiated zirconium alloy cladding tubes, and to investigate the effects of various methods of chemical pretreatment prior to chlorination with 100% chlorine on the average reaction rates and Cl2 usage efficiencies.« less

Dissolution process for ZrO.sub.2 -UO.sub.2 -CaO fuels

DOEpatents

Paige, Bernice E.

1976-06-22

The present invention provides an improved dissolution process for ZrO.sub.2 -UO.sub.2 -CaO-type pressurized water reactor fuels. The zirconium cladding is dissolved with hydrofluoric acid, immersing the ZrO.sub.2 -UO.sub.2 -CaO fuel wafers in the resulting zirconium-dissolver-product in the dissolver vessel, and nitric acid is added to the dissolver vessel to facilitate dissolution of the uranium from the ZrO.sub.2 -UO.sub.2 -CaO fuel wafers.

Influence of oxide microstructure on corrosion behavior of zirconium-based model alloys

NASA Astrophysics Data System (ADS)

Silva, Marcelo Jose Gomes Da

The extensive utilization of zirconium-based alloys in fuel cladding and other reactor internal components in the nuclear power industry has led to the continuous improvement of these alloys. At the present moment, demands for better performing nuclear fuel cladding materials are increasing. Also, new reactor designs have been proposed that would require the materials to withstand even more rigorous conditions. One of the factors that limit s fuel cladding utilization in nuclear reactors is uniform corrosion and the consequent hydriding of the fuel. In an attempt to develop mechanistic understanding of the role of alloying elements in the growth of a stable protective oxide, a series of model zirconium-based alloys was prepared (Zr-xFe-yCr, Zr-xCu-yMo, Zr-xNb-ySn, for various x and y, pure Zr and Zircaloy-4) and examined with advanced characterization techniques. The alloys were corrosion tested in autoclaves under three different conditions: 360°C water, 500°C steam and 500°C supercritical water in excess of 400 days. These autoclave testing conditions simulate nuclear reactor environment for both current designs (360°C water) and the new supercritical water reactor (500°C steam and 500°C supercritical water) proposed by the generation-IV initiative. The oxide films formed were systematically examined at the Advanced Photon Source using microbeam synchrotron radiation diffraction and fluorescence of cross-sectional samples to determine the oxide phases present and their crystallographic texture as a function of distance from the metal/oxide interface. Also, the overall texture of the oxide layers was investigated using synchrotron radiation diffraction in frontal geometry. The corrosion kinetics is a function of the alloy system and showed a wide range of behaviors, from immediately unstable oxide growth to stable behavior. The corrosion weight gains from testing at high temperature are a factor of five higher than those measured at 360°C but the protectiveness ranking of the alloys is similar. Measured pole figures from different oxides in different corrosion regimes showed that monoclinic oxides grow in slightly distinct directions: protective oxides grow along the (-904)m pole, whether non-protective oxides grow along or close to the (-302)m pole. The angle in between these two directions ((-904)m and (-302)m) is about 6°. Microbeam synchrotron radiation diffraction and fluorescence was performed in the oxide layers and systematic differences are observed in protective and non-protective oxides, both near the oxide/metal interface and in the bulk of the oxide layers. The non-protective oxide interfaces show a smooth transition from metal to oxide with metal diffraction peaks disappearing as the monoclinic oxide peaks appear. In contrast, in a protective oxide, a complex structure near the oxide/metal interface was seen, showing peaks from Zr 3O suboxide and a highly oriented tetragonal oxide phase with specific orientation relationships with the monoclinic oxide and the base metal. The highly oriented tetragonal phase, only present in protective oxides, is believed to be a precursor to the formation of monoclinic oxide found in the bulk of the oxide layer. This plane may promote stable growth by causing the oxide to form in a manner that maximizes occupation of the substrate surface and minimizes stress accumulation, leading to more stable oxide growth. The association seen in this work of the precursor oxide phase with protective oxides and its orientation relationship with the monoclinic oxide, combined with the difference in oxide growth direction seen between protective and non-protective oxides, is interpreted as evidence that this phase allows a more properly oriented oxide to grow, in a way that minimizes stress accumulation and therefore delays the oxide transition to larger oxide thicknesses.

Compatibility of refractory materials for nuclear reactor poison control systems

NASA Technical Reports Server (NTRS)

Sinclair, J. H.

1974-01-01

Metal-clad poison rods have been considered for the control system of an advanced space power reactor concept studied at the NASA Lewis Research Center. Such control rods may be required to operate at temperatures of about 140O C. Selected poison materials (including boron carbide and the diborides of zirconium, hafnium, and tantalum) were subjected to 1000-hour screening tests in contact with candidate refractory metal cladding materials (including tungsten and alloys of tantalum, niobium, and molybdenum) to assess the compatibility of these materials combinations at the temperatures of interest. Zirconium and hafnium diborides were compatible with refractory metals at 1400 C, but boron carbide and tantalum diboride reacted with the refractory metals at this temperature. Zirconium diboride also showed promise as a reaction barrier between boron carbide and tungsten.

DOE Office of Scientific and Technical Information (OSTI.GOV)

Jackson, Timothy D; Hollenbach, Daniel F; Shedlock, Daniel

Radiography by Selective Detection (RSD), was investigated for its ability to determine the presence and types of defects in a UO{sub 2} fuel rod surrounded by zirconium cladding. Images created using a Monte Carlo model compared favorably with actual X-ray backscatter images from mock fuel rods. A fuel rod was modeled as a rectangular parallelepiped with zirconium cladding, and pencil beam X-ray sources of 160 kVp (79 keV avg) and 480 kVp (218 keV avg) were generated using the Monte Carlo N-Particle Transport Code to attempt to image void and palladium (Pd) defects in the interior and on the surfacemore » of the fuel pellet. It was found that the 160 kVp spectrum was unable to detect the presence of interior defects, whereas the 480 kVp spectrum detected them with both the standard and the RSD backscatter methods, though the RSD method was very inefficient. It was also found that both energy spectra were able to detect void and Pd defects on the surface using both imaging methods. Additionally, two mock fuel rods were imaged using a backscatter X-ray imaging system, one consisting of hafnium pellets in a Zircaloy-4 cladding and the other consisting of steel pellets in a Zircalloy-4 cladding which was then encased in a steel cladding (a double encapsulation configuration employed in irradiation and experiments). It was found that the system was capable of detecting individual HfO{sub 2} pellets in a Zircaloy-4 cladding and may be capable of detecting individual steel pellets in the double-encapsulated sample. It is expected that the system would also be capable of detecting individual UO{sub 2} pellets in a Zircaloy-4 cladding, though no UO{sub 2} fuel rod was available for imaging.« less

Effects of heat treatment on U-Mo fuel foils with a zirconium diffusion barrier

NASA Astrophysics Data System (ADS)

Jue, Jan-Fong; Trowbridge, Tammy L.; Breckenridge, Cynthia R.; Moore, Glenn A.; Meyer, Mitchell K.; Keiser, Dennis D.

2015-05-01

A monolith fuel design based on U-Mo alloy has been selected as the fuel type for conversion of the United States' high performance research reactors (HPRRs) from highly enriched uranium (HEU) to low-enriched uranium (LEU). In this fuel design, a thin layer of zirconium is used to eliminate the direct interaction between the U-Mo fuel meat and the aluminum-alloy cladding during irradiation. The co-rolling process used to bond the Zr barrier layer to the U-Mo foil during fabrication alters the microstructure of both the U-10Mo fuel meat and the U-Mo/Zr interface. This work studied the effects of post-rolling annealing treatment on the microstructure of the co-rolled U-Mo fuel meat and the U-Mo/Zr interaction layer. Microscopic characterization shows that the grain size of U-Mo fuel meat increases with the annealing temperature, as expected. The grain sizes were ∼9, ∼13, and ∼20 μm for annealing temperature of 650, 750, and 850 °C, respectively. No abnormal grain growth was observed. The U-Mo/Zr interaction-layer thickness increased with the annealing temperature with an Arrhenius constant for growth of 184 kJ/mole, consistent with a previous diffusion-couple study. The interaction layer thickness was 3.2 ± 0.5 μm, 11.1 ± 2.1 μm, 27.1 ± 0.9 μm for annealing temperature of 650, 750, to 850 °C, respectively. The homogeneity of Mo improves with post rolling annealing temperature and with U-Mo coupon homogenization. The phases in the Zr/U-Mo interaction layer produced by co-rolling, however, differ from those reported in the previous diffusion couple studies.

Effects of heat treatment on U–Mo fuel foils with a zirconium diffusion barrier

DOE Office of Scientific and Technical Information (OSTI.GOV)

Jue, Jan-Fong; Trowbridge, Tammy L.; Breckenridge, Cynthia R.

A monolith fuel design based on U–Mo alloy has been selected as the fuel type for conversion of the United States’ high performance research reactors (HPRRs) from highly enriched uranium (HEU) to low-enriched uranium (LEU). In this fuel design, a thin layer of zirconium is used to eliminate the direct interaction between the U–Mo fuel meat and the aluminum-alloy cladding during irradiation. The co-rolling process used to bond the Zr barrier layer to the U–Mo foil during fabrication alters the microstructure of both the U–10Mo fuel meat and the U–Mo/Zr interface. This work studied the effects of post-rolling annealing treatmentmore » on the microstructure of the co-rolled U–Mo fuel meat and the U–Mo/Zr interaction layer. Microscopic characterization shows that the grain size of U–Mo fuel meat increases with the annealing temperature, as expected. The grain sizes were ~9, ~13, and ~20 μm for annealing temperature of 650, 750, and 850 °C, respectively. No abnormal grain growth was observed. The U–Mo/Zr interaction-layer thickness increased with the annealing temperature with an Arrhenius constant for growth of 184 kJ/mole, consistent with a previous diffusion-couple study. The interaction layer thickness was 3.2 ± 0.5 μm, 11.1 ± 2.1 μm, 27.1 ± 0.9 μm for annealing temperature of 650, 750, to 850 °C, respectively. The homogeneity of Mo improves with post rolling annealing temperature and with U–Mo coupon homogenization. The phases in the Zr/U–Mo interaction layer produced by co-rolling, however, differ from those reported in the previous diffusion couple studies.« less

METHOD FOR MAKING FUEL ELEMENTS

DOEpatents

Kates, L.W.; Campbell, R.W.; Heartel, R.H.W.

1960-08-01

A method is given for making zirconium-clad uranium wire. A tube of zirconium is closed with a zirconium plug, after which a chilled uranium core is inserted in the tube to rest against the plug. Additional plugs and cores are inserted alternately as desired. The assembly is then sheathed with iron, hot worked to the desired size, and the iron sheath removed.

Measurement station for interim inspections of Lightbridge metallic fuel rods at the Halden Boiling Water Reactor

NASA Astrophysics Data System (ADS)

Hartmann, C.; Totemeier, A.; Holcombe, S.; Liverud, J.; Limi, M.; Hansen, J. E.; Navestad, E. AB(; )

2018-01-01

Lightbridge Corporation has developed a new Uranium-Zirconium based metallic fuel. The fuel rods aremanufactured via a co-extrusion process, and are characterized by their multi-lobed (cruciform-shaped) cross section. The fuel rods are also helically-twisted in the axial direction. Two experimental fuel assemblies, each containing four Lightbridge fuel rods, are scheduled to be irradiated in the Halden Boiling Water Reactor (HBWR) starting in 2018. In addition to on-line monitoring of fuel rod elongation and critical assembly conditions (e.g. power, flow rates, coolant temperatures, etc.) during the irradiation, several key parameters of the fuel will be measured out-of-core during interim inspections. An inspection measurement station for use in the irradiated fuel handling compartment at the HBWR has therefore been developed for this purpose. The multi-lobed cladding cross section combined with the spiral shape of the Lightbridge metallic fuel rods requires a high-precision guiding system to ensure good position repeatability combined with low-friction guiding. The measurement station is equipped with a combination of instruments and equipment supplied from third-party vendors and instruments and equipment developed at Institute for Energy Technology (IFE). Two sets of floating linear voltage differential transformer (LVDT) pairs are used to measure swelling and diameter changes between the lobes and the valleys over the length of the fuel rods. Eddy current probes are used to measure the thickness of oxide layers in the valleys and on the lobe tips and also to detect possible surface cracks/pores. The measurement station also accommodates gamma scans. Additionally, an eddy-current probe has been developed at IFE specifically to detect potential gaps or discontinuities in the bonding layer between the metallic fuel and the Zirconium alloy cladding. Potential gaps in the bonding layer will be hidden behind a 0.5-1.0 mm thick cladding wall. It has therefore been necessary to perform a careful design study of the probe geometry. For this, finite element analysis (FEA) has been performed in combination with practical validation tests on representative fuel dummies with machined flaws to find the probe geometry that best detects a hidden flaw. Tests performed thus far show that gaps down to 25 μm thickness can be detected with good repeatability and good discrimination from lift-off signals.

Development of new ferritic steels as cladding material for metallic fuel fast breeder reactor

NASA Astrophysics Data System (ADS)

Tokiwai, Moriyasu; Horie, Masaaki; Kako, Kenji; Fujiwara, Masayuki

1993-09-01

The excellent thermal, chemical and neutronic properties of metallic fuel (U-Pu-Zr alloy) will lead to drastic improvements in fast reactor safety and the related fuel cycle economy. Some new high molybdenum 12Cr ferritic stainless steel candidate cladding alloys have been designed to achieve the mechanical properties required for high performance metallic fuel elements. These candidate claddings were irradiated by ion bombardment and tested to determine their strength and creep rupture properties. A 12Cr-8Mo and a 12Cr-8Mo-0.1Y 2O 3 steel were fabricated into cladding via a powder metallurgy process and by a mechanical alloying process, respectively. These claddings had two and three times the creep rupture strength (pressurized at 650°C for 10000 h) of a conventional 12Cr ferritic steel (HT-9). These two steels also showed no void formation up to 350 dpa by Ni 3+ irradiation. A zircaloy-2 lined steel cladding tube has also been fabricated for the purpose of reducing fuel-cladding interdiffusion and chemical interaction.

Irradiation of Wrought FeCrAl Tubes in the High Flux Isotope Reactor

DOE Office of Scientific and Technical Information (OSTI.GOV)

Linton, Kory D.; Field, Kevin G.; Petrie, Christian M.

The Advanced Fuels Campaign within the Nuclear Technology Research and Development program of the Department of Energy Office of Nuclear Energy is seeking to improve the accident tolerance of light water reactors. Alumina-forming ferritic alloys (e.g., FeCrAl) are one of the leading candidate materials for fuel cladding to replace traditional zirconium alloys because of the superior oxidation resistance of FeCrAl. However, there are still some unresolved questions regarding irradiation effects on the microstructure and mechanical properties of FeCrAl at end-of-life dose levels. In particular, there are concerns related to irradiation-induced embrittlement of FeCrAl alloys due to secondary phase formation. Tomore » address this issue, Oak Ridge National Laboratory has developed a new experimental design to irradiate shortened cladding tube specimens with representative 17×17 array pressurized water reactor diameter and thickness in the High Flux Isotope Reactor (HFIR) under relevant temperatures (300–350°C). Post-irradiation examination will include studies of dimensional change, microstructural changes, and mechanical performance. This report briefly summarizes the capsule design concept and the irradiation test matrix for six rabbit capsules. Each rabbit contains two FeCrAl alloy tube specimens. The specimens include Generation I and Generation II FeCrAl alloys with varying processing conditions, Cr concentrations, and minor alloying elements. The rabbits were successfully assembled, welded, evaluated, and delivered to the HFIR along with a complete quality assurance fabrication package. Pictures of the rabbit assembly process and detailed dimensional inspection of select specimens are included in this report. The rabbits were inserted into HFIR starting in cycle 472 (May 2017).« less

The study of the modes of Ta-Zr powder mixture non-vacuum electron-beam cladding on the surface of the cp-titanium plates

NASA Astrophysics Data System (ADS)

Samoylenko, V. V.; Lozhkina, E. A.; Polyakov, I. A.; Lenivtseva, O. G.; Ivanchik, I. S.; Matts, O. E.

2016-11-01

The effect of the modes of non-vacuum electron-beam cladding of Ta-Zr powder mixtures on the structure and properties of the layers formed on the surface of cp-titanium were studied. The mode of the electron-beam alloying of titanium with zirconium and tantalum, which ensured the formation of a defect-free layer with a high content of alloying elements was selected. Metallographic examination indicated the presence of a dendritic- and plate-type structure of cladded layers. The microhardness of the layers, formed at the optimum mode, was not changed in the cross section and was equal to 450 HV.

NUCLEAR REACTOR FUEL ELEMENTS AND METHOD OF PREPARATION

DOEpatents

Kingston, W.E.; Kopelman, B.; Hausner, H.H.

1963-07-01

A fuel element consisting of uranium nitride and uranium carbide in the form of discrete particles in a solid coherent matrix of a metal such as steel, beryllium, uranium, or zirconium and clad with a metal such as steel, aluminum, zirconium, or beryllium is described. The element is made by mixing powdered uranium nitride and uranium carbide with powdered matrix metal, then compacting and sintering the mixture. (AEC)

Effect of hydrogenation conditions on the microstructure and mechanical properties of zirconium hydride

NASA Astrophysics Data System (ADS)

Muta, Hiroaki; Nishikane, Ryoji; Ando, Yusuke; Matsunaga, Junji; Sakamoto, Kan; Harjo, Stefanus; Kawasaki, Takuro; Ohishi, Yuji; Kurosaki, Ken; Yamanaka, Shinsuke

2018-03-01

Precipitation of brittle zirconium hydrides deteriorate the fracture toughness of the fuel cladding tubes of light water reactor. Although the hydride embrittlement has been studied extensively, little is known about physical properties of the hydride due to the experimental difficulties. In the present study, to elucidate relationship between mechanical properties and microstructure, two δ-phase zirconium hydrides and one ε-phase zirconium hydride were carefully fabricated considering volume changes at the metal-to-hydride transformation. The δ-hydride that was fabricated from α-zirconium exhibits numerous inner cracks due to the large volume change. Analyses of the neutron diffraction pattern and electron backscatter diffraction (EBSD) data show that the sample displays significant stacking faults in the {111} plane and in the pseudo-layered microstructure. On the other hand, the δ-hydride sample fabricated from β-zirconium at a higher temperature displays equiaxed grains and no cracks. The strong crystal orientation dependence of mechanical properties were confirmed by indentation test and EBSD observation. The δ-hydride hydrogenated from α-zirconium displays a lower Young's modulus than that prepared from β-zirconium. The difference is attributed to stacking faults within the {111} plane, for which the Young's modulus exhibits the highest value in the perpendicular direction. The strong influence of the crystal orientation and dislocation density on the mechanical properties should be considered when evaluating hydride precipitates in nuclear fuel cladding.

Status Report on the Fabrication of Fuel Cladding Chemical Interaction Test Articles for ATR Irradiations

DOE Office of Scientific and Technical Information (OSTI.GOV)

Field, Kevin G.; Howard, Richard H.

FeCrAl alloys are a promising new class of alloys for light water reactor (LWR) applications due to their superior oxidation and corrosion resistance in high temperature environments. The current R&D efforts have focused on the alloy composition and processing routes to generate nuclear grade FeCrAl alloys with optimized properties for enhanced accident tolerance while maintaining properties needed for normal operation conditions. Therefore, the composition and processing routes must be optimized to maintain the high temperature steam oxidation (typically achieved by increasing the Cr and Al content) while still exhibiting properties conducive to normal operation in a LWR (such as radiationmore » tolerance where reducing Cr content is favorable). Within this balancing act is the addition of understanding the influence on composition and processing routes on the FeCrAl alloys for fuel-cladding chemical interactions (FCCI). Currently, limited knowledge exists on FCCI for the FeCrAl-UO 2 clad-fuel system. To overcome the knowledge gaps on the FCCI for the FeCrAl-UO2 clad-fuel system a series of fueled irradiation tests have been developed for irradiation in the Advanced Test Reactor (ATR) housed at the Idaho National Laboratory (INL). The first series of tests has already been reported. These tests used miniaturized 17x17 PWR fuel geometry rodlets of second-generation FeCrAl alloys fueled with industrial Westinghouse UO 2 fuel. These rodlets were encapsulated within a stainless steel housing.To provide high fidelity experiments and more robust testing, a new series of rodlets have been developed deemed the Accident Tolerant Fuel Experiment #1 Oak Ridge National Laboratory FCCI test (ATF-1 ORNL FCCI). The main driving factor, which is discussed in detail, was to provide a radiation environment where prototypical fuel-clad interface temperatures are met while still maintaining constant contact between industrial fuel and the candidate cladding alloys, hence promoting FCCI between the fuel-clad systems. The other factor was to develop a test bed where multiple candidate alloys could be evaluated within a single irradiation test train, thereby reducing overall costs and increasing efficiency in alloy screening efforts. A collaboration between ORNL and INL was developed to facilitate the completion of the test bed for FCCI testing. The report highlights the activities related to the development of the ATF-1 ORNL FCCI rodlets for irradiation in INL’s ATR as part of the on-going ATF-1 experiments.« less

Dislocation dynamics simulations of interactions between gliding dislocations and radiation induced prismatic loops in zirconium

NASA Astrophysics Data System (ADS)

Drouet, Julie; Dupuy, Laurent; Onimus, Fabien; Mompiou, Frédéric; Perusin, Simon; Ambard, Antoine

2014-06-01

The mechanical behavior of Pressurized Water Reactor fuel cladding tubes made of zirconium alloys is strongly affected by neutron irradiation due to the high density of radiation induced dislocation loops. In order to investigate the interaction mechanisms between gliding dislocations and loops in zirconium, a new nodal dislocation dynamics code, adapted to Hexagonal Close Packed metals, has been used. Various configurations have been systematically computed considering different glide planes, basal or prismatic, and different characters, edge or screw, for gliding dislocations with -type Burgers vectors. Simulations show various interaction mechanisms such as (i) absorption of a loop on an edge dislocation leading to the formation of a double super-jog, (ii) creation of a helical turn, on a screw dislocation, that acts as a strong pinning point or (iii) sweeping of a loop by a gliding dislocation. It is shown that the clearing of loops is more favorable when the dislocation glides in the basal plane than in the prismatic plane explaining the easy dislocation channeling in the basal plane observed after neutron irradiation by transmission electron microscopy.

A Multi-Stage Wear Model for Grid-to-Rod Fretting of Nuclear Fuel Rods

DOE Office of Scientific and Technical Information (OSTI.GOV)

Blau, Peter Julian

The wear of fuel rod cladding against the supporting structures in the cores of pressurized water nuclear reactors (PWRs) is an important and potentially costly tribological issue. Grid-to-rod fretting (GTRF), as it is known, involves not only time-varying contact conditions, but also elevated temperatures, flowing hot water, aqueous tribo-corrosion, and the embrittling effects of neutron fluences. The multi-stage, closed-form analytical model described in this paper relies on published out-of-reactor wear and corrosion data and a set of simplifying assumptions to portray the conversion of frictional work into wear depth. The cladding material of interest is a zirconium-based alloy called Zircaloy-4,more » and the grid support is made of a harder and more wear-resistant material. Focus is on the wear of the cladding. The model involves an incubation stage, a surface oxide wear stage, and a base alloy wear stage. The wear coefficient, which is a measure of the efficiency of conversion of frictional work into wear damage, can change to reflect the evolving metallurgical condition of the alloy. Wear coefficients for Zircaloy-4 and for a polyphase zirconia layer were back-calculated for a range of times required to wear to a critical depth. Inputs for the model, like the friction coefficient, are taken from the tribology literature in lieu of in-reactor tribological data. Concepts of classical fretting were used as a basis, but are modified to enable the model to accommodate the complexities of the PWR environment. Factors like grid spring relaxation, pre-oxidation of the cladding, multiple oxide phases, gap formation, impact, and hydrogen embrittlement are part of the problem definition but uncertainties in their relative roles limits the ability to validate the model. Sample calculations of wear depth versus time in the cladding illustrate how GTRF wear might occur in a discontinuous fashion during months-long reactor operating cycles. A means to account for grid/rod gaps and repetitive impact effects on GTRF wear is proposed« less

Composite construction for nuclear fuel containers

DOEpatents

Cheng, Bo-Ching [Fremont, CA; Rosenbaum, Herman S [Fremont, CA; Armijo, Joseph S [Saratoga, CA

1987-01-01

An improved method for producing nuclear fuel containers of a composite construction having components providing therein a barrier system for resisting destructive action by volatile fission products or impurities and also interdiffusion of metal constituents, and the product thereof. The composite nuclear fuel containers of the method comprise a casing of zirconium or alloy thereof with a layer of copper overlying an oxidized surface portion of the zirconium or alloy thereof.

PROCESS FOR DISSOLVING BINARY URANIUM-ZIRCONIUM OR ZIRCONIUM-BASE ALLOYS

DOEpatents

Jonke, A.A.; Barghusen, J.J.; Levitz, N.M.

1962-08-14

A process of dissolving uranium-- zirconium and zircaloy alloys, e.g. jackets of fuel elements, with an anhydrous hydrogen fluoride containing from 10 to 32% by weight of hydrogen chloride at between 400 and 450 deg C., preferably while in contact with a fluidized inert powder, such as calcium fluoride is described. (AEC)

Characterization of deformation mechanisms in zirconium alloys: effect of temperature and irradiation

NASA Astrophysics Data System (ADS)

Long, Fei

Zirconium alloys have been widely used in the CANDU (CANada Deuterium Uranium) reactor as core structural materials. Alloy such as Zircaloy-2 has been used for calandria tubes; fuel cladding; the pressure tube is manufactured from alloy Zr-2.5Nb. During in-reactor service, these alloys are exposed to a high flux of fast neutron at elevated temperatures. It is important to understand the effect of temperature and irradiation on the deformation mechanism of zirconium alloys. Aiming to provide experimental guidance for future modeling predictions on the properties of zirconium alloys this thesis describes the result of an investigation of the change of slip and twinning modes in Zircaloy-2 and Zr-2.5Nb as a function of temperature and irradiation. The aim is to provide scientific fundamentals and experimental evidences for future industry modeling in processing technique design, and in-reactor property change prediction of zirconium components. In situ neutron diffraction mechanical tests carried out on alloy Zircaloy-2 at three temperatures: 100¢ªC, 300¢ªC, and 500¢ªC, and described in Chapter 3. The evolution of the lattice strain of individual grain families in the loading and Poisson's directions during deformation, which probes the operation of slip and twinning modes at different stress levels, are described. By using the same type of in situ neutron diffraction technique, tests on Zr-2.5Nb pressure tube material samples, in either the fast-neutron irradiated or un-irradiated condition, are reported in Chapter 4. In Chapter 5, the measurement of dislocation density by means of line profile analysis of neutron diffraction patterns, as well as TEM observations of the dislocation microstructural evolution, is described. In Chapter 6 a hot-rolled Zr-2.5Nb with a larger grain size compared with the pressure tubing was used to study the development of dislocation microstructures with increasing plastic strain. In Chapter 7, in situ loading of heavy ion irradiated hot-rolled Zr-2.5Nb alloy is described, providing evidence for the interaction between moving dislocations and irradiation induced loops. Chapter 8 gives the effect on the dislocation structure of different levels of compressive strains along two directions in the hot-rolled Zr-2.5Nb alloy. By using high resolution neutron diffraction and TEM observations, the evolution of type and dislocation densities, as well as changes of dislocation microstructure with plastic strain were characterized.

Composite construction for nuclear fuel containers

DOEpatents

Cheng, B. C.; Rosenbaum, H. S.; Armijo, J. S.

1987-04-21

Disclosed is an improved method for producing nuclear fuel containers of a composite construction having components providing therein a barrier system for resisting destructive action by volatile fission products or impurities and also interdiffusion of metal constituents, and the product thereof. The composite nuclear fuel containers of the method comprise a casing of zirconium or alloy thereof with a layer of copper overlying an oxidized surface portion of the zirconium or alloy thereof. 1 fig.

PROCESS OF DISSOLVING FUEL ELEMENTS OF NUCLEAR REACTORS

DOEpatents

Wall, E.M.V.; Bauer, D.T.; Hahn, H.T.

1963-09-01

A process is described for dissolving stainless-steelor zirconium-clad uranium dioxide fuel elements by immersing the elements in molten lead chloride, adding copper, cuprous chloride, or cupric chloride as a catalyst and passing chlorine through the salt mixture. (AEC)

Process for massively hydriding zirconium--uranium fuel elements

DOEpatents

Katz, N.H.

1973-12-01

A method is described of hydriding uranium-zirconium alloy by heating the alloy in a vacuum, introducing hydrogen and maintaining an elevated temperature until occurrence of the beta--delta phase transformation and isobarically cooling the composition. (Official Gazette)

NUCLEAR REACTOR COMPENENT CLADDING MATERIAL

DOEpatents

Draley, J.E.; Ruther, W.E.

1959-01-27

Fuel elements and coolant tubes used in nuclear reactors of the heterogeneous, water-cooled type are described, wherein the coolant tubes extend through the moderator and are adapted to contain the fuel elements. The invention comprises forming the coolant tubes and the fuel element cladding material from an alloy of aluminum and nickel, or an alloy of aluminum, nickel, alloys are selected to prevent intergranular corrosion of these components by water at temperatures up to 35O deg C.

Duct and cladding alloy

DOEpatents

Korenko, Michael K.

1983-01-01

An austenitic alloy having good thermal stability and resistance to sodium corrosion at 700.degree. C. consists essentially of 35-45% nickel 7.5-14% chromium 0.8-3.2% molybdenum 0.3-1.0% silicon 0.2-1.0% manganese 0-0.1% zirconium 2.0-3.5% titanium 1.0-2.0% aluminum 0.02-0.1% carbon 0-0.01% boron and the balance iron.

Fabrication of Monolithic RERTR Fuels by Hot Isostatic Pressing

DOE Office of Scientific and Technical Information (OSTI.GOV)

Jan-Fong Jue; Blair H. Park; Curtis R. Clark

2010-11-01

The RERTR (Reduced Enrichment for Research and Test Reactors) Program is developing advanced nuclear fuels for high-power test reactors. Monolithic fuel design provides higher uranium loading than that of the traditional dispersion fuel design. Hot isostatic pressing is a promising process for low-cost batch fabrication of monolithic RERTR fuel plates for these high-power reactors. Bonding U Mo fuel foil and 6061 Al cladding by hot isostatic press bonding was successfully developed at Idaho National Laboratory. Due to the relatively high processing temperature, the interaction between fuel meat and aluminum cladding is a concern. Two different methods were employed to mitigatemore » this effect: (1) a diffusion barrier and (2) a doping addition to the interface. Both types of fuel plates have been fabricated by hot isostatic press bonding. Preliminary results show that the direct fuel/cladding interaction during the bonding process was eliminated by introducing a thin zirconium diffusion barrier layer between the fuel and the cladding. Fuel plates were also produced and characterized with a silicon-rich interlayer between fuel and cladding. This paper reports the recent progress of this developmental effort and identifies the areas that need further attention.« less

Method for forming nuclear fuel containers of a composite construction and the product thereof

DOEpatents

Cheng, Bo-Ching; Rosenbaum, Herman S.; Armijo, Joseph S.

1984-01-01

An improved method for producing nuclear fuel containers of a composite construction having components providing therein a barrier system for resisting destructive action by volatile fission products or impurities and also interdiffusion of metal constituents, and the product thereof. The composite nuclear fuel containers of the method comprise a casing of zirconium or alloy thereof with a layer of copper overlying an oxidized surface portion of the zirconium or alloy thereof.

Powder Metallurgy of Uranium Alloy Fuels for TRU-Burning Reactors Final Technical Report

DOE Office of Scientific and Technical Information (OSTI.GOV)

McDeavitt, Sean M

2011-04-29

Overview Fast reactors were evaluated to enable the transmutation of transuranic isotopes generated by nuclear energy systems. The motivation for this was that TRU isotopes have high radiotoxicity and relatively long half-lives, making them unattractive for disposal in a long-term geologic repository. Fast reactors provide an efficient means to utilize the energy content of the TRUs while destroying them. An enabling technology that requires research and development is the fabrication metallic fuel containing TRU isotopes using powder metallurgy methods. This project focused upon developing a powder metallurgical fabrication method to produce U-Zr-transuranic (TRU) alloys at relatively low processing temperatures (500ºCmore » to 600ºC) using either hot extrusion or alpha-phase sintering for charecterization. Researchers quantified the fundamental aspects of both processing methods using surrogate metals to simulate the TRU elements. The process produced novel solutions to some of the issues relating to metallic fuels, such as fuel-cladding chemical interactions, fuel swelling, volatility losses during casting, and casting mold material losses. Workscope There were two primary tasks associated with this project: 1. Hot working fabrication using mechanical alloying and extrusion • Design, fabricate, and assemble extrusion equipment • Extrusion database on DU metal • Extrusion database on U-10Zr alloys • Extrusion database on U-20xx-10Zr alloys • Evaluation and testing of tube sheath metals 2. Low-temperature sintering of U alloys • Design, fabricate, and assemble equipment • Sintering database on DU metal • Sintering database on U-10Zr alloys • Liquid assisted phase sintering on U-20xx-10Zr alloys Appendices Outline Appendix A contains a Fuel Cycle Research & Development (FCR&D) poster and contact presentation where TAMU made primary contributions. Appendix B contains MSNE theses and final defense presentations by David Garnetti and Grant Helmreich outlining the beginning of the materials processing setup. Also included within this section is a thesis proposal by Jeff Hausaman. Appendix C contains the public papers and presentations introduced at the 2010 American Nuclear Society Winter Meeting. Appendix A—MSNE theses of David Garnetti and Grant Helmreich and proposal by Jeff Hausaman A.1 December 2009 Thesis by David Garnetti entitled “Uranium Powder Production Via Hydride Formation and Alpha Phase Sintering of Uranium and Uranium-Zirconium Alloys for Advanced Nuclear Fuel Applications” A.2 September 2009 Presentation by David Garnetti (same title as document in Appendix B.1) A.3 December 2010 Thesis by Grant Helmreich entitled “Characterization of Alpha-Phase Sintering of Uranium and Uranium-Zirconium Alloys for Advanced Nuclear Fuel Applications” A.4 October 2010 Presentation by Grant Helmreich (same title as document in Appendix B.3) A.5 Thesis Proposal by Jeffrey Hausaman entitled “Hot Extrusion of Alpha Phase Uranium-Zirconium Alloys for TRU Burning Fast Reactors” Appendix B—External presentations introduced at the 2010 ANS Winter Meeting B.1 J.S. Hausaman, D.J. Garnetti, and S.M. McDeavitt, “Powder Metallurgy of Alpha Phase Uranium Alloys for TRU Burning Fast Reactors,” Proceedings of 2010 ANS Winter Meeting, Las Vegas, Nevada, USA, November 7-10, 2010 B.2 PowerPoint Presentation Slides from C.1 B.3 G.W. Helmreich, W.J. Sames, D.J. Garnetti, and S.M. McDeavitt, “Uranium Powder Production Using a Hydride-Dehydride Process,” Proceedings of 2010 ANS Winter Meeting, Las Vegas, Nevada, USA, November 7-10, 2010 B.4. PowerPoint Presentation Slides from C.3 B.5 Poster Presentation from C.3 Appendix C—Fuel cycle research and development undergraduate materials and poster presentation C.1 Poster entitled “Characterization of Alpha-Phase Sintering of Uranium and Uranium-Zirconium Alloys” presented at the Fuel Cycle Technologies Program Annual Meeting C.2 April 2011 Honors Undergraduate Thesis by William Sames, Research Fellow, entitled “Uranium Metal Powder Production, Particle Distribution Analysis, and Reaction Rate Studies of a Hydride-Dehydride Process"« less

Severe Accident Scoping Simulations of Accident Tolerant Fuel Concepts for BWRs

DOE Office of Scientific and Technical Information (OSTI.GOV)

Robb, Kevin R.

2015-08-01

Accident-tolerant fuels (ATFs) are fuels and/or cladding that, in comparison with the standard uranium dioxide Zircaloy system, can tolerate loss of active cooling in the core for a considerably longer time period while maintaining or improving the fuel performance during normal operations [1]. It is important to note that the currently used uranium dioxide Zircaloy fuel system tolerates design basis accidents (and anticipated operational occurrences and normal operation) as prescribed by the US Nuclear Regulatory Commission. Previously, preliminary simulations of the plant response have been performed under a range of accident scenarios using various ATF cladding concepts and fully ceramicmore » microencapsulated fuel. Design basis loss of coolant accidents (LOCAs) and station blackout (SBO) severe accidents were analyzed at Oak Ridge National Laboratory (ORNL) for boiling water reactors (BWRs) [2]. Researchers have investigated the effects of thermal conductivity on design basis accidents [3], investigated silicon carbide (SiC) cladding [4], as well as the effects of ATF concepts on the late stage accident progression [5]. These preliminary analyses were performed to provide initial insight into the possible improvements that ATF concepts could provide and to identify issues with respect to modeling ATF concepts. More recently, preliminary analyses for a range of ATF concepts have been evaluated internationally for LOCA and severe accident scenarios for the Chinese CPR1000 [6] and the South Korean OPR-1000 [7] pressurized water reactors (PWRs). In addition to these scoping studies, a common methodology and set of performance metrics were developed to compare and support prioritizing ATF concepts [8]. A proposed ATF concept is based on iron-chromium-aluminum alloys (FeCrAl) [9]. With respect to enhancing accident tolerance, FeCrAl alloys have substantially slower oxidation kinetics compared to the zirconium alloys typically employed. During a severe accident, FeCrAl would tend to generate heat and hydrogen from oxidation at a slower rate compared to the zirconium-based alloys in use today. The previous study, [2], of the FeCrAl ATF concept during station blackout (SBO) severe accident scenarios in BWRs was based on simulating short term SBO (STSBO), long term SBO (LTSBO), and modified SBO scenarios occurring in a BWR-4 reactor with MARK-I containment. The analysis indicated that FeCrAl had the potential to delay the onset of fuel failure by a few hours depending on the scenario, and it could delay lower head failure by several hours. The analysis demonstrated reduced in-vessel hydrogen production. However, the work was preliminary and was based on limited knowledge of material properties for FeCrAl. Limitations of the MELCOR code were identified for direct use in modeling ATF concepts. This effort used an older version of MELCOR (1.8.5). Since these analyses, the BWR model has been updated for use in MELCOR 1.8.6 [10], and more representative material properties for FeCrAl have been modeled. Sections 2 4 present updated analyses for the FeCrAl ATF concept response during severe accidents in a BWR. The purpose of the study is to estimate the potential gains afforded by the FeCrAl ATF concept during BWR SBO scenarios.« less

Hydrogenation behavior of Ti-implanted Zr-1Nb alloy with TiN films deposited using filtered vacuum arc and magnetron sputtering

NASA Astrophysics Data System (ADS)

Kashkarov, E. B.; Nikitenkov, N. N.; Sutygina, A. N.; Bezmaternykh, A. O.; Kudiiarov, V. N.; Syrtanov, M. S.; Pryamushko, T. S.

2018-02-01

More than 60 years of operation of water-cooled reactors have shown that local or general critical hydrogen concentration is one of the basic limiting criteria of zirconium-based fuel element claddings. During the coolant radiolysis, released hydrogen penetrates and accumulates in zirconium alloys. Hydrogenation of zirconium alloys leads to degradation of their mechanical properties, hydride cracking and stress corrosion cracking. In this research the effect of titanium nitride (TiN) deposition on hydrogenation behavior of Ti-implanted Zr-1Nb alloy was described. Ti-implanted interlayer was fabricated by plasma immersion ion implantation (PIII) at the pulsed bias voltage of 1500 V to improve the adhesion of TiN and reduce hydrogen penetration into Zr-1Nb alloy. We conducted the comparative analysis on hydrogenation behavior of the Ti-implanted alloy with sputtered and evaporated TiN films by reactive dc magnetron sputtering (dcMS) and filtered cathodic vacuum arc deposition (FVAD), respectively. The crystalline structure and surface morphology were investigated using X-ray diffraction (XRD) and scanning electron microscopy (SEM). The elemental distribution was analyzed using glow-discharge optical emission spectroscopy (GD-OES). Hydrogenation was performed from gas atmosphere at 350 °C and 2 atm hydrogen pressure. The results revealed that TiN films as well as Ti implantation significantly reduce hydrogen absorption rate of Zr-1Nb alloy. The best performance to reduce the rate of hydrogen absorption is Ti-implanted layer with evaporated TiN film. Morphology of the films impacted hydrogen permeation through TiN films: the denser film the lower hydrogen permeation. The Ti-implanted interface plays an important role of hydrogen accumulation layer for trapping the penetrated hydrogen. No deterioration of adhesive properties of TiN films on Zr-1Nb alloy with Ti-implanted interface occurs under high-temperature hydrogen exposure. Thus, the fabrication of Ti-implanted layer with dense TiN films can be an effective way to protect Zr-1Nb alloy from hydrogen embrittlement.

Examination of T-111 clad uranium nitride fuel pins irradiated up to 13,000 hours at a clad temperature of 990 C

NASA Technical Reports Server (NTRS)

Slaby, J. G.; Siegel, B. L.

1973-01-01

The examination of 27 fuel pins irradiated for up to 13,000 hours at 990 C is described. The fuel pin clad was a tantalum alloy with uranium nitride as the nuclear fuel. Two nominal fuel pin diameters were tested with a maximum burnup of 2.34 atom percent. Twenty-two fuel pins were tested for fission gas leaks; thirteen pins leaked. Clad ductility tests indicated clad embrittlement. The embrittlement is attributed to hydrogen from an n,p reaction in the fuel. Fuel swelling was burnup dependent, and the amount of fission gas release was low, generally less than 0.5 percent. No incompatibilities between fuel, liner, and clad were in evidence.

Equations of state for crystalline zirconium iodide: The role of dispersion

NASA Astrophysics Data System (ADS)

Rossi, Matthew L.; Taylor, Christopher D.

2013-02-01

We present the first-principle equations of state of several zirconium iodides, ZrI2, ZrI3, and ZrI4, computed using density functional theory methods that apply various methods for introducing the dispersion correction. Iodides formed due to reaction of molecular or atomic iodine with zirconium and zircaloys are of particular interest due to their application to the cladding material used in the fabrication of nuclear fuel rods. Stress corrosion cracking (SCC), associated with fission product chemistry with the clad material, is a major concern in the life cycle of nuclear fuels, as many of the observed rod failures have occurred due to pellet-cladding chemical interactions (PCCI) [A. Atrens, G. Dannhäuser, G. Bäro, Stress-corrosion-cracking of zircaloy-4 cladding tubes, Journal of Nuclear Materials 126 (1984) 91-102; P. Rudling, R. Adamson, B. Cox, F. Garzarolli, A. Strasser, High burn-up fuel issues, Nuclear Engineering and Technology 40 (2008) 1-8]. A proper understanding of the physical properties of the corrosion products is, therefore, required for the development of a comprehensive SCC model. In this particular work, we emphasize that, while existing modeling techniques include methods to compute crystal structures and associated properties, it is important to capture intermolecular forces not traditionally included, such as van der Waals (dispersion) correction. Furthermore, crystal structures with stoichiometries favoring a high I:Zr ratio are found to be particularly sensitive, such that traditional density functional theory approaches that do not incorporate dispersion incorrectly predict significantly larger volumes of the lattice. This latter point is related to the diffuse nature of the iodide electron cloud.

Evaluation of Tritium Content and Release from Pressurized Water Reactor Fuel Cladding

DOE Office of Scientific and Technical Information (OSTI.GOV)

Robinson, Sharon M.; Chattin, Marc Rhea; Giaquinto, Joseph

2015-09-01

It is expected that tritium pretreatment will be required in future reprocessing plants to prevent the release of tritium to the environment (except for long-cooled fuels). To design and operate future reprocessing plants in a safe and environmentally compliant manner, the amount and form of tritium in the used nuclear fuel (UNF) must be understood and quantified. Tritium in light water reactor (LWR) fuel is dispersed between the fuel matrix and the fuel cladding, and some tritium may be in the plenum, probably as tritium labelled water (THO) or T 2O. In a standard processing flowsheet, tritium management would bemore » accomplished by treatment of liquid streams within the plant. Pretreating the fuel prior to dissolution to release the tritium into a single off-gas stream could simplify tritium management, so the removal of tritium in the liquid streams throughout the plant may not be required. The fraction of tritium remaining in the cladding may be reduced as a result of tritium pretreatment. Since Zircaloy® cladding makes up roughly 25% by mass of UNF in the United States, processes are being considered to reduce the volume of reprocessing waste for Zircaloy® clad fuel by recovering the zirconium from the cladding for reuse. These recycle processes could release the tritium in the cladding. For Zircaloy-clad fuels from light water reactors, the tritium produced from ternary fission and other sources is expected to be divided between the fuel, where it is generated, and the cladding. It has been previously documented that a fraction of the tritium produced in uranium oxide fuel from LWRs can migrate and become trapped in the cladding. Estimates of the percentage of tritium in the cladding typically range from 0–96%. There is relatively limited data on how the tritium content of the cladding varies with burnup and fuel history (temperature, power, etc.) and how pretreatment impacts its release. To gain a better understanding of how tritium in cladding will behave during processing, scoping tests are being performed to determine the tritium content in the cladding pre- and post-tritium pretreatment. Samples of Surry-2 and H.B. Robinson pressurized water reactor cladding were heated to 1100–1200°C to oxidize the zirconium and release all of the tritium in the cladding sample. Cladding samples were also heated within the temperature range of 480–600ºC expected for standard air tritium pretreatment systems, and to a slightly higher temperature (700ºC) to determine the impact of tritium pretreatment on tritium release from the cladding. The tritium content of the Surry-2 and H.B. Robinson cladding was measured to be ~234 and ~500 µCi/g, respectively. Heating the Surry-2 cladding at 500°C for 24 h removed ~0.2% of the tritium from the cladding, and heating at 700°C for 24 h removed ~9%. Heating the H.B. Robinson cladding at 700°C for 24 h removed ~11% of the tritium. When samples of the Surry-2 and H.B. Robinson claddings were heated at 700°C for 96 h, essentially all of the tritium in the cladding was removed. However, only ~3% of the tritium was removed when a sample of Surry-2 cladding was heated at 600°C for 96 h. These data indicate that the amount of tritium released from tritium pretreatment systems will be dependent on both the operating temperature and length of time in the system. Under certain conditions, a significant fraction of the tritium could remain bound in the cladding and would need to be considered in operations involving cladding recycle.« less

High Temperature Fuel Cladding Chemical Interactions Between TRIGA Fuels and 304 Stainless Steel

DOE Office of Scientific and Technical Information (OSTI.GOV)

Perez, Emmanuel; Keiser, Jr., Dennis D.; Forsmann, Bryan

High-temperature fuel-cladding chemical interactions (FCCI) between TRIGA (Training, Research, Isotopes, General Atomics) fuel elements and the 304 stainless steel (304SS) are of interest to develop an understanding of the fuel behavior during transient reactor scenarios. TRIGA fuels are composed of uranium (U) particles dispersed in a zirconium-hydride (Zr-H) matrix. In reactor, the fuel is encased in 304-stainless-steel (304SS) or Incoloy 800 clad tubes. At high temperatures, the fuel can readily interact with the cladding, resulting in FCCI. A number of FCCI can take place in this system. Interactions can be expected between the cladding and the Zr-H matrix, and/or betweenmore » the cladding and the U-particles. Other interactions may be expected between the Zr-H matrix and the U-particles. Furthermore, the fuel contains erbium-oxide (Er-O) additions. Interactions can also be expected between the Er-O, the cladding, the Zr-H and the U-particles. The overall result is that very complex interactions may take place as a result of fuel and cladding exposures to high temperatures. This report discusses the characterization of the baseline fuel microstructure in the as-received state (prior to exposure to high temperature), characterization of the fuel after annealing at 950C for 24 hours and the results from diffusion couple experiments carries out at 1000C for 5 and 24 hours. Characterization was carried out via scanning electron microscopy (SEM) and transmission electron microscopy (TEM) with sample preparation via focused ion beam in situ-liftout-technique.« less

Testing of uranium nitride fuel in T-111 cladding at 1200 K cladding temperature

NASA Technical Reports Server (NTRS)

Rohal, R. G.; Tambling, T. N.; Smith, R. L.

1973-01-01

Two groups of six fuel pins each were assembled, encapsulated, and irradiated in the Plum Brook Reactor. The fuel pins employed uranium mononitride (UN) in a tantalum alloy clad. The first group of fuel pins was irradiated for 1500 hours to a maximum burnup of 0.7-atom-percent uranium. The second group of fuel pins was irradiated for about 3000 hours to a maximum burnup of 1.0-atom-percent uranium. The average clad surface temperature during irradiation of both groups of fuel pins was approximately 1200 K. The postirradiation examination revealed the following: no clad failures or fuel swelling occurred; less than 1 percent of the fission gases escaped from the fuel; and the clad of the first group of fuel pins experienced clad embrittlement whereas the second group, which had modified assembly and fabrication procedures to minimize contamination, had a ductile clad after irradiation.

Numerical Simulations on the Laser Spot Welding of Zirconium Alloy Endplate for Nuclear Fuel Bundle Assembly

NASA Astrophysics Data System (ADS)

Satyanarayana, G.; Narayana, K. L.; Boggarapu, Nageswara Rao

2018-03-01

In the nuclear industry, a critical welding process is joining of an end plate to a fuel rod to form a fuel bundle. Literature on zirconium welding in such a critical operation is limited. A CFD model is developed and performed for the three-dimensional non-linear thermo-fluid analysis incorporating buoyancy and Marnangoni stress and specifying temperature dependent properties to predict weld geometry and temperature field in and around the melt pool of laser spot during welding of a zirconium alloy E110 endplate with a fuel rod. Using this method, it is possible to estimate the weld pool dimensions for the specified laser power and laser-on-time. The temperature profiles will estimate the HAZ and microstructure. The adequacy of generic nature of the model is validated with existing experimental data.

Nuclear-powered pacemaker fuel cladding study. [Difficulty of dissolving cladding and /sup 238/PuO/sub 2/ for obtaining materials for acts of terrorism

DOE Office of Scientific and Technical Information (OSTI.GOV)

Shoup, R.L.

1976-07-01

The fabrication of fuel capsules with refractory metal and alloy clads used in nuclear-powered cardiac pacemakers precludes the expedient dissolution of the clad in inorganic acid solutions. An experiment to measure penetration rates of acids on commonly used fuel pellet clads indicated that it is not impossible, but that it would be very difficult to dissolve the multiple cladding. This work was performed because of a suggestion that a /sup 238/PuO/sub 2/-powered pacemaker could be transformed into a terrorism weapon.

Layer Formation On Metal Surfaces In Lead-Bismuth At High Temperatures In Presence Of Zirconium

DOE Office of Scientific and Technical Information (OSTI.GOV)

Loewen, Eric Paul; Yount, Hannah J.; Volk, Kevin

If the operating temperature lead–bismuth cooled fission reactor could be extended to 800 °C, they could produce hydrogen directly from water. A key issue for the deployment of this technology at these temperatures is the corrosion of the fuel cladding and structural materials by the lead–bismuth. Corrosion studies of several metals were performed to correlate the interaction layer formation rate as a function of time, temperature, and alloy compositions. The interaction layer is defined as the narrow band between the alloy substrate and the solidified lead–bismuth eutectic on the surface. Coupons of HT-9, 410, 316L, and F22 were tested atmore » 550 and 650 °C for 1000 h inside a zirconium corrosion cell. The oxygen potential ranged from approximately 10-22 to 10-19 Pa. Analyses were performed on the coupons to determine the depth of the interaction layer and the composition, at each time step (100, 300, and 1000 h). The thickness of the interaction layer on F22 at 550 °C was 25.3 µm, the highest of all the alloys tested, whereas at 650 °C, the layer thickness was only 5.6 µm, the lowest of all the alloys tested. The growth of the interaction layer on F22 at 650 °C was suppressed, owing to the presence of Zr (at 1500 wppm) in the LBE. In the case of 316L, the interaction layers of 4.9 and 10.6 µm were formed at 550 and 650 °C, respectively.« less

Interfacing VPSC with finite element codes. Demonstration of irradiation growth simulation in a cladding tube

DOE Office of Scientific and Technical Information (OSTI.GOV)

Patra, Anirban; Tome, Carlos

This Milestone report shows good progress in interfacing VPSC with the FE codes ABAQUS and MOOSE, to perform component-level simulations of irradiation-induced deformation in Zirconium alloys. In this preliminary application, we have performed an irradiation growth simulation in the quarter geometry of a cladding tube. We have benchmarked VPSC-ABAQUS and VPSC-MOOSE predictions with VPSC-SA predictions to verify the accuracy of the VPSCFE interface. Predictions from the FE simulations are in general agreement with VPSC-SA simulations and also with experimental trends.

Zirconium behaviour during electrorefining of actinide-zirconium alloy in molten LiCl-KCl on aluminium cathodes

NASA Astrophysics Data System (ADS)

Meier, R.; Souček, P.; Malmbeck, R.; Krachler, M.; Rodrigues, A.; Claux, B.; Glatz, J.-P.; Fanghänel, Th.

2016-04-01

A pyrochemical electrorefining process for the recovery of actinides from metallic nuclear fuel based on actinide-zirconium alloys (An-Zr) in a molten salt is being investigated. In this process actinides are group-selectively recovered on solid aluminium cathodes as An-Al alloys using a LiCl-KCl eutectic melt at a temperature of 450 °C. In the present study the electrochemical behaviour of zirconium during electrorefining was investigated. The maximum amount of actinides that can be oxidised without anodic co-dissolution of zirconium was determined at a selected constant cathodic current density. The experiment consisted of three steps to assess the different stages of the electrorefining process, each of which employing a fresh aluminium cathode. The results indicate that almost a complete dissolution of the actinides without co-dissolution of zirconium is possible under the applied experimental conditions.

METHOD OF FORMING A FUEL ELEMENT FOR A NUCLEAR REACTOR

DOEpatents

Layer, E.H. Jr.; Peet, C.S.

1962-01-23

A method is given for preparing a fuel element for a nuclear reactor. The method includes the steps of sandblasting a body of uranium dioxide to roughen the surface thereof, depositing a thin layer of carbon thereon by thermal decomposition of methane, and cladding the uranium dioxide body with zirconium by gas pressure bonding. (AEC)

Optimized manufacture of nuclear fuel cladding tubes by FEA of hot extrusion and cold pilgering processes

NASA Astrophysics Data System (ADS)

Gaillac, Alexis; Ly, Céline

2018-05-01

Within the forming route of Zirconium alloy cladding tubes, hot extrusion is used to deform the forged billets into tube hollows, which are then cold rolled to produce the final tubes with the suitable properties for in-reactor use. The hot extrusion goals are to give the appropriate geometry for cold pilgering, without creating surface defects and microstructural heterogeneities which are detrimental for subsequent rolling. In order to ensure a good quality of the tube hollows, hot extrusion parameters have to be carefully chosen. For this purpose, finite element models are used in addition to experimental tests. These models can take into account the thermo-mechanical coupling conditions obtained in the tube and the tools during extrusion, and provide a good prediction of the extrusion load and the thermo-mechanical history of the extruded product. This last result can be used to calculate the fragmentation of the microstructure in the die and the meta-dynamic recrystallization after extrusion. To further optimize the manufacturing route, a numerical model of the cold pilgering process is also applied, taking into account the complex geometry of the tools and the pseudo-steady state rolling sequence of this incremental forming process. The strain and stress history of the tube during rolling can then be used to assess the damage risk thanks to the use of ductile damage models. Once validated vs. experimental data, both numerical models were used to optimize the manufacturing route and the quality of zirconium cladding tubes. This goal was achieved by selecting hot extrusion parameters giving better recrystallized microstructure that improves the subsequent formability. Cold pilgering parameters were also optimized in order to reduce the potential ductile damage in the cold rolled tubes.

Hydrogen in Ti and Zr alloys: industrial perspective, failure modes and mechanistic understanding

NASA Astrophysics Data System (ADS)

Chapman, T. P.; Dye, D.; Rugg, D.

2017-06-01

Titanium is widely used in demanding applications, such as in aerospace. Its strength-to-weight ratio and corrosion resistance make it well suited to highly stressed rotating components. Zirconium has a no less critical application where its low neutron capture cross section and good corrosion resistance in hot water and steam make it well suited to reactor core use, including fuel cladding and structures. The similar metallurgical behaviour of these alloy systems makes it alluring to compare and contrast their behaviour. This is rarely undertaken, mostly because the industrial and academic communities studying these alloys have little overlap. The similarities with respect to hydrogen are remarkable, albeit potentially unsurprising, and so this paper aims to provide an overview of the role hydrogen has to play through the material life cycle. This includes the relationship between alloy design and manufacturing process windows, the role of hydrogen in degradation and failure mechanisms and some of the underpinning metallurgy. The potential role of some advanced experimental and modelling techniques will also be explored to give a tentative view of potential for advances in this field in the next decade or so. This article is part of the themed issue 'The challenges of hydrogen and metals'.

Feasibility of processing the experimental breeder reactor-II driver fuel from the Idaho National Laboratory through Savannah River Site's H-Canyon facility

DOE Office of Scientific and Technical Information (OSTI.GOV)

Magoulas, V. E.

Savannah River National Laboratory (SRNL) was requested to evaluate the potential to receive and process the Idaho National Laboratory (INL) uranium (U) recovered from the Experimental Breeder Reactor II (EBR-II) driver fuel through the Savannah River Site’s (SRS) H-Canyon as a way to disposition the material. INL recovers the uranium from the sodium bonded metallic fuel irradiated in the EBR-II reactor using an electrorefining process. There were two compositions of EBR-II driver fuel. The early generation fuel was U-5Fs, which consisted of 95% U metal alloyed with 5% noble metal elements “fissium” (2.5% molybdenum, 2.0% ruthenium, 0.3% rhodium, 0.1% palladium,more » and 0.1% zirconium), while the later generation was U-10Zr which was 90% U metal alloyed with 10% zirconium. A potential concern during the H-Canyon nitric acid dissolution process of the U metal containing zirconium (Zr) is the explosive behavior that has been reported for alloys of these materials. For this reason, this evaluation was focused on the ability to process the lower Zr content materials, the U-5Fs material.« less

Hydride reorientation and its impact on ambient temperature mechanical properties of high burn-up irradiated and unirradiated recrystallized Zircaloy-2 nuclear fuel cladding with an inner liner

NASA Astrophysics Data System (ADS)

Auzoux, Q.; Bouffioux, P.; Machiels, A.; Yagnik, S.; Bourdiliau, B.; Mallet, C.; Mozzani, N.; Colas, K.

2017-10-01

Precipitation of radial hydrides in zirconium-based alloy cladding concomitant with the cooling of spent nuclear fuel during dry storage can potentially compromise cladding integrity during its subsequent handling and transportation. This paper investigates hydride reorientation and its impact on ductility in unirradiated and irradiated recrystallized Zircaloy-2 cladding with an inner liner (cladding for boiling water reactors) subjected to hydride reorientation treatments. Cooling from 400 °C, hydride reorientation occurs in recrystallized Zircaloy-2 with liner at a lower effective stress in irradiated samples (below 40 MPa) than in unirradiated specimens (between 40 and 80 MPa). Despite significant hydride reorientation, unirradiated recrystallized Zircaloy-2 with liner cladding containing ∼200 wppm hydrogen shows a high diametral strain at fracture (>15%) during burst tests at ambient temperature. This ductile behavior is due to (1) the lower yield stress of the recrystallized cladding materials in comparison to hydride fracture strength (corrected by the compression stress arising from the precipitation) and (2) the hydride or hydrogen-depleted zone as a result of segregation of hydrogen into the liner layer. In irradiated Zircaloy-2 with liner cladding containing ∼340 wppm hydrogen, the conservation of some ductility during ring tensile tests at ambient temperature after reorientation treatment at 400 °C with cooling rates of ∼60 °C/h is also attributed to the existence of a hydride-depleted zone. Treatments at lower cooling rates (∼6 °C/h and 0.6 °C/h) promote greater levels of hydrogen segregation into the liner and allow for increased irradiation defect annealing, both of which result in a significant increase in ductility. Based on this investigation, given the very low cooling rates typical of dry storage systems, it can be concluded that the thermal transients associated with dry storage should not degrade, and more likely should actually improve, ductility of recrystallized Zircaloy-2 cladding with inner liner with such hydrogen content.

Production of nuclear grade zirconium: A review

NASA Astrophysics Data System (ADS)

Xu, L.; Xiao, Y.; van Sandwijk, A.; Xu, Q.; Yang, Y.

2015-11-01

Zirconium is an ideal material for nuclear reactors due to its low absorption cross-section for thermal neutrons, whereas the typically contained hafnium with strong neutron-absorption is very harmful for zirconium as a fuel cladding material. This paper provides an overview of the processes for nuclear grade zirconium production with emphasis on the methods of Zr-Hf separation. The separation processes are roughly classified into hydro- and pyrometallurgical routes. The known pyrometallurgical Zr-Hf separation methods are discussed based on the following reaction features: redox characteristics, volatility, electrochemical properties and molten salt-metal equilibrium. In the present paper, the available Zr-Hf separation technologies are compared. The advantages and disadvantages as well as future directions of research and development for nuclear grade zirconium production are discussed.

Physical and Mechanical Metallurgy of Zirconium Alloys for Nuclear Applications: A Multi-Scale Computational Study

NASA Astrophysics Data System (ADS)

Glazoff, Michael Vasily

In the post-Fukushima world, thermal and structural stability of materials under extreme conditions is an important issue for the safety of nuclear reactors. Because the nuclear industry will continue using zirconium (Zr) cladding for the foreseeable future, it becomes critical to gain a fundamental understanding of several interconnected problems. First, what are the thermodynamic and kinetic factors affecting oxidation and hydrogen pick-up by these materials at normal, off-normal conditions, and in long-term storage? Secondly, what protective coatings could be used in order to gain valuable time at off-normal conditions (temperature exceeds ~1200°C (2200°F)? Thirdly, the kinetics of the coating's oxidation must be understood. Lastly, one needs automated inspection algorithms allowing identifying cladding's defects. This work attempts to explore the problem from a computational perspective, utilizing first principles atomistic simulations, computational thermodynamics, plasticity theory, and morphological algorithms of image processing for defect identification. It consists of the four parts dealing with these four problem areas preceded by the introduction. In the 1st part, computational thermodynamics and ab initio calculations were used to shed light upon the different stages of zircaloy oxidation and hydrogen pickup, and microstructure optimization to increase thermal stability. The 2 nd part describes the kinetic theory of oxidation of the several materials considered to be perspective coatings for Zr alloys: SiC and ZrSiO4. The 3rd part deals with understanding the respective roles of the two different plasticity mechanisms in Zr nuclear alloys: twinning (at low T) and crystallographic slip (higher T's). For that goal, an advanced plasticity model was proposed. In the 4th part projectional algorithms for defect identification in zircaloy coatings are described. Conclusions and recommendations are presented in the 5th part. This integrative approach's value is in developing multi-faceted understanding of complex processes taking place in nuclear fuel rods. It helped identify several problems pertaining to the safe operations with nuclear fuel: limits of temperature that should be strictly obeyed in storage to retard zircaloy hydriding; understanding the benefits and limitations of coatings; developing in-depth understanding of Zr plasticity; developing original algorithms for defect identification in SiC-braided zircaloy. The obtained results will be useful for the nuclear industry.

Studies of Lanthanide Transport in Metallic Fuel

DOE Office of Scientific and Technical Information (OSTI.GOV)

Zhang, Jinsuo; Taylor, Christopher

Metallic nuclear fuels were tested in fast reactor programs and performed well. However, metallic fuels have shown the phenomenon of FCCI that are due to deleterious reactions between lanthanide fission products and cladding material. As the burnup is increased, lanthanide fission products that contact with the cladding could react with cladding constituents such as iron and chrome. These reactions produce higher-melting intermetallic compounds and low-melting alloys, and weaken the mechanical integrity.

Preliminary calculations related to the accident at Three Mile Island

DOE Office of Scientific and Technical Information (OSTI.GOV)

Kirchner, W.L.; Stevenson, M.G.

This report discusses preliminary studies of the Three Mile Island Unit 2 (TMI-2) accident based on available methods and data. The work reported includes: (1) a TRAC base case calculation out to 3 hours into the accident sequence; (2) TRAC parametric calculations, these are the same as the base case except for a single hypothetical change in the system conditions, such as assuming the high pressure injection (HPI) system operated as designed rather than as in the accident; (3) fuel rod cladding failure, cladding oxidation due to zirconium metal-steam reactions, hydrogen release due to cladding oxidation, cladding ballooning, cladding embrittlement,more » and subsequent cladding breakup estimates based on TRAC calculated cladding temperatures and system pressures. Some conclusions of this work are: the TRAC base case accident calculation agrees very well with known system conditions to nearly 3 hours into the accident; the parametric calculations indicate that, loss-of-core cooling was most influenced by the throttling of High-Pressure Injection (HPI) flows, given the accident initiating events and the pressurizer electromagnetic-operated valve (EMOV) failing to close as designed; failure of nearly all the rods and gaseous fission product gas release from the failed rods is predicted to have occurred at about 2 hours and 30 minutes; cladding oxidation (zirconium-steam reaction) up to 3 hours resulted in the production of approximately 40 kilograms of hydrogen.« less

COMPARTMENTED REACTOR FUEL ELEMENT

DOEpatents

Cain, F.M. Jr.

1962-09-11

A method of making a nuclear reactor fuel element of the elongated red type is given wherein the fissionable fuel material is enclosed within a tubular metal cladding. The method comprises coating the metal cladding tube on its inside wall with a brazing alloy, inserting groups of cylindrical pellets of fissionable fuel material into the tube with spacing members between adjacent groups of pellets, sealing the ends of the tubes to leave a void space therewithin, heating the tube and its contents to an elevated temperature to melt the brazing alloy and to expand the pellets to their maximum dimensions under predetermined operating conditions thereby automatically positioning the spacing members along the tube, and finally cooling the tube to room temperature whereby the spacing disks become permanently fixed at their edges in the brazing alloy and define a hermetically sealed compartment for each fl group of fuel pellets. Upon cooling, the pellets contract thus leaving a space to accommodate thermal expansion of the pellets when in use in a reactor. The spacing members also provide lateral support for the tubular cladding to prevent collapse thereof when subjected to a reactor environment. (AEC)

Impact of neutron irradiation on mechanical performance of FeCrAl alloy laser-beam weldments

NASA Astrophysics Data System (ADS)

Gussev, M. N.; Cakmak, E.; Field, K. G.

2018-06-01

Oxidation-resistant iron-chromium-aluminum (FeCrAl) alloys demonstrate better performance in Loss-of-Coolant Accidents, compared with austenitic- and zirconium-based alloys. However, further deployment of FeCrAl-based materials requires detailed characterization of their performance under irradiation; moreover, since welding is one of the key operations in fabrication of light water reactor fuel cladding, FeCrAl alloy weldment performance and properties also should be determined prior to and after irradiation. Here, advanced C35M alloy (Fe-13%Cr-5%Al) and variants with aluminum (+2%) or titanium carbide (+1%) additions were characterized after neutron irradiation in Oak Ridge National Laboratory's High Flux Isotope Reactor at 1.8-1.9 dpa in a temperature range of 195-559 °C. Specimen sets included as-received (AR) materials and specimens after controlled laser-beam welding. Tensile tests with digital image correlation (DIC), scanning electron microscopy-electron back scatter diffraction analysis, fractography, and x-ray tomography analysis were performed. DIC allowed for investigating local yield stress in the weldments, deformation hardening behavior, and plastic anisotropy. Both AR and welded material revealed a high degree of radiation-induced hardening for low-temperature irradiation; however, irradiation at high-temperatures (i.e., 559 °C) had little overall effect on the mechanical performance.

Evaluation of refractory-metal-clad uranium nitride and uranium dioxide fuel pins after irradiation for times up to 10 450 hours at 990 C

NASA Technical Reports Server (NTRS)

Bowles, K. J.; Gluyas, R. E.

1975-01-01

The effects of some materials variables on the irradiation performance of fuel pins for a lithium-cooled space power reactor design concept were examined. The variables studied were UN fuel density, fuel composition, and cladding alloy. All pins were irradiated at about 990 C in a thermal neutron environment to the design fuel burnup. An 85-percent dense UN fuel gave the best overall results in meeting the operational goals. The T-111 cladding on all specimens was embrittled, possibly by hydrogen in the case of the UN fuel and by uranium and oxygen in the case of the UO2 fuel. Tests with Cb-1Zr cladding indicate potential use of this cladding material. The UO2 fueled specimens met the operational goals of less than 1 percent cladding strain, but other factors make UO2 less attractive than low-density UN for the contemplated space power reactor use.

System analysis with improved thermo-mechanical fuel rod models for modeling current and advanced LWR materials in accident scenarios

NASA Astrophysics Data System (ADS)

Porter, Ian Edward

A nuclear reactor systems code has the ability to model the system response in an accident scenario based on known initial conditions at the onset of the transient. However, there has been a tendency for these codes to lack the detailed thermo-mechanical fuel rod response models needed for accurate prediction of fuel rod failure. This proposed work will couple today's most widely used steady-state (FRAPCON) and transient (FRAPTRAN) fuel rod models with a systems code TRACE for best-estimate modeling of system response in accident scenarios such as a loss of coolant accident (LOCA). In doing so, code modifications will be made to model gamma heating in LWRs during steady-state and accident conditions and to improve fuel rod thermal/mechanical analysis by allowing axial nodalization of burnup-dependent phenomena such as swelling, cladding creep and oxidation. With the ability to model both burnup-dependent parameters and transient fuel rod response, a fuel dispersal study will be conducted using a hypothetical accident scenario under both PWR and BWR conditions to determine the amount of fuel dispersed under varying conditions. Due to the fuel fragmentation size and internal rod pressure both being dependent on burnup, this analysis will be conducted at beginning, middle and end of cycle to examine the effects that cycle time can play on fuel rod failure and dispersal. Current fuel rod and system codes used by the Nuclear Regulatory Commission (NRC) are compilations of legacy codes with only commonly used light water reactor materials, Uranium Dioxide (UO2), Mixed Oxide (U/PuO 2) and zirconium alloys. However, the events at Fukushima Daiichi and Three Mile Island accident have shown the need for exploration into advanced materials possessing improved accident tolerance. This work looks to further modify the NRC codes to include silicon carbide (SiC), an advanced cladding material proposed by current DOE funded research on accident tolerant fuels (ATF). Several additional fuels will also be analyzed, including uranium nitride (UN), uranium carbide (UC) and uranium silicide (U3Si2). Focusing on the system response in an accident scenario, an emphasis is placed on the fracture mechanics of the ceramic cladding by design the fuel rods to eliminate pellet cladding mechanical interaction (PCMI). The time to failure and how much of the fuel in the reactor fails with an advanced fuel design will be analyzed and compared to the current UO2/Zircaloy design using a full scale reactor model.

Clad metals by roll bonding for SOFC interconnects

NASA Astrophysics Data System (ADS)

Chen, L.; Jha, B.; Yang, Zhenguo; Xia, Guang-Guang; Stevenson, Jeffry W.; Singh, Prabhakar

2006-08-01

High-temperature oxidation-resistant alloys are currently considered as a candidate material for construction of interconnects in intermediate-temperature solid oxide fuel cells. Among these alloys, however, different groups of alloys demonstrate different advantages and disadvantages, and few, if any, can completely satisfy the stringent requirements for the application. To integrate the advantages and avoid the disadvantages of different groups of alloys, cladding has been proposed as one approach in fabricating metallic layered interconnect structures. To examine the feasibility of this approach, the austenitic Ni-base alloy Haynes 230 and the ferritic stainless steel AL 453 were selected as examples and manufactured into a clad metal. Its suitability as an interconnect construction material was investigated. This paper provides a brief overview of the cladding approach and discusses the viability of this technology to fabricate the metallic layered-structure interconnects.

DOE Office of Scientific and Technical Information (OSTI.GOV)

Maloy, Stuart Andrew; Pestovich, Kimberly Shay; Anderoglu, Osman

The Fuel Cycle Research and Development program is investigating methods of transmuting minor actinides in various fuel cycle options. To achieve this goal, new fuels and cladding materials must be developed and tested to high burnup levels (e.g. >20%) requiring cladding to withstand very high doses (greater than 200 dpa) while in contact with the coolant and the fuel. To develop and qualify materials to a total fluence greater than 200 dpa requires development of advanced alloys and irradiations in fast reactors to test these alloys. Recent results from testing numerous ferritic/martensitic steels at low temperatures suggest that improvements inmore » low temperature radiation tolerance can be achieved through carefully controlling the nitrogen content in these alloys. Thus, four new heats of HT-9 were produced with controlled nitrogen content: two by Metalwerks and two by Sophisticated Alloys. Initial results on these new alloys are presented including microstructural analysis and hardness testing. Future testing will include irradiation testing with ions and in reactor.« less

Cladding burst behavior of Fe-based alloys under LOCA

DOE PAGES

Terrani, Kurt A.; Dryepondt, Sebastien N.; Pint, Bruce A.; ...

2015-12-17

Burst behavior of austenitic and ferritic Fe-based alloy tubes has been examined under a simulated large break loss of coolant accident. Specifically, type 304 stainless steel (304SS) and oxidation resistant FeCrAl tubes were studied alongside Zircaloy-2 and Zircaloy-4 that are considered reference fuel cladding materials. Following the burst test, characterization of the cladding materials was carried out to gain insights regarding the integral burst behavior. Given the widespread availability of a comprehensive set of thermo-mechanical data at elevated temperatures for 304SS, a modeling framework was implemented to simulate the various processes that affect burst behavior in this Fe-based alloy. Themore » most important conclusion is that cladding ballooning due to creep is negligible for Fe-based alloys. Thus, unlike Zr-based alloys, cladding cross-sectional area remains largely unchanged up to the point of burst. Furthermore, for a given rod internal pressure, the temperature onset of burst in Fe-based alloys appears to be simply a function of the alloy's ultimate tensile strength, particularly at high rod internal pressures.« less

Irradiation of three T-111 clad uranium nitride fuel pins for 8070 hours at 990 C (1815 F)

NASA Technical Reports Server (NTRS)

Slaby, J. G.; Siegel, B. L.; Gedeon, L.; Galbo, R. J.

1973-01-01

The design and successful operation of three tantalum alloy (Ta-8W-2Hf) clad uranium mononitride (UN) fuel pins irradiated for 8070 hr at 990 C (1815 F) is described. Two pin diameters having measured burnups of 0.47 and 0.90 uranium atom percent were tested. No clad failures or swelling was detected; however, postirradiation clad samples tested failed with 1 percent strain. The fuel density decrease was 2 percent, and the fission gas release was less than 0.05 percent. Isotropic fuel swelling, which averaged about 0.5 percent, was less than fuel pin assembly clearances. Thus the clad was not strained. Thermocouples with a modified hot zone operated at average temperatures to 1100 C (2012 F) without failure. Factors that influence the ability to maintain uniform clad temperature as well as the results of the heat transfer calculations are discussed.

Fabrication and testing of U–7Mo monolithic plate fuel with Zircaloy cladding

DOE PAGES

Pasqualini, E. E.; Robinson, A. B.; Porter, D. L.; ...

2016-07-15

The Materials Management and Minimization program is developing fuel designs to replace highly enriched fuel with fuels of low enrichment. In the most challenging cases, U–(7–10wt%)Mo monolithic plate fuel are proposed. The chosen design includes aluminum-alloy cladding, which provides some challenges in fabrication and fuel/cladding interaction in service. We investigated zircaloy cladding, specifically Zry–4as an alternative cladding, and development of a fabrication method was performed by researchers with the Comisión Nacionalde Energia Atómica (CNEA) in Argentina, resulting in test fuel plates (Zry–4 clad U–7Mo) which were subsequently tested in the Advanced Test Reactor in Idaho. Because Zry–4 and U–(7–10)Mo havemore » similar high-temperature mechanical properties, fabrication was simplified in that the fuel foil and cladding could be co-rolled and bonded. The challenge was to prevent a thermal-expansion mismatch which could destroy the fuel/cladding bond before complete bonding was achieved; the solution was to prevent the composites from cooling significantly between roll passes. Our final product performed very well in-reactor, showing good bonding, very little fuel/cladding interaction, either from fabrication or in-reactor testing, and little swelling, especially no detectable heterogeneous bubble formation at the fuel/cladding interface tested to a fission density of up to 2.54E+21« less

Fabrication and testing of U–7Mo monolithic plate fuel with Zircaloy cladding

DOE Office of Scientific and Technical Information (OSTI.GOV)

Pasqualini, E. E.; Robinson, A. B.; Porter, D. L.

The Materials Management and Minimization program is developing fuel designs to replace highly enriched fuel with fuels of low enrichment. In the most challenging cases, U–(7–10wt%)Mo monolithic plate fuel are proposed. The chosen design includes aluminum-alloy cladding, which provides some challenges in fabrication and fuel/cladding interaction in service. We investigated zircaloy cladding, specifically Zry–4as an alternative cladding, and development of a fabrication method was performed by researchers with the Comisión Nacionalde Energia Atómica (CNEA) in Argentina, resulting in test fuel plates (Zry–4 clad U–7Mo) which were subsequently tested in the Advanced Test Reactor in Idaho. Because Zry–4 and U–(7–10)Mo havemore » similar high-temperature mechanical properties, fabrication was simplified in that the fuel foil and cladding could be co-rolled and bonded. The challenge was to prevent a thermal-expansion mismatch which could destroy the fuel/cladding bond before complete bonding was achieved; the solution was to prevent the composites from cooling significantly between roll passes. Our final product performed very well in-reactor, showing good bonding, very little fuel/cladding interaction, either from fabrication or in-reactor testing, and little swelling, especially no detectable heterogeneous bubble formation at the fuel/cladding interface tested to a fission density of up to 2.54E+21« less

RERTR-9 Summary Report

DOE Office of Scientific and Technical Information (OSTI.GOV)

D. M. Perez

2011-05-01

The RERTR-9 experiment was designed to test the effect of modified fuel/clad interfaces in monolithic fuel plates and to demonstrate that the addition of Si to the matrix material in dispersion plates continued to be effective at high loading (~8.5 g U/cc). Several monolithic fuel plates were fabricated by Hot Isostatic Pressing (HIP) and Friction Bonding (FB) with thin layers of Si inserted and by HIP with a Zr diffusion barrier between the fuel and cladding. Si was applied to the interface by thermal spray of Al Si mixtures and by the insertion of thin Si-rich Al alloy foil betweenmore » the fuel/clad interface. The dispersion fuel plates were fabricated by semi-standard rolling techniques (the reduction by rolling was lowered to limit fabrication defects). Matrix materials consisted of Al-Si alloys and mixtures with various levels of Si. The following report summarizes the life of the RERTR-9A/B experiment through end of irradiation, including as-run neutronic analysis, thermal analysis and hydraulic testing results.« less

DOE Office of Scientific and Technical Information (OSTI.GOV)

Pickman, D.O.

Various aspects of zirconium alloy development for light water reactors in the UK and Scandinavia are reviewed, including the contribution made by some unique nuclear testing facilities. Among the problems encountered were the irradiation enhancement of corrosion and hydrogen pickup, crud deposition, iodine-induced stress-corrosion cracking on power ramping, and severe cladding deformation in loss-of-coolant accident conditions. The causes and behavior of defects, including hydride defects and fretting corrosion, are discussed.

Iron-nickel-chromium alloy having improved swelling resistance and low neutron absorbence

DOEpatents

Korenko, Michael K.

1986-01-01

An iron-nickel-chromium age-hardenable alloy suitable for use in fast breeder reactor ducts and cladding which utilizes the gamma-double prime strengthening phase and characterized in having a delta or eta phase distributed at or near grain boundaries. The alloy consists essentially of about 33-39.5% nickel, 7.5-16% chromium, 1.5-4% niobium, 0.1-0.7% silicon, 0.01-0.2% zirconium, 1-3% titanium, 0.2-0.6% aluminum, and the remainder essentially all iron. Up to 0.4% manganese and up to 0.010% magnesium can be added to inhibit trace element effects.

Ion irradiation testing and characterization of FeCrAl candidate alloys

DOE Office of Scientific and Technical Information (OSTI.GOV)

Anderoglu, Osman; Aydogan, Eda; Maloy, Stuart Andrew

2014-10-29

The Fuel Cycle Research and Development program’s Advanced Fuels Campaign has initiated a multifold effort aimed at facilitating development of accident tolerant fuels. This effort involves development of fuel cladding materials that will be resistant to oxidizing environments for extended period of time such as loss of coolant accident. Ferritic FeCrAl alloys are among the promising candidates due to formation of a stable Al₂O₃ oxide scale. In addition to being oxidation resistant, these promising alloys need to be radiation tolerant under LWR conditions (maximum dose of 10-15 dpa at 250 – 350°C). Thus, in addition to a number of commerciallymore » available alloys, nuclear grade FeCrAl alloys developed at ORNL were tested using high energy proton irradiations and subsequent characterization of irradiation hardening and damage microstructure. This report summarizes ion irradiation testing and characterization of three nuclear grade FeCrAl cladding materials developed at ORNL and four commercially available Kanthal series FeCrAl alloys in FY14 toward satisfying FCRD campaign goals.« less

Clad metals, roll bonding and their applications for SOFC interconnects

NASA Astrophysics Data System (ADS)

Chen, Lichun; Yang, Zhenguo; Jha, Bijendra; Xia, Guanguang; Stevenson, Jeffry W.

Metallic interconnects have been becoming an increasingly interesting topic in the development in intermediate temperature solid oxide fuel cells (SOFC). High temperature oxidation resistant alloys are currently considered as candidate materials. Among these alloys however, different groups of alloys demonstrate different advantages and disadvantages, and few if any can completely satisfy the stringent requirements for the application. To integrate the advantages and avoid the disadvantages of different groups of alloys, clad metal has been proposed for SOFC interconnect applications and interconnect structures. This paper gives a brief overview of the cladding approach and its applications, and discuss the viability of this technology to fabricate the metallic layered-structure interconnects. To examine the feasibility of this approach, the austenitic Ni-base alloy Haynes 230 and the ferritic stainless steel AL 453 were selected as examples and manufactured into a clad metal. Its suitability as an interconnect construction material was investigated.

Hydrogen in Ti and Zr alloys: industrial perspective, failure modes and mechanistic understanding.

PubMed

Chapman, T P; Dye, D; Rugg, D

2017-07-28

Titanium is widely used in demanding applications, such as in aerospace. Its strength-to-weight ratio and corrosion resistance make it well suited to highly stressed rotating components. Zirconium has a no less critical application where its low neutron capture cross section and good corrosion resistance in hot water and steam make it well suited to reactor core use, including fuel cladding and structures. The similar metallurgical behaviour of these alloy systems makes it alluring to compare and contrast their behaviour. This is rarely undertaken, mostly because the industrial and academic communities studying these alloys have little overlap. The similarities with respect to hydrogen are remarkable, albeit potentially unsurprising, and so this paper aims to provide an overview of the role hydrogen has to play through the material life cycle. This includes the relationship between alloy design and manufacturing process windows, the role of hydrogen in degradation and failure mechanisms and some of the underpinning metallurgy. The potential role of some advanced experimental and modelling techniques will also be explored to give a tentative view of potential for advances in this field in the next decade or so.This article is part of the themed issue 'The challenges of hydrogen and metals'. © 2017 The Author(s).

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

DOE Office of Scientific and Technical Information (OSTI.GOV)

Dryepondt, Sebastien N.; Massey, Caleb P.; Edmondson, Philip D.

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

Occurence and prediction of sigma phase in fuel cladding alloys for breeder reactors. [LMFBR

DOE Office of Scientific and Technical Information (OSTI.GOV)

Anantatmula, R.P.

1982-01-01

In sodium-cooled fast reactor systems, fuel cladding materials will be exposed for several thousand hours to liquid sodium. Satisfactory performance of the materials depends in part on the sodium compatibility and phase stability of the materials. This paper mainly deals with the phase stability aspect, with particular emphasis on sigma phase formation of the cladding materials upon extended exposures to liquid sodium. A new method of predicting sigma phase formation is proposed for austenitic stainless steels and predictions are compared with the experimental results on fuel cladding materials. Excellent agreement is obtained between theory and experiment. The new method ismore » different from the empirical methods suggested for superalloys and does not suffer from the same drawbacks. The present method uses the Fe-Cr-Ni ternary phase diagram for predicting the sigma-forming tendencies and exhibits a wide range of applicability to austenitic stainless steels and heat-resistant Fe-Cr-Ni alloys.« less

Fabrication and testing of U-7Mo monolithic plate fuel with Zircaloy cladding

NASA Astrophysics Data System (ADS)

Pasqualini, E. E.; Robinson, A. B.; Porter, D. L.; Wachs, D. M.; Finlay, M. R.

2016-10-01

Nuclear fuel designs are being developed to replace highly enriched fuel used in research and test reactors with fuels of low enrichment. In the most challenging cases, U-(7-10 wt%)Mo monolithic plate fuels are proposed. One of the considered designs includes aluminum-alloy cladding, which provides some challenges in fabrication and fuel/cladding interaction during service. Zircaloy cladding, specifically Zry-4, was investigated as an alternative cladding, and development of a fabrication method was performed by researchers with the Comisión Nacionalde Energia Atómica (CNEA) in Argentina, resulting in test fuel plates (Zry-4 clad U-7Mo) which were subsequently tested in the Advanced Test Reactor in Idaho. Because Zry-4 and U-(7-10)Mo have similar high-temperature mechanical properties, fabrication was simplified in that the fuel foil and cladding could be co-rolled and bonded. The challenge was to prevent a thermal-expansion mismatch, which could destroy the fuel/cladding bond before complete bonding was achieved; the solution was to prevent the composites from cooling significantly during or between roll passes. The final product performed very well in-reactor, showing good bonding, very little fuel/cladding interaction-either from fabrication or in-reactor testing-and little swelling, especially no detectable heterogeneous bubble formation at the fuel/cladding interface tested to a fission density of up to 2.7E+21 (average) fissions/cm3, 3.8E+21 (peak).

As-cast uranium-molybdenum based metallic fuel candidates and the effects of carbon addition

NASA Astrophysics Data System (ADS)

Blackwood, Van Stephen

The objective of this research was to develop and recommend a metallic nuclear fuel candidate that lowered the onset temperature of gamma phase formation comparable or better than the uranium-10 wt. pct. molybdenum alloy, offered a solidus temperature as high or higher than uranium-10 wt. pct. zirconium (1250°C), and stabilized the fuel phase against interaction with iron and steel at least as much as uranium-10 wt. pct. zirconium stabilized the fuel phase. Two new as-cast alloy compositions were characterized to assess thermal equilibrium boundaries of the gamma phase field and the effect of carbon addition up to 0.22 wt. pct. The first system investigated was uranium- x wt. pct. M where x ranged between 5-20 wt. pct. M was held at a constant ratio of 50 wt. pct. molybdenum, 43 wt. pct. titanium, and 7 wt. pct. zirconium. The second system investigated was the uranium-molybdenum-tungsten system in the range 90 wt. pct. uranium - 10 wt. pct. molybdenum - 0 wt. pct. tungsten to 80 wt. pct. uranium - 10 wt. pct. molybdenum - 10 wt. pct. tungsten. The results showed that the solidus temperature increased with increased addition of M up to 12.5 wt. pct. for the uranium-M system. Alloy additions of titanium and zirconium were removed from uranium-molybdenum solid solution by carbide formation and segregation. The uranium-molybdenum-tungsten system solidus temperature increased to 1218°C at 2.5 wt. pct. with no significant change in temperature up to 5 wt. pct. tungsten suggesting the solubility limit of tungsten had been reached. Carbides were observed with surrounding areas enriched in both molybdenum and tungsten. The peak solidus temperatures for the alloy systems were roughly the same at 1226°C for the uranium-M system and 1218°C for the uranium-molybdenum-tungsten system. The uranium-molybdenum-tungsten system required less alloy addition to achieve similar solidus temperatures as the uranium-M system.

Anisotropic Azimuthal Power and Temperature distribution on FuelRod. Impact on Hydride Distribution

DOE Office of Scientific and Technical Information (OSTI.GOV)

Motta, Arthur; Ivanov, Kostadin; Arramova, Maria

2015-04-29

The degradation of the zirconium cladding may limit nuclear fuel performance. In the high temperature environment of a reactor, the zirconium in the cladding corrodes, releasing hydrogen in the process. Some of this hydrogen is absorbed by the cladding in a highly inhomogeneous manner. The distribution of the absorbed hydrogen is extremely sensitive to temperature and stress concentration gradients. The absorbed hydrogen tends to concentrate near lower temperatures. This hydrogen absorption and hydride formation can cause cladding failure. This project set out to improve the hydrogen distribution prediction capabilities of the BISON fuel performance code. The project was split intomore » two primary sections, first was the use of a high fidelity multi-physics coupling to accurately predict temperature gradients as a function of r, θ , and z, and the second was to use experimental data to create an analytical hydrogen precipitation model. The Penn State version of thermal hydraulics code COBRA-TF (CTF) was successfully coupled to the DeCART neutronics code. This coupled system was verified by testing and validated by comparison to FRAPCON data. The hydrogen diffusion and precipitation experiments successfully calculated the heat of transport and precipitation rate constant values to be used within the hydrogen model in BISON. These values can only be determined experimentally. These values were successfully implemented in precipitation, diffusion and dissolution kernels that were implemented in the BISON code. The coupled output was fed into BISON models and the hydrogen and hydride distributions behaved as expected. Simulations were conducted in the radial, axial and azimuthal directions to showcase the full capabilities of the hydrogen model.« less

Multiphysics phase field modeling of hydrogen diffusion and delta-hydride precipitation in alpha-zirconium

NASA Astrophysics Data System (ADS)

Jokisaari, Andrea M.

Hydride precipitation in zirconium is a significant factor limiting the lifetime of nuclear fuel cladding, because hydride microstructures play a key role in the degradation of fuel cladding. However, the behavior of hydrogen in zirconium has typically been modeled using mean field approaches, which do not consider microstructural evolution. This thesis describes a quantitative microstructural evolution model for the alpha-zirconium/delta-hydride system and the associated numerical methods and algorithms that were developed. The multiphysics, phase field-based model incorporates CALPHAD free energy descriptions, linear elastic solid mechanics, and classical nucleation theory. A flexible simulation software implementing the model, Hyrax, is built on the Multiphysics Object Oriented Simulation Environment (MOOSE) finite element framework. Hyrax is open-source and freely available; moreover, the numerical methods and algorithms that have been developed are generalizable to other systems. The algorithms are described in detail, and verification studies for each are discussed. In addition, analyses of the sensitivity of the simulation results to the choice of numerical parameters are presented. For example, threshold values for the CALPHAD free energy algorithm and the use of mesh and time adaptivity when employing the nucleation algorithm are studied. Furthermore, preliminary insights into the nucleation behavior of delta-hydrides are described. These include a) the sensitivities of the nucleation rate to temperature, interfacial energy, composition and elastic energy, b) the spatial variation of the nucleation rate around a single precipitate, and c) the effect of interfacial energy and nucleation rate on the precipitate microstructure. Finally, several avenues for future work are discussed. Topics encompass the terminal solid solubility hysteresis of hydrogen in zirconium and the effects of the alpha/delta interfacial energy, as well as thermodiffusion, plasticity, and irradiation, which are not yet accounted for in the model.

Improved Accident Tolerance of Austenitic Stainless Steel Cladding through Colossal Supersaturation with Interstitial Solutes

DOE Office of Scientific and Technical Information (OSTI.GOV)

Ernst, Frank

We proposed a program-supporting research project in the area of fuel-cycle R&D, specifically on the topic of advanced fuels. Our goal was to investigate whether SECIS (surface engineering by concentrated interstitial solute – carbon, nitrogen) can improve the properties of austenitic stainless steels and related structural alloys such that they can be used for nuclear fuel cladding in LWRs (light-water reactors) and significantly excel currently used alloys with regard to performance, safety, service life, and accident tolerance. We intended to demonstrate that SECIS can be adapted for post-processing of clad tubing to significantly enhance mechanical properties (hardness, wear resistance, andmore » fatigue life), corrosion resistance, resistance to stress–corrosion cracking (hydrogen-induced embrittlement), and – potentially – radiation resistance (against electron-, neutron-, or ion-radiation damage). To test this hypothesis, we measured various relevant properties of the surface-engineered alloys and compared them with corresponding properties of the non–treated, as-received alloys. In particular, we studied the impact of heat exposure corresponding to BWR (boiling-water reactor) working and accident (loss-of-coolant) conditions and the effect of ion irradiation.« less

Laser and Pressure Resistance Weld of Thin-Wall Cladding for LWR Accident-Tolerant Fuels

NASA Astrophysics Data System (ADS)

Gan, J.; Jerred, N.; Perez, E.; Haggard, D. C.

2017-12-01

FeCrAl alloy with typical composition of approximately Fe-15Cr-5Al is considered a primary candidate cladding material for light water reactor accident-tolerant fuel because of its superior resistance to oxidation in high-temperature steam compared with Zircaloy cladding. Thin-walled FeCrAl cladding at 350 μm wall thickness is required, and techniques for joining endplug to cladding need to be developed. Fusion-based laser weld and solid-state joining with pressure resistance weld were investigated in this study. The results of microstructural characterization, mechanical property evaluation by tensile testing, and hydraulic pressure burst testing of the welds for the cladding-endplug specimen are discussed.

Laser and Pressure Resistance Weld of Thin-Wall Cladding for LWR Accident-Tolerant Fuels

NASA Astrophysics Data System (ADS)

Gan, J.; Jerred, N.; Perez, E.; Haggard, D. C.

2018-02-01

FeCrAl alloy with typical composition of approximately Fe-15Cr-5Al is considered a primary candidate cladding material for light water reactor accident-tolerant fuel because of its superior resistance to oxidation in high-temperature steam compared with Zircaloy cladding. Thin-walled FeCrAl cladding at 350 μm wall thickness is required, and techniques for joining endplug to cladding need to be developed. Fusion-based laser weld and solid-state joining with pressure resistance weld were investigated in this study. The results of microstructural characterization, mechanical property evaluation by tensile testing, and hydraulic pressure burst testing of the welds for the cladding-endplug specimen are discussed.

Corrosion of aluminum clad spent nuclear fuel in the 70 ton cask during transfer from L area to H-canyon

DOE Office of Scientific and Technical Information (OSTI.GOV)

Mickalonis, J. I.

2015-08-31

Aluminum-clad spent nuclear fuel will be transported for processing in the 70-ton nuclear fuel element cask from L Basin to H-canyon. During transport these fuels would be expected to experience high temperature aqueous corrosion from the residual L Basin water that will be present in the cask. Cladding corrosion losses during transport were calculated for material test reactor (MTR) and high flux isotope reactors (HFIR) fuels using literature and site information on aqueous corrosion at a range of time/temperature conditions. Calculations of the cladding corrosion loss were based on Arrhenius relationships developed for aluminum alloys typical of cladding material withmore » the primary assumption that an adherent passive film does not form to retard the initial corrosion rate. For MTR fuels a cladding thickness loss of 33 % was found after 1 year in the cask with a maximum temperature of 263 °C. HFIR fuels showed a thickness loss of only 6% after 1 year at a maximum temperature of 180 °C. These losses are not expected to impact the overall confinement function of the aluminum cladding.« less

Corrosion of aluminum clad spent nuclear fuel in the 70 ton cask during transfer from L area to H-canyon

DOE Office of Scientific and Technical Information (OSTI.GOV)

Mickalonis, J. I.

2015-08-01

Aluminum-clad spent nuclear fuel will be transported for processing in the 70-ton nuclear fuel element cask from L Basin to H-canyon. During transport these fuels would be expected to experience high temperature aqueous corrosion from the residual L Basin water that will be present in the cask. Cladding corrosion losses during transport were calculated for material test reactor (MTR) and high flux isotope reactors (HFIR) fuels using literature and site information on aqueous corrosion at a range of time/temperature conditions. Calculations of the cladding corrosion loss were based on Arrhenius relationships developed for aluminum alloys typical of cladding material withmore » the primary assumption that an adherent passive film does not form to retard the initial corrosion rate. For MTR fuels a cladding thickness loss of 33% was found after 1 year in the cask with a maximum temperature of 263 °C. HFIR fuels showed a thickness loss of only 6% after 1 year at a maximum temperature of 180 °C. These losses are not expected to impact the overall confinement function of the aluminum cladding.« less

Texture and hydride orientation relationship of Zircaloy-4 fuel clad tube during its fabrication for pressurized heavy water reactors

NASA Astrophysics Data System (ADS)

Vaibhaw, Kumar; Rao, S. V. R.; Jha, S. K.; Saibaba, N.; Jayaraj, R. N.

2008-12-01

Zircaloy-4 material is used for cladding tube in pressurized heavy water reactors (PHWRs) of 220 MWe and 540 MWe capacity in India. These tubes are fabricated by using various combinations of thermo-mechanical processes to achieve desired mechanical and corrosion properties. Cladding tube develops crystallographic texture during its fabrication, which has significant influence on its in-reactor performance. Due to radiolytic decomposition of water Zircaloy-4 picks-up hydrogen. This hydrogen in excess of its maximum solubility in reactor operating condition (˜300 °C), precipitates as zirconium hydrides causing embrittlement of cladding tube. Hydride orientation in the radial direction of the tube limits the service life and lowers the fuel burn-up in reactor. The orientation of the hydride primarily depends on texture developed during fabrication. A correlation between hydride orientation ( F n) with the texture in the tube during its fabrication has been developed using a second order polynomial. The present work is aimed at quantification and correlation of texture evolved in Zircaloy-4 cladding tube using Kearn's f-parameter during its fabrication process.

Effect of indium addition in U-Zr metallic fuel on lanthanide migration

DOE Office of Scientific and Technical Information (OSTI.GOV)

Kim, Yeon Soo; Wiencek, T.; O'Hare, E.

Advanced fast reactor concepts to achieve ultra-high burnup (~50%) require prevention of fuel-cladding chemical interaction (FCCI). Fission product lanthanide accumulation at high burnup is substantial and significantly contributes to FCCI upon migration to the cladding interface. Diffusion barriers are typically used to prevent interaction of the lanthanides with the cladding. A more active method has been proposed which immobilizes the lanthanides through formation of stable compounds with an additive. Theoretical analysis showed that indium, thallium, and antimony are good candidates. Indium was the strongest candidate because of its low reactivity with iron-based cladding alloys. Characterization of the as-fabricated alloys wasmore » performed to determine the effectiveness of the indium addition in forming compounds with lanthanides, represented by cerium. Tests to examine how effectively the dopant prevents lanthanide migration under a thermal gradient were also performed. The results showed that indium effectively prevented cerium migration.« less

Process for making a martensitic steel alloy fuel cladding product

DOEpatents

Johnson, Gerald D.; Lobsinger, Ralph J.; Hamilton, Margaret L.; Gelles, David S.

1990-01-01

This is a very narrowly defined martensitic steel alloy fuel cladding material for liquid metal cooled reactors, and a process for making such a martensitic steel alloy material. The alloy contains about 10.6 wt. % chromium, about 1.5 wt. % molybdenum, about 0.85 wt. % manganese, about 0.2 wt. % niobium, about 0.37 wt. % silicon, about 0.2 wt. % carbon, about 0.2 wt. % vanadium, 0.05 maximum wt. % nickel, about 0.015 wt. % nitrogen, about 0.015 wt. % sulfur, about 0.05 wt. % copper, about 0.007 wt. % boron, about 0.007 wt. % phosphorous, and with the remainder being essentially iron. The process utilizes preparing such an alloy and homogenizing said alloy at about 1000.degree. C. for 16 hours; annealing said homogenized alloy at 1150.degree. C. for 15 minutes; and tempering said annealed alloy at 700.degree. C. for 2 hours. The material exhibits good high temperature strength (especially long stress rupture life) at elevated temperature (500.degree.-760.degree. C.).

Kr ion irradiation study of the depleted-uranium alloys

NASA Astrophysics Data System (ADS)

Gan, J.; Keiser, D. D.; Miller, B. D.; Kirk, M. A.; Rest, J.; Allen, T. R.; Wachs, D. M.

2010-12-01

Fuel development for the reduced enrichment research and test reactor (RERTR) program is tasked with the development of new low enrichment uranium nuclear fuels that can be employed to replace existing high enrichment uranium fuels currently used in some research reactors throughout the world. For dispersion type fuels, radiation stability of the fuel-cladding interaction product has a strong impact on fuel performance. Three depleted-uranium alloys are cast for the radiation stability studies of the fuel-cladding interaction product using Kr ion irradiation to investigate radiation damage from fission products. SEM analysis indicates the presence of the phases of interest: U(Al, Si) 3, (U, Mo)(Al, Si) 3, UMo 2Al 20, U 6Mo 4Al 43 and UAl 4. Irradiations of TEM disc samples were conducted with 500 keV Kr ions at 200 °C to ion doses up to 2.5 × 10 19 ions/m 2 (˜10 dpa) with an Kr ion flux of 10 16 ions/m 2/s (˜4.0 × 10 -3 dpa/s). Microstructural evolution of the phases relevant to fuel-cladding interaction products was investigated using transmission electron microscopy.

Posttest examination results of recent treat tests on metal fuel

DOE Office of Scientific and Technical Information (OSTI.GOV)

Holland, J.W.; Wright, A.E.; Bauer, T.H.

A series of in-reactor transient tests is underway to study the characteristics of metal-alloy fuel during transient-overpower-without-scam conditions. The initial tests focused on determining the margin to cladding breach and the axial fuel motions that would mitigate the power excursion. The tests were conducted in flowing-sodium loops with uranium - 5% fissium EBR-II Mark-II driver fuel elements in the TREAT facility. Posttest examination of the tests evaluated fuel elongation in intact pins and postfailure fuel motion. Microscopic examination of the intact pins studied the nature and extent of fuel/cladding interaction, fuel melt fraction and mass distribution, and distribution of porosity.more » Eutectic penetration and failure of the cladding were also examined in the failed pins.« less

General-Purpose Heat Source Safety Verification Test Program: Edge-on flyer plate tests

NASA Astrophysics Data System (ADS)

George, T. G.

1987-03-01

The radioisotope thermoelectric generator (RTG) that will supply power for the Galileo and Ulysses space missions contains 18 General-Purpose Heat Source (GPHS) modules. The GPHS modules provide power by transmitting the heat of Pu-238 alpha-decay to an array of thermoelectric elements. Each module contains four Pu-238O2-fueled clads and generates 250 W(t). Because the possibility of a launch vehicle explosion always exists, and because such an explosion could generate a field of high-energy fragments, the fueled clads within each GPHS module must survive fragment impact. The edge-on flyer plate tests were included in the Safety Verification Test series to provide information on the module/clad response to the impact of high-energy plate fragments. The test results indicate that the edge-on impact of a 3.2-mm-thick, aluminum-alloy (2219-T87) plate traveling at 915 m/s causes the complete release of fuel from capsules contained within a bare GPHS module, and that the threshold velocity sufficient to cause the breach of a bare, simulant-fueled clad impacted by a 3.5-mm-thick, aluminum-alloy (5052-TO) plate is approximately 140 m/s.

Technique development for modulus, microcracking, hermeticity, and coating evaluation capability characterization of SiC/SiC tubes

DOE Office of Scientific and Technical Information (OSTI.GOV)

Hu, Xunxiang; Ang, Caen K.; Singh, Gyanender P.

Driven by the need to enlarge the safety margins of nuclear fission reactors in accident scenarios, research and development of accident-tolerant fuel has become an important topic in the nuclear engineering and materials community. A continuous-fiber SiC/SiC composite is under consideration as a replacement for traditional zirconium alloy cladding owing to its high-temperature stability, chemical inertness, and exceptional irradiation resistance. An important task is the development of characterization techniques for SiC/SiC cladding, since traditional work using rectangular bars or disks cannot directly provide useful information on the properties of SiC/SiC composite tubes for fuel cladding applications. At Oak Ridge Nationalmore » Laboratory, experimental capabilities are under development to characterize the modulus, microcracking, and hermeticity of as-fabricated, as-irradiated SiC/SiC composite tubes. Resonant ultrasound spectroscopy has been validated as a promising technique to evaluate the elastic properties of SiC/SiC composite tubes and microcracking within the material. A similar technique, impulse excitation, is efficient in determining the basic mechanical properties of SiC bars prepared by chemical vapor deposition; it also has potential for application in studying the mechanical properties of SiC/SiC composite tubes. Complete evaluation of the quality of the developed coatings, a major mitigation strategy against gas permeation and hydrothermal corrosion, requires the deployment of various experimental techniques, such as scratch indentation, tensile pulling-off tests, and scanning electron microscopy. In addition, a comprehensive permeation test station is being established to assess the hermeticity of SiC/SiC composite tubes and to determine the H/D/He permeability of SiC/SiC composites. This report summarizes the current status of the development of these experimental capabilities.« less

An investigation of FeCrAl cladding behavior under normal operating and loss of coolant conditions

DOE PAGES

Gamble, Kyle A.; Barani, Tommaso; Pizzocri, David; ...

2017-04-30

Iron-chromium-aluminum (FeCrAl) alloys are candidates to be used as nuclear fuel cladding for increased accident tolerance. An analysis of the response of FeCrAl under normal operating and loss of coolant conditions has been performed using fuel performance modeling. In particular, recent information on FeCrAl material properties and phenomena from separate effects tests has been implemented in the BISON fuel performance code and analyses of integral fuel rod behavior with FeCrAl cladding have been performed. BISON simulations included both light water reactor normal operation and loss-of-coolant accidental transients. In order to model fuel rod behavior during accidents, a cladding failure criterionmore » is desirable. For FeCrAl alloys, a failure criterion is developed using recent burst experiments under loss of coolant like conditions. The added material models are utilized to perform comparative studies with Zircaloy-4 under normal operating conditions and oxidizing and non-oxidizing out-of-pile loss of coolant conditions. The results indicate that for all conditions studied, FeCrAl behaves similarly to Zircaloy-4 with the exception of improved oxidation performance. Here, further experiments are required to confirm these observations.« less

An investigation of FeCrAl cladding behavior under normal operating and loss of coolant conditions

DOE Office of Scientific and Technical Information (OSTI.GOV)

Gamble, Kyle A.; Barani, Tommaso; Pizzocri, David

Iron-chromium-aluminum (FeCrAl) alloys are candidates to be used as nuclear fuel cladding for increased accident tolerance. An analysis of the response of FeCrAl under normal operating and loss of coolant conditions has been performed using fuel performance modeling. In particular, recent information on FeCrAl material properties and phenomena from separate effects tests has been implemented in the BISON fuel performance code and analyses of integral fuel rod behavior with FeCrAl cladding have been performed. BISON simulations included both light water reactor normal operation and loss-of-coolant accidental transients. In order to model fuel rod behavior during accidents, a cladding failure criterionmore » is desirable. For FeCrAl alloys, a failure criterion is developed using recent burst experiments under loss of coolant like conditions. The added material models are utilized to perform comparative studies with Zircaloy-4 under normal operating conditions and oxidizing and non-oxidizing out-of-pile loss of coolant conditions. The results indicate that for all conditions studied, FeCrAl behaves similarly to Zircaloy-4 with the exception of improved oxidation performance. Here, further experiments are required to confirm these observations.« less

Effects of the shape of the foil corners on the irradiation performance of U10Mo alloy based monolithic mini-plates

DOE Office of Scientific and Technical Information (OSTI.GOV)

Ozaltun, Hakan; Medvedev, Pavel G

2015-06-01

Monolithic plate-type fuel is a fuel form being developed for high performance research and test reactors to minimize the use of enriched material. These fuel elements are comprised of a high density, low enrichment, U-Mo alloy based fuel foil, sandwiched between Zirconium liners and encapsulated in Aluminum cladding. The use of a high density fuel in a foil form presents a number of fabrication and operational concerns, such as: foil centering, flatness of the foil, fuel thickness variation, geometrical tilting, foil corner shape etc. To benchmark this new design, effects of various geometrical and operational variables on irradiation performance havemore » been evaluated. As a part of these series of sensitivity studies, the shape of the foil corners were studied. To understand the effects of the corner shapes of the foil on thermo-mechanical performance of the plates, a behavioral model was developed for a selected plate from RERTR-12 experiments (Plate L1P785). Both fabrication and irradiation processes were simulated. Once the thermo-mechanical behavior the plate is understood for the nominal case, the simulations were repeated for two additional corner shapes to observe the changes in temperature, displacement and stress-strain fields. The results from the fabrication simulations indicated that the foil corners do not alter the post-fabrication stress-strain magnitudes. Furthermore, the irradiation simulations revealed that post-fabrication stresses of the foil would be relieved very quickly in operation. While, foils with chamfered and filleted corners yielded stresses with comparable magnitudes, they are slightly lower in magnitudes, and provided a more favorable mechanical response compared with the foil with sharp corners.« less

The Influence of the In-Situ Clad Staining on the Corrosion of Zircaloy in PWR Water Environment

DOE Office of Scientific and Technical Information (OSTI.GOV)

Kammenzind, B.F., Eklund, K.L. and Bajaj, R.

Zircaloy cladding tubes strain in-situ during service life in the corrosive environment of a Pressurized Water Reactor for a variety of reasons. First, the tube undergoes stress free growth due to the preferential alignment of irradiation induced vacancy loops on basal planes. Positive strains develop in the textured tubes along prism orientations while negative strains develop along basal orientations (Reference (a)). Second, early in life, free standing tubes will often shrink by creep in the diametrical direction under the external pressure of the water environment, but potentially grow later in life in the diametrical direction once the expanding fuel pelletmore » contacts the cladding inner wall (Reference (b)). Finally, the Zircaloy cladding absorbs hydrogen as a by product of the corrosion reaction (Reference (c)). Once above the solubility limit in Zircaloy, the hydride precipitates as zirconium hydride (References (c) through (j)). Both hydrogen in solid solution and precipitated as Zirconium hydride cause a volume expansion of the Zircaloy metal (Reference (k)). Few studies are reported on that have investigated the influence that in-situ clad straining has on corrosion of Zircaloy. If Zircaloy corrosion rates are governed by diffusion of anions through a thin passivating boundary layer at the oxide-to-metal interface (References (l) through (n)), in-situ straining of the cladding could accelerate the corrosion process by prematurely breaking that passivating oxide boundary layer. References (o) through (q) investigated the influence that an applied tensile stress has on the corrosion resistance of Zircaloy. Knights and Perkins, Reference (o), reported that the applied tensile stress increased corrosion rates above a critical stress level in 400 C and 475 C steam, but not at lower temperatures nor in dry oxygen environments. This latter observation suggested that hydrogen either in the oxide or at the oxide-to-metal interface is involved in the observed stress effect. Kim et al. (Reference (p)) and Kim and Kim (Reference (q)) more recently investigated the influence that an applied hoop stress has on the corrosion resistance of Zircaloy tubes in a 400 C steam and in a 350 C concentrated lithia water environment. Both of these studies found the applied tensile hoop stress to have no effect on cladding corrosion rates in the 400 C steam environment but to have accelerated corrosion in the lithiated water environment. In both cases, the corrosion acceleration in the lithiated water environment was attributed to the accumulation of the increased hydrogen picked up in the lithiated environment into the tensile regions of the test specimen. Dense hydride rims have been shown, independent of clad strain, to accelerate the corrosion of Zirconium alloys (References (r) and (s)), suggesting that the primary effect of applied stresses on the corrosion of Zircaloy in the above studies is through the accumulation of hydrogen at the oxide-to-metal interface and not through a direct mechanical breakdown of the passivating boundary layer. To further investigate the potential role of in-situ clad straining (or stress) on Zircaloy corrosion rates, two experimental studies were performed. First, several samples that were irradiated with and without an applied stress were destructively examined for the extent of corrosion occurring in strained and nonstrained regions of the test samples. The extent of corrosion was determined, posttest, by metallographic examination. Second, the corrosion process was monitored in-situ using electrochemical impedance spectroscopy on samples exposed out-of-reactor with and without an applied stress. Post test, these autoclave samples were also metallographically examined.« less

Solid solution strengthened duct and cladding alloy D9-B1

DOEpatents

Korenko, Michael K.

1983-01-01

A modified AISI type 316 stainless steel is described for use in an atmosphere where the alloy will be subject to neutron irradiation. The alloy is characterized by its phase stability in both the annealed as well as cold work condition and above all by its superior resistance to radiation induced swelling. Graphical data is included to demonstrate the superior swelling resistance of the alloy which contains from about 0.5% to 2.2% manganese, from about 0.7% to about 1.1% silicon, from about 12.5% to 14% chromium, from about 14.5% to about 16.5% nickel, from about 1.2% to about 1.6% molybdenum, from 0.15% to 0.30% titanium, from 0.02% to 0.08% zirconium, and the balance iron with incidental impurities.

FISSILE MATERIAL AND FUEL ELEMENTS FOR NEUTRONIC REACTORS

DOEpatents

Shaner, B.E.

1961-08-15

The fissile material consists of about 64 to 70% (weight) zirconium dioxide, 15 to 19% uranium dioxide, and 8 to 17% calcium oxide. The fissile material is formed into sintered composites which are disposed in a compartmented fuel element, comprising essentially a flat filler plate having a plurality of compartments therein, enclosed in cladding plates of the same material as the filler plate. The resultant fuel has good resistance to corrosion in high temperature pressurized water, good dimensional stability to elevated temperatures, and good resistance to thermal shock. (AEC)

Novel Accident-Tolerant Fuel Meat and Cladding

DOE Office of Scientific and Technical Information (OSTI.GOV)

Robert D. Mariani; Pavel G Medvedev; Douglas L Porter

A novel accident-tolerant fuel meat and cladding are here proposed. The fuel meat design incorporates annular fuel with inserts and discs that are fabricated from a material having high thermal conductivity, for example niobium. The inserts are rods or tubes. Discs separate the fuel pellets. Using the BISON fuel performance code it was found that the peak fuel temperature can be lowered by more than 600 degrees C for one set of conditions with niobium metal as the thermal conductor. In addition to improved safety margin, several advantages are expected from the lower temperature such as decreased fission gas releasemore » and fuel cracking. Advantages and disadvantages are discussed. An enrichment of only 7.5% fully compensates the lost reactivity of the displaced UO2. Slightly higher enrichments, such as 9%, allow uprates and increased burnups to offset the initial costs for retooling. The design has applications for fast reactors and transuranic burning, which may accelerate its development. A zirconium silicide coating is also described for accident tolerant applications. A self-limiting degradation behavior for this coating is expected to produce a glassy, self-healing layer that becomes more protective at elevated temperature, with some similarities to MoSi2 and other silicides. Both the fuel and coating may benefit from the existing technology infrastructure and the associated wide expertise for a more rapid development in comparison to other, more novel fuels and cladding.« less

Use of the Hugoniot elastic limit in laser shockwave experiments to relate velocity measurements

NASA Astrophysics Data System (ADS)

Smith, James A.; Lacy, Jeffrey M.; Lévesque, Daniel; Monchalin, Jean-Pierre; Lord, Martin

2016-02-01

The US National Nuclear Security Agency has a Global Threat Reduction Initiative (GTRI) with the goal of reducing the worldwide use of high-enriched uranium (HEU). A salient component of that initiative is the conversion of research reactors from HEU to low enriched uranium (LEU) fuels. An innovative fuel is being developed to replace HEU in high-power research reactors. The new LEU fuel is a monolithic fuel made from a U-Mo alloy foil encapsulated in Al-6061 cladding. In order to support the fuel qualification process, the Laser Shockwave Technique (LST) is being developed to characterize the clad-clad and fuel-clad interface strengths in fresh and irradiated fuel plates. This fuel-cladding interface qualification will ensure the survivability of the fuel plates in the harsh reactor environment even under abnormal operating conditions. One of the concerns of the project is the difficulty of calibrating and standardizing the laser shock technique. An analytical study under development and experimental testing supports the hypothesis that the Hugoniot Elastic Limit (HEL) in materials can be a robust and simple benchmark to compare stresses generated by different laser shock systems.

Microstructures and properties of ceramic particle-reinforced metal matrix composite layers produced by laser cladding

NASA Astrophysics Data System (ADS)

Zhang, Qingmao; He, Jingjiang; Liu, Wenjin; Zhong, Minlin

2005-01-01

Different weight ratio of titanium, zirconium, WC and Fe-based alloy powders were mixed, and cladded onto a medium carbon steel substrate using a 3kW continuous wave CO2 laser, aiming at producing Ceramic particles- reinforced metal matrix composites (MMCs) layers. The microstructures of the layers are typical hypoeutectic, and the major phases are Ni3Si2, TiSi2, Fe3C, FeNi, MC, Fe7Mo3, Fe3B, γ(residual austenite) and M(martensite). The microstructure morphologies of MMCs layers are dendrites/cells. The MC-type reinforcements are in situ synthesis Carbides which main compositions consist of transition elements Zr, Ti, W. The MC-type particles distributed within dendrite and interdendritic regions with different volume fractions for single and overlapping clad layers. The MMCs layers are dense and free of cracks with a good metallurgical bonding between the layer and substrate. The addition ratio of WC in the mixtures has the remarkable effect on the microhardness of clad layers.

Selection of Nuclear Fuel for TREAT: UO 2 vs U 3O 8

DOE Office of Scientific and Technical Information (OSTI.GOV)

Glazoff, Michael Vasily; Van Rooyen, Isabella Johanna; Coryell, Benjamin David

The Transient Reactor Test (TREAT) that resides at the Materials and Fuels Complex (MFC) at Idaho National Laboratory (INL), first achieved criticality in 1959, and successfully performed many transient tests on nuclear fuel until 1994 when its operations were suspended. Resumption of operations at TREAT was approved in February 2014 to meet the U.S. Department of Energy (DOE) Office of Nuclear Energy’s objectives in transient testing of nuclear fuels. The National Nuclear Security Administration’s is converting TREAT from its existing highly enriched uranium (HEU) core to a new core containing low enriched uranium (LEU) (i.e., U-235< 20% by weight). Themore » TREAT Conversion project is currently progressing with conceptual design phase activities. Dimensional stability of the fuel element assemblies, predictable fuel can oxidation and sufficient heat conductivity by the fuel blocks are some of the critical performance requirements of the new LEU fuel. Furthermore, to enable the design team to design fuel block and can specifications, it is amongst the objectives to evaluate TREAT LEU fuel and cladding material’s chemical interaction. This information is important to understand the viability of Zr-based alloys and fuel characteristics for the fabrication of the TREAT LEU fuel and cladding. Also, it is very important to make the right decision on what type of nuclear fuel will be used at TREAT. In particular, one has to consider different oxides of uranium, and most importantly, UO 2 vs U 3O 8. In this report, the results are documented pertaining to the choice mentioned above (UO 2 vs U 3O 8). The conclusion in favor of using UO 2 was made based on the analysis of historical data, up-to-date literature, and self-consistent calculations of phase equilibria and thermodynamic properties in the U-O and U-O-C systems. The report is organized as follows. First, the criteria that were used to make the choice are analyzed. Secondly, existing historical data and current literature were reviewed. This analysis was supplemented by the construction and examination of the U-O and U-O-C phase diagrams at pressure close to negligent, thereby mimicking the conditions in which nuclear fuel is supposed to function inside the zirconium-based cladding in the reactor. Finally, our conclusion in favor of the UO 2 down selection was summarized and explained in the last Section of this document.« less

Sample environment for in situ synchrotron corrosion studies of materials in extreme environments

DOE Office of Scientific and Technical Information (OSTI.GOV)

Elbakhshwan, Mohamed S.; Gill, Simerjeet K.; Motta, Arthur T.

A new in situ sample environment has been designed and developed to study the interfacial interactions of nuclear cladding alloys with high temperature steam. The sample environment is particularly optimized for synchrotron X-ray diffraction (XRD) studies for in situ structural analysis. The sample environment is highly corrosion resistant and can be readily adapted for steam environments. The in situ sample environment design complies with G2 ASTM standards for studying corrosion in zirconium and its alloys and offers remote temperature and pressure monitoring during the in situ data collection. The use of the in situ sample environment is exemplified by monitoringmore » the oxidation of metallic zirconium during exposure to steam at 350°C. Finally, the in situ sample environment provides a powerful tool for fundamental understanding of corrosion mechanisms by elucidating the substoichiometric oxide phases formed during early stages of corrosion, which can provide a better understanding the oxidation process.« less

Sample environment for in situ synchrotron corrosion studies of materials in extreme environments

DOE PAGES

Elbakhshwan, Mohamed S.; Gill, Simerjeet K.; Motta, Arthur T.; ...

2016-10-25

A new in situ sample environment has been designed and developed to study the interfacial interactions of nuclear cladding alloys with high temperature steam. The sample environment is particularly optimized for synchrotron X-ray diffraction (XRD) studies for in situ structural analysis. The sample environment is highly corrosion resistant and can be readily adapted for steam environments. The in situ sample environment design complies with G2 ASTM standards for studying corrosion in zirconium and its alloys and offers remote temperature and pressure monitoring during the in situ data collection. The use of the in situ sample environment is exemplified by monitoringmore » the oxidation of metallic zirconium during exposure to steam at 350°C. Finally, the in situ sample environment provides a powerful tool for fundamental understanding of corrosion mechanisms by elucidating the substoichiometric oxide phases formed during early stages of corrosion, which can provide a better understanding the oxidation process.« less

Pulsed Magnetic Welding for Advanced Core and Cladding Steel

DOE Office of Scientific and Technical Information (OSTI.GOV)

Cao, Guoping; Yang, Yong

2013-12-19

To investigate a solid-state joining method, pulsed magnetic welding (PMW), for welding the advanced core and cladding steels to be used in Generation IV systems, with a specific application for fuel pin end-plug welding. As another alternative solid state welding technique, pulsed magnetic welding (PMW) has not been extensively explored on the advanced steels. The resultant weld can be free from microstructure defects (pores, non-metallic inclusions, segregation of alloying elements). More specifically, the following objectives are to be achieved: 1. To design a suitable welding apparatus fixture, and optimize welding parameters for repeatable and acceptable joining of the fuel pinmore » end-plug. The welding will be evaluated using tensile tests for lap joint weldments and helium leak tests for the fuel pin end-plug; 2 Investigate the microstructural and mechanical properties changes in PMW weldments of proposed advanced core and cladding alloys; 3. Simulate the irradiation effects on the PWM weldments using ion irradiation.« less

Development of ODS FeCrAl alloys for accident-tolerant fuel cladding

DOE Office of Scientific and Technical Information (OSTI.GOV)

Dryepondt, Sebastien N.; Hoelzer, David T.; Pint, Bruce A.

2015-09-18

FeCrAl alloys are prime candidates for accident-tolerant fuel cladding due to their excellent oxidation resistance up to 1400 C and good mechanical properties at intermediate temperature. Former commercial oxide dispersion strengthened (ODS) FeCrAl alloys such as PM2000 exhibit significantly better tensile strength than wrought FeCrAl alloys, which would alloy for the fabrication of a very thin (~250 m) ODS FeCrAl cladding and limit the neutronic penalty from the replacement of Zr-based alloys by Fe-based alloys. Several Fe-12-Cr-5Al ODS alloys where therefore fabricated by ball milling FeCrAl powders with Y2O3 and additional oxides such as TiO 2 or ZrO 2. Themore » new Fe-12Cr-5Al ODS alloys showed excellent tensile strength up to 800 C but limited ductility. Good oxidation resistance in steam at 1200 and 1400 C was observed except for one ODS FeCrAl alloy containing Ti. Rolling trials were conducted at 300, 600 C and 800 C to simulate the fabrication of thin tube cladding and a plate thickness of ~0.6mm was reached before the formation of multiple edge cracks. Hardness measurements at different stages of the rolling process, before and after annealing for 1h at 1000 C, showed that a thinner plate thickness could likely be achieved by using a multi-step approach combining warm rolling and high temperature annealing. Finally, new Fe-10-12Cr-5.5-6Al-Z gas atomized powders have been purchased to fabricate the second generation of low-Cr ODS FeCrAl alloys. The main goals are to assess the effect of O, C, N and Zr contents on the ODS FeCrAl microstructure and mechanical properties, and to optimize the fabrication process to improve the ductility of the 2nd gen ODS FeCrAl while maintaining good mechanical strength and oxidation resistance.« less

Evaluation of tantalum-alloy-clad uranium mononitride fuel specimens from 7500-hour, 1040 C pumped-lithium-loop test

NASA Technical Reports Server (NTRS)

Watson, G. K.

1974-01-01

Simulated nuclear fuel element specimens, consisting of uranium mononitride (UN) fuel cylinders clad with tungsten-lined T-111, were exposed for up to 7500 hr at 1040 C (1900 F) in a pumped-lithium loop. The lithium flow velocity was 1.5 m/sec (5 ft/sec) in the specimen test section. No evidence of any compatibility problems between the specimens and the flowing lithium was found based on appearance, weight change, chemistry, and metallography. Direct exposure of the UN to the lithium through a simulated cladding crack resulted in some erosion of the UN in the area of the defect. The T-111 cladding was ductile after lithium exposure, but it was sensitive to hydrogen embrittlement during post-test handling.

TERNARY ALLOY-CONTAINING PLUTONIUM

DOEpatents

Waber, J.T.

1960-02-23

Ternary alloys of uranium and plutonium containing as the third element either molybdenum or zirconium are reported. Such alloys are particularly useful as reactor fuels in fast breeder reactors. The alloy contains from 2 to 25 at.% of molybdenum or zirconium, the balance being a combination of uranium and plutonium in the ratio of from 1 to 9 atoms of uranlum for each atom of plutonium. These alloys are prepared by melting the constituent elements, treating them at an elevated temperature for homogenization, and cooling them to room temperature, the rate of cooling varying with the oomposition and the desired phase structure. The preferred embodiment contains 12 to 25 at.% of molybdenum and is treated by quenching to obtain a body centered cubic crystal structure. The most important advantage of these alloys over prior binary alloys of both plutonium and uranium is the lack of cracking during casting and their ready machinability.

Deformation behavior of laser welds in high temperature oxidation resistant Fe-Cr-Al alloys for fuel cladding applications

NASA Astrophysics Data System (ADS)

Field, Kevin G.; Gussev, Maxim N.; Yamamoto, Yukinori; Snead, Lance L.

2014-11-01

Ferritic-structured Fe-Cr-Al alloys are being developed and show promise as oxidation resistant accident tolerant light water reactor fuel cladding. This study focuses on investigating the weldability and post-weld mechanical behavior of three model alloys in a range of Fe-(13-17.5)Cr-(3-4.4)Al (wt.%) with a minor addition of yttrium using modern laser-welding techniques. A detailed study on the mechanical performance of bead-on-plate welds using sub-sized, flat dog-bone tensile specimens and digital image correlation (DIC) has been carried out to determine the performance of welds as a function of alloy composition. Results indicated a reduction in the yield strength within the fusion zone compared to the base metal. Yield strength reduction was found to be primarily constrained to the fusion zone due to grain coarsening with a less severe reduction in the heat affected zone. For all proposed alloys, laser welding resulted in a defect free weld devoid of cracking or inclusions.

DIMENSIONALLY STABLE, CORROSION RESISTANT NUCLEAR FUEL

DOEpatents

Kittel, J.H.

1963-10-31

A method of making a uranium alloy of improved corrosion resistance and dimensional stability is described. The alloy contains from 0-9 weight per cent of an additive of zirconium and niobium in the proportions by weight of 5 to 1 1/ 2. The alloy is cold rolled, heated to two different temperatures, air-cooled, heated to a third temperature, and quenched in water. (AEC)

An Innovative Accident Tolerant LWR Fuel Rod Design Based on Uranium-Molybdenum Metal Alloy

DOE Office of Scientific and Technical Information (OSTI.GOV)

Montgomery, Robert O.; Bennett, Wendy D.; Henager, Charles H.

2016-09-12

The US Department of Energy is developing a uranium-molybdenum metal alloy Enhanced Accident Tolerant Fuel concept for Light Water Reactor applications that provides improved fuel performance during normal operation, anticipated operational occurrences, and postulated accidents. The high initial uranium atom density, the high thermal conductivity, and a low heat capacity permit a U-Mo-based fuel assembly to meet important design and safety requirements. These attributes also result in a fuel design that can satisfy increased fuel utilization demands and allow for improved accident tolerance in LWRs. This paper summarizes the results obtained from the on-going activities to; 1) evaluate the impactmore » of the U-10wt%Mo thermal properties on operational and accident safety margins, 2) produce a triple extrusion of stainless steel cladding/niobium liner/U-10Mo fuel rod specimen and 3) test the high temperature water corrosion of rodlet samples containing a drilled hole in the cladding. Characterization of the cladding and liner thickness uniformity, microstructural features of the U-Mo gamma phase, and the metallurgical bond between the component materials will be presented. The results from corrosion testing will be discussed which yield insights into the resistance to attack by water ingress during high temperature water exposure for the triple extruded samples containing a drilled hole. These preliminary evaluations find that the U-10Mo fuel design concept has many beneficial features that can meet or improve conventional LWR fuel performance requirements under normal operation, AOOs, and postulated accidents. The viability of a deployable U-Mo fuel design hinges on demonstrating that fabrication processes and alloying additions can produce acceptable irradiation stability during normal operation and accident conditions and controlled metal-water reaction rates in the unlikely event of a cladding perforation. In the area of enhanced accident tolerance, a key objective is to establish that the lower stored energy of the U-Mo fuel design can provide the emergency core cooling systems the opportunity to maintain the reactor core in a coolable geometry following an accident.« less

Oxidation of aluminum alloy cladding for research and test reactor fuel

NASA Astrophysics Data System (ADS)

Kim, Yeon Soo; Hofman, G. L.; Robinson, A. B.; Snelgrove, J. L.; Hanan, N.

2008-08-01

The oxide thicknesses on aluminum alloy cladding were measured for the test plates from irradiation tests RERTR-6 and 7A in the ATR (advanced test reactor). The measured thicknesses were substantially lower than those of test plates with similar power from other reactors available in the literature. The main reason is believed to be due to the lower pH (pH 5.1-5.3) of the primary coolant water in the ATR than in the other reactors (pH 5.9-6.5) for which we have data. An empirical model for oxide film thickness predictions on aluminum alloy used as fuel cladding in the test reactors was developed as a function of irradiation time, temperature, surface heat flux, pH, and coolant flow rate. The applicable ranges of pH and coolant flow rates cover most research and test reactors. The predictions by the new model are in good agreement with the in-pile test data available in the literature as well as with the RERTR test data measured in the ATR.

PLUTONIUM METALLIC FUELS FOR FAST REACTORS

DOE Office of Scientific and Technical Information (OSTI.GOV)

STAN, MARIUS; HECKER, SIEGFRIED S.

2007-02-07

Early interest in metallic plutonium fuels for fast reactors led to much research on plutonium alloy systems including binary solid solutions with the addition of aluminum, gallium, or zirconium and low-melting eutectic alloys with iron and nickel or cobalt. There was also interest in ternaries of these elements with plutonium and cerium. The solid solution and eutectic alloys have most unusual properties, including negative thermal expansion in some solid-solution alloys and the highest viscosity known for liquid metals in the Pu-Fe system. Although metallic fuels have many potential advantages over ceramic fuels, the early attempts were unsuccessful because these fuelsmore » suffered from high swelling rates during burn up and high smearing densities. The liquid metal fuels experienced excessive corrosion. Subsequent work on higher-melting U-PuZr metallic fuels was much more promising. In light of the recent rebirth of interest in fast reactors, we review some of the key properties of the early fuels and discuss the challenges presented by the ternary alloys.« less

High weldability nickel-base superalloy

DOEpatents

Gibson, Robert C.; Korenko, Michael K.

1980-01-01

This is a nickel-base superalloy with excellent weldability and high strength. Its composition consists essentially of, by weight percent, 10-20 iron, 57-63 nickel, 7-18 chromium, 4-6 molybdenum, 1-2 niobium, 0.2-0.8 silicon, 0.01-0.05 zirconium, 1.0-2.5 titanium, 1.0-2.5 aluminum, 0.02-0.06 carbon, and 0.002-0.015 boron. The weldability and strength of this alloy give it a variety of applications. The long-time structural stability of this alloy together with its low swelling under nuclear radiation conditions, make it especially suitable for use as a duct material and controlling element cladding for sodium-cooled nuclear reactors.

In-situ tube burst testing and high-temperature deformation behavior of candidate materials for accident tolerant fuel cladding

DOE PAGES

Byun, Thak Sang; Yamamoto, Yukinori; Maloy, Stuart A.; ...

2015-08-25

Here, one of the most essential properties of accident tolerant fuel (ATF) for maintaining structural integrity during a loss-of-coolant accident (LOCA) is high resistance of the cladding to plastic deformation and burst failure, since the deformation and burst behavior governs the cooling efficiency of flow channels and the process of fission product release. To simulate and evaluate the deformation and burst process of thin-walled cladding, an in-situ testing and evaluation method has been developed on the basis of visual imaging and image analysis techniques. The method uses a specialized optics system consisting of a high-resolution video camera, a light filteringmore » unit, and monochromatic light sources. The in-situ testing is performed using a 50 mm long pressurized thin-walled tubular specimen set in a programmable furnace. As the first application, ten (10) candidate cladding materials for ATF, i.e., five FeCrAl alloys and five nanostructured steels, were tested using the newly developed method, and the time-dependent images were analyzed to produce detailed deformation and burst data such as true hoop stress, strain (creep) rate, and failure stress. Relatively soft FeCrAl alloys deformed and burst below 800 °C, while negligible strain rates were measured for higher strength alloys.« less

Severe Accident Test Station Activity Report

DOE Office of Scientific and Technical Information (OSTI.GOV)

Pint, Bruce A.; Terrani, Kurt A.

2015-06-01

Enhancing safety margins in light water reactor (LWR) severe accidents is currently the focus of a number of international R&D programs. The current UO2/Zr-based alloy fuel system is particularly susceptible since the Zr-based cladding experiences rapid oxidation kinetics in steam at elevated temperatures. Therefore, alternative cladding materials that offer slower oxidation kinetics and a smaller enthalpy of oxidation can significantly reduce the rate of heat and hydrogen generation in the core during a coolant-limited severe accident. In the U.S. program, the high temperature steam oxidation performance of accident tolerant fuel (ATF) cladding solutions has been evaluated in the Severe Accidentmore » Test Station (SATS) at Oak Ridge National Laboratory (ORNL) since 2012. This report summarizes the capabilities of the SATS and provides an overview of the oxidation kinetics of several candidate cladding materials. A suggested baseline for evaluating ATF candidates is a two order of magnitude reduction in the steam oxidation resistance above 1000ºC compared to Zr-based alloys. The ATF candidates are categorized based on the protective external oxide or scale that forms during exposure to steam at high temperature: chromia, alumina, and silica. Comparisons are made to literature and SATS data for Zr-based alloys and other less-protective materials.« less

Modeling and simulation challenges pursued by the Consortium for Advanced Simulation of Light Water Reactors (CASL)

NASA Astrophysics Data System (ADS)

Turinsky, Paul J.; Kothe, Douglas B.

2016-05-01

The Consortium for the Advanced Simulation of Light Water Reactors (CASL), the first Energy Innovation Hub of the Department of Energy, was established in 2010 with the goal of providing modeling and simulation (M&S) capabilities that support and accelerate the improvement of nuclear energy's economic competitiveness and the reduction of spent nuclear fuel volume per unit energy, and all while assuring nuclear safety. To accomplish this requires advances in M&S capabilities in radiation transport, thermal-hydraulics, fuel performance and corrosion chemistry. To focus CASL's R&D, industry challenge problems have been defined, which equate with long standing issues of the nuclear power industry that M&S can assist in addressing. To date CASL has developed a multi-physics ;core simulator; based upon pin-resolved radiation transport and subchannel (within fuel assembly) thermal-hydraulics, capitalizing on the capabilities of high performance computing. CASL's fuel performance M&S capability can also be optionally integrated into the core simulator, yielding a coupled multi-physics capability with untapped predictive potential. Material models have been developed to enhance predictive capabilities of fuel clad creep and growth, along with deeper understanding of zirconium alloy clad oxidation and hydrogen pickup. Understanding of corrosion chemistry (e.g., CRUD formation) has evolved at all scales: micro, meso and macro. CFD R&D has focused on improvement in closure models for subcooled boiling and bubbly flow, and the formulation of robust numerical solution algorithms. For multiphysics integration, several iterative acceleration methods have been assessed, illuminating areas where further research is needed. Finally, uncertainty quantification and data assimilation techniques, based upon sampling approaches, have been made more feasible for practicing nuclear engineers via R&D on dimensional reduction and biased sampling. Industry adoption of CASL's evolving M&S capabilities, which is in progress, will assist in addressing long-standing and future operational and safety challenges of the nuclear industry.

AN EVALUATION OF POTENTIAL LINER MATERIALS FOR ELIMINATING FCCI IN IRRADIATED METALLIC NUCLEAR FUEL ELEMENTS

DOE Office of Scientific and Technical Information (OSTI.GOV)

D. D. Keiser; J. I. Cole

2007-09-01

Metallic nuclear fuels are being looked at as part of the Global Nuclear Energy Program for transmuting longlive transuranic actinide isotopes contained in spent nuclear fuel into shorter-lived fission products. In order to optimize the performance of these fuels, the concept of using liners to eliminate the fuel/cladding chemical interactions that can occur during irradiation of a fuel element has been investigated. The potential liner materials Zr and V have been tested using solid-solid diffusion couples, consisting of liner materials butted against fuel alloys and against cladding materials. The couples were annealed at the relatively high temperature of 700°C. Thismore » temperature would be the absolute maximum temperature present at the fuel/cladding interface for a fuel element in-reactor. Analysis was performed using a scanning electron microscope equipped with energy-dispersive and wavelengthdispersive spectrometers (SEM/EDS/WDS) to evaluate any developed diffusion structures. At 700°C, minimal interaction was observed between the metallic fuels and either Zr or V. Similarly, limited interaction was observed between the Zr and V and the cladding materials. The best performing liner material appeared to be the V, based on amounts of interaction.« less

Development of low-Cr ODS FeCrAl alloys for accident-tolerant fuel cladding

NASA Astrophysics Data System (ADS)

Dryepondt, Sebastien; Unocic, Kinga A.; Hoelzer, David T.; Massey, Caleb P.; Pint, Bruce A.

2018-04-01

Low-Cr oxide dispersion strengthened (ODS) FeCrAl alloys were developed as accident tolerant fuel cladding because of their excellent oxidation resistance at very high temperature, high strength and improved radiation tolerance. Fe-12Cr-5Al wt.% gas atomized powder was ball milled with Y2O3+FeO, Y2O3+ZrO2 or Y2O3+TiO2, and the resulting powders were extruded at 950 °C. The resulting fine grain structure, particularly for the Ti and Zr containing alloys, led to very high strength but limited ductility. Comparison with variants of commercial PM2000 (Fe-20Cr-5Al) highlighted the significant impact of the powder consolidation step on the alloy grain size and, therefore, on the alloy mechanical properties at T < 500 °C. These low-Cr compositions exhibited good oxidation resistance at 1400 °C in air and steam for 4 h but could not form a protective alumina scale at 1450 °C, similar to observations for fine grained PM2000 alloys. The effect of alloy grain size, Zr and Ti additions, and impurities on the alloy mechanical and oxidation behaviors are discussed.

Neutronic analysis of candidate accident-tolerant cladding concepts in pressurized water reactors

DOE PAGES

George, Nathan Michael; Terrani, Kurt A.; Powers, Jeffrey J.; ...

2014-09-29

A study analyzed the neutronics of alternate cladding materials in a pressurized water reactor (PWR) environment. Austenitic type 310 (310SS) and 304 stainless steels, ferritic Fe-20Cr-5Al (FeCrAl) and APMT™ alloys, and silicon carbide (SiC)-based materials were considered and compared with Zircaloy-4. SCALE 6.1 was used to analyze the associated neutronics penalty/advantage, changes in reactivity coefficients, and spectral variations once a transition in the cladding was made. In the cases examined, materials containing higher absorbing isotopes invoked a reduction in reactivity due to an increase in neutron absorption in the cladding. Higher absorbing materials produced a harder neutron spectrum in themore » fuel pellet, leading to a slight increase in plutonium production. A parametric study determined the geometric conditions required to match cycle length requirements for each alternate cladding material in a PWR. A method for estimating the end of cycle reactivity was implemented to compare each model to that of standard Zircaloy-4 cladding. By using a thinner cladding of 350 μm and keeping a constant outer diameter, austenitic stainless steels require an increase of no more than 0.5 wt% enriched 235U to match fuel cycle requirements, while the required increase for FeCrAl was about 0.1%. When modeling SiC (with slightly lower thermal absorption properties than that of Zircaloy), a standard cladding thickness could be implemented with marginally less enriched uranium (~0.1%). Moderator temperature and void coefficients were calculated throughout the depletion cycle. Nearly identical reactivity responses were found when coolant temperature and void properties were perturbed for each cladding material. By splitting the pellet into 10 equal areal sections, relative fission power as a function of radius was found to be similar for each cladding material. FeCrAl and 310SS cladding have a slightly higher fission power near the pellet’s periphery due to the harder neutron spectrum in the system, causing more 239Pu breeding. An economic assessment calculated the change in fuel pellet production costs for use of each cladding. Furthermore, implementing FeCrAl alloys would increase fuel pellet production costs about 15% because of increased 235U enrichment and the additional UO 2 pellet volume enabled by using thinner cladding.« less

Diffusion Barrier Selection from Refractory Metals (Zr, Mo and Nb) via Interdiffusion Investigation for U-Mo RERTR Fuel Alloy

DOE Office of Scientific and Technical Information (OSTI.GOV)

K. Huang; C. Kammerer; D. D. Keiser, Jr.

2014-04-01

U-Mo alloys are being developed as low enrichment monolithic fuel under the Reduced Enrichment for Research and Test Reactor (RERTR) Program. Diffusional interactions between the U-Mo fuel alloy and Al-alloy cladding within the monolithic fuel plate construct necessitate incorporation of a barrier layer. Fundamentally, a diffusion barrier candidate must have good thermal conductivity, high melting point, minimal metallurgical interaction, and good irradiation performance. Refractory metals, Zr, Mo, and Nb are considered based on their physical properties, and the diffusion behavior must be carefully examined first with U-Mo fuel alloy. Solid-to-solid U-10wt.%Mo vs. Mo, Zr, or Nb diffusion couples were assembledmore » and annealed at 600, 700, 800, 900 and 1000 degrees C for various times. The interdiffusion microstructures and chemical composition were examined via scanning electron microscopy and electron probe microanalysis, respectively. For all three systems, the growth rate of interdiffusion zone were calculated at 1000, 900 and 800 degrees C under the assumption of parabolic growth, and calculated for lower temperature of 700, 600 and 500 degrees C according to Arrhenius relationship. The growth rate was determined to be about 10 3 times slower for Zr, 10 5 times slower for Mo and 10 6 times slower for Nb, than the growth rates reported for the interaction between the U-Mo fuel alloy and pure Al or Al-Si cladding alloys. Zr, however was selected as the barrier metal due to a concern for thermo- mechanical behavior of UMo/Nb interface observed from diffusion couples, and for ductile-to-brittle transition of Mo near room temperature.« less

Purification of nuclear grade Zr scrap as the high purity dense Zr deposits from Zirlo scrap by electrorefining in LiF-KF-ZrF4 molten fluorides

NASA Astrophysics Data System (ADS)

Park, Kyoung Tae; Lee, Tae Hyuk; Jo, Nam Chan; Nersisyan, Hayk H.; Chun, Byong Sun; Lee, Hyuk Hee; Lee, Jong Hyeon

2013-05-01

Zirconium (Zr) has commonly been used as a cladding material of nuclear fuel. Moreover, it is regarded as the only material that can be used for nuclear fuel cladding because it has the lowest neutron capture cross section of any metal element and because it has high corrosion resistance and size stability. In this study, Hf-free Zr tubes (Zr-1Nb-1Sn-0.1Fe) were used as anode materials and electrorefining was performed in a LiF-KF eutectic 6 wt.% ZrF4 molten fluoride salt system. As a result of electrolysis, Zr scrap metal was recycled into pure Zr with low levels of impurities, and the size and density of the Zr deposit was controlled using applied current density.

Chemical Dissolution of Simulant FCA Cladding and Plates

DOE Office of Scientific and Technical Information (OSTI.GOV)

Daniel, G.; Pierce, R.; O'Rourke, P.

The Savannah River Site (SRS) has received some fast critical assembly (FCA) fuel from the Japan Atomic Energy Agency (JAEA) for disposition. Among the JAEA FCA fuel are approximately 7090 rectangular Stainless Steel clad fuel elements. Each element has an internal Pu-10.6Al alloy metal wafer. The thickness of each element is either 1/16 inch or 1/32 inch. The dimensions of each element ranges from 2 inches x 1 inch to 2 inches x 4 inches. This report discusses the potential chemical dissolution of the FCA clad material or stainless steel. This technology uses nitric acid-potassium fluoride (HNO 3-KF) flowsheets ofmore » H-Canyon to dissolve the FCA elements from a rack of materials. Historically, dissolution flowsheets have aimed to maximize Pu dissolution rates while minimizing stainless steel dissolution (corrosion) rates. Because the FCA cladding is made of stainless steel, this work sought to accelerate stainless steel dissolution.« less

First overpower tests of metallic IFR [Integral Fast Reactor] fuel in TREAT [Transient Reactor Test Facility]: Data and analysis from tests M5, M6, and M7

DOE Office of Scientific and Technical Information (OSTI.GOV)

Bauer, T. H.; Robinson, W. R.; Holland, J. W.

1989-12-01

Results and analyses of margin to cladding failure and pre-failure axial expansion of metallic fuel are reported for TREAT in-pile transient overpower tests M5--M7. These are the first such tests on reference binary and ternary alloy fuel of the Integral Fast Reactor (IFR) concept with burnup ranging from 1 to 10 at. %. In all cases, test fuel was subjected to an exponential power rise on an 8 s period until either incipient or actual cladding failure was achieved. Objectives, designs and methods are described with emphasis on developments unique to metal fuel safety testing. The resulting database for claddingmore » failure threshold and prefailure fuel expansion is presented. The nature of the observed cladding failure and resultant fuel dispersals is described. Simple models of cladding failures and pre-failure axial expansions are described and compared with experimental results. Reported results include: temperature, flow, and pressure data from test instrumentation; fuel motion diagnostic data principally from the fast neutron hodoscope; and test remains described from both destructive and non-destructive post-test examination. 24 refs., 144 figs., 17 tabs.« less

Development of Metallic Fuels for Actinide Transmutation

DOE Office of Scientific and Technical Information (OSTI.GOV)

Hayes, Steven Lowe; Fielding, Randall Sidney; Benson, Michael Timothy

Research and development activities on metallic fuels are focused on their potential use for actinide transmutation in future sodium fast reactors. As part of this application, there is also a need for a near zero-loss fabrication process and a desire to demonstrate a multifold increase in burnup potential. The incorporation of Am and Np into the traditional U-20Pu-10Zr metallic fuel alloy was demonstrated in the US during the Integral Fast Reactor Program of the 1980’s and early 1990’s. However, the conventional counter gravity injection casting method performed under vacuum, previously used to fabricate these metallic fuel alloys, was not optimizedmore » for mitigating loss of the volatile Am constituent in the casting charge; as a result, approximately 40% of the Am casting charge failed to be incorporated into the as-cast fuel alloys. Fabrication development efforts of the past few years have pursued an optimized bottom-pour casting method to increase utilization of the melted charge to near 100%, and a differential pressure casting approach, performed under an argon overpressure, has been demonstrated to result in essentially no loss of Am due to volatilization during fabrication. In short, a path toward zero-loss fabrication of metallic fuels including minor actinides has been shown to be feasible. Irradiation testing of advanced metallic fuel alloys in the Advanced Test Reactor (ATR) has been underway since 2003. Testing in the ATR is performed inside of cadmium-shrouded positions to remove >99% of the thermal flux incident on the test fuels, resulting in an epi-thermal driven fuel test that is free from gross flux depression and producing an essentially prototypic radial temperature profile inside the fuel rodlets. To date, three irradiation test series (AFC-1,2,3) have been completed. Over 20 different metallic fuel alloys have been tested to burnups as high as 30% with constituent compositions of Pu up to 30%, Am up to 12%, Np up to 10%, and Zr between 10 and 60%. In general, the performance of all of these substantially disparate metallic fuel alloys has been observed to be excellent, and their irradiation behaviors are generally consistent with historic norms for metallic fuels without minor actinide additions and having lower Pu or Zr contents. Future work is being undertaken with a view toward increasing the burnup potential of metallic fuels even more. Design innovations under investigation include: 1) lowering the fuel smear density in order to accommodate more swelling, 2) annular fuel geometry to eliminate the need for a sodium bond, 3) minor alloy additions to stabilize lanthanide fission products inside the fuel and prevent their transport to the cladding where they can participate in fuel-cladding chemical interaction (FCCI), and 4) coatings/liners on the cladding inner surface to mitigate FCCI and enable higher temperature operation. This paper will present the current state of development of metallic fuels for actinide transmutation in the US. Highlights will include recent results from metallic fuel casting experiments, experiments to identify alloy additions to immobilize lanthanide fission products, and postirradiation examinations of annular metallic fuels at low burnup.« less

Microstructure Instability of Candidate Fuel Cladding Alloys: Corrosion and Stress Corrosion Cracking Implications

NASA Astrophysics Data System (ADS)

Jiao, Yinan; Zheng, Wenyue; Guzonas, David; Kish, Joseph

2016-02-01

This paper addresses some of the overarching aspects of microstructure instability expected from both high temperature and radiation exposure that could affect the corrosion and stress corrosion cracking (SCC) resistance of the candidate austenitic Fe-Cr-Ni alloys being considered for the fuel cladding of the Canadian supercritical water-cooled reactor (SCWR) concept. An overview of the microstructure instability expected by both exposures is presented prior to turning the focus onto the implications of such instability on the corrosion and SCC resistance. Results from testing conducted using pre-treated (thermally-aged) Type 310S stainless steel to shed some light on this important issue are included to help identify the outstanding corrosion resistance assessment needs.

Artefacts in multimodal imaging of titanium, zirconium and binary titanium–zirconium alloy dental implants: an in vitro study

PubMed Central

Schöllchen, Maximilian; Aarabi, Ghazal; Assaf, Alexandre T; Rendenbach, Carsten; Beck-Broichsitter, Benedicta; Semmusch, Jan; Sedlacik, Jan; Heiland, Max; Fiehler, Jens; Siemonsen, Susanne

2017-01-01

Objectives: To analyze and evaluate imaging artefacts induced by zirconium, titanium and titanium–zirconium alloy dental implants. Methods: Zirconium, titanium and titanium–zirconium alloy implants were embedded in gelatin and MRI, CT and CBCT were performed. Standard protocols were used for each modality. For MRI, line–distance profiles were plotted to quantify the accuracy of size determination. For CT and CBCT, six shells surrounding the implant were defined every 0.5 cm from the implant surface and histogram parameters were determined for each shell. Results: While titanium and titanium–zirconium alloy induced extensive signal voids in MRI owing to strong susceptibility, zirconium implants were clearly definable with only minor distortion artefacts. For titanium and titanium–zirconium alloy, the MR signal was attenuated up to 14.1 mm from the implant. In CT, titanium and titanium–zirconium alloy resulted in less streak artefacts in comparison with zirconium. In CBCT, titanium–zirconium alloy induced more severe artefacts than zirconium and titanium. Conclusions: MRI allows for an excellent image contrast and limited artefacts in patients with zirconium implants. CT and CBCT examinations are less affected by artefacts from titanium and titanium–zirconium alloy implants compared with MRI. The knowledge about differences of artefacts through different implant materials and image modalities might help support clinical decisions for the choice of implant material or imaging device in the clinical setting. PMID:27910719

Artefacts in multimodal imaging of titanium, zirconium and binary titanium-zirconium alloy dental implants: an in vitro study.

PubMed

Smeets, Ralf; Schöllchen, Maximilian; Gauer, Tobias; Aarabi, Ghazal; Assaf, Alexandre T; Rendenbach, Carsten; Beck-Broichsitter, Benedicta; Semmusch, Jan; Sedlacik, Jan; Heiland, Max; Fiehler, Jens; Siemonsen, Susanne

2017-02-01

To analyze and evaluate imaging artefacts induced by zirconium, titanium and titanium-zirconium alloy dental implants. Zirconium, titanium and titanium-zirconium alloy implants were embedded in gelatin and MRI, CT and CBCT were performed. Standard protocols were used for each modality. For MRI, line-distance profiles were plotted to quantify the accuracy of size determination. For CT and CBCT, six shells surrounding the implant were defined every 0.5 cm from the implant surface and histogram parameters were determined for each shell. While titanium and titanium-zirconium alloy induced extensive signal voids in MRI owing to strong susceptibility, zirconium implants were clearly definable with only minor distortion artefacts. For titanium and titanium-zirconium alloy, the MR signal was attenuated up to 14.1 mm from the implant. In CT, titanium and titanium-zirconium alloy resulted in less streak artefacts in comparison with zirconium. In CBCT, titanium-zirconium alloy induced more severe artefacts than zirconium and titanium. MRI allows for an excellent image contrast and limited artefacts in patients with zirconium implants. CT and CBCT examinations are less affected by artefacts from titanium and titanium-zirconium alloy implants compared with MRI. The knowledge about differences of artefacts through different implant materials and image modalities might help support clinical decisions for the choice of implant material or imaging device in the clinical setting.

Summary of LCRE fuel element design including supporting experimental data

DOE Office of Scientific and Technical Information (OSTI.GOV)

None, None

Declassified 18 Sep 1973. The design basis of the LCRE fuel pin is presented. The fuel pin consists of a Cb-1 Zr alloy cladding tube 0.305 inch diameter, 0.015 inch wall thickness and 35.96 inches long. The active fuel section is 13.5 inches long, with top and bottom reflector rods each 6.9 inches long and with a 4 inch gas accumulation space at each end. The cladding is designed as a pressure vessel to contain the gases released from the fuel and end refiector materials, which results in an internal gas pressure buildup in the pins during reactor operation. (23more » referencea) (auth)« less

Use of ion beams to simulate reaction of reactor fuels with their cladding

NASA Astrophysics Data System (ADS)

Birtcher, R. C.; Baldo, P.

2006-01-01

Processes occurring within reactor cores are not amenable to direct experimental observation. Among major concerns are damage, fission gas accumulation and reaction between the fuel and its cladding all of which lead to swelling. These questions can be investigated through simulation with ion beams. As an example, we discuss the irradiation driven interaction of uranium-molybdenum alloys, intended for use as low-enrichment reactor fuels, with aluminum, which is used as fuel cladding. Uranium-molybdenum coated with a 100 nm thin film of aluminum was irradiated with 3 MeV Kr ions to simulate fission fragment damage. Mixing and diffusion of aluminum was followed as a function of irradiation with RBS and nuclear reaction analysis using the 27Al(p,γ)28Si reaction which occurs at a proton energy of 991.9 keV. During irradiation at 150 °C, aluminum diffused into the uranium alloy at a irradiation driven diffusion rate of 30 nm2/dpa. At a dose of 90 dpa, uranium diffusion into the aluminum layer resulted in formation of an aluminide phase at the initial interface. The thickness of this phase grew until it consumed the aluminum layer. The rapid diffusion of Al into these reactor fuels may offer explanation of the observation that porosity is not observed in the fuel particles but on their periphery.

Behavior of an improved Zr fuel cladding with oxidation resistant coating under loss-of-coolant accident conditions

NASA Astrophysics Data System (ADS)

Park, Dong Jun; Kim, Hyun Gil; Jung, Yang Il; Park, Jung Hwan; Yang, Jae Ho; Koo, Yang Hyun

2016-12-01

This study investigates protective coatings for improving the high temperature oxidation resistance of Zr fuel claddings for light water nuclear reactors. FeCrAl alloy and Cr layers were deposited onto Zr plates and tubes using cold spraying. For the FeCrAl/Zr system, a Mo layer was introduced between the FeCrAl coating and the Zr matrix to prevent inter-diffusion at high temperatures. Both the FeCrAl and Cr coatings improved the oxidation resistance compared to that of the uncoated Zr alloy when exposed to a steam environment at 1200 °C. The ballooning behavior and mechanical properties of the coated cladding samples were studied under simulated loss-of-coolant accident conditions. The coated samples showed higher burst temperatures, lower circumferential strain, and smaller rupture openings compared to the uncoated Zr. Although 4-point bend tests of the coated samples showed a small increase in the maximum load, ring compression tests of a sectioned sample showed increased ductility.

Developing a laser shockwave model for characterizing diffusion bonded interfaces

NASA Astrophysics Data System (ADS)

Lacy, Jeffrey M.; Smith, James A.; Rabin, Barry H.

2015-03-01

The US National Nuclear Security Agency has a Global Threat Reduction Initiative (GTRI) with the goal of reducing the worldwide use of high-enriched uranium (HEU). A salient component of that initiative is the conversion of research reactors from HEU to low enriched uranium (LEU) fuels. An innovative fuel is being developed to replace HEU in high-power research reactors. The new LEU fuel is a monolithic fuel made from a U-Mo alloy foil encapsulated in Al-6061 cladding. In order to support the fuel qualification process, the Laser Shockwave Technique (LST) is being developed to characterize the clad-clad and fuel-clad interface strengths in fresh and irradiated fuel plates. LST is a non-contact method that uses lasers for the generation and detection of large amplitude acoustic waves to characterize interfaces in nuclear fuel plates. However, because the deposition of laser energy into the containment layer on a specimen's surface is intractably complex, the shock wave energy is inferred from the surface velocity measured on the backside of the fuel plate and the depth of the impression left on the surface by the high pressure plasma pulse created by the shock laser. To help quantify the stresses generated at the interfaces, a finite element method (FEM) model is being utilized. This paper will report on initial efforts to develop and validate the model by comparing numerical and experimental results for back surface velocities and front surface depressions in a single aluminum plate representative of the fuel cladding.

A new code for predicting the thermo-mechanical and irradiation behavior of metallic fuels in sodium fast reactors

NASA Astrophysics Data System (ADS)

Karahan, Aydın; Buongiorno, Jacopo

2010-01-01

An engineering code to predict the irradiation behavior of U-Zr and U-Pu-Zr metallic alloy fuel pins and UO2-PuO2 mixed oxide fuel pins in sodium-cooled fast reactors was developed. The code was named Fuel Engineering and Structural analysis Tool (FEAST). FEAST has several modules working in coupled form with an explicit numerical algorithm. These modules describe fission gas release and fuel swelling, fuel chemistry and restructuring, temperature distribution, fuel-clad chemical interaction, and fuel and clad mechanical analysis including transient creep-fracture for the clad. Given the fuel pin geometry, composition and irradiation history, FEAST can analyze fuel and clad thermo-mechanical behavior at both steady-state and design-basis (non-disruptive) transient scenarios. FEAST was written in FORTRAN-90 and has a simple input file similar to that of the LWR fuel code FRAPCON. The metal-fuel version is called FEAST-METAL, and is described in this paper. The oxide-fuel version, FEAST-OXIDE is described in a companion paper. With respect to the old Argonne National Laboratory code LIFE-METAL and other same-generation codes, FEAST-METAL emphasizes more mechanistic, less empirical models, whenever available. Specifically, fission gas release and swelling are modeled with the GRSIS algorithm, which is based on detailed tracking of fission gas bubbles within the metal fuel. Migration of the fuel constituents is modeled by means of thermo-transport theory. Fuel-clad chemical interaction models based on precipitation kinetics were developed for steady-state operation and transients. Finally, a transient intergranular creep-fracture model for the clad, which tracks the nucleation and growth of the cavities at the grain boundaries, was developed for and implemented in the code. Reducing the empiricism in the constitutive models should make it more acceptable to extrapolate FEAST-METAL to new fuel compositions and higher burnup, as envisioned in advanced sodium reactors. FEAST-METAL was benchmarked against the open-literature EBR-II database for steady state and furnace tests (transients). The results show that the code is able to predict important phenomena such as clad strain, fission gas release, clad wastage, clad failure time, axial fuel slug deformation and fuel constituent redistribution, satisfactorily.

Reduced yield stress for zirconium exposed to iodine: Reactive force field simulation

DOE PAGES

Rossi, Matthew L.; Taylor, Christopher D.; van Duin, Adri C. T.

2014-11-04

Iodine-induced stress-corrosion cracking (ISCC), a known failure mode for nuclear fuel cladding, occurs when iodine generated during the irradiation of a nuclear fuel pellet escapes the pellet through diffusion or thermal cracking and chemically interacts with the inner surface of the clad material, inducing a subsequent effect on the cladding’s resistance to mechanical stress. To complement experimental investigations of ISCC, a reactive force field (ReaxFF) compatible with the Zr-I chemical and materials systems has been developed and applied to simulate the impact of iodine exposure on the mechanical strength of the material. The study shows that the material’s resistance tomore » stress (as captured by the yield stress of a high-energy grain boundary) is related to the surface coverage of iodine, with the implication that ISCC is the result of adsorption-enhanced decohesion.« less

Design of a 25-kWe Surface Reactor System Based on SNAP Reactor Technologies

NASA Astrophysics Data System (ADS)

Dixon, David D.; Hiatt, Matthew T.; Poston, David I.; Kapernick, Richard J.

2006-01-01

A Hastelloy-X clad, sodium-potassium (NaK-78) cooled, moderated spectrum reactor using uranium zirconium hydride (UZrH) fuel based on the SNAP program reactors is a promising design for use in surface power systems. This paper presents a 98 kWth reactor for a power system the uses multiple Stirling engines to produce 25 kWe-net for 5 years. The design utilizes a pin type geometry containing UZrHx fuel clad with Hastelloy-X and NaK-78 flowing around the pins as coolant. A compelling feature of this design is its use of 49.9% enriched U, allowing it to be classified as a category III-D attractiveness and reducing facility costs relative to highly-enriched space reactor concepts. Presented below are both the design and an analysis of this reactor's criticality under various safety and operations scenarios.

Irradiated microstructure of U-10Mo monolithic fuel plate at very high fission density

NASA Astrophysics Data System (ADS)

Gan, J.; Miller, B. D.; Keiser, D. D.; Jue, J. F.; Madden, J. W.; Robinson, A. B.; Ozaltun, H.; Moore, G.; Meyer, M. K.

2017-08-01

Monolithic U-10Mo alloy fuel plates with Al-6061 cladding are being developed for use in research and test reactors as low enrichment fuel (<20% U-235 enrichment) as a result of its high uranium loading capacity compared to that of U-7Mo dispersion fuel. These fuel plates contain a Zr diffusion barrier between the U-10Mo fuel and Al-6061 cladding that suppresses the interaction between the U-Mo fuel foil and Al alloy cladding that is known to be problematic under irradiation. Different methods have been employed to fabricate monolithic fuel plates, including hot-rolling with no cold-rolling. L1P09T is a hot-rolled fuel plate irradiated to high fission density in the RERTR-9B experiment. This paper discusses the TEM characterization results for this U-10Mo/Zr/Al6061 monolithic fuel plate (∼59% U-235 enrichment) irradiated in Advanced Test Reactor at Idaho National Laboratory with an unprecedented high local fission density of 9.8E+21 fissions/cm3. The calculated fuel foil centerline temperature at the beginning of life and the end of life is 141 and 194 °C, respectively. TEM lamellas were prepared using focus ion beam lift-out technique. The estimated U-Mo fuel swelling, based on the fuel foil thickness change from SEM, is approximately 76%. Large bubbles (>1 μm) are distributed evenly in U-Mo and interlink of these bubbles is evident. The average size of subdivided grains at this fission density appears similar to that at 5.2E+21 fissions/cm3. The measured average Mo and Zr content in the fuel matrix is ∼30 at% and ∼7 at%, respectively, in general agreement with the calculated Mo and Zr from fission density.

Steam Oxidation Testing in the Severe Accident Test Station

DOE Office of Scientific and Technical Information (OSTI.GOV)

Pint, Bruce A.; McMurray, Jake W.

2016-08-01

Since 2011, Oak Ridge National Laboratory (ORNL) has been conducting high temperature steam oxidation testing of candidate alloys for accident tolerant fuel (ATF) cladding. These concepts are designed to enhance safety margins in light water reactors (LWR) during severe accident scenarios. In the US ATF community, the Severe Accident Test Station (SATS) has been evaluating candidate materials (including coatings) since 2012. Compared to the current UO 2/Zr-based alloy fuel system, alternative cladding materials need to offer slower oxidation kinetics and a smaller enthalpy of oxidation in order to significantly reduce the rate of heat and hydrogen generation in the coremore » during a coolant-limited severe accident. The steam oxidation behavior of candidate materials is a key metric in the evaluation of ATF concepts and also an important input into models. However, prior modeling work of FeCrAl cladding has used incomplete information on the physical properties of FeCrAl. Also, the steam oxidation data being collected at 1200°-1700°C is unique as no prior work has considered steam oxidation of alloys at such high temperatures. In some cases, the results have been difficult to interpret and more fundamental information is needed such as the stability of alumina in flowing steam at 1400°-1500°C. This report summarizes recent work to measure the steam oxidation kinetics of candidate alloys, the evaporation rate of alumina in steam and the development of integral data on FeCrAl compared to conventional Zr-based cladding.« less

DOE Office of Scientific and Technical Information (OSTI.GOV)

Vienna, John D.; Todd, Terry A.; Gray, Kimberly D.

The U.S. Department of Energy, Office of Nuclear Energy has chartered an effort to develop technologies to enable safe and cost effective recycle of commercial used nuclear fuel (UNF) in the U.S. Part of this effort includes the evaluation of exiting waste management technologies for effective treatment of wastes in the context of current U.S. regulations and development of waste forms and processes with significant cost and/or performance benefits over those existing. This study summarizes the results of these ongoing efforts with a focus on the highly radioactive primary waste streams. The primary streams considered and the recommended waste formsmore » include: •Tritium separated from either a low volume gas stream or a high volume water stream. The recommended waste form is low-water cement in high integrity containers. •Iodine-129 separated from off-gas streams in aqueous processing. There are a range of potentially suitable waste forms. As a reference case, a glass composite material (GCM) formed by the encapsulation of the silver Mordenite (AgZ) getter material in a low-temperature glass is assumed. A number of alternatives with distinct advantages are also considered including a fused silica waste form with encapsulated nano-sized AgI crystals. •Carbon-14 separated from LWR fuel treatment off-gases and immobilized as a CaCO3 in a cement waste form. •Krypton-85 separated from LWR and SFR fuel treatment off-gases and stored as a compressed gas. •An aqueous reprocessing high-level waste (HLW) raffinate waste which is immobilized by the vitrification process in one of three forms: a single phase borosilicate glass, a borosilicate based glass ceramic, or a multi-phased titanate ceramic [e.g., synthetic rock (Synroc)]. •An undissolved solids (UDS) fraction from aqueous reprocessing of LWR fuel that is either included in the borosilicate HLW glass or is immobilized in the form of a metal alloy in the case of glass ceramics or titanate ceramics. •Zirconium-based LWR fuel cladding hulls and stainless steel (SS) fuel assembly hardware that are washed and super-compacted for disposal or as an alternative Zr purification and reuse (or disposal as low-level waste, LLW) by reactive gas separations. •Electrochemical process salt HLW which is immobilized in a glass bonded Sodalite waste form known as the ceramic waste form (CWF). •Electrochemical process UDS and SS cladding hulls which are melted into an iron based alloy waste form. Mass and volume estimates for each of the recommended waste forms based on the source terms from a representative flowsheet are reported.« less

DOE Office of Scientific and Technical Information (OSTI.GOV)

Brown, Nicholas; Burns, Joseph R.

The aftermath of the Tōhoku earthquake and the Fukushima accident has led to a global push to improve the safety of existing light water reactors. A key component of this initiative is the development of nuclear fuel and cladding materials with potentially enhanced accident tolerance, also known as accident-tolerant fuels (ATF). These materials are intended to improve core fuel and cladding integrity under beyond design basis accident conditions while maintaining or enhancing reactor performance and safety characteristics during normal operation. To complement research that has already been carried out to characterize ATF neutronics, the present study provides an initial investigationmore » of the sensitivity and uncertainty of ATF systems responses to nuclear cross section data. ATF concepts incorporate novel materials, including SiC and FeCrAl cladding and high density uranium silicide composite fuels, in turn introducing new cross section sensitivities and uncertainties which may behave differently from traditional fuel and cladding materials. In this paper, we conducted sensitivity and uncertainty analysis using the TSUNAMI-2D sequence of SCALE with infinite lattice models of ATF assemblies. Of all the ATF materials considered, it is found that radiative capture in 56Fe in FeCrAl cladding is the most significant contributor to eigenvalue uncertainty. 56Fe yields significant potential eigenvalue uncertainty associated with its radiative capture cross section; this is by far the largest ATF-specific uncertainty found in these cases, exceeding even those of uranium. We found that while significant new sensitivities indeed arise, the general sensitivity behavior of ATF assemblies does not markedly differ from traditional UO2/zirconium-based fuel/cladding systems, especially with regard to uncertainties associated with uranium. We assessed the similarity of the IPEN/MB-01 reactor benchmark model to application models with FeCrAl cladding. We used TSUNAMI-IP to calculate similarity indices of the application model and IPEN/MB-01 reactor benchmark model. This benchmark was selected for its use of SS304 as a cladding and structural material, with significant 56Fe content. The similarity indices suggest that while many differences in reactor physics arise from differences in design, sensitivity to and behavior of 56Fe absorption is comparable between systems, thus indicating the potential for this benchmark to reduce uncertainties in 56Fe radiative capture cross sections.« less

Method of making crack-free zirconium hydride

DOEpatents

Sullivan, Richard W.

1980-01-01

Crack-free hydrides of zirconium and zirconium-uranium alloys are produced by alloying the zirconium or zirconium-uranium alloy with beryllium, or nickel, or beryllium and scandium, or nickel and scandium, or beryllium and nickel, or beryllium, nickel and scandium and thereafter hydriding.

Versatile Oxide Films Protect FeCrAl Alloys Under Normal Operation and Accident Conditions in Light Water Power Reactors

NASA Astrophysics Data System (ADS)

Rebak, Raul B.

2018-02-01

The US has currently a fleet of 99 nuclear power light water reactors which generate approximately 20% of the electricity consumed in the country. Near 90% of the reactors are at least 30 years old. There are incentives to make the existing reactors safer by using accident tolerant fuels (ATF). Compared to the standard UO2-zirconium-based system, ATF need to tolerate loss of active cooling in the core for a considerably longer time while maintaining or improving the fuel performance during normal operation conditions. Ferritic iron-chromium-aluminum (FeCrAl) alloys have been identified as an alternative to replace current zirconium alloys. They contain Fe (base) + 10-22 Cr + 4-6 Al and may contain smaller amounts of other elements such as molybdenum and traces of others. FeCrAl alloys offer outstanding resistance to attack by superheated steam by developing an alumina oxide on the surface in case of a loss of coolant accident like at Fukushima. FeCrAl alloys also perform well under normal operation conditions both in boiling water reactors and pressurized water reactors because they are protected by a thin oxide rich in chromium. Under normal operation condition, the key element is Cr and under accident conditions it is Al.

FUEL ELEMENT AND METHOD OF PREPARATION

DOEpatents

Kingston, W.E.

1961-04-25

A nuclear fuel element in the form of a wire is reported. A bar of uranium is enclosed in a thin layer of aluminum and the composite is sheathed in beryllium, zirconium, or stainnless steel. The sheathed article is then drawn to wire form, heated to alloy the aluminum with both uranium and sheath, and finally cold worked.

Irradiated microstructure of U-10Mo monolithic fuel plate at very high fission density

DOE Office of Scientific and Technical Information (OSTI.GOV)

Gan, J.; Miller, B. D.; Keiser, D. D.

Monolithic U-10Mo alloy fuel plates with Al-6061 cladding are being developed for use in research and test reactors as low enrichment fuel (< 20% U-235 enrichment) as a result of its high uranium loading capacity compared to that of U-7Mo dispersion fuel. These fuel plates contain a Zr diffusion barrier between the U-10Mo fuel and Al-6061 cladding that suppresses the interaction between the U-Mo fuel foil and Al alloy cladding that is known to be problematic under irradiation. This paper discusses the TEM results of the U-10Mo/Zr/Al6061 monolithic fuel plate (Plate ID: L1P09T, ~ 59% U-235 enrichment) irradiated in Advancedmore » Test Reactor at Idaho National Laboratory as part of RERTR-9B irradiation campaign with an unprecedented high local fission density of 9.8E+21 fissions/cm3. The calculated fuel foil centerline temperature at the beginning of life and the end of life is 141 and 194 C, respectively. A total of 5 TEM lamellas were prepared using focus ion beam lift-out technique. The estimated U-Mo fuel swelling, based on the fuel foil thickness change from SEM, is approximately 76%. Large bubbles (> 1 µm) are distributed evenly in U-Mo and interlink of these bubbles is evident. The average size of subdivided grains at this fission density appears similar to that at 5.2E+21 fissions/cm3. The measured average Mo and Zr content in the fuel matrix is ~ 30 at% and ~ 7 at%, respectively, in general agreement with the calculated Mo and Zr from fission density.« less

Concept Feasibility Report for Electroplating Zirconium onto Uranium Foil - Year 2

DOE Office of Scientific and Technical Information (OSTI.GOV)

Coffey, Greg W.; Meinhardt, Kerry D.; Joshi, Vineet V.

2015-03-01

The Fuel Fabrication Capability within the U.S. High Performance Research Reactor Conversion Program is funded through the National Nuclear Security Administration (NNSA) NA-26 (Office of Material Management and Minimization). An investigation was commissioned to determine the feasibility of using electroplating techniques to apply a coating of zirconium onto depleted uranium/molybdenum alloy (U-10Mo). Electroplating would provide an alternative method to the existing process of hot roll-bonding zirconium foil onto the U-10Mo fuel foil during the fabrication of fuel elements for high-performance research reactors. The objective of this research was to develop a reproducible and scalable plating process that will produce amore » uniform, 25 μm thick zirconium metal coating on U-10Mo foil. In previous work, Pacific Northwest National Laboratory (PNNL) established a molten salt electroplating apparatus and protocol to plate zirconium metal onto molybdenum foil (Coffey 2015). During this second year of the research, PNNL furthered this work by moving to the U-10Mo alloy system (90 percent uranium:10 percent molybdenum). The original plating apparatus was disassembled and re-assembled in a laboratory capable of handling low-level radioactive materials. Initially, the work followed the previous year’s approach, and the salt bath composition was targeted at the eutectic composition (LiF:NaF:ZrF4 = 26:37:37 mol%). Early results indicated that the formation of uranium fluoride compounds would be problematic. Other salt bath compositions were investigated in order to eliminate the uranium fluoride production (LiF:NaF = 61:39 mol% and LiF:NaF:KF = 46.5:11.5:42 mol% ). Zirconium metal was used as the crucible for the molten salt. Three plating methods were used—isopotential, galvano static, and pulsed plating. The molten salt method for zirconium metal application provided high-quality plating on molybdenum in PNNL’s previous work. A key advantage of this approach is that plating can be performed under conditions that would greatly reduce the quantity of intermetallics that form at the interface between the zirconium and U-10Mo; unlike roll bonding, the molten salt plating approach would allow for complete coverage of the U-10Mo foil with zirconium. When utilizing the experimental parameters developed for zirconium plating onto molybdenum, a uranium fluoride reaction product was formed at the Zr/U-10Mo interface. By controlling the initial plating potential, the uranium fluoride could be prevented; however, the targeted zirconium thickness (25 ±12.5 μm) could not be achieved while maintaining 100% coverage.« less

Implications of Zircaloy creep and growth to light water reactor performance

NASA Astrophysics Data System (ADS)

Franklin, David G.; Adamson, Ronald B.

1988-10-01

Deformation of zirconium alloy components in nuclear reactors has been a concern since the decision of Admiral Rickover to use them in the US Navy submarine reactors. With the exception of the first few light water reactors (LWRs) most of the core structural materials have been fabricated from either Zircaloy-2 or Zircaloy-4. Performance of these alloys has been extremely good, even though the effects of irradiation on deformation magnitudes and mechanisms were not fully appreciated until extensive service and in-reactor tests were accomplished. Since the reactor components are designed to operate at stress levels well below yield for normal conditions, the only significant deformation is time dependent. Although creep was anticipated, the enhancement by neutron irradiation and the stress-free, nearly constant-volume shape change known as irradiation growth were not known prior to materials testing in reactors under controlled conditions. Both of these phenomena have significant impact on performance and must be accounted for properly in design. Although irradiation creep and growth have resulted in only one significant performance problem (creep collapse of fuel cladding, which has been eliminated), deformation magnitudes and, particularly, differentials in strain magnitudes, are a continuing source of interest. Factors that affect dimensional stability due to both creep and growth include temperature, fluence, residual stress, texture, and microstructure. The first two are reactor variables and the others are related to component fabrication history. This paper includes a review of the applications of Zircaloy creep and growth to LWR fuel designs, a review of the impact of in-reactor creep and growth on fuel rod and fuel assembly performance, and comments on potential improvements. Since the reactor design, fuel design and the core environment in BWRs and PWRs are quite different, appropriate separation of the application of effects are made; of course, the basic phenomena are the same in both systems.

Precipitation hardenable iron-nickel-chromium alloy having good swelling resistance and low neutron absorbence

DOEpatents

Korenko, Michael K.; Merrick, Howard F.; Gibson, Robert C.

1980-01-01

An iron-nickel-chromium age-hardenable alloy suitable for use in fast breeder reactor ducts and cladding which utilizes the gamma-double prime strengthening phase and characterized in having a morphology of the gamma-double prime phase enveloping the gamma-prime phase and delta phase distributed at or near the grain boundaries. The alloy consists essentially of about 40-50% nickel, 7.5-14% chromium, 1.5-4% niobium, 0.25-0.75% silicon, 1-3% titanium, 0.1-0.5% aluminum, 0.02-0.1% carbon, 0.002-0.015% boron, and the balance iron. Up to 2% manganese and up to 0.01% magnesium may be added to inhibit trace element effects; up to 0.1% zirconium may be added to increase radiation swelling resistance; and up to 3% molybdenum may be added to increase strength.

DOE Office of Scientific and Technical Information (OSTI.GOV)

Hayes, S. L.; Harp, J. M.; Chichester, H. J. M.

Research and development activities on metallic fuels in the US are focused on their potential use for actinide transmutation in future sodium fast reactors. As part of this application, there is a desire to demonstrate a multifold increase in burnup potential. A number of metallic fuel design innovations are under investigation with a view toward significantly increasing the burnup potential of metallic fuels, since higher discharge burnups equate to lower potential actinide losses during recycle. Promising innovations under investigation include: 1) lowering the fuel smeared density in order to accommodate the additional swelling expected as burnups increase, 2) utilizing anmore » annular fuel geometry for better geometrical stability at low smeared densities, as well as the potential to eliminate the need for a sodium bond, and 3) minor alloy additions to immobilize lanthanide fission products inside the metallic fuel matrix and prevent their transport to the cladding resulting in fuel-cladding chemical interaction. This paper presents results from these efforts to advance metallic fuel technology in support of high burnup and actinide transmutation objectives. Highlights include examples of fabrication of low smeared density annular metallic fuels, experiments to identify alloy additions effective in immobilizing lanthanide fission products, and early postirradiation examinations of annular metallic fuels having low smeared densities and palladium additions for fission product immobilization.« less

Developing a laser shockwave model for characterizing diffusion bonded interfaces

DOE Office of Scientific and Technical Information (OSTI.GOV)

Lacy, Jeffrey M., E-mail: Jeffrey.Lacy@inl.gov; Smith, James A., E-mail: Jeffrey.Lacy@inl.gov; Rabin, Barry H., E-mail: Jeffrey.Lacy@inl.gov

2015-03-31

The US National Nuclear Security Agency has a Global Threat Reduction Initiative (GTRI) with the goal of reducing the worldwide use of high-enriched uranium (HEU). A salient component of that initiative is the conversion of research reactors from HEU to low enriched uranium (LEU) fuels. An innovative fuel is being developed to replace HEU in high-power research reactors. The new LEU fuel is a monolithic fuel made from a U-Mo alloy foil encapsulated in Al-6061 cladding. In order to support the fuel qualification process, the Laser Shockwave Technique (LST) is being developed to characterize the clad-clad and fuel-clad interface strengthsmore » in fresh and irradiated fuel plates. LST is a non-contact method that uses lasers for the generation and detection of large amplitude acoustic waves to characterize interfaces in nuclear fuel plates. However, because the deposition of laser energy into the containment layer on a specimen's surface is intractably complex, the shock wave energy is inferred from the surface velocity measured on the backside of the fuel plate and the depth of the impression left on the surface by the high pressure plasma pulse created by the shock laser. To help quantify the stresses generated at the interfaces, a finite element method (FEM) model is being utilized. This paper will report on initial efforts to develop and validate the model by comparing numerical and experimental results for back surface velocities and front surface depressions in a single aluminum plate representative of the fuel cladding.« less

ORNL Interim Progress Report on Hydride Reorientation CIRFT Tests

DOE Office of Scientific and Technical Information (OSTI.GOV)

Wang, Jy-An John; Yan, Yong; Wang, Hong

A systematic study of H. B. Robinson (HBR) high burnup spent nuclear fuel (SNF) vibration integrity was performed in Phase I project under simulated transportation environments, using the Cyclic Integrated Reversible-Bending Fatigue Tester (CIRFT) hot cell testing technology developed at Oak Ridge National Laboratory in 2013–14. The data analysis on the as-irradiated HBR SNF rods demonstrated that the load amplitude is the dominant factor that controls the fatigue life of bending rods. However, previous studies have shown that the hydrogen content and hydride morphology has an important effect on zirconium alloy mechanical properties. To address the effect of radial hydridesmore » in SNF rods, in Phase II a test procedure was developed to simulate the effects of elevated temperatures, pressures, and stresses during transfer-drying operations. Pressurized and sealed fuel segments were heated to the target temperature for a preset hold time and slow-cooled at a controlled rate. The procedure was applied to both non-irradiated/prehydrided and high-burnup Zircaloy-4 fueled cladding segments using the Nuclear Regulatory Commission-recommended 400°C maximum temperature limit at various cooling rates. Before testing high-burnup cladding, four out-of-cell tests were conducted to optimize the hydride reorientation (R) test condition with pre-hydride Zircaloy-4 cladding, which has the same geometry as the high burnup fuel samples. Test HR-HBR#1 was conducted at the maximum hoop stress of 145 MPa, at a 400°C maximum temperature and a 5°C/h cooling rate. On the other hand, thermal cycling was performed for tests HR-HBR#2, HR-HBR#3, and HR-HBR#4 to generate more radial hydrides. It is clear that thermal cycling increases the ratio of the radial hydride to circumferential hydrides. The internal pressure also has a significant effect on the radial hydride morphology. This report describes a procedure and experimental results of the four out-of-cell hydride reorientation tests of hydrided Zircaloy-4 cladding, which served as a guideline to prepare in-cell hydride reorientation samples with high burnup HBR fuel segments. This report also provides the Phase II CIRFT test data for the hydride reorientation irradiated samples. The variations in fatigue life are provided in terms of moment, equivalent stress, curvature, and equivalent strain for the tested SNFs. The CIRFT results appear to indicate that hydride reoriented treatment (HRT) have a negative effect on fatigue life, in addition to hydride reorientation effect. For HR4 specimen that had no pressurization procedure applied, the thermal annealing treatment alone showed a negative impact on the fatigue life compared to the HBR rod.« less

Effects of Lower Drying-Storage Temperature on the Ductility of High-Burnup PWR Cladding

DOE Office of Scientific and Technical Information (OSTI.GOV)

Billone, M. C.; Burtseva, T. A.

2016-08-30

The purpose of this research effort is to determine the effects of canister and/or cask drying and storage on radial hydride precipitation in, and potential embrittlement of, high-burnup (HBU) pressurized water reactor (PWR) cladding alloys during cooling for a range of peak drying-storage temperatures (PCT) and hoop stresses. Extensive precipitation of radial hydrides could lower the failure hoop stresses and strains, relative to limits established for as-irradiated cladding from discharged fuel rods stored in pools, at temperatures below the ductile-to-brittle transition temperature (DBTT).

Modeling and simulation challenges pursued by the Consortium for Advanced Simulation of Light Water Reactors (CASL)

DOE Office of Scientific and Technical Information (OSTI.GOV)

Turinsky, Paul J., E-mail: turinsky@ncsu.edu; Kothe, Douglas B., E-mail: kothe@ornl.gov

The Consortium for the Advanced Simulation of Light Water Reactors (CASL), the first Energy Innovation Hub of the Department of Energy, was established in 2010 with the goal of providing modeling and simulation (M&S) capabilities that support and accelerate the improvement of nuclear energy's economic competitiveness and the reduction of spent nuclear fuel volume per unit energy, and all while assuring nuclear safety. To accomplish this requires advances in M&S capabilities in radiation transport, thermal-hydraulics, fuel performance and corrosion chemistry. To focus CASL's R&D, industry challenge problems have been defined, which equate with long standing issues of the nuclear powermore » industry that M&S can assist in addressing. To date CASL has developed a multi-physics “core simulator” based upon pin-resolved radiation transport and subchannel (within fuel assembly) thermal-hydraulics, capitalizing on the capabilities of high performance computing. CASL's fuel performance M&S capability can also be optionally integrated into the core simulator, yielding a coupled multi-physics capability with untapped predictive potential. Material models have been developed to enhance predictive capabilities of fuel clad creep and growth, along with deeper understanding of zirconium alloy clad oxidation and hydrogen pickup. Understanding of corrosion chemistry (e.g., CRUD formation) has evolved at all scales: micro, meso and macro. CFD R&D has focused on improvement in closure models for subcooled boiling and bubbly flow, and the formulation of robust numerical solution algorithms. For multiphysics integration, several iterative acceleration methods have been assessed, illuminating areas where further research is needed. Finally, uncertainty quantification and data assimilation techniques, based upon sampling approaches, have been made more feasible for practicing nuclear engineers via R&D on dimensional reduction and biased sampling. Industry adoption of CASL's evolving M&S capabilities, which is in progress, will assist in addressing long-standing and future operational and safety challenges of the nuclear industry. - Highlights: • Complexity of physics based modeling of light water reactor cores being addressed. • Capability developed to help address problems that have challenged the nuclear power industry. • Simulation capabilities that take advantage of high performance computing developed.« less

Design and development of novel MRI compatible zirconium- ruthenium alloys with ultralow magnetic susceptibility.

PubMed

Li, H F; Zhou, F Y; Li, L; Zheng, Y F

2016-04-19

In the present study, novel MRI compatible zirconium-ruthenium alloys with ultralow magnetic susceptibility were developed for biomedical and therapeutic devices under MRI diagnostics environments. The results demonstrated that alloying with ruthenium into pure zirconium would significantly increase the strength and hardness properties. The corrosion resistance of zirconium-ruthenium alloys increased significantly. High cell viability could be found and healthy cell morphology observed when culturing MG 63 osteoblast-like cells and L-929 fibroblast cells with zirconium-ruthenium alloys, whereas the hemolysis rates of zirconium-ruthenium alloys are <1%, much lower than 5%, the safe value for biomaterials according to ISO 10993-4 standard. Compared with conventional biomedical 316L stainless steel, Co-Cr alloys and Ti-based alloys, the magnetic susceptibilities of the zirconium-ruthenium alloys (1.25 × 10(-6) cm(3)·g(-1)-1.29 × 10(-6) cm(3)·g(-1) for zirconium-ruthenium alloys) are ultralow, about one-third that of Ti-based alloys (Ti-6Al-4V, ~3.5 × 10(-6) cm(3)·g(-1), CP Ti and Ti-6Al-7Nb, ~3.0 × 10(-6) cm(3)·g(-1)), and one-sixth that of Co-Cr alloys (Co-Cr-Mo, ~7.7 × 10(-6) cm(3)·g(-1)). Among the Zr-Ru alloy series, Zr-1Ru demonstrates enhanced mechanical properties, excellent corrosion resistance and cell viability with lowest magnetic susceptibility, and thus is the optimal Zr-Ru alloy system as therapeutic devices under MRI diagnostics environments.

Interdiffusion behavior of U3Si2 with FeCrAl via diffusion couple studies

NASA Astrophysics Data System (ADS)

Hoggan, Rita E.; He, Lingfeng; Harp, Jason M.

2018-04-01

Uranium silicide (U3Si2) is a candidate to replace uranium oxide (UO2) as light water reactor (LWR) fuel because of its higher thermal conductivity and higher fissile density relative to the current standard, UO2. A class of Fe, Cr, Al alloys collectively known as FeCrAl alloys that have superior mechanical and oxidation resistance are being considered as an alternative to the standard Zirconium based LWR cladding. The interdiffusion behavior between FeCrAl and U3Si2 is investigated in this study. Commercially available FeCrAl, along with U3Si2 pellets were placed in diffusion couples. Individual tests were ran at temperatures ranging from 500 °C to 1000 °C for 30 h and 100 h. The interdiffusion was analyzed with an optical microscope, scanning electron microscope, and transmission electron microscope. Uniform and planar interdiffusion layers along the material interface were illustrated with backscatter electron micrographs and energy-dispersive X-ray spectroscopy. Electron diffraction was used to validate phases present in the system, including distinct U2Fe3Si/UFe2 and UFeSi layers at the material interface. U and Fe diffused far into the FeCrAl and U3Si2 matrix, respectively, in the higher temperature tests. No interaction was observed at 500 °C for 30 h.

Design and development of novel MRI compatible zirconium- ruthenium alloys with ultralow magnetic susceptibility

PubMed Central

Li, H.F.; Zhou, F.Y.; Li, L.; Zheng, Y.F.

2016-01-01

In the present study, novel MRI compatible zirconium-ruthenium alloys with ultralow magnetic susceptibility were developed for biomedical and therapeutic devices under MRI diagnostics environments. The results demonstrated that alloying with ruthenium into pure zirconium would significantly increase the strength and hardness properties. The corrosion resistance of zirconium-ruthenium alloys increased significantly. High cell viability could be found and healthy cell morphology observed when culturing MG 63 osteoblast-like cells and L-929 fibroblast cells with zirconium-ruthenium alloys, whereas the hemolysis rates of zirconium-ruthenium alloys are <1%, much lower than 5%, the safe value for biomaterials according to ISO 10993-4 standard. Compared with conventional biomedical 316L stainless steel, Co–Cr alloys and Ti-based alloys, the magnetic susceptibilities of the zirconium-ruthenium alloys (1.25 × 10−6 cm3·g−1–1.29 × 10−6 cm3·g−1 for zirconium-ruthenium alloys) are ultralow, about one-third that of Ti-based alloys (Ti–6Al–4V, ~3.5 × 10−6 cm3·g−1, CP Ti and Ti–6Al–7Nb, ~3.0 × 10−6 cm3·g−1), and one-sixth that of Co–Cr alloys (Co–Cr–Mo, ~7.7 × 10−6 cm3·g−1). Among the Zr–Ru alloy series, Zr–1Ru demonstrates enhanced mechanical properties, excellent corrosion resistance and cell viability with lowest magnetic susceptibility, and thus is the optimal Zr–Ru alloy system as therapeutic devices under MRI diagnostics environments. PMID:27090955

PRESSURIZED WATER REACTOR PROGRAM TECHNICAL PROGRESS REPORT FOR THE PERIOD MAY 5, 1955 TO JUNE 16, 1955

DOE Office of Scientific and Technical Information (OSTI.GOV)

None

The current PWR plant and core parameters are listed. Resign requirements are briefly summarized for a radiation monitoring system, a fuel handling water system, a coolant purification system, an electrical power distribution system, and component shielding. Results of studies on thermal bowing and stressing of UO/sub 2/ are reported. A graph is presented of reactor power vs. reactor flow for various hot channel conditions. Development of U-- Mo and U-Nb alloys has been stopped because of the recent selection of UO/sub 2/ fuel material for the PWR core and blanket. The fabrication characteristics of UO/sub 2/ powders are being studied.more » Seamless Zircaloy-2 tubing has been tested to determine elastic limits, bursting pressures, and corrosion resistance. Fabrication techniques and tests for corrosion and defects in Zircaloy-clad U-Mo and UO/sub 2/ fuel rods are described. The preparation of UO/sub 2/ by various methods is being studied to determine which method produces a material most suitable for PWR fuel elements. The stability of UO/sub 2/ compacts in high temperature water and steam is being determined. Surface area and density measurements have been performed on samples of UO/sub 2/ powder prepared by various methods. Revelopment work on U-- Mo and U--Nb alloys has included studies of the effect on corrosion behavior of additions to the test water, additions to the alloys, homogenization of the alloys, annealing times, cladding, and fabrication techniques. Data are presented on relaxation in spring materials after exposure to a corrosive environment. Results are reported from loop and autoclave tests on fission product and crud deposition. Results of irradiation and corrosion testing of clad and unclad U--Mo and U-Nh alloys are described. The UO/sub 2/ irradiation program has included studies of dimensional changes, release of fission gases, and activity in the water surrounding the samples. A review of the methods of calculating reactor physics parameters has been completed, and the established procedures have been applied to determination of PWR reference design parameters. Critical experiments and primary loop shielding analyses are described. (D.E.B.)« less

Understanding thermally activated plastic deformation behavior of Zircaloy-4

NASA Astrophysics Data System (ADS)

Kumar, N.; Alomari, A.; Murty, K. L.

2018-06-01

Understanding micromechanics of plastic deformation of existing materials is essential for improving their properties further and/or developing advanced materials for much more severe load bearing applications. The objective of the present work was to understand micromechanics of plastic deformation of Zircaloy-4, a zirconium-based alloy used as fuel cladding and channel (in BWRs) material in nuclear reactors. The Zircaloy-4 in recrystallized (at 973 K for 4 h) condition was subjected to uniaxial tensile testing at a constant cross-head velocity at temperatures in the range 293 K-1073 K and repeated stress relaxation tests at 293 K, 573 K, and 773 K. The minimum in the total elongation was indicative of dynamic strain aging phenomenon in this alloy in the intermediate temperature regime. The yield stress of the alloy was separated into effective and athermal components and the transition from thermally activated dislocation glide to athermal regime took place at around 673 K with the athermal stress estimated to be 115 MPa. The activation volume was found to be in the range of 40 b3 to 160 b3. The activation volume values and the data analyses using the solid-solution models in literature indicated dislocation-solute interaction to be a potential deformation mechanism in thermally activated regime. The activation energy calculated at 573 K was very close to that found for diffusivity of oxygen in α-Zr that was suggestive of dislocations-oxygen interaction during plastic deformation. This type of information may be helpful in alloy design in selecting different elements to control the deformation behavior of the material and impart desired mechanical properties in those materials for specific applications.

Elastic Modulus Measurement of ORNL ATF FeCrAl Alloys

DOE Office of Scientific and Technical Information (OSTI.GOV)

Thompson, Zachary T.; Terrani, Kurt A.; Yamamoto, Yukinori

2015-10-01

Elastic modulus and Poisson’s ratio for a number of wrought FeCrAl alloys, intended for accident tolerant fuel cladding application, are determined via resonant ultrasonic spectroscopy. The results are reported as a function of temperature from room temperature to 850°C. The wrought alloys were in the fully annealed and unirradiated state. The elastic modulus for the wrought FeCrAl alloys is at least twice that of Zr-based alloys over the temperature range of this study. The Poisson’s ratio of the alloys was 0.28 on average and increased very slightly with increasing temperature.

Effects of the foil flatness on the stress-strain characteristics of U10Mo alloy based monolithic mini-plates

DOE Office of Scientific and Technical Information (OSTI.GOV)

Hakan Ozaltun; Pavel Medvedev

The effects of the foil flatness on stress-strain behavior of monolithic fuel mini-plates during fabrication and irradiation were studied. Monolithic plate-type fuels are a new fuel form being developed for research and test reactors to achieve higher uranium densities. This concept facilitates the use of low-enriched uranium fuel in the reactor. These fuel elements are comprised of a high density, low enrichment, U–Mo alloy based fuel foil encapsulated in a cladding material made of Aluminum. To evaluate the effects of the foil flatness on the stress-strain behavior of the plates during fabrication, irradiation and shutdown stages, a representative plate frommore » RERTR-12 experiments (Plate L1P756) was considered. Both fabrication and irradiation processes of the plate were simulated by using actual irradiation parameters. The simulations were repeated for various foil curvatures to observe the effects of the foil flatness on the peak stress and strain magnitudes of the fuel elements. Results of fabrication simulations revealed that the flatness of the foil does not have a considerable impact on the post fabrication stress-strain fields. Furthermore, the irradiation simulations indicated that any post-fabrication stresses in the foil would be relieved relatively fast in the reactor. While, the perfectly flat foil provided the slightly better mechanical performance, overall difference between the flat-foil case and curved-foil case was not significant. Even though the peak stresses are less affected, the foil curvature has several implications on the strain magnitudes in the cladding. It was observed that with an increasing foil curvature, there is a slight increase in the cladding strains.« less

Pre-Licensing Evaluation of Legacy SFR Metallic Fuel Data

DOE Office of Scientific and Technical Information (OSTI.GOV)

Yacout, A. M.; Billone, M. C.

2016-09-16

The US sodium cooled fast reactor (SFR) metallic fuel performance data that are of interest to advanced fast reactors applications, can be attributed mostly to the Integral Fast Reactor (IFR) program between 1984 and 1994. Metallic fuel data collected prior to the IFR program were associated with types of fuel that are not of interest to future advanced reactors deployment (e.g., previous U-Fissium alloy fuel). The IFR fuels data were collected from irradiation of U-Zr based fuel alloy, with and without Pu additions, and clad in different types of steels, including HT9, D9, and 316 stainless-steel. Different types of datamore » were generated during the program, and were based on the requirements associated with the DOE Advanced Liquid Metal Cooled Reactor (ALMR) program.« less

Investigation of the Performance of D 2O-Cooled High-Conversion Reactors for Fuel Cycle Calculations

DOE Office of Scientific and Technical Information (OSTI.GOV)

Hiruta, Hikaru; Youinou, Gilles

2013-09-01

This report presents FY13 activities for the analysis of D 2O cooled tight-pitch High-Conversion PWRs (HCPWRs) with U-Pu and Th-U fueled cores aiming at break-even or near breeder conditions while retaining the negative void reactivity. The analyses are carried out from several aspects which could not be covered in FY12 activities. SCALE 6.1 code system is utilized, and a series of simple 3D fuel pin-cell models are developed in order to perform Monte Carlo based criticality and burnup calculations. The performance of U-Pu fueled cores with axial and internal blankets is analyzed in terms of their impact on the relativemore » fissile Pu mass balance, initial Pu enrichment, and void coefficient. In FY12, Pu conversion performances of D 2O-cooled HCPWRs fueled with MOX were evaluated with small sized axial/internal DU blankets (approximately 4cm of axial length) in order to ensure the negative void reactivity, which evidently limits the conversion performance of HCPWRs. In this fiscal year report, the axial sizes of DU blankets are extended up to 30 cm in order to evaluate the amount of DU necessary to reach break-even and/or breeding conditions. Several attempts are made in order to attain the milestone of the HCPWR designs (i.e., break-even condition and negative void reactivity) by modeling of HCPWRs under different conditions such as boiling of D 2O coolant, MOX with different 235U enrichment, and different target burnups. A similar set of analyses are performed for Th-U fueled cores. Several promising characteristics of 233U over other fissile like 239Pu and 235U, most notably its higher fission neutrons per absorption in thermal and epithermal ranges combined with lower ___ in the fast range than 239Pu allows Th-U cores to be taller than MOX ones. Such an advantage results in 4% higher relative fissile mass balance than that of U-Pu fueled cores while retaining the negative void reactivity until the target burnup of 51 GWd/t. Several other distinctions between U-Pu and Th-U fueled cores are identified by evaluating the sensitivity coefficients of keff, mass balance, and void coefficient. The effect of advanced iron alloy cladding (i.e., FeCrAl) on the performance of Pu conversion in MOX fueled cores is studied instead of using standard stainless-steel cladding. Variations in clad thickness and coolant-to-fuel volume ratio are also exercised. The use of FeCrAl instead of SS as a cladding alloy reduces the required Pu enrichment and improves the Pu conversion rate primarily due to the absence of nickel in the cladding alloy that results in the reduction of the neutron absorption. Also the difference in void coefficients between SS and FeCrAl alloys is nearly 500 pcm over the entire burnup range. The report also shows sensitivity and uncertainty analyses in order to characterize D 2O cooled HCPWRs from different aspects. The uncertainties of integral parameters (keff and void coefficient) for selected reactor cores are evaluated at different burnup points in order to find similarities and trends respect to D 2O-HCPWR.« less

Savannah River Site Spent Nuclear Fuel Management Final Environmental Impact Statement

DOE Office of Scientific and Technical Information (OSTI.GOV)

N /A

The proposed DOE action considered in this environmental impact statement (EIS) is to implement appropriate processes for the safe and efficient management of spent nuclear fuel and targets at the Savannah River Site (SRS) in Aiken County, South Carolina, including placing these materials in forms suitable for ultimate disposition. Options to treat, package, and store this material are discussed. The material included in this EIS consists of approximately 68 metric tons heavy metal (MTHM) of spent nuclear fuel 20 MTHM of aluminum-based spent nuclear fuel at SRS, as much as 28 MTHM of aluminum-clad spent nuclear fuel from foreign andmore » domestic research reactors to be shipped to SRS through 2035, and 20 MTHM of stainless-steel or zirconium-clad spent nuclear fuel and some Americium/Curium Targets stored at SRS. Alternatives considered in this EIS encompass a range of new packaging, new processing, and conventional processing technologies, as well as the No Action Alternative. A preferred alternative is identified in which DOE would prepare about 97% by volume (about 60% by mass) of the aluminum-based fuel for disposition using a melt and dilute treatment process. The remaining 3% by volume (about 40% by mass) would be managed using chemical separation. Impacts are assessed primarily in the areas of water resources, air resources, public and worker health, waste management, socioeconomic, and cumulative impacts.« less

U-Mo Monolithic Fuel for Nuclear Research and Test Reactors

DOE Office of Scientific and Technical Information (OSTI.GOV)

Prabhakaran, Ramprashad

The metallic fuel selected to replace the current HEU fuels in the research and test reactors is the LEU-10 weight % Mo alloy in the form of a thin sheet or foil encapsulated in AA6061 aluminum alloy with a zirconium interlayer. In order to effectively lead this pursuit, new developments in processing and fabrication of the fuel elements have been initiated, along with a better understanding of material behavior before and after irradiation as a result of these new developments. This editorial note gives an introduction about research and test reactors, need for HEU to LEU conversion, fuel requirements, highmore » uranium density monolithic fuel development and an overview of the four articles published in the December 2017 issue of JOM under a special topic titled “U-Mo Monolithic Fuel for Nuclear Research and Test Reactors”.« less

Diffusion Couple Alloying of Refractory Metals in Austenitic and Ferritic/Martensitic Steels

DTIC Science & Technology

2012-03-01

applications of austenitic stainless steel and ferritic/martensitic steel can vary from structural and support components in the reactor core to reactor fuel ... fuel . It serves as a boundary to prevent both fission products from escaping to the core coolant, and segregates the fuel from the coolant to...uranium oxide (UO2) fuel in the core . It resists corrosion by the fuel matrix on the inner surface of the cladding and the liquid sodium coolant on

Hydrogen motion in Zircaloy-4 cladding during a LOCA transient

NASA Astrophysics Data System (ADS)

Elodie, T.; Jean, D.; Séverine, G.; M-Christine, B.; Michel, C.; Berger, P.; Martine, B.; Antoine, A.

2016-04-01

Hydrogen and oxygen are key elements influencing the embrittlement of zirconium-based nuclear fuel cladding during the quench phase following a Loss Of Coolant Accident (LOCA). The understanding of the mechanisms influencing the motion of these two chemical elements in the metal is required to fully describe the material embrittlement. High temperature steam oxidation tests were performed on pre-hydrided Zircaloy-4 samples with hydrogen contents ranging between 11 and 400 wppm prior to LOCA transient. Thanks to the use of both Electron Probe Micro-Analysis (EPMA) and Elastic Recoil Detection Analysis (μ-ERDA), the chemical elements partitioning has been systematically quantified inside the prior-β phase. Image analysis and metallographic examinations were combined to provide an average oxygen profile as well as hydrogen profile within the cladding thickness after LOCA transient. The measured hydrogen profile is far from homogeneous. Experimental distributions are compared to those predicted numerically using calculations derived from a finite difference thermo-diffusion code (DIFFOX) developed at IRSN.

Non-destructive Quantitative Phase Analysis and Microstructural Characterization of Zirconium Coated U-10Mo Fuel Foils via Neutron Diffraction

DOE Office of Scientific and Technical Information (OSTI.GOV)

Cummins, Dustin Ray; Vogel, Sven C.; Hollis, Kendall Jon

2016-10-18

This report uses neutron diffraction to investigate the crystal phase composition of uranium-molybdenum alloy foils (U-10Mo) for the CONVERT MP-1 Reactor Conversion Project, and determines the effect on alpha-uranium contamination following the deposition of a Zr metal diffusion layer by various methods: plasma spray deposition of Zr powders at LANL and hot co-rolling with Zr foils at BWXT. In summary, there is minimal decomposition of the gamma phase U-10Mo foil to alpha phase contamination following both plasma spraying and hot co-rolling. The average unit cell volume, i.e. lattice spacing, of the Zr layer can be mathematically extracted from the diffractionmore » data; co-rolled Zr matches well with literature values of bulk Zr, while plasma sprayed Zr shows a slight increase in the lattice spacing, indicative of interstitial oxygen in the lattice. Neutron diffraction is a beneficial alternative to conventional methods of phase composition, i.e. x ray diffraction (XRD) and destructive metallography. XRD has minimal penetration depth in high atomic number materials, particularly uranium, and can only probe the first few microns of the fuel plate; neutrons pass completely through the foil, allowing for bulk analysis of the foil composition and no issues with addition of cladding layers, as in the final, aluminum-clad reactor fuel plates. Destructive metallography requires skilled technicians, cutting of the foil into small sections, hazardous etching conditions, long polishing and microscopy times, etc.; the neutron diffraction system has an automated sample loader and can fit larger foils, so there is minimal analysis preparation; the total spectrum acquisition time is ~ 1 hour per sample. The neutron diffraction results are limited by spectra refinement/calculation times and the availability of the neutron beam source. In the case of LANSCE at Los Alamos, the beam operates ~50% of the year. Following the lessons learned from these preliminary results, optimizations to the process and analysis can be made, and neutron diffraction can become a viable and efficient technique for gamma/alpha phase composition determination for nuclear fuels.« less

Production of FR Tubing from Advanced ODS Alloys

DOE Office of Scientific and Technical Information (OSTI.GOV)

Maloy, Stuart Andrew; Lavender, Curt; Omberg, Ron

2016-10-25

Significant research is underway to develop LWR nuclear fuels with improved accident tolerance. One of the leading candidate materials for cladding are the FeCrAl alloys. New alloys produced at ORNL called Gen I and Gen II FeCrAl alloys possess excellent oxidation resistance in steam up to 1400°C and in parallel methods are being developed to produce tubing from these alloys. Century tubing continues to produce excellent tubing from FeCrAl alloys. This memo reports receipt of ~21 feet of Gen I FeCrAl alloy tubing. This tubing will be used for future tests including burst testing, mechanical testing and irradiation testing.

Nuclear Energy Advanced Modeling and Simulation (NEAMS) Accident Tolerant Fuels High Impact Problem: Coordinate Multiscale FeCrAl Modeling

DOE Office of Scientific and Technical Information (OSTI.GOV)

Gamble, K. A.; Hales, J. D.; Zhang, Y.

Since the events at the Fukushima-Daiichi nuclear power plant in March 2011 significant research has unfolded at national laboratories, universities and other institutions into alternative materials that have potential enhanced ac- cident tolerance when compared to traditional UO2 fuel zircaloy clad fuel rods. One of the potential replacement claddings are iron-chromium-alunimum (FeCrAl) alloys due to their increased oxidation resistance [1–4] and higher strength [1, 2]. While the oxidation characteristics of FeCrAl are a benefit for accident tolerance, the thermal neu- tron absorption cross section of FeCrAl is about ten times that of Zircaloy. This neutronic penalty necessitates thinner cladding. Thismore » allows for slightly larger pellets to give the same cold gap width in the rod. However, the slight increase in pellet diameter is not sufficient to compensate for the neutronic penalty and enriching the fuel beyond the current 5% limit appears to be necessary [5]. Current estimates indicate that this neutronic penalty will impose an increase in fuel cost of 15-35% [1, 2]. In addition to the neutronic disadvantage, it is anticipated that tritium release to the coolant will be larger because the permeability of hydrogen in FeCrAl is about 100 times higher than in Zircaloy [6]. Also, radiation-induced hardening and embrittlement of FeCrAl need to be fully characterized experimentally [7]. Due to the aggressive development schedule for inserting some of the potential materials into lead test assemblies or rods by 2022 [8] multiscale multiphysics modeling approaches have been used to provide insight into these the use of FeCrAl as a cladding material. The purpose of this letter report is to highlight the multiscale modeling effort for iron-chromium-alunimum (FeCrAl) cladding alloys as part of the Nuclear Energy Advanced Modeling and Simulation (NEAMS) program through its Accident Tolerant Fuel (ATF) High Impact Problem (HIP). The approach taken throughout the HIP is to utilize lower length scale approaches (e.g., density functional theory, cluster dynamics, rate theory, phase field, and Visco-Plastic- Self-Consistent (VPSC)) to develop more physically informed models at the engineering scale for use in the BISON [9] fuel performance code.« less

The R&D PERFROI Project on Thermal Mechanical and Thermal Hydraulics Behaviors of a Fuel Rod Assembly during a Loss of Coolant Accident

DOE Office of Scientific and Technical Information (OSTI.GOV)

Repetto, G.; Dominguez, C.; Durville, B.

The safety principle in case of a LOCA is to preserve the short and long term coolability of the core. The associated safety requirements are to ensure the resistance of the fuel rods upon quench and post-quench loads and to maintain a coolable geometry in the core. An R&D program has been launched by IRSN with the support of EDF, to perform both experimental and modeling activities in the frame of the LOCA transient, on technical issues such as: - flow blockage within a fuel rods bundle and its potential impact on coolability, - fuel fragment relocation in the balloonedmore » areas: its potential impact on cladding PCT (Peak Cladding Temperature) and on the maximum oxidation rate, - potential loss of cladding integrity upon quench and post-quench loads. The PERFROI project (2014-2019) focusing on the first above issue, is structured in two axes: 1. axis 1: thermal mechanical behavior of deformation and rupture of cladding taking into account the contact between fuel rods; specific research at LaMCoS laboratory focus on the hydrogen behavior in cladding alloys and its impact on the mechanical behavior of the rod; and, 2. axis 2: thermal hydraulics study of a partially blocked region of the core (ballooned area taking into account the fuel relocation with local over power), during cooling phase by water injection; More detailed activities foreseen in collaboration with LEMTA laboratory will focus on the characterization of two phase flows with heat transfer in deformed structures.« less

Closed Fuel Cycle Waste Treatment Strategy

DOE Office of Scientific and Technical Information (OSTI.GOV)

Vienna, J. D.; Collins, E. D.; Crum, J. V.

This study is aimed at evaluating the existing waste management approaches for nuclear fuel cycle facilities in comparison to the objectives of implementing an advanced fuel cycle in the U.S. under current legal, regulatory, and logistical constructs. The study begins with the Global Nuclear Energy Partnership (GNEP) Integrated Waste Management Strategy (IWMS) (Gombert et al. 2008) as a general strategy and associated Waste Treatment Baseline Study (WTBS) (Gombert et al. 2007). The tenets of the IWMS are equally valid to the current waste management study. However, the flowsheet details have changed significantly from those considered under GNEP. In addition, significantmore » additional waste management technology development has occurred since the GNEP waste management studies were performed. This study updates the information found in the WTBS, summarizes the results of more recent technology development efforts, and describes waste management approaches as they apply to a representative full recycle reprocessing flowsheet. Many of the waste management technologies discussed also apply to other potential flowsheets that involve reprocessing. These applications are occasionally discussed where the data are more readily available. The report summarizes the waste arising from aqueous reprocessing of a typical light-water reactor (LWR) fuel to separate actinides for use in fabricating metal sodium fast reactor (SFR) fuel and from electrochemical reprocessing of the metal SFR fuel to separate actinides for recycle back into the SFR in the form of metal fuel. The primary streams considered and the recommended waste forms include; Tritium in low-water cement in high integrity containers (HICs); Iodine-129: As a reference case, a glass composite material (GCM) formed by the encapsulation of the silver Mordenite (AgZ) getter material in a low-temperature glass is assumed. A number of alternatives with distinct advantages are also considered including a fused silica waste form with encapsulated nano-sized AgI crystals; Carbon-14 immobilized as a CaCO3 in a cement waste form; Krypton-85 stored as a compressed gas; An aqueous reprocessing high-level waste (HLW) raffinate waste immobilized by the vitrification process; An undissolved solids (UDS) fraction from aqueous reprocessing of LWR fuel either included in the borosilicate HLW glass or immobilized in the form of a metal alloy or titanate ceramics; Zirconium-based LWR fuel cladding hulls and stainless steel (SS) fuel assembly hardware super-compacted for disposal or purified for reuse (or disposal as low-level waste, LLW) of Zr by reactive gas separations; Electrochemical process salt HLW incorporated into a glass bonded Sodalite waste form; and Electrochemical process UDS and SS cladding hulls melted into an iron based alloy waste form. Mass and volume estimates for each of the recommended waste forms based on the source terms from a representative flowsheet are reported. In addition to the above listed primary waste streams, a range of secondary process wastes are generated by aqueous reprocessing of LWR fuel, metal SFR fuel fabrication, and electrochemical reprocessing of SFR fuel. These secondary wastes have been summarized and volumes estimated by type and classification. The important waste management data gaps and research needs have been summarized for each primary waste stream and selected waste process.« less

Feasibility study on AFR-100 fuel conversion from uranium-based fuel to thorium-based fuel

DOE Office of Scientific and Technical Information (OSTI.GOV)

Heidet, F.; Kim, T.; Grandy, C.

2012-07-30

Although thorium has long been considered as an alternative to uranium-based fuels, most of the reactors built to-date have been fueled with uranium-based fuel with the exception of a few reactors. The decision to use uranium-based fuels was initially made based on the technology maturity compared to thorium-based fuels. As a result of this experience, lot of knowledge and data have been accumulated for uranium-based fuels that made it the predominant nuclear fuel type for extant nuclear power. However, following the recent concerns about the extent and availability of uranium resources, thorium-based fuels have regained significant interest worldwide. Thorium ismore » more abundant than uranium and can be readily exploited in many countries and thus is now seen as a possible alternative. As thorium-based fuel technologies mature, fuel conversion from uranium to thorium is expected to become a major interest in both thermal and fast reactors. In this study the feasibility of fuel conversion in a fast reactor is assessed and several possible approaches are proposed. The analyses are performed using the Advanced Fast Reactor (AFR-100) design, a fast reactor core concept recently developed by ANL. The AFR-100 is a small 100 MW{sub e} reactor developed under the US-DOE program relying on innovative fast reactor technologies and advanced structural and cladding materials. It was designed to be inherently safe and offers sufficient margins with respect to the fuel melting temperature and the fuel-cladding eutectic temperature when using U-10Zr binary metal fuel. Thorium-based metal fuel was preferred to other thorium fuel forms because of its higher heavy metal density and it does not need to be alloyed with zirconium to reduce its radiation swelling. The various approaches explored cover the use of pure thorium fuel as well as the use of thorium mixed with transuranics (TRU). Sensitivity studies were performed for the different scenarios envisioned in order to determine the best core performance characteristics for each of them. With the exception of the fuel type and enrichment, the reference AFR-100 core design characteristics were kept unchanged, including the general core layout and dimensions, assembly dimensions, materials and power rating. In addition, the mass of {sup 235}U required was kept within a reasonable range from that of the reference AFR-100 design. The core performance characteristics, kinetics parameters and reactivity feedback coefficients were calculated using the ANL suite of fast reactor analysis code systems. Orifice design calculations and the steady-state thermal-hydraulic analyses were performed using the SE2-ANL code. The thermal margins were evaluated by comparing the peak temperatures to the design limits for parameters such as the fuel melting temperature and the fuel-cladding eutectic temperature. The inherent safety features of AFR-100 cores proposed were assessed using the integral reactivity parameters of the quasi-static reactivity balance analysis. The design objectives and requirements, the computation methods used as well as a description of the core concept are provided in Section 2. The three major approaches considered are introduced in Section 3 and the neutronics performances of those approaches are discussed in the same section. The orifice zoning strategies used and the steady-state thermal-hydraulic performance are provided in Section 4. The kinetics and reactivity coefficients, including the inherent safety characteristics, are provided in Section 5, and the Conclusions in Section 6. Other scenarios studied and sensitivity studies are provided in the Appendix section.« less

Surface treatment to form a dispersed Y2O3 layer on Zircaloy-4 tubes

NASA Astrophysics Data System (ADS)

Jung, Yang-Il; Kim, Hyun-Gil; Guim, Hwan-Uk; Lim, Yoon-Soo; Park, Jung-Hwan; Park, Dong-Jun; Yang, Jae-Ho

2018-01-01

Zircaloy-4 is a traditional zirconium-based alloy developed for application in nuclear fuel cladding tubes. The surfaces of Zircaloy-4 tubes were treated using a laser beam to increase their mechanical strength. Laser beam scanning of a tube coated with yttrium oxide (Y2O3) resulted in the formation of a dispersed oxide layer in the tube's surface region. Y2O3 particles penetrated the Zircaloy-4 during the laser treatment and were distributed uniformly in the surface region. The thickness of the dispersed oxide layer varied from 50 to 140 μm depending on the laser beam trajectory. The laser treatment also modified the texture of the tube. The preferred basal orientation along the normal to the tube surface disappeared, and a random structure appeared after laser processing. The most obvious result was an increase in the mechanical strength. The tensile strength of Zircaloy-4 increased by 10-20% with the formation of the dispersed oxide layer. The compressive yield stress also increased, by more than 15%. Brittle fracture was observed in the surface-treated samples during tensile and compressive deformation at room temperature; however, the fracture behavior was changed in ductile at elevated temperatures.

Microstructural development from interdiffusion and reaction between Usbnd Mo and AA6061 alloys annealed at 600° and 550 °C

NASA Astrophysics Data System (ADS)

Perez, E.; Keiser, D. D.; Sohn, Y. H.

2016-08-01

The U.S. Material Management and Minimization Reactor Conversion Program is developing low enrichment fuel systems encased in Al-alloy for use in research and test reactors. Monolithic fuel plates have local regions where the Usbnd Mo fuel plate may come into contact with the Al-alloy 6061 (AA6061) cladding. This results in the development of interdiffusion zones with complex microstructures with multiple phases. In this study, the microstructural development of diffusion couples, Usbnd 7 wt%Mo, Usbnd 10 wt%Mo, and Usbnd 12 wt%Mo vs. AA6061, annealed at 600 °C for 24 h and at 550 °C for 1, 5, and 20 h, were analyzed by scanning electron microscopy with x-ray energy dispersive spectroscopy. The microstructural development and kinetics were compared to diffusion couples Usbnd Mo vs. high purity Al and binary Alsbnd Si alloys. The diffusion couples developed complex interaction regions where phase development was influenced by the alloying additions of the AA6061.

Microstructure Characterization of RERTR Fuel

DOE Office of Scientific and Technical Information (OSTI.GOV)

J. Gan; B. D. Miller; D. D. Keiser

2008-09-01

A variety of phases have the potential to develop in the irradiated fuels for the reduced enrichment research test reactor (RERTR) program. To study the radiation stability of these potential phases, three depleted uranium alloys were cast. The phases of interest were identified including U(Si,Al)3, (U,Mo)(Si,Al)3, UMo2Al20, UAl4, and U6Mo4Al43. These alloys were irradiated with 2.6 MeV protons at 200ºC up to 3.0 dpa. The microstructure is characterized using SEM and TEM. Microstructural characterization for an archive dispersion fuel plate (U-7Mo fuel particles in Al-2%Si cladding) was also carried out. TEM sample preparation for the irradiated dispersion fuel has beenmore » developed.« less

Effect of He implantation on the microstructure of zircaloy-4 studied using in situ TEM

NASA Astrophysics Data System (ADS)

Tunes, M. A.; Harrison, R. W.; Greaves, G.; Hinks, J. A.; Donnelly, S. E.

2017-09-01

Zirconium alloys are of great importance to the nuclear industry as they have been widely used as cladding materials in light-water reactors since the 1960s. This work examines the behaviour of these alloys under He ion implantation for the purposes of developing understanding of the fundamental processes behind their response to irradiation. Characterization of zircaloy-4 samples using TEM with in situ 6 keV He irradiation up to a fluence of 2.7 ×1017ions ·cm-2 in the temperature range of 298 to 1148 K has been performed. Ordered arrays of He bubbles were observed at 473 and 1148 K at a fluence of 1.7 ×1017ions ·cm-2 in αZr, the hexagonal compact (HCP) and in βZr, the body centred cubic (BCC) phases, respectively. In addition, the dissolution behaviour of cubic Zr hydrides under He irradiation has been investigated.

Protective claddings for high strength chromium alloys

NASA Technical Reports Server (NTRS)

Collins, J. F.

1971-01-01

The application of a Cr-Y-Hf-Th alloy as a protective cladding for a high strength chromium alloy was investigated for its effectiveness in inhibiting nitrogen embrittlement of a core alloy. Cladding was accomplished by a combination of hot gas pressure bonding and roll cladding techniques. Based on bend DBTT, the cladding alloy was effective in inhibiting nitrogen embrittlement of the chromium core alloy for up to 720 ks (200hours) in air at 1422 K (2100 F). A significant increase in the bend DBTT occurred with longer time exposures at 1422 K or short time exposures at 1589 K (2400 F).

Hybrid nuclear reactor grey rod to obtain required reactivity worth

DOEpatents

Miller, John V.; Carlson, William R.; Yarbrough, Michael B.

1991-01-01

Hybrid nuclear reactor grey rods are described, wherein geometric combinations of relatively weak neutron absorber materials such as stainless steel, zirconium or INCONEL, and relatively strong neutron absorber materials, such as hafnium, silver-indium cadmium and boron carbide, are used to obtain the reactivity worths required to reach zero boron change load follow. One embodiment includes a grey rod which has combinations of weak and strong neutron absorber pellets in a stainless steel cladding. The respective pellets can be of differing heights. A second embodiment includes a grey rod with a relatively thick stainless steel cladding receiving relatively strong neutron absorber pellets only. A third embodiment includes annular relatively weak netron absorber pellets with a smaller diameter pellet of relatively strong absorber material contained within the aperture of each relatively weak absorber pellet. The fourth embodiment includes pellets made of a homogeneous alloy of hafnium and a relatively weak absorber material, with the percentage of hafnium chosen to obtain the desired reactivity worth.

Radiation tolerance of neutron-irradiated model Fe-Cr-Al alloys

DOE PAGES

Field, Kevin G.; Hu, Xunxiang; Littrell, Kenneth C.; ...

2015-07-14

The Fe Cr Al alloy system has the potential to form an important class of enhanced accident-tolerant cladding materials in the nuclear power industry owing to the alloy system's higher oxidation resistance in high-temperature steam environments compared with traditional zirconium-based alloys. However, radiation tolerance of Fe Cr Al alloys has not been fully established. In this study, a series of Fe Cr Al alloys with 10 18 wt % Cr and 2.9 4.9 wt % Al were neutron irradiated at 382 C to 1.8 dpa to investigate the irradiation-induced microstructural and mechanical property evolution as a function of alloy composition.more » Dislocation loops with Burgers vector of a/2 111 and a 100 were detected and quantified. Results indicate precipitation of Cr-rich is primarily dependent on the bulk chromium composition. Mechanical testing of sub-size-irradiated tensile specimens indicates the hardening response seen after irradiation is dependent on the bulk chromium composition. Furthermore, a structure property relationship was developed; it indicated that the change in yield strength after irradiation is caused by the formation of these radiation-induced defects and is dominated by the large number density of Cr-rich α' precipitates at sufficiently high chromium contents after irradiation.« less

Development and Validation of Capabilities to Measure Thermal Properties of Layered Monolithic U-Mo Alloy Plate-Type Fuel

NASA Astrophysics Data System (ADS)

Burkes, Douglas E.; Casella, Andrew M.; Buck, Edgar C.; Casella, Amanda J.; Edwards, Matthew K.; MacFarlan, Paul J.; Pool, Karl N.; Smith, Frances N.; Steen, Franciska H.

2014-07-01

The uranium-molybdenum (U-Mo) alloy in a monolithic form has been proposed as one fuel design capable of converting some of the world's highest power research reactors from the use of high enriched uranium to low enriched uranium. One aspect of the fuel development and qualification process is to demonstrate appropriate understanding of the thermal-conductivity behavior of the fuel system as a function of temperature and expected irradiation conditions. The purpose of this paper is to verify functionality of equipment installed in hot cells for eventual measurements on irradiated uranium-molybdenum (U-Mo) monolithic fuel specimens, refine procedures to operate the equipment, and validate models to extract the desired thermal properties. The results presented here demonstrate the adequacy of the equipment, procedures, and models that have been developed for this purpose based on measurements conducted on surrogate depleted uranium-molybdenum (DU-Mo) alloy samples containing a Zr diffusion barrier and clad in aluminum alloy 6061 (AA6061). The results are in excellent agreement with thermal property data reported in the literature for similar U-Mo alloys as a function of temperature.

EPRI-NASA Cooperative Project on Stress Corrosion Cracking of Zircaloys. [nuclear fuel failures

NASA Technical Reports Server (NTRS)

Cubicciotti, D.; Jones, R. L.

1978-01-01

Examinations of the inside surface of irradiated fuel cladding from two reactors show the Zircaloy cladding is exposed to a number of aggressive substances, among them iodine, cadmium, and iron-contaminated cesium. Iodine-induced stress corrosion cracking (SCC) of well characterized samples of Zircaloy sheet and tubing was studied. Results indicate that a threshold stress must be exceeded for iodine SCC to occur. The existence of a threshold stress indicates that crack formation probably is the key step in iodine SCC. Investigation of the crack formation process showed that the cracks responsible for SCC failure nucleated at locations in the metal surface that contained higher than average concentrations of alloying elements and impurities. A four-stage model of iodine SCC is proposed based on the experimental results and the relevance of the observations to pellet cladding interaction failures is discussed.

Evaluation of steam corrosion and water quenching behavior of zirconium-silicide coated LWR fuel claddings

NASA Astrophysics Data System (ADS)

Yeom, Hwasung; Lockhart, Cody; Mariani, Robert; Xu, Peng; Corradini, Michael; Sridharan, Kumar

2018-02-01

This study investigates steam corrosion of bulk ZrSi2, pure Si, and zirconium-silicide coatings as well as water quenching behavior of ZrSi2 coatings to evaluate its feasibility as a potential accident-tolerant fuel cladding coating material in light water nuclear reactor. The ZrSi2 coating and Zr2Si-ZrSi2 coating were deposited on Zircaloy-4 flats, SiC flats, and cylindrical Zircaloy-4 rodlets using magnetron sputter deposition. Bulk ZrSi2 and pure Si samples showed weight loss after the corrosion test in pure steam at 400 °C and 10.3 MPa for 72 h. Silicon depletion on the ZrSi2 surface during the steam test was related to the surface recession observed in the silicon samples. ZrSi2 coating (∼3.9 μm) pre-oxidized in 700 °C air prevented substrate oxidation but thin porous ZrO2 formed on the coating. The only condition which achieved complete silicon immobilization in the oxide scale in aqueous environments was the formation of ZrSiO4 via ZrSi2 coating oxidation in 1400 °C air. In addition, ZrSi2 coatings were beneficial in enhancing quenching heat transfer - the minimum film boiling temperature increased by 6-8% in the three different environmental conditions tested. During repeated thermal cycles (water quenching from 700 °C to 85 °C for 20 s) performed as a part of quench tests, no spallation and cracking was observed and the coating prevented oxidation of the underlying Zircaloy-4 substrate.

Carbon diffusion in bulk hcp zirconium: A multi-scale approach

NASA Astrophysics Data System (ADS)

Xu, Y.; Roques, J.; Domain, C.; Simoni, E.

2016-05-01

In the framework of the geological repository of the used fuel claddings of pressurized water reactor, carbon behavior in bulk zirconium is studied by periodic Density Functional Theory calculations. The C interstitial sites were investigated and it was found that there are two possible carbon interstitial sites: a distorted basal tetragonal site and an octahedral site. There are four types of possible atomic jumps between them. After calculating the migration energies, the attempt frequencies and the jump probabilities for each possible migration path, kinetic Monte Carlo (KMC) simulations were performed to simulate carbon diffusion at the macroscopic scale. The results show that carbon diffusion in pure Zr bulk is extremely limited at the storage temperature (50 °C). Since there are defects in Zr bulk, in a second step, the effect of atomic vacancy was studied and it was proved that vacancies cannot increase carbon diffusion.

PATHFINDER ATOMIC POWER PLANT TECHNICAL PROGRESS REPORT FOR JULY 1, 1959- SEPTEMBER 30, 1959

DOE Office of Scientific and Technical Information (OSTI.GOV)

None

1960-10-31

ABS>Fuel Element Research and Development. Dynamic and static corrosion tests on 8001 Al were completed. Annealmmmg of 1100 cladding on 5083 and M400 cladding on X2219 were tested at 500 deg C, and investigation continued on producing X8101 Al alloy cladding in tube plates by extrusion. Boiler fuel element capsule irradiation tests and subassembly tests are described Heat transfer loop studies and fuel fabrication for the critical facility are reported. Boiler fuel element mechanical design and testing progress is desc ribed. and the superheater fuel element temperature evaluating routine is discussed. Low- enrichment superheater fuel element development included design studiesmore » and stainless steel powder and UO/sub 2/ powder fabrication studies Reactor Mechanical Studies. Research is reported on vessel and structure design, fabrication, and testing, recirculation system design, steam separator tests, and control rod studies. Nuclear Analysis. Reactor physics studies are reported on nuclear constants, baffle plate analysis, comparison of core representations, delayed neutron fraction. and shielding analysis of the reactor building. Reactor and system dynamics and critical experiments were also studied. Chemistry. Progress is reported on recombiner. radioactive gas removal and storage, ion exchanger and radiochemical processing. (For preceding period see ACNP-5915.) (T.R.H.)« less

Electroslag Strip Cladding of Steam Generators With Alloy 690

DOE Office of Scientific and Technical Information (OSTI.GOV)

Consonni, M.; Maggioni, F.; Brioschi, F.

2006-07-01

The present paper details the results of electroslag cladding and tube-to-tubesheet welding qualification tests conducted by Ansaldo-Camozzi ESC with Alloy 690 (Alloy 52 filler metal) on steel for nuclear power stations' steam generators shell, tubesheet and head; the possibility of submerged arc cladding on first layer was also considered. Test results, in terms of chemical analysis, mechanical properties and microstructure are reproducible and confidently applicable to production cladding and show that electroslag process can be used for Alloy 52 cladding with exceptionally stable and regular operation and high productivity. The application of submerged arc cladding process to the first layermore » leads to a higher base metal dilution, which should be avoided. Moreover, though the heat affected zone is deeper with electroslag cladding, in both cases no coarsened grain zone is found due to recrystallization effect of second cladding layer. Finally, the application of electroslag process to cladding of Alloy 52 with modified chemical composition, was proved to be highly beneficial as it strongly reduces hot cracking sensitivity, which is typical of submerged arc cladded Alloy 52, both during tube-to-tubesheet welding and first re-welding. (authors)« less

Burst Ductility of Zirconium Clads: The Defining Role of Residual Stress

NASA Astrophysics Data System (ADS)

Kumar, Gulshan; Kanjarla, A. K.; Lodh, Arijit; Singh, Jaiveer; Singh, Ramesh; Srivastava, D.; Dey, G. K.; Saibaba, N.; Doherty, R. D.; Samajdar, Indradev

2016-08-01

Closed end burst tests, using room temperature water as pressurizing medium, were performed on a number of industrially produced zirconium (Zr) clads. A total of 31 samples were selected based on observed differences in burst ductility. The latter was represented as total circumferential elongation or TCE. The selected samples, with a range of TCE values (5 to 35 pct), did not show any correlation with mechanical properties along axial direction, microstructural parameters, crystallographic textures, and outer tube-surface normal ( σ 11) and shear ( τ 13) components of the residual stress matrix. TCEs, however, had a clear correlation with hydrostatic residual stress ( P h), as estimated from tri-axial stress analysis on the outer tube surface. Estimated P h also scaled with measured normal stress ( σ 33) at the tube cross section. An elastic-plastic finite element model with ductile damage failure criterion was developed to understand the burst mechanism of zirconium clads. Experimentally measured P h gradients were imposed on a solid element continuum finite element (FE) simulation to mimic the residual stresses present prior to pressurization. Trends in experimental TCEs were also brought out with computationally efficient shell element-based FE simulations imposing the outer tube-surface P h values. Suitable components of the residual stress matrix thus determined the burst performance of the Zr clads.

Laser cladding of tungsten carbides (Spherotene ®) hardfacing alloys for the mining and mineral industry

NASA Astrophysics Data System (ADS)

Amado, J. M.; Tobar, M. J.; Alvarez, J. C.; Lamas, J.; Yáñez, A.

2009-03-01

The abrasive nature of the mechanical processes involved in mining and mineral industry often causes significant wear to the associated equipment and derives non-negligible economic costs. One of the possible strategies to improve the wear resistance of the various components is the deposition of hardfacing layers on the bulk parts. The use of high power lasers for hardfacing (laser cladding) has attracted a great attention in the last decade as an alternative to other more standard methods (arc welding, oxy-fuel gas welding, thermal spraying). In laser cladding the hardfacing material is used in powder form. For high hardness applications Ni-, Co- or Fe-based alloys containing hard phase carbides at different ratios are commonly used. Tungsten carbides (WC) can provide coating hardness well above 1000 HV (Vickers). In this respect, commercially available WC powders normally contain spherical micro-particles consisting of crushed WC agglomerates. Some years ago, Spherotene ® powders consisting of spherical-fused monocrystaline WC particles, being extremely hard, between 1800 and 3000 HV, were patented. Very recently, mixtures of Ni-based alloy with Spherotene powders optimized for laser processing were presented (Technolase ®). These mixtures have been used in our study. Laser cladding tests with these powders were performed on low carbon steel (C25) substrates, and results in terms of microstructure and hardness will be discussed.

Iron aluminide alloys with improved properties for high temperature applications

DOEpatents

McKamey, Claudette G.; Liu, Chain T.

1990-01-01

An improved iron aluminide alloy of the DO.sub.3 type that has increased room temperature ductility and improved high elevated temperature strength. The alloy system further is resistant to corrosive attack in the environments of advanced energy corrosion systems such as those using fossil fuels. The resultant alloy is relatively inexpensive as contrasted to nickel based and high nickel steels currently utilized for structural components. The alloy system consists essentially of 26-30 at. % aluminum, 0.5-10 at. % chromium, 0.02-0.3 at. % boron plus carbon, up to 2 at. % molybdenum, up to 1 at. % niobium, up to 0.5 at. % zirconium, up to 0.1 at. % yttrium, up to 0.5 at. % vanadium and the balance iron.

Iron aluminide alloys with improved properties for high temperature applications

DOEpatents

McKamey, C.G.; Liu, C.T.

1990-10-09

An improved iron aluminide alloy of the DO[sub 3] type is described that has increased room temperature ductility and improved high elevated temperature strength. The alloy system further is resistant to corrosive attack in the environments of advanced energy conversion systems such as those using fossil fuels. The resultant alloy is relatively inexpensive as contrasted to nickel based and high nickel steels currently utilized for structural components. The alloy system consists essentially of 26--30 at. % aluminum, 0.5--10 at. % chromium, 0.02--0.3 at. % boron plus carbon, up to 2 at. % molybdenum, up to 1 at. % niobium, up to 0.5 at. % zirconium, up to 0.1 at. % yttrium, up to 0.5 at. % vanadium and the balance iron. 3 figs.

Material selection for accident tolerant fuel cladding

DOE PAGES

Pint, B. A.; Terrani, K. A.; Yamamoto, Y.; ...

2015-09-14

Alternative cladding materials are being investigated for accident tolerance, which can be defined as >100X improvement (compared to current Zr-based alloys) in oxidation resistance in steam environments at ≥1200°C for short (≤4 h) times. After reviewing a wide range of candidates, current steam oxidation testing is being conducted on Mo, MAX phases and FeCrAl alloys. Recently reported low mass losses for Mo in steam at 800°C could not be reproduced. Both FeCrAl and MAX phase Ti 2AlC form a protective alumina scale in steam. Therefore, commercial Ti 2AlC that is not single phase, formed a much thicker oxide at 1200°Cmore » in steam and significant TiO 2, and therefore may be challenging to use as a cladding or a coating. Alloy development for FeCrAl is seeking to maintain its steam oxidation resistance to 1475°C, while reducing its Cr content to minimize susceptibility to irradiation assisted Cr-rich α’ formation. The composition effects and critical limits to retaining protective scale formation at >1400°C are still being evaluated.« less

FY-16 Technology Gap Study Technical Report: Analysis of Undissolved Anode Materials of Mark-IV Electrorefiner

DOE Office of Scientific and Technical Information (OSTI.GOV)

Yoo, Tae-Sic; Vaden, DeeEarl; Westphal, Brian Robert

2016-01-01

The Experimental Breeder Reactor II (EBR-II) is a sodium cooled fast reactor developed at Argonne National Laboratory (ANL). The used fuels from the EBR-II are currently being treated in the Fuel Conditioning Facility (FCF) at the Idaho National Laboratory (INL). The Mark IV (Mk-IV) electrorefiner (ER) is a unit process in the FCF, which is primarily assigned to treating the used driver fuels. The stainless steel anode baskets hold the chopped spent driver fuel segments. During electrorefining, the anode baskets are immersed into the electrolyte and the used fuel is dissolved electrochemically. Perforated sides and bottoms allow the flow ofmore » the electrolyte into and out of the anode baskets. The steel cathode is also immersed into the electrolyte and collects the reduced products. The active metal contents in the used fuel (e.g., Cs, Sr, lanthanides, Pu, etc.) reacts with uranium cations in the electrolyte and progressively reports to the electrolyte. Noble metals are mostly retained in the cladding hulls. Varying quantities of zirconium are retained in the cladding hulls depending on the operational conditions of the Mk-IV ER. The undissolved anode materials are removed from the anode baskets and stored for subsequent metal waste form processing. These undissolved materials typically include undissolved fuels, stainless steel cladding, and adhering electrolyte. A couple of hulls are retrieved for chemical analysis and used for estimating the composition of the entire undissolved anode materials. The mass balance attempt based on this practice of estimating the undissolved anode materials has been a challenge due to inherently high sampling errors associated with heterogeneous undissolved material compositions. Responding to the prescribed challenge, this report investigates chemical analysis data as a whole and finds noticeable trends in the compositions of undissolved anode material samples with respect to the mass of the whole undissolved anode materials. Based upon this discovery, an empirical model is proposed.« less

A simple spectrophotometric method for determination of zirconium or hafnium in selected molybdenum-base alloys

NASA Technical Reports Server (NTRS)

Dupraw, W. A.

1972-01-01

A simple analytical procedure is described for accurately and precisely determining the zirconium or hafnium content of molybdenum-base alloys. The procedure is based on the reaction of the reagent Arsenazo III with zirconium or hafnium in strong hydrochloric acid solution. The colored complexes of zirconium or hafnium are formed in the presence of molybdenum. Titanium or rhenium in the alloy have no adverse effect on the zirconium or hafnium complex at the following levels in the selected aliquot: Mo, 10 mg; Re, 10 mg; Ti, 1 mg. The spectrophotometric measurement of the zirconium or hafnium complex is accomplished without prior separation with a relative standard deviation of 1.3 to 2.7 percent.

Microstructural development from interdiffusion and reaction between U–Mo and AA6061 alloys annealed at 600° and 550 °C

DOE PAGES

Perez, E.; Keiser, D. D.; Sohn, Y. H.

2016-05-10

The U.S. Material Management and Minimization Reactor Conversion Program is developing low enrichment fuel systems encased in Al-alloy for use in research and test reactors. Monolithic fuel plates have local regions where the Usingle bondMo fuel plate may come into contact with the Al-alloy 6061 (AA6061) cladding. This results in the development of interdiffusion zones with complex microstructures with multiple phases. In this study, the microstructural development of diffusion couples, U–7 wt%Mo, U–10 wt%Mo, and U–12 wt%Mo vs. AA6061, annealed at 600 °C for 24 h and at 550 °C for 1, 5, and 20 h, were analyzed by scanningmore » electron microscopy with x-ray energy dispersive spectroscopy. The microstructural development and kinetics were compared to diffusion couples U–Mo vs. high purity Al and binary Al–Si alloys. As a result, the diffusion couples developed complex interaction regions where phase development was influenced by the alloying additions of the AA6061.« less

Preliminary Modeling of Accident Tolerant Fuel Concepts under Accident Conditions

DOE Office of Scientific and Technical Information (OSTI.GOV)

Gamble, Kyle A.; Hales, Jason D.

2016-12-01

The catastrophic events that occurred at the Fukushima-Daiichi nuclear power plant in 2011 have led to widespread interest in research of alternative fuels and claddings that are proposed to be accident tolerant. Thus, the United States Department of Energy through its NEAMS (Nuclear Energy Advanced Modeling and Simulation) program has funded an Accident Tolerant Fuel (ATF) High Impact Problem (HIP). The ATF HIP is funded for a three-year period. The purpose of the HIP is to perform research into two potential accident tolerant concepts and provide an in-depth report to the Advanced Fuels Campaign (AFC) describing the behavior of themore » concepts, both of which are being considered for inclusion in a lead test assembly scheduled for placement into a commercial reactor in 2022. The initial focus of the HIP is on uranium silicide fuel and iron-chromium-aluminum (FeCrAl) alloy cladding. Utilizing the expertise of three national laboratory participants (INL, LANL, and ANL) a comprehensive mulitscale approach to modeling is being used including atomistic modeling, molecular dynamics, rate theory, phase-field, and fuel performance simulations. In this paper, we present simulations of two proposed accident tolerant fuel systems: U3Si2 fuel with Zircaloy-4 cladding, and UO2 fuel with FeCrAl cladding. The simulations investigate the fuel performance response of the proposed ATF systems under Loss of Coolant and Station Blackout conditions using the BISON code. Sensitivity analyses are completed using Sandia National Laboratories’ DAKOTA software to determine which input parameters (e.g., fuel specific heat) have the greatest influence on the output metrics of interest (e.g., fuel centerline temperature). Early results indicate that each concept has significant advantages as well as areas of concern. Further work is required prior to formulating the proposition report for the Advanced Fuels Campaign.« less

Modelling Accident Tolerant Fuel Concepts

DOE Office of Scientific and Technical Information (OSTI.GOV)

Hales, Jason Dean; Gamble, Kyle Allan Lawrence

2016-05-01

The catastrophic events that occurred at the Fukushima-Daiichi nuclear power plant in 2011 have led to widespread interest in research of alternative fuels and claddings that are proposed to be accident tolerant. The United States Department of Energy (DOE) through its Nuclear Energy Advanced Modeling and Simulation (NEAMS) program has funded an Accident Tolerant Fuel (ATF) High Impact Problem (HIP). The ATF HIP is a three-year project to perform research on two accident tolerant concepts. The final outcome of the ATF HIP will be an in-depth report to the DOE Advanced Fuels Campaign (AFC) giving a recommendation on whether eithermore » of the two concepts should be included in their lead test assembly scheduled for placement into a commercial reactor in 2022. The two ATF concepts under investigation in the HIP are uranium silicide fuel and iron-chromium-aluminum (FeCrAl) alloy cladding. Utilizing the expertise of three national laboratory participants (Idaho National Laboratory, Los Alamos National Laboratory, and Argonne National Laboratory), a comprehensive multiscale approach to modeling is being used that includes atomistic modeling, molecular dynamics, rate theory, phase-field, and fuel performance simulations. Model development and fuel performance analysis are critical since a full suite of experimental studies will not be complete before AFC must prioritize concepts for focused development. In this paper, we present simulations of the two proposed accident tolerance fuel systems: U3Si2 fuel with Zircaloy-4 cladding, and UO2 fuel with FeCrAl cladding. Sensitivity analyses are completed using Sandia National Laboratories’ Dakota software to determine which input parameters (e.g., fuel specific heat) have the greatest influence on the output metrics of interest (e.g., fuel centerline temperature). We also outline the multiscale modelling approach being employed. Considerable additional work is required prior to preparing the recommendation report for the Advanced Fuels Campaign.« less

Copper-acrylic enamel serves as lubricant for cold drawing of refractory metals

NASA Technical Reports Server (NTRS)

Beane, C.; Karasek, F.

1966-01-01

Acrylic enamel spray containing metallic copper pigment lubricates refractory metal tubing during cold drawing operations so that the tubing surface remains free from scratches and nicks and does not seize in the die. Zirconium alloys, zirconium, tantalum alloys, niobium alloys, vanandium alloys and titanium alloys have been drawn using this lubricant.

High temperature mechanical properties of a zirconium-modified, precipitation- strengthened nickel, 30 percent copper alloy

NASA Technical Reports Server (NTRS)

Whittenberger, J. D.

1974-01-01

A precipitation-strengthened Monel-type alloy has been developed through minor alloying additions of zirconium to a base Ni-30Cu alloy. The results of this exploratory study indicate that thermomechanical processing of a solution-treated Ni-30Cu-0.2Zr alloy produced a dispersion of precipitates. The precipitates have been tentatively identified as a Ni5Zr compound. A comparison of the mechanical properties, as determined by testing in air, of the zirconium-modified alloy to those of a Ni-30Cu alloy reveals that the precipitation-strengthened alloy has improved tensile properties to 1200 K and improved stress-rupture properties to 1100 K. The oxidation characteristics of the modified alloy appeared to be equivalent to those of the base Ni-30Cu alloy.

Advanced ODS FeCrAl alloys for accident-tolerant fuel cladding

DOE Office of Scientific and Technical Information (OSTI.GOV)

Dryepondt, Sebastien N; Unocic, Kinga A; Hoelzer, David T

2014-09-01

ODS FeCrAl alloys are being developed with optimum composition and properties for accident tolerant fuel cladding. Two oxide dispersion strengthened (ODS) Fe-15Cr-5Al+Y2O3 alloys were fabricated by ball milling and extrusion of gas atomized metallic powder mixed with Y2O3 powder. To assess the impact of Mo on the alloy mechanical properties, one alloy contained 1%Mo. The hardness and tensile properties of the two alloys were close and higher than the values reported for fine grain PM2000 alloy. This is likely due to the combination of a very fine grain structure and the presence of nano oxide precipitates. The nano oxide dispersionmore » was however not sufficient to prevent grain boundary sliding at 800 C and the creep properties of the alloys were similar or only slightly superior to fine grain PM2000 alloy. Both alloys formed a protective alumina scale at 1200 C in air and steam and the mass gain curves were similar to curves generated with 12Cr-5Al+Y2O3 (+Hf or Zr) ODS alloys fabricated for a different project. To estimate the maximum temperature limit of use for the two alloys in steam, ramp tests at a rate of 5 C/min were carried out in steam. Like other ODS alloys, the two alloys showed a significant increase of the mas gains at T~ 1380 C compared with ~1480 C for wrought alloys of similar composition. The beneficial effect of Yttrium for wrought FeCrAl does not seem effective for most ODS FeCrAl alloys. Characterization of the hardness of annealed specimens revealed that the microstructure of the two alloys was not stable above 1000 C. Concurrent radiation results suggested that Cr levels <15wt% are desirable and the creep and oxidation results from the 12Cr ODS alloys indicate that a lower Cr, high strength ODS alloy with a higher maximum use temperature could be achieved.« less

Braze material for joining ceramic to metal and ceramic to ceramic surfaces and joined ceramic to metal and ceramic to ceramic article

DOEpatents

Hunt, T.K.; Novak, R.F.

1991-05-07

An improved active metal braze filler material is provided in which the coefficient of thermal expansion of the braze filler is more closely matched with that of the ceramic and metal, or two ceramics, to provide ceramic to metal, or ceramic to ceramic, sealed joints and articles which can withstand both high temperatures and repeated thermal cycling without failing. The braze filler material comprises a mixture of a material, preferably in the form of a powder, selected from the group consisting of molybdenum, tungsten, silicon carbide and mixtures thereof, and an active metal filler material selected from the group consisting of alloys or mixtures of nickel and titanium, alloys or mixtures of nickel and zirconium, alloys or mixtures of nickel, titanium, and copper, alloys or mixtures of nickel, titanium, and zirconium, alloys or mixtures of niobium and nickel, alloys or mixtures of niobium and zirconium, alloys or mixtures of niobium and titanium, alloys or mixtures of niobium, titanium, and nickel, alloys or mixtures of niobium, zirconium, and nickel, and alloys or mixtures of niobium, titanium, zirconium, and nickel. The powder component is selected such that its coefficient of thermal expansion will effect the overall coefficient of thermal expansion of the braze material so that it more closely matches the coefficients of thermal expansion of the ceramic and metal parts to be joined. 3 figures.

Braze material for joining ceramic to metal and ceramic to ceramic surfaces and joined ceramic to metal and ceramic to ceramic article

DOEpatents

Hunt, Thomas K.; Novak, Robert F.

1991-01-01

An improved active metal braze filler material is provided in which the coefficient of thermal expansion of the braze filler is more closely matched with that of the ceramic and metal, or two ceramics, to provide ceramic to metal, or ceramic to ceramic, sealed joints and articles which can withstand both high temperatures and repeated thermal cycling without failing. The braze filler material comprises a mixture of a material, preferably in the form of a powder, selected from the group consisting of molybdenum, tungsten, silicon carbide and mixtures thereof, and an active metal filler material selected from the group consisting of alloys or mixtures of nickel and titanium, alloys or mixtures of nickel and zirconium, alloys or mixtures of nickel, titanium, and copper, alloys or mixtures of nickel, titanium, and zirconium, alloys or mixtures of niobium and nickel, alloys or mixtures of niobium and zirconium, alloys or mixtures of niobium and titanium, alloys or mixtures of niobium, titanium, and nickel, alloys or mixtures of niobium, zirconium, and nickel, and alloys or mixtures of niobium, titanium, zirconium, and nickel. The powder component is selected such that its coefficient of thermal expansion will effect the overall coefficient of thermal expansion of the braze material so that it more closely matches the coefficients of thermal expansion of the ceramic and metal parts to be joined.

Finite element analysis of the tetragonal to monoclinic phase transformation during oxidation of zirconium alloys

NASA Astrophysics Data System (ADS)

Platt, P.; Frankel, P.; Gass, M.; Howells, R.; Preuss, M.

2014-11-01

Corrosion is a key limiting factor in the degradation of zirconium alloys in light water reactors. Developing a mechanistic understanding of the corrosion process offers a route towards improving safety and efficiency as demand increases for higher burn-up of fuel. Oxides formed on zirconium alloys are composed of both monoclinic and meta-stable tetragonal phases, and are subject to a number of potential mechanical degradation mechanisms. The work presented investigates the link between the tetragonal to monoclinic oxide phase transformation and degradation of the protective character of the oxide layer. To achieve this, Abaqus finite element analysis of the oxide phase transformation has been carried out. Study of the change in transformation strain energy shows how relaxation of oxidation induced stress and fast fracture at the metal-oxide interface could destabilise the tetragonal phase. Central to this is the identification of the transformation variant most likely to form, and understanding why twinning of the transformed grain is likely to occur. Development of transformation strain tensors and analysis of the strain components allows some separation of dilatation and shear effects. Maximum principal stress is used as an indication of fracture in the surrounding oxide layer. Study of the stress distributions shows the way oxide fracture is likely to occur and the differing effects of dilatation and shape change. Comparison with literature provides qualitative validation of the finite element simulations.

Enhanced Low-Enriched Uranium Fuel Element for the Advanced Test Reactor

DOE Office of Scientific and Technical Information (OSTI.GOV)

Pope, M. A.; DeHart, M. D.; Morrell, S. R.

2015-03-01

Under the current US Department of Energy (DOE) policy and planning scenario, the Advanced Test Reactor (ATR) and its associated critical facility (ATRC) will be reconfigured to operate on low-enriched uranium (LEU) fuel. This effort has produced a conceptual design for an Enhanced LEU Fuel (ELF) element. This fuel features monolithic U-10Mo fuel foils and aluminum cladding separated by a thin zirconium barrier. As with previous iterations of the ELF design, radial power peaking is managed using different U-10Mo foil thicknesses in different plates of the element. The lead fuel element design, ELF Mk1A, features only three fuel meat thicknesses,more » a reduction from the previous iterations meant to simplify manufacturing. Evaluation of the ELF Mk1A fuel design against reactor performance requirements is ongoing, as are investigations of the impact of manufacturing uncertainty on safety margins. The element design has been evaluated in what are expected to be the most demanding design basis accident scenarios and has met all initial thermal-hydraulic criteria.« less

Cladding of Mg alloy with Zr based BMG Alloy

NASA Astrophysics Data System (ADS)

Prasada Rao, A. K.; Oh, Y. S.; Faisal, M. K.; Kim, N. J.

2016-02-01

In the present work, an attempt has been made to clad AZ31 magnesium alloy with Zr-based bulk metallic glassy alloy (Vit-1), by casting method. The interface studies conducted using SEM-EDS line scan indicate that a good bond is formed at the clad interface of Zr and Mg. And the mechanism involved is discussed herein.

Stability of Y–Ti–O precipitates in friction stir welded nanostructured ferritic alloys

DOE PAGES

Yu, Xinghua; Mazumder, B.; Miller, M. K.; ...

2015-01-19

Nanostructured ferritic alloys, which have complex microstructures which consist of ultrafine ferritic grains with a dispersion of stable oxide particles and nanoclusters, are promising materials for fuel cladding and structural applications in the next generation nuclear reactor. This paper evaluates microstructure of friction stir welded nanostructured ferritic alloys using electron microscopy and atom probe tomography techniques. Atom probe tomography results revealed that nanoclusters are coarsened and inhomogeneously distributed in the stir zone and thermomechanically affected zone. Three hypotheses on coarsening of nanoclusters are presented. Finally, the hardness difference in different regions of friction stir weld has been explained.

DOE Office of Scientific and Technical Information (OSTI.GOV)

Lombardo, N.J.; Marseille, T.J.; White, M.D.

TRUMP-BD (Boil Down) is an extension of the TRUMP (Edwards 1972) computer program for the analysis of nuclear fuel assemblies under severe accident conditions. This extension allows prediction of the heat transfer rates, metal-water oxidation rates, fission product release rates, steam generation and consumption rates, and temperature distributions for nuclear fuel assemblies under core uncovery conditions. The heat transfer processes include conduction in solid structures, convection across fluid-solid boundaries, and radiation between interacting surfaces. Metal-water reaction kinetics are modeled with empirical relationships to predict the oxidation rates of steam-exposed Zircaloy and uranium metal. The metal-water oxidation models are parabolic inmore » form with an Arrhenius temperature dependence. Uranium oxidation begins when fuel cladding failure occurs; Zircaloy oxidation occurs continuously at temperatures above 13000{degree}F when metal and steam are available. From the metal-water reactions, the hydrogen generation rate, total hydrogen release, and temporal and spatial distribution of oxide formations are computed. Consumption of steam from the oxidation reactions and the effect of hydrogen on the coolant properties is modeled for independent coolant flow channels. Fission product release from exposed uranium metal Zircaloy-clad fuel is modeled using empirical time and temperature relationships that consider the release to be subject to oxidation and volitization/diffusion ( bake-out'') release mechanisms. Release of the volatile species of iodine (I), tellurium (Te), cesium (Ce), ruthenium (Ru), strontium (Sr), zirconium (Zr), cerium (Cr), and barium (Ba) from uranium metal fuel may be modeled.« less

Human biokinetic data and a new compartmental model of zirconium--a tracer study with enriched stable isotopes.

PubMed

Greiter, Matthias B; Giussani, Augusto; Höllriegl, Vera; Li, Wei Bo; Oeh, Uwe

2011-09-01

Biokinetic models describing the uptake, distribution and excretion of trace elements are an essential tool in nutrition, toxicology, or internal dosimetry of radionuclides. Zirconium, especially its radioisotope (95)Zr, is relevant to radiation protection due to its production in uranium fission and neutron activation of nuclear fuel cladding material. We present a comprehensive set of human data from a tracer study with stable isotopes of zirconium. The data are used to refine a biokinetic model of zirconium. Six female and seven male healthy adult volunteers participated in the study. It includes 16 complete double tracer investigations with oral ingestion and intravenous injection, and seven supplemental investigations. Tracer concentrations were measured in blood plasma and urine collected up to 100 d after tracer administration. The four data sets (two chemical tracer forms in plasma and urine) each encompass 105-240 measured concentration values above detection limits. Total fractional absorption of ingested zirconium was found to be 0.001 for zirconium in citrate-buffered drinking solution and 0.007 for zirconium oxalate solution. Biokinetic models were developed based on the linear first-order kinetic compartmental model approach used by the International Commission on Radiological Protection (ICRP). The main differences of the optimized systemic model of zirconium to the current ICRP model are (1) recycling into the transfer compartment made necessary by the observed tracer clearance from plasma, (2) different parameters related to fractional absorption for each form of the ingested tracer, and (3) a physiologically based excretion pathway to urine. The study considerably expands the knowledge on the biokinetics of zirconium, which was until now dominated by data from animal studies. The proposed systemic model improves the existing ICRP model, yet is based on the same principles and fits well into the ICRP radiation protection approach. Copyright © 2011 Elsevier B.V. All rights reserved.

Fretting wear behavior of zirconium alloy in B-Li water at 300 °C

NASA Astrophysics Data System (ADS)

Zhang, Lefu; Lai, Ping; Liu, Qingdong; Zeng, Qifeng; Lu, Junqiang; Guo, Xianglong

2018-02-01

The tangential fretting wear of three kinds of zirconium alloys tube mated with 304 stainless steel (SS) plate was investigated. The tests were conducted in an autoclave containing 300 °C pressurized B-Li water for tube-on-plate contact configuration. The worn surfaces were examined with scanning electron microscopy (SEM), energy dispersive spectroscopy (EDS) and 3D microscopy. The cross-section of wear scar was examined with transmission electron microscope (TEM). The results indicated that the dominant wear mechanism of zirconium alloys in this test condition was delamination and oxidation. The oxide layer on the fretted area consists of outer oxide layer composed of iron oxide and zirconium oxide and inner oxide layer composed of zirconium oxide.

The Preparation and Microstructure of Nanocrystal 3C-SiC/ZrO2 Bilayer Films

PubMed Central

Ye, Chao; Ran, Guang; Zhou, Wei; Qu, Yazhou; Yan, Xin; Cheng, Qijin; Li, Ning

2017-01-01

The nanocrystal 3C-SiC/ZrO2 bilayer films that could be used as the protective coatings of zirconium alloy fuel cladding were prepared on a single-crystal Si substrate. The corresponding nanocrystal 3C-SiC film and nanocrystal ZrO2 film were also dividedly synthesized. The microstructure of nanocrystal films was analyzed by grazing incidence X-ray diffraction (GIXRD) and cross-sectional transmission electron microscopy (TEM). The 3C-SiC film with less than 30 nm crystal size was synthesized by Plasma Enhanced Chemical Vapor Deposition (PECVD) and annealing. The corresponding formation mechanism of some impurities in SiC film was analyzed and discussed. An amorphous Zr layer about 600 nm in width was first deposited by magnetron sputtering and then oxidized to form a nanocrystal ZrO2 layer during the annealing process. The interface characteristics of 3C-SiC/ZrO2 bilayer films prepared by two different processes were obviously different. SiZr and SiO2 compounds were formed at the interface of 3C-SiC/ZrO2 bilayer films. A corrosion test of 3C-SiC/ZrO2 bilayer films was conducted to qualitatively analyze the surface corrosion resistance and the binding force of the interface. PMID:29168782

History of fast reactor fuel development

NASA Astrophysics Data System (ADS)

Kittel, J. H.; Frost, B. R. T.; Mustelier, J. P.; Bagley, K. Q.; Crittenden, G. C.; Van Dievoet, J.

1993-09-01

The first fast breeder reactors, constructed in the 1945-1960 time period, used metallic fuels composed of uranium, plutonium, or their alloys. They were chosen because most existing reactor operating experience had been obtained on metallic fuels and because they provided the highest breeding ratios. Difficulties in obtaining adequate dimensional stability in metallic fuel elements under conditions of high fuel burnup led in the 1960s to the virtual worldwide choice of ceramic fuels. Although ceramic fuels provide lower breeding performance, this objective is no longer an important consideration in most national programs. Mixed uranium and plutonium dioxide became the ceramic fuel that has received the widest use. The more advanced ceramic fuels, mixed uranium and plutonium carbides and nitrides, continue under development. More recently, metal fuel elements of improved design have joined ceramic fuels in achieving goal burnups of 15 to 20 percent. Low-swelling fuel cladding alloys have also been continuously developed to deal with the unexpected problem of void formation in stainless steels subjected to fast neutron irradiation, a phenomenon first observed in the 1960s.

Manufacturing process to reduce large grain growth in zirconium alloys

DOEpatents

Rosecrans, Peter M.

1987-01-01

A method of treating cold-worked zirconium alloys to reduce large grain gth during thermal treatment at temperatures above the recrystallization temperature of the alloy comprising heating the cold-worked alloy between about 1300.degree.-1350.degree. F. for 1 to 3 hours prior to treatment above its recrystallization temperature.

PLUTONIUM FUEL RODS FOR PREPARATION OF TRANSPLUTONIC ELEMENTS

DOE Office of Scientific and Technical Information (OSTI.GOV)

Bailey, W.J.

1962-02-01

Production by coextrusion of metallurgically bonded, Alclad, Al-7.35 wt% Pu alloy fuel rods with integral ends is discussed. The rods had a diameter of 0.94 in., length of, 60 in., and a nominal cladding thickness of 0.070 in. The Pu concentration was maintained at 83.3 g/rod. The coextrusion billets can be assembled with fuel cores in the as-cast condition. The casting hot-tops can be returned to the process stream. The process is useful for preparing transplutonic elements and production of high-exposure Pu. (J.R.D.)

Capabilities to improve corrosion resistance of fuel claddings by using powerful laser and plasma sources

NASA Astrophysics Data System (ADS)

Borisov, V. M.; Trofimov, V. N.; Sapozhkov, A. Yu.; Kuzmenko, V. A.; Mikhaylov, V. B.; Cherkovets, V. Ye.; Yakushkin, A. A.; Yakushin, V. L.; Dzhumayev, P. S.

2016-12-01

The treatment conditions of fuel claddings of the E110 alloy by using powerful UV or IR laser radiation, which lead to the increase in the corrosion resistance at the high-temperature ( T = 1100°C) oxidation simulating a loss-of-coolant accident, are determined. The possibility of the complete suppression of corrosion under these conditions by using pulsed laser deposition of a Cr layer is demonstrated. The behavior of protective coatings of Al, Al2O3, and Cr planted on steel EP823 by pulsed laser deposition, which is planned to be used in the BREST-OD-300, is studied. The methods of the almost complete suppression of corrosion in liquid lead to the temperature of 720°C are shown.

METHOD AND ALLOY FOR BONDING TO ZIRCONIUM

DOEpatents

McCuaig, F.D.; Misch, R.D.

1960-04-19

A brazing alloy can be used for bonding zirconium and its alloys to other metals, ceramics, and cermets, and consists of 6 to 9 wt.% Ni, 6 to 9 wn~.% Cr, Mo, or W, 0 to 7.5 wt.% Fe, and the balance Zr.

Influence of laser radiation on structure and properties of steels and alloys

NASA Astrophysics Data System (ADS)

Tarasova, T.; Popova, E.

2013-03-01

In present study, and laser alloying of different steels and laser cladding of Ti and SiC powders mixtures was carried out, and microstructure, as well as microhardness profile and wear properties were examined. Research of the influence of lasers alloying modes on the elastic and plastic characteristics of the surface was conducted. As a result of chemical reactions in the cladded layer, a new phase (TiC) was synthesized during cladding process. The results showed that, in the clad layer, TiC was solidified to form dendrites in the clad zone. Produced coatings have high microhardness values in the upper and middle clad areas, about two time higher than clad matrix microhardness.

Development of Protective Coatings for Chromium-Base Alloys

NASA Technical Reports Server (NTRS)

English, J. J.; MacMillan, C. A.; Williams, D. N.; Bartlett, E. S.

1966-01-01

Chromium alloy sheet was clad with 5 to 10-mil-thick oxidation-resistant nickel-base alloy foils. Specimens also contained 1/2 to 1-mil-thick intermediate layers of platinum, tungsten, and/or W-25Re. Cladding was done by the isostatic hot gas-pressure bonding,.process. The clad chromium-alloy specimens were cyclic oxidation tested at 2100 F and 2300 F for up to 200 hours to determine the effectiveness of these metal claddings in protecting the chromium alloy Cr-5W from oxidation and contamination. Cladding systems consisting of 5-mil-thick Ni-20Cr-20W modified with 3 to 5 weight percent aluminum and containing a 1 /2-mil tungsten diffusion barrier demonstrated potential for long-time service at temperatures as high as 2300 F.

Analysis of the FeCrAl Accident Tolerant Fuel Concept Benefits during BWR Station Blackout Accidents

DOE Office of Scientific and Technical Information (OSTI.GOV)

Robb, Kevin R

2015-01-01

Iron-chromium-aluminum (FeCrAl) alloys are being considered for fuel concepts with enhanced accident tolerance. FeCrAl alloys have very slow oxidation kinetics and good strength at high temperatures. FeCrAl could be used for fuel cladding in light water reactors and/or as channel box material in boiling water reactors (BWRs). To estimate the potential safety gains afforded by the FeCrAl concept, the MELCOR code was used to analyze a range of postulated station blackout severe accident scenarios in a BWR/4 reactor employing FeCrAl. The simulations utilize the most recently known thermophysical properties and oxidation kinetics for FeCrAl. Overall, when compared to the traditionalmore » Zircaloy-based cladding and channel box, the FeCrAl concept provides a few extra hours of time for operators to take mitigating actions and/or for evacuations to take place. A coolable core geometry is retained longer, enhancing the ability to stabilize an accident. Finally, due to the slower oxidation kinetics, substantially less hydrogen is generated, and the generation is delayed in time. This decreases the amount of non-condensable gases in containment and the potential for deflagrations to inhibit the accident response.« less

Phase decomposition of γ-U (bcc) in U-10 wt% Mo fuel alloy during hot isostatic pressing of monolithic fuel plate

NASA Astrophysics Data System (ADS)

Park, Y.; Eriksson, N.; Newell, R.; Keiser, D. D.; Sohn, Y. H.

2016-11-01

Eutectoid decomposition of γ-phase (cI2) into α-phase (oC4) and γ‧-phase (tI6) during the hot isostatic pressing (HIP) of the U-10 wt% Mo (U10Mo) alloy was investigated using monolithic fuel plate samples consisting of U10Mo fuel alloy, Zr diffusion barrier and AA6061 cladding. The decomposition of the γ-phase was observed because the HIP process is carried out near the eutectoid temperature, 555 °C. Initially, a cellular structure, consisting of γ‧-phase surrounded by α-phase, developed from the destabilization of the γ-phase. The cellular structure further developed into an alternating lamellar structure of α- and γ‧-phases. Using scanning electron microscopy and transmission electron microscopy, qualitative and quantitative microstructural analyses were carried out to identify the phase constituents, and elucidate the microstructural development based on time-temperature-transformation diagram of the U10Mo alloy. The destabilization of γ -phase into α- and γ‧-phases would be minimized when HIP process was carried out with rapid ramping/cooling rate and dwell temperature higher than 560 °C.

Status of Wrought FeCrAl-UO 2 Capsules Irradiated in the Advanced Test Reactor

DOE Office of Scientific and Technical Information (OSTI.GOV)

Field, Kevin G.; Harp, J.; Core, G.

2017-07-01

Candidate cladding materials for accident tolerant fuel applications require extensive testing and validation prior to commercial deployment within the nuclear power industry. One class of cladding materials, FeCrAl alloys, is currently undergoing such effort. Within these activities is a series of irradiation programs within the Advanced Test Reactor. These programs are developed to aid in commercial maturation and understand the fundamental mechanisms controlling the cladding performance during normal operation of a typical light water reactor. Three different irradiation programs are on-going; one designed as a simple proof-of-principle concept, the other to evaluate the susceptibility of FeCrAl to fuel-cladding chemical interaction,more » and the last to fully simulate the conditions of a pressurized water reactor experimentally. To date, nondestructive post-irradiation examination has been completed on the rodlet deemed FCA-L3 from the simple proof-of-concept irradiation program. Initial results show possible breach of the rodlet under irradiation but further studies are needed to conclusively determine whether breach has occurred and the underlying reasons for such a possible failure. Further work includes characterizing additional rodlets following irradiation.« less

Strengthening Effect of Incremental Shear Deformation on Ti Alloy Clad Plate with a Ni-Based Alloy Laser-Clad Layer

NASA Astrophysics Data System (ADS)

Zhao, W.; Zha, G. C.; Kong, F. X.; Wu, M. L.; Feng, X.; Gao, S. Y.

2017-05-01

A Ti-6Al-4V alloy clad plate with a Tribaloy 700 alloy laser-clad layer is subjected to incremental shear deformation, and we evaluate the structural evolution and mechanical properties of the specimens. Results indicate the significance of the incremental shear deformation on the strengthening effect. The wear resistance and Vickers hardness of the laser-clad layer are enhanced due to increased dislocation density. The incremental shear deformation can increase the bonding strength of the laser-clad layer and the corresponding substrate and can break the columnar crystals in the laser-clad layer near the interface. These phenomena suggest that shear deformation eliminates the defects on the interface of the laser-clad layer and the substrate. Substrate hardness is evidently improved, and the strengthening effect is caused by the increased dislocation density and shear deformation. This deformation can then transform the α- and β-phases in the substrate into a high-intensity ω-phase.

Experiments in anodic film effects during electrorefining of scrap U-10Mo fuels in support of modeling efforts

DOE Office of Scientific and Technical Information (OSTI.GOV)

Van Kleeck, M.; Chemical Sciences and Engineering Division, Argonne National Laboratory, Argonne, IL 60439; Willit, J.

A monolithic uranium molybdenum alloy clad in zirconium has been proposed as a low enriched uranium (LEU) fuel option for research and test reactors, as part of the Reduced Enrichment for Research and Test Reactors program. Scrap from the fuel's manufacture will contain a significant portion of recoverable LEU. Pyroprocessing has been identified as an option to perform this recovery. A model of a pyroprocessing recovery procedure has been developed to assist in refining the LEU recovery process and designing the facility. Corrosion theory and a two mechanism transport model were implemented on a Mat-Lab platform to perform the modeling.more » In developing this model, improved anodic behavior prediction became necessary since a dense uranium-rich salt film was observed at the anode surface during electrorefining experiments. Experiments were conducted on uranium metal to determine the film's character and the conditions under which it forms. The electro-refiner salt used in all the experiments was eutectic LiCl/KCl containing UCl{sub 3}. The anodic film material was analyzed with ICP-OES to determine its composition. Both cyclic voltammetry and potentiodynamic scans were conducted at operating temperatures between 475 and 575 C. degrees to interrogate the electrochemical behavior of the uranium. The results show that an anodic film was produced on the uranium electrode. The film initially passivated the surface of the uranium on the working electrode. At high over potentials after a trans-passive region, the current observed was nearly equal to the current observed at the initial active level. Analytical results support the presence of K{sub 2}UCl{sub 6} at the uranium surface, within the error of the analytical method.« less

DOE Office of Scientific and Technical Information (OSTI.GOV)

James A. Smith; Jeffrey M. Lacy; Barry H. Rabin

12. Other advances in QNDE and related topics: Preferred Session Laser-ultrasonics Developing A Laser Shockwave Model For Characterizing Diffusion Bonded Interfaces 41st Annual Review of Progress in Quantitative Nondestructive Evaluation Conference QNDE Conference July 20-25, 2014 Boise Centre 850 West Front Street Boise, Idaho 83702 James A. Smith, Jeffrey M. Lacy, Barry H. Rabin, Idaho National Laboratory, Idaho Falls, ID ABSTRACT: The US National Nuclear Security Agency has a Global Threat Reduction Initiative (GTRI) which is assigned with reducing the worldwide use of high-enriched uranium (HEU). A salient component of that initiative is the conversion of research reactors from HEUmore » to low enriched uranium (LEU) fuels. An innovative fuel is being developed to replace HEU. The new LEU fuel is based on a monolithic fuel made from a U-Mo alloy foil encapsulated in Al-6061 cladding. In order to complete the fuel qualification process, the laser shock technique is being developed to characterize the clad-clad and fuel-clad interface strengths in fresh and irradiated fuel plates. The Laser Shockwave Technique (LST) is being investigated to characterize interface strength in fuel plates. LST is a non-contact method that uses lasers for the generation and detection of large amplitude acoustic waves to characterize interfaces in nuclear fuel plates. However the deposition of laser energy into the containment layer on specimen’s surface is intractably complex. The shock wave energy is inferred from the velocity on the backside and the depth of the impression left on the surface from the high pressure plasma pulse created by the shock laser. To help quantify the stresses and strengths at the interface, a finite element model is being developed and validated by comparing numerical and experimental results for back face velocities and front face depressions with experimental results. This paper will report on initial efforts to develop a finite element model for laser shock.« less

Steam Oxidation Testing in the Severe Accident Test Station

DOE Office of Scientific and Technical Information (OSTI.GOV)

Pint, Bruce A.

After the March 2011 accident at Fukushima Daiichi, Oak Ridge National Laboratory (ORNL) began conducting high temperature steam oxidation testing of candidate materials for accident tolerant fuel (ATF) cladding in August 2011 [1-11]. The ATF concept is to enhance safety margins in light water reactors (LWR) during severe accident scenarios by identifying materials with 100× slower steam oxidation rates compared to current Zr-based alloys. In 2012, the ORNL laboratory equipment was expanded and made available to the entire ATF community as the Severe Accident Test Station (SATS) [4,12]. Compared to the current UO2/Zr-based alloy fuel system, an ATF alternative wouldmore » significantly reduce the rate of heat and hydrogen generation in the core during a coolant-limited severe accident [13-14]. The steam oxidation behavior of candidate materials is a key metric in the evaluation of ATF concepts and also an important input into models [15-17]. However, initial modeling work of FeCrAl cladding has used incomplete information on the physical properties of FeCrAl. Also, the steam oxidation data being collected at 1200°-1700°C is unique as no prior work has considered steam oxidation of alloys at such high temperatures. Also, because many accident scenarios include steadily increasing temperatures, the required data are not traditional isothermal exposures but exposures with varying “ramp” rates. In some cases, the steam oxidation behavior has been surprising and difficult to interpret. Thus, more fundamental information continues to be collected. In addition, more work continues to focus on commercially-manufactured tube material. This report summarizes recent work to characterize the behavior of candidate alloys exposed to high temperature steam, evaluate steam oxidation behavior in various ramp scenarios and continue to collect integral data on FeCrAl compared to conventional Zr-based cladding.« less

Superconductivity in zirconium-rhodium alloys

NASA Technical Reports Server (NTRS)

Zegler, S. T.

1969-01-01

Metallographic studies and transition temperature measurements were made with isothermally annealed and water-quenched zirconium-rhodium alloys. The results clarify both the solid-state phase relations at the Zr-rich end of the Zr-Rh alloy system and the influence upon the superconducting transition temperature of structure and composition.

Fuel Thermo-physical Characterization Project. Fiscal Year 2014 Final Report

DOE Office of Scientific and Technical Information (OSTI.GOV)

Burkes, Douglas; Casella, Andrew M.; Buck, Edgar C.

2015-03-15

The Office of Material Management and Minimization (M3) Reactor Conversion Fuel Thermo-Physical Characterization Project at Pacific Northwest National Laboratory (PNNL) was tasked with using PNNL facilities and processes to receive irradiated low enriched uranium–molybdenum (LEU-Mo) fuel plate samples and perform analysis in support of the M3 Reactor Conversion Program. This work is in support of the M3 Reactor Conversion Fuel Development Pillar that is managed by Idaho National Laboratory. The primary research scope was to determine the thermo-physical properties as a function of temperature and burnup. Work conducted in Fiscal Year (FY) 2014 complemented measurements performed in FY 2013 onmore » four additional irradiated LEU-Mo fuel plate samples. Specifically, the work in FY 2014 investigated the influence of different processing methods on thermal property behavior, the absence of aluminum alloy cladding on thermal property behavior for additional model validation, and the influence of higher operating surface heat flux / more aggressive irradiation conditions on thermal property behavior. The model developed in FY 2013 and refined in FY 2014 to extract thermal properties of the U-Mo alloy from the measurements conducted on an integral fuel plate sample (i.e., U-Mo alloy with a thin Zr coating and clad in AA6061) continues to perform very well. Measurements conducted in FY 2014 on samples irradiated under similar conditions compare well to measurements performed in FY 2013. In general, there is no gross influence of fabrication method on thermal property behavior, although the difference in LEU-Mo foil microstructure does have a noticeable influence on recrystallization of grains during irradiation. Samples irradiated under more aggressive irradiation conditions, e.g., higher surface heat flux, revealed lower thermal conductivity when compared to samples irradiated at moderate surface heat fluxes, with the exception of one sample. This report documents thermal property measurements conducted in FY 2014 and compares results to values obtained from literature and measurements performed in FY 2013, where applicable, along with appropriate discussion.« less

Nuclear Fuel Reprocessing

DOE Office of Scientific and Technical Information (OSTI.GOV)

Harold F. McFarlane; Terry Todd

2013-11-01

Reprocessing is essential to closing nuclear fuel cycle. Natural uranium contains only 0.7 percent 235U, the fissile (see glossary for technical terms) isotope that produces most of the fission energy in a nuclear power plant. Prior to being used in commercial nuclear fuel, uranium is typically enriched to 3–5% in 235U. If the enrichment process discards depleted uranium at 0.2 percent 235U, it takes more than seven tonnes of uranium feed to produce one tonne of 4%-enriched uranium. Nuclear fuel discharged at the end of its economic lifetime contains less one percent 235U, but still more than the natural ore.more » Less than one percent of the uranium that enters the fuel cycle is actually used in a single pass through the reactor. The other naturally occurring isotope, 238U, directly contributes in a minor way to power generation. However, its main role is to transmute into plutoniumby neutron capture and subsequent radioactive decay of unstable uraniumand neptuniumisotopes. 239Pu and 241Pu are fissile isotopes that produce more than 40% of the fission energy in commercially deployed reactors. It is recovery of the plutonium (and to a lesser extent the uranium) for use in recycled nuclear fuel that has been the primary focus of commercial reprocessing. Uraniumtargets irradiated in special purpose reactors are also reprocessed to obtain the fission product 99Mo, the parent isotope of technetium, which is widely used inmedical procedures. Among the fission products, recovery of such expensive metals as platinum and rhodium is technically achievable, but not economically viable in current market and regulatory conditions. During the past 60 years, many different techniques for reprocessing used nuclear fuel have been proposed and tested in the laboratory. However, commercial reprocessing has been implemented along a single line of aqueous solvent extraction technology called plutonium uranium reduction extraction process (PUREX). Similarly, hundreds of types of reactor fuels have been irradiated for different purposes, but the vast majority of commercial fuel is uranium oxide clad in zirconium alloy tubing. As a result, commercial reprocessing plants have relatively narrow technical requirements for used nuclear that is accepted for processing.« less

Fabrication and Evaluation of Titanium and Zirconium based Wires for use during Extended, Deep Space, Missions

NASA Technical Reports Server (NTRS)

Grugel, Richard N.

2006-01-01

Novel materials and designs are necessary for transport vessels and propulsion systems to fulfill NASA's vision of easier access to space and the expansion of human exploration beyond low-earth orbit. Spacecraft components must necessarily be lighter and stronger than their predecessors and will likely be required to serve new purposes. Furthermore, they must be resilient to the thermal, vacuum, and radiation environment of space for extended periods of time and may need to perform in the near proximity of a nuclear fuel source. To this end research has been initiated to fabricate novel, composite, wires based on titanium and zirconium pearlitic alloys. It is expected that the fabricated wire will well endure in the space environment with application as tethers, sail components, fasteners, and a myriad of other (including earth-based) uses. A background on pearlitic wire, novel alloy development, microstructural characterization, and initial mechanical testing results will be presented and discussed.

Stress corrosion cracking of Zircaloys in unirradiated and irradiated CsI

NASA Astrophysics Data System (ADS)

Cox, B.; Surette, B. A.; Wood, J. C.

1986-03-01

Unirradiated split-ring specimens of Zircaloy fuel cladding, coated with CsI, cracked when stressed at elevated temperatures. The specimens have been reexamined fractographically and metallographically in order to confirm that the cause of cracking was stress corrosion (SCC) and not delayed hydride cracking (DHC). Further specimens have been cracked at 350°C by a solution of CsI in a fused mixture of nitrates of rubidium, cesium, strontium and barium, by a similar mechanism. CsI dissolved in a fused molybdate melt was not stable at 400°C, and rapidly evolved iodine, leaving a melt that was incapable of causing SCC. Irradiation of stressed split-ring specimens of Zircaloy fuel cladding in a γ-irradiator of 10 6 R/h and in the U-5 loop in the NRU reactor at an estimated 10 9 R/h caused SCC when the specimens were packed in dry CsI powder. Care had to be taken to dry the CsI, otherwise cracking occurred by a DHC mechanism from hydrogen absorbed from residual moisture in the CsI. Fractography showed that the crack surfaces obtained with dry CsI were typical of iodine-induced SCC rather than cesium-induced metal vapour embrittlement. Thus, if a transport process is provided for the iodide to obtain access to the zirconium surface, CsI is capable of causing SCC of Zircaloy. This transport process might be ionic diffusion in a fission product oxide melt in the fuel-clad gap, however, radiolysis of CsI to form a volatile iodine species in a radiation field is the more probable explanation of PCI failures.

Capabilities to improve corrosion resistance of fuel claddings by using powerful laser and plasma sources

DOE Office of Scientific and Technical Information (OSTI.GOV)

Borisov, V. M., E-mail: borisov@triniti.ru; Trofimov, V. N.; Sapozhkov, A. Yu.

2016-12-15

The treatment conditions of fuel claddings of the E110 alloy by using powerful UV or IR laser radiation, which lead to the increase in the corrosion resistance at the high-temperature (T = 1100°C) oxidation simulating a loss-of-coolant accident, are determined. The possibility of the complete suppression of corrosion under these conditions by using pulsed laser deposition of a Cr layer is demonstrated. The behavior of protective coatings of Al, Al{sub 2}O{sub 3}, and Cr planted on steel EP823 by pulsed laser deposition, which is planned to be used in the BREST-OD-300, is studied. The methods of the almost complete suppressionmore » of corrosion in liquid lead to the temperature of 720°C are shown.« less

ZIRCONIUM-TITANIUM-BERYLLIUM BRAZING ALLOY

DOEpatents

Gilliland, R.G.; Patriarca, P.; Slaughter, G.M.; Williams, L.C.

1962-06-12

A new and improved ternary alloy is described which is of particular utility in braze-bonding parts made of a refractory metal selected from Group IV, V, and VI of the periodic table and alloys containing said metal as a predominating alloying ingredient. The brazing alloy contains, by weight, 40 to 50 per cent zirconium, 40 to 50 per cent titanium, and the balance beryllium in amounts ranging from 1 to 20 per cent, said alloy having a melting point in the range 950 to 1400 deg C. (AEC)

Integral Fast Reactor fuel pin processor

DOE Office of Scientific and Technical Information (OSTI.GOV)

Levinskas, D.

1993-01-01

This report discusses the pin processor which receives metal alloy pins cast from recycled Integral Fast Reactor (IFR) fuel and prepares them for assembly into new IFR fuel elements. Either full length as-cast or precut pins are fed to the machine from a magazine, cut if necessary, and measured for length, weight, diameter and deviation from straightness. Accepted pins are loaded into cladding jackets located in a magazine, while rejects and cutting scraps are separated into trays. The magazines, trays, and the individual modules that perform the different machine functions are assembled and removed using remote manipulators and master-slaves.

Integral Fast Reactor fuel pin processor

DOE Office of Scientific and Technical Information (OSTI.GOV)

Levinskas, D.

1993-03-01

This report discusses the pin processor which receives metal alloy pins cast from recycled Integral Fast Reactor (IFR) fuel and prepares them for assembly into new IFR fuel elements. Either full length as-cast or precut pins are fed to the machine from a magazine, cut if necessary, and measured for length, weight, diameter and deviation from straightness. Accepted pins are loaded into cladding jackets located in a magazine, while rejects and cutting scraps are separated into trays. The magazines, trays, and the individual modules that perform the different machine functions are assembled and removed using remote manipulators and master-slaves.

PROCESS OF DISSOLVING ZIRCONIUM ALLOYS

DOEpatents

Shor, R.S.; Vogler, S.

1958-01-21

A process is described for dissolving binary zirconium-uranium alloys where the uranium content is about 2%. In prior dissolution procedures for these alloys, an oxidizing agent was added to prevent the precipitation of uranium tetrafluoride. In the present method complete dissolution is accomplished without the use of the oxidizing agent by using only the stoichiometric amount or slight excess of HF required by the zirconium. The concentration of the acid may range from 2M to 10M and the dissolution is advatageously carried out at a temperature of 80 deg C.

Oxidation performance of platinum-clad Mo-47Re alloy

NASA Technical Reports Server (NTRS)

Clark, Ronald K.; Wallace, Terryl A.

1994-01-01

The alloy Mo-47Re has favorable mechanical properties at temperatures above 1400 C, but it undergoes severe oxidation when used in air with no protective coating. To shield the alloy from oxidation, platinum cladding has been evaluated. The unprotected alloy undergoes catastrophic oxidation under static and dynamic oxidation conditions. The platinum cladding provides good protection from static and dynamic oxidation for moderate times at 1260 C. Samples tested for longer times under static oxidation conditions experienced severe oxidation. The data suggest that oxidation results from the transport of oxygen through the grain boundaries and through the pinhole defects of the platinum cladding.

A study on the reaction of Zircaloy-4 tube with hydrogen/steam mixture

NASA Astrophysics Data System (ADS)

Lee, Ji-Min; Kook, Dong-Hak; Cho, Il-Je; Kim, Yong-Soo

2017-08-01

In order to fundamentally understand the secondary hydriding mechanism of zirconium alloy cladding, the reaction of commercial Zircaloy-4 tubes with hydrogen and steam mixture was studied using a thermo-gravimetric analyser with two variables, H2/H2O ratio and temperature. Phenomenological analysis revealed that in the steam starvation condition, i.e., when the H2/H2O ratio is greater than 104, hydriding is the dominant reaction and the weight gain increases linearly after a short incubation time. On the other hand, when the gas ratio is 5 × 102 or 103, both hydriding and oxidation reactions take place simultaneously, leading to three distinct regimes: primary hydriding, enhanced oxidation, and massive hydriding. Microstructural changes of oxide demonstrate that when the weight gain exceeds a certain critical value, massive hydriding takes place due to the significant localized crack development within the oxide, which possibly simulates the secondary hydriding failure in a defective fuel operation. This study reveals that the steam starvation condition above the critical H2/H2O ratio is only a necessary condition for the secondary hydriding failure and, as a sufficient condition, oxide needs to grow sufficiently to reach the critical thickness that produces substantial crack development. In other words, in a real defective fuel operation incident, the secondary failure is initiated only when both steam starvation and oxide degradation conditions are simultaneously met. Therefore, it is concluded that the indispensable time for the critical oxide growth primarily determines the triggering time of massive hydriding failure.

Laser Cladding of Ni, Nb, and Mg Alloys for Improved Environmental Resistance at High Temperature

DTIC Science & Technology

1989-01-01

v*LASER CLADDING OF NI , Nb AND Mg ALLOYS < FOR 7IMPR-OVED ENVIIONM ENTAL I RESISTANCE AT HIGH TEMPERATURE Final Report for Research Conducted through...resistance at high temperature. Major emphasis has been on Ni -Cr-Al-Hf system. Microstructural evolution and oxidation properties of Ni and Nb alloys ...metastable crystalline and amorphous structure on a) the high temperature oxidation properties of laser clad Ni and Nb alloys , and b) the corrosion

Development of Nitride Coating Using Atomic Layer Deposition for Low-Enriched Uranium Fuel Powder

NASA Astrophysics Data System (ADS)

Bhattacharya, Sumit

High-performance research reactors require fuel that operates at high specific power and can withstand high fission density, but at relatively low temperatures. The design of the research reactor fuels is done for efficient heat emission, and consists of assemblies of thin-plates cladding made from aluminum alloy. The low-enriched fuels (LEU) were developed for replacing high-enriched fuels (HEU) for these reactors necessitates a significantly increased uranium density in the fuel to counterbalance the decrease in enrichment. One of the most promising new fuel candidate is U-Mo alloy, in a U-Mo/Al dispersion fuel form, due to its high uranium loading as well as excellent irradiation resistance performance, is being developed extensively to convert from HEU fuel to LEU fuel for high-performance research reactors. However, the formation of an interaction layer (IL) between U-Mo particles and the Al matrix, and the associated pore formation, under high heat flux and high burnup conditions, degrade the irradiation performance of the U-Mo/Al dispersion fuel. From the recent tests results accumulated from the surface engineering of low enriched uranium fuel (SELENIUM) and MIR reactor displayed that a surface barrier coating like physical vapor deposited (PVD) zirconium nitride (ZrN) can significantly reduce the interaction layer. The barrier coating performed well at low burn up but above a fluence rate of 5x 1021 ions/cm2 the swelling reappeared due to formation interaction layer. With this result in mind the objective of this research was to develop an ultrathin ZrN coating over particulate uranium-molybdenum nuclear fuel using a modified savannah 200 atomic layer deposition (ALD) system. This is done in support of the US Department of Energy's (DOE) effort to slow down the interaction at fluence rate and reach higher burn up for high power research reactor. The low-pressure Savannah 200 ALD system is modified to be designed as a batch powder coating system using the metal organic chemical precursors tetrakis dimethylamido zirconium (TDMAZr) and ammonia( NH3) for succesful deposition of ZrN coating. Nitrogen (N2) gas carried the chemicals to a hot wall reactor maintained at a temperature range of 235 to 245 °C. The ALD system design evolved over the course of this research as the process variables were steadily improved. The conditions found deemed for attaining best coating were at a temperature of 245 °C, with pulse time of 0.8 seconds for TDMAZr and 0.1 seconds for NH3 along with 15 seconds of purge time in-between each cycle. The ALD system was successful in making 1-micrometer (um) ZrN with low levels of chemical impurities over U-Mo powder batches. The deposited coatings were characterized using scanning electron microscopy (SEM), energy dispersive spectroscopy (EDS), electron energy loss spectroscopy (EELS) and Transmission electron microscope (TEM). This document describes the establishment of the Savannah 200 ALD system, precursor surface reaction procedures and finally the nature of the coating achieved, including characterization of the coating at the different stages of deposition. It was found that an interlayer of alumina in between ZrN and the U-Mo surface was required to reduce the residual stress generated during the ALD procedure. The alumina not only removed the risk of cracking and spallation of the ZrN coating but also provided adequate strength for the barrier layer to withstand the fuel plate rolling conditions. The ZrN coating was nano crystalline in nature, with grain size varying from 5-10 nm, the deposited layer was found to be dense consisting of a layered structure. The coating could retain its crystallinity and maintain its phase when irradiated with 1 MeV single charged ion Kr to produce a damage of 10 displacement per atom (DPA) at intermediate voltage electron microscopy (IVEM).

Feasibility of an on-line fission-gas-leak detection system

NASA Technical Reports Server (NTRS)

Lustig, P. H.

1973-01-01

Calculations were made to determine if a cladding failure could be detected in a 100-kW zirconium hydride reactor primary system by monitoring the highly radioactive NaK coolant for the presence of I-131. The system is to be completely sealed. A leak of 0.01 percent from a single fuel pin was postulated. The 0.364-MeV gamma of I-131 could be monitored on an almost continuous basis, while its presence could be varified by using a longer counting time for the 0.638-MeV gamma. A lithium-drifted germanium detector would eliminate radioactive corrosion product interference that could occur with a sodium iodide scintillation detector.

Processing fissile material mixtures containing zirconium and/or carbon

DOEpatents

Johnson, Michael Ernest; Maloney, Martin David

2013-07-02

A method of processing spent TRIZO-coated nuclear fuel may include adding fluoride to complex zirconium present in a dissolved TRIZO-coated fuel. Complexing the zirconium with fluoride may reduce or eliminate the potential for zirconium to interfere with the extraction of uranium and/or transuranics from fission materials in the spent nuclear fuel.

NPF MECHANICAL CELL NaK DISPOSAL AND FUME ABATEMENT

DOE Office of Scientific and Technical Information (OSTI.GOV)

Rey, G.

Some of the fuels originally scheduled for processing in the nonproduction fuel (NPF) processing program incorporated sodium or sodium- potassium alloy (NaK) as the bonding material between stainless-steel cladding and the uranium or uranium-molybdenum alloy core. Because of the special hazards involved in handling NaK, studies were made to determine safe methods for processing NaK-containing fuels. An underwater NaK dispensing system was installed, and tests were made to determine the characteristics of the NaK-water reaction. The equipment consisted of a dispenser, reaction pan, and off-gas scrubber. After initinl studies, a prototype test was made wherein U-Mo canned slugs containing NaKmore » reservoirs were hack sawed underwater. The studies demonstrated that the NaK reservoirs can be safely deactivated by hack sawing under a submerged hood in a shallow water bath. (W.L.H.)« less

CHARACTERISTICS OF ANODIC AND CORROSION FILMS ON ZIRCONIUM

DOE Office of Scientific and Technical Information (OSTI.GOV)

Misch, R.D.

1960-05-01

Zirconium anodizes similarly to tungsten in respect to the change of interference colors with applied voltage. However, the oxide layer on tungsten cannot reach as great a thickness. Hafnium does not anodize in the same way as zirconium but is similar to tantalum. By measuring the interference color and capacitative thicknesses on zirconium (Grades I and III) and a 2.5 wt.% tin ailoy, the film was found to grow less rapidly in terms of capacitance than in terms of iaterference colors. This was interpreted to mean that cracks develop in the oxide as it thickens. The effect was most pronouncedmore » on Grade III zirconium and least pronounced on the tin alloy. The reduction in capacitative thickness was especially noticeable when white oxide appeared. Comparative measurements on Grade I zirconium and 2.5 wt.% tin alloy indicated that the thickness of the oxide film on the tin alloy (after 16 hours in water) increased more rapidly with temperature than the film on zirconium. Tin is believed to act in ways to counteract the tendency of the oxide to form cracks, and to produce vacancies which promote ionic diffusion. (auth)« less

Chemical compatibility between UO2 fuel and SiC cladding for LWRs. Application to ATF (Accident-Tolerant Fuels)

NASA Astrophysics Data System (ADS)

Braun, James; Guéneau, Christine; Alpettaz, Thierry; Sauder, Cédric; Brackx, Emmanuelle; Domenger, Renaud; Gossé, Stéphane; Balbaud-Célérier, Fanny

2017-04-01

Silicon carbide-silicon carbide (SiC/SiC) composites are considered to replace the current zirconium-based cladding materials thanks to their good behavior under irradiation and their resistance under oxidative environments at high temperature. In the present work, a thermodynamic analysis of the UO2±x/SiC system is performed. Moreover, using two different experimental methods, the chemical compatibility of SiC towards uranium dioxide, with various oxygen contents (UO2±x) is investigated in the 1500-1970 K temperature range. The reaction leads to the formation of mainly uranium silicides and carbides phases along with CO and SiO gas release. Knudsen Cell Mass Spectrometry is used to measure the gas release occurring during the reaction between UO2+x and SiC powders as function of time and temperature. These experimental conditions are representative of an open system. Diffusion couple experiments with pellets are also performed to study the reaction kinetics in closed system conditions. In both cases, a limited chemical reaction is observed below 1700 K, whereas the reaction is enhanced at higher temperature due to the decomposition of SiC leading to Si vaporization. The temperature of formation of the liquid phase is found to lie between 1850 < T < 1950 K.

Laser Powder Cladding of Ti-6Al-4V α/β Alloy

PubMed Central

Al-Sayed Ali, Samar Reda; Hussein, Abdel Hamid Ahmed; Nofal, Adel Abdel Menam Saleh; Elgazzar, Haytham Abdelrafea; Sabour, Hassan Abdel

2017-01-01

Laser cladding process was performed on a commercial Ti-6Al-4V (α + β) titanium alloy by means of tungsten carbide-nickel based alloy powder blend. Nd:YAG laser with a 2.2-KW continuous wave was used with coaxial jet nozzle coupled with a standard powder feeding system. Four-track deposition of a blended powder consisting of 60 wt % tungsten carbide (WC) and 40 wt % NiCrBSi was successfully made on the alloy. The high content of the hard WC particles is intended to enhance the abrasion resistance of the titanium alloy. The goal was to create a uniform distribution of hard WC particles that is crack-free and nonporous to enhance the wear resistance of such alloy. This was achieved by changing the laser cladding parameters to reach the optimum conditions for favorable mechanical properties. The laser cladding samples were subjected to thorough microstructure examinations, microhardness and abrasion tests. Phase identification was obtained by X-ray diffraction (XRD). The obtained results revealed that the best clad layers were achieved at a specific heat input value of 59.5 J·mm−2. An increase by more than three folds in the microhardness values of the clad layers was achieved and the wear resistance was improved by values reaching 400 times. PMID:29036935

Laser Powder Cladding of Ti-6Al-4V α/β Alloy.

PubMed

Al-Sayed Ali, Samar Reda; Hussein, Abdel Hamid Ahmed; Nofal, Adel Abdel Menam Saleh; Hasseb Elnaby, Salah Elden Ibrahim; Elgazzar, Haytham Abdelrafea; Sabour, Hassan Abdel

2017-10-15

Laser cladding process was performed on a commercial Ti-6Al-4V (α + β) titanium alloy by means of tungsten carbide-nickel based alloy powder blend. Nd:YAG laser with a 2.2-KW continuous wave was used with coaxial jet nozzle coupled with a standard powder feeding system. Four-track deposition of a blended powder consisting of 60 wt % tungsten carbide (WC) and 40 wt % NiCrBSi was successfully made on the alloy. The high content of the hard WC particles is intended to enhance the abrasion resistance of the titanium alloy. The goal was to create a uniform distribution of hard WC particles that is crack-free and nonporous to enhance the wear resistance of such alloy. This was achieved by changing the laser cladding parameters to reach the optimum conditions for favorable mechanical properties. The laser cladding samples were subjected to thorough microstructure examinations, microhardness and abrasion tests. Phase identification was obtained by X-ray diffraction (XRD). The obtained results revealed that the best clad layers were achieved at a specific heat input value of 59.5 J·mm -2 . An increase by more than three folds in the microhardness values of the clad layers was achieved and the wear resistance was improved by values reaching 400 times.

Microstructure evolution of recrystallized Zircaloy-4 under charged particles irradiation

NASA Astrophysics Data System (ADS)

Gaumé, M.; Onimus, F.; Dupuy, L.; Tissot, O.; Bachelet, C.; Mompiou, F.

2017-11-01

Recrystallized zirconium alloys are used as nuclear fuel cladding tubes of Pressurized Water Reactors. During operation, these alloys are submitted to fast neutron irradiation which leads to their in-reactor deformation and to a change of their mechanical properties. These phenomena are directly related to the microstructure evolution under irradiation and especially to the formation of -type dislocation loops. In the present work, the radiation damage evolution in recrystallized Zircaloy-4 has been studied using charged particles irradiation. The loop nucleation and growth kinetics, and also the helical climb of linear dislocations, were observed in-situ using a High Voltage Electron Microscope (HVEM) under 1 MeV electron irradiation at 673 and 723 K. In addition, 600 keV Zr+ ion irradiations were conducted at the same temperature. Transmission Electron Microscopy (TEM) characterizations have been performed after both types of irradiations, and show dislocation loops with a Burgers vector belonging to planes close to { 10 1 bar 0 } first order prismatic planes. The nature of the loops has been characterized. Only interstitial dislocation loops have been observed after ion irradiation at 723 K. However, after electron irradiation conducted at 673 and 723 K, both interstitial and vacancy loops were observed, the proportion of interstitial loops increasing as the temperature is increased. The loop growth kinetics analysis shows that as the temperature increases, the loop number density decreases and the loop growth rate tends to increase. An increase of the flux leads to an increase of the loop number density and a decrease of the loop growth rate. The results are compared to previous works and discussed in the light of point defects diffusion.

Gas-deposit-alloy corrosion interactions in simulated combustion environments

NASA Astrophysics Data System (ADS)

Luer, Kevin Raymond

High temperature corrosion in aggressive coal combustion environments involves simultaneous corrosion reactions between combustion gases, ash deposits, and alloys. This research investigated the behavior of a ferritic steel (SA387-Gr11) and three weld claddings (309L SS, Alloy 72, and Alloy 622) in five combustion environments beneath solid deposits at 500°C for up to 1000 hours. The synthetic gases consisted of N2-CO-CO-H2-H2O-H 2S-SO2 mixtures that simulated a range of fuel-rich or fuel-lean combustion environments with a constant sulfur content. The synthetic deposits contained FeS2, FeS, Fe3O4 and/or carbon. Reaction kinetics was studied in individual gas-metal, gas deposit, and deposit-alloy systems. A test method was developed to investigate simultaneous gas-deposit-metal corrosion reactions. The results showed reaction kinetics varied widely, depending on the gas-alloy system and followed linear, parabolic, and logarithmic rate laws. Under reducing conditions, the alloys exhibited a range of corrosion mechanisms including carburization-sulfidation, sulfidation, and sulfidation-oxidation. Most alloys were not resistant to the highly reducing gases but offered moderate resistance to mixed oxidation-sulfidation by demonstrating parabolic or logarithmic behavior. Under oxidizing conditions, all of the alloys were resistant. Under oxidizing-sulfating conditions, alloys with high Fe or Cr contents sulfated whereas an alloy containing Mo and W was resistant. In the gas-deposit-metal tests, FeS2-bearing deposits were extremely corrosive to low alloy steel under both reducing and oxidizing conditions but they had little influence on the weld claddings. Accelerated corrosion was attributed to rapid decomposition or oxidation of FeS2 particles that generated sulfur-rich gases above the alloy surface. In contrast, FeS-type deposits had no influence under reducing conditions but they were aggressive to low alloy steel under oxidizing conditions. The extent of damage correlated with the initial sulfur content in the deposit. Fe3O4 in the deposit was beneficial because it acted as a sulfur getter or oxygen source. Carbon had a mixed effect. The reaction behavior was modeled using computational thermochemistry based on Gibbs free energy minimization. A calculation method was introduced to predict equilibrium corrosion microstructures and trace reaction paths in complex gas-deposit-metal environments. Kinetic factors were identified where equilibrium reaction products were not experimentally observed.

Advanced materials for space nuclear power systems

NASA Technical Reports Server (NTRS)

Titran, Robert H.; Grobstein, Toni L.; Ellis, David L.

1991-01-01

The overall philosophy of the research was to develop and characterize new high temperature power conversion and radiator materials and to provide spacecraft designers with material selection options and design information. Research on three candidate materials (carbide strengthened niobium alloy PWC-11 for fuel cladding, graphite fiber reinforced copper matrix composites for heat rejection fins, and tungsten fiber reinforced niobium matrix composites for fuel containment and structural supports considered for space power system applications is discussed. Each of these types of materials offers unique advantages for space power applications.

Atomistic modeling of high temperature uranium-zirconium alloy structure and thermodynamics

NASA Astrophysics Data System (ADS)

Moore, A. P.; Beeler, B.; Deo, C.; Baskes, M. I.; Okuniewski, M. A.

2015-12-01

A semi-empirical Modified Embedded Atom Method (MEAM) potential is developed for application to the high temperature body-centered-cubic uranium-zirconium alloy (γ-U-Zr) phase and employed with molecular dynamics (MD) simulations to investigate the high temperature thermo-physical properties of U-Zr alloys. Uranium-rich U-Zr alloys (e.g. U-10Zr) have been tested and qualified for use as metallic nuclear fuel in U.S. fast reactors such as the Integral Fast Reactor and the Experimental Breeder Reactors, and are a common sub-system of ternary metallic alloys like U-Pu-Zr and U-Zr-Nb. The potential was constructed to ensure that basic properties (e.g., elastic constants, bulk modulus, and formation energies) were in agreement with first principles calculations and experimental results. After which, slight adjustments were made to the potential to fit the known thermal properties and thermodynamics of the system. The potentials successfully reproduce the experimental melting point, enthalpy of fusion, volume change upon melting, thermal expansion, and the heat capacity of pure U and Zr. Simulations of the U-Zr system are found to be in good agreement with experimental thermal expansion values, Vegard's law for the lattice constants, and the experimental enthalpy of mixing. This is the first simulation to reproduce the experimental thermodynamics of the high temperature γ-U-Zr metallic alloy system. The MEAM potential is then used to explore thermodynamics properties of the high temperature U-Zr system including the constant volume heat capacity, isothermal compressibility, adiabatic index, and the Grüneisen parameters.

Explosion Clad for Upstream Oil and Gas Equipment

NASA Astrophysics Data System (ADS)

Banker, John G.; Massarello, Jack; Pauly, Stephane

2011-01-01

Today's upstream oil and gas facilities frequently involve the combination of high pressures, high temperatures, and highly corrosive environments, requiring equipment that is thick wall, corrosion resistant, and cost effective. When significant concentrations of CO2 and/or H2S and/or chlorides are present, corrosion resistant alloys (CRA) can become the material of choice for separator equipment, piping, related components, and line pipe. They can provide reliable resistance to both corrosion and hydrogen embrittlement. For these applications, the more commonly used CRA's are 316L, 317L and duplex stainless steels, alloy 825 and alloy 625, dependent upon the application and the severity of the environment. Titanium is also an exceptional choice from the technical perspective, but is less commonly used except for heat exchangers. Explosion clad offers significant savings by providing a relatively thin corrosion resistant alloy on the surface metallurgically bonded to a thick, lower cost, steel substrate for the pressure containment. Developed and industrialized in the 1960's the explosion cladding technology can be used for cladding the more commonly used nickel based and stainless steel CRA's as well as titanium. It has many years of proven experience as a reliable and highly robust clad manufacturing process. The unique cold welding characteristics of explosion cladding reduce problems of alloy sensitization and dissimilar metal incompatibility. Explosion clad materials have been used extensively in both upstream and downstream oil, gas and petrochemical facilities for well over 40 years. The explosion clad equipment has demonstrated excellent resistance to corrosion, embrittlement and disbonding. Factors critical to insure reliable clad manufacture and equipment design and fabrication are addressed.

Novel strip-cast Mg/Al clad sheets with excellent tensile and interfacial bonding properties

PubMed Central

Kim, Jung-Su; Lee, Dong Ho; Jung, Seung-Pill; Lee, Kwang Seok; Kim, Ki Jong; Kim, Hyoung Seop; Lee, Byeong-Joo; Chang, Young Won; Yuh, Junhan; Lee, Sunghak

2016-01-01

In order to broaden industrial applications of Mg alloys, as lightest-weight metal alloys in practical uses, many efforts have been dedicated to manufacture various clad sheets which can complement inherent shortcomings of Mg alloys. Here, we present a new fabrication method of Mg/Al clad sheets by bonding thin Al alloy sheet on to Mg alloy melt during strip casting. In the as-strip-cast Mg/Al clad sheet, homogeneously distributed equi-axed dendrites existed in the Mg alloy side, and two types of thin reaction layers, i.e., γ (Mg17Al12) and β (Mg2Al3) phases, were formed along the Mg/Al interface. After post-treatments (homogenization, warm rolling, and annealing), the interfacial layers were deformed in a sawtooth shape by forming deformation bands in the Mg alloy and interfacial layers, which favorably led to dramatic improvement in tensile and interfacial bonding properties. This work presents new applications to multi-functional lightweight alloy sheets requiring excellent formability, surface quality, and corrosion resistance as well as tensile and interfacial bonding properties. PMID:27245687

Novel strip-cast Mg/Al clad sheets with excellent tensile and interfacial bonding properties.

PubMed

Kim, Jung-Su; Lee, Dong Ho; Jung, Seung-Pill; Lee, Kwang Seok; Kim, Ki Jong; Kim, Hyoung Seop; Lee, Byeong-Joo; Chang, Young Won; Yuh, Junhan; Lee, Sunghak

2016-06-01

In order to broaden industrial applications of Mg alloys, as lightest-weight metal alloys in practical uses, many efforts have been dedicated to manufacture various clad sheets which can complement inherent shortcomings of Mg alloys. Here, we present a new fabrication method of Mg/Al clad sheets by bonding thin Al alloy sheet on to Mg alloy melt during strip casting. In the as-strip-cast Mg/Al clad sheet, homogeneously distributed equi-axed dendrites existed in the Mg alloy side, and two types of thin reaction layers, i.e., γ (Mg17Al12) and β (Mg2Al3) phases, were formed along the Mg/Al interface. After post-treatments (homogenization, warm rolling, and annealing), the interfacial layers were deformed in a sawtooth shape by forming deformation bands in the Mg alloy and interfacial layers, which favorably led to dramatic improvement in tensile and interfacial bonding properties. This work presents new applications to multi-functional lightweight alloy sheets requiring excellent formability, surface quality, and corrosion resistance as well as tensile and interfacial bonding properties.

Using graphitic foam as the bonding material in metal fuel pins for sodium fast reactors

NASA Astrophysics Data System (ADS)

Karahan, Aydın; Kazimi, Mujid S.

2013-10-01

The study evaluates the possible use of graphite foam as the bonding material between U-Pu-Zr metallic fuel and steel clad for sodium fast reactor applications using FEAST-METAL fuel performance code. Furthermore, the applicability of FEAST-METAL to the advanced fuel designs is demonstrated. Replacing the sodium bond with a chemically stable foam material would eliminate fuel clad metallurgical interactions, and allow for fuel swelling under low external stress. Hence, a significant improvement is expected for the steady state and transient performance. FEAST-METAL was used to assess the thermo-mechanical behavior of the new fuel form and a reference metallic fuel pin. Nearly unity conversion ratio, 75% smear density U-15Pu-6Zr metallic fuel pin with sodium bond, and T91 cladding was selected as a reference case. It was found that operating the reference case at high clad temperatures (600-660 °C) results in (1) excessive clad wastage formation/clad thinning due to lanthanide migration and formation of brittle phases at clad inner surface, and (2) excessive clad hoop strain at the upper axial section due mainly to the occurrence of thermal creep. The combination of these two factors may lead to cladding breach. The work concludes that replacing the sodium bond with 80% porous graphite foam and reducing the fuel smear density to 70%, it is likely that the fuel clad metallurgical interaction would be eliminated while the fuel swelling is allowed without excessive fuel clad mechanical interaction. The suggested design appears as an alternative for a high performance metallic fuel design for sodium fast reactors.

Metal-water reaction and cladding deformation models for RELAP5/MOD3

DOE Office of Scientific and Technical Information (OSTI.GOV)

Caraher, D.L.; Shumway, R.W.

1989-06-01

A model for calculating the reaction of zirconium with steam according to the Cathcart-Pawel correlation has been incorporated into RELAP5/MOD3. A cladding deformation model which computes swelling and rupture of the cladding according to the empirical correlations for Powers and Meyer has also been incorporated into RELAP5/MOD3. This report gives the background of the models, documents their implantation into the RELAP5 subroutines, and reports the developmental assessment done on the models. 4 refs., 9 figs., 9 tabs.

Radiation Resistance of the U(Al, Si)3 Alloy: Ion-Induced Disordering

PubMed Central

Yaniv, Gili; Horak, Pavel; Vacik, Jiri; Mykytenko, Natalia; Rafailov, Gennady; Dahan, Itzchak; Fuks, David; Kiv, Arik

2018-01-01

During the exploitation of nuclear reactors, various U-Al based ternary intermetallides are formed in the fuel-cladding interaction layer. Structure and physical properties of these intermetallides determine the radiation resistance of cladding and, ultimately, the reliability and lifetime of the nuclear reactor. In current research, U(Al, Si)3 composition was studied as a potential constituent of an interaction layer. Phase content of the alloy of an interest was ordered U(Al, Si)3, structure of which was reported earlier, and pure Al (constituting less than 20 vol % of the alloy). This alloy was investigated prior and after the irradiation performed by Ar ions at 30 keV. The irradiation was performed on the transmission electron microscopy (TEM, JEOL, Japan) samples, characterized before and after the irradiation process. Irradiation induced disorder accompanied by stress relief. Furthermore, it was found that there is a dose threshold for disordering of the crystalline matter in the irradiated region. Irradiation at doses equal or higher than this threshold resulted in almost solely disordered phase. Using the program “Stopping and Range of Ions in Matter” (SRIM), the parameters of penetration of Ar ions into the irradiated samples were estimated. Based on these estimations, the dose threshold for ion-induced disordering of the studied material was assessed. PMID:29393870

Radiation Resistance of the U(Al, Si)₃ Alloy: Ion-Induced Disordering.

PubMed

Meshi, Louisa; Yaniv, Gili; Horak, Pavel; Vacik, Jiri; Mykytenko, Natalia; Rafailov, Gennady; Dahan, Itzchak; Fuks, David; Kiv, Arik

2018-02-02

During the exploitation of nuclear reactors, various U-Al based ternary intermetallides are formed in the fuel-cladding interaction layer. Structure and physical properties of these intermetallides determine the radiation resistance of cladding and, ultimately, the reliability and lifetime of the nuclear reactor. In current research, U(Al, Si)₃ composition was studied as a potential constituent of an interaction layer. Phase content of the alloy of an interest was ordered U(Al, Si)₃, structure of which was reported earlier, and pure Al (constituting less than 20 vol % of the alloy). This alloy was investigated prior and after the irradiation performed by Ar ions at 30 keV. The irradiation was performed on the transmission electron microscopy (TEM, JEOL, Japan) samples, characterized before and after the irradiation process. Irradiation induced disorder accompanied by stress relief. Furthermore, it was found that there is a dose threshold for disordering of the crystalline matter in the irradiated region. Irradiation at doses equal or higher than this threshold resulted in almost solely disordered phase. Using the program "Stopping and Range of Ions in Matter" (SRIM), the parameters of penetration of Ar ions into the irradiated samples were estimated. Based on these estimations, the dose threshold for ion-induced disordering of the studied material was assessed.

Analysis and Implementation of Accident Tolerant Nuclear Fuels

NASA Astrophysics Data System (ADS)

Prewitt, Benjamin Joseph

To improve the reliability and robustness of LWR, accident tolerant nuclear fuels and cladding materials are being developed to possibly replace the current UO2/zirconium system. This research highlights UN and U3Si 2, two of the most favorable accident tolerant fuels being developed. To evaluate the commercial feasiblilty of these fuels, two areas of research were conducted. Chemical fabrication routes for both fuels were investigated in detail, considering UO2 and UF6 as potential starting materials. Potential pathways for industrial scale fabrication using these methods were discussed. Neutronic performance of 70%UN-30%U3Si2 composite was evaluated in MNCP using PWR assembly and core models. The results showed comparable performance to an identical UO2 fueled simulation with the same configuration. The parameters simulated for composite and oxide fuel include the following: fuel to moderator ratio curves; energy dependent flux spectra; temperature coefficients for fuel and moderator; delayed neutron fractions; power peaking factors; axial and radial flux profiles in 2D and 3D; burnup; critical boron concentration; and shutdown margin. Overall, the neutronic parameters suggest that the transition from UO2 to composite in existing nuclear systems will not require significant changes in operating procedures or modifications to standards and regulations.

Transport property correlations for the niobium-1% zirconium alloy

NASA Astrophysics Data System (ADS)

Senor, David J.; Thomas, J. Kelly; Peddicord, K. L.

1990-10-01

Correlations were developed for the electrical resistivity (ρ), thermal conductivity ( k), and hemispherical total emittance (ɛ) of niobium-1% zirconium as functions of temperature. All three correlations were developed as empirical fits to experimental data. ρ = 5.571 + 4.160 × 10 -2(T) - 4.192 × 10 -6(T) 2 μΩcm , k = 13.16( T) 0.2149W/ mK, ɛ = 6.39 × 10 -2 + 4.98 × 10 -5( T) + 3.62 × 10 -8( T) 2 - 7.28 × 10 -12( T) 3. The relative standard deviation of the electrical resistivity correlation is 1.72% and it is valid over the temperature range 273 to 2700 K. The thermal conductivity correlation has a relative standard deviation of 3.24% and is valid over the temperature range 379 to 1421 K. The hemispherical total emittance correlation was developed for smooth surface materials only and represents a conservative estimate of the emittance of the alloy for space reactor fuel element modeling applications. It has a relative standard deviation of 9.50% and is valid over the temperature range 755 to 2670 K.

Examination of UC-ZrC after long term irradiation at thermionic temperature

NASA Technical Reports Server (NTRS)

Yang, L.; Johnson, H. O.

1972-01-01

Two fluoride tungsten clad UC-ZrC fueled capsules, designated as V-2C and V-2D, were examined a hot cell after irradiation in NASA Plum Brook Reactor at a maximum cladding temperature of 1930 K for 11,089 and 12,031 hours to burnups of 3.0 x 10 to the 20th power and 2.1 x 10 to the 20th power fission/c.c. respectively. Percentage of fission gas release from the fuel material was measured by radiochemical means. Cladding deformation, fuel-cladding interaction and microstructures of fuel, cladding, and fuel-cladding interface were studied metallographically. Compositions of dispersions in fuel, fuel matrix and fuel-cladding interaction layer were analyzed by electron microprobe techniques. Axial and radial distributions of burnup were determined by gamma-scan, autoradiography and isotopic burnup analysis. The results are presented and discussed in conjunction with the requirements of thermionic fuel elements for space power application.

Investigation on wear resistance and corrosion resistance of electron beam cladding co-alloy coating on Inconel617

NASA Astrophysics Data System (ADS)

Liu, Hailang; Zhang, Guopei; Huang, Yiping; Qi, Zhengwei; Wang, Bo; Yu, Zhibiao; Wang, Dezhi

2018-04-01

To improve surface properties of Inconel 617 alloy (referred to as 617 alloy), co-alloy coating metallurgically bonded to substrate was prepared on the surface of 617 alloy by electron beam cladding. The microstructure, phase composition, microhardness, tribological properties and corrosion resistance of the coatings were investigated. The XRD results of the coatings reinforced by co-alloy (Co800) revealed the presence of γ-Co, CoCx and Cr23C6 phase as matrix and new metastable phases of Cr2Ni3 and Co3Mo2Si. These hypoeutectic structures contain primary dendrites and interdendritic eutectics. The metallurgical bonding forms well between the cladding layer and the matrix of 617 alloy. In most studied conditions, the co-alloy coating displays a better hardness, tribological performance, i.e., lower coefficient of frictions and wear rates, corrosion resistance in 1 mol L‑1 HCl solution, than the 617 alloy.

Nickel aluminide alloy for high temperature structural use

DOEpatents

Liu, Chain T.; Sikka, Vinod K.

1991-01-01

The specification discloses nickel aluminide alloys including nickel, aluminum, chromium, zirconium and boron wherein the concentration of zirconium is maintained in the range of from about 0.05 to about 0.35 atomic percent to improve the ductility, strength and fabricability of the alloys at 1200.degree. C. Titanium may be added in an amount equal to about 0.2 to about 0.5 atomic percent to improve the mechanical properties of the alloys and the addition of a small amount of carbon further improves hot fabricability.

Parametric Evaluation of SiC/SiC Composite Cladding with UO2 Fuel for LWR Applications: Fuel Rod Interactions and Impact of Nonuniform Power Profile in Fuel Rod

NASA Astrophysics Data System (ADS)

Singh, G.; Sweet, R.; Brown, N. R.; Wirth, B. D.; Katoh, Y.; Terrani, K.

2018-02-01

SiC/SiC composites are candidates for accident tolerant fuel cladding in light water reactors. In the extreme nuclear reactor environment, SiC-based fuel cladding will be exposed to neutron damage, significant heat flux, and a corrosive environment. To ensure reliable and safe operation of accident tolerant fuel cladding concepts such as SiC-based materials, it is important to assess thermo-mechanical performance under in-reactor conditions including irradiation and realistic temperature distributions. The effect of non-uniform dimensional changes caused by neutron irradiation with spatially varying temperatures, along with the closing of the fuel-cladding gap, on the stress development in the cladding over the course of irradiation were evaluated. The effect of non-uniform circumferential power profile in the fuel rod on the mechanical performance of the cladding is also evaluated. These analyses have been performed using the BISON fuel performance modeling code and the commercial finite element analysis code Abaqus. A constitutive model is constructed and solved numerically to predict the stress distribution in the cladding under normal operating conditions. The dependence of dimensions and thermophysical properties on irradiation dose and temperature has been incorporated into the models. Initial scoping results from parametric analyses provide time varying stress distributions in the cladding as well as the interaction of fuel rod with the cladding under different conditions of initial fuel rod-cladding gap and linear heat rate. It is found that a non-uniform circumferential power profile in the fuel rod may cause significant lateral bowing in the cladding, and motivates further analysis and evaluation.

Irradiation testing of high density uranium alloy dispersion fuels

DOE Office of Scientific and Technical Information (OSTI.GOV)

Hayes, S.L.; Trybus, C.L.; Meyer, M.K.

1997-10-01

Two irradiation test vehicles have been designed, fabricated, and inserted into the Advanced Test Reactor in Idaho. Irradiation of these experiments began in August 1997. These irradiation tests were designed to obtain irradiation performance information on a variety of potential new, high-density dispersion fuels. Each of the two irradiation vehicles contains 32 microplates. Each microplate is aluminum clad, having an aluminum matrix phase and containing one of the following compositions as the fuel phase: U-10Mo, U-8Mo, U-6Mo, U-4Mo, U-9Nb-3Zr, U-6Nb-4Zr, U-5Nb-3Zr, U-6Mo-1Pt, U-6Mo-0.6Ru, U-10Mo-0.05Sn, U{sub 2}Mo, or U{sub 3}Si{sub 2}. These experiments will be discharged at peak fuel burnups ofmore » 40% and 80%. Of particular interest is the fission gas retention/swelling characteristics of these new fuel alloys. This paper presents the design of the irradiation vehicles and the irradiation conditions.« less

Roll Casting of Aluminum Alloy Clad Strip

DOE Office of Scientific and Technical Information (OSTI.GOV)

Nakamura, R.; Tsuge, H.; Haga, T.

2011-01-17

Casting of aluminum alloy three layers of clad strip was tried using the two sets of twin roll casters, and effects of the casting parameters on the cladding conditions were investigated. One twin roll caster was mounted on the other twin roll caster. Base strip was 8079 aluminum alloy and overlay strips were 6022 aluminum alloy. Effects of roll-load of upper and lower casters and melt temperature of the lower caster were investigated. When the roll-load of the upper and lower caster was large enough, the overlay strip could be solidified and be connected. The overlay strip could be connectedmore » when the melt of the overlay strip cast by the lower caster was low enough. Sound three layers of clad strip could be cast by proper conditions.« less

Aluminum-Scandium Alloys: Material Characterization, Friction Stir Welding, and Compatibility With Hydrogen Peroxide (MSFC Center Director's Discretionary Fund Final Report, Proj. No. 04-14)

NASA Technical Reports Server (NTRS)

Lee, J. A.; Chen, P. S.

2004-01-01

This Technical Memorandum describes the development of several high-strength aluminum (Al) alloys that are compatible with hydrogen peroxide (H2O2) propellant for NASA Hypersonic-X (Hyper-X) vehicles fuel tanks and structures. The yield strengths for some of these Al-magnesium-based alloys are more than 3 times stronger than the conventional 5254-H112 Al alloy, while maintaining excellent H2O2 compatibility similar to class 1 5254 alloy. The alloy development strategy is to add scandium, zirconium, and other transitional metals with unique electrochemical properties, which will not act as catalysts, to decompose the highly concentrated 90 percent H2O2. Test coupons are machined from sheet metals for H2O2 long-term exposure testing and mechanical properties testing. In addition, the ability to weld the new alloys using friction stir welding has also been explored. The new high-strength alloys could represent an enabling material technology for Hyper-X vehicles, where flight weight reduction is a critical requirement.

Phase Transformation Temperatures and Solute Redistribution in a Quaternary Zirconium Alloy

NASA Astrophysics Data System (ADS)

Cochrane, C.; Daymond, M. R.

2018-05-01

This study investigates the phase stability and redistribution of solute during heating and cooling of a quaternary zirconium alloy, Excel (Zr-3.2Sn-0.8Mo-0.8Nb). Time-of-flight neutron diffraction data are analyzed using a novel Vegard's law-based approach to determine the phase fractions and location of substitutional solute atoms in situ during heating from room temperature up to 1050 °C. It is seen that this alloy exhibits direct nucleation of the β Zr phase from martensite during tempering, and stable retention of the β Zr phase to high temperatures, unlike other two-phase zirconium alloys. The transformation strains resulting from the α \\leftrightarrow β transformation are shown to have a direct impact on the development of microstructure and crystallographic texture.

DOE Office of Scientific and Technical Information (OSTI.GOV)

Ballinger, Ronald G

A material that resists lead-bismuth eutectic (LBE) attack and retains its strength at 700°C would be an enabling technology for LBE-cooled reactors. No single alloy currently exists that can economically meet the required performance criteria of high strength and corrosion resistance. A Functionally Graded Composite (FGC) was developed with layers engineered to perform these functions. F91 was chosen as the structural layer of the composite for its strength and radiation resistance. Fe-12Cr-2Si, an alloy developed from previous work in the Fe-Cr-Si system, was chosen as the corrosion-resistant cladding layer because of its chemical similarity to F91 and its superior corrosionmore » resistance in both oxidizing and reducing environments. Fe-12Cr-2Si experienced minimal corrosion due to its self-passivation in oxidizing and reducing environments. Extrapolated corrosion rates are below one micron per year at 700ï°C. Corrosion of F91 was faster, but predictable and manageable. Diffusion studies showed that 17 microns of the cladding layer will be diffusionally diluted during the three year life of fuel cladding. 33 microns must be accounted for during the sixty year life of coolant piping. 5 cm coolant piping and 6.35 mm fuel cladding preforms were produced on a commercial scale by weld-overlaying Fe-12Cr-2Si onto F91 billets and co-extruding them. An ASME certified weld was performed followed by the prescribed quench-and-tempering heat treatment for F91. A minimal heat affected zone was observed, demonstrating field weldability. Finally, corrosion tests were performed on the fabricated FGC at 700ï°C after completely breaching the cladding in a small area to induce galvanic corrosion at the interface. None was observed. This FGC has significant impacts on LBE reactor design. The increases in outlet temperature and coolant velocity allow a large increase in power density, leading to either a smaller core for the same power rating or more power output for the same size core. This FGC represents an enabling technology for LBE cooled fast reactors.« less

Atomistic modeling and simulation of the role of Be and Bi in Al diffusion in U-Mo fuel

NASA Astrophysics Data System (ADS)

Hofman, G. L.; Bozzolo, G.; Mosca, H. O.; Yacout, A. M.

2011-07-01

Within the RERTR program, previous experimental and modeling studies identified Si as the alloying addition to the Al cladding responsible for inhibiting Al interdiffusion in the UMo fuel. However, difficulties with reprocessing have rendered this choice inappropriate, leading to the need to study alternative elements. In this work, we discuss the results of an atomistic modeling effort which allows for the systematic study of several possible alloying additions. Based on the behavior observed in the phase diagrams, beryllium or bismuth additions suggest themselves as possible options to replace Si. The results of temperature-dependent simulations using the Bozzolo-Ferrante-Smith (BFS) method for the energetics for varying concentrations of either element are shown, indicating that Be could have a substantial effect in stopping Al interdiffusion, while Bi does not. Details of the calculations and the dependence of the role of each alloying addition as a function of temperature and concentration (of beryllium or bismuth in Al) are shown.

Fast, quantitative, and nondestructive evaluation of hydrided LWR fuel cladding by small angle incoherent neutron scattering of hydrogen

DOE PAGES

Yan, Y.; Qian, S.; Littrell, K.; ...

2015-02-13

A non-destructive neutron scattering method to precisely measure the uptake of hydrogen and the distribution of hydride precipitates in light water reactor (LWR) fuel cladding was developed. Zircaloy-4 cladding used in commercial LWRs was used to produce hydrided specimens. The hydriding apparatus consists of a closed stainless steel vessel that contains Zr alloy specimens and hydrogen gas. Following hydrogen charging, the hydrogen content of the hydrided specimens was measured using the vacuum hot extraction method, by which the samples with desired hydrogen concentration were selected for the neutron study. Optical microscopy shows that our hydriding procedure results in uniform distributionmore » of circumferential hydrides across the wall. Small angle neutron incoherent scattering was performed in the High Flux Isotope Reactor at Oak Ridge National Laboratory. This study demonstrates that the hydrogen in commercial Zircaloy-4 cladding can be measured very accurately in minutes by this nondestructive method over a wide range of hydrogen concentrations from a very small amount ( 20 ppm) to over 1000 ppm. The hydrogen distribution in a tube sample was obtained by scaling the neutron scattering rate with a factor determined by a calibration process using standard, destructive direct chemical analysis methods on the specimens. This scale factor will be used in future tests with unknown hydrogen concentrations, thus providing a nondestructive method for absolute hydrogen concentration determination.« less

Pellet cladding mechanical interactions of ceramic claddings fuels under light water reactor conditions

NASA Astrophysics Data System (ADS)

Li, Bo-Shiuan

Ceramic materials such as silicon carbide (SiC) are promising candidate materials for nuclear fuel cladding and are of interest as part of a potential accident tolerant fuel design due to its high temperature strength, dimensional stability under irradiation, corrosion resistance, and lower neutron absorption cross-section. It also offers drastically lower hydrogen generation in loss of coolant accidents such as that experienced at Fukushima. With the implementation of SiC material properties to the fuel performance code, FRAPCON, performances of the SiC-clad fuel are compared with the conventional Zircaloy-clad fuel. Due to negligible creep and high stiffness, SiC-clad fuel allows gap closure at higher burnup and insignificant cladding dimensional change. However, severe degradation of SiC thermal conductivity with neutron irradiation will lead to higher fuel temperature with larger fission gas release. High stiffness of SiC has a drawback of accumulating large interfacial pressure upon pellet-cladding mechanical interactions (PCMI). This large stress will eventually reach the flexural strength of SiC, causing failure of SiC cladding instantly in a brittle manner instead of the graceful failure of ductile metallic cladding. The large interfacial pressure causes phenomena that were previously of only marginal significance and thus ignored (such as creep of the fuel) to now have an important role in PCMI. Consideration of the fuel pellet creep and elastic deformation in PCMI models in FRAPCON provide for an improved understanding of the magnitude of accumulated interfacial pressure. Outward swelling of the pellet is retarded by the inward irradiation-induced creep, which then reduces the rate of interfacial pressure buildup. Effect of PCMI can also be reduced and by increasing gap width and cladding thickness. However, increasing gap width and cladding thickness also increases the overall thermal resistance which leads to higher fuel temperature and larger fission gas release. An optimum design is sought considering both thermal and mechanical models of this ceramic cladding with UO2 and advanced high density fuels.

[Influence of different types of posts and cores on color of IPS-Empress 2 crown].

PubMed

Li, Dong-fang; Yang, Jing-yuan; Yang, Xing-mei; Yang, Liu; Xu, Qiang; Guan, Hong-yu; Wan, Qian-bing

2007-10-01

To evaluate the influence of different types of posts and cores on the final color of the IPS-Emperss 2 crown. Five types of posts and cores (Cerapost with Empress cosmo, Cerapost with composite resin, gilded Ni-Cr alloy, gold alloy and Ni-Cr alloy) were made. The shifts in color of three points of IPS-Empress 2 crown surface (cervical, middle and incisal) with different posts and cores was measured with a spectroradiometer (PR-650). The L* a* b* values of zirconium oxide and gilded Ni-Cr alloy posts and cores with ceramic crown were the highest. The L* a* values of zirconium oxide posts composite cores were higher while the b* values were lower. The L* a* b* values of Ni-Cr alloy were lower than that of gold alloy and were the lowest. In combination with IPS-Empress 2 crown, zirconium oxide posts are suitable for routine use in the anterior dentition, and gilded Ni-Cr alloy and gold alloy posts and cores can be recommended for clinical practice. Ni-Cr alloy posts and cores can not be recommended for clinical practice.

THE ANALYSIS OF URANIUM-ZIRCONIUM ALLOYS

DOE Office of Scientific and Technical Information (OSTI.GOV)

Milner, G.W.C.; Skewies, A.F.

1953-03-01

A satisfactory procedure is described for the analysis of uranium-zirconium alloys containing up to 25% zirconium. It is based on the separation of the zirconium from the uranium by dissolving the cupferron complex of the former element into chloroform. After the evaporation of the solvent from the combined organic extracts, the residue is ignited to zirconium oxide. The latter is then re-dissolved and zirconium is separated from other elements co-extracted in the solvent extraction procedure by precipitation with mandelic acid. The zirconium mandelate is finally ignited to oxide at 960 deg C. The uranium is separated from the aqueous solutionmore » remaining from the cupferron extraction by precipitating with tannin at a pH of 8; the precipitate being removed by filtration and then ignited a t 800 deg C. The residue is dissolved in nitric acid and the uranium is finally determined by precipitating as ammonium diuranate and then igniting to U{sub 3}O{sub 8}. (auth)« less

Effects of Cr Content and Surface Finishes on Oxidation Behaviors of Austenitic Fe-Cr-Ni Alloys Exposed in Supercritical Water (SCW)

NASA Astrophysics Data System (ADS)

Xing, Bo

The scope of this work was to characterize the corrosion resistance of candidate austenitic alloys in supercritical water for the use of the fuel cladding material within the Canadian supercritical water-cooled reactor (SCWR) concept. A series of Commercial austenitic stainless steels (SS) and alloys were exposed to supercritical water for different exposure times up to 500 hours. Two surface finishes were applied - a coarse grinding with 120 grit abrasive or polishing with either 1200 grit or 0.05 microm alumina suspension. Gravimetric measurements and electron microscopy techniques were used to evaluate the oxidation behaviors of tested alloys. The superior corrosion resistance of alloy 310S was benefited from a critical Cr content of 25 wt.%. The surface finish played a significant role to vary the oxidation behavior of alloys containing slightly less than the critical Cr content. However, Oxide exfoliation was observed on low Cr content alloys.

Database on Performance of Neutron Irradiated FeCrAl Alloys

DOE Office of Scientific and Technical Information (OSTI.GOV)

Field, Kevin G.; Briggs, Samuel A.; Littrell, Ken

The present report summarizes and discusses the database on radiation tolerance for Generation I, Generation II, and commercial FeCrAl alloys. This database has been built upon mechanical testing and microstructural characterization on selected alloys irradiated within the High Flux Isotope Reactor (HFIR) at Oak Ridge National Laboratory (ORNL) up to doses of 13.8 dpa at temperatures ranging from 200°C to 550°C. The structure and performance of these irradiated alloys were characterized using advanced microstructural characterization techniques and mechanical testing. The primary objective of developing this database is to enhance the rapid development of a mechanistic understanding on the radiation tolerancemore » of FeCrAl alloys, thereby enabling informed decisions on the optimization of composition and microstructure of FeCrAl alloys for application as an accident tolerant fuel (ATF) cladding. This report is structured to provide a brief summary of critical results related to the database on radiation tolerance of FeCrAl alloys.« less

ELECTROLYTIC CLADDING OF ZIRCONIUM ON URANIUM

DOEpatents

Wick, J.J.

1959-09-22

A method is presented for coating uranium with zircoalum by rendering the uranium surface smooth and oxidefree, immersing it in a molten electrolytic bath in NaCI, K/sub 2/ZrF/sub 6/, KF, and ZrO/sub 2/, and before the article reaches temperature equilibrium with the bath, applying an electrolyzing current of 60 amperes per square dectmeter at approximately 3 volts to form a layer of zirconium metal on the uranium.

About structural phase state of coating based on zirconium oxide formed by microplasma oxidation method

NASA Astrophysics Data System (ADS)

Gubaidulina, Tatiana A.; Sergeev, Viktor P.; Kuzmin, Oleg S.; Fedorischeva, Marina V.; Kalashnikov, Mark P.

2017-12-01

The oxide-ceramic coating based of zirconium oxide is formed by the method of microplasma oxidation. The producing modes of the oxide layers on E110 zirconium alloy are under testing. It was found that using microplasma treatment of E110 zirconium in aluminosilicate electrolyte makes possible the formation of porous oxide-ceramic coatings based on zirconium alloyed by aluminum and niobium. The study is focused on the modes how to form heat-shielding coatings with controlled porosity and minimal amount of microcracks. The structural-phase state of the coating is studied by X-ray diffraction analysis and scanning electron microscopy (SEM). It was found that the ratio of the monoclinic and tetragonal phases changes with the change occurring in the coating formation modes.

Interfacial Characterization of Dissimilar Joints Between Al/Mg/Al-Trilayered Clad Sheet to High-Strength Low-Alloy Steel

NASA Astrophysics Data System (ADS)

Macwan, A.; Jiang, X. Q.; Chen, D. L.

2015-07-01

Magnesium (Mg) alloys are increasingly used in the automotive and aerospace sectors to reduce vehicle weight. Al/Mg/Al tri-layered clad sheets are deemed as a promising alternative to improve the corrosion resistance and formability of Mg alloys. The structural application of Al/Mg/Al tri-layered clad sheets inevitably involves welding and joining in the multi-material vehicle body manufacturing. This study aimed to characterize the bonding interface microstructure of the Al/Mg/Al-clad sheet to high-strength low-alloy steel with and without Zn coating using ultrasonic spot welding at different levels of welding energy. It was observed that the presence of Zn coating improved the bonding at the interface due to the formation of Al-Zn eutectic structure via enhanced diffusion. At a higher level of welding energy, characteristic flow patterns of Zn into Al-clad layer were observed with an extensive penetration mainly along some high angle grain boundaries. The dissimilar joints without Zn coating made at a high welding energy of 800 J failed partially from the Al/Fe weld interface and partially from the Al/Mg clad interface, while the joints with Zn coating failed from the Al/Mg clad interface due to the presence of brittle Al12Mg17 phase.

Effect of Heat Treatment on Borides Precipitation and Mechanical Properties of CoCrFeNiAl1.8Cu0.7B0.3Si0.1 High-Entropy Alloy Prepared by Arc-Melting and Laser-Cladding

NASA Astrophysics Data System (ADS)

Zhang, H.; Tang, H.; He, Y. Z.; Zhang, J. L.; Li, W. H.; Guo, S.

2017-11-01

Effects of heat treatment on borides precipitation and mechanical properties of arc-melted and laser-cladded CoCrNiFeAl1.8Cu0.7B0.3Si0.1 high-entropy alloys were comparatively studied. The arc-melted alloy contains lots of long strip borides distributed in the body-centered cubic phase, with a hardness about 643 HV0.5. Laser-cladding can effectively inhibit the boride precipitation and the laser-cladded alloy is mainly composed of a simple bcc solid solution, with a high hardness about 769 HV0.5, indicating the strengthening effect by interstitial boron atoms is greater than the strengthening by borides precipitation. Heat treatments between 800°C and 1200°C can simultaneously improve the hardness and fracture toughness of arc-melted alloys, owing to the boride spheroidization, dissolution, re-precipitation, and hence the increased boron solubility and nano-precipitation in the bcc solid solution. By contrast, the hardness of laser-cladded alloys reduce after heat treatments in the same temperature range, due to the decreased boron solubility in the matrix.

Novel twin-roll-cast Ti/Al clad sheets with excellent tensile properties.

PubMed

Kim, Dae Woong; Lee, Dong Ho; Kim, Jung-Su; Sohn, Seok Su; Kim, Hyoung Seop; Lee, Sunghak

2017-08-14

Pure Ti or Ti alloys are recently spot-lighted in construction industries because they have excellent resistance to corrosions, chemicals, and climates as well as various coloring characteristics, but their wide applications are postponed by their expensiveness and poor formability. We present a new fabrication process of Ti/Al clad sheets by bonding a thin Ti sheet on to a 5052 Al alloy melt during vertical-twin-roll casting. This process has merits of reduced production costs as well as improved tensile properties. In the as-twin-roll-cast clad sheet, the homogeneously cast microstructure existed in the Al alloy substrate side, while the Ti/Al interface did not contain any reaction products, pores, cracks, or lateral delamination, which indicated the successful twin-roll casting. When this sheet was annealed at 350 °C~600 °C, the metallurgical bonding was expanded by interfacial diffusion, thereby leading to improvement in tensile properties over those calculated by a rule of mixtures. The ductility was also improved over that of 5052-O Al alloy (25%) or pure Ti (25%) by synergic effect of homogeneous deformation due to excellent Ti/Al bonding. This work provides new applications of Ti/Al clad sheets to lightweight-alloy clad sheets requiring excellent formability and corrosion resistance as well as alloy cost saving.

Inert matrix fuel in dispersion type fuel elements

NASA Astrophysics Data System (ADS)

Savchenko, A. M.; Vatulin, A. V.; Morozov, A. V.; Sirotin, V. L.; Dobrikova, I. V.; Kulakov, G. V.; Ershov, S. A.; Kostomarov, V. P.; Stelyuk, Y. I.

2006-06-01

The advantages of using inert matrix fuel (IMF) as a dispersion fuel in an aluminium alloy matrix are considered, in particular, low temperatures in the fuel centre, achievable high burn-ups, serviceability in transients and an environmentally friendly process of fuel rod fabrication. Two main versions of IMF are under development at A.A. Bochvar Institute, i.e. heterogeneous or isolated distribution of plutonium. The out-of-pile results on IMF loaded with uranium dioxide as plutonium simulator are presented. Fuel elements with uranium dioxide composition fabricated at A.A. Bochvar Institute are currently under MIR tests (RIAR, Dimitrovgrad). The fuel elements reached a burn-up of 88 MW d kg-1 (equivalent to the burn up of the standard uranium dioxide pelletized fuel) without loss of leak-tightness of the cladding. The feasibility of fabricating IMF of these particular types with plutonium dioxide is considered with a view to in-pile irradiation.

METHOD FOR ANNEALING AND ROLLING ZIRCONIUM-BASE ALLOYS

DOEpatents

Picklesimer, M.L.

1959-07-14

A fabrication procedure is presented for alpha-stabilized zirconium-base alloys, and in particular Zircaloy-2. The alloy is initially worked at a temperature outside the alpha-plus-beta range (810 to 970 deg ), held at a temperature above 970 deg C for 30 minutes and cooled rapidly. The alloy is then cold-worked to reduce the size at least 20% and annealed at a temperature from 700 to 810 deg C. This procedure serves both to prevent the formation of stringers and to provide a randomly oriented crystal structure.

Development of Improved Burnable Poisons for Commercial Nuclear Power Reactors

DOE Office of Scientific and Technical Information (OSTI.GOV)

Renier, J.A.

2002-04-17

Burnable poisons are used in all modern nuclear reactors to permit higher loading of fuel without the necessity of an overly large control rod system. This not only permits a longer core life but can also be used to level the power distribution. Commercial nuclear reactors commonly use B{sub 4}C in separate non-fueled rods and more recently, zirconium boride coatings on the fuel pellets or gadolinium oxide mixed with the fuel. Although the advantages are great, there are problems with using these materials. Boron, which is an effective neutron absorber, transmutes to lithium and helium upon absorption of a neutron.more » Helium is insoluble and is eventually released to the interior of the fuel rod, where it produces an internal pressure. When sufficiently high, this pressure stress could cause separation of the cladding from the fuel, causing overly high centerline temperatures. Gadolinium has several very strongly absorbing isotopes, but not all have large cross sections and result in residual burnable poison reactivity worth at the end of the fuel life. Even if the amount of this residual absorber is small and the penalty in operation small, the cost of this penalty, even if only several days, can be very high. The objective of this investigation was to study the performance of single isotopes in order to reduce the residual negative reactivity left over at the end of the fuel cycle. Since the behavior of burnable poisons can be strongly influenced by their configuration, four forms for the absorbers were studied: homogeneously mixed with the fuel, mixed with only the outer one-third of the fuel pellet, coated on the perimeter of the fuel pellets, and alloyed with the cladding. In addition, the numbers of fuel rods containing burnable poison were chosen as 8, 16, 64, and 104. Other configurations were chosen for a few special cases. An enrichment of 4.5 wt% {sup 235}U was chosen for most cases for study in order to achieve a 4-year fuel cycle. A standard pressurized water reactor fuel core was chosen for the study, and state-of-the-art neutronic reactor core computer codes were used for analysis. Power distribution, fuel burnup, reactivity due to burnable poisons and other fission products, spectrum shift, core reactivity, moderator void coefficients, as well as other parameters were calculated as a function of time and fuel burnup. The results not only showed advantages of separation of burnable poison isotopes but revealed benefits to be achieved by careful selection of the configuration of even naturally occurring elements used as burnable poisons. The savings in terms of additional days of operation is shown in Figure 1, where the savings is plotted for each of six favorable isotopes in the four configurations. The benefit of isotope separation is most dramatic for dysprosium, but even the time savings in the case of gadolinium is several days. For a modern nuclear plant, one day's worth of electricity is worth about one million dollars, so the resulting savings of only a few days is considerable. It is also apparent that the amount of savings depends upon the configuration of the burnable poison.« less

Microstructural Characterization of the U-9.1Mo Fuel/AA6061 Cladding Interface in Friction-Bonded Monolithic Fuel Plates Irradiated in the RERTR-6 Experiment

DOE PAGES

Keiser, Dennis D.; Jue, Jan-Fong; Miller, Brandon; ...

2015-09-03

Low-enrichment (U-235 < 20%) U-Mo monolithic fuel is being developed for use in research and test reactors. The earliest design for this fuel that was investigated via reactor testing was comprised of a nominally U-10Mo fuel foil encased in AA6061 (Al-6061) cladding. For a fuel design to be deemed adequate for final use in a reactor, it must maintain dimensional stability and retain fission products throughout irradiation, which means that there must be good integrity at the fuel foil/cladding interface. To investigate the nature of the fuel/cladding interface for this fuel type after irradiation, fuel plates that were tested inmore » INL's Advanced Test Reactor (ATR) were subsequently characterized using optical metallography, scanning electron microscopy, and transmission electron microscopy. Results of this characterization showed that the fuel/cladding interaction layers present at the U-Mo fuel/AA6061 cladding interface after fabrication became amorphous during irradiation. Up to two main interaction layers, based on composition, could be found at the fuel/cladding interface, depending on location. After irradiation, an Al-rich layer contained very few fission gas bubbles, but did exhibit Xe enrichment near the AA6061 cladding interface. Another layer, which contained more Si, had more observable fission gas bubbles. Adjacent to the AA6061 cladding were Mg-rich precipitates, which was in close proximity to the region where Xe is observed to be enriched. In samples produced using a focused ion beam at the interaction zone/AA6061 cladding interface were possible indications of porosity/debonding, which suggested that the interface in this location is relatively weak.« less

Nuclear reactor fuel element having improved heat transfer

DOEpatents

Garnier, J.E.; Begej, S.; Williford, R.E.; Christensen, J.A.

1982-03-03

A nuclear reactor fuel element having improved heat transfer between fuel material and cladding is described. The element consists of an outer cladding tube divided into an upper fuel section containing a central core of fissionable or mixed fissionable and fertile fuel material, slightly smaller in diameter than the inner surface of the cladding tube and a small lower accumulator section, the cladding tube being which is filled with a low molecular weight gas to transfer heat from fuel material to cladding during irradiation. A plurality of essentially vertical grooves in the fuel section extend downward and communicate with the accumulator section. The radial depth of the grooves is sufficient to provide a thermal gradient between the hot fuel surface and the relatively cooler cladding surface to allow thermal segregation to take place between the low molecular weight heat transfer gas and high molecular weight fission product gases produced by the fuel material during irradiation.

The Effect of Boron and Zirconium on the Structure and Tensile Properties of the Cast Nickel-Based Superalloy ATI 718Plus

NASA Astrophysics Data System (ADS)

Hosseini, Seyed Ali; Abbasi, Seyed Mehdi; Madar, Karim Zangeneh

2018-04-01

The effects of boron and zirconium on cast structure, hardness, and tensile properties of the nickel-based superalloy 718Plus were investigated. For this purpose, five alloys with different contents of boron and zirconium were cast via vacuum induction melting and then purified via vacuum arc remelting. Microstructural analysis by light-optical microscope and scanning electron microscope equipped with energy-dispersive x-ray spectroscopy and phase studies by x-ray diffraction analysis were performed. The results showed that boron and zirconium tend to significantly reduce dendritic arm spacing and increase the amount of Laves, Laves/gamma eutectic, and carbide phases. It was also found that boron led to the formation of B4C and (Cr, Fe, Mo, Ni, Ti)3B2 phases and zirconium led to the formation of intermetallic phases and ZrC carbide. In the presence of boron and zirconium, the hardness and its difference between dendritic branches and inter-dendritic spaces increased by concentrating such phases as Laves in the inter-dendritic spaces. These elements had a negative effect on tensile properties of the alloy, including ductility and strength, mainly because of the increase in the Laves phase. It should be noted that the largest degradation of the tensile properties occurred in the alloys containing the maximum amount of zirconium.

Microstructure and corrosion resistance of TC2 Ti alloy by laser cladding with Ti/TiC/TiB2 powders

NASA Astrophysics Data System (ADS)

Diao, Yunhua; Zhang, Kemin

2015-10-01

In the present work, a TiC/TiB2 composite coating was produced onto a TC2 Ti alloy by laser cladding with Ti/TiC/TiB2 powders. The surface microstructure, phase components and compositions were characterized with methods of optical microscopy (OM), scanning electron microscopy (SEM), X-ray diffractometry (XRD), and energy dispersive spectrometry (EDS). The cladding layer is consisted of Ti, TiC and TiB2. And the surface microhardness was measured. After laser cladding, a maximum hardness of 1100 HV is achieved in the laser cladding surface layer, which is more three times higher than that of the TC2 substrate (∼300 HV). Due to the formation of TiC and TiB2 intermetallic compounds in the alloyed region and grain refinement, the microhardness of coating is higher than TC2 Ti alloy. In this paper, the corrosion property of matrix material and treated samples were both measured in NaCl (3.5 wt%) aqueous solution. From the result we can see that the laser cladding specimens' corrosion property is clearly becoming better than that of the substrate.

Corrosion inhibition of steam generator tubesheet by Alloy 690 cladding in secondary side environments

NASA Astrophysics Data System (ADS)

Hur, Do Haeng; Choi, Myung Sik; Lee, Deok Hyun; Han, Jung Ho; Shim, Hee Sang

2013-11-01

Denting is a phenomenon that a steam generator tube is distorted by a volume expansion of corrosion products of the tube support and tubesheet materials adjacent to the tube. Although denting has been mitigated by a modification of the design and material of the tube support structures, it has been an inevitable concern in the crevice region of the top of tubesheet. This paper provides a new technology to prevent denting by cladding the secondary surface of the tubesheet with a corrosion resistant material. In this study, Alloy 690 material was cladded onto the surface of an SA508 tubesheet to a thickness of about 9 mm. The corrosion rates of the original SA508 tubesheet and the Alloy 690 clad material were measured in acidic and alkaline simulated environments. Using Alloy 690 cladding, the corrosion rate of the tubesheet within a magnetite sludge pile decreased by a factor of 680 in 0.1 M NiCl2 solution at 300 °C, and by a factor of 58 in 2 M NaOH solution at 315 °C. This means that denting can drastically be prevented by cladding the secondary tubesheet surface with corrosion resistant materials.

A neutronics feasibility study for the LEU conversion of Poland's Maria research reactor.

DOE Office of Scientific and Technical Information (OSTI.GOV)

Bretscher, M. M.

1998-10-14

The MARIA reactor is a high-flux multipurpose research reactor which is water-cooled and moderated with both beryllium and water. Standard HEU (80% {sup 235}U)fuel assemblies consist of six concentric fuel tubes of a U-Al alloy clad in aluminum. Although the inventory of HEU (80%) fuel is nearly exhausted, a supply of highly-loaded 36%-enriched fuel assemblies is available at the reactor site. Neutronic equilibrium studies have been made to determine the relative performance of fuels with enrichments of 80%, 36% and 19.7%. These studies indicate that LEU (19.7%) densities of about 2.5 gU/cm{sup 3} and 3.8 gU/cm{sup 3} are required tomore » match the performance of the MARIA reactor with 80%-enriched and with 36%-enriched fuels, respectively.« less

Benefits of barrier fuel on fuel cycle economics

DOE Office of Scientific and Technical Information (OSTI.GOV)

Crowther, R.L.; Kunz, C.L.

1988-01-01

Barrier fuel rod cladding was developed to eliminate fuel rod failures from pellet/cladding stress/corrosion interaction and to eliminate the associated need to restrict the rate at which fuel rod power can be increased. The performance of barrier cladding has been demonstrated through extensive testing and through production application to many boiling water reactors (BWRs). Power reactor data have shown that barrier fuel rod cladding has a significant beneficial effect on plant capacity factor and plant operating costs and significantly increases fuel reliability. Independent of the fuel reliability benefit, it is less obvious that barrier fuel has a beneficial effect ofmore » fuel cycle costs, since barrier cladding is more costly to fabricate. Evaluations, measurements, and development activities, however, have shown that the fuel cycle cost benefits of barrier fuel are large. This paper is a summary of development activities that have shown that application of barrier fuel significantly reduces BWR fuel cycle costs.« less

Microstructural Characterization of the U-9.1Mo Fuel/AA6061 Cladding Interface in Friction-Bonded Monolithic Fuel Plates Irradiated in the RERTR-6 Experiment

NASA Astrophysics Data System (ADS)

Keiser, Dennis D.; Jue, Jan-Fong; Miller, Brandon; Gan, Jian; Robinson, Adam; Medvedev, Pavel; Madden, James; Wachs, Dan; Clark, Curtis; Meyer, Mitch

2015-09-01

Low-enrichment (235U < 20 pct) U-Mo monolithic fuel is being developed for use in research and test reactors. The earliest design for this fuel that was investigated via reactor testing consisted of a nominally U-10Mo fuel foil encased in AA6061 (Al-6061) cladding. For a fuel design to be deemed adequate for final use in a reactor, it must maintain dimensional stability and retain fission products throughout irradiation, which means that there must be good integrity at the fuel foil/cladding interface. To investigate the nature of the fuel/cladding interface for this fuel type after irradiation, fuel plates were fabricated using a friction bonding process, tested in INL's advanced test reactor (ATR), and then subsequently characterized using optical metallography, scanning electron microscopy, and transmission electron microscopy. Results of this characterization showed that the fuel/cladding interaction layers present at the U-Mo fuel/AA6061 cladding interface after fabrication became amorphous during irradiation. Up to two main interaction layers, based on composition, could be found at the fuel/cladding interface, depending on location. After irradiation, an Al-rich layer contained very few fission gas bubbles, but did exhibit Xe enrichment near the AA6061 cladding interface. Another layer, which contained more Si, had more observable fission gas bubbles. In the samples produced using a focused ion beam at the interaction zone/AA6061 cladding interface, possible indications of porosity/debonding were found, which suggested that the interface in this location is relatively weak.

Microstructure and properties of laser-clad high-temperature wear-resistant alloys

NASA Astrophysics Data System (ADS)

Yang, Yongqiang

1999-02-01

A 2-kW CO 2 laser with a powder feeder was used to produce alloy coatings with high temperature-wear resistance on the surface of steel substrates. To analyze the microstructure and microchemical composition of the laser-clad layers, a scanning electron microscope (SEM) equipped with an energy dispersive X-ray microanalysis system was employed. X-ray diffraction techniques were applied to characterize the phases formed during the cladding process. The results show that the microstructure of the cladding alloy consists mainly of many dispersed particles (W 2C, (W,Ti)C 1- x, WC), a lamellar eutectic carbide M 12C, and an (f.c.c) matrix. Hardness tested at room and high temperature showed that the laser-clad zone has a moderate room temperature hardness and relatively higher elevated temperature hardness. The application of the laser-clad layer to a hot tool was very successful, and its operational life span was prolonged 1 to 4 times.

Analysis of the Gas Core Actinide Transmutation Reactor (GCATR)

NASA Technical Reports Server (NTRS)

Clement, J. D.; Rust, J. H.

1977-01-01

Design power plant studies were carried out for two applications of the plasma core reactor: (1) As a breeder reactor, (2) As a reactor able to transmute actinides effectively. In addition to the above applications the reactor produced electrical power with a high efficiency. A reactor subsystem was designed for each of the two applications. For the breeder reactor, neutronics calculations were carried out for a U-233 plasma core with a molten salt breeding blanket. A reactor was designed with a low critical mass (less than a few hundred kilograms U-233) and a breeding ratio of 1.01. The plasma core actinide transmutation reactor was designed to transmute the nuclear waste from conventional LWR's. The spent fuel is reprocessed during which 100% of Np, Am, Cm, and higher actinides are separated from the other components. These actinides are then manufactured as oxides into zirconium clad fuel rods and charged as fuel assemblies in the reflector region of the plasma core actinide transmutation reactor. In the equilibrium cycle, about 7% of the actinides are directly fissioned away, while about 31% are removed by reprocessing.

Effect of Copper and Zirconium Addition on Properties of Fe-Co-Si-B-Nb Bulk Metallic Glasses

NASA Astrophysics Data System (ADS)

Ikram, Haris; Khalid, Fazal Ahmad; Akmal, Muhammad; Abbas, Zameer

2017-07-01

In this research work, iron-based bulk metallic glasses (BMGs) have been fabricated, characterized and compared with Fe-Si alloy. BMG alloys of composition ((Fe0.6Co0.4)0.75B0.20Si0.05)96Nb4) were synthesized by suction casting technique using chilled copper die. Effect of copper and zirconium addition on magnetic, mechanical, thermal and electrochemical behavior of ((Fe0.6Co0.4)0.75B0.20Si0.05)96Nb4 BMGs was investigated. Furthermore, effect of annealing on nano-crystallization and subsequently on magnetic and mechanical behavior was also analyzed. Amorphousness of structure was evidenced by XRD analysis and microscopic visualization, whereas nano-crystallization behavior was identified by peak broadening of XRD patterns. Magnetic properties, measured by vibrating sample magnetometer, were found to be improved for as-cast BMG alloys by copper addition and further enhanced by nano-crystallization after annealing. Mechanical properties were observed to be increased by zirconium addition while slightly declined by copper addition. Potentiodynamic polarization analysis manifested the positive role of zirconium in enhancing corrosion resistance of BMGs in acidic, basic and brine mediums. Moreover, mechanical properties and corrosion analysis results affirmed the superiority of BMG alloys over Fe-Si alloy.

Survey of Thermal-Fluids Evaluation and Confirmatory Experimental Validation Requirements of Accident Tolerant Cladding Concepts with Focus on Boiling Heat Transfer Characteristics

DOE Office of Scientific and Technical Information (OSTI.GOV)

Brown, Nicholas R.; Wysocki, Aaron J.; Terrani, Kurt A.

The U.S. Department of Energy Office of Nuclear Energy (DOE-NE) Advanced Fuels Campaign (AFC) is working closely with the nuclear industry to develop fuel and cladding candidates with potentially enhanced accident tolerance, also known as accident tolerant fuel (ATF). Thermal-fluids characteristics are a vital element of a holistic engineering evaluation of ATF concepts. One vital characteristic related to boiling heat transfer is the critical heat flux (CHF). CHF plays a vital role in determining safety margins during normal operation and also in the progression of potential transient or accident scenarios. This deliverable is a scoping survey of thermal-fluids evaluation andmore » confirmatory experimental validation requirements of accident tolerant cladding concepts with a focus on boiling heat transfer characteristics. The key takeaway messages of this report are: 1. CHF prediction accuracy is important and the correlations may have significant uncertainty. 2. Surface conditions are important factors for CHF, primarily the wettability that is characterized by contact angle. Smaller contact angle indicates greater wettability, which increases the CHF. Surface roughness also impacts wettability. Results in the literature for pool boiling experiments indicate changes in CHF by up to 60% for several ATF cladding candidates. 3. The measured wettability of FeCrAl (i.e., contact angle and roughness) indicates that CHF should be investigated further through pool boiling and flow boiling experiments. 4. Initial measurements of static advancing contact angle and surface roughness indicate that FeCrAl is expected to have a higher CHF than Zircaloy. The measured contact angle of different FeCrAl alloy samples depends on oxide layer thickness and composition. The static advancing contact angle tends to decrease as the oxide layer thickness increases.« less

Microstructure and abrasive wear properties of Fe-Cr-C hardfacing alloy cladding manufactured by Gas Tungsten Arc Welding (GTAW)

NASA Astrophysics Data System (ADS)

Chen, Jie-Hao; Hsieh, Chih-Chun; Hua, Pei-Shing; Chang, Chia-Ming; Lin, Chi-Ming; Wu, Paxon Ti-Yuan; Wu, Weite

2013-01-01

A series of Fe-Cr-C hardfacing alloys is deposited by gas tungsten arc welding and subjected to abrasive wear testing. Pure Fe with various amounts of CrC (Cr:C=4:1) powders are mixed as the fillers and used to deposit hardfacing alloys on low carbon steel. Depending on the various CrC additions to the alloy fillers, the claddings mainly contain hypoeutectic, near eutectic, or hypereutectic microstructures of austenite γ-Fe phase and (Cr,Fe)7C3 carbides on hardfacing alloys, respectively. When 30% CrC is added to the filler, the finest microstructure is achieved, which corresponds to the γ-Fe+(Cr,Fe)7C3 eutectic structure. With the addition of 35% and 40% CrC to the fillers, the results show that the cladding consists of the massive primary (Cr,Fe)7C3 as the reinforcing phase and interdendritic γ-Fe+(Cr,Fe)7C3 eutectics as the matrix. The (Cr,Fe)7C3 carbide-reinforced claddings have high hardness and excellent wear resistance under abrasive wear test conditions. Concerning the abrasive wear feature observable on the worn surface, the formation and fraction of massive primary (Cr,Fe)7C3 carbides predominates the wear resistance of hardfacing alloys. Abrasive particles result in continuous plastic grooves when the cladding has primary γ-Fe phase in a hypoeutectic structure.

Zirconium determination by cooling curve analysis during the pyroprocessing of used nuclear fuel

NASA Astrophysics Data System (ADS)

Westphal, B. R.; Price, J. C.; Bateman, K. J.; Marsden, K. C.

2015-02-01

An alternative method to sampling and chemical analyses has been developed to monitor the concentration of zirconium in real-time during the casting of uranium products from the pyroprocessing of used nuclear fuel. The method utilizes the solidification characteristics of the uranium products to determine zirconium levels based on standard cooling curve analyses and established binary phase diagram data. Numerous uranium products have been analyzed for their zirconium content and compared against measured zirconium data. From this data, the following equation was derived for the zirconium content of uranium products:

Engineered Zircaloy Cladding Modifications for Improved Accident Tolerance of LWR Nuclear Fuel

DOE Office of Scientific and Technical Information (OSTI.GOV)

Heuser, Brent; Stubbins, James; Kozlowski, Tomasz

The DOE NEUP sponsored IRP on accident tolerant fuel (ATF) entitled Engineered Zircaloy Cladding Modifications for Improved Accident Tolerance of LWR Nuclear Fuel involved three academic institutions, Idaho National Laboratory (INL), and ATI Materials (ATI). Detailed descriptions of the work at the University of Illinois (UIUC, prime), the University of Florida (UF), the University of Michigan (UMich), and INL are included in this document as separate sections. This summary provides a synopsis of the work performed across the IRP team. Two ATF solution pathways were initially proposed, coatings on monolithic Zr-based LWR cladding material and selfhealing modifications of Zr-based alloys.more » The coating pathway was extensively investigated, both experimentally and in computations. Experimental activities related to ATF coatings were centered at UIUC, UF, and UMich and involved coating development and testing, and ion irradiation. Neutronic and thermal hydraulic aspects of ATF coatings were the focus of computational work at UIUC and UMich, while materials science aspects were the focus of computational work at UF and INL. ATI provided monolithic Zircaloy 2 and 4 material and a binary Zr-Y alloy material. The selfhealing pathway was investigated with advanced computations only. Beryllium was identified as a valid self-healing additive early in this work. However, all attempts to fabricate a Zr-Be alloy failed. Several avenues of fabrication were explored. ATI ultimately declined our fabrication request over health concerns associated with Be (we note that Be was not part of the original work scope and the ATI SOW). Likewise, Ames Laboratory declined our fabrication request, citing known litigation dating to the 1980s and 1990s involving the U.S. Federal government and U.S. National Laboratory employees involving the use of Be. Materion (formerly, Brush Wellman) also declined our fabrication request, citing the difficulty in working with a highly reactive Zr and Be. International fabrication options were explored in Europe and Asia, but this proved to be impractical, if not impossible. Consequently, experimental investigation of the Zr-Be binary system was dropped and exploration binary Zr-Y binary system was initiated. The motivation behind the Zr-Y system is the known thermodynamic stability of yttria over zirconia.« less

Filler wire for aluminum alloys and method of welding

NASA Technical Reports Server (NTRS)

Bjorkman, Jr., Gerald W. O. (Inventor); Cho, Alex (Inventor); Russell, Carolyn K. (Inventor)

2003-01-01

A weld filler wire chemistry has been developed for fusion welding 2195 aluminum-lithium. The weld filler wire chemistry is an aluminum-copper based alloy containing high additions of titanium and zirconium. The additions of titanium and zirconium reduce the crack susceptibility of aluminum alloy welds while producing good weld mechanical properties. The addition of silver further improves the weld properties of the weld filler wire. The reduced weld crack susceptibility enhances the repair weldability, including when planishing is required.

Interdiffusion and reactions between U-Mo and Zr at 650 °C as a function of time

NASA Astrophysics Data System (ADS)

Park, Y.; Keiser, D. D.; Sohn, Y. H.

2015-01-01

Development of monolithic U-Mo alloy fuel (typically U-10 wt.%Mo) for the Reduced Enrichment for Research and Test Reactors (RERTR) program entails a use of Zr diffusion barrier to eliminate the interdiffusion-reactions between the fuel alloy and Al-alloy cladding. The application of Zr barrier to the U-Mo fuel system requires a co-rolling process that utilizes a soaking temperature of 650 °C, which represents the highest temperature the fuel system is exposed to during both fuel manufacturing and reactor application. Therefore, in this study, development of phase constituents, microstructure and diffusion kinetics of U-10 wt.%Mo and Zr was examined using solid-to-solid diffusion couples annealed at 650 °C for 240, 480 and 720 h. Phase constituents and microstructural development were analyzed by scanning electron microscopy (SEM) and transmission electron microscopy (TEM). Concentration profiles were mapped as diffusion paths on the isothermal ternary phase diagram. Within the diffusion zone, single-phase layers of β-Zr and β-U were observed along with a discontinuous layer of Mo2Zr between the β-Zr and β-U layers. In the vicinity of Mo2Zr phase, islands of α-Zr phases were also found. In addition, acicular α-Zr and U6Zr3Mo phases were observed within the γ-U(Mo) terminal alloy. Growth rate of the interdiffusion-reaction zone was determined to be 7.75 (± 5.84) × 10-16 m2/s at 650 °C, however with an assumption of a certain incubation period.

Calculations of hydrogen diffusivity in Zr-based alloys: Influence of alloying elements and effect of stress

DOE Office of Scientific and Technical Information (OSTI.GOV)

Yu, J.; Jiang, C.; Zhang, Y.

This report summarizes the progress on modeling hydrogen diffusivity in Zr-based alloys. The presence of hydrogen (H) can detrimentally affect the mechanical properties of many metals and alloys. To mitigate these detrimental effects requires fundamental understanding of the thermodynamics and kinetics governing H pickup and hydride formation. In this work, we focus on H diffusion in Zr-based alloys by studying the effects of alloying elements and stress, factors that have been shown to strongly affect H pickup and hydride formation in nuclear fuel claddings. A recently developed accelerated kinetic Monte Carlo method is used for the study. It is foundmore » that for the alloys considered here, H diffusivity depends weakly on composition, with negligible effect at high temperatures in the range of 600-1200 K. Therefore, the small variation in compositions of these alloys is likely not a major cause of the very different H pickup rates. In contrast, stress strongly affects H diffusivity. This effect needs to be considered for studying hydride formation and delayed hydride cracking.« less

Joining of Zirconium Diboride-Based Ceramic Composites to Metallic Systems for High-Temperature Applications

NASA Technical Reports Server (NTRS)

Asthana, R.; Singh, M.

2008-01-01

Three types of hot-pressed zirconium diboride (ZrB2)-based ultra-high-temperature ceramic composites (UHTCC), ZrB2-SiC (ZS), ZrB2-SiC-C (ZSC), and ZrB2-SCS9-SiC (ZSS), were joined to Cu-clad-Mo using two Ag-Cu brazes (Cusil-ABA and Ticusil, T(sub L) approx.1073-1173 K) and two Pd-base brazes (Palco and Palni, T(sub L) approx.1493-1513 K). Scanning Electron Microscopy (SEM) coupled with energy-dispersive spectroscopy (EDS) revealed greater chemical interaction in joints made using Pd-base brazes than in joints made using Ag-Cu based active brazes. The degree of densification achieved in hot pressed composites influenced the Knoop hardness of the UHTCC and the hardness distribution across the braze interlayer. The braze region in Pd-base system displayed higher hardness in joints made using fully-dense ZS composites than in joints made using partially-dense ZSS composites and the carbon-containing ZSC composites. Calculations indicate a small negative elastic strain energy and an increase in the UHTCC's fracture stress up to a critical clad layer thickness . Above this critical thickness, strain energy in the UHTCC is positive, and it increases with increasing clad layer thickness. Empirical projections show a reduction in the effective thermal resistance of the joints and highlight the potential benefits of joining the UHTCC to Cu-clad-Mo.

Microstructure and wear resistance of laser cladded Ni-Cr-Co-Ti-V high-entropy alloy coating after laser remelting processing

NASA Astrophysics Data System (ADS)

Cai, Zhaobing; Cui, Xiufang; Liu, Zhe; Li, Yang; Dong, Meiling; Jin, Guo

2018-02-01

An attempt, combined with the technologies of laser cladding and laser remelting, has been made to develop a Ni-Cr-Co-Ti-V high entropy alloy coating. The phase composition, microstructure, micro-hardness and wear resistance (rolling friction) were studied in detail. The results show that after laser remelting, the phase composition remains unchanged, that is, as-cladded coating and as-remelted coatings are all composed of (Ni, Co)Ti2 intermetallic compound, Ti-rich phase and BCC solid solution phase. However, after laser remelting, the volume fraction of Ti-rich phase increases significantly. Moreover, the micro-hardness is increased, up to ∼900 HV at the laser remelting parameters: laser power of 1 kW, laser spot diameter of 3 mm, and laser speed of 10 mm/s. Compared to the as-cladded high-entropy alloy coating, the as-remelted high-entropy alloy coatings have high friction coefficient and low wear mass loss, indicating that the wear resistance of as-remelted coatings is improved and suggesting practical applications, like coatings on brake pads for wear protection. The worn surface morphologies show that the worn mechanism of as-cladded and as-remelted high-entropy alloy coatings are adhesive wear.

Mechanical properties of zirconium alloys and zirconium hydrides predicted from density functional perturbation theory

DOE PAGES

Weck, Philippe F.; Kim, Eunja; Tikare, Veena; ...

2015-10-13

Here, the elastic properties and mechanical stability of zirconium alloys and zirconium hydrides have been investigated within the framework of density functional perturbation theory. Results show that the lowest-energy cubic Pn-3m with combining macron]m polymorph of δ-ZrH 1.5 does not satisfy all the Born requirements for mechanical stability, unlike its nearly degenerate tetragonal P4 2/ mcm polymorph. Elastic moduli predicted with the Voigt–Reuss–Hill approximations suggest that mechanical stability of α-Zr, Zr-alloy and Zr-hydride polycrystalline aggregates is limited by the shear modulus. According to both Pugh's and Poisson's ratios, α-Zr, Zr-alloy and Zr-hydride polycrystalline aggregates can be considered ductile. The Debyemore » temperatures predicted for γ-ZrH, δ-ZrH 1.5 and ε-ZrH 2 are θ D = 299.7, 415.6 and 356.9 K, respectively, while θ D = 273.6, 284.2, 264.1 and 257.1 K for the α-Zr, Zry-4, ZIRLO and M5 matrices, i.e. suggesting that Zry-4 possesses the highest micro-hardness among Zr matrices.« less

Laser cladding of stainless steel with a copper-silver alloy to generate surfaces of high antimicrobial activity

NASA Astrophysics Data System (ADS)

Hans, Michael; Támara, Juan Carlos; Mathews, Salima; Bax, Benjamin; Hegetschweiler, Andreas; Kautenburger, Ralf; Solioz, Marc; Mücklich, Frank

2014-11-01

Copper and silver are used as antimicrobial agents in the healthcare sector in an effort to curb infections caused by bacteria resistant to multiple antibiotics. While the bactericidal potential of copper and silver alone are well documented, not much is known about the antimicrobial properties of copper-silver alloys. This study focuses on the antibacterial activity and material aspects of a copper-silver model alloy with 10 wt% Ag. The alloy was generated as a coating with controlled intermixing of copper and silver on stainless steel by a laser cladding process. The microstructure of the clad was found to be two-phased and in thermal equilibrium with minor Cu2O inclusions. Ion release and killing of Escherichia coli under wet conditions were assessed with the alloy, pure silver, pure copper and stainless steel. It was found that the copper-silver alloy, compared to the pure elements, exhibited enhanced killing of E. coli, which correlated with an up to 28-fold increased release of copper ions. The results show that laser cladding with copper and silver allows the generation of surfaces with enhanced antimicrobial properties. The process is particularly attractive since it can be applied to existing surfaces.

Electrical heating tests of uranium dioxide external fuel configuration at emitter temperature of 1900 K

NASA Technical Reports Server (NTRS)

Diianni, D. C.; Mayer, J. T.

1974-01-01

Testing of two fuel clad specimens for thermionic reactor application is described. The annular UO2 fuel was clad on both sides with tungsten; heat rejection was radially inward. The tests were intended to study inner clad stability, fuel redistribution, and fuel melting problems. The specimens were tested in a vacuum chamber using electron bombardment heating. Fuel structural changes were studied using periodic gammagraphs and posttest metallography. The first specimen test was terminated at 50 hours because of a braze failure. The second specimen was tested for 240 hours when an outer clad leak developed due to a tungsten-water reaction. The fuel developed numerous cracks on cooldown but the inner clad remained dimensionally stable. The fuel cover gas did not impede the rate of fuel redistribution. Posttest examination showed the fuel had not melted during operation.

Laser Cladding of Ultra-Thin Nickel-Based Superalloy Sheets.

PubMed

Gabriel, Tobias; Rommel, Daniel; Scherm, Florian; Gorywoda, Marek; Glatzel, Uwe

2017-03-10

Laser cladding is a well-established process to apply coatings on metals. However, on substrates considerably thinner than 1 mm it is only rarely described in the literature. In this work 200 µm thin sheets of nickel-based superalloy 718 are coated with a powder of a cobalt-based alloy, Co-28Cr-9W-1.5Si, by laser cladding. The process window is very narrow, therefore, a precisely controlled Yb fiber laser was used. To minimize the input of energy into the substrate, lines were deposited by setting single overlapping points. In a design of experiments (DoE) study, the process parameters of laser power, laser spot area, step size, exposure time, and solidification time were varied and optimized by examining the clad width, weld penetration, and alloying depth. The microstructure of the samples was investigated by optical microscope (OM) and scanning electron microscopy (SEM), combined with electron backscatter diffraction (EBSD) and energy dispersive X-ray spectroscopy (EDX). Similarly to laser cladding of thicker substrates, the laser power shows the highest influence on the resulting clad. With a higher laser power, the clad width and alloying depth increase, and with a larger laser spot area the weld penetration decreases. If the process parameters are controlled precisely, laser cladding of such thin sheets is manageable.

Laser Cladding of Ultra-Thin Nickel-Based Superalloy Sheets

PubMed Central

Gabriel, Tobias; Rommel, Daniel; Scherm, Florian; Gorywoda, Marek; Glatzel, Uwe

2017-01-01

Laser cladding is a well-established process to apply coatings on metals. However, on substrates considerably thinner than 1 mm it is only rarely described in the literature. In this work 200 µm thin sheets of nickel-based superalloy 718 are coated with a powder of a cobalt-based alloy, Co–28Cr–9W–1.5Si, by laser cladding. The process window is very narrow, therefore, a precisely controlled Yb fiber laser was used. To minimize the input of energy into the substrate, lines were deposited by setting single overlapping points. In a design of experiments (DoE) study, the process parameters of laser power, laser spot area, step size, exposure time, and solidification time were varied and optimized by examining the clad width, weld penetration, and alloying depth. The microstructure of the samples was investigated by optical microscope (OM) and scanning electron microscopy (SEM), combined with electron backscatter diffraction (EBSD) and energy dispersive X-ray spectroscopy (EDX). Similarly to laser cladding of thicker substrates, the laser power shows the highest influence on the resulting clad. With a higher laser power, the clad width and alloying depth increase, and with a larger laser spot area the weld penetration decreases. If the process parameters are controlled precisely, laser cladding of such thin sheets is manageable. PMID:28772639

Demonstration of fuel resistant to pellet-cladding interaction. Phase I. Final report

DOE Office of Scientific and Technical Information (OSTI.GOV)

Rosenbaum, H.S.

1979-03-01

This program has as its ultimate objective the demonstration of an advanced fuel design that is resistant to the failure mechanism known as fuel pellet-cladding interaction (PCI). Two fuel concepts are being developed for possible demonstration within this program: (a) Cu-barrier fuel, and (b) Zr-liner fuel. These advanced fuels (known collectively as barrier fuels) have special fuel cladding designed to protect the Zircaloy cladding tube from the harmful effects of localized stress, and reactive fission products during reactor service. This is the final report for PHASE 1 of this program. Support tests have shown that the barrier fuel resists PCImore » far better than does the conventional Zircaloy-clad fuel. Power ramp tests thus far have shown good PCI resistance for Cu-barrier fuel at burnup > 12 MWd/kg-U and for Zr-liner fuel > 16 MWd/kg-U. The program calls for continued testing to still higher burnup levels in PHASE 2.« less

High-temperature Chemical Compatibility of As-fabricated TRIGA Fuel and Type 304 Stainless Steel Cladding

DOE Office of Scientific and Technical Information (OSTI.GOV)

Dennis D. Keiser, Jr.; Jan-Fong Jue; Eric Woolstenhulme

2012-09-01

Chemical interaction between TRIGA fuel and Type-304 stainless steel cladding at relatively high temperatures is of interest from the point of view of understanding fuel behavior during different TRIGA reactor transient scenarios. Since TRIGA fuel comes into close contact with the cladding during irradiation, there is an opportunity for interdiffusion between the U in the fuel and the Fe in the cladding to form an interaction zone that contains U-Fe phases. Based on the equilibrium U-Fe phase diagram, a eutectic can develop at a composition between the U6Fe and UFe2 phases. This eutectic composition can become a liquid at aroundmore » 725°C. From the standpoint of safe operation of TRIGA fuel, it is of interest to develop better understanding of how a phase with this composition may develop in irradiated TRIGA fuel at relatively high temperatures. One technique for investigating the development of a eutectic phase at the fuel/cladding interface is to perform out-of-pile diffusion-couple experiments at relatively high temperatures. This information is most relevant for lightly irradiated fuel that just starts to touch the cladding due to fuel swelling. Similar testing using fuel irradiated to different fission densities should be tested in a similar fashion to generate data more relevant to more heavily irradiated fuel. This report describes the results for TRIGA fuel/Type-304 stainless steel diffusion couples that were annealed for one hour at 730 and 800°C. Scanning electron microscopy with energy- and wavelength-dispersive spectroscopy was employed to characterize the fuel/cladding interface for each diffusion couple to look for evidence of any chemical interaction. Overall, negligible fuel/cladding interaction was observed for each diffusion couple.« less

Input Correlations for Irradiation Creep of FeCrAl and SiC Based on In-Pile Halden Test Results

DOE Office of Scientific and Technical Information (OSTI.GOV)

Terrani, K. A.; Karlsen, T. M.; Yamamoto, Yukinori

2016-05-01

Swelling and creep behavior of wrought FeCrAl alloys and CVD-SiC, two candidate accident tolerant fuel cladding materials, are being examined using in-pile tests at the Halden reactor. The outcome of these tests are material property correlations that are inputs into fuel performance analysis tools. The results are discussed and compared with what is available in literature from irradiation experiments in other reactors or out-of-pile tests. Specific recommendation on what correlations should be used for swelling, thermal, and irradiation creep for each material are provided in this document.

Microstructure and high temperature oxidation resistance of Ti-Ni gradient coating on TA2 titanium alloy fabricated by laser cladding

NASA Astrophysics Data System (ADS)

Liu, Fencheng; Mao, Yuqing; Lin, Xin; Zhou, Baosheng; Qian, Tao

2016-09-01

To improve the high temperature oxidation resistance of TA2 titanium alloy, a gradient Ni-Ti coating was laser cladded on the surface of the TA2 titanium alloy substrate, and the microstructure and oxidation behavior of the laser cladded coating were investigated experimentally. The gradient coating with a thickness of about 420-490 μm contains two different layers, e.g. a bright layer with coarse equiaxed grain and a dark layer with fine and columnar dendrites, and a transition layer with a thickness of about 10 μm exists between the substrate and the cladded coating. NiTi, NiTi2 and Ni3Ti intermetallic compounds are the main constructive phases of the laser cladded coating. The appearance of these phases enhances the microhardness, and the dense structure of the coating improves its oxidation resistance. The solidification procedure of the gradient coating is analyzed and different kinds of solidification processes occur due to the heat dissipation during the laser cladding process.

Cyclic furnace oxidation of clad WI-52 systems at 1040 C and 1090 C

NASA Technical Reports Server (NTRS)

Gedwill, M. A.

1972-01-01

Cyclic furnace oxidation studies were conducted on the cobalt alloy WI-52 clad with Ni-30Cr, Fe-25Cr-4A1, and Ni-20Cr-4A1 foils (0.051 to 0.254 mm thick). Tests as long as 400 hours using 1- and 20-hour cycles showed that the Ni-Cr- and Fe-Cr-A1 claddings were about equally protective at both temperatures. The protective ability of these alloys was influenced by exposure temperature and cladding thickness. At both temperatures, they protected WI-52 about as well as, or better than, a widely used commercial aluminide coating. The Ni-Cr-Al claddings did not protect WI-52 nearly as well. Interdiffusion generally influenced the oxidation behavior of all clad WI-52 systems.

Effects of Laves phase particles on recovery and recrystallization behaviors of Nb-containing FeCrAl alloys

DOE PAGES

Sun, Zhiqian; Edmondson, Philip D.; Yamamoto, Yukinori

2017-11-15

The microstructures and mechanical properties of deformed and annealed Nb-containing FeCrAl alloys were investigated. Fine dispersion of Fe 2Nb-type Laves phase particles was observed in the bcc-Fe matrix after applying a thermomechanical treatment, especially along grain/subgrain boundaries, which effectively stabilized the recovered and recrystallized microstructures compared with the Nb-free FeCrAl alloy. The stability of recovered areas increased with Nb content up to 1 wt%. The recrystallized grain structure in Nb-containing FeCrAl alloys consisted of elongated grains along the rolling direction with a weak texture when annealed below 1100 °C. An abnormal relationship between recrystallized grain size and annealing temperature wasmore » found. Microstructural inhomogeneity in the deformed and annealed states was explained based on the Taylor factor. Annealed Nb-containing FeCrAl alloys showed a good combination of strength and ductility, which is desirable for their application as fuel cladding in light-water reactors.« less

Dislocation loop formation in model FeCrAl alloys after neutron irradiation below 1 dpa

DOE PAGES

Field, Kevin G.; Briggs, Samuel A.; Sridharan, Kumar; ...

2017-08-01

FeCrAl alloys with varying compositions and microstructures are under consideration for accident-tolerant fuel cladding, but limited details exist on dislocation loop formation and growth for this class of alloys under neutron irradiation. Four model FeCrAl alloys with chromium contents ranging from 10.01 to 17.51 wt % and alunimum contents of 4.78 to 2.93 wt % were neutron irradiated to doses of 0.3–0.8 displacements per atom (dpa) at temperatures of 335–355°C. On-zone STEM imaging revealed a mixed population of black dots and larger dislocation loops with either a/2< 111 > or a< 100 > Burgers vectors. Weak composition dependencies were observedmore » and varied depending on whether the defect size, number density, or ratio of defect types was of interest. Here, the results were found to mirror those of previous studies on FeCrAl and FeCr alloys irradiated under similar conditions, although distinct differences exist.« less

Dislocation loop formation in model FeCrAl alloys after neutron irradiation below 1 dpa

NASA Astrophysics Data System (ADS)

Field, Kevin G.; Briggs, Samuel A.; Sridharan, Kumar; Yamamoto, Yukinori; Howard, Richard H.

2017-11-01

FeCrAl alloys with varying compositions and microstructures are under consideration for accident-tolerant fuel cladding, but limited details exist on dislocation loop formation and growth for this class of alloys under neutron irradiation. Four model FeCrAl alloys with chromium contents ranging from 10.01 to 17.51 wt % and aluminum contents of 4.78 to 2.93 wt % were neutron irradiated to doses of 0.3-0.8 displacements per atom (dpa) at temperatures of 335-355 °C. On-zone STEM imaging revealed a mixed population of black dots and larger dislocation loops with either a / 2 〈 111 〉 or a 〈 100 〉 Burgers vectors. Weak composition dependencies were observed and varied depending on whether the defect size, number density, or ratio of defect types was of interest. Results were found to mirror those of previous studies on FeCrAl and FeCr alloys irradiated under similar conditions, although distinct differences exist.

Viability of thin wall tube forming of ATF FeCrAl

DOE Office of Scientific and Technical Information (OSTI.GOV)

Maloy, Stuart Andrew; Aydogan, Eda; Anderoglu, Osman

Fabrication of thin walled tubing of FeCrAl alloys is critical to its success as a candidate enhanced accident-tolerant fuel cladding material. Alloys that are being investigated are Generation I and Generation II FeCrAl alloys produced at ORNL and an ODS FeCrAl alloy, MA-956 produced by Special Metals. Gen I and Gen II FeCrAl alloys were provided by ORNL and MA-956 was provided by LANL (initially produced by Special Metals). Three tube development efforts were undertaken. ORNL led the FeCrAl Gen I and Gen II alloy development and tube processing studies through drawing tubes at Rhenium Corporation. LANL received alloys frommore » ORNL and led tube processing studies through drawing tubes at Century Tubing. PNNL led the development of tube processing studies on MA-956 through pilger processing working with Sandvik Corporation. A summary of the recent progress on tube development is provided in the following report and a separate ORNL report: ORNL/TM-2015/478, “Development and Quality Assessments of Commercial Heat Production of ATF FeCrAl Tubes”.« less

High Temperature Steam Corrosion of Cladding for Nuclear Applications: Experimental

DOE Office of Scientific and Technical Information (OSTI.GOV)

McHugh, Kevin M; Garnier, John E; Sergey Rashkeev

2013-01-01

Stability of cladding materials under off-normal conditions is an important issue for the safe operation of light water nuclear reactors. Metals, ceramics, and metal/ceramic composites are being investigated as substitutes for traditional zirconium-based cladding. To support down-selection of these advanced materials and designs, a test apparatus was constructed to study the onset and evolution of cladding oxidation, and deformation behavior of cladding materials, under loss-of-coolant accident scenarios. Preliminary oxidation tests were conducted in dry oxygen and in saturated steam/air environments at 1000OC. Tube samples of Zr-702, Zr-702 reinforced with 1 ply of a ß-SiC CMC overbraid, and sintered a-SiC weremore » tested. Samples were induction heated by coupling to a molybdenum susceptor inside the tubes. The deformation behavior of He-pressurized tubes of Zr-702 and SiC CMC-reinforced Zr-702, heated to rupture, was also examined.« less

RIA simulation tests using driver tube for ATF cladding

DOE Office of Scientific and Technical Information (OSTI.GOV)

Cinbiz, Mahmut N.; Brown, N. R.; Lowden, R. R.

Pellet-cladding mechanical interaction (PCMI) is a potential failure mechanism for accident-tolerant fuel (ATF) cladding candidates during a reactivity-initiated accident (RIA). This report summarizes Fiscal Year (FY) 2017 research activities that were undertaken to evaluate the PCMI-like hoop-strain-driven mechanical response of ATF cladding candidates. To achieve various RIA-like conditions, a modified-burst test (MBT) device was developed to produce different mechanical pulses. The calibration of the MBT instrument was accomplished by performing mechanical tests on unirradiated Generation-I iron-chromium-aluminum (FeCrAl) alloy samples. Shakedown tests were also conducted in both FY 2016 and FY 2017 using unirradiated hydrided ZIRLO™ tube samples. This milestone reportmore » focuses on testing of ATF materials, but the benchmark tests with hydrided ZIRLO™ tube samples are documented in a recent journal article.a For the calibration and benchmark tests, the hoop strain was monitored using strain gauges attached to the sample surface in the hoop direction. A novel digital image correlation (DIC) system composed of a single high-speed camera and an array of six mirrors was developed for the MBT instrument to better resolve the failure behavior of samples and to provide useful data for validation of high-fidelity modeling and simulation tools. The DIC system enable a 360° view of a sample’s outer surface. This feature was added to the instrument to determine the precise failure location on a sample’s surface for strain predictions. The DIC system was tested on several silicon carbide fiber/silicon carbide matrix (SiC/SiC) composite tube samples at various pressurization rates of the driver tube (which correspond to the strain rates for the samples). The hoop strains for various loading conditions were determined for the SiC/SiC composite tube samples. Future work is planned to enhance understanding of the failure behavior of the ATF cladding candidates of age-hardened FeCrAl alloys and SiC/SiC composites in detail during RIA conditions informed by the computational studies performed under the US Department of Energy Office of Nuclear Energy Advanced Fuels Campaign. The testing instrument and the new DIC system will be further developed to reach different stress-state conditions and to perform tests at elevated temperatures.« less

On the formation features, microstructure and microhardness of single laser tracks formed by laser cladding of a NiCrBSi self-fluxing alloy

NASA Astrophysics Data System (ADS)

Devojno, O. G.; Feldshtein, E.; Kardapolava, M. A.; Lutsko, N. I.

2018-07-01

In the present paper, the influence of laser cladding conditions on the powder flow conditions, as well as the microstructure, phases and microhardness of an Ni-based self-fluxing alloy coating are described. The optimal granulations of a self-fluxing alloy powder and the relationship between the flow of powder of various fractions and the flow rate and pressure of the transporting gas have been determined. The laser beam speed, track pitch and the distance from the nozzle to the coated surface influence the height and width of single tracks. Regularities in the formation of microstructure under different cladding conditions are defined, as well as regularity of distribution of elements over the track depth and in the transient zone. The patterns of microhardness distribution over the track depth for different cladding conditions are found. These patterns as well as the optimal laser spot pitch allowed obtaining a uniform cladding layer.

Final report on accident tolerant fuel performance analysis of APMT-Steel Clad/UO₂ fuel and APMT-Steel Clad/UN-U₃Si₅ fuel concepts

DOE Office of Scientific and Technical Information (OSTI.GOV)

Unal, Cetin; Galloway, Jack D.

2014-09-12

In FY2014 our group completed and documented analysis of new Accident Tolerant Fuel (ATF) concepts using BISON. We have modeled the viability of moving from Zircaloy to stainless steel cladding in traditional light water reactors (LWRs). We have explored the reactivity penalty of this change using the MCNP-based burnup code Monteburns, while attempting to minimize this penalty by increasing the fuel pellet radius and decreasing the cladding thickness. Fuel performance simulations using BISON have also been performed to quantify changes to structural integrity resulting from thinner stainless steel claddings. We account for thermal and irradiation creep, fission gas swelling, thermalmore » swelling and fuel relocation in the models for both Zircaloy and stainless steel claddings. Additional models that account for the lower oxidation stainless steel APMT are also invoked where available. Irradiation data for HT9 is used as a fallback in the absence of appropriate models. In this study the isotopic vectors within each natural element are varied to assess potential reactivity gains if advanced enrichment capabilities were levied towards cladding technologies. Recommendations on cladding thicknesses for a robust cladding as well as the constitutive components of a less penalizing composition are provided. In the first section (section 1-3), we present results accepted for publication in the 2014 TOPFUEL conference regarding the APMT/UO₂ ATF concept (J. Galloway & C. Unal, Accident Tolerant and Neutronically Favorable LWR Cladding, Proceedings of WRFPM 2014, Sendai, Japan, Paper No.1000050). Next we discuss our preliminary findings from the thermo-mechanical analysis of UN-U₃Si₅ fuel with APMT clad. In this analysis we used models developed from limited data that need to be updated when the irradiation data from ATF-1 test is available. Initial results indicate a swelling rate less than 1.5% is needed to prevent excessive clad stress.« less

Tensile properties from room temperature to 1315 C of tungsten-lined tantalum-alloy (T-111) tubing fabricated by hot isostatic pressing

NASA Technical Reports Server (NTRS)

Buzzard, R. J.; Metroka, R. R.

1974-01-01

The effects were studied of a thin tungsten liner on the tensile properties of T-111 tubing considered for fuel cladding in a space power nuclear reactor concept. The results indicate that the metallurgically bonded liner had no appreciable effects on the properties of the T-111 tubing. A hot isostatic pressing method used to apply the liners is described along with a means for overcoming the possible embrittling effects of hydrogen contamination.

Metallography and fuel cladding chemical interaction in fast flux test facility irradiated metallic U-10Zr MFF-3 and MFF-5 fuel pins

DOE PAGES

Carmack, W. Jon; Chichester, Heather M.; Porter, Douglas L.; ...

2016-02-27

The Mechanistic Fuel Failure (MFF) series of metal fuel irradiations conducted in the Fast Flux Test Facility (FFTF) provides an important potential comparison between data generated in the Experimental Breeder Reactor (EBR-II) and that expected in a larger-scale fast reactor. The irradiations were the beginning tests to qualify U-10wt%Zr as a driver fuel for FFTF. The FFTF core, with a 91.4 cm tall fuel column and a chopped cosine neutron flux profile, operated with a peak cladding temperature at the top of the fuel column, but developed peak burnup at the centerline of the core. This then places the peakmore » fuel temperature midway between the core center and the top of fuel, lower in the fuel column than in previous EBR-II experiments that had a 32-cm height core. The MFF-3 and MFF-5 qualification assemblies operated in FFTF to >10 at% burnup, and performed very well with no cladding breaches. The MFF-3 assembly operated to 13.8 at% burnup with a peak inner cladding temperature of 643°C, and the MFF-5 assembly operated to 10.1 at% burnup with a peak inner cladding temperature of 651°C. Because of the very high operating temperatures for both the fuel and the cladding, data from the MFF assemblies are most comparable to the data obtained from the EBR-II X447 experiment, which experienced two pin breaches. The X447 breaches were strongly influenced by a large amount of fuel/cladding chemical interaction (FCCI). The MFF pins benefitted from different axial locations of high burnup and peak cladding temperature, which helped to reduce interdiffusion between rare earth fission products and stainless steel cladding. Post-irradiation examination evidence illustrates this advantage. After comparing other performance data of the long MFF pins to prior EBR-II test data, the MFF fuel inside the cladding grew less axially, and the gas release data did not reveal a definitive difference.« less

Metallography and fuel cladding chemical interaction in fast flux test facility irradiated metallic U-10Zr MFF-3 and MFF-5 fuel pins

DOE Office of Scientific and Technical Information (OSTI.GOV)

Carmack, W. J.; Chichester, H. M.; Porter, D. L.

2016-05-01

Abstract The Mechanistic Fuel Failure (MFF) series of metal fuel irradiations conducted in the Fast Flux Test Facility (FFTF) provides an important potential comparison between data generated in the Experimental Breeder Reactor (EBR-II) and that expected in a larger-scale fast reactor. The irradiations were the beginning tests to qualify U-10wt%Zr as a driver fuel for FFTF. The FFTF core, with a 91.4 cm tall fuel column and a chopped cosine neutron flux profile, operated with a peak cladding temperature at the top of the fuel column, but developed peak burnup at the centerline of the core. This places the peakmore » fuel temperature midway between the core center and the top of fuel, lower in the fuel column than in previous EBR-II experiments that had a 32-cm height core. The MFF-3 and MFF-5 qualification assemblies operated in FFTF to >10 at% burnup, and performed very well with no cladding breaches. The MFF-3 assembly operated to 13.8 at% burnup with a peak inner cladding temperature of 643°C, and the MFF-5 assembly operated to 10.1 at% burnup with a peak inner cladding temperature of 651°C. Because of the very high operating temperatures for both the fuel and the cladding, data from the MFF assemblies are most comparable to the data obtained from the EBR-II X447 experiment, which experienced two pin breaches. The X447 breaches were strongly influenced by a large amount of fuel/cladding chemical interaction (FCCI). The MFF pins benefitted from different axial locations of high burnup and peak cladding temperature, which helped to reduce interdiffusion between rare earth fission products and stainless steel cladding. Post-irradiation examination evidence illustrates this advantage. Comparing other performance data of the long MFF pins to prior EBR-II test data, the MFF fuel inside the cladding grew less axially, and the gas release data did not reveal a definitive difference.« less

Influence of the pulsed plasma treatment on the corrosion resistance of the low-alloy steel plated by Ni-based alloy

NASA Astrophysics Data System (ADS)

Dzhumaev, P.; Yakushin, V.; Kalin, B.; Polsky, V.; Yurlova, M.

2016-04-01

This paper presents investigation results of the influence of high temperature pulsed plasma flows (HTPPF) treatment on the corrosion resistance of low-alloy steel 0.2C-Cr-Mn- Ni-Mo cladded by the rapidly quenched nickel-based alloy. A technique that allows obtaining a defect-free clad layer with a good adhesion to the substrate was developed. It is shown that the preliminary treatment of steel samples by nitrogen plasma flows significantly increases their corrosion resistance in the conditions of intergranular corrosion test in a water solution of sulfuric acid. A change of the corrosion mechanism of the clad layer from intergranular to uniform corrosion was observed as a result of sub-microcrystalline structure formation and homogeneous distribution of alloying elements in the plasma treated surface layer thus leading to the significant increase of the corrosion resistance.

The behavior of breached boiling water reactor fuel rods on long-term exposure to air and argon at 598 K

DOE Office of Scientific and Technical Information (OSTI.GOV)

Kohli, R.; Gilbert, E.R.; Johnson, A.B.

1985-05-01

Two irradiated boiling water reactor fuel rods with breached cladding were exposed to argon and to air at 598 K for 7.56 Ms (2100 h). These tests were conducted to determine fuel swelling and cladding crack propagation under conditions that promote UO/sub 2/ fuel oxidation and to observe the behavior of water-logged breached fuel in an inert gas environment. The two rods were selected for testing after extensive hot cell examination had shown the cladding of both rods to be breached with several centimetres of open cracks; the cracks were characterized in detail before the test. As part of themore » experiment, the amount of the readily removable water contained in the fuel rods was determined. To oxidize the fuel to a significant level ( about10%), the air in the annealine capsule was replenished approximately daily. The depletion of oxygen available in the air capsule due to fuel oxidation occurred in about0.036 Ms (10 h). At the end of the test period, about6% of the fuel is estimated to have oxidized. Posttest examination of the rods showed that cladding degradation resulted from swelling due to oxidation of the fuel in the air environment. The cladding degradation was localized and fuel oxidation did not measurably extend beyond the cladding breach. No cladding degradation was measurable in the breached fuel rod tested in argon.« less

Physical and mechanical metallurgy of zirconium alloys for nuclear applications: a multi-scale computational study

DOE Office of Scientific and Technical Information (OSTI.GOV)

Glazoff, Michael Vasily

2014-10-01

In the post-Fukushima world, the stability of materials under extreme conditions is an important issue for the safety of nuclear reactors. Because the nuclear industry is going to continue using advanced zirconium cladding materials in the foreseeable future, it become critical to gain fundamental understanding of the several interconnected problems. First, what are the thermodynamic and kinetic factors affecting the oxidation and hydrogen pick-up by these materials at normal, off-normal conditions, and in long-term storage? Secondly, what protective coatings (if any) could be used in order to gain extremely valuable time at off-normal conditions, e.g., when temperature exceeds the criticalmore » value of 2200°F? Thirdly, the kinetics of oxidation of such protective coating or braiding needs to be quantified. Lastly, even if some degree of success is achieved along this path, it is absolutely critical to have automated inspection algorithms allowing identifying defects of cladding as soon as possible. This work strives to explore these interconnected factors from the most advanced computational perspective, utilizing such modern techniques as first-principles atomistic simulations, computational thermodynamics of materials, diffusion modeling, and the morphological algorithms of image processing for defect identification. Consequently, it consists of the four parts dealing with these four problem areas preceded by the introduction and formulation of the studied problems. In the 1st part an effort was made to employ computational thermodynamics and ab initio calculations to shed light upon the different stages of oxidation of ziraloys (2 and 4), the role of microstructure optimization in increasing their thermal stability, and the process of hydrogen pick-up, both in normal working conditions and in long-term storage. The 2nd part deals with the need to understand the influence and respective roles of the two different plasticity mechanisms in Zr nuclear alloys: twinning (at low T) and crystallographic slip (higher T’s). For that goal, a description of the advanced plasticity model is outlined featuring the non-associated flow rule in hcp materials including Zr. The 3rd part describes the kinetic theory of oxidation of the several materials considered to be perspective coating materials for Zr alloys: SiC and ZrSiO 4. In the 4th part novel and advanced projectional algorithms for defect identification in zircaloy coatings are described. In so doing, the author capitalized on some 12 years of his applied industrial research in this area. Our conclusions and recommendations are presented in the 5th part of this work, along with the list of used literature and the scripts for atomistic, thermodynamic, kinetic, and morphological computations.« less

A model to describe the surface gradient-nanograin formation and property of friction stir processed laser Co-Cr-Ni-Mo alloy

NASA Astrophysics Data System (ADS)

Li, Ruidi; Yuan, Tiechui; Qiu, Zili

2014-07-01

A gradient-nanograin surface layer of Co-base alloy was prepared by friction stir processing (FSP) of laser-clad coating in this work. However, it is lack of a quantitatively function relationship between grain refinement and FSP conditions. Based on this, an analytic model is derived for the correlations between carbide size, hardness and rotary speed, layer depth during in-situ FSP of laser-clad Co-Cr-Ni-Mo alloy. The model is based on the principle of typical plastic flow in friction welding and dynamic recrystallization. The FSP experiment for modification of laser-clad Co-based alloy was conducted and its gradient nanograin and hardness were characterized. It shows that the model is consistent with experimental results.

The effect of copper, chromium, and zirconium on the microstructure and mechanical properties of Al-Zn-Mg-Cu alloys

NASA Technical Reports Server (NTRS)

Wagner, John A.; Shenoy, R. N.

1991-01-01

The present study evaluates the effect of the systematic variation of copper, chromium, and zirconium contents on the microstructure and mechanical properties of a 7000-type aluminum alloy. Fracture toughness and tensile properties are evaluated for each alloy in both the peak aging, T8, and the overaging, T73, conditions. Results show that dimpled rupture essentially characterize the fracture process in these alloys. In the T8 condition, a significant loss of toughness is observed for alloys containing 2.5 pct Cu due to the increase in the quantity of Al-Cu-Mg-rich S-phase particles. An examination of T8 alloys at constant Cu levels shows that Zr-bearing alloys exhibit higher strength and toughness than the Cr-bearing alloys. In the T73 condition, Cr-bearing alloys are inherently tougher than Zr-bearing alloys. A void nucleation and growth mechanism accounts for the loss of toughness in these alloys with increasing copper content.

Handbook of the Materials Properties of FeCrAl Alloys For Nuclear Power Production Applications

DOE Office of Scientific and Technical Information (OSTI.GOV)

Yamamoto, Yukinori; Snead, Mary A.; Field, Kevin G.

FeCrAl alloys are a class of alloys that have seen increased interest for nuclear power applications including as accident tolerant fuel cladding, structural components for fast fission reactors, and as first wall and blanket structures for fusion reactors. FeCrAl alloys are under consideration for these applications due to their inherent corrosion resistance, stress corrosion cracking resistance, radiation-induced swelling resistance, and high temperature oxidation resistance. A substantial amount of research effort has been completed to design, develop, and begin commercial scaling of FeCrAl alloys for nuclear power applications over the past half a century. These efforts have led to the developmentmore » of an extensive database on material properties and process knowledge for FeCrAl alloys but not within a consolidated format. The following report is the first edition of a materials handbook to consolidate the state-of-the-art on FeCrAl alloys for nuclear power applications. This centralized database focuses solely on wrought FeCrAl alloys, oxide dispersion strengthened alloys, although discussed in brief, are not covered. Where appropriate, recommendations for applications of the data is provided and current knowledge gaps are identified.« less

Multiscale Multiphysics Developments for Accident Tolerant Fuel Concepts

DOE Office of Scientific and Technical Information (OSTI.GOV)

Gamble, K. A.; Hales, J. D.; Yu, J.

2015-09-01

U 3Si 2 and iron-chromium-aluminum (Fe-Cr-Al) alloys are two of many proposed accident-tolerant fuel concepts for the fuel and cladding, respectively. The behavior of these materials under normal operating and accident reactor conditions is not well known. As part of the Department of Energy’s Accident Tolerant Fuel High Impact Problem program significant work has been conducted to investigate the U 3Si 2 and FeCrAl behavior under reactor conditions. This report presents the multiscale and multiphysics effort completed in fiscal year 2015. The report is split into four major categories including Density Functional Theory Developments, Molecular Dynamics Developments, Mesoscale Developments, andmore » Engineering Scale Developments. The work shown here is a compilation of a collaborative effort between Idaho National Laboratory, Los Alamos National Laboratory, Argonne National Laboratory and Anatech Corp.« less

Computational and Experimental Studies of Microstructure-Scale Porosity in Metallic Fuels for Improved Gas Swelling Behavior

DOE Office of Scientific and Technical Information (OSTI.GOV)

Mllett, Paul; McDeavitt, Sean; Deo, Chaitanya

This proposal will investigate the stability of bimodal pore size distributions in metallic uranium and uranium-zirconium alloys during sintering and re-sintering annealing treatments. The project will utilize both computational and experimental approaches. The computational approach includes both Molecular Dynamics simulations to determine the self-diffusion coefficients in pure U and U-Zr alloys in single crystals, grain boundaries, and free surfaces, as well as calculations of grain boundary and free surface interfacial energies. Phase-field simulations using MOOSE will be conducted to study pore and grain structure evolution in microstructures with bimodal pore size distributions. Experiments will also be performed to validate themore » simulations, and measure the time-dependent densification of bimodal porous compacts.« less

THE CREEP BEHAVIOUR OF THE MAGNESIUM-ZIRCONIUM ALLOY ZA AT 400 AND 450 C IN CARBON DIOXIDE CONTAINING /approximately equals/200 PPM MOISTURE

DOE Office of Scientific and Technical Information (OSTI.GOV)

Kent, R.P.; Wells, T.C.

1963-03-01

The creep behavior of the magnesium-zirconium alloy ZA was studied in tests of up to 5600 hr duration at 400 deg C and up to 12 600 hr duration at 450 deg C, in an atmosphere of carbon dioxide containing approximately 200 ppm water. The accompanying microstructural changes were observed by optical and electron microscopy. The alloy is stronger at 450 deg C than at 400 deg C and additional strengthening obtains from prestraining at 250 deg C prior to creep-testing. In stress rupture tests at 200 deg C subsequent to creep-testing, the time to rupture and the rupture ductilitymore » are lower in specimens previously tested at 450 deg C than in those tested at 400 deg C. The increase in creep strength at 450 deg C, and subsequent loss of ductility, are attributed principally to the precipitation of a zirconium-rich phase, tentatively identified as epsilon - zirconium hydride, which forms both intragranularly (as ribbons and thin hexagonal plates) and as intergranular particles. (auth)« less

Pellet Cladding Mechanical Interaction Modeling Using the Extended Finite Element Method

DOE Office of Scientific and Technical Information (OSTI.GOV)

Spencer, Benjamin W.; Jiang, Wen; Dolbow, John E.

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 themore » 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.« less

Annealing of (DU-10Mo)-Zr Co-Rolled Foils

DOE Office of Scientific and Technical Information (OSTI.GOV)

Pacheco, Robin Montoya; Alexander, David John; Mccabe, Rodney James

2017-01-20

Producing uranium-10wt% molybdenum (DU-10Mo) foils to clad with Al first requires initial bonding of the DU-10Mo foil to zirconium (Zr) by hot rolling, followed by cold rolling to final thickness. Rolling often produces wavy (DU-10Mo)-Zr foils that should be flattened before further processing, as any distortions could affect the final alignment and bonding of the Al cladding to the Zr co-rolled surface layer; this bonding is achieved by a hot isostatic pressing (HIP) process. Distortions in the (DU-10Mo)-Zr foil may cause the fuel foil to press against the Al cladding and thus create thinner or thicker areas in the Almore » cladding layer during the HIP cycle. Post machining is difficult and risky at this stage in the process since there is a chance of hitting the DU-10Mo. Therefore, it is very important to establish a process to flatten and remove any waviness. This study was conducted to determine if a simple annealing treatment could flatten wavy foils. Using the same starting material (i.e. DU-10Mo coupons of the same thickness), five different levels of hot rolling and cold rolling, combined with five different annealing treatments, were performed to determine the effect of these processing variables on flatness, bonding of layers, annealing response, microstructure, and hardness. The same final thickness was reached in all cases. Micrographs, textures, and hardness measurements were obtained for the various processing combinations. Based on these results, it was concluded that annealing at 650°C or higher is an effective treatment to appreciably reduce foil waviness.« less

Molten uranium dioxide structure and dynamics

DOE PAGES

Skinner, L. B.; Parise, J. B.; Benmore, C. J.; ...

2014-11-21

Uranium dioxide (UO 2) is the major nuclear fuel component of fission power reactors. A key concern during severe accidents is the melting and leakage of radioactive UO 2 as it corrodes through its zirconium cladding and steel containment. Yet, the very high temperatures (>3140 kelvin) and chemical reactivity of molten UO 2 have prevented structural studies. In this work, we combine laser heating, sample levitation, and synchrotron x-rays to obtain pair distribution function measurements of hot solid and molten UO 2. The hot solid shows a substantial increase in oxygen disorder around the lambda transition (2670 K) but negligiblemore » U-O coordination change. On melting, the average U-O coordination drops from 8 to 6.7 ± 0.5. Molecular dynamics models refined to this structure predict higher U-U mobility than 8-coordinated melts.« less

Nuclear reactor fuel element with vanadium getter on cladding

DOEpatents

Johnson, Carl E.; Carroll, Kenneth G.

1977-01-01

A nuclear reactor fuel element is described which has an outer cladding, a central core of fissionable or mixed fissionable and fertile fuel material and a layer of vanadium as an oxygen getter on the inner surface of the cladding. The vanadium reacts with oxygen released by the fissionable material during irradiation of the core to prevent the oxygen from reacting with and corroding the cladding. Also described is a method for coating the inner surface of small diameter tubes of cladding with a layer of vanadium.

EPRI/DOE High-Burnup Fuel Sister Rod Test Plan Simplification and Visualization

DOE Office of Scientific and Technical Information (OSTI.GOV)

Saltzstein, Sylvia J.; Sorenson, Ken B.; Hanson, B. D.

The EPRI/DOE High-Burnup Confirmatory Data Project (herein called the “Demo”) is a multi-year, multi-entity test with the purpose of providing quantitative and qualitative data to show if high-burnup fuel mechanical properties change in dry storage over a ten-year period. The Demo involves obtaining 32 assemblies of high-burnup PWR fuel of common cladding alloys from the North Anna Nuclear Power Plant, loading them in an NRC-licensed TN-32B cask, drying them according to standard plant procedures, and then storing them on the North Anna dry storage pad for ten years. After the ten-year storage time, the cask will be opened and themore » mechanical properties of the rods will be tested and analyzed.« less

Upgraded HFIR Fuel Element Welding System

DOE Office of Scientific and Technical Information (OSTI.GOV)

Sease, John D

2010-02-01

The welding of aluminum-clad fuel plates into aluminum alloy 6061 side plate tubing is a unique design feature of the High Flux Isotope Reactor (HFIR) fuel assemblies as 101 full-penetration circumferential gas metal arc welds (GMAW) are required in the fabrication of each assembly. In a HFIR fuel assembly, 540 aluminum-clad fuel plates are assembled into two nested annular fuel elements 610 mm (24-inches) long. The welding process for the HFIR fuel elements was developed in the early 1960 s and about 450 HFIR fuel assemblies have been successfully welded using the GMAW process qualified in the 1960 s. Inmore » recent years because of the degradation of the electronic and mechanical components in the old HFIR welding system, reportable defects in plate attachment or adapter welds have been present in almost all completed fuel assemblies. In October 2008, a contract was awarded to AMET, Inc., of Rexburg, Idaho, to replace the old welding equipment with standard commercially available welding components to the maximum extent possible while maintaining the qualified HFIR welding process. The upgraded HFIR welding system represents a major improvement in the welding system used in welding HFIR fuel elements for the previous 40 years. In this upgrade, the new inner GMAW torch is a significant advancement over the original inner GMAW torch previously used. The innovative breakthrough in the new inner welding torch design is the way the direction of the cast in the 0.762 mm (0.030-inch) diameter aluminum weld wire is changed so that the weld wire emerging from the contact tip is straight in the plane perpendicular to the welding direction without creating any significant drag resistance in the feeding of the weld wire.« less

Phase Constituents and Microstructure of Ti3Al/Fe3Al + TiN/TiB2 Composite Coating on Titanium Alloy

NASA Astrophysics Data System (ADS)

Li, Jianing; Chen, Chuanzhong; Zhang, Cuifang

Laser cladding of the Fe3Al + B4C/TiN + Al2O3 pre-placed powders on the Ti-6Al-4V alloy can form the Ti3Al/Fe3Al + TiN/TiB2 composite coating, which improved the wear resistance of the Ti-6Al-4V alloy surface. In this study, the Ti3Al/Fe3Al + TiN/TiB2 composite coating has been researched by means of X-ray diffraction and scanning electron microscope. It was found that during the laser cladding process, Al2O3 can react with TiB2, leading to the formations of Ti3Al and B. This principle can be used to improve the Fe3Al + B4C/TiN laser-cladded coating on the Ti-6Al-4V alloy. Furthermore, during the cladding process, C consumed the oxygen in Fe3Al + B4C /TiN + Al2O3 molten pool, which retarded the productions of the redundant metal oxides.

A SURVEY OF THE CORROSION OF MARTENSITIC AND FERRITIC STAINLESS STEELS IN PRESSURIZED WATER

DOE Office of Scientific and Technical Information (OSTI.GOV)

Beaver, R.J.; Leitten, C.F. Jr.

1963-07-16

>The corrosion resistance of mantensitic and ferritic austenitic stainless steels and carbon steels in pressurized water at 500 to 600 deg F is compared. Included are specific out-of-pile data for austenitic stainless steels, AISI types types 410, 420, 431, and 440C; the ferritic AISI types 430, 442, and 446; the precipitation-hardening type 17-4PH; and carbon steels, ASTM 212 A and B. Available corrosion results obtained under irradiation at exposures in the range of 7 x 10/sup 16/ to 3 x 10/sup 19/ nvt are also included for types 304, types of martensitic and ferritic stainless steels which were evaluated domore » not contain nickel. For application where it is desirable to minimize Co/sup 58/ activity produced from nickel, selection of a martensitic or ferritic stainless steel may be more appropriate than choosing the more popular nickel-bearing austenitic stainless steel or a fuel-element cladding material. Interpretation of the data indicates that, on the average, martensitic and ferritic stainless steels corrode more rapidly than austenitic alloys but more slowly than carbon and low-alloy steels. Under selected controlled water conditions or under irradiation, the corrosion of the nickel-free stainless steels appears to differ little from the austenitics. The corrosion of martensitic and ferritic stainless steels in pressurized-water systems therefore does not appear of such magnitude as to rule out development of these materials as the cladding fuel elements for specific applications. (auth)« less

ZIRCONIUM ALLOY

DOEpatents

Wilhelm, H.A.; Ames, D.P.

1959-02-01

A binary zirconiuin--antimony alloy is presented which is corrosion resistant and hard containing from 0.07% to 1.6% by weight of Sb. The alloys have good corrosion resistance and are useful in building equipment for the chemical industry.

Study of metal corrosion using ac impedance techniques in the STS launch environment

NASA Technical Reports Server (NTRS)

Calle, Luz M.

1989-01-01

AC impedance measurements were performed to investigate the corrosion resistance of 19 alloys under conditions similar to the STS launch environment. The alloys were: Zirconium 702, Hastelloy C-22, Inconel 625, Hastelloy C-276, Hastelloy C-4, Inconel 600, 7Mo + N, Ferralium 255, Inco Alloy G-3, 20Cb-3, SS 904L, Inconel 825, SS 304LN, SS 316L, SS 317L, ES 2205, SS 304L, Hastelloy B-2, and Monel 400. AC impedance data were gathered for each alloy after one hour immersion time in each of the following three electrolyte solutions: 3.55 percent NaCl, 3.55 percent NaCl-0.1N HCl, and 3.55 percent NaCl-1.0N HCl. The data were analyzed qualitatively using the Nyquist plot and quantitatively using the Bode plot. Polarization resistance, Rp, values were obtained using the Bode plot. Zirconium 702 was the most corrosion resistant alloy in the three electrolytes. The ordering of the other alloys according the their resistance to corrosion varied as the concentration of hydrochloric acid in the electrolyte increased. The corrosion resistance of Zirconium 702 and Ferralium 255 increased as the concentration of hydrochloric acid in the electrolyte increased. The corrosion resistance of the other 17 alloys decreased as the concentration of the hyrdochloric acid in the electrolyte increased.

DOE Office of Scientific and Technical Information (OSTI.GOV)

Sun, Zhiqian; Yamamoto, Yukinori

The processability of a Mo-containing FeCrAl alloy (Fe-13Cr-5.2Al-2Mo base, in wt%), developed for accident-tolerant nuclear fuel claddings, was evaluated through a stepwise rolling process at 400 °C under two different inter-pass annealing conditions (i.e., 650 °C for 1 h and at 870 °C for 30 min). The inter-pass annealing at 870 °C easily softened the FeCrAl alloy; however, it led to the formation of coarse grains of ~200 µm. On the other hand, the FeCrAl alloy maintained elongated, deformed grains with the inter-pass annealing at 650 °C, but the annealed samples showed relatively high deformation resistance and strong texture. Importantmore » aspects concerning the processability and microstructural control of FeCrAl alloys, such as deformation inhomogeneity, texture development, and grain coarsening, were discussed. Optimized processing conditions were recommended, based on the results, to achieve desirable microstructures with balanced processability and mechanical properties.« less

Proving the viability of manufacturing of multi-layer steel/vanadium alloy/steel composite tubes by numerical simulations and experiment

NASA Astrophysics Data System (ADS)

Nechaykina, T.; Nikulin, S.; Rozhnov, A.; Molotnikov, A.; Zavodchikov, S.; Estrin, Y.

2018-05-01

Vanadium alloys are promising structural materials for fuel cladding tubes for fast-neutron reactors. However, high solubility of oxygen and nitrogen in vanadium alloys at operating temperatures of 700 °C limits their application. In this work, we present a novel composite structure consisting of vanadium alloy V-4Ti-4Cr (provides high long-term strength of the material) and stainless steel Fe-0.2C-13Cr (as a corrosion resistant protective layer). It is produced by co-extrusion of these materials forming a three-layered tube. Finite element simulations were utilised to explore the influence of the various co-extrusion parameters on manufacturability of multi-layered tubes. Experimental verification of the numerical modelling was performed using co-extrusion with the process parameters suggested by the numerical simulations. Scanning electron microscopy and microhardness measurements revealed a defect-free diffusion layer at the interfaces between both materials indicating a good quality bonding for these co-extrusion conditions.

Review of CTF s Fuel Rod Modeling Using FRAPCON-4.0 s Centerline Temperature Predictions

DOE Office of Scientific and Technical Information (OSTI.GOV)

Toptan, Aysenur; Salko, Robert K; Avramova, Maria

Coolant Boiling in Rod Arrays Two Fluid (COBRA-TF), or CTF1 [1], is a nuclear thermal hydraulic subchannel code used throughout academia and industry. CTF s fuel rod modeling is originally developed for VIPRE code [2]. Its methodology is based on GAPCON [3] and FRAP [4] fuel performance codes, and material properties are included from MATPRO handbook [5]. This work focuses on review of CTF s fuel rod modeling to address shortcomings in CTF s temperature predictions. CTF is compared to FRAPCON which is U.S. NRC s steady-state fuel performance code for light-water reactor fuel rods. FRAPCON calculates the changes inmore » fuel rod variables and temperatures including the eects of cladding hoop strain, cladding oxidation, hydriding, fuel irradiation swelling, densification, fission gas release and rod internal gas pressure. It uses fuel, clad and gap material properties from MATPRO. Additionally, it has its own models for fission gas release, cladding corrosion and cladding hydrogen pickup. It allows finite dierence or finite element approaches for its mechanical model. In this study, FRAPCON-4.0 [6] is used as a reference fuel performance code. In comparison, Halden Reactor Data for IFA432 Rod 1 and Rod 3. CTF simulations are performed in two ways; informing CTF with gap conductance value from FRAPCON, and using CTF s dynamic gap conductance model. First case is chosen to show temperature is predicted correctly with CTF s models for thermal and cladding conductivities once gap conductance is provided. Latter is to review CTF s dynamic gap conductance model. These Halden test cases are selected to be representative of cases with and without any physical contact between fuel-pellet and clad while reviewing functionality of CTF s dynamic gap conductance model. Improving the CTF s dynamic gap conductance model will allow prediction of fuel and cladding thermo-mechanical behavior under irradiation, and better temperature feedbacks from CTF in transient calculations.« less

JOYO-1 Irradiation Test Campaign Technical Close-out, For Information

DOE Office of Scientific and Technical Information (OSTI.GOV)

G. Borges

2006-01-31

The JOYO-1 irradiation testing was designed to screen the irradiation performance of candidate cladding, structural and reflector materials in support of space reactor development. The JOYO-1 designation refers to the first of four planned irradiation tests in the JOYO reactor. Limited irradiated material performance data for the candidate materials exists for the expected Prometheus-1 duration, fluences and temperatures. Materials of interest include fuel element cladding and core materials (refractory metal alloys and silicon carbide (Sic)), vessel and plant structural materials (refractory metal alloys and nickel-base superalloys), and control and reflector materials (BeO). Key issues to be evaluated were long termmore » microstructure and material property stability. The JOYO-1 test campaign was initiated to irradiate a matrix of specimens at prototypical temperatures and fluences anticipated for the Prometheus-1 reactor [Reference (1)]. Enclosures 1 through 9 describe the specimen and temperature monitors/dosimetry fabrication efforts, capsule design, disposition of structural material irradiation rigs, and plans for post-irradiation examination. These enclosures provide a detailed overview of Naval Reactors Prime Contractor Team (NRPCT) progress in specific areas; however, efforts were in various states of completion at the termination of NRPCT involvement with and restructuring of Project Prometheus.« less

Static Recovery Modeling of Dislocation Density in a Cold Rolled Clad Aluminum Alloy

NASA Astrophysics Data System (ADS)

Penlington, Alex

Clad alloys feature one or more different alloys bonded to the outside of a core alloy, with non-equilibrium, interalloy interfaces. There is limited understanding of the recovery and recrystallization behaviour of cold rolled clad aluminum alloys. In order to optimize the properties of such alloys, new heat treatment processes may be required that differ from what is used for the monolithic alloys. This study examines the recovery behaviour of a cold rolled Novelis Fusion(TM) alloy containing an AA6XXX core with an AA3003 cladding on one side. The bond between alloys appears microscopically discrete and continuous, but has a 30 microm wide chemical gradient. The as-deformed structure at the interalloy region consists of pancaked sub-grains with dislocations at the misorientation boundaries and a lower density organized within the more open interiors. X-ray line broadening was used to extract the dislocation density from the interalloy region and an equivalently deformed AA6XXX following static annealing using a modified Williamson-Hall analysis. This analysis assumed that Gaussian broadening contributions in a pseudo-Voigt function corresponded only to strain from dislocations. The kinetics of the dislocation density evolution to recrystallization were studied isothermally at 2 minute intervals, and isochronally at 175 and 205°C. The data fit the Nes model, in which the interalloy region recovered faster than AA6XXX at 175°C, but was slower at 205°C. This was most likely caused by change in texture and chemistry within this region such as over-aging of AA6XXX . Simulation of a continuous annealing and self homogenization process both with and without pre-recovery indicates a detectable, though small change in the texture and grain size in the interalloy region.

DOE Office of Scientific and Technical Information (OSTI.GOV)

Konyashov, Vadim V.; Krasnov, Alexander M.

Results are provided of the experimental investigation of radioactive fission product (RFP) release, i.e., krypton, xenon, and iodine radionuclides from fuel elements with initial defects during long-term (3 to 5 yr) irradiation under low linear power (5 to 12 kW/m) and during special experiments in the VK-50 vessel-type boiling water reactor.The calculation model for the RFP release from the fuel-to-cladding gap of the defective fuel element into coolant was developed. It takes into account the convective transport in the fuel-to-cladding gap and RFP sorption on the internal cladding surface and is in good agreement with the available experimental data. Anmore » approximate analytical solution of the transport equation is given. The calculation dependencies of the RFP release coefficients on the main parameters such as defect size, fuel-to-cladding gap, temperature of the internal cladding surface, and radioactive decay constant were analyzed.It is shown that the change of the RFP release from the fuel elements with the initial defects during long-term irradiation is, mainly, caused by fuel swelling followed by reduction of the fuel-to-cladding gap and the fuel temperature. The calculation model for the RFP release from defective fuel elements applicable to light water reactors (LWRs) was developed. It takes into account the change of the defective fuel element parameters during long-term irradiation. The calculation error according to the program does not exceed 30% over all the linear power change range of the LWR fuel elements (from 5 to 26 kW/m)« less

DOE Office of Scientific and Technical Information (OSTI.GOV)

Montgomery, Rose; Scaglione, John M; Bevard, Bruce Balkcom

The High Burnup Spent Fuel Data project pulled 25 sister rods (9 from the project assemblies and 16 from similar HBU assemblies) for characterization. The 25 sister rods are all high burnup and cover the range of modern domestic cladding alloys. The 25 sister rods were shipped to Oak Ridge National Laboratory (ORNL) in early 2016 for detailed non-destructive and destructive examination. Examinations are intended to provide baseline data on the initial physical state of the cladding and fuel prior to the loading, drying, and long-term dry storage process. Further examinations are focused on determining the effects of temperatures encounteredmore » during and following drying. Similar tests will be performed on rods taken from the project assemblies at the end of their long-term storage in a TN-32 dry storage cask (the cask rods ) to identify any significant changes in the fuel rods that may have occurred during the dry storage period. Additionally, some of the sister rods will be used for separate effects testing to expand the applicability of the project data to the fleet, and to address some of the data-related gaps associated with extended storage and subsequent transportation of high burnup fuel. A draft test plan is being developed that describes the experimental work to be conducted on the sister rods. This paper summarizes the draft test plan and necessary coordination activities for the multi-year experimental program to supply data relevant to the assessment of the safety of long-term storage followed by transportation of high burnup spent fuel.« less

Fission products and nuclear fuel behaviour under severe accident conditions part 2: Fuel behaviour in the VERDON-1 sample

NASA Astrophysics Data System (ADS)

Geiger, E.; Le Gall, C.; Gallais-During, A.; Pontillon, Y.; Lamontagne, J.; Hanus, E.; Ducros, G.

2017-11-01

Within the framework of the International Source Term Programme (ISTP), the VERDON programme aims at quantifying the source term of radioactive materials in case of a hypothetical severe accident in a light water reactor (LWR). Tests were performed in a new experimental laboratory (VERDON) built in the LECA-STAR facility (CEA Cadarache). The VERDON-1 test was devoted to the study of a high burn-up UO2 fuel and FP releases at very high temperature (≈2873 K) in a reducing atmosphere. Post-test qualitative and quantitative characterisations of the VERDON-1 sample led to the proposal of a scenario explaining the phenomena occurring during the experimental sequence. Hence, the fuel and the cladding may have interacted which led to the melting of UO2-ZrO2 alloy. Although no relocation was observed during the test, it may have been imminent.

Microstructural Characterization of High Burn-up Mixed Oxide Fast Reactor Fuel

DOE Office of Scientific and Technical Information (OSTI.GOV)

Melissa C. Teague; Brian P. Gorman; Steven L. Hayes

2013-10-01

High burn-up mixed oxide fuel with local burn-ups of 3.4–23.7% FIMA (fissions per initial metal atom) were destructively examined as part of a research project to understand the performance of oxide fuel at extreme burn-ups. Optical metallography of fuel cross-sections measured the fuel-to-cladding gap, clad thickness, and central void evolution in the samples. The fuel-to-cladding gap closed significantly in samples with burn-ups below 7–9% FIMA. Samples with burn-ups in excess of 7–9% FIMA had a reopening of the fuel-to-cladding gap and evidence of joint oxide-gain (JOG) formation. Signs of axial fuel migration to the top of the fuel column weremore » observed in the fuel pin with a peak burn-up of 23.7% FIMA. Additionally, high burn-up structure (HBS) was observed in the two highest burn-up samples (23.7% and 21.3% FIMA). The HBS layers were found to be 3–5 times thicker than the layers found in typical LWR fuel. The results of the study indicate that formation of JOG and or HBS prevents any significant fuel-cladding mechanical interaction from occurring, thereby extending the potential life of the fuel elements.« less

Processability evaluation of a Mo-containing FeCrAl alloy for seamless thin-wall tube fabrication

DOE PAGES

Sun, Zhiqian; Yamamoto, Yukinori

2017-06-10

The processability of a Mo-containing FeCrAl alloy (Fe-13Cr-5.2Al-2Mo base, in wt%), developed for accident-tolerant nuclear fuel claddings, was evaluated through a stepwise rolling process at 400 °C under two different inter-pass annealing conditions (i.e., 650 °C for 1 h and at 870 °C for 30 min). The inter-pass annealing at 870 °C easily softened the FeCrAl alloy; however, it led to the formation of coarse grains of ~200 µm. On the other hand, the FeCrAl alloy maintained elongated, deformed grains with the inter-pass annealing at 650 °C, but the annealed samples showed relatively high deformation resistance and strong texture. Importantmore » aspects concerning the processability and microstructural control of FeCrAl alloys, such as deformation inhomogeneity, texture development, and grain coarsening, were discussed. Optimized processing conditions were recommended, based on the results, to achieve desirable microstructures with balanced processability and mechanical properties.« less

Development of ODS FeCrAl for compatibility in fusion and fission energy applications

DOE PAGES

Pint, Bruce A.; Dryepondt, Sebastien N.; Unocic, Kinga A.; ...

2014-11-15

In this paper, oxide dispersion strengthened (ODS) FeCrAl alloys with 12–15% Cr are being evaluated for improved compatibility with Pb-Li for a fusion energy application and with high temperature steam for a more accident-tolerant light water reactor fuel cladding application. A 12% Cr content alloy showed low mass losses in static Pb-Li at 700°C, where a LiAlO 2 surface oxide formed and inhibited dissolution into the liquid metal. All the evaluated compositions formed a protective scale in steam at 1200°C, which is not possible with ODS FeCr alloys. However, most of the compositions were not protective at 1400°C, which ismore » a general and somewhat surprising problem with ODS FeCrAl alloys that is still being studied. More work is needed to optimize the alloy composition, microstructure and oxide dispersion, but initial promising tensile and creep results have been obtained with mixed oxide additions, i.e. Y 2O 3 with ZrO 2, HfO 2 or TiO 2.« less

Nuclear reactor fuel element

DOEpatents

Johnson, Carl E.; Crouthamel, Carl E.

1980-01-01

A nuclear reactor fuel element is described which has an outer cladding, a central core of fissionable or mixed fissionable and fertile fuel material and a layer of oxygen gettering material on the inner surface of the cladding. The gettering material reacts with oxygen released by the fissionable material during irradiation of the core thereby preventing the oxygen from reacting with and corroding the cladding. Also described is an improved method for coating the inner surface of the cladding with a layer of gettering material.

High-intensity low energy titanium ion implantation into zirconium alloy

NASA Astrophysics Data System (ADS)

Ryabchikov, A. I.; Kashkarov, E. B.; Pushilina, N. S.; Syrtanov, M. S.; Shevelev, A. E.; Korneva, O. S.; Sutygina, A. N.; Lider, A. M.

2018-05-01

This research describes the possibility of ultra-high dose deep titanium ion implantation for surface modification of zirconium alloy Zr-1Nb. The developed method based on repetitively pulsed high intensity low energy titanium ion implantation was used to modify the surface layer. The DC vacuum arc source was used to produce metal plasma. Plasma immersion titanium ions extraction and their ballistic focusing in equipotential space of biased electrode were used to produce high intensity titanium ion beam with the amplitude of 0.5 A at the ion current density 120 and 170 mA/cm2. The solar eclipse effect was used to prevent vacuum arc titanium macroparticles from appearing in the implantation area of Zr sample. Titanium low energy (mean ion energy E = 3 keV) ions were implanted into zirconium alloy with the dose in the range of (5.4-9.56) × 1020 ion/cm2. The effect of ion current density, implantation dose on the phase composition, microstructure and distribution of elements was studied by X-ray diffraction, scanning electron microscopy and glow-discharge optical emission spectroscopy, respectively. The results show the appearance of Zr-Ti intermetallic phases of different stoichiometry after Ti implantation. The intermetallic phases are transformed from both Zr0.7Ti0.3 and Zr0.5Ti0.5 to single Zr0.6Ti0.4 phase with the increase in the implantation dose. The changes in phase composition are attributed to Ti dissolution in zirconium lattice accompanied by the lattice distortions and appearance of macrostrains in intermetallic phases. The depth of Ti penetration into the bulk of Zr increases from 6 to 13 μm with the implantation dose. The hardness and wear resistance of the Ti-implanted zirconium alloy were increased by 1.5 and 1.4 times, respectively. The higher current density (170 mA/cm2) leads to the increase in the grain size and surface roughness negatively affecting the tribological properties of the alloy.

Fabrication of (U, Zr) C-fueled/tungsten-clad specimens for irradiation in the Plum Brook Reactor Facility

NASA Technical Reports Server (NTRS)

1972-01-01

Fuel samples, 90UC - 10 ZrC, and chemically vapor deposited tungsten fuel cups were fabricated for the study of the long term dimensional stability and compatibility of the carbide-tungsten fuel-cladding systems under irradiation. These fuel samples and fuel cups were assembled into the fuel pins of two capsules, designated as V-2E and V-2F, for irradiation in NASA Plum Brook Reactor Facility at a fission power density of 172 watts/c.c. and a miximum cladding temperature of 1823 K. Fabrication methods and characteristics of the fuel samples and fuel cups prepared are described.

Pre-irradiation testing and analysis to support the LWRS Hybrid SiC-CMC-Zircaloy-04 unfueled rodlet irradiation

DOE Office of Scientific and Technical Information (OSTI.GOV)

Isabella J van Rooyen

2012-09-01

Nuclear fuel performance is a significant driver of nuclear power plant operational performance, safety, economics and waste disposal requirements. The Advanced Light Water Reactor (LWR) Nuclear Fuel Development Pathway focuses on improving the scientific knowledge basis to enable the development of high-performance, high burn-up fuels with improved safety and cladding integrity and improved nuclear fuel cycle economics. To achieve significant improvements, fundamental changes are required in the areas of nuclear fuel composition, cladding integrity, and fuel/cladding interaction.

Pre-irradiation testing and analysis to support the LWRS Hybrid SiC-CMC-Zircaloy-04 unfueled rodlet irradiation

DOE Office of Scientific and Technical Information (OSTI.GOV)

Isabella J van Rooyen

2013-01-01

Nuclear fuel performance is a significant driver of nuclear power plant operational performance, safety, economics and waste disposal requirements. The Advanced Light Water Reactor (LWR) Nuclear Fuel Development Pathway focuses on improving the scientific knowledge basis to enable the development of high-performance, high burn-up fuels with improved safety and cladding integrity and improved nuclear fuel cycle economics. To achieve significant improvements, fundamental changes are required in the areas of nuclear fuel composition, cladding integrity, and fuel/cladding interaction.

Method For Processing Spent (Trn,Zr)N Fuel

DOEpatents

Miller, William E.; Richmann, Michael K.

2004-07-27

A new process for recycling spent nuclear fuels, in particular, mixed nitrides of transuranic elements and zirconium. The process consists of two electrorefiner cells in series configuration. A transuranic element such as plutonium is reduced at the cathode in the first cell, zirconium at the cathode in the second cell, and nitrogen-15 is released and captured for reuse to make transuranic and zirconium nitrides.

Microstructure and mechanical properties of FeCrAl alloys under heavy ion irradiations

NASA Astrophysics Data System (ADS)

Aydogan, E.; Weaver, J. S.; Maloy, S. A.; El-Atwani, O.; Wang, Y. Q.; Mara, N. A.

2018-05-01

FeCrAl ferritic alloys are excellent cladding candidates for accident tolerant fuel systems due to their high resistance to oxidation as a result of formation of a protective Al2O3 scale at high temperatures in steam. In this study, we report the irradiation response of the 10Cr and 13Cr FeCrAl cladding tubes under Fe2+ ion irradiation up to ∼16 dpa at 300 °C. Dislocation loop size, density and characteristics were determined using both two-beam bright field transmission electron microscopy and on-zone scanning transmission electron microscopy techniques. 10Cr (C06M2) tube has a lower dislocation density, larger grain size and a slightly weaker texture compared to the 13Cr (C36M3) tube before irradiation. After irradiation to 0.7 dpa and 16 dpa, the fraction of <100> type sessile dislocations decreases with increasing Cr amount in the alloys. It has been found that there is neither void formation nor α‧ precipitation as a result of ion irradiations in either alloy. Therefore, dislocation loops were determined to be the only irradiation induced defects contributing to the hardening. Nanoindentation testing before the irradiation revealed that the average nanohardness of the C36M3 tube is higher than that of the C06M2 tube. The average nanohardness of irradiated tube samples saturated at 1.6-2.0 GPa hardening for both tubes between ∼3.4 dpa and ∼16 dpa. The hardening calculated based on transmission electron microscopy was found to be consistent with nanohardness measurements.

Microstructure and mechanical properties of FeCrAl alloys under heavy ion irradiations

DOE Office of Scientific and Technical Information (OSTI.GOV)

Aydogan, E.; Weaver, J. S.; Maloy, S. A.

FeCrAl ferritic alloys are excellent cladding candidates for accident tolerant fuel systems due to their high resistance to oxidation as a result of formation of a protective Al 2O 3 scale at high temperatures in steam. In this study, we report the irradiation response of the 10Cr and 13Cr FeCrAl cladding tubes under Fe 2+ ion irradiation up to ~16 dpa at 300 °C. Dislocation loop size, density and characteristics were determined using both two beam bright field transmission electron microscopy and on-zone scanning transmission electron microscopy techniques. 10Cr (C06M2) tube has a lower dislocation density, larger grain size andmore » a slightly weaker texture compared to the 13Cr (C36M3) tube before irradiation. After irradiation to 0.7 dpa and 16 dpa, the fraction of <100> type sessile dislocations decreases with increasing Cr amount in the alloys. It has been found that there is neither void formation nor α' precipitation as a result of ion irradiations in either alloy. Therefore, dislocation loops were determined to be the only irradiation induced defects contributing to the hardening. Nanoindentation testing before the irradiation revealed that the average nanohardness of the C36M3 tube is higher than that of the C06M2 tube. The average nanohardness of irradiated tube samples saturated at 1.6-2.0 GPa hardening for both tubes between ~3.4 dpa and ~16 dpa. The hardening calculated based on transmission electron microscopy was found to be consistent with nanohardness measurements.« less

Microstructure and mechanical properties of FeCrAl alloys under heavy ion irradiations

DOE PAGES

Aydogan, E.; Weaver, J. S.; Maloy, S. A.; ...

2018-03-02

FeCrAl ferritic alloys are excellent cladding candidates for accident tolerant fuel systems due to their high resistance to oxidation as a result of formation of a protective Al 2O 3 scale at high temperatures in steam. In this study, we report the irradiation response of the 10Cr and 13Cr FeCrAl cladding tubes under Fe 2+ ion irradiation up to ~16 dpa at 300 °C. Dislocation loop size, density and characteristics were determined using both two beam bright field transmission electron microscopy and on-zone scanning transmission electron microscopy techniques. 10Cr (C06M2) tube has a lower dislocation density, larger grain size andmore » a slightly weaker texture compared to the 13Cr (C36M3) tube before irradiation. After irradiation to 0.7 dpa and 16 dpa, the fraction of <100> type sessile dislocations decreases with increasing Cr amount in the alloys. It has been found that there is neither void formation nor α' precipitation as a result of ion irradiations in either alloy. Therefore, dislocation loops were determined to be the only irradiation induced defects contributing to the hardening. Nanoindentation testing before the irradiation revealed that the average nanohardness of the C36M3 tube is higher than that of the C06M2 tube. The average nanohardness of irradiated tube samples saturated at 1.6-2.0 GPa hardening for both tubes between ~3.4 dpa and ~16 dpa. The hardening calculated based on transmission electron microscopy was found to be consistent with nanohardness measurements.« less

Intermetallic alloy welding wires and method for fabricating the same

DOEpatents

Santella, M.L.; Sikka, V.K.

1996-06-11

Welding wires for welding together intermetallic alloys of nickel aluminides, nickel-iron aluminides, iron aluminides, or titanium aluminides, and preferably including additional alloying constituents are fabricated as two-component, clad structures in which one component contains the primary alloying constituent(s) except for aluminum and the other component contains the aluminum constituent. This two-component approach for fabricating the welding wire overcomes the difficulties associated with mechanically forming welding wires from intermetallic alloys which possess high strength and limited ductilities at elevated temperatures normally employed in conventional metal working processes. The composition of the clad welding wires is readily tailored so that the welding wire composition when melted will form an alloy defined by the weld deposit which substantially corresponds to the composition of the intermetallic alloy being joined. 4 figs.

Intermetallic alloy welding wires and method for fabricating the same

DOEpatents

Santella, Michael L.; Sikka, Vinod K.

1996-01-01

Welding wires for welding together intermetallic alloys of nickel aluminides, nickel-iron aluminides, iron aluminides, or titanium aluminides, and preferably including additional alloying constituents are fabricated as two-component, clad structures in which one component contains the primary alloying constituent(s) except for aluminum and the other component contains the aluminum constituent. This two-component approach for fabricating the welding wire overcomes the difficulties associated with mechanically forming welding wires from intermetallic alloys which possess high strength and limited ductilities at elevated temperatures normally employed in conventional metal working processes. The composition of the clad welding wires is readily tailored so that the welding wire composition when melted will form an alloy defined by the weld deposit which substantially corresponds to the composition of the intermetallic alloy being joined.

A review of inherent safety characteristics of metal alloy sodium-cooled fast reactor fuel against postulated accidents

DOE PAGES

Sofu, Tanju

2015-04-01

The thermal, mechanical, and neutronic performance of the metal alloy fast reactor fuel design complements the safety advantages of the liquid metal cooling and the pool-type primary system. Together, these features provide large safety margins in both normal operating modes and for a wide range of postulated accidents. In particular, they maximize the measures of safety associated with inherent reactor response to unprotected, double-fault accidents, and to minimize risk to the public and plant investment. High thermal conductivity and high gap conductance play the most significant role in safety advantages of the metallic fuel, resulting in a flatter radial temperaturemore » profile within the pin and much lower normal operation and transient temperatures in comparison to oxide fuel. Despite the big difference in melting point, both oxide and metal fuels have a relatively similar margin to melting during postulated accidents. When the metal fuel cladding fails, it typically occurs below the coolant boiling point and the damaged fuel pins remain coolable. Metal fuel is compatible with sodium coolant, eliminating the potential of energetic fuel--coolant reactions and flow blockages. All these, and the low retained heat leading to a longer grace period for operator action, are significant contributing factors to the inherently benign response of metallic fuel to postulated accidents. This paper summarizes the past analytical and experimental results obtained in past sodium-cooled fast reactor safety programs in the United States, and presents an overview of fuel safety performance as observed in laboratory and in-pile tests.« less

A review of inherent safety characteristics of metal alloy sodium-cooled fast reactor fuel against postulated accidents

DOE Office of Scientific and Technical Information (OSTI.GOV)

Sofu, Tanju

2015-04-01

The thermal, mechanical, and neutronic performance of the metal alloy fast reactor fuel design complements the safety advantages of the liquid metal cooling and the pool-type primary system. Together, these features provide large safety margins in both normal operating modes and for a wide range of postulated accidents. In particular, they maximize the measures of safety associated with inherent reactor response to unprotected, double-fault accidents, and to minimize risk to the public and plant investment. High thermal conductivity and high gap conductance play the most significant role in safety advantages of the metallic fuel, resulting in a flatter radial temperaturemore » profile within the pin and much lower normal operation and transient temperatures in comparison to oxide fuel. Despite the big difference in melting point, both oxide and metal fuels have a relatively similar margin to melting during postulated accidents. When the metal fuel cladding fails, it typically occurs below the coolant boiling point and the damaged fuel pins remain cool-able. Metal fuel is compatible with sodium coolant, eliminating the potential of energetic fuel coolant reactions and flow blockages. All these, and the low retained heat leading to a longer grace period for operator action, are significant contributing factors to the inherently benign response of metallic fuel to postulated accidents. This paper summarizes the past analytical and experimental results obtained in past sodium-cooled fast reactor safety programs in the United States, and presents an overview of fuel safety performance as observed in laboratory and in-pile tests.« less

Fuel clad chemical interactions in fast reactor MOX fuels

NASA Astrophysics Data System (ADS)

Viswanathan, R.

2014-01-01

Clad corrosion being one of the factors limiting the life of a mixed-oxide fast reactor fuel element pin at high burn-up, some aspects known about the key elements (oxygen, cesium, tellurium, iodine) in the clad-attack are discussed and many Fuel-Clad-Chemical-Interaction (FCCI) models available in the literature are also discussed. Based on its relatively superior predictive ability, the HEDL (Hanford Engineering Development Laboratory) relation is recommended: d/μm = ({0.507 ṡ [B/(at.% fission)] ṡ (T/K-705) ṡ [(O/M)i-1.935]} + 20.5) for (O/M)i ⩽ 1.98. A new model is proposed for (O/M)i ⩾ 1.98: d/μm = [B/(at.% fission)] ṡ (T/K-800)0.5 ṡ [(O/M)i-1.94] ṡ [P/(W cm-1)]0.5. Here, d is the maximum depth of clad attack, B is the burn-up, T is the clad inner surface temperature, (O/M)i is the initial oxygen-to-(uranium + plutonium) ratio, and P is the linear power rating. For fuels with [n(Pu)/n(M = U + Pu)] > 0.25, multiplication factors f are recommended to consider the potential increase in the depth of clad-attack.

Report on the Synchrotron Characterization of U-Mo and U-Zr Alloys and the Modeling Results

DOE Office of Scientific and Technical Information (OSTI.GOV)

Okuniewski, Maria A.; Ganapathy, Varsha; Hamilton, Brenden

2016-09-01

ABSTRACT Uranium-molybdenum (U-Mo) and uranium-zirconium (U-Zr) are two promising fuel candidates for nuclear transmutation reactors which burn long-lived minor actinides and fission products within fast spectrum reactors. The objectives of this research are centered on understanding the early stages of fuel performance through the examination of the irradiation induced microstructural changes in U-Zr and U-Mo alloys subjected to low neutron fluences. Specimens that were analyzed include those that were previously irradiated in the Advanced Test Reactor at INL. This most recent work has focused on a sub-set of the irradiated specimens, specifically U-Zr and U-Mo alloys that were irradiated tomore » 0.01 dpa at temperatures ranging from (150-800oC). These specimens were analyzed with two types of synchrotron techniques, including X-ray absorption fine structure and X-ray diffraction. These techniques provide non-destructive microstructural analysis, including phase identification and quantitation, lattice parameters, crystallite sizes, as well as bonding, structure, and chemistry. Preliminary research has shown changes in the phase fractions, crystallite sizes, and lattice parameters as a function of irradiation and temperature. Future data analyses will continue to explore these microstructural changes.« less

Irradiation performance of PFBR MOX fuel after 112 GWd/t burn-up

NASA Astrophysics Data System (ADS)

Venkiteswaran, C. N.; Jayaraj, V. V.; Ojha, B. K.; Anandaraj, V.; Padalakshmi, M.; Vinodkumar, S.; Karthik, V.; Vijaykumar, Ran; Vijayaraghavan, A.; Divakar, R.; Johny, T.; Joseph, Jojo; Thirunavakkarasu, S.; Saravanan, T.; Philip, John; Rao, B. P. C.; Kasiviswanathan, K. V.; Jayakumar, T.

2014-06-01

The 500 MWe Prototype Fast Breeder Reactor (PFBR) which is in advanced stage of construction at Kalpakkam, India, will use mixed oxide (MOX) fuel with a target burnup of 100 GWd/t. The fuel pellet is of annular design to enable operation at a peak linear power of 450 W/cm with the requirement of minimum duration of pre-conditioning. The performance of the MOX fuel and the D9 clad and wrapper material was assessed through Post Irradiation Examinations (PIE) after test irradiation of 37 fuel pin subassembly in Fast Breeder Test Reactor (FBTR) to a burn-up of 112 GWd/t. Fission product distribution, swelling and fuel-clad gap evolution, central hole diameter variation, restructuring, fission gas release and clad wastage due to fuel-clad chemical interaction were evaluated through non-destructive and destructive examinations. The examinations have indicated that the MOX fuel can safely attain the desired target burn-up in PFBR.

Observations Derived From the Characterization of Monolithic Fuel Plates Irradiated as Part of the RERTR-6 Experiment

DOE Office of Scientific and Technical Information (OSTI.GOV)

D. D. Keiser, Jr.; A. B. Robinson; M. R. Finlay

2007-09-01

Evaluation of the PIE results of the monolithic plates that were irradiated as part of the RERTR-6 experiment has continued. Specifically, comparisons have been made between the microstructures of the fuel plates before and after irradiation. Using the results from the rigorous characterization that was performed on the as-fabricated plates using scanning electron microscopy, it is possible to improve understanding of how monolithic fuel plates perform when they are irradiated. This paper will discuss the changes that occur, if any, in the microstructure of a monolithic fuel plate that is fabricated using techniques like what were employed for fabricating RERTR-6more » fuel plates. In addition, the performance of fuel/cladding interaction layers that were present in the fuel plates due to the fabrication process will be discussed, particularly in the context of swelling of these layers and how these layers exhibit different behaviors depending on whether the fuel alloy in the fuel plate is U-7Mo or U-10Mo.« less

The effect of particle size on the heat affected zone during laser cladding of Ni-Cr-Si-B alloy on C45 carbon steel

NASA Astrophysics Data System (ADS)

Tanigawa, Daichi; Abe, Nobuyuki; Tsukamoto, Masahiro; Hayashi, Yoshihiko; Yamazaki, Hiroyuki; Tatsumi, Yoshihiro; Yoneyama, Mikio

2018-02-01

Laser cladding is one of the most useful surface coating methods for improving the wear and corrosion resistance of material surfaces. Although the heat input associated with laser cladding is small, a heat affected zone (HAZ) is still generated within the substrate because this is a thermal process. In order to reduce the area of the HAZ, the heat input must therefore be reduced. In the present study, we examined the effects of the powdered raw material particle size on the heat input and the extent of the HAZ during powder bed laser cladding. Ni-Cr-Si-B alloy layers were produced on C45 carbon steel substrates in conjunction with alloy powders having average particle sizes of 30, 40 and 55 μm, while measuring the HAZ area by optical microscopy. The heat input required for layer formation was found to decrease as smaller particles were used, such that the HAZ area was also reduced.

High temperature, low-cycle fatigue of copper-base alloys in argon. Part 1: Preliminary results for 12 alloys at 1000 F (538 C)

NASA Technical Reports Server (NTRS)

Conway, J. B.; Stentz, R. H.; Berling, J. T.

1973-01-01

Short-term tensile evaluations at room temperature and 538 C and low-cycle fatigue evaluations at 538 C are presented for the following materials: Zirconium copper-annealed, Zirconium copper-1/4 hard, Zirconium copper-1/2 hard, Tellurium copper-1/2 hard, Chromium copper-SA and aged, OFHC copper-hard, OFHC copper-1/4 hard, OFHC copper-annealed, Silver-as drawn, Zr-Cr-Mg copper-SA, CW and aged, Electroformed copper-30-35 ksi, and Co-Be-Zr- copper-SA, aged. A total of 50 tensile tests and 76 low-cycle fatigue tests were performed using a strain rate of 0.2 percent per second.

Fuel Performance Calculations for FeCrAl Cladding in BWRs

DOE Office of Scientific and Technical Information (OSTI.GOV)

George, Nathan; Sweet, Ryan; Maldonado, G. Ivan

2015-01-01

This study expands upon previous neutronics analyses of the reactivity impact of alternate cladding concepts in boiling water reactor (BWR) cores and directs focus toward contrasting fuel performance characteristics of FeCrAl cladding against those of traditional Zircaloy. Using neutronics results from a modern version of the 3D nodal simulator NESTLE, linear power histories were generated and supplied to the BISON-CASL code for fuel performance evaluations. BISON-CASL (formerly Peregrine) expands on material libraries implemented in the BISON fuel performance code and the MOOSE framework by providing proprietary material data. By creating material libraries for Zircaloy and FeCrAl cladding, the thermomechanical behaviormore » of the fuel rod (e.g., strains, centerline fuel temperature, and time to gap closure) were investigated and contrasted.« less

A study on wear resistance and microcrack of the Ti 3Al/TiAl + TiC ceramic layer deposited by laser cladding on Ti-6Al-4V alloy

NASA Astrophysics Data System (ADS)

Li, Jianing; Chen, Chuanzhong; Squartini, Tiziano; He, Qingshan

2010-12-01

Laser cladding of the Al + TiC alloy powder on Ti-6Al-4V alloy can form the Ti 3Al/TiAl + TiC ceramic layer. In this study, TiC particle-dispersed Ti 3Al/TiAl matrix ceramic layer on the Ti-6Al-4V alloy by laser cladding has been researched by means of X-ray diffraction, scanning electron microscope, electron probe micro-analyzer, energy dispersive spectrometer. The main difference from the earlier reports is that Ti 3Al/TiAl has been chosen as the matrix of the composite coating. The wear resistance of the Al + 30 wt.% TiC and the Al + 40 wt.% TiC cladding layer was approximately 2 times greater than that of the Ti-6Al-4V substrate due to the reinforcement of the Ti 3Al/TiAl + TiC hard phases. However, when the TiC mass percent was above 40 wt.%, the thermal stress value was greater than the materials yield strength limit in the ceramic layer, the microcrack was present and its wear resistance decreased.

Suppression of dilution in Ni-Cr-Si-B alloy cladding layer by controlling diode laser beam profile

NASA Astrophysics Data System (ADS)

Tanigawa, Daichi; Funada, Yoshinori; Abe, Nobuyuki; Tsukamoto, Masahiro; Hayashi, Yoshihiko; Yamazaki, Hiroyuki; Tatsumi, Yoshihiro; Yoneyama, Mikio

2018-02-01

A Ni-Cr-Si-B alloy layer was produced on a type 304 stainless steel plate by laser cladding. In order to produce cladding layer with smooth surface and low dilution, influence of laser beam profile on cladding layer was investigated. A laser beam with a constant spatial intensity at the focus spot was used to suppress droplet formation during the cladding layer formation. This line spot, formed with a focussing unit designed by our group, suppressed droplet generation. The layer formed using this line spot with a constant spatial intensity had a much smoother surface compared to a layer formed using a line spot with a Gaussian-like beam. In addition, the dilution of the former layer was much smaller. These results indicated that a line spot with a constant spatial intensity was more effective in producing a cladding layer with smooth surface and low dilution because it suppressed droplet generation.

Models for the Configuration and Integrity of Partially Oxidized Fuel Rod Cladding at High Temperatures

DOE Office of Scientific and Technical Information (OSTI.GOV)

Siefken, L.J.

1999-01-01

Models were designed to resolve deficiencies in the SCDAP/RELAP5/MOD3.2 calculations of the configuration and integrity of hot, partially oxidized cladding. These models are expected to improve the calculations of several important aspects of fuel rod behavior. First, an improved mapping was established from a compilation of PIE results from severe fuel damage tests of the configuration of melted metallic cladding that is retained by an oxide layer. The improved mapping accounts for the relocation of melted cladding in the circumferential direction. Then, rules based on PIE results were established for calculating the effect of cladding that has relocated from abovemore » on the oxidation and integrity of the lower intact cladding upon which it solidifies. Next, three different methods were identified for calculating the extent of dissolution of the oxidic part of the cladding due to its contact with the metallic part. The extent of dissolution effects the stress and thus the integrity of the oxidic part of the cladding. Then, an empirical equation was presented for calculating the stress in the oxidic part of the cladding and evaluating its integrity based on this calculated stress. This empirical equation replaces the current criterion for loss of integrity which is based on temperature and extent of oxidation. Finally, a new rule based on theoretical and experimental results was established for identifying the regions of a fuel rod with oxidation of both the inside and outside surfaces of the cladding. The implementation of these models is expected to eliminate the tendency of the SCDAP/RELAP5 code to overpredict the extent of oxidation of the upper part of fuel rods and to underpredict the extent of oxidation of the lower part of fuel rods and the part with a high concentration of relocated material. This report is a revision and reissue of the report entitled, Improvements in Modeling of Cladding Oxidation and Meltdown.« less

Lattice-mismatched GaInP LED devices and methods of fabricating same

DOEpatents

Mascarenhas, Angelo; Steiner, Myles A; Bhusal, Lekhnath; Zhang, Yong

2014-10-21

A method (100) of fabricating an LED or the active regions of an LED and an LED (200). The method includes growing, depositing or otherwise providing a bottom cladding layer (208) of a selected semiconductor alloy with an adjusted bandgap provided by intentionally disordering the structure of the cladding layer (208). A first active layer (202) may be grown above the bottom cladding layer (208) wherein the first active layer (202) is fabricated of the same semiconductor alloy, with however, a partially ordered structure. The first active layer (202) will also be fabricated to include a selected n or p type doping. The method further includes growing a second active layer (204) above the first active layer (202) where the second active layer (204) Is fabricated from the same semiconductor alloy.

Improvement in Microstructure Performance of the NiCrBSi Reinforced Coating on TA15 Titanium Alloy

NASA Astrophysics Data System (ADS)

Peng, Li

2012-10-01

This work is based on the dry sliding wear of NiCrBSi reinforced coating deposited on TA15 titanium alloy using the laser cladding technique, the parameters of which were such as to provide almost crack-free coatings with minimum dilution and very low porosity. SEM results indicated that a laser clad coating with metallurgical joint to the substrate was formed. Compared with TA15 substrate, an improvement of the micro-hardness and wear resistance was observed for this composite coating. Rare earth oxide Y2O3 was beneficial in producing of the amorphous phases in laser clad coating. With addition of Y2O3, more amorphous alloys were produced, which increased the micro-hardness and wear resistance of the coating.

Oxide particle size distribution from shearing irradiated and unirradiated LWR fuels in Zircaloy and stainless steel cladding: significance for risk assessment

DOE Office of Scientific and Technical Information (OSTI.GOV)

Davis, W. Jr.; West, G.A.; Stacy, R.G.

1979-03-22

Sieve fractionation was performed with oxide particles dislodged during shearing of unirradiated or irradiated fuel bundles or single rods of UO/sub 2/ or 96 to 97% ThO/sub 2/--3 to 4% UO/sub 2/. Analyses of these data by nonlinear least-squares techniques demonstrated that the particle size distribution is lognormal. Variables involved in the numerical analyses include lognormal median size, lognormal standard deviation, and shear cut length. Sieve-fractionation data are presented for unirradiated bundles of stainless-steel-clad or Zircaloy-2-clad UO/sub 2/ or ThO/sub 2/--UO/sub 2/ sheared into lengths from 0.5 to 2.0 in. Data are also presented for irradiated single rods (sheared intomore » lengths of 0.25 to 2.0 in.) of Zircaloy-2-clad UO/sub 2/ from BWRs and of Zircaloy-4-clad UO/sub 2/ from PWRs. Median particle sizes of UO/sub 2/ from shearing irradiated stainless-steel-clad fuel ranged from 103 to 182 ..mu..m; particle sizes of ThO/sub 2/--UO/sub 2/, under these same conditions, ranged from 137 to 202 ..mu..m. Similarly, median particle sizes of UO/sub 2/ from shearing unirradiated Zircaloy-2-clad fuel ranged from 230 to 957 ..mu..m. Irradiation levels of fuels from reactors ranged from 9,000 to 28,000 MWd/MTU. In general, particle sizes from shearing these irradiated fuels are larger than those from the unirradiated fuels; however, unirradiated fuel from vendors was not available for performing comparative shearing experiments. In addition, variations in particle size parameters pertaining to samples of a single vendor varied as much as those between different vendors. The fraction of fuel dislodged from the cladding is nearly proportional to the reciprocal of the shear cut length, until the cut length attains some minimum value below which all fuel is dislodged. Particles of fuel are generally elongated with a long-to-short axis ratio usually less than 3. Using parameters of the lognormal distribution estimates can be made of fractions of dislodged fuel having dimensions less than specified values.« less

Acoustic emission characteristics of copper alloys under low-cycle fatigue conditions

NASA Technical Reports Server (NTRS)

Krampfner, Y.; Kawamoto, A.; Ono, K.; Green, A.

1975-01-01

The acoustic emission (AE) characteristics of pure copper, zirconium-copper, and several copper alloys were determined to develop nondestructive evaluation schemes of thrust chambers through AE techniques. The AE counts rms voltages, frequency spectrum, and amplitude distribution analysis evaluated AE behavior under fatigue loading conditions. The results were interpreted with the evaluation of wave forms, crack propagation characteristics, as well as scanning electron fractographs of fatigue-tested samples. AE signals at the beginning of a fatigue test were produced by a sample of annealed alloys. A sample of zirconium-containing alloys annealed repeatedly after each fatigue loading cycle showed numerous surface cracks during the subsequent fatigue cycle, emitting strong-burst AE signals. Amplitude distribution analysis exhibits responses that are characteristic of certain types of AE signals.

Uranium dioxide fuel cladding strain investigation with the use of CYGRO-2 computer program

NASA Technical Reports Server (NTRS)

Smith, J. R.

1973-01-01

Previously irradiated UO2 thermionic fuel pins in which gross fuel-cladding strain occurred were modeled with the use of a computer program to define controlling parameters which may contribute to cladding strain. The computed strain was compared with measured strain, and the computer input data were studied in an attempt to get agreement with measured strain. Because of the limitations of the program and uncertainties in input data, good agreement with measured cladding strain was not attained. A discussion of these limitations is presented.

Reactor Physics Assessment of Thick Silicon Carbide Clad PWR Fuels

DTIC Science & Technology

2013-06-01

Densities ............................................................................................................ 21 2.3 Fuel Mass (Core Total...70 7.1 Geometry, Material Density, and Mass Summary for All Cores...21 Table 3: Fuel Rod Masses for Different Clads

Between-cycle laser system for depressurization and resealing of modified design nuclear fuel assemblies

DOEpatents

Bradley, John G.

1982-01-01

A laser beam is used to puncture fuel cladding for release of contained pressurized fission gas from plenum sections or irradiated fuel pins. Exhausted fission gases are collected and trapped for safe disposal. The laser beam, adjusted to welding mode, is subsequently used to reseal the puncture holes. The fuel assembly is returned to additional irradiation or, if at end of reactivity lifetime, is routed to reprocess. The fuel assembly design provides graded cladding lengths, by rows or arrays, such that the cladding of each component fuel element of the assembly is accessible to laser beam reception.

Early implementation of SiC cladding fuel performance models in BISON

DOE Office of Scientific and Technical Information (OSTI.GOV)

Powers, Jeffrey J.

2015-09-18

SiC-based ceramic matrix composites (CMCs) [5–8] are being developed and evaluated internationally as potential LWR cladding options. These development activities include interests within both the DOE-NE LWR Sustainability (LWRS) Program and the DOE-NE Advanced Fuels Campaign. The LWRS Program considers SiC ceramic matrix composites (CMCs) as offering potentially revolutionary gains as a cladding material, with possible benefits including more efficient normal operating conditions and higher safety margins under accident conditions [9]. Within the Advanced Fuels Campaign, SiC-based composites are a candidate ATF cladding material that could achieve several goals, such as reducing the rates of heat and hydrogen generation duemore » to lower cladding oxidation rates in HT steam [10]. This work focuses on the application of SiC cladding as an ATF cladding material in PWRs, but these work efforts also support the general development and assessment of SiC as an LWR cladding material in a much broader sense.« less

Risk Assessment of Structural Integrity of Transportation Casks after Extended Storage

DOE Office of Scientific and Technical Information (OSTI.GOV)

Ibarra, Luis; Medina, Ricardo; Yang, Haori

This study assessed the risk of loss of structural integrity of transportation casks and fuel cladding after extended storage. Although it is known that fuel rods discharged from NPPs have a small percentage of rod cladding defects, the behavior of fuel cladding and the structural elements of assemblies during transportation after long-term storage is not well understood. If the fuel degrades during extended storage, it could be susceptible to damage from vibration and impact loads during transport operations, releasing fission-product gases into the canister or the cask interior (NWTRB 2010). Degradation of cladding may occur due to mechanisms associated withmore » hydrogen embrittlement, delayed hydride cracking, low temperature creep, and stress corrosion cracking (SCC) that may affect fuel cladding and canister components after extended storage of hundreds of years. Over extended periods at low temperatures, these mechanisms affect the ductility, strength, and fracture toughness of the fuel cladding, which becomes brittle. For transportation purposes, the fuel may be transferred from storage to shipping casks, or dual-purpose casks may be used for storage and transportation. Currently, most of the transportation casks will be the former case. A risk assessment evaluation is conducted based on results from experimental tests and simulations with advanced numerical models. A novel contribution of this study is the evaluation of the combined effect of component aging and vibration/impact loads in transportation scenarios. The expected levels of deterioration will be obtained from previous and current studies on the effect of aging on fuel and cask components. The emphasis of the study is placed on the structural integrity of fuel cladding and canisters.« less

Microstructure and properties of Fe-based composite coating by laser cladding Fe-Ti-V-Cr-C-CeO2 powder

NASA Astrophysics Data System (ADS)

Zhang, Hui; Zou, Yong; Zou, Zengda; Wu, Dongting

2015-01-01

In situ TiC-VC reinforced Fe-based cladding layer was obtained on low carbon steel surface by laser cladding with Fe-Ti-V-Cr-C-CeO2 alloy powder. The microstructure, phases and properties of the cladding layer were investigated by X-ray diffractometry (XRD), scanning electron microscopy (SEM), energy dispersive spectrometry (EDS), transmission electron microscopy (TEM), potentio-dynamic polarization and electro-chemical impedance spectroscopy (EIS). Results showed Fe-Ti-V-Cr-C-CeO2 alloy powder formed a good cladding layer without defects such as cracks and pores. The phases of the cladding layer were α-Fe, γ-Fe, TiC, VC and TiVC2. The microstructures of the cladding layer matrix were lath martensite and retained austenite. The carbides were polygonal blocks with a size of 0.5-2 μm and distributed uniformly in the cladding layer. High resolution transmission electron microscopy showed the carbide was a complex matter composed of nano TiC, VC and TiVC2. The cladding layer with a hardness of 1030 HV0.2 possessed good wear and corrosion resistance, which was about 16.85 and 9.06 times than that of the substrate respectively.

Irradiation of TZM: Uranium dioxide fuel pin at 1700 K

NASA Technical Reports Server (NTRS)

Mcdonald, G. E.

1973-01-01

A fuel pin clad with TZM and containing solid pellets of uranium dioxide was fission heated in a static helium-cooled capsule at a maximum surface temperature of 1700 K for approximately 1000 hr and to a total burnup of 2.0 percent of the uranium-235. The results of the postirradiation examination indicated: (1) A transverse, intergranular failure of the fuel pin occurred when the fuel pin reached 2.0-percent burnup. This corresponds to 1330 kW-hr/cu cm, where the volume is the sum of the fuel, clad, and void volumes in the fuel region. (2) The maximum swelling of the fuel pin was less than 1.5 percent on the fuel-pin diameter. (3) There was no visible interaction between the TZM clad and the UO2. (4) Irradiation at 1700 K produced a course-grained structure, with an average grain diameter of 0.02 centimeter and with some of the grains extending one-half of the thickness of the clad. (5) Below approximately 1500 K, the irradiation of the clad produced a moderately fine-grained structure, with an average grain diameter of 0.004 centimeter.

Submersion Quenching of Undercooled Liquid Metals in an Electrostatic Levitator

NASA Technical Reports Server (NTRS)

SanSoucie, Michael P.; Rogers, Jan R.

2016-01-01

The NASA Marshall Space Flight Center (MSFC) electrostatic levitation (ESL) laboratory has a long history of providing materials research and thermophysical property data. The laboratory has recently added a new capability, a rapid quench system. This system allows samples to be dropped into a quench vessel that can be filled with a low melting point material, such as a gallium or indium alloy. Thereby allowing rapid quenching of undercooled liquid metals and alloys. This is the first submersion quench system inside an electrostatic levitator. The system has been tested successfully with samples of zirconium, iron-cobalt alloys, titanium-zirconium-nickel alloys, and silicon-cobalt alloys. This rapid quench system will allow materials science studies of undercooled materials and new materials development, including studies of metastable phases and transient microstructures. In this presentation, the system is described and some initial results are presented.

BISON Investigation of the Effect of the Fuel- Cladding Contact Irregularities on the Peak Cladding Temperature and FCCI Observed in AFC-3A Rodlet 4

DOE Office of Scientific and Technical Information (OSTI.GOV)

Medvedev, Pavel G.

2016-09-01

The primary objective of this report is to document results of BISON analyses supporting Fuel Cycle Research and Development (FCRD) activities. Specifically, the present report seeks to provide explanation for the microstructural features observed during post irradiation examination of the helium-bonded annular U-10Zr fuel irradiated during the AFC-3A experiment. Post irradiation examination of the AFC-3A rodlet revealed microstructural features indicative of the fuel-cladding chemical interaction (FCCI) at the fuel-cladding interface. Presence of large voids was also observed in the same locations. BISON analyses were performed to examine stress and temperature profiles and to investigate possible correlation between the voids andmore » FCCI. It was found that presence of the large voids lead to a formation of circumferential temperature gradients in the fuel that may have redirected migrating lanthanides to the locations where fuel and cladding are in contact. Resulting localized increase of lanthanide concentration is expected to accelerate FCCI. The results of this work provide important guidance to the post irradiation examination studies. Specifically, the hypothesis of lanthanides being redirected from the voids to the locations where the fuel and the cladding are in contact should be verified by conducting quantitative electron microscopy or Electron Probe Micro-Analyzer (EPMA). The results also highlight the need for computer models capable of simulating lanthanide diffusion in metallic fuel and establish a basis for validation of such models.« less

Double-clad nuclear fuel safety rod

DOEpatents

McCarthy, William H.; Atcheson, Donald B.; Vaidyanathan, Swaminathan

1984-01-01

A device for shutting down a nuclear reactor during an undercooling or overpower event, whether or not the reactor's scram system operates properly. This is accomplished by double-clad fuel safety rods positioned at various locations throughout the reactor core, wherein melting of a secondary internal cladding of the rod allows the fuel column therein to shift from the reactor core to place the reactor in a subcritical condition.

Double-clad nuclear-fuel safety rod

DOEpatents

McCarthy, W.H.; Atcheson, D.B.

1981-12-30

A device for shutting down a nuclear reactor during an undercooling or overpower event, whether or not the reactor's scram system operates properly. This is accomplished by double-clad fuel safety rods positioned at various locations throughout the reactor core, wherein melting of a secondary internal cladding of the rod allows the fuel column therein to shift from the reactor core to place the reactor in a subcritical condition.

FUEL ELEMENT CONSTRUCTION

DOEpatents

Zumwalt, L.R.

1961-08-01

Fuel elements having a solid core of fissionable material encased in a cladding material are described. A conversion material is provided within the cladding to react with the fission products to form stable, relatively non- volatile compounds thereby minimizing the migration of the fission products into the coolant. The conversion material is preferably a metallic fluoride, such as lead difluoride, and may be in the form of a coating on the fuel core or interior of the cladding, or dispersed within the fuel core. (AEC)

High temperature, low-cycle fatigue of copper-base alloys in argon. Part 2: Zirconium-copper at 482, 538 and 593 C

NASA Technical Reports Server (NTRS)

Conway, J. B.; Stentz, R. H.; Berling, J. T.

1973-01-01

Zirconium-copper (1/2 hard) was tested in argon over the temperature range from 482 to 593 C in an evaluation of short-term tensile and low-cycle fatigue behavior. The effect of strain rate on the tensile properties was evaluated at 538 C and in general it was found that the yield and ultimate strengths increased as the strain rate was increased from 0.0004 to 0.01/sec. Ductility was essentially insensitive to strain rate in the case of the zirconium-copper alloy. Strain-rate and hold-time effects on the low cycle fatigue behavior of zirconium-copper were evaluated in argon at 538 C. These effects were as expected in that decreased fatigue life was noted as the strain rate decreased and when hold times were introduced into the tension portion of the strain-cycle. Hold times in compression were much less detrimental than hold times in tension.

Axisymmetric whole pin life modelling of advanced gas-cooled reactor nuclear fuel

NASA Astrophysics Data System (ADS)

Mella, R.; Wenman, M. R.

2013-06-01

Thermo-mechanical contributions to pellet-clad interaction (PCI) in advanced gas-cooled reactors (AGRs) are modelled in the ABAQUS finite element (FE) code. User supplied sub-routines permit the modelling of the non-linear behaviour of AGR fuel through life. Through utilisation of ABAQUS's well-developed pre- and post-processing ability, the behaviour of the axially constrained steel clad fuel was modelled. The 2D axisymmetric model includes thermo-mechanical behaviour of the fuel with time and condition dependent material properties. Pellet cladding gap dynamics and thermal behaviour are also modelled. The model treats heat up as a fully coupled temperature-displacement study. Dwell time and direct power cycling was applied to model the impact of online refuelling, a key feature of the AGR. The model includes the visco-plastic behaviour of the fuel under the stress and irradiation conditions within an AGR core and a non-linear heat transfer model. A multiscale fission gas release model is applied to compute pin pressure; this model is coupled to the PCI gap model through an explicit fission gas inventory code. Whole pin, whole life, models are able to show the impact of the fuel on all segments of cladding including weld end caps and cladding pellet locking mechanisms (unique to AGR fuel). The development of this model in a commercial FE package shows that the development of a potentially verified and future-proof fuel performance code can be created and used. The usability of a FE based fuel performance code would be an enhancement over past codes. Pre- and post-processors have lowered the entry barrier for the development of a fuel performance model to permit the ability to model complicated systems. Typical runtimes for a 5 year axisymmetric model takes less than one hour on a single core workstation. The current model has implemented: Non-linear fuel thermal behaviour, including a complex description of heat flow in the fuel. Coupled with a variety of different FE and finite difference models. Non-linear mechanical behaviour of the fuel and cladding including, fuel creep and swelling and cladding creep and plasticity each with dependencies on a variety of different properties. A fission gas release model which takes inputs from first principles calculations. Explicitly integrated inventory calculations performed in a coupled manner. Freedom to model steady state and transient behaviour using implicit time integration. The whole pin geometry is considered over an entire typical fuel life. The model showed by examination of normal operation and a subsequent transient chosen for software demonstration purposes: ABAQUS may be a sufficiently flexible platform to develop a complete and verified fuel performance code. The importance and effectiveness of the geometry of the fuel spacer pellets was characterised. The fuels performance under normal conditions (high friction no power spikes) would not suggest serious degradation of the cladding in fuel life. Large plastic strains were found when pellet bonding was strong, these would appear at all pellets cladding triple points and all pellet radial crack and cladding interfaces thus showing a possible axial direction to cracks forming from ductility exhaustion.

Development of modified MDA (M-MDA), PWR fuel cladding tube for high duty operation in future

DOE Office of Scientific and Technical Information (OSTI.GOV)

Watanabe, Seiichi; Kido, Toshiya; Arakawa, Yasushi

2007-07-01

A new cladding material of M-MDA has been developed in order to prepare for a strong growing demand for advanced fuel which can maintain its integrity even under high duties due to more efficient operation such as higher burnup, higher LHR, and longer operation cycle which will contribute the suppression of environmental burdens like CO{sub 2} emission. The main aim of M-MDA is to have excellent corrosion resistance while the other properties are inherited from MDA, which has been adopted to the step 2 fuel, instead of Zry-4, of Japanese PWR plant whose upper limit of assembly discharged burnup ismore » 55 MWd/kgU. And we could confirm that the main aim of M-MDA was achieved by means of out-of-pile tests. In order to confirm improvement of corrosion resistance of M-MDA in the actual operation, irradiation test of M-MDA in the commercial reactor of Vandellos II is ongoing. The latest results of on-site examination after every end of cycle showed that oxide thickness of M-MDA-SR was much smaller than that of MDA at rod discharged burnup of approximately 60 MWd/kgU. The final irradiation cycle was completed on April 2007 and then we will obtain corrosion data of M-MDA over 70 MWd/kgU. M-MDA is a candidate alloy for advanced fuel under higher duty usage. (authors)« less

77 FR 52765 - Dominion Nuclear Connecticut, Inc. Millstone Power Station, Unit 3; Exemption

Federal Register 2010, 2011, 2012, 2013, 2014

2012-08-30

... energy release, hydrogen generation, and cladding oxidation from the metal/water reaction to be calculated using the Baker-Just equation (Baker, L., Just, L.C., ``Studies of Metal Water Reactions at High Temperatures, III. Experimental and Theoretical Studies of the Zirconium-Water Reaction,'' ANL-6548, page 7...

Full-length U-xPu-10Zr (x = 0, 8, 19 wt.%) fast reactor fuel test in FFTF

NASA Astrophysics Data System (ADS)

Porter, D. L.; Tsai, Hanchung

2012-08-01

The Integral Fast Reactor-1 (IFR-1) experiment performed in the Fast Flux Test Facility (FFTF) was the only U-Pu-10Zr (Pu-0, 8 and 19 wt.%) metallic fast reactor test with commercial-length (91.4-cm active fuel-column length) conducted to date. With few remaining test reactors, there is little opportunity for performing another test with a long active fuel column. The assembly was irradiated to the goal burnup of 10 at.%. The beginning-of-life (BOL) peak cladding temperature of the hottest pin was 608 °C, cooling to 522 °C at end-of-life (EOL). Selected fuel pins were examined non-destructively using neutron radiography, precision axial gamma scanning, and both laser and spiral contact cladding profilometry. Destructive exams included plenum gas pressure, volume, and gas composition determinations on a number of pins followed by optical metallography, electron probe microanalysis (EPMA), and alpha and beta-gamma autoradiography on a single U-19Pu-10Zr pin. The post-irradiation examinations (PIEs) showed very few differences compared to the short-pin (34.3-cm fuel column) testing performed on fuels of similar composition in Experimental Breeder Reactor-II (EBR-II). The fuel column grew axially slightly less than observed in the short pins, but with the same pattern of decreasing growth with increasing Pu content. There was a difference in the fuel-cladding chemical interaction (FCCI) in that the maximum cladding penetration by interdiffusion with fuel/fission products did not occur at the top of the fuel column where the cladding temperature is highest, as observed in EBR-II tests. Instead, the more exaggerated fission-rate profile of the FFTF pins resulted in a peak FCCI at ˜0.7 X/L axial location along the fuel column. This resulted from a higher production of rare-earth fission products at this location and a higher ΔT between fuel center and cladding than at core center, together providing more rare earths at the cladding and more FCCI. This behavior could actually help extend the life of a fuel pin in a "long pin" reactor design to a higher peak fuel burnup.

Boron and Zirconium from Crucible Refractories in a Complex Heat-Resistant Alloy

NASA Technical Reports Server (NTRS)

Decker, R F; Rowe, John P; Freeman, J W

1958-01-01

In a laboratory study of the factors involved in the influence of induction vacuum melting on 55ni-20cr-15co-4mo-3ti-3al heat resistant alloy, it was found that the major factor was the type of ceramic used as the crucible. The study concluded that trace amounts of boron or zirconium derived from reaction of the melt with the crucible refactories improved creep-rupture properties at 1,600 degrees F. Boron was most effective and, in addition, markedly improved hot-workability.

Basic elements of light water reactor fuel rod design. [FUELROD code

DOE Office of Scientific and Technical Information (OSTI.GOV)

Weisman, J.; Eckart, R.

1981-06-01

Basic design techniques and equations are presented to allow students to understand and perform preliminary fuel design for normal reactor conditions. Each of the important design considerations is presented and discussed in detail. These include the interaction between fuel pellets and cladding and the changes in fuel and cladding that occur during the operating lifetime of the fuel. A simple, student-oriented, fuel rod design computer program, called FUELROD, is described. The FUELROD program models the in-pile pellet cladding interaction and allows a realistic exploration of the effect of various design parameters. By use of FUELROD, the student can gain anmore » appreciation of the fuel rod design process. 34 refs.« less

URANIUM ALLOYS

DOEpatents

Seybolt, A.U.

1958-04-15

Uranium alloys containing from 0.1 to 10% by weight, but preferably at least 5%, of either zirconium, niobium, or molybdenum exhibit highly desirable nuclear and structural properties which may be improved by heating the alloy to about 900 d C for an extended period of time and then rapidly quenching it.

Mechanistic Considerations Used in the Development of the PROFIT PCI Failure Model

DOE Office of Scientific and Technical Information (OSTI.GOV)

Pankaskie, P. J.

A fuel Pellet-Zircaloy Cladding (thermo-mechanical-chemical) Interactions (PC!) failure model for estimating the probability of failure in !ransient increases in power (PROFIT) was developed. PROFIT is based on 1) standard statistical methods applied to available PC! fuel failure data and 2) a mechanistic analysis of the environmental and strain-rate-dependent stress versus strain characteristics of Zircaloy cladding. The statistical analysis of fuel failures attributable to PCI suggested that parameters in addition to power, transient increase in power, and burnup are needed to define PCI fuel failures in terms of probability estimates with known confidence limits. The PROFIT model, therefore, introduces an environmentalmore » and strain-rate dependent strain energy absorption to failure (SEAF) concept to account for the stress versus strain anomalies attributable to interstitial-disloction interaction effects in the Zircaloy cladding. Assuming that the power ramping rate is the operating corollary of strain-rate in the Zircaloy cladding, then the variables of first order importance in the PCI fuel failure phenomenon are postulated to be: 1. pre-transient fuel rod power, P{sub I}, 2. transient increase in fuel rod power, {Delta}P, 3. fuel burnup, Bu, and 4. the constitutive material property of the Zircaloy cladding, SEAF.« less

iMAST FY2007 Annual Report

DTIC Science & Technology

2007-01-01

laser cladding techniques. Customer: COMSUBPAC NAVSEASYSCOM Pearl Harbor Naval Shipyard...motion device to laser clad and re-dimension the affected tube to original specifications. Benefits: ° Reduce life cycle costs of tube...coatings via cold gas dynamic spraying and EB–PVD ° Spray-formed HT aluminum alloys ° Localized laser HT and cladding for wear

Amorphous metal alloy

DOEpatents

Wang, R.; Merz, M.D.

1980-04-09

Amorphous metal alloys of the iron-chromium and nickel-chromium type have excellent corrosion resistance and high temperature stability and are suitable for use as a protective coating on less corrosion resistant substrates. The alloys are stabilized in the amorphous state by one or more elements of titanium, zirconium, hafnium, niobium, tantalum, molybdenum, and tungsten. The alloy is preferably prepared by sputter deposition.

METALLURGY DIVISION QUARTERLY REPORT FOR JULY, AUGUST, AND SEPTEMBER 1957

DOE Office of Scientific and Technical Information (OSTI.GOV)

None

1958-10-01

Advanced Water Reactor Program. Three firings were made of initial closed-porosity fuel pellet bodies. Each firing coatained pellets of the composition 90 wt.% ThO/sub 2/-10 wt.%fl U0/sub 2/ with various additives and firing variables. Fast Power Breeder Reactor Program. To determine the potential usefulness of a Zr-5 wt. % Pu alloy, the fabricability of the alloy was tested. The manufacture of rod stock from which fuel and blanket elements for the Mark III loading of the EBR-1 were prcduced has been completed. The effect of irradiation on extruded and heat-treated U-2 wt.% Zr alloy for the EBR- 1 is reported.more » Fabrication procedures for making graphite-U/sub 3/O/sub 8/ test specimens for the TREAT Reactor were investigated. Advanced Engineering and Development. Ultrasonic bond tests were conducted on 590 EBR-1 Mark III blanket fuel elemeats. The blanket rods and part of the fuel rcds for the EBR-1 Mark III loading are being checked for cladding thickness by an eddy current system. Investigations of corrosionresistant Zr-Nb alloy were coatinued. Corrosion of MR alloys is being studied Ln support of the Mighty Mouse reactor program. Dynamic corrosion tests were performed on aluminum alloys, and results are included. Prcduction, Treatment, and Properties of Materials. The progress of the program of preparing highpurity Pu by fused salt electrolysis is summarized. Velocities of ultrasonic waves propagated in directions suitable for determining the room- temperature elastic moduli C/sub 12/, C/sub 13/, and C/sub 23/ of alpha U were determined. investigation of recrystallization in heavily coldrolled alpha- uranium sheet without a texture change was essentially concluded during this quarter. Selfdiffasion runs in polycrystalline uranium in the gamma phase, using the sputtering technique, have yielded a tentative value for the diffusion coefficient between 10/sup -8/ and 10/sup -7/ cm/sup 2/second. The preparation of high-purity U-Pan alloys is reponted. The data for the alpha-tobeta transformation temperatures in high-purity U and U-C alloys were confirmed by experiments on new specimens. Microstructure, density, and thermal arrest data were obtained for several injection cast, nominal U-5 wt.%fl fissium and U-8 wt.%fl fissium alloys. Phase diagrams are preseated for U-Mo and U-Ru alloys. Alloy Theory and The Nature of Solids. Four new isomorphs of Ti/sub 2/Ni have been discovered. Effects of Irradiation on Materials. The experimental and analytical work on the radial distribution of thermal neutrons within cylindrically shaped fuel specimens during irradiation was completed. (For preceding period see ANL-5790.) (W.L.H.)« less

The SAS4A/SASSYS-1 Safety Analysis Code System, Version 5

DOE Office of Scientific and Technical Information (OSTI.GOV)

Fanning, T. H.; Brunett, A. J.; Sumner, T.

The SAS4A/SASSYS-1 computer code is developed by Argonne National Laboratory for thermal, hydraulic, and neutronic analysis of power and flow transients in liquidmetal- cooled nuclear reactors (LMRs). SAS4A was developed to analyze severe core disruption accidents with coolant boiling and fuel melting and relocation, initiated by a very low probability coincidence of an accident precursor and failure of one or more safety systems. SASSYS-1, originally developed to address loss-of-decay-heat-removal accidents, has evolved into a tool for margin assessment in design basis accident (DBA) analysis and for consequence assessment in beyond-design-basis accident (BDBA) analysis. SAS4A contains detailed, mechanistic models of transientmore » thermal, hydraulic, neutronic, and mechanical phenomena to describe the response of the reactor core, its coolant, fuel elements, and structural members to accident conditions. The core channel models in SAS4A provide the capability to analyze the initial phase of core disruptive accidents, through coolant heat-up and boiling, fuel element failure, and fuel melting and relocation. Originally developed to analyze oxide fuel clad with stainless steel, the models in SAS4A have been extended and specialized to metallic fuel with advanced alloy cladding. SASSYS-1 provides the capability to perform a detailed thermal/hydraulic simulation of the primary and secondary sodium coolant circuits and the balance-ofplant steam/water circuit. These sodium and steam circuit models include component models for heat exchangers, pumps, valves, turbines, and condensers, and thermal/hydraulic models of pipes and plena. SASSYS-1 also contains a plant protection and control system modeling capability, which provides digital representations of reactor, pump, and valve controllers and their response to input signal changes.« less

TEM study on the initial oxidation of Zircaloy-4 thin foil specimens heated in a low vacuum air condition at 280-300 °C

NASA Astrophysics Data System (ADS)

Wang, Zhen; Zhou, Bang-xin; Zhu, Wei; Wen, Bang; Yao, Mei-yi; Li, Qiang; Wu, Lu; Zhang, Jin-long; Fang, Zhong-qiang

2017-04-01

As one of the important structural materials in nuclear industry, the corrosion resistance of zirconium alloy limits their in-pile application. Therefore, it is necessary to investigate the corrosion mechanism of zirconium alloys. The zirconium-oxygen reaction at the O/M interface is one of the factors that affect the oxidation process. There are few reports in this regard. Ideally, the reaction process at the O/M interface has certain relevance with the initiation oxidation of zirconium, which provided a new way to investigate the reaction process by observing the initiation oxidation behaviours. To investigate the oxidation behaviours of zirconium alloy at the initial stage, in this paper, zircaloy-4 TEM thin foil specimens in 3 mm diameter were studied by TEM observation after heating in air condition with a vacuum of 3 Pa at 280 °C, 290 °C and 300 °C for 30 min exposures. The results show that, ZrO2 begin to nucleate at a size of 3-5 nm at a high Zr/O ratio of 10.4 and oxide layer formed while Zr/O was 4.6. As a result of stress caused by the P.B ratio of Zr, slip bands formed and a bcc structure sub-oxide b-ZrOx (a = 0.51 nm) grew up along with the slip bands was observed. At both sides of b-ZrOx, two hcp structure sub-oxides having the same a-axis lattice parameter and different c-axis lattice parameter were detected.

NEAMS-ATF M3 Milestone Report: Literature Review of Modeling of Radiation-Induced Swelling in Fe-Cr-Al Steels

DOE Office of Scientific and Technical Information (OSTI.GOV)

Bai, Xianming; Biner, Suleyman Bulent; Jiang, Chao

2015-12-01

Fe-Cr-Al steels are proposed as accident-tolerant-fuel (ATF) cladding materials in light water reactors due to their excellent oxidation resistance at high temperatures. Currently, the understanding of their performance in reactor environment is still limited. In this review, firstly we reviewed the experimental studies of Fe-Cr-Al based alloys with particular focus on the radiation effects in these alloys. Although limited data are available in literature, several previous and recent experimental studies have shown that Fe-Cr-Al based alloys have very good void swelling resistance at low and moderate irradiation doses but the growth of dislocation loops is very active. Overall, the behaviormore » of radiation damage evolution is similar to that in Fe-Cr ferritic/martensitic alloys. Secondly, we reviewed the rate theory-based modeling methods for modeling the coevolution of voids and dislocation loops in materials under irradiation such as Frenkel pair three-dimensional diffusion model (FP3DM) and cluster dynamics. Finally, we summarized and discussed our review and proposed our future plans for modeling radiation damage in Fe-Cr-Al based alloys.« less

Fabrication of Titanium-Niobium-Zirconium-Tantalium Alloy (TNZT) Bioimplant Components with Controllable Porosity by Spark Plasma Sintering

PubMed Central

Rechtin, Jack; Torresani, Elisa; Ivanov, Eugene; Olevsky, Eugene

2018-01-01

Spark Plasma Sintering (SPS) is used to fabricate Titanium-Niobium-Zirconium-Tantalum alloy (TNZT) powder—based bioimplant components with controllable porosity. The developed densification maps show the effects of final SPS temperature, pressure, holding time, and initial particle size on final sample relative density. Correlations between the final sample density and mechanical properties of the fabricated TNZT components are also investigated and microstructural analysis of the processed material is conducted. A densification model is proposed and used to calculate the TNZT alloy creep activation energy. The obtained experimental data can be utilized for the optimized fabrication of TNZT components with specific microstructural and mechanical properties suitable for biomedical applications. PMID:29364165

Numerical assessment of bone remodeling around conventionally and early loaded titanium and titanium-zirconium alloy dental implants.

PubMed

Akça, Kıvanç; Eser, Atılım; Çavuşoğlu, Yeliz; Sağırkaya, Elçin; Çehreli, Murat Cavit

2015-05-01

The aim of this study was to investigate conventionally and early loaded titanium and titanium-zirconium alloy implants by three-dimensional finite element stress analysis. Three-dimensional model of a dental implant was created and a thread area was established as a region of interest in trabecular bone to study a localized part of the global model with a refined mesh. The peri-implant tissues around conventionally loaded (model 1) and early loaded (model 2) implants were implemented and were used to explore principal stresses, displacement values, and equivalent strains in the peri-implant region of titanium and titanium-zirconium implants under static load of 300 N with or without 30° inclination applied on top of the abutment surface. Under axial loading, principal stresses in both models were comparable for both implants and models. Under oblique loading, principal stresses around titanium-zirconium implants were slightly higher in both models. Comparable stress magnitudes were observed in both models. The displacement values and equivalent strain amplitudes around both implants and models were similar. Peri-implant bone around titanium and titanium-zirconium implants experiences similar stress magnitudes coupled with intraosseous implant displacement values under conventional loading and early loading simulations. Titanium-zirconium implants have biomechanical outcome comparable to conventional titanium implants under conventional loading and early loading.

Characterization of Brazed Joints of C-C Composite to Cu-clad-Molybdenum

NASA Technical Reports Server (NTRS)

Singh, M.; Asthana, R.

2008-01-01

Carbon-carbon composites with either pitch+CVI matrix or resin-derived matrix were joined to copper-clad molybdenum using two active braze alloys, Cusil-ABA (1.75% Ti) and Ticusil (4.5% Ti). The brazed joints revealed good interfacial bonding, preferential precipitation of Ti at the composite/braze interface, and a tendency toward de-lamination in resin-derived C-C composite due to its low inter-laminar shear strength. Extensive braze penetration of the inter-fiber channels in the pitch+CVI C-C composites was observed. The relatively low brazing temperatures (<950 C) precluded melting of the clad layer and restricted the redistribution of alloying elements but led to metallurgically sound composite joints. The Knoop microhardness (HK) distribution across the joint interfaces revealed sharp gradients at the Cu-clad-Mo/braze interface and higher hardness in Ticusil (approx.85-250 HK) than in Cusil-ABA (approx.50-150 HK). These C-C/Cu-clad-Mo joints with relatively low thermal resistance may be promising for thermal management applications.

Study of diffusion bond development in 6061 aluminum and its relationship to future high density fuels fabrication.

DOE Office of Scientific and Technical Information (OSTI.GOV)

Prokofiev, I.; Wiencek, T.; McGann, D.

1997-10-07

Powder metallurgy dispersions of uranium alloys and silicides in an aluminum matrix have been developed by the RERTR program as a new generation of proliferation-resistant fuels. Testing is done with miniplate-type fuel plates to simulate standard fuel with cladding and matrix in plate-type configurations. In order to seal the dispersion fuel plates, a diffusion bond must exist between the aluminum coverplates surrounding the fuel meat. Four different variations in the standard method for roll-bonding 6061 aluminum were studied. They included mechanical cleaning, addition of a getter material, modifications to the standard chemical etching, and welding methods. Aluminum test pieces weremore » subjected to a bend test after each rolling pass. Results, based on 400 samples, indicate that at least a 70% reduction in thickness is required to produce a diffusion bond using the standard rollbonding method versus a 60% reduction using the Type II method in which the assembly was welded 100% and contained open 9mm holes at frame corners.« less

Fuel pin

DOEpatents

Christiansen, D.W.; Karnesky, R.A.; Leggett, R.D.; Baker, R.B.

1987-11-24

A fuel pin for a liquid metal nuclear reactor is provided. The fuel pin includes a generally cylindrical cladding member with metallic fuel material disposed therein. At least a portion of the fuel material extends radially outwardly to the inner diameter of the cladding member to promote efficient transfer of heat to the reactor coolant system. The fuel material defines at least one void space therein to facilitate swelling of the fuel material during fission.

Fuel pin

DOEpatents

Christiansen, David W.; Karnesky, Richard A.; Leggett, Robert D.; Baker, Ronald B.

1989-10-03

A fuel pin for a liquid metal nuclear reactor is provided. The fuel pin includes a generally cylindrical cladding member with metallic fuel material disposed therein. At least a portion of the fuel material extends radially outwardly to the inner diameter of the cladding member to promote efficient transfer of heat to the reactor coolant system. The fuel material defines at least one void space therein to facilitate swelling of the fuel material during fission.

Fuel pin

DOEpatents

Christiansen, David W.; Karnesky, Richard A.; Leggett, Robert D.; Baker, Ronald B.

1989-01-01

A fuel pin for a liquid metal nuclear reactor is provided. The fuel pin includes a generally cylindrical cladding member with metallic fuel material disposed therein. At least a portion of the fuel material extends radially outwardly to the inner diameter of the cladding member to promote efficient transfer of heat to the reactor coolant system. The fuel material defines at least one void space therein to facilitate swelling of the fuel material during fission.

Microstructural characterization of annealed U-12Zr-4Pd and U-12Zr-4Pd-5Ln: Investigating Pd as a metallic fuel additive

NASA Astrophysics Data System (ADS)

Benson, Michael T.; He, Lingfeng; King, James A.; Mariani, Robert D.

2018-04-01

Palladium is being investigated as a potential additive to metallic fuel to control fuel-cladding chemical interaction (FCCI). A primary cause of FCCI is the lanthanide fission products moving to the fuel periphery and interacting with the cladding. This interaction will lead to wastage of the cladding and, given enough time or burn-up, eventually to a cladding breach. The current study is a scanning electron microscopy (SEM) and transmission electron microscopy (TEM) characterization of annealed U-12Zr-4Pd and U-12Zr-4Pd-5Ln, where Ln = 53Nd-25Ce-16Pr-6La. The present study shows that Pd preferentially binds the lanthanides over other fuel constituents, which may prevent lanthanide migration and interaction with the cladding during irradiation. The SEM analysis indicates the 1:1 Pd-Ln compound is being formed, while the TEM analysis, due to higher resolution, found the 1:1 compound, as well as Pd-rich compounds Pd2Ln and Pd3Ln2.