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At least 217 records · Page 12

Fabrication of Natural Uranium UO 2 Disks (Phase II): Texas A&M Work for Others Summary Document

The steps to fabricate natural UO 2 disks for an irradiation campaign led by Texas A&M University are outlined. The process was initiated with stoichiometry adjustment of parent, U 3 O 8 powder. The next stage of sample preparation involved exploratory pellet pressing and sintering to achieve the desired natural UO 2 pellet densities. Ideal densities were achieved through the use of a bimodal powder size blend. The steps involved with disk fabrication are also presented, describing the coring and thinning process executed to achieve final dimensionality.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Characterization of ceramic fuel powder packing fractions to support INFLUX

Triply periodic minimal surface (TPMS)-based structures show marked potential in novel nuclear reactor fuel designs, as their high surface area-to-volume ratio increases the efficiency of heat transfer out of the fuel, enabling safer, more innovative reactor designs. This milestone report addresses the role of dUO 2 powder processing route on the fill behavior of TPMS-based cladding shells to understand and advance the feasibility of manufacturing TPMS-based nuclear fuel forms. dUO 2 powder was processed through either a dry granulation route, varying consolidation pressure, or through milling, varying milling time, milling method and milled size distribution. The lowest tapped bulk densities (TBD), but best powder flowabilities, were obtained when testing unprocessed dUO 2 powder which was prone to self-agglomeration and formed low-density spheroids. The highest TBD and lowest flowabilities were obtained when using powder produced by hammer-milling dUO 2 powder to pass through a 200-mesh sieve, which led to particles with angular morphologies. Powder produced by dry granulation exhibited TBD that varied according to the consolidation pressure used to form the initial pellets and exhibited improved flowabilities when compared to hammer-milled material. Because of the large span of granule sizes formed as well as the irregular shape associated with the granules, a packing fraction of 0.69 was achieved, exceeding the analytical solution for random close packing of mono-sized spheres. TPMS polymer shells were loaded with unprocessed, granulated, and hammer-milled dUO 2 powders, and their qualitative packing behaviors were analyzed using x-ray computed tomography (xCT). TBDs calculated after loading TPMS polymer shells were 10-20% lower when compared to tapped bulk density measurements taken in a glass graduated cylinder, indicating a non-trivial impact on the tapped bulk density of either the TPMS channel size, TPMS channel surface material, powder cohesiveness, or a combination of the two parameters. A metallic zircaloy-4 TPMS shell will be loaded with hammer-milled dUO 2 powder upon receipt of the shell from Oak Ridge National Laboratory (ORNL) and shipped to Idaho National Labs (INL) for subsequent hot isostatic pressing (HIP) densification experiments.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Microstructure evolution in Xe-irradiated UO2 at room temperature

In situ Transmission Electron Microscopy was conducted for single crystal UO2 to understand the microstructure evolution during 300 keV Xe irradiation at room temperature. The dislocation microstructure evolution was shown to occur as nucleation and growth of dislocation loops at low irradiation doses, followed by transformation to extended dislocation segments and tangles at higher doses. Xe bubbles with dimensions of 1-2 nm were observed after room-temperature irradiation. Electron Energy Loss Spectroscopy indicated that UO2 remained stoichiometric under room temperature Xe irradiation.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Rare Earth Carbide (Nd-C and Ce-C) Synthesis and Characterization to Inform Phase Equilibrium in Advanced Nuclear Fuels

As advances are being made regarding the performance of nuclear fuels, uranium carbides, and composites, such as (U,Zr)C and UO2 + UCx, have recently gained significant interest for deployment in nuclear space propulsion and high temperature gas-cooled reactors, respectively. However, the phase equilibria of several fission products in carbide systems remain unknown and may impact the overall fuel performance, specifically for particle nuclear fuels that are designed for commercial nuclear energy. Furthermore, comprehensive thermodynamic data on Rare Earth (RE) carbides, such as the Nd-C and Ce-C binary systems, remain limited. Presented in this study are the synthesis methods and characterizations of several Nd-C and Ce-C compositions. The findings from this research provide insights on the stability of RE-C binaries that form in irradiated nuclear fuels and address a critical knowledge gap in the current state of thermodynamics for two key RE-C systems.

Cavazos, Steven J. (ORCID:0009000130329363)↗

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

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. 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.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Preliminary Investigation of Candidate Materials for Use in Accident Resistant Fuel

As part of a Collaborative Research and Development Agreement (CRADA) with industry, Idaho National Laboratory (INL) is investigating several options for accident resistant uranium compounds including silicides, and nitrides for use in future light water reactor (LWR) fuels. This work is part of a larger effort to create accident tolerant fuel forms where changes to the fuel pellets, cladding, and cladding treatment are considered. The goal fuel form should have a resistance to water corrosion comparable to UO2, have an equal to or larger thermal conductivity than uranium dioxide, a melting temperature that allows the material to stay solid under power reactor conditions, and a uranium loading that maintains or improves current LWR power densities. During the course of this research, fuel fabricated at INL will be characterized, irradiated at the INL Advanced Test Reactor, and examined after irradiation at INL facilities to help inform industrial partners on candidate technologies.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Characterization of urania vaporization with transpiration coupled thermogravimetry

Determining equilibrium vapor pressures of materials is made easier by transpiration measurements. However, the traditional technique involves condensing the volatiles entrained in a carrier gas outside of the hot measurement zone. One potential problem is deposition en route to a cooled collector. Thermogravimetric analysis (TGA) can be used to measure in situ mass loss due to vaporization and therefore obviate the need to analyze the entire gas train due to premature plating of vapor species. Therefore, a transpiration coupled TGA technique was used to determine equilibrium pressures of UO3 gas over fluorite structure UO2+x and U3O8 at T = (1573 and 1773) K. Moreover, we compared to calculations from models and databases in the open literature. Our study gives clarity to the thermochemical data for UO3 gas and validates the mass loss transpiration method using thermogravimetry for determining equilibrium vapor pressures of non-stoichiometric oxides.

36 MATERIALS SCIENCE↗

A U-bearing composite waste form for electrochemical processing wastes

Metallic/ceramic composite waste forms are being developed to immobilize combined metallic and oxide waste streams generated during electrochemical recycling of used nuclear fuel. Composites were made for corrosion testing by reacting HT9 steel to represent fuel cladding, Zr and Mo to simulate metallic fuel waste, and a mixture of ZrO2, Nd2O3, and UO2 to represent oxide wastes. More than half of the added UO2 was reduced to metal and formed Fe-Zr-U intermetallics and most of the remaining UO2 and all of the Nd2O3 reacted to form zirconates. Fe-Cr-Mo intermetallics were also formed. Microstructure characterization of the intermetallic and ceramic phases that were generated and tests conducted to evaluate their corrosion behaviors indicate composite waste forms can accommodate both metallic and oxidized waste streams in durable host phases. (c) 2018 Elsevier B.V. All rights reserved.

Chen, X. (ORCID:0000000332734431)↗

Dissolution of Mechanically Mixed UO2-PuO2 and Insoluble Residue Characteristics

During the reprocessing operations of mixed oxide fuel the dissolution step plays a very important role in the attainment of an acceptable plutonium recovery yield. The importance of this step on the overall fuel cycle was recognized by many authors but was especially treated in depth by Lerch [1] and Nicholson [2].

De Regge, P.↗

Development of a UO2 Densification Model in the MARMOT Tool

A phase-field model for irradiation-enhanced densification is currently under development in the NEAMS code MARMOT. To begin, a simplified model of sintering without irradiation effects is developed. This model requires a method to generate sintering initial conditions, and the accepted phase-field rigid-body motion sintering model must either be fully implemented in MARMOT or shown to be unnecessary. It is shown to be unnecessary. Sintering simulation results without rigid body motion are shown. Shortcomings in the results are discussed and plans on how to address them are presented.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

An Investigation of the Use of Fully Ceramic Microencapsulated Fuel for Transuranic Waste Recycling in Pressurized Water Reactors

An investigation of the utilization of TRistructural- ISOtropic (TRISO)-coated fuel particles for the burning of plutonium/neptunium (Pu/Np) isotopes in typical Westinghouse four-loop pressurized water reactors is presented. Though numerous studies have evaluated the burning of transuranic isotopes in light water reactors (LWRs), this work differentiates itself by employing Pu/Np-loaded TRISO particles embedded within a silicon carbide (SiC) matrix and formed into pellets, constituting the fully ceramic microencapsulated (FCM) fuel concept that can be loaded into standard LWR fuel element cladding. This approach provides the capability of Pu/Np burning and, by virtue of the multibarrier TRISO particle design and SiC matrix properties, will allow for greater burnup of Pu/Np material, plus improved fuel reliability and thermal performance. In this study, a variety of heterogeneous assembly layouts, which utilize a mix of FCM rods and typical UO2 rods, and core loading patterns were analyzed to demonstrate the neutronic feasibility of Pu/Np-loaded TRISO fuel. The assembly and core designs herein reported are not fully optimized and require fine-tuning to flatten power peaks; however, the progress achieved thus far strongly supports the conclusion that with further rod/assembly/core loading and placement optimization, Pu/Np-loaded TRISO fuel and core designs that are capable of balancing Pu/Np production and destruction can be designed within the standard constraints for thermal and reactivity performance in pressurized water reactors.

Gentry, Cole A↗

Thermophysical properties of urania-zirconia (U,Zr)O 2 mixed oxides by molecular dynamics

Molecular dynamics simulations were used to investigate the thermophysical properties of (U,Zr)O 2 between 300 K and 3500 K. For compositions with <25% UO 2 the tetragonal phase is stable but beyond 25% the cubic fluorite phase becomes stable for all temperatures. Thermal expansion, heat capacity and thermal conductivity have been predicted. The addition of ZrO 2 to UO 2 causes a reduction in thermal conductivity however this effect decreases with increased temperature and, beyond 1000 K, becomes insignificant. Thermal expansion of (U,Zr)O 2 mixtures with >25% UO 2 , which are in the cubic fluorite phase, is similar to that of the pure UO 2 end member. A superionic transition is observed in cubic (U,Zr)O 2 at temperatures between 1500 K and 3000 K, occurring at progressively lower temperatures with increasing ZrO 2 content. Here, the heat capacity of these mixed oxides increases from 80 J/mol.K up to 130 J/mol.K at temperatures relevant to accident conditions, possibly retarding heating in fuels with a significant pellet-clad bonding layer.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Documentation, assessment, and improvements of fission gas modeling capabilities in BISON

Fission gas behavior critically affects nuclear fuel performance, influencing thermal conductivity, microstructure, swelling, and fuel-cladding interactions. The Simple Integrated Fission Gas Release and Swelling (Sifgrs) model, implemented within the BISON fuel performance code, provides advanced capabilities for modeling these phenomena. This manuscript reviews and assesses Sifgrs’ modular structure and submodels describing intragranular, intergranular, and release mechanisms. The modular implementation enables rapid improvements as our understanding advances and new fuel forms emerge. After an overview of capabilities, we present a comprehensive validation suite, comparing predictions to experimental data from tests under normal and transient conditions, including reproduction of the Vitanza curve. Results demonstrate Sifgrs’ accuracy, robustness, and applicability. Current limitations and ongoing efforts are discussed, including mechanistic, multiscale modeling, uncertainty quantification, and validation within the Nuclear Energy Advanced Modeling and Simulation (NEAMS) program, supporting the safe and efficient use of nuclear fuels.

BISON↗

Modelling oxygen self-diffusion in UO 2 under pressure

Access to values for oxygen self-diffusion over a range of temperatures and pressures in UO 2 is important to nuclear fuel applications. Here, elastic and expansivity data are used in the framework of a thermodynamic model, the cBΩ model, to derive the oxygen self-diffusion coefficient in UO 2 over a range of pressures (0–10 GPa) and temperatures (300–1900 K). Furthermore, the significant reduction in oxygen self-diffusion as a function of increasing hydrostatic pressure, and the associated increase in activation energy, is identified.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Preliminary Evaluation of FeCrAl Cladding for Accident Tolerant Fuel Concepts

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 normal operations and operational transients. This report presents early work in developing thermal and mechanical models for FeCrAl, a proposed cladding material. BISON, the finite element-based fuel performance code in development at Idaho National Laboratory, was used to compare results from normal operation conditions with UO2/Zr-4 behavior. In addition, sensitivity studies are presented for evaluating the relative importance of material parameters such as elastic constants and thermal conductivity in order to provide guidance on future experiments for this material.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

ATF material model development and validation for priority fuel concepts

Development, implementation, and validation of material and behavior models for accident tolerant fuel (ATF) concepts in the Bison fuel performance code began in 2014 in response to the events that occurred at the Fukushima Daichii nuclear power plant in March 2011. Early on the focus was on U 3 Si 2 fuel and FeCrAl cladding as part of a high impact problem through the Nuclear Energy and Advanced Modeling Simulation (NEAMS) program. Then, developments for Cr 2 O 3 -doped UO 2 fuel, and SiC-SiC and Cr-coated zirconium-based claddings began based upon industry interests. In late fiscal year 2018 the Consortium for Advanced Simulation of Light Water Reactors (CASL) took over further ATF work in Bison in support of the Nuclear Regulatory Commission (NRC) engagement. Discussions with the NRC identified their list of priority fuel and cladding concepts, which included Cr 2 O 3 -doped UO 2 and U 3 Si 2 fuels, and Cr-coated zirconium-based and FeCrAl claddings. In particular, the NRC suggested that reports similar in form to NUREG/CR-7024 [1] that was developed for traditional LWR materials UO 2 and zirconium-based claddings (i.e., Zircaloy-4, M5®, ZIRLO) be created for the priority ATF concepts. The approach to ATF capability development in Bison since the beginning has been two-fold: (1) empirical correlations and (2) multiscale model development. Both approaches have uncertainty inherent to them. Uncertainty in empirical correlations is bounded by the experimental data upon which with the correlation was developed. Models developed through a multiscale approach have uncertainty associated with the lower length scale calculations and input parameters that must be propagated to the engineering scale model in Bison. In this report, the recommended models, their range of applicability (e.g., temperature, burnup), and associated uncertainty for the NRC priority fuel concepts Cr 2 O 3 -doped UO 2 and U 3 Si 2 are presented in a manner similar to the aforementioned NUREG. In addition, the Cr 2 O 3 -doped UO 2 models are validated to the Halden Reactor tess IFA-677.1 rods 1 and 5 and IFA-716.1 rod 1. For U 3 Si 2 the models are validated to the recent post-irradiation examination (PIE) data ATF-13 and ATF-15 rods that were irradiated in the Advanced Test Reactor (ATR) at Idaho National Laboratory. Finally, an uncertainty quantification (UQ) and sensitivity analysis (SA) is completed on a single rod for each fuel concept that takes into account the defined uncertainty in select models. The results of the UQ and SA analyses indicate that given the large uncertainty in some of the input ATF models that the uncertainty on the Bison predictions of fuel performance metrics of interest bound the available experimental data. Correlation coefficients are also reported that identified the uncertain inputs with the strongest correlation (positive or negative) with the outputs of interest. Fuel performance metrics investigated include fuel elongation, rod internal pressure, fuel centerline temperature, and fission gas release.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Bridging multimodal microscopy for advanced characterization on nuclear fuel using machine learning

Uranium dioxide (UO 2 ), widely used as driver fuel in light water reactors, experiences microstructure and property change by nuclear fission reactions. This paper bridges the characterization of fresh UO 2 fuel at different length scales, serving as a baseline for future post irradiation examination of irradiated UO 2 fuel. To characterize the microstructural change of nuclear fuel, modern approaches cover a wide range of length scales through different characterization techniques, such as mm scale for Synchrotron-based X-ray computed tomography (SXCT) and microscale for focused ion beam (FIB) and scanning electron microscopy (SEM). It is challenging to bridge the data and knowledge of the same sample in different length scales. This paper proposed a deep learning framework leveraging transfer learning to detect microstructural defects, trained from a sparse FIB, SEM, and SXCT images. The proposed model achieved superior performance in defect segmentation on multiscale microscopic data compared to four of the latest deep learning models.

36 MATERIALS SCIENCE↗