Engineering Papers⌕ Search

SEARCH · Engineering Papers

Results for “Zirconium cladding”

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

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 415 records · Page 23
All sourcesNASA NTRSDOE OSTI
DOE OSTI2016

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

A large effort is underway under the leadership of US DOE Fuel Cycle Research 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 mechanical 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. (authors)

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2018

The challenge of acquiring a satisfactory EBSD result of CWSR Zircaloy-4 cladding tube

This article presents a methodology combining SEM, EDS, conventional EBSD, and transmission-EBSD to analyse a recrystallised Zircaloy-4 sheet and cold-worked stress-relieved (CWSR) Zircaloy-4 cladding in unprecedented detail. Second-phase precipitates (SPPs) in Zircaloy-4 specimens were revealed after chemical polishing using a solution containing hydrofluoric acid (HF). Pitting corrosion of Zircaloy-4 specimens was revealed after electropolishing using an electrolyte containing HClO4. A zirconium coupon without SPPs was used to confirm the chemical response of SPPs on surface morphology. Intrinsic features of cold-worked Zircaloy-4 such as relatively small grain sizes, high dislocation density, and complex microstructure make it significantly more difficult to collect excellent EBSD results compared to recrystallised Zircaloy-4. The fine hydride structure of as-hydrided CWSR Zircaloy-4 cladding further increases the level of challenge on EBSD analysis.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2015

Protective structures on the surface of zirconium components of light water reactor cores: Formation, testing, and prototype equipment

The results of tests of plasma treatment of zirconium and deposition of protective yttrium coatings used as the methods of protection of zirconium components of light water reactor cores against hydrogenation are detailed. The amount of hydrogen in the treated sample exposed to superheated steam for 2500 h at temperature T = 400°C and pressure p = 1 atm was five times lower than the corresponding value for the untreated one. The amount of hydrogen in the sample coated with yttrium remained almost unchanged in 4000 h of exposure. A plasma method for rapid testing for hydrogen resistance is proposed. The hydrogenation rate provided by this method is 700 times higher than that in tests with superheated steam. The results of preliminary experiments confirm the possibility of constructing a unit for batch processing of the surfaces of fuel rod claddings.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2019

Systematic Technology Evaluation Program for SiC-based BWR Channel Box

Silicon carbide (SiC) –based accident-tolerant fuel (ATF) cladding of light water reactors (LWRs) has become a topic of great interest in nuclear material development since the Fukushima Dai-ichi Nuclear Power Plant accident. Extensive development of SiC cladding has identified benefits of the concept, including its inherent accident resistance and neutronic performance. Advancements achieved during the development of SiC-based ATF cladding have made it attractive for use in accident-tolerant cores of LWRs. In this document, we consider the use of SiC-based materials to replace the zirconium alloy used for the channel boxes of boiling water reactors. Both accident resistance and prevention of the bowing observed in current grades of channel boxes are needs driving the exploration of a new channel box system. To provide a pathway for channel box development, this document lays out (1) a current technology overview, (2) the technology gap, and (3) a systematic technology evaluation plan. The objectives of the technology evaluation plan are to address key feasibility issues revealed by the knowledge gap analysis and to contribute to advancing the technology readiness level. Further development will be required in the technology implementation phase. The technology evaluations include understanding the behavior of channel boxes under both normal and off-normal conditions, identifying potential mitigation strategies for the issues if necessary, and improving channel box performance based on the knowledge obtained. The structure of the technology evaluation plan and each task are shown in Figure S.1. The knowledge gap analysis identified key research areas, including irradiation effects, hydrothermal corrosion, accident behavior, and design and manufacture. These are common issues between SiC-based channel boxes and SiC-based fuel cladding, although technical evaluations specific for the channel box components are required. This document also describes details of the technical feasibility evaluation methods and plans.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2015

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

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. 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.

36 MATERIALS SCIENCE↗
DOE OSTI2016

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

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 mechanical 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.

Field, Kevin G↗
DOE OSTI2014

Report on Plasma Spraying of Full-Sized Foils (FY13)

This report is the deliverable fulfilling task B40700. The application of the Zr diffusion barrier between the U-­Mo fuel and the Al cladding has been an ongoing area of research [1-8]. The goal of the research described in this report was to demonstrate the plasma spraying technique for depositing zirconium (Zr) onto full sized U-Mo foils to demonstrate scale up of the process from the mini foil samples (1”x4”x ~0.015”) coated previously. Full size denotes one of the actual fuel foil sizes for one of the five research reactors (MURR, NIST, MIT, HFIR, ATR) to be converted to LEU fuel in the US research reactor Convert program. The smallest full sized fuel foil is for the NIST reactor with a size of 11.37”x2.436”x0.020”. The largest full sized fuel foil is for the ATR reactor with a size of 48.01”x3.43”x0.020”. The widest full sized fuel foil is for the MURR reactor with a size of 24”x4.052”x0.020”. The current LANL vacuum plasma spray system can accommodate a foil length of 24” or less. Therefore, as a demonstration of the widest foil in the program and the maximum length foil that can be processed on the current LANL system, a nominal 24”x4”x0.020” foil was chosen as the goal for scale up activities.

36 MATERIALS SCIENCE↗
DOE OSTI2016

Understanding of corrosion mechanisms after irradiation: effect of ion irradiation of the oxide layers on the corrosion rate of M5 - 2016-0081

Irradiation damage in fuel cladding material is mainly caused by the neutron flux that results from fission reactions occurring in the fuel. To avoid the constraints inherent in handling radioactive material, the irradiation effects on the corrosion resistance of zirconium alloys can be studied by irradiating the materials with ions. We performed an original experiment using ion irradiation to more specifically study the influence of irradiation damage in the oxide on the corrosion rate of M5{sup R}. It has been established that irradiation with a 1.3-MeV helium ion at a fluence of 10{sup 17} cm{sup -2} results in significant modifications of oxide properties, oxygen diffusion flux, and oxidation kinetics, as evidenced by Raman spectroscopy, secondary ion mass spectrometry (SIMS) analyses, and measurements of mass gains. A newly identified Raman vibration band at 712 cm{sup -1} was linked to the presence of irradiation defects and allowed the evolution of their concentrations to be followed. The oxygen diffusion flux was significantly reduced after irradiation partly due to a surface concentration decrease of oxygen. The defects remained present in the oxide after 100 days of annealing in pressurized water reactor (PWR) conditions and were thus very stable in PWR conditions, which probably means that these defects would be stable in the reactor. According to the kinetics and in agreement with the results obtained by SIMS analyses, the oxidation rate was significantly reduced after ion irradiation, and this effect remained beyond 100 days in agreement with the high stability of irradiation defects in PWR conditions. An original model described quite well the oxidation kinetic results. (authors)

36 MATERIALS SCIENCE↗
DOE OSTI2012

Comprehensive Nuclear Materials

This book encompasses a rich seam of current information on the vast and multidisciplinary field of nuclear materials employed in fission and prototype fusion systems. Discussion includes both historical and contemporary international research in nuclear materials, from Actinides to Zirconium alloys, from the worlds leading scientists and engineers. Synthesizes pertinent current science to support the selection, assessment, validation and engineering of materials in extreme nuclear environments. The work discusses the major classes of materials suitable for usage in nuclear fission, fusion reactors and high power accelerators, and for diverse functions in fuels, cladding, moderator and control materials, structural, functional, and waste materials.

36 MATERIALS SCIENCE↗
DOE OSTI2016

Out-of-reactor test of corrosion and hydrogen pickup in fuel cladding materials in contact with nickel metal - 2016-0038

Increased reactor coolant hydrogen concentration in pressurized water reactors (PWRs) is under consideration for potential benefits in reducing primary water stress corrosion cracking (PWSCC) crack growth rate as well as increasing PWSCC crack initiation time in nickel-based alloys. Potential concerns related to fuel performance include possible increases in hydrogen pickup (HPU) by zirconium based alloys and the enhancement of the pickup through the so-called nickel-window effect. Although the risk of this occurrence may be low, the consequences of increased HPU could be substantial. We examined the impact of dissolved hydrogen (DH) concentrations on Zircaloy-4 corrosion and HPU when the samples are in contact with nickel sources. The work was completed in conjunction with a large project that evaluated the impact of dissolved hydrogen on various fuel cladding and spacer weld specimens of M5{sup R}, ZIRLO{sup R}, Optimized ZIRLO{sup TM}, Low-Tin ZIRLO{sup TM}, Optimized Low-Tin Zircaloy-4, and Zircaloy-2 in either as-received or pre-oxidized conditions for exposures up to 730 days in high-pressure, out-of-reactor autoclave systems operating with a simulated PWR coolant at three different DH concentrations: 30, 100, and 500 cm{sup 3} (cc) H{sub 2}/kg H{sub 2}O. A significant increase in HPU was observed for some Zircaloy-4 specimens in contact with synthetic crud at elevated DH levels. The HPU increased with increasing DH and a metallic nickel fraction in the synthetic crud. The formation of metallic nickel in the synthetic crud samples at elevated DH levels was confirmed. (authors)

36 MATERIALS SCIENCE↗
DOE OSTI2018

Completion of a Chlorination Test Using 250 grams of High-Burnup Used Fuel Cladding from a North Anna Pressurized Water Reactor

A second large -scale chlorination test was completed in February 2017 by chlorinating 250 g of used nuclear fuel (UNF) cladding from a North Anna pressurized water reactor (PWR). Analytical results and a Zr mass balance from this test are described and compared with previous results obtained by the Zirconium Recovery and Recycle Project.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2023

Irradiation creep measurement and microstructural analysis of chromium nitride–coated zirconium alloy using pressurized tubes

Environmental barrier coatings for Zr-based materials are currently under development to reduce oxidation and embrittlement in light-water reactors. Chromium nitride is one such candidate for this application, particularly as accident-tolerant fuel cladding. However, quantifying the impact of coatings on the irradiation-induced creep of zircaloy (Zry) is critical as this mechanism often exceeds thermal creep rates under light-water reactor operating conditions and can be a limiting design characteristic. Additionally, examining irradiation effects in the microstructure at the coating interface is key to understanding the compatibility of the material system. Here, to accelerate the experimental measurement of irradiation creep and microstructure evolution in CrN-Zry, compact, pressurized creep tubes were fabricated and irradiated in the High Flux Isotope Reactor (HFIR) at Oak Ridge National Laboratory. Miniature, thin-walled rodlets fabricated from annealed Zr-Sn barstock were coated with CrN using physical vapor deposition (PVD) to nominal thicknesses of 4 and 8 μm. Coated and uncoated rodlet specimens were internally pressurized and welded, generating nominal circumferential hoop stresses of 0, 90, or 180 MPa under 300°C irradiation conditions. Twelve specimens were measured diametrically prior to irradiation using a low-cost, automated, contactless laser profilometer developed for this work. Specimens were irradiated in sealed capsules for one 25-day HFIR cycle, accumulating approximately 1.8 $\times$ 10 21 n/cm 2 fast fluence (E n > 10 MeV). The irradiated samples were retrieved and remeasured using the same profilometry system in a shielded hot cell facility. Irradiation creep between specimens was compared using standard statistical tests and showed that both thicknesses of CrN coating had a negligible effect on the irradiation creep strain of the Zry material. Microstructure characterization of pre- and post-irradiated CrN-Zry specimens showed minimal changes due to irradiation but did show a substantial O-rich region at the Zry-CrN interface.

36 MATERIALS SCIENCE↗
DOE OSTI2013

Zr electrorefining process for the treatment of cladding hull waste in LiCl-KCl molten salts

Zr electrorefining for the treatment of Zircaloy-4 cladding hull waste is demonstrated in LiCl-KCl-ZrCl{sub 4} molten salts. Although a Zr oxide layer thicker than 5 μm strongly inhibits the Zr dissolution process, pre-treatment processes increases the dissolution kinetics. For 10 g-scale experiments, the purities of the recovered Zr were 99.54 wt.% and 99.74 wt.% for fresh and oxidized cladding tubes, respectively, with no electrical contact issue. The optimal condition for Zr electrorefining has been found to improve the morphological feature of the recovered Zr, which reduces the salt incorporation by examining the effect of the process parameters such as the ZrCl{sub 4} concentration and the applied potential.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2016

Investigation and modeling of the degradation of Zr-based fuel claddings during corrosion in steam and air-steam mixtures at high temperatures - 6.3 STP-2016-0033

This paper presents the main results of a study conducted to quantify and to model the degradation state of Zr-based fuel claddings submitted to severe accident conditions in a nuclear reactor core: high temperatures and either pure steam or air-steam mixture. Due to the progressive thickening of a dense and protective ZrO{sub 2} layer, the oxidation kinetics of Zr-based claddings in steam at high temperatures typical of nuclear severe accidents, is generally cubic or parabolic. However, for some temperature domains, this oxide layer may crack, becoming porous and non-protective anymore. In these 'breakaway' conditions, the oxidation kinetics change from (sub-)parabolic to linear or even accelerated. Additionally, the temperature increase can lead core materials to melt and to relocate down to the vessel lower head, threatening its integrity. If it fails, and for specific conditions, air ingress may take place into the reactor. Hence, oxygen and nitrogen both react with Zr-based claddings, successively through oxidation of Zr (forming ZrO{sub 2} layer), nitriding of Zr (forming ZrN particles) and oxidation of ZrN (forming ZrO{sub 2} and releasing nitrogen). These self-sustained chemical reactions enhance the deterioration of Zr-based claddings and of their ZrO{sub 2} layers, inducing a rise of their open porosity. To quantify this porosity, a series of two-step experiments was conducted. First, Zirlo{sup TM} cladding samples were isothermally oxidized in various conditions: in pure steam or in 50- 50 mol% air-steam mix, at several temperatures, and for different durations. The main thermal effects on reaction kinetics and the high impact of air on the cladding degradation are all confirmed by experimental results. Second, pioneering porosimetry measurements by Hg intrusion were realized for the first time on such corroded cladding samples. In both atmospheres, it is pointed out that 1200 and 1250 K lead to particularly porous oxide layers, especially due to strong 'breakaway' effects. Moreover, it is confirmed that the presence of air strongly enhances the oxide cracking: cladding samples are more porous when oxidized in the air-steam mixture than under pure steam. Finally, it is observed that in all conditions, the open porous volume fraction of Zirlo{sup TM} claddings continuously rises during their corrosion process. Hence, for each experimental condition, porosity correlations are determined through linear regressions, and porosity increase rates are deduced by derivation versus time and validated against porosimetry results of cladding samples corroded in transient (nonisothermal) conditions. (authors)

36 MATERIALS SCIENCE↗
DOE OSTI2013

Novel Accident-Tolerant Fuel Meat and Cladding

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 release 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.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
NASA NTRS2008

Joining of Zirconium Diboride-Based Ceramic Composites to Metallic Systems for High-Temperature Applications

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.

Asthana, R.↗
DOE OSTI2021

Test Plan for Investigation of Hydrogen Generation in SNF Canisters

This report presents a test plan to investigate radiolytic hydrogen generation in spent nuclear fuel (SNF) canisters containing Zr-based cladding materials. The initial primary contributor to the generation of radiolytic hydrogen is estimated to be the residual physisorbed water on the ZrO 2 film, post-dry out. Over the longer term the primary hydrogen source is associated with the aluminum hydroxides and water vapor. The proposed testing to be conducted in FY22 would consist of lab-scale testing on non-radioactive surrogates of oxidized ZIRLO tubing and unalloyed zirconium using a miniature steel canister (“mini-canister") designed to allow intermittent, in-situ sampling of the canister gas during irradiation. The mini-canister approach for irradiation with in-situ monitoring system was used in a recent and on-going study [McNamara and Verst, 2020a & 2020b; Verst et al., 2021] to measure radiolytic hydrogen generation from aluminum SNF cladding surrogate materials. This proposed testing will form part of the overall materials performance evaluation of the commercial SNF-in-canister system and is part of the technical bases for their continued safe dry storage

08 HYDROGEN↗
DOE OSTI2014

Ferritic Alloys as Accident Tolerant Fuel Cladding Material for Light Water Reactors

The objective of the GE project is to demonstrate that advanced steels such as iron-chromium-aluminum (FeCrAl) alloys could be used as accident tolerant fuel cladding material in commercial light water reactors. The GE project does not include fuel development. Current findings support the concept that a FeCrAl alloy could be used for the cladding of commercial nuclear fuel. The use of this alloy will benefit the public since it is going to make the power generating light water reactors safer. In the Phase 1A of this cost shared project, GE (GRC + GNF) teamed with the University of Michigan, Los Alamos National Laboratory, Brookhaven National Laboratory, Idaho National Laboratory, and Oak Ridge National Laboratory to study the environmental and mechanical behavior of more than eight candidate cladding materials both under normal operation conditions of commercial nuclear reactors and under accident conditions in superheated steam (loss of coolant condition). The main findings are as follows: (1) Under normal operation conditions the candidate alloys (e.g. APMT, Alloy 33) showed excellent resistance to general corrosion, shadow corrosion and to environmentally assisted cracking. APMT also showed resistance to proton irradiation up to 5 dpa. (2) Under accident conditions the selected candidate materials showed several orders of magnitude improvement in the reaction with superheated steam as compared with the current zirconium based alloys. (3) Tube fabrication feasibility studies of FeCrAl alloys are underway. The aim is to obtain a wall thickness that is below 400 µm. (4) A strategy is outlined for the regulatory path approval and for the insertion of a lead fuel assembly in a commercial reactor by 2022. (5) The GE team worked closely with INL to have four rodlets tested in the ATR. GE provided the raw stock for the alloys, the fuel for the rodlets and the cost for fabrication/welding of the rodlets. INL fabricated the rodlets and the caps and welded them to provide hermetic seal. The replacement of a zirconium alloy using a ferritic material containing chromium and aluminum appears to be the most near term implementation for accident tolerant nuclear fuels.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗