Results for “Fuel Performance Modeling” — Page 4

DOE OSTI2017

FY17 end of year MARMOT materials model development update

This document summarizes the lower length scale progress made in FY17 in developing materials models for fuel performance modeling of oxide fuels and their implementation in the MARMOT code. The progress covers the development of a phase field recrystallization model for high-burnup structure formation in oxide fuels, a phase field model for studying stage-3 fission gas release in UO 2 , a phase-field model for irradiation-enhanced densification in UO 2 , a quantitative model for hydride morphology in Zirconium based cladding, and the calculation of hydrogen diffusivity under stress in various Zirconium based alloys as cladding candidates. Further development in the MARMOT code has been carried out as well to improve the multi-phase, multi-component phase field model, the representation of interfacial energy in the Kim-Kim-Suzuki model, and the description of interfacial stress. For most of the above, separated reports have been generated with detailed description. Here a brief summary is provided, with references pointing to the detailed reports to guide interested readers.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2020

A Metallic Fuel Performance Benchmark Problem Based on the IFR-1 Experiment

Metallic nuclear fuels are an active area of research and development for use in advanced reactors. Robust and accurate metallic fuel performance models are necessary for the design, safety analysis, and licensing of such reactors. However, metallic fuel performance models are not as mature as ceramic fuel performance models and require additional development. In order to better gauge the accuracy of existing models, identify high-priority models for development, and quantify the improvements made by future model development, ORNL has developed a benchmark problem based on the IFR-1 experiment. This work gathers all relevant information on the IFR-1 experiment and uses it to develop the benchmark problem. It simulates the problem using the fuel performance code BISON and compare the results to post-irradiation examination data from the experiment. Then a sensitivity analysis is performed on the BISON model to determine the benchmark problem’s sensitivity to uncertainty in the input parameters. The results suggest that BISON’s mechanical models require additional development. Plastic deformation is under-predicted in the cladding and axial swelling is over-predicted in the fuel. These problems may be related. Additionally, there is a bias in the temperature which may be a result of uncertainty in the input parameters rather than an issue with the fuel performance models.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2016

MARMOT update for oxide fuel modeling

This report summarizes the lower-length-scale research and development progresses in FY16 at Idaho National Laboratory in developing mechanistic materials models for oxide fuels, in parallel to the development of the MARMOT code which will be summarized in a separate report. This effort is a critical component of the microstructure based fuel performance modeling approach, supported by the Fuels Product Line in the Nuclear Energy Advanced Modeling and Simulation (NEAMS) program. The progresses can be classified into three categories: 1) development of materials models to be used in engineering scale fuel performance modeling regarding the effect of lattice defects on thermal conductivity, 2) development of modeling capabilities for mesoscale fuel behaviors including stage-3 gas release, grain growth, high burn-up structure, fracture and creep, and 3) improved understanding in material science by calculating the anisotropic grain boundary energies in UO$_2$ and obtaining thermodynamic data for solid fission products. Many of these topics are still under active development. They are updated in the report with proper amount of details. For some topics, separate reports are generated in parallel and so stated in the text. The accomplishments have led to better understanding of fuel behaviors and enhance capability of the MOOSE-BISON-MARMOT toolkit.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2021

Advanced Fuels Campaign Execution Plan

The Advanced Fuels Campaign (AFC) Execution Plan outlines the strategy, mission, scope, near-term and long-term goals, structure, and organization associated with nuclear fuels and materials research, development, and demonstration activities within the Department of Energy’s (DOE) Nuclear Fuel Cycle and Supply Chain (NFCSC) program. NFCSC has been given responsibility to identify and mature advanced fuel technologies for the DOE using a science-based approach, focused on developing a fundamental understanding of nuclear fuels and materials to drive development of integrated nuclear fuel and materials technology. This science-based approach combines theory, experiments, and multiscale modeling and simulation to achieve a predictive understanding of relevant behaviors ranging from fuel fabrication processes (and their resulting fuel microstructures) through fuel/cladding performance under irradiation (in contrast to more empirical, observation-based approaches frequently used in fuel performance modeling and fuel qualification). The traditional scope of AFC includes the evaluation and development of multiple fuel forms to support two fuel cycle options: once-through and full recycle. The word “fuel” is used generically to include conventional fuels, transmutation targets, and any associated cladding or duct materials. The once-through fuel cycle addresses advanced light water reactor fuels with enhanced performance, extended burnup, and reduced waste generation. In fiscal year (FY) 2012, AFC’s scope expanded to include research, development, and demonstration (RD&D) for light water reactor (LWR) fuels with enhanced accident tolerance. Fuel fabrication activities include the development of innovative methods to enhance process efficiencies, reduce waste, and improve control over as-fabricated fuel microstructural properties to achieve desired in-reactor performance. Using modern modeling and simulation approaches, the objective is to predict fresh fuel properties given the feedstock characteristics and fabrication process parameters. The performance-related activities include small-scale, in-reactor, and out-of-reactor phenomenological testing (distinct from, but synergistic with, integral prototypic testing) and extensive, quantitative characterization (focusing on characterization of fuel and cladding materials at the scale of microstructure) both before and after testing. Larger-scale, prototypic experiments are conducted in concert with phenomenological testing to drive a Fuel Development and Qualification program, incorporating a fundamental understanding of fuel behavior performance characteristics. Then, using the tools developed under the productive science-based approach, fuels will be optimized to meet specific performance requirements, thereby minimizing the need to repeatedly perform large-scale, integral experiments over a wide parametric range as a means of experimental exploration. Two significant initiatives are underway within AFC. First, a gap analysis completed in early FY 2019 identified critical irradiation testing needs that are lacking within the national light water reactor (LWR) fuels testbed since the shutdown of the Halden Reactor in 2018. The identified gaps are for instrumented, prototypic testing of LWR fuels, especially under boiling water reactor conditions, ramp conditions, and conditions leading to fuel failure; these needs exist for supporting current LWR fuels and their possible extension to higher burnups, but are especially urgent relative to near-term development and qualification of accident-tolerant fuels. Recommendations that resulted from the Halden Gap Analysis focused on enhancements at Advanced Test Reactor (ATR) and Transient Reactor Test Facility (TREAT) to fill gaps in testing capabilities relative to these needs. Second, a concerted effort to develop and demonstrate a systematic approach to accelerating the development, testing, and qualification of new fuel systems has been initiated. This is highlighted by a test strategy that combines the considerable advances in multiscale, mechanistic fuel modeling of recent years with a MiniFuel separate effects test program in the High Flux Isotope Reactor (HFIR) and a Fission Accelerated Steady-state Testing (FAST) semi-integral accelerated test program in ATR. This approach is being tested/demonstrated using the metallic fuel system, but if successful it is expected to be extensible to multiple fuel types and diverse applications. This document includes an overview of the NFCSC program, a definition of science-based development of nuclear fuels, near-term goals for Advanced LWR fuels (ALFs), and longer-term goals for Advanced Reactor Fuels (ARFs) RD&D. This includes the activities that will be conducted to achieve success toward the grand challenge, as well as the goals and milestones to be achieved over the next few decades of research and development. Long-term goals are based on the DOE Office of Nuclear Energ

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2024

Advanced Fuels Campaign Execution Plan

The Advanced Fuels Campaign (AFC) Execution Plan outlines the strategy, mission, scope, near-term and long-term goals, structure, and organization associated with nuclear fuels and materials research, development, and demonstration activities within the Department of Energy’s (DOE) Nuclear Fuel Cycle and Supply Chain (NFCSC) program. NFCSC has been given responsibility to identify and mature advanced fuel technologies for the DOE using a science-based approach, focused on developing a fundamental understanding of nuclear fuels and materials to drive development of integrated nuclear fuel and materials technology. This science-based approach combines theory, experiments, and multiscale modeling and simulation to achieve a predictive understanding of relevant behaviors ranging from fuel fabrication processes (and their resulting fuel microstructures) through fuel/cladding performance under irradiation (in contrast to more empirical, observation-based approaches frequently used in fuel performance modeling and fuel qualification). The traditional scope of AFC includes the evaluation and development of multiple fuel forms to support two fuel cycle options: once-through and full recycle. The word “fuel” is used generically to include conventional fuels, transmutation targets, and any associated cladding or duct materials. The once-through fuel cycle addresses advanced light water reactor fuels with enhanced performance, extended burnup, and reduced waste generation. In fiscal year (FY) 2012, AFC’s scope expanded to include research, development, and demonstration (RD&D) for light water reactor (LWR) fuels with enhanced accident tolerance. Fuel fabrication activities include the development of innovative methods to enhance process efficiencies, reduce waste, and improve control over as-fabricated fuel microstructural properties to achieve desired in-reactor performance. Using modern modeling and simulation approaches, the objective is to predict fresh fuel properties given the feedstock characteristics and fabrication process parameters. The performance-related activities include small-scale, in-reactor, and out-of-reactor phenomenological testing (distinct from, but synergistic with, integral prototypic testing) and extensive, quantitative characterization (focusing on characterization of fuel and cladding materials at the scale of microstructure) both before and after testing. Larger-scale, prototypic experiments are conducted in concert with phenomenological testing to drive a Fuel Development and Qualification program, incorporating a fundamental understanding of fuel behavior performance characteristics. Then, using the tools developed under the productive science-based approach, fuels will be optimized to meet specific performance requirements, thereby minimizing the need to repeatedly perform large-scale, integral experiments over a wide parametric range as a means of experimental exploration. Two significant initiatives are underway within AFC. First, a gap analysis completed in early FY 2019 identified critical irradiation testing needs that are lacking within the national light water reactor (LWR) fuels testbed since the shutdown of the Halden Reactor in 2018. The identified gaps are for instrumented, prototypic testing of LWR fuels, especially under boiling water reactor conditions, ramp conditions, and conditions leading to fuel failure; these needs exist for supporting current LWR fuels and their possible extension to higher burnups, but are especially urgent relative to near-term development and qualification of accident-tolerant fuels. Recommendations that resulted from the Halden Gap Analysis focused on enhancements at Advanced Test Reactor (ATR) and Transient Reactor Test Facility (TREAT) to fill gaps in testing capabilities relative to these needs. Second, a concerted effort to develop and demonstrate a systematic approach to accelerating the development, testing, and qualification of new fuel systems has been initiated. This is highlighted by a test strategy that combines the considerable advances in multiscale, mechanistic fuel modeling of recent years with a MiniFuel separate effects test program in the High Flux Isotope Reactor (HFIR) and a Fission Accelerated Steady-state Testing (FAST) semi-integral accelerated test program in ATR. This approach is being tested/demonstrated using the metallic fuel system, but if successful it is expected to be extensible to multiple fuel types and diverse applications. This document includes an overview of the NFCSC program, a definition of science-based development of nuclear fuels, near-term goals for Advanced LWR fuels (ALFs), and longer-term goals for Advanced Reactor Fuels (ARFs) RD&D. This includes the activities that will be conducted to achieve success toward the grand challenge, as well as the goals and milestones to be achieved over the next few decades of research and development. Long-term goals are based on the DOE Office of Nuclear Energ

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2017

Improvements to Modeling Capabilities of ATF Concepts in the BISON Fuel Performance Code

Research into accident tolerant materials for the fuel and cladding in Light Water Reactors has been at the forefront of the nuclear fuel research community since the events that oc- curred at the Fukushima Daiichi nuclear power plant in March 2011. Accident tolerant materials are defined as those that provide significantly increased response time in the event of an accident while providing similar or improved performance as the conventional UO2/zirconium-based cladding fuel rods dur- ing normal operation [1]. In particular, qualitative attributes for materials with enhanced accident tolerance include im- proved reaction (e.g., oxidation) kinetics with steam, resulting in slower hydrogen (or other combustible gases) generation rate, while maintaining acceptable thermo-mechanical prop- erties, fuel-clad interactions, and fission-product behavior [1]. Through its Office of Nuclear Energy the United States De- partment of Energy (U.S. DOE) has accelerated research in this area through the Fuel Cycle Research and Development (FCRD) Advanced Fuels Campaign (AFC). The goal of the AFC Accident Tolerant Fuel (ATF) program is to guide se- lection of promising concepts for insertion into a commercial reactor as part of a lead test rod or assembly in 2022. Given the aggressive development schedule, it is impossi- ble to perform a comprehensive set of experiments to provide material characterization data. Therefore, the AFC is utilizing computational analysis tools in an effort to understand the proposed accident tolerant materials. The two materials of interest in this work are iron-chromium-aluminum (FeCrAl) cladding and U3Si2. From a fuel performance standpoint, the correlations available to describe the behavior of these two materials is limited. Therefore, as additional experimental data becomes available and correlations are updated, the fuel performance models must be updated to represent the current state of the art understanding of these materials. In this paper we demonstrate the importance of utilizing the latest state-of-the-art models for fuel performance simula- tions by comparing old and new thermal conductivity models for U3Si2 fuel and old and new oxidation models for FeCrAl cladding alloys using the BISON [2, 3] fuel performance code under normal operating conditions. The results indicate that the latest thermal conductivity model for U3Si2 results in fuel centerline temperatures that are on average approximately 3% higher than the previous model. For the oxidation behavior of FeCrAl alloys the new model predicts observable but small ox- ide thickness (~6 µm) compared to the previous model which predicted zero oxide scale formation.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2021

Development of a U-19Pu-10Zr fuel performance benchmark case based on the IFR-1 experiment

Metallic nuclear fuels are subject to research and development for use in advanced reactors. Robust, accurate metallic fuel performance models are important for the design, safety analysis, and licensing of these reactors. However, metallic fuel performance models require additional development; they are not as mature as UO 2 fuel performance models. A benchmark case based on the IFR-1 experiment was developed to better gauge the accuracy of existing models, identify models for high-priority development, and potentially quantify any future improvements made by further model development.This work collected publicly available information on the IFR-1 experiment and used it to develop the benchmark case. Fuel behavior during the IFR-1 irradiation was simulated by using the fuel performance code BISON, and the predicted results were compared with postirradiation examination data from the IFR-1 experiment. Furthermore, a sensitivity study and tuning studies were performed as a preliminary investigation into the causes of inaccurate temperature and dimensional change predictions.The benchmark predicted reasonably accurate values for the burnup and fission gas release. There was error in the predicted temperatures, which could be explained by uncertainty in the input parameters and legacy temperatures. BISON over-predicted dimensional changes in the fuel and cladding. The sensitivity study showed that the dimensional changes were most sensitive to the fuel swelling anisotropy and the cladding void swelling model. Future benchmark and model development should focus on cladding swelling behaviors to improve dimensional change predictions.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2016

CAMPUS: Fully Coupled Multiphysics Modeling and Simulation of LWR and FBR Nuclear Fuel Behavior

Nuclear fuels operate in an environment that involves complex multiphysics phenomena, and the multiphysics behavior is often tightly coupled. The prediction of fuel behavior under irradiation involves very complex material behavior that is not seen in any other engineering discipline. Understanding and predicting the evolving material properties and phenomenal behaviors of nuclear fuels are major challenges for fuel design and behavior prediction. The multiphysics behavior is often a tightly coupled thermal, mechanical and chemical phenomenon associated with a large number of control parameters and uncertainties, which requires an advanced fuel performance modeling and simulation capability to improve the existing reactors performance, to address environmental and reactor safety concerns. Nuclear fuel performance modeling and simulation capability is necessary as a result of the high cost and difficulty in experimental measurements. So, a fuel performance code called CityU Advanced Multiphysics Nuclear Fuels Performance with User-defined Simulations (CAMPUS) was developed to predict both light water reactor and fast reactor fuel behavior. An effective approach was developed using self-defined multiphysics models based on the framework of COMSOL Multiphysics to manage the nonlinearities associated with light water reactor and fast reactor fuels performance analysis. The modelling and simulations approach is of particular importance since it demonstrates highly interrelated and nonlinear fuel performance models can be developed and implemented into a multiphysics platform, and thus more efforts can be put into physics model development and improvement. The modelling results can be used to identify the important phenomena and parameters, to direct and design experiments and to assist in post analysis of expensive nuclear experiments for light water reactor and fast reactor nuclear fuel performance analysis. (authors)

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2014

Comparison of Fission Product Release Predictions Using PARFUME with Results from the AGR-1 Irradiation Experiment

This report documents comparisons between post-irradiation examination measurements and model predictions of silver (Ag), cesium (Cs), and strontium (Sr) release from selected tristructural isotropic (TRISO) fuel particles and compacts during the first irradiation test of the Advanced Gas Reactor program that occurred from December 2006 to November 2009 in the Advanced Test Reactor (ATR) at Idaho National Laboratory (INL). The modeling was performed using the particle fuel model computer code PARFUME (PARticle FUel ModEl) developed at INL. PARFUME is an advanced gas-cooled reactor fuel performance modeling and analysis code (Miller 2009). It has been developed as an integrated mechanistic code that evaluates the thermal, mechanical, and physico-chemical behavior of fuel particles during irradiation to determine the failure probability of a population of fuel particles given the particle-to-particle statistical variations in physical dimensions and material properties that arise from the fuel fabrication process, accounting for all viable mechanisms that can lead to particle failure. The code also determines the diffusion of fission products from the fuel through the particle coating layers, and through the fuel matrix to the coolant boundary. The subsequent release of fission products is calculated at the compact level (release of fission products from the compact) but it can be assessed at the particle level by adjusting the diffusivity in the fuel matrix to very high values. Furthermore, the diffusivity of each layer can be individually set to a high value (typically 10-6 m2/s) to simulate a failed layer with no capability of fission product retention. In this study, the comparison to PIE focused on fission product release and because of the lack of failure in the irradiation, the probability of particle failure was not calculated. During the AGR-1 irradiation campaign, the fuel kernel produced and released fission products, which migrated through the successive layers of the TRISO-coated particle and potentially through the compact matrix. The release of these fission products was measured in PIE and modeled with PARFUME.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2017

Improvements to Modeling Capabilities of ATF Concepts in the BISON Fuel Performance Code

Research into accident tolerant materials for the fuel and cladding in Light Water Reactors has been at the forefront of the nuclear fuel research community since the events that occurred at the Fukushima Daiichi nuclear power plant in March 2011. Accident tolerant materials are defined as those that provide significantly increased response time in the event of an accident while providing similar or improved performance as the conventional UO{sub 2}/zirconium-based cladding fuel rods during normal operation. In particular, qualitative attributes for materials with enhanced accident tolerance include improved reaction (e.g., oxidation) kinetics with steam, resulting in lower hydrogen (or other combustible gases) generation rate, while maintaining acceptable thermo-mechanical properties, fuel-clad interactions, and fission-product behavior. Through it's Office of Nuclear Energy, the United States Department of Energy (U.S. DOE) has accelerated research in this area through the Fuel Cycle Research and Development (FCRD) Advanced Fuels Campaign (AFC). The goal of the AFC Accident Tolerant Fuel (ATF) program is to guide selection of promising concepts for insertion into a commercial reactor as part of a lead test rod or assembly in 2022. Given the aggressive development schedule, it is impossible to perform a comprehensive set of experiments to provide material characterization data. Therefore, the AFC is utilizing computational analysis tools in an effort to understand the proposed accident tolerant materials. The two materials of interest in this work are iron-chromium-aluminum (FeCrAl) cladding and U{sub 3}Si{sub 2}. From a fuel performance standpoint, the correlations available to describe the behavior of these two materials is limited. Therefore, as additional experimental data becomes available and correlations are updated, the fuel performance models must be updated as well to assure that the material models reflect the latest experimental findings. In this paper we demonstrate the importance of utilizing the latest state-of-the-art models for fuel performance simulations by comparing the change in the updated thermal conductivity model for U{sub 3}Si{sub 2} fuel and oxidation model for FeCrAl cladding alloys using the BISON fuel performance code under normal operating conditions. The results indicate that the latest thermal conductivity model for U{sub 3}Si{sub 2} results in fuel centerline temperatures that are on average approximately 3% higher than the previous model. For the oxidation behavior of FeCrAl alloys the new model predicts observable but small oxide thickness (6 μm) compared to the previous model which predicted essentially zero oxide scale formation.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2017

AGR-5/6/7 Irradiation Test Predictions using PARFUME

PARFUME, (PARticle FUel ModEl) a fuel performance modeling code used for high temperature gas-cooled reactors (HTGRs), was used to model the Advanced Gas Reactor (AGR)-5/6/7 irradiation test using predicted physics and thermal hydraulics data. The AGR-5/6/7 test consists of the combined fifth, sixth, and seventh planned irradiations of the AGR Fuel Development and Qualification Program. The AGR-5/6/7 test train is a multi-capsule, instrumented experiment that is designed for irradiation in the 133.4-mm diameter north east flux trap (NEFT) position of Advanced Test Reactor (ATR). Each capsule contains compacts filled with uranium oxycarbide (UCO) unaltered fuel particles. This report documents the calculations performed to predict the failure probability of tristructural isotropic (TRISO)-coated fuel particles during the AGR-5/6/7 experiment. In addition, this report documents the calculated source term from the driver fuel. The calculations include modeling of the AGR-5/6/7 irradiation that is scheduled to occur from October 2017 to April 2021 over a total of 13 ATR cycles, including nine normal cycles and four Power Axial Locator Mechanism (PALM) cycle for a total between 500 – 550 effective full power days (EFPD). The irradiation conditions and material properties of the AGR-5/6/7 test predicted zero fuel particle failures in Capsules 1, 2, and 4. Fuel particle failures were predicted in Capsule 3 due to internal particle pressure. These failures were predicted in the highest temperature compacts. Capsule 5 fuel particle failures were due to inner pyrolytic carbon (IPyC) cracking causing localized stresses concentrations in the SiC layer. This capsule predicted the highest particle failures due to the lower irradiation temperature. In addition, shrinkage of the buffer and IPyC layer during irradiation resulted in formation of a buffer-IPyC gap. The two capsules at the two ends of the test train, Capsules 1 and 5 experienced the smallest buffer-IPyC gap formation due to the lower irradiation fluences and temperatures. Capsule 3 experienced the largest buffer-IPyC gap formation of just under 24 µm. The release fraction of fission products Ag, Cs, and Sr silver (Ag), cesium (Cs), and strontium (Sr) vary depending on capsule location and irradiation temperature. The maximum release fraction of Ag occurs in Capsule 3, reaching up to 84.8% for the TRISO fuel particles. The release fraction of the other two fission products, Cs and Sr are much smaller and, in most cases, less than 1%. The notable exception is again in Capsule 3, where the release fraction for Cs and Sr reach up to 9.7% and 19.1%, respectively.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2021

Evaluation of the anisotropic grain boundaries and surfaces of α -U via molecular dynamics

Alloys based on uranium-zirconium are gaining renewed interest as fuels for the Versatile Test Reactor and a number of microreactor designs. Implementing metallic fuel in reactors creates the need for robust descriptive and predictive fuel performance modeling. Here, the current state of metallic fuel performance modeling relies on empirical equations derived from historical experiments, which may be unreliable when applied outside of their temperature, power, and composition phase space. One area where such data is lacking is the irradiation behavior of alpha -U, specifically tearing and porosity formation at the early stages of irradiation. While grain boundaries likely play a key role in this fuel behavior, relatively little is known about grain boundaries in alpha-U. Thus, we evaluate the grain boundary, surface energy, and work of adhesion of alpha -U utilizing molecular dynamics. Symmetric tilt grain boundaries (STGBs) are analyzed with the tilt plane oriented along each major crystallographic axis, for a total of eighty unique grain boundaries. The effect of temperature, tilt plane, and misorientation angle on interfacial energies are analyzed. The interfacial energies typically increase with temperature and there is significant variance as a function of misorientation angle, irrespective of the tilt plane. At 500 K, the average surface energy (1.23 J/m 2 ) is approximately 1.5 times the grain boundary energy (0.79 J/m 2 ), and the work of adhesion is approximately twice the grain boundary energy (1.68 J/m 2 ). Orientations for the likely formation of twins and likely failure planes are identified.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2018

Axial Relocation Model Extension in Bison

Fuel rods subjected to a Loss of Coolant Accident (LOCA) in a nuclear reactor can undergo a complex process known as fuel fragmentation, relocation, and dispersal (FFRD). The loss of coolant results in a severe degradation of the thermal heat transfer coefficient on the waterside surface of the cladding. This, coupled with the loss of coolant pressure causes the cladding to distend (balloon) outward. If the cladding distention is large enough, fuel fragmented during irradiation, may relocate from upper regions of the rod into the ballooned region. This mass relocation results in increased localized heating due to the presence of more fuel within the balloon resulting in further clad distention leading to potential rupture of the cladding. In the event that cladding rupture occurs the relocated fragmented fuel may disperse outside of the rupture opening if the size of the fuel fragments is small enough. Fuel performance modeling can be used to help understand the behavior of fuel rods during the LOCA transient. Existing models are particularly limited in regards to FFRD. This report briefly describes the existing state of the art for fuel performance modeling of fragmentation and fuel axial relocation. A more in depth description the axial relocation model implemented into the Bison fuel performance code in FY17 is provided. In this report, the extension of this existing model from a layered 1D framework to a 2D framework that allows for the introduction of azimuthal variation in the boundary conditions as experienced during a LOCA is discussed. The 2D framework utilized has been developed by the author of this report as part of his dissertation research ongoing at the University of South Carolina under the direction of Professor Travis W. Knight. The report briefly describes the 2D framework used and highlights in more detail the required developments in Bison to facilitate the extension of the axial relocation model to work within this framework. Finally, a few demonstration cases are provided that illustrate the benefit of using the new extended axial relocation model for the simulation of fuel rods under LOCA conditions.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2016

Tailored Microstructure and Properties in UO{sub 2}

Advanced fuels with enhanced safety margin and accident tolerance are of vital importance for safe operation of current light water reactor fleet and the development of future reactor systems. The current UO{sub 2} fuel for LWRs has low thermal conductivity, which will be further reduced upon burn-up. The intrinsically low thermal transfer efficiency of the oxide fuels results in a large temperature gradient within the fuel pellet and high center-line temperature. Thermal swelling of the pellets and fission product accommodation and retention limit the lifetime of UO{sub 2} fuel in the reactor, presenting the great challenges for extending burn-up, effective utilization of nuclear resources and minimization of nuclear waste accumulation. Critical needs also exist in developing accident tolerant fuels that can tolerate loss of coolant accident or improve fuel performance under regular operation or beyond design scenario. Key properties of advanced fuels include high thermal conductivity, oxidation resistance, high temperature mechanical properties, fission gas retention capability and thus improved accident tolerance. The US Nuclear Energy Advanced Modeling and Simulation (NEAMS) program is developing science-based next generation fuel performance modeling capability as part its Fuel Product Line in order to facilitate the predictive capability of nuclear fuel performance and assist the design and analysis of reactor systems. Critical experimental data are needed to validate MARMOT models, particularly on effective thermal transport, fracture mechanisms, grain growth kinetics and fission gas behavior. The fabrication of sintered fuel pellets with well-controlled microstructure is prerequisite to establish the correlation of the microstructure features and fuel behavior in order to develop high fidelity fuel performance models. In this talk, recent advancements on developing advanced UO{sub 2} fuels and properties improvement are overviewed with the emphasis on different accident tolerant fuel (ATF) concepts and tailoring microstructures for MARMOT validation. Current efforts on ATFs include composite fuels and high-density fuels to improve thermal-mechanical properties and fission gas retention capabilities. Different composite UO{sub 2} fuels are fabricated with heterogeneous phases as sintering additives for microstructure and property control, and the potential application of the composites as advanced fuels with enhanced accident tolerance will be discussed. In addition, recent progresses of using field-assisted sintering technologies, specifically spark plasma sintering (SPS), in tailoring and engineering fuel matrix as the target systems for validating MARMOT physics models will be highlighted. Particularly, monolithic UO{sub 2} with tailored microstructure including grain size across multiple length scales from nano-metered to micron-sizes, porosity and stoichiometry can be sintered. The impacts of tailored microstructure on thermal-mechanical properties and grain growth kinetics are discussed within the context of the MARMOT modeling. (authors)

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2024

Segmentation and Classification of Fission as Pores in Reactor Irradiated Annular U–10Zr Metallic Fuel Using Machine Learning Models

Metallic fuels, particularly U—10Zr, are promising candidates for next-generation sodium-cooled fast reactors. Irradiation of nuclear fuels in reactors can lead to the formation of solid and gas fission product which subsequently forms microstructural pores, deteriorating fuel performance. Due to the massive amount of pores and complex phases formed, a quantitative description of fission gas pores is not yet available, preventing the development of microstructure-informed fuel performance modeling for fuel qualification. This paper applied a pre-trained deep learning model to ~10,260 high magnification scanning electron microscopy images. This method increased the accuracy of fission gas pore segmentation and allows statistical features to be extracted which cannot be achieved manually. A pre-trained decision tree model worked on the segemenation results and further classified the pores into different categories to produce a correlation between the pores, movement of lanthanides, and temperature gradient during irradiation. Finally, this paper emphasizes the potentials of machine learning models to accelerate fuel research, development, and qualification for advanced reactors.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Meso-scale modeling of UO2 nuclear fuel to high burnup

To improve the economics of light water reactors for commercial nuclear energy generation, utility operators are seeking to obtain regulatory approval to run UO2 fuel to higher levels of burnup. One potential impediment to obtaining this approval is the phenomenon of fuel fragmentation, relocation, and dispersal (FFRD). FFRD can result when fuel experiences a rapid temperature transient, such as that occurring during a Loss Of Coolant Accident (LOCA). FFRD has historically been most associated with the rim region in UO2 fuel pellets, where the phenomenon of fragmentation is also referred to as pulverization due to the small size of the fragments. More recent evidence suggests that the so-called “dark zone” (due to its appearance in micrographs) that can be observed in the mid-radial regions of high burnup fuel is also susceptible to FFRD. Although empirical fuel performance models have been developed that can adequately predict pulverization in the rim region under typical LWR conditions, a scientific understanding of what underlies fuel restructuring and subsequent FFRD is lacking even in the rim region, and no models are currently available for the behavior the dark zone. To address these challenges, the U.S. Department of Energy’s Nuclear Energy Advanced Modeling and Simulation (NEAMS) program has employed a multi-scale modeling approach to improve scientific understanding and develop new fuel performance models. In this talk, I will focus on meso-scale efforts, which form a crucial link between atomic-scale and engineering-scale models. Phase-field modeling combined with cluster dynamics is used to predict the restructuring process in the rim region. Phase-field fracture modeling, informed by atomistic simulations, is used to predict the onset of pulverization in the rim region. Combining these techniques together allows the extent of rim pulverization to be predicted. The formation and evolution of the dark zone has also been simulated with the phase-field method, using an improved approach to vacancy source term parameterization. The work shows the important impact of microstructure on fuel performance.

fracture↗

DOE OSTI2018

A Revised Capsule Design for the Accelerated Testing of Advanced Reactor Fuels

Testing of fast reactor fuel is currently challenging because of the thermal neutron spectrum of the Advanced Test Reactor (ATR) and the fact that ATR coolant is substantially below typical temperatures found in liquid metal-cooled fast reactors. Despite these issues, since 2003 the Idaho National Laboratory (INL) has successfully tested a variety of metallic, oxide, and nitride fuels for fast reactor applications. There are, however, opportunities to improve the experiments so that the time required to reach a desired burnup can be reduced, and so the sensitivity of the experiments to fabrication tolerances can be minimized. A revised capsule design exploits the use of smaller diameter rodlets to increase power densities and correspondingly reduce the irradiation time required to reach high burnup. Thermal and nuclear analyses indicate that the time to reach 30at% burnup could be reduced from about 12 years to approximately 2-3 years if the fuel diameter is reduced by one-half and to around 1-2 years if the diameter is reduced by one-third. In addition, reducing fuel diameter improves the radial power distribution in the fuel without the use of cadmium shrouding. This observation opens up the possibility of testing advanced reactor fuel systems in Small I locations in the ATR where there is substantial unused capacity. Although not directly tied to a revised capsule design, post-irradiation furnace testing is proposed to provide time-to-failure data that will be helpful in the benchmarking of fuel performance models and in assessing the performance of new fuel designs relative to more standard fast reactor fuel systems. In this paradigm, ATR irradiation experiments will be viewed more as preparation for furnace testing than as experiments that exist in isolation. An added benefit to furnace testing is that uncertainties in temperatures will significantly be reduced relative to non-instrumented capsules in the ATR. The time and cost in developing this experimental capability is expected to be reduced considerably because of the availability of the blister anneal furnace used by the HPRR program. A key issue in the experiment approach is the potential for non-prototypical rodlet dimensions to influence the observed performance of a given fuel design. For example, a qualitative assessment indicates that the effects of fuel-cladding chemical interactions during furnace testing might be more pronounced in reduced diameter rodlets simply because thinner cladding would be more sensitive to a given depth of fission product penetration. In a traditional empirically-driven approach to fuel qualification, any change from prototypical behavior is undesirable because the resulting data cannot easily be assimilated into a statistical correlation. However, in the current approach, systematic variations in fuel diameter provide the opportunity to benchmark fuel performance models over a wider range of parameter space, which in turn is expected to improve understanding and result in better, more physically based models in the long term.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2024

Fuel Performance Evaluation of THOR-C Experiments

The Temperature Heatsink Overpower Response Commissioning (THOR-C) and THOR-Metal (THOR-M) experiments will be performed as part of an ongoing project for testing sodium fast reactor fuels with the Japan Atomic Energy Agency (JAEA). The THOR-C experiments consist of fresh metallic fuel pins and have been analyzed using the ABAQUS, Ansys codes and the BISON fuel performance code. THOR-M-Loss of Flow-1 (THOR-M-LOF-1) is designed to test an EBR-II irradiated fuel pin under LOF conditions. Simulation of the THOR-MLOF-1 experiment required first simulating the base irradiation of the fuel pin in EBR-II. MFUEL module of SAS4A/SASSYS-1 [1] is a physics-based metallic fuel performance model applicable to the normal operation, transient scenarios and fuel failure modeling including scenarios with bulk fuel melting. The model has been validated using EBR-II normal operation, separate effect transient tests as well as TREAT M-Series transient tests [2]. In this study, MFUEL models has been utilized together with a new capsule heat transfer model developed in this project. The new heat transfer model was necessary due to (1) significant amount of heat losses that required 2D heat transfer, (2) the presence of a titanium heat sink, rejecting a significant amount of heat, and (3) stagnant coolant conditions, which are inconsistent with SAS4A/SASSYS-1 (SAS) heat transfer model. Updates to SAS4A/SASSYS-1 and MFUEL has been described below, followed by a preliminary validation effort using the results from THOR-C-2 fresh fuel capsule experiment. A previous study for THOR-C-2 analysis using BISON code is also utilized in this study to model this test [3]. [1] D. O’Grady, A. J. Brunett, L. Ibarra, A. Karahan, T. Kim, T. S. Sumner, R. Thomas, T. H. Fanning, “The SAS4A/SASSYS-2 Version 5.7 Safety Analysis Code System,” Argonne National Laboratory,ANL/NSE-SAS/5.7, (2023). [2] A. Karahan, T. Kim, T. Fanning, D. O’Grady, “Validation of MFUEL Metal Fuel Performance Models of SAS4A/SASSYS-1,” Argonne National Laboratory, ANL/NSE-23/11, (2023). [3] M. Mihelish, A. Zabriskie, K. Paaren, P. Medvedev, C. Jensen, “Fuel Performance Predictions for the TREAT THOR-C Experiments,” Idaho National Laboratory, INL/RPT-23-73397, Revision 0, (2023)

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗