On the Use of Elastic-Plastic Material Characteristics for Linear-Elastic Component Assessments

Abstract

In this paper the procedure of safety assessment of components by fracture mechanics analysis as recommended in TECDOC 717 is applied to two standard specimens of ductile cast iron. It is shown that the use of a pseudo-elastic K_u-value in linear elastic safety analysis may lead to non-conservative results, when elastic-plastic material behaviour can be expected.     

A fracture mechanics safety concept to assess the impact behavior of ductile cast iron containers for shipping and storage of radioactive materials

Within the scope of the German licensing procedures for shipping and storage containers for radioactive materials made of ductile cast iron, BAM performs approval design tests including material tests to ensure the main safety goals of shielding, leaktightness and subcriticality under “Type B accident conditions”. So far the safety assessment concept of BAM is based essentially on the experimental proof of container strength by prototype testing under most damaging test conditions in connection with complete approval design tests, and has been developed especially for cylindrical casks like CASTOR- and TN-design. In connection with the development of new container constructions such as “cubic cast containers”, and the fast developments in the area of numerical calculation methods, there is a need for a more flexible safety concept especially considering fracture mechanics aspects.

This paper presents the state of work at BAM for such an extended safety concept for ductile cast iron containers, based on a detailed brittle fracture safe design proof. The requirements on stress analysis (experimental or numerical), material properties, material qualification, quality assurance provisions and fracture mechanics safety assessment, including well defined and justified factors of safety, are described.     

BAM Production Control Programme for Containers for Transport and Storage of Nuclear Materials

Abstract

In the process of testing spent fuel casks, BAM is gaining a lot of relevant data regarding the quality level of ductile cast iron (DCI). The basic parameters governing the material behaviour of ferritic and ferritic pearlitic DCI are dicussed and the development of container quality over recent years is summarised. The high quality level of German DCI containers is outlined. The effect of microstructure, sample size and loading rate on the fracture toughness of DCI is discussed in the second part of the paper.     

Abstracts on Packaging,Transport, Storage and Security of Radioactive Material

Abstract

The design testing of packages for radioactive materials considers normal operating conditions and accident conditions. A mechanical test, especially under accident conditions, must include the safety assessment of possibly undetected material defects. BAM has developed improved assessment methods, using fracture mechanics, for cracks in the most highly stressed regions of cubic containers made of ductile cast iron. Postulated surface cracks in the centre of the container walls and grooves are investigated numerically. In the static case relations between the crack tip parameters (stress intensity factor or the J integral, respectively), stress load, crack depth, container geometry and material behaviour are derived. In the dynamic case it can be shown by numerical simulations of the drop test of containers onto different targets, even without shock absorbers, that the dynamic crack tip parameter may be estimated by static formulae with the dynamic stress inserted in the intact component. This somewhat surprising result can be explained by the fact that the drop event happens over milliseconds. That is slow enough for the crack to behave quasistatically although the crack is loaded with a dynamic, i.e. time-dependent, stress. Based on these calculations, the critical crack depth is given as a function of the stress, the material quality (defined by the fracture toughness) and the wall thickness for surface cracks in the centre of walls as well as in grooves of a cubic container.     

Fracture Toughness of DCI Casks and Prediction by Small Specimen Test

Abstract

Spent nuclear fuel transport and/or storage containers (casks) must maintain their structural integrity even when subjected to hypothetical accidents during transport or handling accidents at storage facilities. For ductile cast iron (DCI) to be used as a cask containment boundary material, adequate fracture toughness must be demonstrated at service temperatures and Impact loading conditions of concern. In Japan, comprehensive studies of the fracture toughness of heavy section DCI have been undertaken by a number of research organisations to provide the safety assurance for the DCI casks. In the present study, the fracture toughness data were used to develop a lower bound trend curve for heavy section DCI and to examine the prediction methods by small specimen tests. The fracture toughnesses K_Ic, K_IIc and K_IIIc were also obtained to study the safety assessment of DCI casks under different loading mode conditions.     

Probabilistic Evaluation of Brittle Failure Design Criterion of DCI Cask

Abstract

As a cask material, ductile cast iron may be susceptible to failure in a brittle manner under certain temperature and load conditions. A design criterion for ductile cast iron casks against brittle failure due to drop tests, has been proposed by Central Research Institute of Electric Power Industries. This design criterion includes a safety factor which presents the extent between the detectable flaw size and the critical flaw size and may be interpreted as ‘uncertainty factor’ as to the uncertainties regarding stress prediction, fracture toughness and so on. In this report, to verify the proposed design criterion, probabilistic evaluation was performed according to a series of drop tests using a full scale cask and material tests, and it is confirmed that the proposed design criterion is applicable and reliable. Furthermore, applicability of the safety design method described in the IAEA-TECDOC-717 published in August 1993 was investigated.     

Mechanical Properties of Ductile Cast Iron and Cast Steel for Intermediate Level Waste Transport Containers

Abstract

UK Nirex Ltd is developing Type B re-usable shielded transport containers (RSTCs) in a range of shielding thicknesses to transport intermediate level radioactive waste (ILW) to a deep repository. The designs are of an essentially monolithic construction and rely principally on the plastic flow of their material to absorb the energies involved in impact events. Nirex has investigated the feasibility of manufacturing the RSTCs from ductile cast iron (DCI) or cast steel instead of from forgings, since this would bring advantages of reduced manufacturing time and costs. However, cast materials are perceived to lack toughness and ductility and it is necessary to show that sufficient fracture toughness can be obtained to preclude brittle failure modes, particularly at low temperatures. The mechanical testing carried out as part of that programme is described. It shows how the measured properties have been used to demonstrate avoidance of brittle fracture and provide input to computer modelling of the drop tests.     

The Application of Fracture Mechanics to The Safety Assessment of Transport Casks For Radioactive Materials

Abstract

BAM is the responsible authority in Germany for the assessment of the mechanical and thermal design safety of packages for the transport of radioactive materials. The assessment has to cover the proof of brittle fracture safety for package components made of potentially brittle materials. This paper gives a survey of the regulatory and technical requirements for such an assessment according to BAM's new 'Guidelines for the application of ductile cast iron for transport and storage casks for radioactive materials'. Based on these guidelines, higher stresses than before will be permissible, but it is necessary to put more effort into the safety assessment procedure. The fundamentals of such a proof using the methods of fracture mechanics are presented. The recommended procedure takes into account the guidelines of the IAEA's advisory material which are based on the prevention of crack initiation. Examples of BAM's research and safety assessment practices are given. Recommendations for further developments towards package designs with higher acceptable stress levels will conclude the paper.     

Dynamic Fracture Mechanics Assessments for Cubic Ductile Cast Iron Containers

Abstract

An improved BAM safety assessment concept for the cask material ductile cast iron (DCI) to cover higher stresses in the cask body, highly dynamic load scenarios, and a broader range of material qualities will require more extensive fracture mechanics analyses based on a combination of material testing, calculation of applied stresses, and inspection standards. As an example, the brittle fracture mechanics assessment of a surface crack in a plate due to the dynamic load from the 5 m drop of a cubic container (not equipped with impact limiters) onto a reinforced concrete target is investigated. The numerically calculated time-dependent stress intensity factor is compared with a previous static solution with the same loading history inserted. For the scenario studied the differences between the curves are negligible because a dynamic load of the cask within a time scale of millisec9nds can be considered as a quasi static load for the crack.     

Application of IAEA TECDOC 717 to the Assessment of Brittle Fracture in Transport Containers with Plastic Flow Shock Absorbers

Abstract

UK Nirex is developing re-usable shielded transport containers (RSTCs) in a range of shielding thicknesses (from 70 nun to 285 nun) to transport immobilised intermediate level radioactive waste (ILW) to a deep repository. The RSTCs are being designed to meet the requirements of the IAEA Transport Regulations for Type B packages, including the requirement to maintain shielding and containment following a drop of 9 m onto an unyielding surface. The RSTCs are essentially monolithic in construction and the heaviest version weighs up to 65 tonnes when loaded with contents. They rely principally on plastic flow of the material of construction to absorb the high energies involved in impact events. Specific features of the designs, such as the solid metal comer shock absorbers and side ribs have been optimised for this purpose. Nirex has investigated the feasibility of manufacturing the RSTCs from ductile cast iron (DCI) or cast steel instead of from forgings, since this would bring advantages of reduced manufacturing time and costs. In this paper the methodology set out in IAEA-TECDOC-717 is applied to the Nirex RSTC, including the application of elastic plastic fracture mechanics methods.     

Physical properties of nodular cast iron for shipping containers and safety analysis by fracture mechanics

Recently, the dry-storage technique for storing spent fuels or radioactive wastes in shipping containers has been improved as one of the new technologies in the nuclear-fuel cycle. Mitsui Engineering and Shipbuilding has engaged for 5 years in the development of a radioactive waste container made of modular cast iron. This paper describes the physical properties of nodular cast iron and a fracture mechanical study of the container made of this material.The material is equivalent to FCD 37 in the JIS Standard. Many tests were carried out to obtain the mechanical properties, the fracture toughness and other characteristics using specimens machined from a thick-walled casting block.Then, the structural integrity of the cubic-type container made of this material was estimated on the basis of fracture mechanics. The critical flaw sizes regarding stresses occurred during a 9-meter drop test and a 1-meter punch-drop test were calculated. The results indicate that these sizes can be determined by a nondestructive inspection.Consequently, it has been analytically confirmed that nodular cast iron containers are strong enough to withstand an impact load during drop tests if the applied stresses are less than the yield stress.     

Sandia National Ladoratories Cask Drop Test Programme: A Demonstration of Fracture Mechanics Principles for the Prevention of Brittle Fracture

Abstract

Sandia National Laboratories recently completed a cask drop test programme. The aims of the programme were (1) to demonstrate the applicability of a fracture mechanics-based methodology for ensuring cask integrity, and (2) to assess the viability of using a ferritic material for cask containment. The programme consisted of four phases: (i) materials characterisation; (ii) non-destructive examination of the cask; (iii) finite element analyses of the drop events; and (iv) a series of drop tests of a ductile iron cask. The first three phases of the programme provided information for fracture mechanics analyses and predictions for the drop test phase. The drop tests were nominally based upon the lAEA 9 m drop height hypothetical accident scenario, although one drop test was from 18 m. All tests were performed in the side drop orientation at a temperature of ?29°C. A circumferential, mid-axis flaw was introduced into the cask body for each drop test. Flaw depths ranged from 19 to 76 mm. Steel saddles were welded to the side wall of the cask to enhance the stresses imposed upon the cask in the region of the introduced flaw. The programme demonstrated the applicability of a fracture mechanics methodology for predicting the conditions under which brittle fracture may occur and thereby the utility of fracture mechanics design for ensuring cask structural integrity by ensuring an appropriate margin of safety. Positive assessments of ductile iron for cask containment and the quality of the casting process for producing ductile iron casks were made. The results of this programme have provided data to support IAEA efforts to develop brittle fracture acceptance criteria for cask containment.     

Design Assessment for Transport and Storage Casks

Abstract

The design assessment concerning the mechanical behaviour of transport and storage casks for radioactive material to fulfil nuclear safety criteria has to be based on two essential considerations: (1) Effective analysis of the stress–strain state of the cask components under both normal operational and test conditions including hypothetical accident scenarios with suitable accepted methods. (2) Economic estimation of the required properties and the structural state of the cask components with sufficient exactness. In an overview of the codes which are available at GNS/GNB for cask impact strength analyses (ANSYS, ADINA, VDI Codes), procedures and aspects of benchmarking and validation of calculation codes are described. The results of experimental full size cask drop test programs (CASTOR, POLLUX) and corresponding pre-test calculational analyses show the suitability of the codes used. The influence of dynamic effects on the mechanical properties of material (ductile cast iron, wood) has been investigated experimentally. By consideration of these dynamic values in strength analyses of casks at impact a good agreement between experimental and calculational results has been achieved.     

Safety assessment aspects of type B(U) packages containing wet intermediate level waste

Abstract

In Germany, the mechanical and thermal safety assessment of approved packages for the transport of RAM is carried out by BAM as the competent authority according to the International Atomic Energy Agency regulations. BAM was involved in several approval procedures with ductile cast iron containers containing wet intermediate level waste. These contents, which are not dried, only drained, consist of saturated ion exchange resin and a small amount of free water. Compared to the safety assessment of packages with dry content, attention must be paid to some more specific points. The physical and chemical compatibility of the content itself and of the content with materials of the package must be shown. From the mechanical resistance point of view, the package has to withstand the forces resulting from the freezing liquid. The most interesting point, however, is the pressure build-up inside the package due to vapourisation. This could be caused by radiolysis of the liquid and must be taken into account for the storage period. The paper deals primarily with the pressure build-up inside the package caused by the regulatory thermal test (30 min at 800°C) as part of the cumulative test scenario under accident conditions of transport. To determine the pressure, the temperature distribution in the content must be calculated for the whole period from the beginning of the thermal test until cooling down. In this case, calculating the temperature distribution requires, besides the consideration of conduction and heat radiation, consideration of evaporation and condensation including the associated processes of transport.     

Application of IAEA TECDOC 717 to Packagings and Comparison with Reactor Vessels

Abstract

Brittle fracture evaluation is important for type B(U) packagings and packagings carrying fissile materials in conformity with IAEA Regulations. Packaging materials susceptible to brittle fracture can be evaluated by Linear Elastic Fracture Mechanics (LEFM) or other credible methods as shown in IAEA TECDOC 717. Major similarities and differences between the packagings and reactor pressure vessels are here compared in terms of the brittle fracture evaluation. Examples of brittle fracture evaluations of 100 ton class ductile cast iron (DCI) packagings (casks) under hypothetical accident conditions are discussed.     

An Overview of R&D Work Performed in France Concerning the Risk of Brittle Fracture of Transport Casks

Abstract

An overview is given of the methodology followed in France to evaluate the risk of brittle fracture in transport casks. Various aspects are considered in this evaluation. First: the material characterisation: effect of strain rate and temperature on tensile properties and toughness. Secondly: evaluation of applied stress under dynamic loading and criteria to define worst cases (time, distribution). Thirdly: the global validation is presented to demonstrate that the whole methodology is conservative; consideration of representative analytical cases where initiation is obtained under controlled conditions. Results are presented concerning cast ductile iron and carbon steel materials.     

Extended Drop Tests Of DCI Casks with Artificial Flaws Demonstrating the Existing Safety Margins

Abstract

The use of spent fuel shipping and storage casks made of ductile cast iron (DCI) has been common practice for about 15 years when the development of such casks started in Germany where qualified foundries are able to produce these heavy section castings at the high quality level needed for this kind of application. To promote the discussion on safety against brittle failure a lot of research had been carried out in different countries. The two test programmes in Germany on casks with big artificial flaws under severe impact conditions is summarised in this paper. The first test object was a thick walled DCI ‘pipe’ (150 mm wall thickness) with dimensions equivalent to a 1:2.5 scale cask model. It was dropped with a 40 mm deep laser sharpended flaw from heights of up to 9 m onto rails. As a second test object a full scale CASTOR VHLW cask was used. This specimen had a flaw with a depth of 120 mm in a 260 mm thick wall. With increasing drop heights (up to 14 m) and stress intensity factors (up to material fracture toughness) this object was also dropped onto rails. For both cases the measured data (decelerations, crack opening displacement, strains, material properties) are presented. No brittle failure occurred, although in the 14 m drop of the CASTOR VHLW Cask the impact was 6.5 times higher than the impact measured in the mechanical test of the type B package design. The results demonstrate that DCI casks have significantly high safety margins even in the hypothetical case of an impact beyond type B package design requirements.     

Determination of fire resistance of plutonium storage containers

Abstract

Seismic upgrades to safety systems at the Plutonium Facility at Los Alamos, NM, USA, are needed based on the latest facility safety analysis. The design basis accident of concern is a large scale seismically induced fire on the processing floor. Such an accident could involve large quantities of plutonium in dispersible forms stored in containers that cannot be counted on to prevent material release. As part of the effort to improve the safety posture of the facility in the near term, we developed a test method to evaluate the capability of storage containers to prevent release of their contents in the event of a seismically induced fire. To provide a defensible basis for testing to the Department of Energy (DOE) and Congressional oversight, we adopted standard test methods from consensus codes and standards. These tests included a time–temperature exposure up to 870°C and a 20 L kerosene open pool fire test. After the thermal tests, containers were dropped from a height of 4 ft onto a steel plate. We measured the amount of a non-toxic plutonium surrogate released following the drop tests to establish a conservative value of expected material release (referred to as damage ratio) in the event of the facility accident. The DOE approved thermal and impact test protocols we developed are used to demonstrate a quantitative value for material release from containers where the assumption of total material release results in unacceptably high accident consequences.     

Comments on the Revised IAEA TECDOC 717 from a Foundryman's Point of view

Abstract

The IAEA-TECDOC-717 draft reflects the development of fracture mechanics over recent years. It has a tendency towards the academic state of the art which cannot be fully matched by the technical state of the art. There are a number of proposed requirements that at present sound confusing to the package designer. Other requirements would increase the cost of quality assurance without necessarily improving safety. Treating the potential embedded ductile iron microporosities as crack-tipped reference-sized flaws represents a highly conservative approach. Drop tests have never resulted in failures, not even for oversized artificial flaws. This verifies the conservatism of the fracture mechanics approach. The stress intensity factors of surface and sub-surface reference flaws are compared to each other in a numerical example. In contrast to the TECDOC statement on this matter they are of the same magnitude.     

Mechanical characteristics of fuel rod claddings in transport conditions

Abstract

A synthesis on the mechanical characteristics of unirradiated and irradiated fuel rod claddings was performed by the French Institut de Radioprotection et de Sûreté Nucléaire (IRSN) in order to have reference data for the assessment of the safety demonstrations in normal and accident conditions of transport required by the procedure of package licensing. Indeed, the transport conditions correspond to a range of cladding temperatures (200–550°C) which is only partly covered by the data acquired within the framework of the safety demonstration relative to the reactor normal operating conditions, especially beyond 400°C. This work concerned Zircaloy-4 cladding material (Zry-4) and M5^TM. Data about mechanical properties (elastic and ductile properties, creep behaviour), oxidation (in reactor and under air during transport), hydrides and fracture toughness have been collected and synthesised. The laws presented in the document can be used to obtain orders of magnitude of oxide layer thickness, hydrogen content and creep deformation rate. The following phenomena which could influence the mechanical behaviour of the cladding were more particularly studied: oxidation which could become very important during transport in case of cladding temperatures of ～500°C; creep for which only a few data ～500°C are available and which depends in particular on the internal pressure of the rods, the cladding oxidation and the presence of the hydrides; and recrystallisation of Zry-4 at ～500°C, which could have consequences on the mechanical properties of the cladding after cooling during the storage. For other topics of interest for the study of the mechanical behaviour of the cladding, such as the fracture toughness for example, it was identified that the data available is scarce.