Irradiation performance of fast reactor MOX fuel pins with ferritic/martensitic cladding irradiated to high burnups

The ACO-3 irradiation test, which attained extremely high burnups of about 232 GWd/t and resisted a high neutron fluence (E > 0.1 MeV) of about 39 × 10²⁶ n/m² as one of the lead tests of the Core Demonstration Experiment in the Fast Flux Test Facility, demonstrated that the fuel pin cladding made of ferritic/martensitic HT-9 alloy had superior void swelling resistance. The measured diameter profiles of the irradiated ACO-3 fuel pins showed axially extensive incremental strain in the MOX fuel column region and localized incremental strain near the interfaces between the MOX fuel and upper blanket columns. These incremental strains were as low as 1.5% despite the extremely high level of the fast neutron fluence. Evaluation of the pin diametral strain indicated that the incremental strain in the MOX fuel column region was substantially due to cladding void swelling and irradiation creep caused by internal fission gas pressure, while the localized strain near the MOX fuel/upper blanket interface was likely the result of the pellet/cladding mechanical interaction (PCMI) caused by cesium/fuel reactions. The evaluation also suggested that the PCMI was effectively mitigated by a large gap size between the cladding and blanket column.     

Irradiation Performance of Fast Reactor MOX Fuel Assemblies Irradiated to High Burnups

Mixed oxide fuel assemblies (MFA-1 and MFA-2 assemblies) were irradiated in the fast flux test facility to evaluate the irradiation performance of fast reactor core fuels at high burnups and high fast neutron fluences. The MFA-1 and MFA-2 assemblies achieved respective peak pellet burnups of 147 and 162GWd/t, and resisted to respective peak fast neutron fluences (E > 0:1 MeV) of 21:4 _ 1026 and 23:8 _ 1026 n/m2, without any indication of fuel pin breaching. Structural components of these assemblies were made of modified type 316 stainless steel and 15Cr-20Ni base advanced austenitic stainless steel. Postirradiation examinations of these assemblies revealed dimensional changes of fuel pins and assembly ducts due to irradiation-induced void swelling and irradiation creep, and fuel cladding local oval distortions due to bundle-duct interaction (BDI). The swelling resistance of 15Cr-20Ni base advanced austenitic stainless steel fuel pin cladding was almost the same as that of the modified type 316 stainless steel cladding, while the assembly duct of the former material had a slightly higher swelling resistance than that of the latter material. Analyses of fuel pin bundle deformations indicated that these assemblies likely mitigate BDI mainly by fuel pin bowings and cladding oval distortions.     

MOX Fuel Performance Experiment Specified for Japanese PWR Utilisation in the HBWR

In order to obtain high burn-up MOX fuel irradiation performance data, SBR and MIMAS MOX fuel rods with Pufissile enrichment of about 6 wt% have been irradiated in the HBWR. In-pile performance data of MOX have been obtained, and the peak burn-up of MOX pellet have reached to 66 GWd/tM as of October 2004. MOX fuel temperature is confirmed to have no significant difference compared to UO₂, if taking into account adequately for thermal conductivity degradation due to PuO₂ addition and burn-up development, and measured fuel temperature agrees well with HB-FINE code calculation up to high burn-up region. Fission gas release of MOX is possibly larger than UO₂ based on temperature and pressure assessment. No significant difference is confirmed between SBR and MIMAS MOX on FGR behaviour. MOX fuel swelling rate agrees well with solid swelling rate. Cladding elongation data shows onset of PCMI in high power region. Ramp test data from other experiment programs with various types of MOX fabrication route confirms superior PCI resistance of MOX compared to UO₂, due to enhanced creep rate of MOX. The irradiation is expected to continue until achieving of 70 GWd/tM (MOX pellet peak).     

Fuel-cladding mechanical interaction in fast breeder fuel pins; observations and analysis

The problems of fuel-cladding mechanical interaction are considered, and a survey is given of the causal processes in oxide fuel pins. Their importance is judged by relevant results from irradiation experiments in thermal and fast test reactors, and by corresponding modelling computations. It is demonstrated that critical cladding strain has to be expected only in case of large, fast rod power increase, primarily from reduced power to full power, and maybe also in case of serious cesium accumulation at the fuel/blanket interface. Steady-state fuel swelling does not make any considerable contribution to cladding strain by thermal creep or plastic flow.     

Analysis of MOX fuel behavior in reduced-moderation water reactor by fuel performance code FEMAXI-RM

To assess the feasibility of the 31% Pu-MOX fuel rod design of reduced-moderation water reactor (RMWR) in terms of thermal and mechanical behaviors, a single rod assumed to be irradiated in the core of RMWR up to 106 GWd/tHM has been analyzed by a fuel performance code FEMAXI-RM which is an extended version of FEMAXI-6 code. In the analysis, design specifications of fuel rod and irradiation conditions have been input, and available models of both MOX fuel and UO₂ fuel have been used as appropriate. The results are: fission gas release is several tens of percent, rod internal pressure does not exceed the coolant pressure, and the highest fuel center temperature is 2400 K, while cladding diameter increase caused by pellet swelling is within 1% strain. These predictions suggest that the MOX fuel rod integrity will be held during irradiation in RMWR, though actual behavior of MOX pellet swelling and cladding oxidation require to be investigated in detail.     

Model of fracture for the Zry cladding of nuclear fuel rods included in the code DIONISIO 1.0

The DIONISIO code describes most of the main phenomena occurring in a fuel rod during normal operation of a nuclear power reactor. Starting from the irradiation history, the code predicts the temperature distribution, elastic and plastic stress and strain, creep, swelling and densification, release of fission gases, caesium and iodine to the internal rod volume, gas mixing, pressure increase, irradiation growth of the cladding, development of an oxide layer on its surface and hydrogen uptake, restructuring and grain growth in the pellet.This work presents the model of Zircaloy fracture included in the code DIONISIO 1.0. The model of pellet-cladding mechanical interaction (PCMI) provides the forces caused by the solid-solid contact which add to the changing internal pressure and to the constant external pressure. Besides, the program evaluates the effects of a corrosive atmosphere (stress corrosion cracking, SCC) internal or external. With these data, the code calculates the J integral around the tip of an initiated crack, and proceeds to analyze, according to the quantity of corrosive substance dissolved and the cladding stress field, if the crack remains unchanged, if it grows due to the I-SCC mechanism, or if propagation is ductile, following the R curve of the material.Results corresponding to different PHWR and PWR reactors are presented and compared with code results. In particular, good agreement is obtained in the simulation of MOX experiments, where the cladding failed due to propagation of cracks originated in SCC.     

The OECD Halden reactor project fuels testing programme: methods, selected results and plans

The fuels testing programme conducted in the Halden reactor (heavy boiling water reactor (HBWR)) is aimed at providing data for a mechanistic understanding of phenomena, which may affect fuel performance and safety parameters. The investigations focus on implications of high burnup and address thermal property changes, fission gas release as influenced by power level and operation mode, fuel swelling, and pellet–clad interaction. Relevant burnup levels (>50 MWd kg⁻¹ U) are provided through long-term irradiation in the HBWR and through utilisation of re-instrumented fuel segments from commercial light water reactors (LWR). Both urania and MOX fuels are being studied regarding thermal behaviour, conductivity degradation, and aspects of fission gas release. Experiments are also conducted to assess the cladding creep behaviour at different stress levels and to establish the overpressure below which the combination of fuel swelling and cladding creep does not cause increasing fuel temperatures. Clad elongation measurements provide information on the strain during a power increase, the relaxation behaviour and the extent of a possible ratcheting effect during consecutive start-ups. Investigations foreseen in the programme period 2000–2002 include the behaviour of MOX and Gd-bearing fuel and other variants developed in conjunction with burnup extension programmes. Some LWR-irradiated fuel segments will undergo a burnup increase in the HBWR to exposures not yet achieved in LWRs, while others will be re-instrumented and tested for shorter durations.     

Transient Elongation of a Fresh Fuel Rod under Reactivity Initiated Accident Conditions

In-pile experiments of fresh fuel rods under reactivity initiated accident (RIA) conditions have been performed in the Nuclear Safety Research Reactor at the Japan Atomic Energy Research Institute in order to understand the basic pellet cladding mechanical interaction (PCMI) behavior. Rapid fuel pellet expansion due to a power excursion would cause radial and longitudinal deformation of the cladding. This PCMI could be one of the possible incipient failure modes of an embrittled cladding of a high burnup fuel under the RIA conditions.

Basic PCMI behavior was studied by measuring cladding deformation of a fresh fuel rod without complicated irradiation effects. The transient elongation measurements of the fuel with two kinds of gap width indicated not only PCMI-induced cladding elongation, but also reduction of the pellet stack displacement by the cladding constraint. In the tests under a high-pressure and high-temperature condition simulating an operation condition of BWRs, additional ridge-type cladding deformation was generated due to the axial collapse of the cladding. A preliminary analysis for interpretation of the tests was made using a computer code for the transient analysis of fuel rods, FRAP-T6.     

Design of a fuel element for a lead-cooled fast reactor

The options of a lead-cooled fast reactor (LFR) of the fourth generation (GEN-IV) reactor with the electric power of 600 MW are investigated in the ELSY Project. The fuel selection, design and optimization are important steps of the project. Three types of fuel are considered as candidates: highly enriched Pu-U mixed oxide (MOX) fuel for the first core, the MOX containing between 2.5% and 5.0% of the minor actinides (MA) for next core and Pu-U-MA nitride fuel as an advanced option. Reference fuel rods with claddings made of T91 ferrite-martensitic steel and two alternative fuel assembly designs (one uses a closed hexagonal wrapper and the other is an open square variant without wrapper) have been assessed. This study focuses on the core variant with the closed hexagonal fuel assemblies. Based on the neutronic parameters provided by Monte-Carlo modeling with MCNP5 and ALEPH codes, simulations have been carried out to assess the long-term thermal-mechanical behaviour of the hottest fuel rods. A modified version of the fuel performance code FEMAXI-SCK-1, adapted for fast neutron spectrum, new fuels, cladding materials and coolant, was utilized for these calculations. The obtained results show that the fuel rods can withstand more than four effective full power years under the normal operation conditions without pellet-cladding mechanical interaction (PCMI). In a variant with solid fuel pellets, a mild PCMI can appear during the fifth year, however, it remains at an acceptable level up to the end of operation when the peak fuel pellet burnup ∼80 MW d kg⁻¹ of heavy metal (HM) and the maximum clad damage of about 82 displacements per atom (dpa) are reached. Annular pellets permit to delay PCMI for about 1 year. Based on the results of this simulation, further steps are envisioned for the optimization of the fuel rod design, aiming at achieving the fuel burnup of 100 MW d kg⁻¹ of HM.     

FARST — A computer code for the evaluation of FBR fuel rod behavior under steady-state/transient conditions

FARST, a computer code for the evaluation of fuel rod thermal and mechanical behavior under steady-state/transient conditions has been developed. The code characteristics are summarized as follows:

1. (i) FARST evaluates the fuel rod behavior under the transient conditions. The code analyzes thermal and mechanical phenomena within a fuel rod, taking into account the temperature change in coolant surrounding the fuel rod.

2. (ii) Permanent strains such as plastic, creep and swelling strains as well as thermoelastic deformations can be analyzed by using the strain increment method.

3. (iii) Axial force and contact pressure which act on the fuel stack and cladding are analyzed based on the stick/slip conditions.

4. (iv) FARST used a pellet swelling model which depends on the contact pressure between pellet and cladding, and an empirical pellet relocation model, designated as “jump relocation model”.

The code was successfully applied to analyses of the fuel rod irradiation data from pulse reactor for nuclear safety research in Cadarache (CABRI) and pulse reactor for nuclear safety research in Japan Atomic Energy Research Institute (NSRR).The code was further applied to stress analysis of a 1000 MW class large FBR plant fuel rod during transient conditions. The steady-state model which was used so far gave the conservative results for cladding stress during overpower transient, but underestimated the results for cladding stress during a rapid temperature decrease of coolant.     

Development of Long Life FBR Fuels with Particular Emphasis on Cladding Material Improvement and Fuel Fabrication

The development of FBR fuel systems with high reliability and long in-core residence capability is required to make the fast reactor economically competitive with other electrical energy sources. PNC program of fuels and materials development has been primarily focused on mixed uranium/plutonium oxide (MOX) fuel with cold-worked 316 stainless steel for the past 20 years. Modified 316 stainless steel with excellent swelling resistance and high creep rupture strength was obtained for cladding and duct of the fast prototype reactor MONJU. Advanced austenitic alloys and high strength ferritic alloys are also being investigated for high burnup fuel assemblies of a long life core in large scale FBRs.

In MOX fuel fabrication technology, extensive progress has been achieved during driver fuel fabrication for the experimental reactor JOYO. A new MOX production facility PFPF has been completed with fully automatic and remote handling systems. This facility serves for MONJU core fuel production. The improvement of fuel fabrication technologies promotes cost reduction, safety operation and security from a physical protection standpoint.     

U-10Mo/Zr单片式燃料元件堆内稳态热-力学性能研究

本文建立了U-10Mo/Zr单片式燃料元件的辐照性能模型以及热-力学本构关系,采用有限元方法进行非均匀辐照场中燃料元件稳态热-力学性能的数值模拟,获得并分析了U-10Mo/Zr单片式燃料元件温度、形变和应力的分布特点及变化规律。研究结果表明,燃料芯体厚度增量在芯体和包壳结合面附近达到最大,主要受到燃料辐照蠕变的影响;在较低燃耗条件下,燃料芯体高温辐照肿胀模拟结果与低温辐照肿胀试验结果相当;燃料芯体边角区域和包壳端面外侧区域存在应力集中。      

Simulation of the fracture behavior of Zircaloy-4 cladding under reactivity-initiated accident conditions with a damage mechanics model combined with fuel performance codes FEMAXI-7 and RANNS

A continuum damage mechanics model using FEM calculations was proposed to be applied to an analysis of the fuel failure due to pellet cladding mechanical interaction (PCMI) under reactivity-initiated accident conditions. The model expressed ductile fracture via two processes: damage nucleation related to void nucleation and damage evolution related to void growth and linkage. The boundary conditions for the simulations were input from the fuel performance codes FEMAXI-7 and RANNS. The simulation made reasonable predictions for the cladding hoop strain at failure and reproduced the typical fracture behavior of the fuel cladding under the PCMI loading, characterized by a ductile shear zone in the inner region of the cladding wall. It was shown that occurrence of a through-wall crack is determined at an early stage of crack propagation, and the rest of the through-wall penetration process is achieved with a negligible increment in strain. The effect of a local temperature rise in the cladding inner region on the failure strain was found to be less than 5% for the conditions investigated. Failure strains predicted under a plane strain loading were smaller by 20%–30% than those predicted under equibiaxial tensions between the hoop and the axial directions.     

Failure of high burnup fuels under reactivity-initiated accident conditions

Pulse irradiation experiments of high burnup light-water-reactor fuels were performed to assess the fuel failure limit in a postulated reactivity-initiated accident (RIA). A BWR-UO₂ rod at a burnup of 69 GW d/t failed due to pellet-cladding mechanical interaction (PCMI) in the test LS-1. The fuel enthalpy at which fuel failure occurred was comparable to those for PWR-UO₂ rods of 71 to 77 GW d/t with more corroded cladding. Comparison of cladding metallographs between the BWR and PWR fuel rods suggested that the morphology of hydride precipitation, which depends on the cladding texture, affects the fuel failure limit. The tests BZ-1 and BZ-2 with PWR-MOX rods of 48 and 59 GW d/t, respectively, also resulted in PCMI failure. The fuel enthalpies at failure were consistent with a tendency formed by the previous test results with UO₂ fuel rods, if the failure enthalpy is plotted as a function of the cladding outer oxide thickness. Therefore, the PCMI failure limit under RIA conditions depends on the cladding corrosion states including oxidation and hydride precipitation, and the same failure limit is applicable to UO₂ and MOX fuels below 59 GW d/t.     

Irradiation swelling, creep and thermal-stress analysis of LWR fuel elements, computer code isune-2

The irradiation swelling, creep, and thermal-stress analysis of light-water reactor (LWR) oxide (UO₂) fuel elements is analysed. The analysis is based on the basic physical and mathematical assumptions and the experimental data of the fuel and cladding (or canning) materials. In the analysis, the nuclear, physical, metallurgical, and thermo-mechanical properties of the fuel and cladding materials under irradiation environment are examined carefully. The objectives of the paper are mainly (1) to formulate and carry out the irradiation swelling, irradiation creep, and thermal-stress analysis of fuel elements for LWR power reactors, and (2) to develop a computer code which will facilitate the computations for fuel element design, safety analysis, and economic optimization of the power reactors. In a general procedure of the analysis, the irradiation swelling, irradiation creep, temperature distribution, etc. in the fuel and cladding of the oxide fuel elements during the reactor in operation are studied. Some theoretical models and empirical relations (on the basis of accepted experimental data) for irradiation swelling and creep in the fuel and irradiation creep in cladding materials are postulated and developed. Some analytical and empirical relations (based on test results) for heat generation and temperature distribution in the fuel during fuel restructuring are derived. The fuel restructure is, in general, divided into the central void, columnar grain, equiaxed grain, and unaffected grain zones (or regions) after a sufficiently long period for the fuel elements to be irradiated (or operated). From these relations derived for irradiation swelling, irradiation creep, and temperature distribution in the fuel and cladding, together with the well-known strain-stress, incompressibility, compatibility, and stress equilibrium equations, the irradiation swelling, creep, and thermal-stress analysis for the LWR fuel elements can be carried out.From the analytical results obtained, a computer code, ISUNE-2 (which is in the sequence of computer code ISUNE-1 and -1A developed and used previously for liquid-metal fast breeder reactor fuel element design and safety and economic analysis), can be developed. With some reliable experimental data (measured during fuel elements in operation) as input, the computer code may predict various cases of LWR (oxide or carbide) fuel elements in operation. The general scope and resulting contribution of this paper is to provide a realistic analysis and a reliable operating LWR fuel element code for use by nuclear power utilities to predict the fuel element behavior in power reactors. The fuel element design, safety analysis, and economic optimization depend largely on the fuel element behavior in the power reactors.     

Stress biaxiality in high-burnup PWR fuel cladding under reactivity-initiated accident conditions

In order to promote a better understanding of failure mechanisms of high-burnup pressurized water reactor (PWR) fuels under reactivity-initiated accident (RIA) conditions, stress biaxiality in cladding has been estimated for the pellet-cladding (PC) mechanical interaction (PCMI) phase. The estimation was based on an analysis of the transient elongations of a pellet stack and a cladding tube measured in RIA-simulating experiments in the nuclear safety research reactor (NSRR) using the RANNS code. Stress biaxiality in the high-burnup PWR fuel cladding during the PCMI phase has been estimated to be 0.7–0.8, on average, at the mid-wall of the cladding. A comparison with fresh fuel test results and a sensitivity analysis showed that the effects of burnup and pulse width on cladding stress biaxiality are less than 10% for the investigated range. The present analysis also indicated that PC friction is strong, and that the cladding constraint on pellet stack elongation is significant irrespective of burnup. Therefore, it is recommended that strong PC friction be assumed, which is similar to the mechanical bonding condition, and that fuel pellets be treated as deformable materials in models of fuel behavior during the PCMI phase.     

Entropy change for the λ-type transition in nonstoichiometric U4O9 − y

Cladding dilatation of irradiated fuel pins near the fuel-blanket transition zone and strong Cs-peaks in γ-scanning curves indicated an accumulation of Cs resulting in a reaction with uranium oxide. Simulation experiments confirmed that formation of cesium uranate can cause a dilatation of the cladding. The possible influence of Ba, which may migrate via volatile parent products, has also been examined. Finally, simulation experiments were performed in order to examine whether formation of cesium uranate can be avoided by reducing the oxygen potential by means of uranium and niobium getters.     

Enhanced irradiation creep deformation due to gradual temperature reductions

Large irradiation creep strains were observed in WSA-4 mixed-oxide fuel pins at 7% burn-up and 10²³ n cm^?2 (E>0.1 MeV) which were exposed to temperature variations relative to pins irradiated at approximately constant temperature. A comparison of the fuel pin and pressurized tube samples exposed to gradual temperature reductions shows similar behaviour. The results show that the irradiation creep coefficient increases with increasing temperature reduction and initial irradiation temperature. The increase in irradiation creep and the previously reported increase in swelling with temperature reduction appears similar to other macroscopic strain reports of irradiation creep and swelling association.     

Thresholds for failure of high-burnup LWR fuels by Pellet Cladding mechanical interaction under reactivity-initiated accident conditions

ABSTRACT

To contribute to the future updating on the Japanese safety criteria for pellet/cladding mechanical interaction (PCMI) failure of light water reactor fuels under reactivity-initiated accident (RIA) conditions, this paper summarizes the recent important outcomes from research programs with the Nuclear Safety Research Reactor (NSRR). Applicability of current criteria, which are defined as a function of fuel burnup and possibility of introducing another parameter for new criteria were evaluated based on the results of the RIA-simulated pulse irradiation tests, post-test examinations, and supporting analytical work, such as the reevaluation of fuel enthalpies in earlier NSRR experiments. Failure-threshold curves based on cladding hydrogen content as a primary measure of fuel degradation have been proposed as a possible alternative that can be used to judge the occurrence of PCMI failure to ensure conservativeness in a more pertinent manner.     

Simulation of pellet-cladding thermomechanical interaction and fission gas release

This paper summarizes the present status of a computer code that describes some of the main phenomena occurring in a nuclear fuel rod throughout its life. Temperature distribution, thermal expansion, elastic and plastic strains, creep, mechanical interaction between pellet and cladding, fission gas release, gas mixing, swelling, and densification are modeled. The modular structure of the code allows for the incorporation of models to simulate different phenomena and material properties. Collapsible rods can be also simulated.The code is bidimensional, assumes cylindrical symmetry for the rod and uses the finite element method to integrate the differential equations. The stress–strain and heat conduction problems are nonlinear due to plasticity and to the temperature dependence of the thermal conductivity. The fission gas inventory is calculated with a diffusion model, assuming spherical grains and using a one-dimensional finite element scheme. Pressure increase, swelling and densification are coupled with the stress field.Good results are obtained for the simulation of the irradiation tests of the first argentine prototypes of MOX fuels, where the bamboo effect is clearly observed, and of the FUMEX series for the fuel centerline temperature, the inside rod pressure and the fractional gas release.