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.     

Voids resulting from fast neutron irradiation of a stabilized stainless steel

A 16 Cr-13 Ni-niobium stabilized stainless steel (Type 1.4988) was irradiated as fuel pin cladding in the DFR reactor. The irradiation temperatures ranged from 300 to 650 °C. Neutron fluences from 3.3 to 4.0 n/cm²$\text{(E > 0.1 MeV)}$ were achieved. Swelling behavior was studied in this material by transmission electron microscopy, immersion density determinations and diametral change measurements.Void formation was observed in the temperature range 360–610 °C. Void concentration values at lower temperatures (< 480 °C) are comparable to those cited for the unstabilized stainless steels AISI 304 and 316, however, they decrease more strongly with increasing irradiation temperatures. The mean and maximum diameters show a pronounced maximum at about 530 °C. The decrease of the void diameters at higher temperatures can be explained by the nature of the cavities observed. Annealing experiments with specimens irradiated at 610 °C have revealed a bubble or a mixed void-bubble character for these cavities.Swelling in type 1.4988 was found to be lower than that reported previously for types 304 and 316 at comparable irradiation and material conditions. This is especially pronounced at higher temperature. Diameter changes of the pin at $\text{T >- 610 °C}$ cannot be explained by void-formation.     

Anisotropic growth of reactor fuel pin cladding

Anisotropic growth of 316 stainless steel reactor fuel pin cladding was found to occur after irradiation in the Experimental Breeder Reactor-II (EBR-II). Pressurized tube specimens were irradiated to a peak fluence of 10²³n/cm² (E >0.1 MeV) at temperature ranging from 430°C to approximately 590°C. Growth was observed in both the annealed and 20% cold worked conditions and was found to decrease with increasing hoop stress. The anisotropic growth is more pronounced in the cold worked condition. The growth is attributed to a preferred orientation of Burgers vectors in the preirradiated cold worked dislocation structure.     

Diametral strain of fast reactor MOX fuel pins with austenitic stainless steel cladding irradiated to high burnup

The C3M irradiation test, which was conducted in the experimental fast reactor, “Joyo”, demonstrated that mixed oxide (MOX) fuel pins with austenitic steel cladding could attain a peak pellet burnup of about 130 GWd/t safely. The test fuel assembly consisted of 61 fuel pins, whose design specifications were similar to those of driver fuel pins of a prototype fast breeder reactor, “Monju”. The irradiated fuel pins exhibited diametral strain due to cladding void swelling and irradiation creep. The cladding irradiation creep strain were due to the pellet-cladding mechanical interaction (PCMI) as well as the internal gas pressure. From the fuel pin ceramographs and ¹³⁷Cs gamma scanning, it was found that the PCMI was associated with the pellet swelling which was enhanced by the rim structure formation or by cesium uranate formation. The PCMI due to cesium uranate, which occurred near the top of the MOX fuel column, significantly affected cladding hoop stress and thermal creep, and the latter effect tended to increase the cumulative damage fraction (CDF) of the cladding though the CDF indicated that the cladding still had some margin to failure due to the creep damage.     

Influence of silicon on swelling and microstructure in Russian austenitic stainless steel EI-847 irradiated to high neutron doses

Void swelling and microstructural development of niobium-stabilized EI-847 austenitic stainless steel with a range of silicon levels were investigated by destructive examination of fuel pin cladding irradiated in three fast reactors located in either Russia or Kazakhstan. The tendency of void swelling to be progressively reduced by increasing silicon concentration appears to be a very general phenomenon in this steel, whether observed in simple, single-variable experiments on well-defined materials or when observed in multivariable, time-dependent irradiations conducted on commercially produced steels over a wide range of irradiation temperatures, neutron spectra and dpa rates. The role of silicon on microstructural development is expressed both in the solid solution via its influence on dislocation and void microstructure and via its influence on formation of radiation-induced phases that in turn alter the matrix composition. Surprisingly, increases in silicon level in this study do not accelerate the formation of silicon-rich G-phase, but act to increase the formation of Nb (C,N) precipitates. Such precipitates are known to be associated with delayed void swelling.     

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.     

Modeling deformation and failure of fast reactor cladding during simulated accident transients

An analysis is made of burst experiments performed on neutron irradiated cladding tubes. This is done by employing a generalized Voce equation to describe the mechanical deformation of type 316 stainless steel, combined with an empirical creep crack growth law, each modified to account for the effects of irradiation matrix hardening, and irradiation induced grain boundary embrittlement, respectively.The results of this analysis indicate that for large initial hoop stress, failure occurs at relatively low temperature and is controlled by the onset of plastic instability. The increase in failure temperature of irradiated material, in low temperature region, is due to irradiation strengthening. Failure in the case of relatively small initial hoop stress occurs at high temperature where the Voce equation reduces to a power law creep formula. The ductility of irradiated material, in this high tem-temperature region, is adequately described through the use of an empirical intergranular crack growth law used in conjunction with the creep law. The effect of neutron irradiation is to reduce the activation energy for crack propagation from the value for creep to some lower value correlated to independent Dorn rupture parameter measurements. The result is a predicted reduced ductility which translates into a reduction in failure temperature at a given hoop stress value for irradiated material.     

Irradiation creep relaxation of void swelling-driven stresses

Swelling-driven-creep test specimens are used to measure the compressive stresses that develop due to constraint of irradiation void swelling. These specimens use a previously non-irradiated 20% CW Type 316 stainless steel holder to axially restrain two Type 304 stainless steel tubular specimens that were previously irradiated in the US Experimental Breeder Reactor (EBR-II) at 490 °C. One specimen was previously irradiated to fluence levels in the void nucleation regime (9 dpa) and the other in the quasi-steady void growth regime (28 dpa). A lift-off compliance measurement technique was used post-irradiation to determine compressive stresses developed during reirradiation of the two specimen assemblies in Row 7 of EBR-II at temperatures of 547 °C and 504 °C, respectively, to additional damage levels each of about 5 dpa. Results obtained on the higher fluence swelling-driven-creep specimen show that compressive stress due to constraint of swelling retards void swelling to a degree that is consistent with active load uniaxial compression specimens that were irradiated as part of a previously reported multiaxial in-reactor creep experiment. Swelling results obtained on the lower fluence swelling-driven creep specimen show a much larger effect of compressive stress in reducing swelling, demonstrating that the larger effect of stress on swelling is on void nucleation as compared to void growth. Test results are analyzed using a recently proposed multiaxial creep-swelling model.     

PFR fuel cladding transient test results and analysis

Fuel Cladding Transient Tests (FCTT) were performed on M316 cladding specimens obtained from mixed-oxide fuel pins irradiated in the Prototype Fast Reactor (PFR) to burnups of 4 and 9 atom percent. In these tests, specimens of fuel cladding were pressurized and heated until failure occurred.Samples of cladding from PFR fuel pins exhibited generally greater strength and ductility than specimens from Experimental Breeder Reactor-II (EBR-II) mixed-oxide fuel pins tested under similar conditions. Apparently, the PFR cladding properties were not degraded by a fuel adjacency effect (FAE) observed in fuel pin cladding from EBR-II irradiations.A recently developed model of grain boundary cavity growth was used to predict the results of the tests conducted on PFR cladding. It was found that the predicted failure temperatures for the relevant internal pressures were in good agreement with experimental failure temperatures.     

Swelling Behaviors in a Fuel Assembly for the Wrapping Wire and Duct Made of Modified 316 Austenitic Stainless Steel

Swelling behaviors in the wrapping wire and duct made of modified type 316 austenitic stainless steel were investigated in a fuel assembly irradiated in a fast breeder reactor. The temperature dependence of volumetric swelling was measured in the wrapping wire and the duct, and the peak temperatures of swelling were evaluated. The void distribution in the material was measured by microstructure observation with electron microscopy, and it was found that the voids prefentially grew near the surface. This phenomenon seemed to be caused by a surface effect on the neutron-irradiated materials.     

Swelling and microstructure of austenitic stainless steel ChS-68 CW after high dose neutron irradiation

Austenitic stainless steel ChS-68 serving as fuel pin cladding was irradiated in the 20% cold-worked condition in the BN-600 fast reactor in the range 56-84 dpa. This steel was developed to replace EI-847 which was limited by its insufficient resistance to void swelling. Comparison of swelling between EI-847 and ChS-68 under similar irradiation conditions showed improvement of the latter steel by an extended transient regime of an additional ∼10 dpa. Concurrent with swelling was the development of a variety of phases. In the temperature range 430-460 °С where the temperature peak of swelling was located, the principal type of phase generated during irradiation was G-phase, with volume fraction increasing linearly with dose to ∼0.5% at 84 dpa. While the onset of swelling is concurrent with formation of G-phase, the action of G-phase cannot be confidently ascribed to significant removal from solution of swelling-suppressive elements such as silicon. A plausible mechanism for the higher resistance to void swelling of ChS-68 as compared with EI-847 may be related to an observed higher stability of faulted dislocation loops in ChS-68 that impedes the formation of a glissile dislocation network. The higher level of boron in ChS-68 is thought to be one contributor that might play this role.     

In-reactor deformation of solution annealed type 304L stainless steel

Over the past six years at EBR-II, a great deal of information has been obtained on the in-reactor behaviour of solution annealed-Type 304L stainless steel. This information consists of the following: (1) Irradiation induced swelling results in the form of immersion density and transmission electron microscope (TEM) measurements on unstressed material that extends over a temperature range of 395° to 530°C and a neutron fluence range of 1.8 to 9.3 × 10²² n/cm² (E > 0.1 MeV). (2) Irradiation induced creep results from helium pressurized capsules irradiated at a temperature of 415°C. The hoop stress range covered in the experiment was 0 to 27.3 ksi, and the peak neutron fluence obtained to date is 7 × 10²² n/cm² (E > 0.1 MeV). (3) Residual stress measurements (slit tube technique) with complementary TEM gradient studies on stressed and unstressed capsules. (4) Comparative swelling studies of stressed cladding material and unstressed capsule material from encapsulated EBR-II driver fuel experiments over wide ranges of temperature and neutron fluences. The deformation information derived from the four above studies represent an extensive data base from which to obtain an understanding of the in-reactor deformation of austenitic stainless steel. It is the purpose of this paper to review our information on the in-reactor deformation of solution annealed Type 304L stainless steel.     

An approach for evaluating fuel system applied in innovative nuclear energy system

One of the important issues in the study of Innovative Nuclear Energy Systems (INES) is the integrity of the fuel system applied. An approach of evaluating fuel system integrity is discussed here based on the procedure currently used in the integrity evaluation of fast reactor fuel. The fuel failure modes controlling fuel life were reviewed and fuel integrity was analyzed and compared with the failure criteria.Metal and nitride fuels with austenitic and ferritic cladding tubes were examined in this study. For the purpose of representative irradiation behavior analyses of the fuel for INES, the correlations of the cladding characteristics were modeled based on well-known characteristics of austenitic modified 316 SS (PNC316), ferritic-martensitic steel (PNC-FMS) and oxide dispersion strengthen steel (PNC-ODS).The analytical result showed that fuel lifetime is limited by channel fracture which is a nonductile type (brittle) failure associated with a high level of irradiation-induced swelling in the case of austenitic steel cladding. In the case of ferritic steel, on the other hand, the fuel life is controlled by cladding creep rupture. The lifetime evaluated here is no more than 200 GWd/t, which is still lower than the target value 400 GWd/t burnup. Possible measures to extend metal fuel lifetime may be reducing fuel smear density and ventilating fission gas in the plenum.     

Role de l''iodure de cesium sur le developpement des reactions combustible-gaine

TEM of thin foils taken from irradiated fuel element ((UPu)O_2−x fuel in type 316 stainless steel cladding) shows precipitates rich in iron and chromium in the fuel, together with a reduction of chromium content in the cladding. We have undertaken simulation experiments out-of-pile to study the compatibility, both isothermally and in thermal gradients, of the steel/CsI and steel/(CsI + UO ₂) systems, making use of metallography, X-ray diffraction and microprobe analysis, with a view to gaining a better understanding of the reactions at the fuel cladding interface in reactor service. The results of the simulation and reactor-irradiation experiments have enabled us to prepare a transport mechanism in the gas phase, of van Arkel type, involving stainsless steel (at low temperature), (UPu)O_2±x (at high temperature) caesium iodide serving as vector. This transport mechanism which essentially involves displacement of manganese, chromium and iron from cold zones to hot zones, is possible only in the presence of an oxygen source (and the mixed oxide, (UPu)O_2±x, in particular).     

Development and verification of a failure-analysis model for FBR fuel-element cladding

Failure-analysis models for Fast-Breeder-Reactor (FBR) fuel elements cladded with 20% cold-worked Type 316 stainless steel are reviewed. A model based on linear damage accumulation and time-to-failure correlations is developed and tested against the data base for pressurized tubes. The model goes beyond the state of the art for damage models in that the failure mode is predicted as well as the failure time. The effects of mechanical and chemical wall thinning, temperature and stress gradients, and irradiation are considered in addition to the traditional parameters of stress and temperature. The proposed failure-analysis model can be used to analyse both fueled and unfueled stainless steel tubes.     

Investigation of the cause of peculiar irradiation behavior of 9Cr-ODS steel in BOR-60 irradiation tests

Four experimental fuel assemblies (EFAs) containing 9Cr-ODS steel cladding fuel pins were previously irradiated in the BOR-60 to demonstrate the in-reactor performance of 9Cr-ODS steel for use as fuel cladding tubes. One of the EFAs achieved the best data, a peak burn-up of 11.9at% and a neutron dose of 51 dpa, without any microstructure instability or any fuel pin rupture. On the other hand, in another EFA (peak burn-up, 10.5at%; peak neutron dose, 44 dpa), peculiar irradiation behaviors, such as microstructure instability and fuel pin rupture, occurred. Investigations of the cause of these peculiar irradiation behaviors were carried out. The detection sensitivity in an ultrasonic inspection test was shown to be low for the metallic Cr and metallic Fe inclusions. The peculiar microstructure change reappeared with high-temperature thermal-aging of the 9Cr-ODS steel containing metallic Cr inclusions. The strength and ductility of the defective part containing metallic Cr inclusions were appreciably lower than those of a standard part without the inclusions. The combined effects of matrix Cr heterogeneity (presence of metallic Cr inclusions) and high-temperature irradiation were concluded to be the main cause of the peculiar microstructure change in 9Cr-ODS steel cladding tubes in the BOR-60 irradiation tests. They contributed to the fuel pin rupture.     

Attack upon the cladding of oxide fuel pins by fuel and fission products

In parallel with post-irradiation examinations, a comprehensive out-of-pile experimental programme has been performed to determine the most important fission product reactions with four austenitic stainless steels at different oxygen potentials. Single as well as groups of fission products (simulated burn-up systems) have been used. Only the elements cesium, iodine and tellurium cause dangerous reactions with the cladding of an oxide fuel pin. The others are either not reactive or produced in such small quantities that their attack on the cladding is insignificant. Molybdenum is often found in the reaction zone of an irradiated oxide pin. However, according to our out-of-pile results it does not look as if molybdenum is a dangerous fission product. A decisive factor for the occurrence of reactions with the cladding is the oxygen potential in the fuel pin. As long as the O/M ratio of the fuel is markedly below 2.00, there are no dangerous reactions, neither with cesium nor with tellurium and iodine. The post-irradiation investigations (burn-up 1 to 10 at %) have shown that the cladding attack below 750 °C is most dependent on the inner wall temperature. Other factors, including fuel density, rod power and burn-up, seem to play a minor role. A noticeable reduction of the cladding attack was observed when the initial O/M ratio of the fuel was less than 1.98. A kinetic evaluation of some of the reactions observed in the out-of-pile tests has been attempted. At temperatures above 700 °C, the influence of temperature decreases markedly and the fission product concentration in the fuel becomes more important. There are indications that this also holds true for in-pile conditions.     

The effect of dose rate on the response of austenitic stainless steels to neutron radiation

Depending on reactor design and component location, austenitic stainless steels may experience significantly different irradiation dose rates in the same reactor. Understanding the effect of dose rate on radiation performance is important to predicting component lifetime. This study examined the effect of dose rate on swelling, grain boundary segregation, and tensile properties in austenitic stainless steels through the examination of components retrieved from the Experimental Breeder Reactor-II (EBR-II) following its shutdown. Annealed 304 stainless steel, stress-relieved 304 stainless steel, 12% cold-worked 316 stainless steel, and 20% cold-worked 316 stainless steel were irradiated over a dose range of 1–56 dpa at temperatures from 371 to 440 °C and dose rates from 0.5 to 5.8 × 10⁻⁷ dpa/s. Density and tensile properties were measured for 304 and 316 stainless steel. Changes in grain boundary composition were examined for 304 stainless steel. Swelling appears to increase at lower dose rates in both 304 and 316 stainless steel, although the effect was not always statistically significant. Grain boundary segregation also appears to increase at lower dose rate in 304 stainless steel. For the range of dose rates examined, no measurable dose rate effect on tensile properties was noted for any of the steels.     

Simulation of the transient behaviour of LMEBR fuel pins under consideration of special burnup phenomena using the BREDA-II model

A new fuel pin model was developed to describe the influence of specific burnup phenomena on the behaviour of fuel pins under transient overpower conditions in a liquid metal fast breeder reactor (LMFBR). It has been used for transient fuel pin deformation analysis during hypothetical core disruptive accidents (HCDA) and for the purpose of interpreting fuel pin failure tests. The fuel pin model, designated as BREDA-II, is based on the equations of the quasi-static theory of thermal elasticity. The fuel is regarded as elastic and the cladding as elasto-plastic material. The equations for the stress-strain analysis are based on the plane strain approximation. A multiregion fuel pin model allows to simulate long-time and transient burnup phenomena. The long-time effects taken into account are the steady state swelling of fuel, the change in fuel porosity and the production and partial release of fission gases. During a power excursion transient fuel swelling and pressure increase due to transient fission gas behaviour are included in the deformation analysis. Potential fuel pin failure is indicated by the application of various criteria of failure. In subsequent model calculations the behaviour of an irradiated LMFBR fuel pin during an overpower transient corresponding to a reactivity ramp of $5/sec is simulated and interpreted from the point of view of reactor safety.