Heavy-Section Steel Irradiation Program Research Articles

Heavy-Section Steel Technology and Irradiation Programs—Retrospective and Prospective Views

In 1965, the Atomic Energy Commission, at the advice of the Advisory Committee on Reactor Safeguards, initiated the process that resulted in the establishment of the Heavy Section Steel Technology (HSST) program at Oak Ridge National Laboratory. In 1989, the Heavy-Section Steel Irradiation (HSSI) program, formerly the HSST task on irradiation effects, was formed as a separate program, and in 2007, the HSST/HSSI programs, sponsored by the U.S. Nuclear Regulatory Commission (USNRC), celebrated 40 years of continuous research oriented toward the safety of light-water nuclear reactor pressure vessels (RPVs). This paper presents a summary of results from those programs with a view to future activities. The HSST program was established in 1967 and initially included extensive investigations of heavy-section low-alloy steel plates, forgings, and welds, including metallurgical studies, mechanical properties, fracture toughness (quasi-static and dynamic), fatigue crack-growth, and crack-arrest toughness. Also included were irradiation effects studies, thermal shock analyses, testing of thick-section tensile and fracture specimens, and nondestructive testing. In the subsequent decades, the HSST Program conducted extensive large-scale experiments with intermediate-size vessels (with varying size flaws) pressurized to failure, similar experiments under conditions of thermal shock and even pressurized thermal shock (PTS), wide-plate crack-arrest tests, and biaxial tests with cruciform-shaped specimens. Extensive analytical and numerical studies accompanied these experiments, including the development of computer codes such as the recent Fracture Analysis of Vessels Oak Ridge code currently being used for PTS evaluations. In the absence of radiation damage to the RPVs, fracture of the vessel is improbable. However, it was recognized that exposure to high energy neutrons can result in embrittlement of radiation-sensitive RPV materials. The HSSI Program conducted a series of experiments to assess the effects of neutron irradiation on RPV material behavior, especially fracture toughness. These studies included RPV plates and welds, varying chemical compositions, and fracture toughness specimens up to 101.6 mm (4 in.) thickness. The results of these investigations, in conjunction with results from commercial reactor surveillance programs, are used to develop a methodology for the prediction of radiation effects on RPV materials. Results from the HSST and HSSI programs are used by the USNRC in the evaluation of RPV integrity and regulation of overall nuclear plant safety.

Applicability of the Fracture Toughness Master Curve to Irradiated Highly Embrittled Steel and Intergranular Fracture

Abstract The Heavy-Section Steel Irradiation Program at Oak Ridge National Laboratory has evaluated a submerged-arc (SA) weld irradiated to a high level of embrittlement and a temper embrittled base metal that exhibits significant intergranular fracture relative to representation by the Master Curve. The temper embrittled steel revealed that the intergranular mechanism significantly extended the transition temperature range up to 150°C above To. For the irradiated highly embrittled SA weld study, a total of 21 1T compact specimens were tested at five different temperatures and showed the Master Curve to be nonconservative relative to the results, although that observation is uncertain due to evidence of intergranular fracture.

Characterization of the Neutron Field in the HSSI Reusable Irradiation Facility at the Ford Nuclear Reactor

The characterization of the neutron environment in a reusable facility for irradiation of metallurgical specimens, located at the Ford Nuclear reactor in Michigan, was performed with a combination of transport calculations, extensive dosimeter measurements, and neutron spectrum adjustment. The average difference between the calculated and “measured” reaction rates was ∼7% (the calculations underpredicted the measurements), and the average absolute difference was ∼10%. Therefore, the calculations and measurements agreed very well. The flexible facility performed excellently during several years of operation but was discontinued when the Ford reactor ceased operation. The heavy-section steel irradiation (HSSI) program is taking the initial steps toward selecting a site for a new irradiation facility, similar to the one described here.

Fracture Toughness, Thermo-Electric Power, and Atom Probe Investigations of JRQ Steel in I, IA, IAR, and IARA Conditions

Abstract The International Atomic Energy Agency has sponsored a number of studies involving a specific plate of A533 grade B class 1 steel designated heat JRQ. In this cooperative study between the Paul Scherrer Institute (PSI) and the Heavy-Section Steel Irradiation Program of Oak Ridge National Laboratory (ORNL), groups of Charpy impact, tensile, and precracked Charpy specimens of the JRQ plate were irradiated by PSI to four different fast neutron fluences [from 0.39 to 5.0 × 1023 n/m2 (>1 MeV)] in a test reactor. Additional specimens were given a post-irradiation thermal annealing treatment at 460°C for 18 h when 50 % of the target fluence was reached, followed by reirradiation to the same target fluences for the four groups of irradiated specimens. Additionally, ORNL thermally annealed some of the reirradiated specimens, as well as some of those in the irradiated only condition. Charpy impact, tensile, fracture toughness, and hardness tests have been performed to evaluate material response in the various conditions and to compare with the unirradiated material. Additionally, thermo-electric power experiments have been conducted by PSI, while atom probe tomography evaluations have been conducted by ORNL. Except at the highest fluence, the results show that the material given an intermediate annealing treatment exhibited irradiation-induced transition temperature shifts about the same as those that were only irradiated. However, the upper-shelf energies were generally higher and the yield strengths were generally lower for the reirradiated groups. The intermediate thermal annealing resulted in less reirradiation embrittlement of fracture toughness than Charpy impact toughness, while annealing after reirradiation resulted in significant increases in Charpy upper-shelf energy above that in the unirradiated condition. Irradiation-induced and IAR Charpy impact transition temperature shifts exhibit a nearly linear correlation with Seebeck coefficient in the I and IAR conditions. ORNL has also sent additional specimens from I, IA, IAR, and IARA test of JRQ for additional TEP testing. After irradiation, a high number density of ultrafine Cu-, Mn-, Ni-, Si-, and P-enriched precipitates were observed by atom probe tomography. Phosphorus segregation to dislocations was also observed. A significantly lower number density of larger Cu-, Mn-, and Ni- enriched precipitates was observed after the second annealing treatment.

Fracture Toughness and Atom Probe Characterization of a Highly Embrittled RPV Weld

Abstract The Heavy-Section Steel Irradiation Program at Oak Ridge National Laboratory (ORNL) includes a task to investigate the shape of the fracture toughness master curve for reactor pressure vessel steel highly embrittled as a consequence of irradiation exposure. A radiation-sensitive reactor pressure vessel (RPV) weld with intentionally enhanced copper content, designed KS-01, is characterized in terms of static initiation (KIc, KJc) and Charpy impact toughness in the unirradiated and irradiated conditions. The objective of this project is to investigate the ability of highly embrittled material to maintain the shape of the unirradiated transition fracture toughness curve, as well as to examine the ability of the Charpy 41-J shift to predict the fracture toughness shift at such a high level of embrittlement. Irradiation of this weld was performed at the University of Michigan Ford Reactor. Specimens of KS-01 weld were irradiated to about 0.74 × 1019 neutron/cm2 at 288°C. Irradiation resulted in Charpy ductile-to-brittle transition temperature (DBTT) shift of 169°C. It was anticipated that this shift would result in a fracture toughness transition temperature (at 100 MPa√m) in the irradiated condition near or slightly above the pressurized thermal shock screening criterion for weld metals, ToPTS = 129°C. The fracture toughness characterization of KS-01 weld in the unirradiated and irradiated conditions was mainly performed by testing 1T C(T), although some 0.5T C(T) and precracked Charpy specimens were used in this study. The master curve analysis showed that this material exhibited shift of reference fracture toughness transition temperature, To, of 165°C as result of radiation, which is in remarkable agreement with Charpy DBTT shift. The absolute value of To in the irradiated condition was determined to be equal to 139°C. This weld exhibited a low ductile initiation toughness (JQ) after irradiation. It left a relatively narrow temperature window to examine the shape of the transition region. Irradiated median fracture toughness values up to 148 MPa√m follow the master curve shape. However, low toughness brittle fractures occurred at temperatures further above To (To + 61°C) than expected with a leveling of the KJc data from the master curve shape. The microstructure of the weld was characterized with the ORNL's energy-compensated optical position-sensitive atom probe. Atom probe tomography revealed a high number density (∼3 × 1024 m−3) of Cu-, Mn-, Ni-, Si-, and P-enriched precipitates and a lower number density (∼1 × 1023 m−3) of P clusters.

TREATMENT OF FRACTURE TOUGHNESS DATA IN THE TRANSITION REGIME

Abstract— Two methods are given in this paper for describing the dependence of fracture toughness on temperature in the transition regime. The first method estimates fracture toughness at, or close to, the onset of stable tearing prior to cleavage fracture. The second method uses a statistical model to describe both initiation and cleavage fracture toughness in terms of stable tearing and specimen thickness.The procedures are illustrated using unirradiated fracture toughness data from the US Heavy Section Steel Irradiation Program 5th Series.

Heavy-section steel irradiation program summary

In light-water-cooled nuclear power plants, a steel reactor pressure vessel (RPV) forms the primary containment boundary for the nuclear fuel assembly. Since a failure of the RPV carries the potential of major contamination release and severe accident, it is imperative to safe reactor operation to understand and be able to accurately predict realistic failure models of the vessel material. A major known risk arises from irradiation-induced degradation of the RPV fracture resistance which occurs as a result of normally occurring neutron flux during the service life of the reactor. Better understanding of the irradiation degradation of the vessel material will provide better input to improve the engineering models vital for prediction of RPV integrity and safe service life. For this reason, the Heavy-Section Steel Irradiation (HSSI) Program has been established with its primary goal to provide a thorough, quantitative assessment of the effects of neutron irradiation on the material behavior, and in particular the fracture toughness properties, of typical pressure vessel steels as they relate to light-water RPVs. The program includes the direct continuation of irradiation studies previously conducted within the Heavy-Section Steel Technology Program augmented by enhanced examinations of the accompanying microstructural changes. Effects of specimen size, material chemistry, product form and microstructure, irradiation fluence, flux, temperature and spectrum, and postirradiation annealing are being examined on a wide range of fracture properties including fracture toughness ( K 1c and J 1c), crack-arrest toughness ( K 1a), ductile tearing resistance (d J/da), Charpy V-notch impact energy, dropweight nil-ductility temperature (NDT), and tensile properties. Models based on observations of radiation-induced microstructural changes using field ion and high-resolution transmission electron microscopy provide a firmer basis for extrapolating the measured changes in fracture properties to wider ranges of irradiation conditions. The principal materials examined within the HSSI Program are highcopper welds since their postirradiation properties are most frequently limiting in the continued safe operation of commercial RPVs. In addition, a limited effort Will focus on stainless steel weld overlay cladding, typical of that used on the inner surface of RPVs, since its postirradiation fracture properties have the potential for strongly affecting the extension of small surface flaws during overcooling transients. Results from the HSSI studies will be integrated to aid in resolving major regulatory issues facing the U.S. Nuclear Regulatory Commission which involve RPV irradiation embrittlement such as pressurized-thermal shock, operating pressure-temperature limits, low-temperature overpressurization, and the specialized problems associated with low upper-shelf welds. Taken together the results of these studies also provide guidance and bases for evaluating both the aging behavior and the potential for plant life extension of light-water RPVs.