Tristructural-isotropic Fuel Research Articles

Failure analysis of nuclear transient-tested UN tristructural isotropic fuel particles in a 3D printed SiC matrix

Fully ceramic microencapsulated fuel elements containing UN tristructural isotropic (TRISO) fuel particles within a 3D printed SiC matrix were subjected to transient testing with varying energy depositions. Detailed post-irradiation examinations were performed, including leaching in hot HNO3 and post-leaching X-ray computed tomography, to quantify the percentage of failed TRISO particles and crack propagation within the particles and surrounding fuel matrix. In parallel, detailed finite element analyses were performed for comparison with experimental findings and to better evaluate transient failure modes. The lowest transient energy deposition—which still exceeded bounding values for high-temperature gas-cooled reactor applications—resulted in no detectable TRISO particle failures or matrix cracking, which was consistent with the simulations. Simulations of the higher-energy transients for which significant TRISO particle failure was expected were generally able to reproduce the transient temperatures and matrix cracking. Thus, the TRISO particle failures were explained based on the effects of local SiC matrix thickness and porosity. Results generally confirmed the high strength of the additively manufactured SiC matrix but also affirmed the need for a modified UN TRISO architecture to prevent SiC matrix cracks from propagating through TRISO layers. This unique failure mode has not historically been considered for TRISO fuels contained in weaker graphite matrices.

Seeing the whole picture: Methods for getting the most from micro X-ray computed tomography of TRISO nuclear fuel particles

Tristructural isotropic (TRISO) coated fuel particles are a nuclear fuel form under extensive study for use in advanced nuclear reactor concepts. TRISO fuels are subjected to high temperature neutron irradiations and then examined to assess their performance by determining fission product retention and studying morphological changes. Micro X-ray computed tomography is one method of nondestructively studying the effects of TRISO performance. This work addresses the need for image processing to remove X-ray tomographic reconstruction artifacts that prevent the study of TRISO features, as the TRISO particles’ high Z kernel can introduce metal artifacts that degrade the image quality in the surrounding low Z coating layers. These metal artifacts were reduced by imaging the TRISO particles with both high- and low-energy X-rays and applying a mask to the radiographs obtained with low-energy X-rays to digitally remove the dense fuel kernel region. These masked radiographs were then used to produce a tomographic reconstruction which was combined with the tomographic reconstruction of the high-energy data. This enabled the relatively-low-density TRISO buffer layer to be examined in more detail, providing information on irradiation induced dimensional changes of the coatings. This methodology, which helps see the full picture of a TRISO particle, is not limited to nuclear fuels but can be applied to systems that contain highly attenuating material surrounded by less dense materials.

Simulation of a TRISO MiniFuel irradiation experiment with data-informed uncertainty quantification

An irradiation experiment using tristructural isotropic (TRISO) fuel particles and the miniature fuel (MiniFuel) irradiation vehicle was performed in Oak Ridge National Laboratory’s High Flux Isotope Reactor (HFIR) to support development of the Kairos Power fluoride salt–cooled, high-temperature reactor (KP-FHR). This paper describes modeling predictions of temperatures and fuel burnup for the as-built experiment. An uncertainty quantification (UQ) analysis was performed to determine the effect of TRISO particle volume and position on the temperature predictions at various fuel heat generation rates (HGRs). This UQ study utilized fuel kernel position and volume measurements previously collected using X-ray computed tomography (XCT) techniques and Monte Carlo sampling methods to generate fuel compact cases that were then analyzed using a finite element thermal model. The UQ analysis indicated that uncertainty in calculated temperatures caused by varying TRISO particle arrangement is relatively small, even at high fuel HGR. Final predictions of particle temperatures throughout the irradiation are shown to be relevant to KP-FHR normal and off-normal operating conditions and to previous TRISO irradiation experiments. The combination of XCT with UQ analyses will inform post-irradiation examination (PIE) of the irradiated fuel compacts, and these analyses can be used to develop fuel performance models for coated particle fuel forms. Both PIE of separate-effects irradiation data and enhanced fuel performance modeling support accelerated qualification of TRISO fuels for a broad range of advanced reactor applications. The novel approach demonstrated here of measuring TRISO particle configurations with XCT methods and generating representative fuel compacts for finite element modeling and UQ analysis could be leveraged by the broader particle fuel community in the development of other TRISO fuel experiments in which these variables may have a significant impact on key outcomes.

Impact of the TRISO fuel homogenisation approximation in the MHTGR

TRistructural ISOtropic (TRISO) fuels are commonly used in High-Temperature Gas cooled Reactors due to their resistance to high temperatures, irradiation, and oxidation. Reactor physics modelling of a fuel form consisting of millions of layered particles is quite challenging, however. Homogenisation techniques are often used to simplify the fuel form, representing it as a solid material to reduce computational costs. The impact of these approximations on reactor physics parameters was evaluated using OpenMC. Geometries at various scales (i.e. fuel pin, fuel block, full core) were developed based on the Modular High-Temperature Gas-cooled Reactor. It was found that homogenisation results in a significant reduction in simulation time. The Reactivity equivalent Physical Transformation (RPT) method was found to be superior to simple Volume-Weighted Homogenization (VWH). The neutron energy spectra and flux distributions calculated by RPT had insignificant differences to the explicit model. Reactivity coefficients were found to be similar, but diverged at very high temperatures.

Stress Profile in Coating Layers of TRISO Fuel Particles in Contact with One Another

This work presents a discussion on a series of finite element analyses that assess stress evolution in the coating layers of tristructural isotropic (TRISO) particles in contact with each other while embedded in a matrix. The initial simulations were of applied uniaxial pressure versus matrix elastic modulus. These simulations predicted increasing stress in the silicon carbide coating layers of the TRISO particles with decreasing matrix elastic modulus. The second set of simulations focused on the effects of heating and cooling and the associated dimensional change on the state of stress in the coating layers. The general finding was that there was no significant difference below the coating layer’s deposition temperature. However, above the deposition temperature, the contacting particles had higher stress compared with those that were separated. The third set of simulations focused on the effects of irradiation, specifically, creep, dimensional change, and swelling. An interface debonding model was introduced since these potential effects have a significant bearing on predicted stresses.

Oxidation mechanism and mechanical property of SiC coating in TRistructural ISOtropic fuels under steam contained environments

Oxidation mechanism and mechanical property of SiC coating in TRistructural ISOtropic fuels under steam contained environments

Reliability estimation of an advanced nuclear fuel using coupled active learning, multifidelity modeling, and subset simulation

Tristructural isotropic (TRISO)-coated particle fuel is a robust nuclear fuel and determining its reliability is critical for the success of advanced nuclear technologies. However, TRISO failure probabilities are small and the associated computational models are expensive. We used coupled active learning, multifidelity modeling, and subset simulation to estimate the failure probabilities of TRISO fuels using several 1D and 2D models. With multifidelity modeling, we replaced expensive high-fidelity (HF) model evaluations with information fusion from two low-fidelity (LF) models. For the 1D TRISO models, we considered three multifidelity modeling strategies: only Kriging, Kriging LF prediction plus Kriging correction, and deep neural network (DNN) LF prediction plus Kriging correction. While the results across these multifidelity modeling strategies compared satisfactorily, strategies employing information fusion from two LF models called the HF model least often. Next, for the 2D TRISO model, we considered two multifidelity modeling strategies: DNN LF prediction plus Kriging correction (data-driven) and 1D TRISO LF prediction plus Kriging correction (physics-based). The physics-based strategy, as expected, consistently required the fewest calls to the HF model. However, the data-driven strategy had a lower overall simulation time since the DNN predictions are instantaneous, and the 1D TRISO model requires a non-negligible simulation time.

Microstructural and Micro-Chemical Evolutions in Irradiated UCO Fuel Kernels of AGR-1 and AGR-2 TRISO Fuel Particles

AGR-1 and AGR-2 tristructural-isotropic (TRISO) fuel particles were fabricated using slightly different fuel kernel chemical compositions, modified fabrication processes, different fuel kernel diameters, and changed 235U enrichments. Extensive microstructural and analytical characterizations were conducted to correlate those differences with the fuel kernels’ responses to neutron irradiations in terms of irradiated fuel microstructure, fission products’ chemical and physical states, and fission gas bubble evolutions. The studies used state-of-the-art transmission electron microscopy (TEM) equipped with energy-dispersive x-ray spectroscopy (EDS) via four silicon solid-state detectors with super sensitivity and rapid speed. The TEM specimens were prepared from selected AGR-1 and AGR-2 irradiated fuel kernels exposed to safety testing after irradiation. The particles were chosen in order to create representative irradiation conditions with fuel burnup in the range of 10.8 to 18.6% fissions per initial metal atom (FIMA) and time-average volume-average temperatures varying from 1070 to 1287°C. The 235U enrichment was 19.74 wt.% and 14.03 wt.% for the AGR-1 and AGR-2 fuel kernels, respectively. The TEM results showed significant microstructural reconstructions in the irradiated fuel kernels from both the AGR-1 and AGR-2 fuels. There are four major phases: fuel matrix of UO2 and UC, U2RuC2, and UMoC2—in the irradiated AGR-2 fuel kernel. Zr and Nd form a solid solution in the UC phase. The UMoC2 phase often features a detectable concentration of Tc. Pd was mainly found to be located in the buffer layer or associated with fission gas bubbles within the UMoC2 phase. EDS maps qualitatively show that rare-earth fission products (Nd et al.) preferentially reside in the UO2 phase. In contrast, in the irradiated AGR-1 fuel kernel, no U2RuC2 or UMoC2 precipitates were positively identified. Instead, there was a high number of rod-shaped precipitates enriched with Ru, Tc, Rh, and Pd observed in the fuel kernel center and edge zone. The differences in irradiated fuel kernel microstructural and micro-chemical evolution when comparing AGR-1 and AGR-2 TRISO fuel particles may result from a combination of irradiation temperature, fuel geometry, and chemical composition. However, irradiation temperature probably plays a more deterministic role. Limited electron energy-loss spectroscopy (EELS) characterizations of the AGR-2 fuel kernel show almost no carbon in the UO2 phase, but a small fraction of oxygen was detected in the UC/UMoC2 phase.

Comparison of Irradiated TRISO Fuel Radioactivity from Multiple Advanced Reactor Designs

The SCALE code system was used to model, deplete, and compare several different tri-structural isotropic (TRISO)–fueled reactor designs: a helium-cooled prismatic reactor, a helium-cooled pebble-bed reactor (PBR), and a fluoride-lithium-beryllium (FLIBE) molten-salt-cooled PBR. The purpose of this comparison was to understand how differences in the reactor designs affect the radioactivity of the fuel after discharge and whether those differences are significant. First, the various reactor designs were built and depleted in the TRITON module for each design and fuel enrichment. Then, the TRITON outputs were used to create burnup-dependent reactor libraries. These libraries were then used by ORIGEN to determine the activities of discharged fuel for each reactor, which were compared to generic Westinghouse 17 × 17 fuel. Overall, the results showed that short-term activities are dominated by reactors with higher operating powers, and the reactor type, initial fuel enrichment, and maximum burnup are of only secondary importance. Although this analysis only focuses on activities in Becquerels, these dependencies are consistent with the expected behavior of decay heat. However, analysis of long-term time periods post irradiation shows that the reactor type and maximum burnup have strong impacts on the activities; initial fuel enrichment has a secondary impact while operating power is inconsequential. These results would be useful for analyses, such as dose assessment and modeling in postrelease scenarios, normal fuel handling operations, and spent fuel transport, storage, and disposal. Of particular interest, the results in this technical note show that analyses that focus on spent nuclear fuel of advanced reactors need to consider each parameter carefully. Unsurprisingly, if the correct operating power is not used in short-term analyses, the results will not be correct. Perhaps unexpectedly, however, if the correct reactor type is not used, then the long-term results will also be incorrect, especially for areas such as permanent disposal. Even though this technical note focuses on the total activity of nuclear fuel, it provides initial results on the effects of various input parameters and also provides a framework to extend the work into other analyses of spent fuel from advanced reactors, especially those employing TRISO fuel.

A neutronic investigation of tristructural isotropic‐duplex fuel in a high‐temperature reactor prismatic seed‐and‐blanket fuel block configuration with reduced power peaking

This paper presents the neutronic analysis of a tristructural isotropic (TRISO)-duplex fuel loaded into the high-temperature reactor (HTR) prismatic fuel block designs for a seed-and-blanket (S&B) reactor model. The selected fuel block design is the simplified model of a representative fuel configuration for the gas turbine–module helium reactor (GT-MHR) and high-temperature engineering test reactor (HTTR). The duplex fuel pellet comprises of UO2 as the seed and ThO2 as the blanket and uses the TRISO fuels. Monte Carlo N-particle extended (MCNPX) simulations were conducted to analyze the power and neutron flux distributions of the reference fuel block and that of the TRIOS-loaded duplex fuel designs. Standard neutronic parameters were computed, such as burnup-dependent infinite multiplication factors (kinf), average block spectrum, and fissile inventory. It was discovered that while the S&B model could attain the highest burnup and the longest cycle duration, its power peaking was more than threefolds than that of the reference model at the beginning of the cycle (BOC). The results also show that the “Duplex-2” model could reduce its power peaking by 24% through the integration of S&B arrangement with the duplex rods. It is noted that spatial distribution of the UO2 seed and 235U enrichment are the chief determining factors in the power optimization of the heterogeneous HTR prismatic fuel blocks loaded with thorium.

Quantification of silicon carbide grain structure in TRISO fuel by BSE image analysis

The grain structure of the silicon carbide (SiC) layer in tristructural-isotropic (TRISO) fuels has commonly been qualified in fuel specifications based on a qualitative comparison to visual standards to ensure undesirable microstructure are not produced. This approach is inherently dependent on subjective judgement and provides limited data for analysis or comparison. An alternative method to rapidly quantify (i.e., provide a numeric measure of) the grain structure of the SiC layer in TRISO fuels has been developed. This method relies on the identification of silicon carbide grain boundaries based on brightness variation in backscattered electron (BSE) images through the application of automated image processing algorithms. The speed with which the requisite BSE imaging and analysis may be completed enables the practical use of this method on an industrial scale as a part of qualifying TRISO fuel to meet a given specification on silicon carbide grain structure, which is an important parameter for TRISO fuel performance. The method is benchmarked by comparison to prior Electron-Backscattered Diffraction (EBSD) results for TRISO particles from the Advanced Gas Reactor (AGR) program.

Understanding of fission products transport in SiC layer of TRISO fuels by nanoscale characterization and modeling

This paper details recent advances in the understanding of both intergranular and intragranular fission product transport in the silicon carbide (SiC) layer of neutron-irradiated tristructural isotropic (TRISO) coated-fuel particles from Advanced Gas Reactor (AGR)-1 and AGR-2 experiments. The SiC layer is the primary barrier responsible for retaining metallic fission products in the fuel particle. Chemical reactions between the SiC layer and fission products have been observed. Previously, intragranular precipitates rich in fission product Pd were identified as nanosized nodular and columnar features, distributed through the irradiated SiC grains. More recent studies reported hexagonal-shaped Pd silicide at Frank loops and stacking faults, where α-SiC (amid the bulk β-SiC) acts as a precursor for Pd silicide formation. While the Pd silicide precipitates were identified as having L12-Pd3Si stoichiometry from electron diffraction study, ab initio phonon calculations performed in this study suggest that the L12-Pd3Si structure remains dynamically unstable from zero pressure up to at least 100 GPa and will spontaneously transform into other lower-symmetry structures via different unstable phonon modes. Apart from the nanoscale hexagonal morphology of the Pd3Si precipitate, a new form of elongated Pd silicide, confined between a pair of stacking faults, has been observed in a high 110mAg-retention TRISO-coated particle. The peculiar discontinuity of such precipitates along the stacking faults raises questions regarding the necessity of α-SiC precursors for their nucleation, as well as the nature of the intragranular-transport pathway of Pd along the radial direction of SiC. The large-scale fission product precipitates in the inner-pyrolytic carbon (IPyC) and grain boundaries of SiC layers were characterized, and different chemically segregated regions were observed within single fission product precipitates.

Local atomic structure of Pd and Ag in the SiC containment layer of TRISO fuel particles fissioned to 20% burn-up

The structure and speciation of fission products within the SiC barrier layer of tristructural-isotropic (TRISO) fuel particles irradiated to 19.6% fissions per initial metal atom (FIMA) burnup in the Advanced Test Reactor (ATR) at Idaho National Laboratory (INL) was investigated. As-irradiated fuel particles, as well as those subjected to simulated accident scenarios, were examined. The TRISO particles were characterized using synchrotron X-ray absorption fine-structure spectroscopy (XAFS) at the Materials Research Collaborative Access Team (MRCAT) beamline at the Advanced Photon Source. The TRISO particles were produced at Oak Ridge National Laboratory under the Advanced Gas Reactor Fuel Development and Qualification Program and sent to the ATR for irradiation. XAFS measurements on the palladium and silver K-edges were collected using the MRCAT undulator beamline. Analysis of the Pd edge indicated the formation of palladium silicides of the form PdxSi (2 ≤ x ≤ 3). In contrast, Ag was found to be metallic within the SiC shell safety tested to 1700 °C. To the best of our knowledge, this is the first result demonstrating metallic bonding of silver from fissioned samples. Knowledge of these reaction pathways will allow for better simulations of radionuclide transport in the various coating layers of TRISO fuels for next generation nuclear reactors. They may also suggest different ways to modify TRISO particles to improve their fuel performance and to mitigate potential fission product release under both normal operation and accident conditions.

X-ray photoelectron spectroscopy study of the chemical interaction at the Pd/SiC interface

In order to study the chemical interaction during interface formation between Pd and SiC, Pd layers of various thicknesses were deposited on structurally disordered SiC surfaces at 800 °C. The Pd/SiC interface, which plays a crucial role for many applications such as high power electronic devices and tristructural-isotropic (TRISO) nuclear fuels, was studied in situ by x-ray photoelectron spectroscopy. We find that after Pd deposition, Si–C and Si–Si bonds are broken in favor of the formation of not only Pd–Si but also Pd–C bonds. In addition, various silicon oxycarbide bonds are observed at the SiC surface and the Pd/SiC interface. These results are not only of relevance for the long-term stability of TRISO fuels but also for a variety of other applications, including Schottky-barrier-type contacts in electronic devices.

Optimization of One-Pass Transuranic Deep Burn in a Modular Helium Reactor

An optimization study of a single-pass transuranic (TRU) deep burn (DB) has been performed for a block-type modular helium reactor (MHR) proposed by General Atomics. A high-burnup TRU feed vector from light water reactors is considered: 50 GWd/tU burnup with 5-yr cooling. For three-dimensional equilibrium cores, the performance analysis is done by using McCARD, a continuous-energy Monte Carlo depletion code. The core optimization is performed from the viewpoints of the core configuration, fuel management, tristructural-isotropic (TRISO) fuel specification, and neutron spectrum. With regard to core configuration, two annular cores are investigated in terms of the neutron economy. A conventional radial shuffling scheme of fuel blocks is compared with an axial-only block-shuffling strategy in terms of the fuel burnup and core power distributions. The impact of the kernel size of the TRISO fuel is evaluated, and a diluted kernel, instead of a conventional concentrated kernel, is introduced to maximize the TRU burnup by reducing the self-shielding effects of the TRISO particles. A higher graphite density is also evaluated in terms of the fuel burnup. In addition, it is shown that the core power distribution can be effectively controlled by a zoning of the packing fraction of the TRISO fuels. We also have shown that a long-cycle DB-MHR core can be designed by using a two- or three-batch fuel-reloading scheme, at the expense of only a marginal decrease of the TRU discharge burnup. Finally, preliminary safety characteristics of a DB-MHR core have been investigated in terms of the temperature coefficients and effective delayed neutron fraction. It has been found that, depending on the fuel management scheme and fuel specifications, the TRU burnup in an optimized DB-MHR core can be well over 60% in a single-pass irradiation campaign.