Richard H. Howard

First Annual Progress Report on Radiation Tolerance of Controlled Fusion Welds in High Temperature Oxidation Resistant FeCrAl Alloys

The present report summarizes and discusses the first year efforts towards developing a modern, nuclear grade FeCrAl alloy designed to have enhanced radiation tolerance and weldability under the Department of Energy (DOE) Nuclear Energy Enabling Technologies (NEET) program. Significant efforts have been made within the first year of this project including the fabrication of seven candidate FeCrAl alloys with well controlled chemistry and microstructure, the microstructural characterization of these alloys using standardized and advanced techniques, mechanical properties testing and evaluation of base alloys, the completion of welding trials and production of weldments for subsequent testing, the design of novel tensile specimen geometry to increase the number of samples that can be irradiated in a single capsule and also shorten the time of their assessment after irradiation, the development of testing procedures for controlled hydrogen ingress studies, and a detailed mechanical and microstructural assessment of weldments prior to irradiation or hydrogen charging. These efforts and research results have shown promise for the FeCrAl alloy class as a new nuclear grade alloy class.

Experimental Plan and Irradiation Target Design for FeCrAl Embrittlement Screening Tests Conducted Using the High Flux Isotope Reactor

The objective of the FeCrAl embrittlement screening tests being conducted through the use of Oak Ridge National Laboratories (ORNL) High Flux Isotope Reactor is to provide data on the radiation-induced changes in the mechanical properties including radiation-induced hardening and embrittlement through systematic testing and analysis. Data developed on the mechanical properties will be supported by extensive microstructural evaluations to assist in the development of structure-property relationships and provide a sound, fundamental understanding of the performance of FeCrAl alloys in intense neutron radiation fields. Data and analysis developed as part of this effort will be used to assist in the determination of FeCrAl alloys as a viable material for commercial light water reactor (LWR) applications with a primary focus as an accident tolerant cladding.

Status Report on Irradiation Capsules Containing Welded FeCrAl Specimens for Radiation Tolerance Evaluation

This status report provides the background and current status of a series of irradiation capsules, or “rabbits”, that were designed and built to test the contributions of microstructure, composition, damage dose, and irradiation temperature on the radiation tolerance of candidate FeCrAl alloys being developed to have enhanced weldability and radiation tolerance. These rabbits will also test the validity of using an ultra-miniature tensile specimen to assess the mechanical properties of irradiated FeCrAl base metal and weldments. All rabbits are to be irradiated in the High Flux Isotope Reactor (HFIR) at Oak Ridge National Laboratory (ORNL) to damage doses up to ≥15 dpa at temperatures between 200-550°C.

Status Report on Irradiation Capsules Designed to Evaluate FeCrAl-UO2 Interactions

This status report provides the background and current status of a series of irradiation capsules that were designed and are being built to test the interactions between candidate FeCrAl cladding for enhanced accident tolerant applications and prototypical enriched commercial UO2 fuel in a neutron radiation environment. These capsules will test the degree, if any, of fuel cladding chemical interactions (FCCI) between FeCrAl and UO2. The capsules are to be irradiated in the Advanced Test Reactor (ATR) at Idaho National Laboratory to burn-ups of 10, 30, and 50 GWd/MT with a nominal target temperature at the interfaces between the pellets and clad of 350°C.

Status of FeCrAl ODS Irradiations in the High Flux Isotope Reactor

FeCrAl oxide-dispersion strengthened (ODS) alloys are an attractive sub-set alloy class of the more global FeCrAl material class for nuclear applications due to their high temperature steam oxidation resistance and hypothesized enhanced radiation tolerance. A need currently exists to determine the radiation tolerance of these newly developed alloys. To address this need, a preliminary study was conducted using the High Flux Isotope Reactor (HFIR) to irradiate an early generation FeCrAl ODS alloy, 125YF. Preliminary post-irradiation examination (PIE) on these irradiated specimens have shown good radiation tolerance at elevated temperatures (≥330°C) but possible radiation-induced hardening and embrittlement at irradiations of 200°C to a damage level of 1.9 displacement per atom (dpa). Building on this experience, a new series of irradiations are currently being conceptualized. This irradiation series called the FCAD irradiation program will irradiate the latest generation FeCrAl ODS and FeCr ODS alloys to significantly higher doses. These experiments will provide the necessary information to determine the mechanical performance of irradiated FeCrAl ODS alloys at light water reactor and fast reactor conditions.

Fabrication Control Plan for ORNL RH-LOCA ATF Test Specimens to be Irradiated in the ATR

The purpose of this fabrication plan is (1) to summarize the design of a set of rodlets that will be fabricated and then irradiated in the Advanced Test Reactor (ATR) and (2) provide requirements for fabrication and acceptance criteria for inspections of the Light Water Reactor (LWR) – Accident Tolerant Fuels (ATF) rodlet components. The functional and operational (F∨) requirements for the ATF program are identified in the ATF Test Plan. The scope of this document only covers fabrication and inspections of rodlet components detailed in drawings 604496 and 604497. It does not cover the assembly of these items to form a completed test irradiation assembly or the inspection of the final assembly, which will be included in a separate INL final test assembly specification/inspection document. The controls support the requirements that the test irradiations must be performed safely and that subsequent examinations must provide valid results.