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22.39 Lecture 1-1
22.39 Reactor Design, Operation and Safety
Materials Issues Relatedto Reactor Design, Operation & Safety
Professor R. G. Ballinger
Department of Nuclear EngineeringDepartment of Materials Science & Engineering
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22.39 Lecture 1-2
22.39 Reactor Design, Operation and Safety
Objective
• To Develop an Understanding of Materials Issues and Their Implications for Design, Operation & Safety
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22.39 Lecture 1-3
22.39 Reactor Design, Operation and Safety
Outline
Lecture #1: Materials Selection
Lecture #2: Radiation Damage/Effects &Implications for Design
Lecture #3: Environmental Degradation & Implications for Design
Lecture #4: Applications to PWR Design (Steam Generator Design, Penetrations)
Lecture #5: Applications to GFR Design
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22.39 Lecture 1-4
22.39 Reactor Design, Operation and Safety
Materials Selection Considerations
• Applicability
• Suitability
• Fabricability
• Availability
• Economics
• Compromise
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22.39 Lecture 1-5
22.39 Reactor Design, Operation and Safety
Assessment of Applicability
1. Mechanical Environment• Stress (Load) History• Strain History• Normal, Transient, Accident
2. Chemical (Electrochemical) Environment• Normal, Faulted
3. Thermal Environment
4. Nuclear Environment
5. Mechanical-Chemical-Thermal-Nuclear
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22.39 Lecture 1-6
22.39 Reactor Design, Operation and Safety
General Material Failure Modes
1. Overload
2. Creep Rupture
3. Fatigue
4. Brittle Fracture
5. Wastage
6. Environmentally Enhanced
7. Radiation Effects Related
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22.39 Lecture 1-7
22.39 Reactor Design, Operation and Safety
Environmentally EnhancedFailure Modes
1. Stress Corrosion Cracking
2. Hydrogen Embrittlement
3. Corrosion Fatigue
4. Intergranular Attack
5. Erosion-Corrosion
6. Creep-Fatigue Interaction
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22.39 Lecture 1-8
22.39 Reactor Design, Operation and Safety
Key Point• Big Difference Between General & Localized
Corrosion– General Corrosion
» Predictable» Slow (Normally)
– Localized Corrosion» “Unpredictable» Potentially Very Rapid» Can be Multi-Phenomena (Pitting leading to Crack
Initiation)– Significant Design Implications
» Example-PWR Steam Generators
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22.39 Lecture 1-9
22.39 Reactor Design, Operation and Safety
Radiation Effects Related
• Radiation Embrittlement• Radiation Enhanced Creep• Swelling• Radiation Induced Growth• Fuel/Clad Interaction
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22.39 Lecture 1-10
22.39 Reactor Design, Operation and Safety
Mechanical Environment
1. Load-Time History (Operational)• Static• Cyclic (Fatigue)• Elastic vs. Plastic
2. Fabrication Related Loads• Welding• Machining
3. Environment Related Loads• Thermal (Static, Cyclic)• Nuclear (Distortion due to swelling)
4. Time Dependent vs. Time Independent• Creep• Creep-Fatigue
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22.39 Lecture 1-11
22.39 Reactor Design, Operation and Safety
Chemical Environment
1. Electrochemical Compatibility
2. Bulk vs. Local
3. Normal vs. Faulted
4. Nominal vs. Actual
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22.39 Lecture 1-12
22.39 Reactor Design, Operation and Safety
Thermal Environment
1. Steady State
2. Startup/Shutdown
3. Transient
4. Accident
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22.39 Lecture 1-13
22.39 Reactor Design, Operation and Safety
Nuclear Environment
1. Effects on Mechanical Properties• Ductility• Toughness• Strength
2. Dynamic Effects• Radiation Induced Segregation (RIS)• Growth• Fission Gas Release & Fuel Swelling
3. Effects on Chemical Environment• Fuel Rod Chemistry• Coolant Chemistry
4. Effects on Corrosion Products• Activation Products
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22.39 Lecture 1-14
22.39 Reactor Design, Operation and Safety
Mechanical/Chemical/Thermal/Nuclear Environment Interactions
• Stress Corrosion Cracking• Corrosion Fatigue• Hydrogen Embrittlement• Creep-Fatigue Interaction• Pellet Clad Mechanical Interaction (PCMI)• Fretting• Corrosion Product Transport• Flow Assisted Corrosion• Radiation Induced Segregation
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22.39 Lecture 1-15
22.39 Reactor Design, Operation and Safety
Interactions
Thermal
Mechanical Chemical
Nuclear
Compromise
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22.39 Lecture 1-16
22.39 Reactor Design, Operation and Safety
Assessment of Suitability
1. Is the material qualified for use in theenvironment?
2. Is there an existing data base?
Is The Material In The ASME Code3. If not, what information will be required?
4. Can the information be obtained in time?
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22.39 Lecture 1-17
22.39 Reactor Design, Operation and Safety
Assessment of Fabricability
1. Thermomechanical Processing
2. Can the component be fabricated fromthe material?
3. Quality Control
4. Quality Assurance
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22.39 Lecture 1-18
22.39 Reactor Design, Operation and Safety
Thermomechanical Processing
1. Can the desired mechanical propertiesbe obtained?
2. Mechanical properties variability? Howmuch can be allowed?
3. Can the desired properties be obtained?
4. Can the desired properties be maintained?
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22.39 Lecture 1-19
22.39 Reactor Design, Operation and Safety
Component Fabrication
1. Fabrication techniques• Welding
Effects on ChemistryEffects on Mechanical PropertiesEffects on Chemical/Electrochem. Props.Effects on Mechanical Environment
• Residual Stress•• Machining
Stress Concentrators2. Assembly
CrevicesCouples
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22.39 Lecture 1-20
22.39 Reactor Design, Operation and Safety
Assessment of Availability
1. Is the Material Available?
2. Is the Source Reliable?
3. Is there Enough of it?
4. At What Cost?
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22.39 Lecture 1-21
22.39 Reactor Design, Operation and Safety
Assessment of Economics
1. How Much Does it Cost Now?
2. How Much Could it Cost?
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22.39 Lecture 1-22
22.39 Reactor Design, Operation and Safety
Compromise
The Great Tragedy of Engineering:
The slaying of a great hypothesis by an ugly fact
Corollary
Don’t Do Stupid Things- a.k.a. Davis Besse
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22.39 Lecture 1-23
22.39 Reactor Design, Operation and Safety
Material Degradation Prevention Options
1. Design:Proper Materials Selection at the Initial Design PhaseMaterial “Friendly” Design
2. RemediationAlteration of Chemical EnvironmentAlteration of Mechanical EnvironmentAlteration of Operating Conditions
3. Replacement
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22.39 Lecture 1-24
22.39 Reactor Design, Operation and Safety
Materials Selection
1. Select The Right Material in the First Place
2. Change the Material Properties
3. Replace the Material
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22.39 Lecture 1-25
22.39 Reactor Design, Operation and Safety
Alteration of Environment
1. Changing System Conditions• Lower Temperature• Change Chemistry
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22.39 Lecture 1-26
22.39 Reactor Design, Operation and Safety
Material “Friendly” Design
1. Avoid Stress/ Stress Concentrations2. Avoid Galvanic Couples3. Avoid Sharp Bends of Velocity Changes
in Piping Systems4. Design Tanks for Complete Draining5. To Weld or Not to Weld?6. Design to Exclude Air7. Avoid Heterogeneity8. Design for Replacement