Thermomechanical Properties of Neutron Irradiated Al\u3csub\u3e3\u3c/sub\u3eHf-Al Thermal Neutron Absorber Materials

A thermal neutron absorber material composed of Al3Hf particles in an aluminum matrix is under development for the Advanced Test Reactor. This metal matrix composite was fabricated via hot pressing of high-purity aluminum and micrometer-size Al3Hf powders at volume fractions of 20.0, 28.4, and 36.5%. Room temperature tensile and hardness testing of unirradiated specimens revealed a linear relationship between volume fraction and strength, while the tensile data showed a strong decrease in elongation between the 20 and 36.5% volume fraction materials. Tensile tests conducted at 200 °C on unirradiated material revealed similar trends. Evaluations were then conducted on specimens irradiated at 66 to 75 °C to four dose levels ranging from approximately 1 to 4 dpa. Tensile properties exhibited the typical increase in strength and decrease in ductility with dose that are common for metallic materials irradiated at ≤0.4Tm. Hardness also increased with neutron dose. The difference in strength between the three different volume fraction materials was roughly constant as the dose increased. Nanoindentation measurements of Al3Hf particles in the 28.4 vol% material showed the expected trend of increased hardness with irradiation dose. Transmission electron microscopy revealed oxygen at the interface between the Al3Hf particles and aluminum matrix in the irradiated material. Scanning electron microscopy of the exterior surface of tensile tested specimens revealed that deformation of the material occurs via plastic deformation of the Al matrix, cracking of the Al3Hf particles, and to a lesser extent, tearing of the matrix away from the particles. The fracture surface of an irradiated 28.4 vol% specimen showed failure by brittle fracture in the particles and ductile tearing of the aluminum matrix with no loss of cohesion between the particles and matrix. The coefficient of thermal expansion decreased upon irradiation, with a maximum change of −6.3% for the annealed irradiated 36.5 vol% specimen

Nondestructive Characterization of Aged Components

It is known that high energy radiation can have numerous effects on materials. In metals and alloys, the effects include, but may not be limited to, mechanical property changes, physical property changes, compositional changes, phase changes, and dimensional changes. Metals and alloys which undergo high energy self-irradiation are also susceptible to these changes. One of the greatest concerns with irradiation of materials is the phenomenon of void swelling which has been observed in a wide variety of metals and alloys. Irradiation causes the formation of a high concentration point defects and microclusters of vacancies and interstitials. With the assistance of an inert atom such as helium, the vacancy-type defects can coalesce to form a stable bubble. This bubble will continue to grow through the net absorption of more vacancy-type defects and helium atoms, and upon reaching a certain critical size, the bubble will begin to grow at an accelerated rate without the assistance of inert atom absorption. The bubble is then said to be an unstably growing void. Depending on the alloy system and environment, swelling values can reach in excess of 50% !V/Vo where Vo is the initial volume of the material. Along with dimensional changes resulting from the formation of bubbles and voids comes changes in the macroscopically observed speed of sound, moduli, electrical resistivity, yield strength, and other properties. These effects can be detrimental to the designed operation of the aged components. In situations where irradiation has sufficient time to cause degradation to materials used in critical applications such as nuclear reactor core structural materials, it is advisable to regularly survey the material properties. It is common practice to use surveillance specimens, but this is not always possible. When surveillance materials are not available, other means for surveying the material properties must be utilized. Sometimes it is possible to core out a small sample which may be used for material properties measurements. A more appealing solution is to use nondestructive evaluation (NDE) methods

Nondestructive Characterization of Aged Components

It is known that high energy radiation can have numerous effects on materials. In metals and alloys, the effects include, but may not be limited to, mechanical property changes, physical property changes, compositional changes, phase changes, and dimensional changes. Metals and alloys which undergo high energy self-irradiation are also susceptible to these changes. One of the greatest concerns with irradiation of materials is the phenomenon of void swelling which has been observed in a wide variety of metals and alloys. Irradiation causes the formation of a high concentration point defects and microclusters of vacancies and interstitials. With the assistance of an inert atom such as helium, the vacancy-type defects can coalesce to form a stable bubble. This bubble will continue to grow through the net absorption of more vacancy-type defects and helium atoms, and upon reaching a certain critical size, the bubble will begin to grow at an accelerated rate without the assistance of inert atom absorption. The bubble is then said to be an unstably growing void. Depending on the alloy system and environment, swelling values can reach in excess of 50% !V/Vo where Vo is the initial volume of the material. Along with dimensional changes resulting from the formation of bubbles and voids comes changes in the macroscopically observed speed of sound, moduli, electrical resistivity, yield strength, and other properties. These effects can be detrimental to the designed operation of the aged components. In situations where irradiation has sufficient time to cause degradation to materials used in critical applications such as nuclear reactor core structural materials, it is advisable to regularly survey the material properties. It is common practice to use surveillance specimens, but this is not always possible. When surveillance materials are not available, other means for surveying the material properties must be utilized. Sometimes it is possible to core out a small sample which may be used for material properties measurements. A more appealing solution is to use nondestructive evaluation (NDE) methods

Physics-Based Stress Corrosion Cracking Component Reliability Model cast in an R7-Compatible Cumulative Damage Framework

This is a working report drafted under the Risk-Informed Safety Margin Characterization pathway of the Light Water Reactor Sustainability Program, describing statistical models of passives component reliabilities

Nondestructive and Destructive Examination Studies on Removed-from-Service Control Rod Drive Mechanism Penetrations

Studies conducted at the Pacific Northwest National Laboratory (PNNL) in Richland, Washington, focused on assessing the effectiveness of nondestructive examination (NDE) techniques for inspecting control rod drive mechanism (CRDM) nozzles and J-groove weldments. The primary objectives of this work are to provide information to the U.S. Nuclear Regulatory Commission (NRC) on the effectiveness of NDE methods as related to the in-service inspection of CRDM nozzles and J-groove weldments and to enhance the knowledge base of primary water stress corrosion cracking (PWSCC) through destructive characterization of the CRDM assemblies. Two CRDM assemblies were removed from service, decontaminated, and then used in a series of NDE and destructive examination (DE) measurements; this report addresses the following questions: 1) What did each NDE technique detect? 2) What did each NDE technique miss? 3) How accurately did each NDE technique characterize the detected flaws? 4) Why did the NDE techniques perform or not perform? Two CRDM assemblies including the CRDM nozzle, the J-groove weld, buttering, and a portion of the ferritic head material were selected for this study. This report focuses on a CRDM assembly that contained suspected PWSCC, based on in-service inspection data and through-wall leakage. The NDE measurements used to examine the CRDM assembly followed standard industry techniques for conducting in-service inspections of CRDM nozzles and the crown of the J-groove welds and buttering. These techniques included eddy current testing (ET), time-of-flight diffraction ultrasound, and penetrant testing. In addition, laboratory-based NDE methods were employed to conduct inspections of the CRDM assembly with particular emphasis on inspecting the J-groove weld and buttering. These techniques included volumetric ultrasonic inspection of the J-groove weld metal and visual testing via replicant material of the J-groove weld. The results from these NDE studies were used to guide the development of the destructive characterization plan. The NDE studies found several crack-like indications. The NDE and DE studies determined that one of these was a through-weld, radially oriented PWSCC crack in the wetted surface of the J-groove weld, located at the transition point between the weld and the buttering. The crack was 6 mm long on the surface and quickly grew to 25 mm long at a depth of 8 mm, covering the length of the weld between the penetration tube and the carbon steel. The NDE studies found that only ET was able to detect the through-weld crack. The crack was oriented poorly for the ultrasonic testing and was too tight for accurate dye penetrant testing or visual testing. The ET voltage response of the through-wall crack was 30% of the response from a deep electrical discharge machined notch. Destructive examination showed the crack is PWSCC and that it initiated on the wetted surface, grew and expanded through the weld metal, and exited into the annulus. The crack was branched and discontinuous along its length

Towards bend-contour-free dislocation imaging via diffraction contrast STEM.

Dislocation imaging using transmission electron microscopy (TEM) has been an invaluable tool for characterizing crystallographic defects in metals. Compared to conventional TEM imaging, diffraction contrast imaging scanning transmission electron microscopy (DCI STEM) with appropriate setting can provide better defect contrast with almost negligible bend contour artifacts, enabling more effective analysis of dislocation structures. Here, we investigated why STEM can suppresses bend contour, and how dislocation contrast behaves along with different STEM imaging parameters. Using a body-centered cubic HT-9 ferritic/martensitic alloy as an example, a simple procedure and operational theory are described at the beginning to help set up DCI STEM experiments. Comparing with conventional TEM and the STEM strictly complying with the principle of reciprocity, we found that a pair of STEM convergence and collection semi-angles, αS and βS, a few milliradians in size is essential for bend-contour-free defect imaging. It works in concert such that the convergence STEM probe opens up the reciprocal space, and then a comparable collection region evens out the rocking-curve oscillation and alleviates bend contours from the reciprocal space. This fundamental advantage is unique in DCI STEM. Practical guidelines regarding STEM parameters and specimen orientation and thickness are then provided for DCI STEM dislocation imaging. Lastly, we show that coupling DCI STEM with spectrum images of electron energy loss spectroscopy and of energy-dispersive X-ray Spectroscopy offers a comprehensive characterization of crystallographic defects and chemical information of complex microstructures

Towards bend-contour-free dislocation imaging via diffraction contrast STEM.

Dislocation imaging using transmission electron microscopy (TEM) has been an invaluable tool for characterizing crystallographic defects in metals. Compared to conventional TEM imaging, diffraction contrast imaging scanning transmission electron microscopy (DCI STEM) with appropriate setting can provide better defect contrast with almost negligible bend contour artifacts, enabling more effective analysis of dislocation structures. Here, we investigated why STEM can suppresses bend contour, and how dislocation contrast behaves along with different STEM imaging parameters. Using a body-centered cubic HT-9 ferritic/martensitic alloy as an example, a simple procedure and operational theory are described at the beginning to help set up DCI STEM experiments. Comparing with conventional TEM and the STEM strictly complying with the principle of reciprocity, we found that a pair of STEM convergence and collection semi-angles, αS and βS, a few milliradians in size is essential for bend-contour-free defect imaging. It works in concert such that the convergence STEM probe opens up the reciprocal space, and then a comparable collection region evens out the rocking-curve oscillation and alleviates bend contours from the reciprocal space. This fundamental advantage is unique in DCI STEM. Practical guidelines regarding STEM parameters and specimen orientation and thickness are then provided for DCI STEM dislocation imaging. Lastly, we show that coupling DCI STEM with spectrum images of electron energy loss spectroscopy and of energy-dispersive X-ray Spectroscopy offers a comprehensive characterization of crystallographic defects and chemical information of complex microstructures

Thermomechanical Properties of Neutron Irradiated Al₃Hf-Al Thermal Neutron Absorber Materials

A thermal neutron absorber material composed of Al3Hf particles in an aluminum matrix is under development for the Advanced Test Reactor. This metal matrix composite was fabricated via hot pressing of high-purity aluminum and micrometer-size Al3Hf powders at volume fractions of 20.0, 28.4, and 36.5%. Room temperature tensile and hardness testing of unirradiated specimens revealed a linear relationship between volume fraction and strength, while the tensile data showed a strong decrease in elongation between the 20 and 36.5% volume fraction materials. Tensile tests conducted at 200 °C on unirradiated material revealed similar trends. Evaluations were then conducted on specimens irradiated at 66 to 75 °C to four dose levels ranging from approximately 1 to 4 dpa. Tensile properties exhibited the typical increase in strength and decrease in ductility with dose that are common for metallic materials irradiated at ≤0.4Tm. Hardness also increased with neutron dose. The difference in strength between the three different volume fraction materials was roughly constant as the dose increased. Nanoindentation measurements of Al3Hf particles in the 28.4 vol% material showed the expected trend of increased hardness with irradiation dose. Transmission electron microscopy revealed oxygen at the interface between the Al3Hf particles and aluminum matrix in the irradiated material. Scanning electron microscopy of the exterior surface of tensile tested specimens revealed that deformation of the material occurs via plastic deformation of the Al matrix, cracking of the Al3Hf particles, and to a lesser extent, tearing of the matrix away from the particles. The fracture surface of an irradiated 28.4 vol% specimen showed failure by brittle fracture in the particles and ductile tearing of the aluminum matrix with no loss of cohesion between the particles and matrix. The coefficient of thermal expansion decreased upon irradiation, with a maximum change of −6.3% for the annealed irradiated 36.5 vol% specimen