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IAEA International Atomic Energy Agency
Structural Materials for Advancer Reactor
Systems: IAEA Support activities
Andrej Zeman
NAPC / Physics section
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Outline
PS introduction
On-going activities
Coordinated Research
Recent activities & education
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The PS supports the IAEA Member
States regarding utilization of: Accelerators
Research reactors
Cross-cutting material research
Controlled fusion
Nuclear instrumentation
PS implements P&B activities based on
MS demand. Organisation of Int.
conferences, Technical and expert
meetings, CRP, Networks, DBs,
Technical Cooperation, etc. Objective is to promote nuclear science &
technology, specifically applied physics and
material science related to nuclear energy.
Physics section profile
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Application of accelerators
In total more than 15.000 accelerators used
world-wide, multidisciplinary use.
Small and medium size facilities; particle and
X-ray machines (CC scheme),
Research & industrial applications, non-
nuclear (semiconductors, medicine, biology,
geology, archeology, etc.) & nuclear (fusion
and fission reactors)
Applications various probing methods (IBA,
PIXE, PIGE, SAXS, XFR, etc.), recently
development & characterization of novel
materials for hydrogen production, storage and
conversion.
www-naweb.iaea.org/napc/physics/accelerators/database/index.html
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Research reactors utilisation
Support of basic & applied research (neutron physics, material science, industrial applications)
Non-nuclear areas: biology, medicine, semiconductors, hydrogen energy systems (storage & conversion).
Operational safety: monitoring and assessment of core components
Approx. 670 research reactors constructed
around the world, about 240 are still operating
Irradiation programs (radio-isotopes, R&D
structural materials, nuclear and non-nuclear
energy applications)
Training activities and know-how
dissemination (professionals & students)
www-naweb.iaea.org/napc/physics/research_reactors/database/database.html
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Activities linked with the rationale of IAEA’s program: 1.4.2.1 (D2) Enhancement of utilization and applications of
RRs, promote the continued development of scientific research and technological development using research reactors.
1.4.3.1 (D3) Accelerator techniques for modification and analysis of materials for nuclear, analytical and computational investigative tools, on the engineering front - new material performance testing technologies,
1.4.4.1 (D4) Supporting plasma physics and fusion research, support of advanced devices operating plasmas that are used for materials research and industrial applications.
PS activities – programmatic view
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Outline
PS introduction
Overview & lessons learned
Coordinated research
Activities and education
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Agency should encourage and assist research and development and practical application of atomic energy for peaceful uses and to foster the exchange of scientific and technical information
Support bilateral and international initiatives and their joint R&D on innovative approaches to nuclear power
Secretariat has to promote the exchange of relevant technical information among interested MS and foster HR trainings
IAEA should identify and explore innovative institutional and infrastructural solutions supporting the future deployment of innovative nuclear energy systems
Coordination and strengthening of research activities among MS (e.g. CRP, WGs, Expert meetings, etc.)
53rd IAEA General Conference, Vienna, 14-18 Sep 2009
Overview & lessons learned
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Zeman et al., Int. School of Physics (ITEP), Moscow, 12-18 February 2007
System of barriers (FP): Fuel matrix - Cladding – Reactor (PL) –
Containment – Emergency planning (transition regimes, sever
accidents)
R(P)V – key component (non-replaceable), LWR (Gen II+ from 1980’s)
designed 40y, some operators plan to extend up to 60 (80y).
Structural materials - have to assure all (designed) parameters of
component will remain in defined limits!
Reactor core components – degradation due to ageing and other factors
(radiation, temperature, chemistry, etc.), it’s linked with component
reliability
Degradation: embrittlement, thermal creep, swelling, cracking, etc. to be
carefully considered in design phase (engineering approach)
Need to understand material behaviour in range of design limits and
beyond (transient and accident scenarios)!
“Defense in depth” principles
Overview & lessons learned
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Design criteria for innovative GCR (GFR/VHTR) Very good overall efficiency (operating at a higher
gas temperature) and modular construction
Proliferation resistance and better fuel management
(higher burn-up)
Bigger primary components (lower power density)
Implementation of passive safety systems
Limited number of reactor/years vs. operational
experiences.
Overview
Critical issues: Structure-Systems-Components and lessons learned (failure of
graphite components, axial crack discovered in the reactor core
Hinkley Point B).
Reactor vessel and core structures / internals, heat exchangers – long
term stability of properties (time & temperature)
Core qualification – engineering approach!
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Technology roadmap of innovative GCR (VHTR, GFR)
Overview
Development & design of full
scale heavy components (RPV,
IHX, Brayton cycle turbo-
machinery
Number of challenges related
to the high performance structural
materials (primary and
secondary)
New materials for fuel
applications (composite
ceramics clad mixed carbide fuel,
advanced fuel particles)
Components for high temperature
process heat (materials for fuel
cells and reaction vessels
What’s really achievable
today, especially in terms of
design, demonstration and
pilot installation?
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Temperature windows and radiation damage
Overview
IAEA CS Meeting, 3 Sep 2010, INTEC, KAERI, Daejeon, Republic of Korea
fusion SiC
V alloy, ODS steel
F/M steel
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Overview IAEA Experts Meeting, 3 Sep 2010, INTEC, KAERI,
Daejeon, Republic of Korea
Innovative GCR systems:
R&D of reactor, core-structural materials
and fuel, several "technological" issues have to be
solved, specifically
(1) Low deformation Swelling, creep and embrittlement
Chemical compatibility and corrosion
Stability at high temperature and
phase transformation
(2) Good performance - mechanical properties Long term stability, trensient and accident
conditions.
Fuel cladding chemical Interaction
reprocessing.
Price, production and fabricability (joining).
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Overview IAEA CS Meeting, 9-12 March 2010, Vienna, Austriaa
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Overview – R&D support
Challenges related to R&D of structural materials incl. viability
concerns faced in the deployment of new fleet of innovative
GCR systems. Some of the issues are linked with specific conditions (e.g. coolant,
high temperature regime, high burn-ups).
In principle R&D has cross-cutting in nature, i.e. common to the
different GCR an fusion reactors as well.
In any case, the assessment of the materials performance and the
prediction of the materials behavior under the specific conditions are
primary issues for the qualification of potential high temperature
stability and irradiation resistant structural materials
International collaboration in the exploitation of experimental
facilities and expertise, harmonisation of experimental procedures
and the creation of a comprehensive database are further important
issues.
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Overview – R&D support
Accomplishment of addressed issues, further international research efforts
require to qualify new and commercially available materials under the
extreme conditions. Several activities have already been initiated in area of structural materials
related to the design safety areas,
Closer collaboration through new IAEA Coordinated Research Projects is
envisaged, it reflects R&D needs identified by the international platforms and
TWGs.
Areas related to R&D of advanced GCR technology (1/2): 1. Advanced thermo-mechanical, irradiation degradation and embrittlement
assessment of the properties of VHTR & GFR candidate structural materials
(joints/welds & coated systems, taking into account coolant properties, high temp
and extended operation period;
2. R&D efforts for the development and harmonisation of codes-of-practice for
advanced testing (non-standard and miniaturised specimens), environmental
testing and test methods and performance assessment under transient off-normal
and accidental conditions (BDBA).
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Overview – R&D support
Areas related to R&D of advanced GCR technology (2/2): 3. Physically-based modelling and experimental validation to contribute to a better
understanding of the materials performance in the respective conditions and
environments, including damage interactions;
4. Strengthening of cross-cutting interactions among interested parties.
The classes of materials investigated comprise: High temperature range (> 800°C): Ni-based alloys, advanced ODS and
refractory-based systems, ceramics (silicon carbide composites), graphite and
carbon-carbon composites.
Intermediate temperature range (600-800°C): traditional and modified austenitic
steels, ODS F/M steels, iron or Ni-based superalloys, refractory alloys;
Low temperature range (300-600°C): austenitic steels, ferritic/martensitic steels,
and ODS alloys;
The activities include (1) Cross cutting R&D of structural materials, and (2) pre-
normative research, codes and standards. Main focus is to contribute to broader
energy issues, specifically energy systems evaluation and energy security.
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Overview – R&D support
Current design and technological issues related to high temperature
applications in innovative GCR:
Corrosion behavior in impure helium of Haynes 230, a nickel base
alloy candidate for heat exchangers in VHTR
Primary focus on formation and the subsequent destruction of the
surface oxide layer at 900 °C and 980 °C.
In-situ gas-phase analysis coupled to post-exposure surface
analyses, it has been confirmed that Cr-rich surface oxide formed on
Haynes 230 at 900 °C is unstable above a critical temperature (Cr-
rich oxide reacts with carbon in solution in the alloy and produce
chromium and CO).
Effect of carbon monoxide partial pressure in the gas phase as well
as the influence of chromium and carbon in the alloy on critical
temperature (understanding of thermodynamics and kinetics aspects
into account).
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Boutard et al., IAEA-EC Topical Meeting, F4E Barcelona, 5-9 October 2009
First Wall Dose (dpa) Temperature appmHe/dpa
ITER Austenitic steel <3 dpa <300 oC
DEMO EUROFER 50-89 dpa <550oC
Power Plant ODS Ferritic Steels 100-150 dpa <750 oC
Power Plant SiCf/SiC Composites 100-150 dpa upto 1100oC
~12
(0.1-0.3 in
Fast Fission
Reactors)
Synergies between fusion and fission:
Reduced Activation approach
9%Cr F/M Steels, SiC-SiC, W-alloys
Low level waste after 80-100y
Nb and Mo are dominating
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Cross-cutting R&D support
IAEA 4th GIF-INPRO Interface Meeting
IAEA HQs, Vienna. 1-3 March, 2010 20
Outline
Outline
PS introduction
On-going activities
Coordinated Research
Activities and education
IAEA
Last decade, main R&D activities driven by fusion community,
ITER and non-ITER countries contributed
Several significant breakthroughs achieved by knowledge form
other fields (e.g. ball-milling for ODS production)
Multi-disciplinary approach, effective application of lessons-
learned (advanced metallurgy, aerospace industry, nano-
science…)
Role of the theoretical modelling should not be over-estimated,
experimental studies are needed and will be crucial in future
material development
Continuous development of semi-mechanistical and multi-scale
models, especially in terms of radiation degradation
mechanisms
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Recent R&D activities
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Coordinated Research Project (on-going)
(1) Better understanding of radiation effects and mechanisms of
material damage and basic physics of accelerator irradiation under
specific conditions,
(2) Improvement of knowledge and data for the present and new
generation of structural materials,
(3) Contribution to developmental of theoretical models for radiation
degradation mechanism,
(4) Fostering of advanced and innovative technologies by support of
round robin testing, collaboration and networking.
IAEA CRP on Accelerator Simulation and Theoretical Modelling
of Radiation Effects (jointly NA-NE)
Deals with several issues related to the proton and ion beam
irradiation in order to achieve very high radiation damage,
project aims to facilitate following issues:
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Coordinated Research Project (on-going)
Project launched 01/2009, last reporting
RCM held in May 2010
Members have presented recent
achievements on experimental testing
of various ODS (MA957, PM2000,
EUROFER, K3, etc.) irradiated at various
temp (up to 550°C), dpa and dose rates
Studies of synergism H/He, combination (validation) of recent
theoretical models.
IAEA CRP on Accelerator Simulation and Theoretical Modelling
of Radiation Effects (jointly NA-NE) - FACTS
Extensive theoretical and experimental studies are being carried out
among participating laboratories form Belgium, China, European
Commission, France, India, Japan, Korea, Kazakhstan, Poland,
Russia, Spain, Slovakia, Ukraine and USA (18 full members).
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Coordinated Research Project (new)
IAEA CRP on Benchmarking of advanced materials pre-selected
for innovative nuclear reactors (jointly NA-NE)
Critical review of structural materials pre-selected for innovative
reactor systems (focus on FR technology), stimulation of further
technological improvements in SM area Response to MS demand in R&D of SM via
coordinated assessment of key parameters
and technological limits.
Performance testing of materials pre-selected
for primary components of new innovative
reactor systems.
Assessment of candidate materials for reactor vessel, internals and fuel
cladding; harmonisation of analysis, consideration of samples miniaturisation,
round robin, etc.).
Methodology for testing of recent ODS-grade steels from ageing other
degradation mechanism point of view (mechanical properties /microstructure).
Project launched recently, RCM will take place 2-6 May 2011, Vienna IAEA TWG Gas Cooled Reactors
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Coordinated Research Project (new)
IAEA CRP on Examination of advanced fuel and core structural
materials for fast reactors” (jointly NA and NE)
Promotion of information exchange related to R&D on materials for FR
core components, combined irradiation experiments.
Project aims to facilitate collaboration and sharing of experience in
characterization and irradiation behaviour of FR core materials under
high neutron fluence
Phase (I) focused on exchange of information via international platform
with aim to review of existing irradiation capabilities with consideration
of urgent needs from individual MS (in/out-of-pile & PIE)
Phase (II) should be initiated afterwards, internationally coordinated
fast neutron irradiation experiments and PIE of samples provided by
CRP members.
To be launched Q3/2011, MS active in fast reactor programs
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Recent scientific events
http://meeting.iaea.org/
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Upcoming activities
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Development of new structural
materials for advanced
fission and fusion reactors
In cooperation with
16 – 20 April 2012
Hosted by JRC Ispra (Italy)
IAEA
Education & training activities
Open to IAEA & UNESCO
Member States, see
Support of international and regional education and trainings
Cooperation with ICTP and other collaborating centres
(ANSTO, RID, Elletra, etc.)
More info: www.ictp.it
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International cooperation
Support of basic R&D to be addressed – material research is
cross-cutting activities – invitation could be achieved in the
framework of broader research community (Universities, non-
GIF members, etc.).
Closer interaction with other Int. organisations is needed (BA,
ITER, SNETP, EERA, IEA-FA…).
International coordination is essential – effective allocation of
resources and sharing of best practice in R&D process.
Active contribution/participation in ongoing and new CRPs, TM
and other initiatives (and vice versa).
Support of educational programs (ICTP/UNESCO, WNU,
Scientific workshops) in order to motivate young professionals
and early stage researchers.
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Main issues – RPV integrity
RPV steel - shift of ductile-to-brittle transition temperature
Yield and hardness ↑ due to defects acting as barriers to motion of
dislocations
Thermal ageing: long-term degradation process of mechanical properties
Chemical composition (alloying elements: Ni, Cr, Mn; impurities: P, Cu, S)
More-complicated for multi-component system - complex issue, many
parameters and variables
Emergency situation - Pressurised-Thermal-Shock (PTS)
transient
Small break LOCA: fast-cooling of RPV (as consequence to
the water safety injection-system), Initial pressure decrease,
followed with a re-pressurisation
Consequence: HP combined with low temperature can cause
the brittle fracture of the RPV (PWR critical scenario - weld
near by core)
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(3.1) Support of nuclear energy
Enhanced safety features – inherent and passive safety systems
Physical barriers and
protection in depth
Physical barriers and protection in
depth
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Main issues – RPV integrity
DESIGN LIMITS: • No less than 40 y of service life or
2.10E5 h of operation at normal power
• Up to 30 planned shutdowns
• Coolant working pressure at the core
outlet of 10-16 MPa ,
• Coolant temperature at steady
operation of 250 to 289°C (inlet) and
269 to 324°C (outlet)
• RPV temperature (considering heating
due to radiation) up to 300°C,
• Maximum neutron flux density at the
level of the core center of around
10E11 n/(s cm2) with respect to
neutrons with energy greater than 0.5
MeV (1 MeV).
PART OF RPV VVER 440 (230) VVER 440 (213) VVER 1000 (320)
(EN > 0,5 MEV)
BASE MATERIAL 2,3 X 1024 2,6 X 1024 6,3 X 1023
WELD MATERIAL 1,6 X 1024 1,8 X 1024 5,7 X 1023
(EN > 1 MEV)
BASE MATERIAL 1,4 X 1024 1,6 X 1024 3,7 X 1023
WELD MATERIAL 1,0 X 1024 1,1 X 1024 3,4 X 1023
PART OF RPV VVER 440 (230) VVER 440 (213) VVER 1000 (320)
(EN > 0,5 MEV)
BASE MATERIAL 2,3 X 1024 2,6 X 1024 6,3 X 1023
WELD MATERIAL 1,6 X 1024 1,8 X 1024 5,7 X 1023
(EN > 1 MEV)
BASE MATERIAL 1,4 X 1024 1,6 X 1024 3,7 X 1023
WELD MATERIAL 1,0 X 1024 1,1 X 1024 3,4 X 1023
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Main issues – embrittlement
NOK OK Serious problem for RPV (non-replaceable)
Normal (ductile) fracture occurs by direct
breaking of atomic bonds along the
crystallographic planes
Brittle fracture spreads through the grains
and grain boundaries because grains are
oriented in different directions, crack
changes direction at the grain boundary
DBTT limits RPV operation!
Zeman et al., Int. School of Physics (ITEP), Moscow, 12-18 February 2007
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Main issues – swelling
Issue for fuel cladding and core components
Garner, IAEA Satellite meeting on Cross-cutting issues of structural materials for fusion and fission applications, ICFRM-13, Sapporo (Japan), 10-11 September 2009
4.5% swelling
~ 250% CW
1.7% swelling
1150 °C/5 min (WQ)
1.2% swelling
750 °C/1hr (AC) Void swelling in Fe irradiated in the BR-10
fast reactor at 400°C to 25.8 dpa at 4 x 10-7
dpa/sec
Variations in neutron flux-spectra can affect
property changes via transmutation rates
and dpa rates.
While recognized as important the impact of
these effects has often been strongly
underestimated.
Traditionally, predictive swelling equations
for steels have ignored these effects
Long-accepted formula (AISI304): % swelling = A(T) (dpa)2
Now-accepted version: % swelling = A (dpa rate)-0.731 (dpa)2
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Direct impact on mechanical properties
Effects like: Direct Matrix Damage (dpa),
Precipitation, Segregation, Phase
transformation, etc.
Phase stability and role of alloying elements.
Thermal and mechanical treatment (CR) can
accelerate or reduce such processes (e.g.
impact on distribution and size of grains).
Effect of Flux (dose rate), energy spectra (En
> 0.5 MeV) and temperature.
Higher doses (> 10 dpa) – Transmutation
LWR: RPV ~ 0.1 dpa, RVI (up 10 dpa)
PHASE PHASE
TRANSFORMATION TRANSFORMATION
(High DPA)(High DPA)
DIRECT
MATRIX
DAMAGE
PRECIPITATIONPRECIPITATION
SEGREG
ATION
SEGREG
ATION
(GB)
(GB)
PHASE PHASE
TRANSFORMATION TRANSFORMATION
(High DPA)(High DPA)
DIRECT
MATRIX
DAMAGE
PRECIPITATIONPRECIPITATION
SEGREG
ATION
SEGREG
ATION
(GB)
(GB)
Defects loopDefects loop
NanovoidNanovoid
Cu Cu precipitprecipit..
P segregationP segregation
Defects loopDefects loop
NanovoidNanovoid
Cu Cu precipitprecipit..
P segregationP segregation
Main issues – radiation damage
100200
300400
500
175
200
225
250
275
300
0.0
5.0x1023
1.0x1024
1.5x1024
2.0x1024
2.5x1024
ML
T (
ps)
Flu
en
ce (m
-2)
Depth (nm)
151.0
169.6
188.3
206.9
225.5
244.1
262.8
281.4
300.0
100
200
300
400
500
400425450475500525550
160
165
170
175
180
1 (p
s)
t (°C)
Dep
th (
nm
)
156.0
159.0
162.0
165.0
168.0
171.0
174.0
177.0
180.0
V. Slugen, A.Zeman, J.Lipka, L.Debarberis, NDT&E Int. 37 (2004) 651-661
(1 dpa = all atoms in lattice displaced!)
Luckily, lattice behaves
differently, recovery
mechanisms, however only
under certain conditions!
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Main issues – prediction models
ΔT = ΔM + ΔP
Total = Matrix + Precipitation
Mechanical (macroscopic) properties
- consequence of micro-structural
changes
Prediction models - designed for EOL
Safety margins vs. lifetime extensions
Study of microstructuctural
mechanisms - more precise models
Benefits for future innovative reactors
(fission and fusion)
Zeman et al., Int. School of Physics (ITEP), Moscow, 12-18 February 2007
ΔT
ΔM
ΔP
Fluence or doseT
0, T
41J,
Y, H
V e
tc. s
hif
t
ΔT
ΔM
ΔP
Fluence or doseT
0, T
41J,
Y, H
V e
tc. s
hif
t
ΔT
ΔM
ΔP
Fluence or doseT
0, T
41J,
Y, H
V e
tc. s
hif
t
FLUENCE [n/cm2], E
n > 1 MeV
1e+17 1e+18 1e+19 1e+20
T
T [
°C]
50
100
150
200
0.35%0.30%
0.25%0.20%
0.15%0.10%
0.08%
UPPER LIMIT
LOW
ER LIM
IT
%Cu =
0.0
8
%P =
0.0
08
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