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This paper proposes a methodology for calibration of industrial robots that uses a concept of measurement sub-regions, allowing low-cost solutions and easy implementation to meet the robot accuracy requirements in industrial applications. The solutions to increasing the accuracy of robots today have high-cost implementation, making calibration throughout the workplace in industry a difficult and unlikely task. Thus, reducing the time spent and the measured workspace volume of the robot end-effector are the main benefits of the implementation of the sub-region concept, ensuring sufficient flexibility in the measurement step of robot calibration procedures. The main contribution of this article is the proposal and discussion of a methodology to calibrate robots using several small measurement sub-regions and gathering the measurement data in a way equivalent to the measurements made in large volume regions, making feasible the use of high-precision measurement systems but limited to small volumes, such as vision-based measurement systems. The robot calibration procedures were simulated according to the literature, such that results from simulation are free from errors due to experimental setups as to isolate the benefits of the measurement proposal methodology. In addition, a method to validate the analytical off-line kinematic model of industrial robots is proposed using the nominal model of the robot supplier incorporated into its controller.

We report a phase-field model for simulating metal hydride formation involving large volume expansion in single- and polycrystals. As an example, we consider δ-hydride formation in α-zirconium (Zr), which involves both displacive crystallographic structural change and hydrogen diffusion process. Thermodynamic Gibbs energy functions are extracted from the available thermodynamic database based on the sublattice model for the interstitial solid solutions. Solute-grain boundary interactions and inhomogeneous elasticity of polycrystals are taken into consideration within the context of diffuse-interface description. The stress-free transformation strains of multiple variants for hcp-Zr (α) to fcc-hydride (δ) transformation are derived based on the well-established orientation relationship between the α and δ phases as well as the corresponding temperature-dependent lattice parameters. In particular, to account for the large volume expansion, we introduced the mixed interfacial coherency concept between those phases—basal planes are coherent and prismatic planes are semi-coherent in computing the strain energy contribution to the thermodynamics. We analyzed the morphological characteristics of hydrides involving multiple structural variants and their interactions with grain boundaries. Moreover, our simulation study allows for the exploration of the possible hydride re-orientation mechanisms when precipitating under applied tensile load, taking into account the variation in the interfacial coherency between hydrides and matrix, their elastic interactions with the applied stress, as well as their morphology-dependent interactions with grain boundaries. The phase-field model presented here is generally applicable to hydride formation in any binary metal–hydrogen systems.

Hydrogen absorbed into zirconium alloy nuclear fuel cladding as a result of the waterside corrosion reaction can affect the properties of nuclear fuel, principally through the precipitation of brittle hydride particles. Multiple phenomena are involved in this overall process: after hydrogen pickup degradation of mechanical properties is controlled by hydrogen transport, hydride precipitation and dissolution kinetics and the formation of specific mesoscale hydride microstructures. The precipitation of hydrides especially affects cladding ductility and fracture toughness, but can also affect other phenomena, including via stress-induced hydride reorientation. These processes can affect cladding performance both during normal operation and during extended dry storage, as hydride morphology can be modified during the preparatory vacuum drying processes. We review the processes of hydrogen transport, hydride precipitation and dissolution and formation of mesoscale hydride microstructures, and highlight where more research is needed, both from an experimental and from a modeling point of view.

The calibration system proposed showed to improve the robot accuracy to well below 1mm. The system allows a large variation in robot configurations, which is essential to proper calibration. A technique was used and a straightforward convention to build kinematic models for a manipulator was developed, ensuring that no singularities are present in the error model. Mathematical tools were implemented to optimize the kinematic model parameterization, avoiding redundancies between parameters and improving the parameter identification process. A portable, ease of use, speedy and reliable Vision-based measuring system using a single camera and a plane calibration board was developed and tested independently of the robot calibration process. The robot calibration system approach proposed here stood out to be a feasible alternative to the expensive and complex systems available today in the market, using a single camera and showing good accuracy and ease of use and setup. Results showed that the RAC model used (with slight modifications) is not very robust, since even for images filling the entire screen and captured at approximately the same distances from the target, the focus length was not constant and showed an average value shifted by approximately 3% from the exact one. This amount of error can produce 3-D measurement errors much larger than acceptable. Practically speaking, the solution for this problem developed here for a set of camera and lens was to use an external measurement system to calibrate the camera, at least once. The measurement accuracy obtained is comparable to the best found in academic literature for this type of system, with median values of accuracy of approximately 1:3,000 when compared to the distance from the target. However, this accuracy was obtained at considerable larger distances and different camera orientations than usual applications for cameras require, making the system suitable for robotic metrology. For future research it is suggested that the target plate and the calibration board have to be improved to permit the camera to be placed at larger ranges of distances from the target, allowing larger calibration volumes to be used. One path that might be followed is to construct a much larger calibration board, with localized clusters of calibration points of different sizes, instead of just one pattern of point distribution. So, if the camera is placed at a greater distance, larger dots can be used all over the area of the calibration board. If the camera is nearer to the target, smaller dots can be used at particular locations on the calibration board. Different dot sizes make easier for the vision processing software to recognize desired clusters of calibration points. Other sources of lens distortions such as decentering and thin prism can be also modeled, and so their influence on the final measurement accuracy can be understood. Another issue concerns the influence orientation measured data may have on the final accuracy. Non-geometric parameters such as link elasticity, gear elasticity and gear backlash might be modeled, and a larger number of parameters introduced in the model parameterization. This procedure may improve the accuracy substantially if the robot is used with greater payloads.

Chlorine-induced stress corrosion cracking is a degradation mechanism of concern for dry storage of used nuclear fuel. Remote detection of chlorine deposited on the stainless steel canister surface presents a challenge, since no direct line-of-sight is available. We demonstrate the design and use of double-pulse laser-induced breakdown spectroscopy installed on a robotic system for remote detection and measurement of the canister surface chlorine concentration. The system meets the stringent requirements of dry cask storage inspection environment, especially the constrained space. The externally located pulsed laser, spectroscopic instrumentation, and data acquisition setup were interfaced to a robotic delivery car using a pair of 25-m long optical fibers. We discuss the design and construction details of the chlorine detection system and its detection performance in both laboratory and field-deployable configurations. We show that chlorine concentrations as low as 10 mg/m2 can be measured in field-compatible operations.

The microstructural evolution of the 21Cr32Ni model alloy under ion irradiation is investigated. A set of bulk materials were irradiated at the Michigan Ion Beam Laboratory using single beam (5 MeV Fe++) to 1, 10 and 20 dpa at 440 °C and dual beam (5 MeV Fe++ plus energy degraded 1.95 MeV He++ ions) to 16.6 dpa at 446 °C. The average diameter and number density of the faulted loops and cavities formed under irradiation were characterized using Transmission Electron Microscopy (TEM). The behavior of faulted loop in the model alloy was also investigated in-situ using the Intermediate Voltage Electron Microscope (IVEM) at Argonne National Laboratory (ANL). Results show that the average faulted loop diameter decreases, but the faulted loop number density increases with increasing dose. In-situ experiments showed that the faulted loops become unfaulted during ion irradiation by interacting with network dislocations. Although the average faulted loop diameter after 16.6 dpa dual beam irradiation at 446 °C was found to be similar to those seen in samples irradiated with single beams to 10 and 20 dpa, the faulted loop number density was significantly higher in the dual beam irradiated sample. Moreover, the dual beam irradiated model alloy exhibits a significantly higher density of smaller cavities. It is also found that the size and density of the faulted loops and voids calculated for the dual beam irradiation of 21Cr32Ni model alloy at 446 °C are in better agreement with those measured in a sample neutron irradiated at 375 °C. Further discussion is presented in this study.

Synchrotron X-Ray transmission diffraction experiments were performed to study hydride precipitation and dissolution in the zirconium/zirconium-hydride system while it occurs. Evidence was found that the hysteresis between the terminal solid solubility for precipitation and dissolution is not observed when hydride particles are already present at the beginning of sample cooldown. Furthermore, experimental results show that, during a temperature hold, the concentration of hydrogen in solid solution becomes lower than the terminal solid solubility for hydride precipitation and eventually reaches the terminal solid solubility for hydride dissolution, indicating that the latter is the actual thermodynamic solubility limit.

The corrosive environment provided by chlorine ions on the welds of stainless steel dry cask storage canisters for used nuclear fuel may contribute to the occurrence of stress corrosion cracking. We demonstrate the use of fiber-optic laser-induced breakdown spectroscopy (FOLIBS) in the double-pulse (DP) configuration for high-sensitivity, remote measurement of the surface concentrations of chlorine compatible in constrained space and challenging environment characteristic for dry cask storage systems. Chlorine surface concentrations as low as 5 mg/m2 have been detected and quantified by use of a laboratory-based and a fieldable DP FOLIBS setup with the calibration curve approach. The compact final optics assembly in the fieldable setup is interfaced via two 25-m long optical fibers for high-power laser pulse delivery and plasma emission collection and can be readily integrated into a multi-sensor robotic delivery system for in-situ inspection of dry cask storage systems.

During operation of a light water reactor, waterside corrosion of the Zircaloy nuclear fuel cladding causes hydrogen pickup. The absorbed hydrogen can redistribute in the cladding driven by existing concentration, stress, and temperature gradients. When the concentration reaches the solubility limit, hydrides precipitate. These hydrides can be more brittle than the Zircaloy matrix, so they can endanger the cladding integrity during a transient if their concentration is too high. In recent years, extensive efforts have been made to understand hydrogen behavior and to develop simulation tools able to predict hydrogen diffusion and hydride precipitation and dissolution. These efforts led to the development of the Hydride Nucleation-Growth-Dissolution (HNGD) model and its implementation into the nuclear fuel performance code Bison. While it offers a significant improvement and accurately predicts the amount of precipitates, this model fails to predict the thickness of the hydride rim under a temperature gradient. The current work presents the limitation of the HNGD model and proposes two hypotheses to improve the model’s accuracy. The first hypothesis introduces a time dependency to the supersolubility to reduce the nucleation barrier as hydrogen atoms find more favorable nucleation sites. The second one introduces a hydride content dependency to the solubility. These hypotheses were validated and implemented into Bison and are now available to the user community. The modified HNGD model accurately predicts the hydride rim thickness, and it was demonstrated that this updated model can be used in Bison to model Zircaloy cladding with a zirconium inner liner. Finally, potential experimental and numerical methods are discussed to further validate these hypotheses.

In light water nuclear reactors, waterside corrosion of the cladding material leads to the production of hydrogen, a fraction of which is picked up by the zirconium cladding and precipitates into brittle hydride particles. These nanoscale hydride particles aggregate into mesoscale hydride clusters. The principal stacking direction of the nanoscale hydrides precipitated in the cladding tube changes from circumferential in the absence of applied stress to radial under circumferential applied stress. A quantitative phase field model has been developed to predict the hydride morphology observed experimentally and identify the mechanisms responsible for nanoscale hydride stacking. The model focuses on nanoscale hydride precipitation in a single zirconium grain with a detailed description of the anisotropic elastic contribution. The model predictions concerning the shape, orientation, and stacking behavior of nanoscale hydride are analyzed and compared with experimental observations. The model accurately accounts for the experimentally observed elongated nanoscale hydride shape and the stacking of hydrides along the basal plane of the hexagonal zirconium matrix. When investigating the role of applied stress in hydride morphology, the model challenges some of the mechanisms previously proposed to explain hydride reorientation. Although hydride reorientation has been hypothesized to be caused by a change in nanoscale hydride shape, the current study shows that these mechanisms are unlikely to occur.

This work assesses the potential of proton irradiation to simulate the neutron damage to the matrix and laves phase Zr(Fe,Cr)2 precipitates in Zircaloy-4. Isothermal proton irradiation has been performed on Zircaloy-4 samples at irradiation temperatures ranging from 250 to 350 °C. Two-step proton irradiation was also performed to enhance the amorphization of and iron loss from the laves phase Zr(Fe,Cr)2 precipitates. The irradiated microstructures, including dislocation loops and rafts near SPPs, were observed in proton irradiated Zircaloy-4, which are consistent with neutron irradiated material at a similar damage level. The amount of irradiation-induced hardening after proton irradiation was similar to post neutron irradiated data. The significant amorphization of the SPPs and concurrent Fe redistribution observed on neutron irradiated materials can be effectively emulated using a two-step proton irradiation on Zircaloy-4. Hence, the neutron irradiation effect on Zircaloy-4 can be mostly captured using the two-step proton irradiation described in this study.

Alloy 800H is a high nickel austenitic stainless steel with good high temperature mechanical properties which is considered for use in current and advanced nuclear reactor designs. The irradiation response of 800H was examined by characterizing samples that had been bulk ion irradiated at the Michigan Ion Beam Laboratory with 5 MeV Fe2+ ions to 1, 10, and 20 dpa at 440 °C. Transmission electron microscopy was used to measure the size and density of both {111} faulted dislocation loops and cavities as functions of depth from the irradiated surface. The faulted loop density increased with dose from 1 dpa up to 10 dpa where it saturated and remained approximately the same until 20 dpa. The faulted loop average diameter decreased between 1 dpa and 10 dpa and again remained approximately constant from 10 dpa to 20 dpa. Cavities were observed after irradiation doses of 10 and 20 dpa, but not after 1 dpa. The average diameter of cavities increased with dose from 10 to 20 dpa, with a corresponding small decrease in density. Cavity denuded zones were observed near the irradiated surface and near the ion implantation peak. To further understand the microstructural evolution of this alloy, FIB lift-out samples from material irradiated in bulk to 1 and 10 dpa were re-irradiated in-situ in their thin-foil geometry with 1 MeV Kr2+ ions at 440 °C at the Intermediate Voltage Electron Microscope. It was observed that the cavities formed during bulk irradiation shrank under thin-foil irradiation in-situ while dislocation loops were observed to grow and incorporate into the dislocation network. The thin-foil geometry used for in-situ irradiation is believed to cause the cavities to shrink.

The microstructural evolution of ternary Fe-21Cr-32Ni (21Cr32Ni) model alloy and of alloy 800H was investigated with a series of in-situ ion irradiation experiments performed using the Intermediate Voltage Electron Microscope (IVEM)-Tandem Facility at Argonne National Laboratory (ANL). Samples were irradiated in-situ with 1 MeV Kr++ ions in the temperature range of 50K to 713K to doses up to 2 dpa. The size distribution of defect clusters, average defect cluster diameter, and defect cluster density were measured and compared. Results showed that the evolution of defects (i.e. the average defect cluster size and number density) in 21Cr32Ni model alloy and alloy 800H with dose were similar at irradiation temperatures up to 300K where they initially increased with dose up to 0.1 dpa after which no significant changes in defect size and density were observed with further irradiation. In addition, both alloys exhibited ordered defect structures along the direction at relatively low temperatures, up to 300K, which remained stable throughout post-irradiation in-situ thermal annealing up to a temperature of 773K. During irradiation at 713K, small defect clusters were observed at low doses (

Hydride production in Zircaloy cladding continues to be one of the main limiting factors for extending the life of nuclear fuel rods in the core. The production of hydrides in the cladding comes as a direct result of corrosion with water during normal operation. Furthermore, the distribution of hydrogen in the cladding depends strongly on the temperature and temperature gradients inside the cladding. In order to accurately predict these temperature gradients, a high-fidelity multi-physics coupling is needed. The Department of Energy (DOE) recognized this need and sponsored a project at the Pennsylvania State University (PSU) in cooperation with North Carolina State University (NCSU) under the Nuclear Energy University Programs (NEUP). The overreaching goal of this project is to couple thermal-hydraulics, neutronics, and fuel performance codes together to predict the distribution of hydrogen and hydrides in the cladding as a function of time and space. This goal is attained through a two-step approach. The first step combines accurate high-fidelity thermal-hydraulic models for heat transfer, reactor physics models for neutron flux, and thermal-mechanics models for fuel performance calculations to acquire detailed temperature and stress distributions in the fuel rod. The second step develops a semi-analytical model and experimentally tests the temperature and/or stress dependent hydrogen pick-up, diffusion, and precipitation in the cladding. This paper aims to show the capabilities of the high-fidelity coupling, their effect on the power and temperature predictions, and subsequent effect on the distribution of hydrogen in the cladding, specifically in the inter-pellet gap region.

Hydrogen enters zirconium metal as a result of the corrosion process and forms hydrides when present in quantities above the solubility limit at a given temperature. Zircaloy-4 coupons of different thicknesses (0.4 mm-2.3 mm) but identical chemistry and processing were corroded in autoclave at 360 °C for various times up to 2800 days. Coupons were periodically removed and weighed to determine weight gain, which allows follow of the corrosion kinetics. Coupon thickness differences resulted in different volumetric concentrations of hydrogen, as quantified using hot vacuum extraction. The thinnest coupons, having the highest concentration of hydrogen, demonstrated acceleration in their corrosion kinetics and shorter transition times when compared to thicker coupons. Furthermore, it was seen that the post-transition corrosion rate was increased with increasing hydrogen concentration. Corrosion rates increased only after the terminal solid solubility (TSS) was exceeded for hydrogen in Zircaloy-4 at 360 °C. Therefore, it is hypothesized that the corrosion acceleration is caused by the formation of hydrides. Scanning electron microscope (SEM) examinations of fractured oxide layers demonstrate the oxide morphology changed with hydrogen content, with more equiaxed oxide grains in the high hydrogen samples than in those with lower hydrogen content. Additionally, locations of advanced oxide growth were correlated with locations of hydrides in the metal. A hypothesis is proposed to explain the accelerated corrosion due to the presence of the hydrides, namely that the metal, locally, is less able to accommodate oxide growth stresses and this leads to earlier loss of oxide protectiveness in the form of more frequent oxide kinetic transitions.

In an effort to develop coatings to increase the oxidation resistance of nuclear fuel cladding during a loss-of-coolant-accident (LOCA), undoped and ytterbium-doped titanium aluminum nitride (TixAl1-xN) coatings were deposited onto ZIRLO® and grade-5 titanium substrates using a hybrid coating technique incorporating both resistance evaporation and cathodic arc physical vapor deposition (CA-PVD). The coating systems consisted of a titanium bond layer, an undoped TiAlN layer, and an outer TiAlN layer doped with varying levels of ytterbium (0.44 to 33.24 at.%). The coated materials were subjected to high temperature atmospheric oxidation testing and differential scanning calorimetry (DSC) to evaluate the effect of different Yb dopant concentrations on the TixAl1-xN coating oxidation resistance. The results showed that the coatings evaluated in this study protected the tubular ZIRLO® cladding material from oxidation when exposed to air at temperatures up to 1200 °C. DSC data showed that the corrosion resistance of coatings with Yb dopant concentrations of 0.44 and 0.64 at.% was better than that of undoped TixAl1-xN coatings and of TixAl1-xN coatings with Yb concentrations ≥ 4.78 at.%. Yb doping and the 0.44 and 0.64 at.% level also resulted in a lower rate of oxide scale growth and improved scale adherence, which further slowed oxidation kinetics. Peak oxidation resistance was observed in the TiAlN coating with a 0.44 at.% ytterbium dopant concentration. Ytterbium concentrations of 4.78 at.% and greater led to accelerated oxidation rates for the testing conditions studied compared to undoped TiAlN. These results show that ytterbium doped coatings are possible candidates for high temperature resistance of accident tolerant fuel coatings.

The development of TEM-visible damage in materials under irradiation at cryogenic temperatures cannot be explained using classical rate theory modeling with thermally activated reactions since at low temperatures thermal reaction rates are too low. Although point defect mobility approaches zero at low temperature, the thermal spikes induced by displacement cascades enable some atom mobility as it cools. In this work a model is developed to calculate “athermal” reaction rates from the atomic mobility within the irradiation-induced thermal spikes, including both displacement cascades and electronic stopping. The athermal reaction rates are added to a simple rate theory cluster dynamics model to allow for the simulation of microstructure evolution during irradiation at cryogenic temperatures. The rate theory model is applied to in-situ irradiation of ZrC and compares well at cryogenic temperatures. The results show that the addition of the thermal spike model makes it possible to rationalize microstructure evolution in the low temperature regime.

This paper presents the design of a FPGA-based embedded system for controlling and monitoring a 5-D.O.F. spherical topology robot specialized in welding for repairing hydraulic turbine blade surfaces. The embedded controller has been developed using a hardware/software co-design approach in which a Nios II soft-processor is configured on a Terasic DE2-115 development kit, along with several support modules (timer, JTAG, I/O, memory and RS-232). Additionally, other dedicated hardware modules were designed to control the motors, encoders, the welding system and a joystick while daughter boards were designed to provide an opto-coupled connection from the FPGA kit to their respective external peripherals. Furthermore, the control system also provides a RS-232 interface to the pan-tilt, which provides the last two degrees-of-freedom to the manipulator. While the control algorithm runs on the FPGA it receives spatial coordinate points via a USB connection maintained with a PC where higher level software uses image processing techniques to map the turbine surface using a 3D LASER scanner and compute the welding trajectories. Finally, the validity of the system is verified with repeatability and welding tests.

Hydrogen pickup during nuclear fuel cladding corrosion is a critical life-limiting degradation mechanism for nuclear fuel. Following a program dedicated to zirconium alloys, corrosion, it has been hypothesized that oxide electronic resistivity determines hydrogen pickup. In-situ electrochemical impedance spectroscopy experiments were performed on Zircaloy-4 and Zr-2.5Nb alloys in 360 °C water. The oxide resistivity was measured as function of time. The results show that as the oxide resistivity increases so does the hydrogen pickup fraction. The resistivity of the oxide layer formed on Zircaloy-4 is higher than on Zr-2.5Nb, resulting in a higher hydrogen pickup fraction of Zircaloy-4, compared to Zr-2.5Nb.

The d-spacing evolution of both in-plane and out-of-plane hydrides has been studied using in situ synchrotron radiation X-ray diffraction during thermo-mechanical cycling of cold-worked stress-relieved Zircaloy-4. The structure of the hydride precipitates is such that the δ{111} d-spacing of the planes aligned with the hydride platelet face is greater than the d-spacing of the 111 planes aligned with the platelet edges. Upon heating from room temperature, the δ{111} planes aligned with hydride plate edges exhibit bi-linear thermally-induced expansion. In contrast, the d-spacing of the (111) plane aligned with the hydride plate face initially contracts upon heating. These experimental results can be understood in terms of a reversal of stress state associated with precipitating or dissolving hydride platelets within the α-zirconium matrix.

In this paper it is proposed a web-based compliant solution for teleoperation of an industrial robot as a contribution to the increasing technological requirements in industry, using open source programming languages and standard communication protocols to provide a complete and flexible solution for academics and industrial applications. With the recent developments of Industry 4.0 concepts, as Cyber-Physical Systems (CPS), Internet of Things (IoT) and Cloud, there is a need for non-proprietary, robust and efficient architectures compatible with any industrial robotic supplier system. Proposed solution provides an open architecture for an emerging generation of Cloud robotics services for advanced manufacturing challenges, using virtual and real environments for architecture validation with the support of ever-present Socket communication method.

This paper presents and discusses a method to calibrate a specially built laser triangulation sensor to scan and map the surface of hydraulic turbine blades and to assign 3D coordinates to a dedicated robot to repair, by welding in layers, the damage on blades eroded by cavitation pitting and/or cracks produced by cyclic loading. Due to the large nonlinearities present in a camera and laser diodes, large range distances become difficult to measure with high precision. Aiming to improve the precision and accuracy of the range measurement sensor based on laser triangulation, a calibration model is proposed that involves the parameters of the camera, lens, laser positions, and sensor position on the robot arm related to the robot base to find the best accuracy in the distance range of the application. The developed sensor is composed of a CMOS camera and two laser diodes that project light lines onto the blade surface and needs image processing to find the 3D coordinates. The distances vary from 250 to 650 mm and the accuracy obtained within the distance range is below 1 mm. The calibration process needs a previous camera calibration and special calibration boards to calculate the correct distance between the laser diodes and the camera. The sensor position fixed on the robot arm is found by moving the robot to selected positions. The experimental procedures show the success of the calibration scheme.

The formation of hydrides, a result from excess hydrogen uptake by the cladding during nuclear reactor operation, can significantly impact cladding integrity. We present a sensitivity and uncertainty analysis of a hydrogen predictive model in the BISON fuel performance code to characterize the key input parameters involved in the model. This includes identifying the key parameters necessary to simulate hydrogen behavior in the fuel cladding, revealing the impact of environmental conditions on hydrogen distribution, and informing the envelope of conditions for ongoing experimental work conducted by the University of Michigan. The Sobol sensitivity analysis reveals the quantitative impacts of environmental conditions on the predicted total hydrogen concentration, as well as the respective impact on their sensitivity with respect to the physical parameters. Overall, the precipitation of hydrogen that occurred at the cold end of the sample is the most important phenomenon in the prediction of hydrogen concentration. The optimization study using the results from sensitivity analysis indicates that the BISON simulations produce accurate hydrogen predictions when the sets of parametric ranges are shifted to enable more precipitation to occur at the cold end. Lastly, the sensitivity and uncertainty (S/U) analysis for the ongoing benchmarking experiments supports the focus of experiments that lies on the measurement of Soret effect of hydrogen driven by linear temperature gradients. The outputs are expected to better characterize the various parameters involved in the hydrogen transport model in the BISON code, and improve the understanding of the hydrogen transport behaviors in zirconium-based fuel cladding in a range of expected environmental conditions.

Because hydride microstructure can significantly influence Zr alloy nuclear fuel cladding’s ductility, a new metric has been developed to quantify hydride microstructure in 2D micrographs and relate it to crack propagation. As cladding failure usually results from a hoop stress, this new metric, called the Radial Hydride Continuous Path (RHCP), is based on quantifying the continuity of brittle hydride particles along the radial direction of the cladding tube. Compared to previous metrics, this approach more closely relates to the propensity of a crack to propagate radially through the cladding tube thickness. The RHCP takes into account hydride length, orientation, and connectivity to choose the optimal path for crack propagation through the cladding thickness. The RHCP can therefore be more closely linked to hydride embrittlement of the Zr alloy material, thus creating a relationship between material structure, properties, and performance. The new definition, along with previously proposed metrics such as the Radial Hydride Fraction (RHF), the Hydride Continuity Coefficient (HCC), and the Radial Hydride Continuity Factor (RHCF), have been implemented and automated in MATLAB. These codes are made available with this publication as supplementary materials. These metrics were verified by comparing their predictions of hydride morphology against expected values in simple cases, and the implementation of the new metric was validated by comparing its predictions with manual measurements of hydride microstructure performed on ImageJ. The RHCP was also validated against experimental measurements of fracture behavior and it was shown to correlate with cladding failure better than previous metrics. The information provided by these metrics will help accurately assess cladding integrity during operation, transportation, and storage.

Irradiation grain growth of CeO2 was studied using in-situ ion irradiation with transmission electron microscopy (TEM). Thin films of ceria were produced by electron beam physical vapor deposition (EB-PVD) and then irradiated at the Intermediate Voltage Electron Microscope (IVEM) with 1 MeV Kr2+ ions at temperatures of 400°C, 600°C, and 800°C. During irradiation at the elevated temperatures, the CeO2 phase remained stable and its grains grew with irradiation. Grain growth was only weakly dependent on irradiation temperature between 400°C and 800°C. The grain growth kinetics were evaluated by a thermal spike model that was used to calculate the activation energy for grain growth.

In an attempt to develop an accident-tolerant fuel (ATF) that can delay the deleterious consequences of loss-of-coolant-accidents (LOCA), multilayer coatings were deposited onto ZIRLO® coupon substrates by cathodic arc physical vapor deposition (CA-PVD). Coatings were composed of alternating TiN (top) and Ti1-xAlxN (2-layer, 4-layer, 8-layer and 16-layer) layers. The minimum TiN top coating thickness and coating architecture were optimized for good corrosion and oxidation resistance. Corrosion tests were performed in static pure water at 360 °C and 18.7 MPa for up to 90 days. The optimized coatings showed no spallation/delamination and had a maximum of 6 mg/dm2 weight gain, which is 6 times smaller than that of a control sample of uncoated ZIRLO® which showed a weight gain of 40.2 mg/dm2. The optimized architecture features a ∼1 μm TiN top layer to prevent boehmite phase formation during corrosion and a TiN/TiAlN 8-layer architecture which provides the best corrosion performance.

Hydride reorientation can occur in spent nuclear fuel cladding when subjected to a tensile hoop stress above a threshold value during cooling. Because in these circumstances the cladding is under a multiaxial stress state, the effect of stress biaxiality on the threshold stress for hydride reorientation is investigated using hydrided CWSR Zircaloy-4 sheet specimens containing ∼180 wt ppm of hydrogen and subjected to a two-cycle thermo-mechanical treatment. The study is based on especially designed specimens within which the stress biaxiality ratios range from uniaxial (σ2/σ1 = 0) to “near-equibiaxial” tension (σ2/σ1 = 0.8). The threshold stress is determined by mapping finite element calculations of the principal stresses and of the stress biaxiality ratio onto the hydride microstructure obtained after the thermo-mechanical treatment. The results show that the threshold stress (maximum principal stress) decreases from 155 to 75 MPa as the stress biaxiality increases from uniaxial to “near-equibiaxial” tension.

In situ irradiations of 15Cr/15Ni Ti and 15Cr/25Ni Ti model austenitic steels were performed at the Intermediate Voltage Electron Microscope (IVEM)-Tandem user Facility (Argonne National Laboratory) at 600 °C using 1 MeV Kr++. The experiment was designed in the framework of cladding development for the GEN IV Sodium Fast Reactors (SFR). It is an extension of previous high dose irradiations on those model alloys at JANNuS-Saclay facility in France, aimed at investigating swelling mechanisms and microstructure evolution of these alloys under irradiation [1]. These studies showed a strong influence of Ni in decreasing swelling. In situ irradiations were used to continuously follow the microstructure evolution during irradiation using both diffraction contrast imaging and recording of diffraction patterns. Defect analysis, including defect size, density and nature, was performed to characterize the evolving microstructure and the swelling. Comparison of 15Cr/15Ni Ti and 15Cr/25Ni Ti irradiated microstructure has lent insight into the effect of nickel content in the development of radiation damage caused by heavy ion irradiation. The results are quantified and discussed in this paper.