Work performed during the quarter is summarized by: loop operations, performance of UO2 fuel, UO2 grain growth and melting studies, fuel rod mechanism failure studies.

Stability tests are to be made in the VBWR (boiling water reactor). The tests are of three types: steady state measurements, rod oscillator tests, and transient tests.

The purpose of this report is to present a conceptual design study on a low power electrical and heat generating plant powered by nuclear energy. The nuclear reactor used in this study is the homogeneous circulating fuel type.

Introduction: The Transition Boiling Heat Transfer Program is sponsored jointly by the USAEC and Euroatom and is being conducted by the General Electric Company. The work commenced on this program February 11, 1963. The objective of this program is to perform basic investigation and measurement of the transition boiling regime in high pressure bulk boiling water flows, with particular emphasis i the high range of steam qualities.

A research program is being conducted to obtain experimental data in the irradiation of plutonium-enriched fuel to confirm a theoretical model for predicting isotopic composition and reactivity changes in plutonium-enriched, light-water-moderated reactors. Quarterly progress: Project fuel fins irradiated to 1860, 3000, and 5300 MWD/T have been successfully sampled in the Radioactive Materials Laboratory. The samples have been dissolved and aliquots delivered to Chemistry for Mass Spectrometry and burnup determination. The first Stanford Pool Irradiation indicated that there was some inconsistency in the thermal flux and the near thermal epithermal flux. The experiment was repeated, increasing the number of foil wheel positions from two to three. The data from the second measurement are being reduced. The EPITHERMOS code modification has been completed. Comparisons between the results computed by the code and experimental data show much improved agreement. The metallographic photomicrographs of a polished half-pellet from rod F, irradiated to 5000 MWD/T, show structure very similar to that shown by the pellet from rod S, irradiated to 1860 MWD/T.

Abstract: A materials exposure program has been established in the Garigliano Nuclear Power Plant to measure the effect of neutron irradiation and time at temperate on the mechanical properties of the reactor pressure vessel steel. Base metal specimens were made from portions of the pressure vessel steel, and weld heat-affected zone and weld metal samples were taken from a weldment made from the pressure vessel steel and simulating a pressure vessel circumferential weld since there are no longitudinal welds in the forged ring shell. The specimens were sealed in helium-filled capsules and placed in the reactor vessel at locations where they will be exposed to a variety of conditions. Tensile property changes will be measured by pre- and post-irradiation tests on small tensile specimens. Fracture characteristic changes will be measured in similar fashion by Charpy V-notch impact tests. The program is planned to cover a 32-year period, with specimens to be removed for test at intervals of 1, 2, 4, 8, 16, and 32 years.

The objective of the Accurate Nuclear Fuel Burnup Analyses program is to develop more accurate methods for burnup analysis for general use than the current method of analysis of Ca-137 or Sr-90. The program will require from three to five years of effort.

Quarterly report describing progress on the EVESR Nuclear Superheat Fuel Development Project.

Technical report describing a UO2-Mo cermet fuel assembly fabricated for long-term irradiation performance testing in the Vallecitos Boiling water Reactor. The design and fabrication histories of this assembly are described and pre-irradiation data on each individual rod are presented. Molybdenum was added to improve the bulk thermal conductivity of the fuel, so that fuel temperatures would remain comparatively low during high-power level operation of the fuel element. The molybdenum was incorporated into the compacts either as fibers or as a thin coating on individual UO2 particles. Fuel pellets were produced from these materials by vacuum hot pressing. The distribution of the molybdenum in both types of cermet fuels appeared favorable to good heat transfer. The fibers were oriented predominantly in the radial planes of the pellet as a result of the uni-directional compaction during the hot-pressing operation. In the pellets made from the coated particles, a continuous network of molybdenum occurred as a result of the coating welding together during the hot-pressing operation. The test assembly contains eight fuel rods; three contain UO2-Mo cermet, three contain the cermet produced from the coated particles, and two are for reference and contain the conventional sintered UO2 pellet fuel. The nominal outside diameter …

Technical report describing how corrosion data and exposure effects were obtained by subjecting metallic samples, during programmed test runs to flowing sodium in 6 test loops fabricated with various combinations of three selected materials, Type 316 stainless steel, 2 1/4 Cr-1 Mo alloy steel, and 5 Cr-1/2 Mo-1/2 Ti alloy steel. Information produced by each test run, including operational and metallurgical data and analyses, is presented. Data are shown in tables, graphs, and drawings.

Abstract. A program was instituted to study and reproduce the in-reactor intergranular failures of Type-304 stainless steel fuel cladding found in superheated steam. The program was directed toward finding ways to eliminate the cause of failure or to use improved alloys that would be less susceptible to failure. A materials screening test was developed in the out-of-pile superheat facilities with 1.5 ppm chloride added as sodium chloride to the recirculating water in the presence of typical boiling water reactor quantities of oxygen and hydrogen. During the test, the heater sheaths were exposed through several cycles to saturated steam (with its accompanying moisture carryover) and superheated steam. Failure of Type-304 stainless steel was obtained in periods of less than two weeks; the failures were predominantly transgranular. Type-347 and vacuum-melted Type-304 stainless steels failed in this NaCl-cycle test while Inconel-600, Incoloy-800, Hastelloy-X, Type-406 stainless steel, and vacuum-melted Type-310 stainless steel were acceptable. An improved chloride cycle test with 0.5 ppm chloride added as ferric chloride to the recirculating water was developed. An intergranular failure was obtained similar to that experienced in the superheat fuel cladding failures in the superheat in-pile loops in the Vallecitos Boiling-Water Reactor. Sensitized Type-304 and Type-316 stainless steels …

Technical report describing the statistically designed empirical approach being used to choose a candidate Zr alloy optimum with respect to corrosion and hydriding rates in steam and having acceptable mechanical properties. The statistical techniques used and the reasons for their use are discussed in detail, with emphasis on the estimation of corrosion rates. Estimation of response surfaces is also considered.

Abstract: The question of how crack-free, protective oxide films can form on zirconium during oxidation when the Pilling-Bedworth ratio is about 1.5 has been considered by a study of the relative plasticity of various forms of zirconia. Hot hardness measurements showed that doping mono-clinic zirconia with iron, nickel, or chromium resulted in softer (more plastic) structures and that yttrium additions slightly reduced the plasticity. Calcia-stabilized cubic zirconia was found to be more plastic than mono-clinic zirconia when tested at temperatures above 200 degrees C. The behavior of anion-deficient oxides indicated that they were more plastic than stoichiometric oxides even though the hardness values were identical at 23 degrees C. The former were free from cracks at the indentions, whereas, stoichiometric oxides exhibited extensive cracking around and between indentions. The behavior of actual, thick (72 microns) oxide films during tensile deformation of oxidized metal samples indicated that considerable plasticity occurs in the oxide at 500 degrees C but that the films are brittle at 23 degrees C. It was concluded that the plasticity of the oxide may be greater than that of the oxygen-contaminated substrate at elevated temperatures and may be the means by which epitaxial strains are minimized.

A research program is being conducted to obtain experimental data in the irradiation of plutonium-enriched fuel to confirm a theoretical model for predicting isotopic composition and reactivity changes in plutonium-enriched, light-water-moderated reactors. Quarterly progress: Forty-six fuel pellet faces have been auto-radiographed. These faces have been prepared from twenty-three pellets by making an exposure before and after the removal of an additional ten mils of fuel. A substantial number of large "hot spots" continue to appear. The largest spot so far observed was 44 mils long, 20 mils wide, and of the order of 20 mils thick. This spot has a PuO2 concentration which varied from 70% on the periphery to 100% at then center. There is some evidence that the segregated regions are elongated with their long axes perpendicular to the direction of the pressing of the green pellet. Determination of the size and concentration distribution is continuing. The EPITHERMOS code now seems to be operating correctly. A test problem for a typical water lattice converged in eleven iterations. The computation of the spectrum for a pure water medium gave results which agreed very well with the expected 1/E spectrum. At the end of the quarter, the program fuel element …

Summary: All experimental work under the Corrosion Mechanism task has been completed. The remaining topical reports are being prepared by D. L. Douglass, now on assignment at Mol. Experimental work on the first round of 31 alloys and on the second round of 10 alloys has been completed. Steam exposures of at least 3000 hours were finished for all the alloys at all test temperatures, with exposures of some coupons to 6700 hours. Mathematical expression have been derived to describe all first round data for corrosion rates and hydriding rates at 300, 400, and 500 degrees C as a function of Nb, Cr, Fe, and Cu content. Solution of the equations for particular service temperatures yield Zr-Cr alloys at optimum at lower temperatures and Zr-Cu-Fe alloys as optimum at the higher temperatures. The second round test results show that neither Ni nor Be additions to Zr-Cr or Zr-Cu improve the performance over that of the optimum Zr-Cr or Zr-Cu-Fe alloys. For the first round heat treatment used, post-corrosion ductility depends on two factors in addition to alloy composition and hydrogen content: crystallographic texture and intermetallic aging reactions. Alloys with a high original ductility are embrittled less by a given amount …

The 300 series stainless steels had been selected originally as the reference fuel cladding material for utilization in several superheat reactor (SHR) systems being built as part of the United States Atomic Energy Commission (USAEC) program. The adequacy of the general corrosion resistance of Type-304 stainless steel for superheat fuel cladding was confirmed in the Phase I portion of the study reported previously. Fuel jacket failures that occurred in Type-304 stainless clad fuel elements exposed in the Vallecitos boiling water reactor superheated steam loop indicated the questionable dependability of such stainless steels for this SHX fuel cladding application. The following conclusions are based on the out-of-pile general corrosion evaluations completed to date on Incoloy-800 as a fuel cladding for nuclear superheat applications: 1. The corrosion data from 4000-hour heat transfer tests indicate good corrosion resistance up to at least a 1300°F metal temperature. By use of a devised method of data treatment, the general corrosion for three years exposure at 1300°F can be calculated to average 0.0016 inch with an upper 95 percent confidence limit of 0.0033 inch. 2. A compositionally-disturbed layer develops at the metal-oxide interface. The disturbed layer depth is a function of time and temperature of exposure. …

The objective of the Accurate Nuclear Fuel Burnup Analyses program is to develop more accurate methods for burnup analysis for general use than the current method of analysis of Ca-137 or Sr-90. The program will require from three to five years of effort.

A research program is being conducted to obtain experimental data in the irradiation of plutonium-enriched fuel to confirm a theoretical model for predicting isotopic composition and reactivity changes in plutonium-enriched, light-water-moderated reactors. Quarterly progress: Work has begun in the Radioactive Materials Laboratory to sample the project fuel from the pins irradiated to 1800 and 5000 MWT/T. Some delay has been experienced due to preemption of the hot cells by priority work. Examination of the autoradiographs of the un-irradiated project fuel showed that in a volume of fuel approximately equivalent to a pellet there were 13 hot spots larger than 15 mils. Evaluation of these spots with the fuel analyzer showed that they contained about 14 mg of PuO2 or about 9% of the total present. The EPITHERMOS code is being modified to automatically normalize the epithermal scattering to the correct value for all moderators. Calibration of the flux wires has been made and the reduction of the data from the VBWR irradiation is nearly complete. A similar resonance activation was made in the water reflector of the Stanford Pool Reactor to obtain the relative activity in a well-defined pure water spectrum. Reduction of these data is also in progress.

Activities in a program to develop techniques in the use of pulsed neutron sources to measure shutdown parameters related to large thermal power reactors are reported. In the course of this program, a new theory was suggested and an experimental apparatus was designed and built. Experiments were carried out to test the new model. This present report contains additional data and information extracted from the experiments at PG&E Humboldt Bay Power Reactor at Eureka, California. During the last days of 1963 a number of control rod and fuel bundle worth measurements were made in the ESADA Vallecitos Experimental Superheat Reactor (EVESR) using the (k[beta]/[script l] technique. A description of the experiments is given in the text of the report and some results are reported. A computer program was written to perform the data analysis of the pulsed neutron experiments and the code is discussed in the Appendix.

Technical report describing an analytical investigation made on the mechanism of the "downstream" effect in the corrosion of stainless steel in sodium. A mechanism of iron alloy corrosion is assumed in which the controlling rate is diffusion of iron-oxygen species, probably a FeO-Na2O complex. A mathematical model is developed for the corrosion, and the predicted results agree with the experimental data. The corroding species is probably present in sodium at concentrations of ~10(-8) g Fe/g Na.

Abstract: Residual and fission gas release from UO2 were studied in the laboratory and in in-reactor experiments. Arc-fused powder and sintered pellets were used to determine the rate of evolution and types of residual gases as a function of temperature. Fission gas release was related to the average UO2 temperature and fission gas release calculations were made using the latest thermal conductivity values, isotopic half lives, and branching ratios available in the literature. The results obtained were compared with those available in the literature, and a satisfactory agreement was found among the groups of comparable data.

Abstract: (1) Grain growth in UO2 pellets was studies between 100 C and 2600 C. The pellets were encapsulated in small vacuum-tight tungsten containers in an argon atmosphere. (2) The grain size-time relationship could be expressed by an equation. A low exponent, m>_ 1/3, was found in those experiments and is related to the type of UO2 investigated. An activation energy of 65 kcal/mole was obtained for the grain growth process. The time exponent, m, increased with increasing temperature if the pellets were not contained in closed capsules bu heated under an argon pressure of 1.5 atm. (3) An interaction between tungsten and UO2 could be observed at a a temperature of 2600 C after prolonged heat treatment.

Summary: The Mixed Spectrum Superheater (MSSR) is an integral superheater reactor in which boiling occurs in an annular Boiling Water Reactor section and steam in superheated in an unmoderated fast section in the center. A Mixed Spectrum Critical Assembly (MSCA) to be operated at the Vallecitos Atomic Laboratory has been designed to mock up a 75-150 MWe prototype MSSR. The principal experimental measurements aimed at proving the feasibility of the MSSR concept include power distribution, Doppler effect, flooding effects, distribution of reactivity, control rod worths, and the effect of the control system on the power distribution.

Summary: Two UO2-filled stainless steel clad fuel rods in which fission gas pressure was measured during irradiation have been subjected to post irradiation examination. Results of free gas analysis and metallographic examination are in general agreement with observed pressures reported previously. Calculated fuel surface temperatures based on extent of fuel recrystallization indicate that in a one-half inch diameter fuel rod with 0.014 inch diametral clearance operated at a maximum heat flux of 531,000 Btu/hr-ft, gap conductance increased with increasing heat flux. An analysis of void configuration indicates that pressure is more sensitive to as-fabricated void volume and changes in this volume resulting from fuel expansion than to fuel central temperature. The decreases in effective void volume with increasing fuel temperatures becomes more significant as initial void volume decreases, and excessive fission gas pressures may be developed in fuel rods operated at high fuel temperatures unless adequate expansion volume is provided in fabrication.