Effects of Hydrided Region Overload on Delayed Hydride Cracking Initiation From Flaws in Zr-2.5 Nb Pressure Tubes

2003 ◽  
Author(s):  
Gordon K. Shek ◽  
Jun Cui
Keyword(s):  
Crack Initiation ◽  
Hydrogen Diffusion ◽  
Test Results ◽  
Loading History ◽  
Hydride Formation ◽  
Pressure Tubes ◽  
Delayed Hydride Cracking ◽  
Reactor Operating ◽  
Increasing Load ◽  
Hydride Cracking

The Zr-2.5 Nb pressure tubes of CANDU™ (CANada Deuterium Uranium) reactors are susceptible to a crack initiation and growth mechanism known as Delayed Hydride Cracking (DHC), which is a process that involves hydrogen diffusion, hydride precipitation, hydrided region formation and fracture at a flaw-tip. An overload occurs when the hydrided region at a flaw is loaded to a stress higher than that at which this region is formed. Flaw disposition requires justification that the hydrided region overload from normal reactor operating and transient loading conditions will not fracture the hydrided region, and will not initiate DHC. To evaluate the effects of hydrided region overload on DHC initiation, a series of monotonically increasing load experiments were performed on specimens prepared from unirradiated pressure tube materials with the hydrided region formed at flaws with root radii varying from 15 to 350 μm, and blunt notches with and without secondary flaws. Test results indicate that the resistance to overload fracture is dependent on a variety of parameters including flaw geometry, hydride formation stress, loading history, and overload test temperature.

Overload Fracture of Hydrided Region at Simulated Blunt Flaws in Zr-2.5Nb Pressure Tube Material

2005 ◽  
Author(s):  
Jun Cui ◽  
Gordon K. Shek
Keyword(s):  
Crack Initiation ◽  
Hydrogen Diffusion ◽  
Preliminary Test ◽  
Pressure Tube ◽  
Test Results ◽  
Hydride Formation ◽  
Repetitive Process ◽  
Pressure Tubes ◽  
Reactor Operating ◽  
Increasing Load

Flaws in Zr-2.5Nb alloy pressure tubes in CANDU nuclear reactors are susceptible to a crack initiation and growth mechanism known as Delayed Hydride Cracking (DHC), which is a repetitive process that involves hydrogen diffusion, hydride precipitation, growth of the hydrided region and fracture of the hydrided region at the flaw-tip. An overload occurs when the hydrided region at a flaw is loaded to a stress higher than that at which this region is formed. Flaw disposition requires justification that the hydrided region overload from normal reactor operating and transient loading conditions will not fracture the hydrided region, and will not initiate DHC. Some preliminary test results on the effect of hydrided region overload on DHC initiation were presented in Reference [1]. In the present work, several series of more systematically designed monotonically increasing load experiments were performed on specimens prepared from an unirradiated pressure tube with hydrided region formed at flaws with a root radius of 0.1 or 0.3 mm under different hydride formation stresses and thermal histories. Crack initiation in the overload tests was detected by the acoustic emission technique. Test results indicate that the resistance to overload fracture is dependent on a variety of parameters including hydride formation stress, thermal history, flaw geometry and hydrogen concentration.

Overload Fracture of Hydrided Region at Simulated Blunt Flaws in Zr-2.5Nb Pressure Tube Material

2009 ◽  
Vol 131 (4) ◽  
Author(s):  
Jun Cui ◽  
Gordon K. Shek ◽  
Zhirui Wang
Keyword(s):  
Crack Initiation ◽  
Hydrogen Diffusion ◽  
Pressure Tube ◽  
Test Results ◽  
Hydride Formation ◽  
Repetitive Process ◽  
Pressure Tubes ◽  
Reactor Operating ◽  
Canada Limited ◽  
Precipitation Formation

A crack initiation and growth mechanism known as delayed hydride cracking (DHC) is a concern for Zr-2.5Nb alloy pressure tubes of CANada Deuterium Uranium or CANDU (CANDU is a trademark of the Atomic Energy of Canada Limited, Ontario, Canada) nuclear reactors. DHC is a repetitive process that involves hydrogen diffusion, hydride precipitation, formation, and fracture of a hydrided region at a flaw tip. An overload occurs when the flaw-tip hydrided region is loaded to a stress, higher than that at which this region is formed. For the fitness-for-service assessment of the pressure tubes, it is required to demonstrate that the overload from the normal reactor operating and transient loading conditions will not fracture the hydrided region, and will not initiate DHC. In this work, several series of systematically designed, monotonically increasing load experiments are performed on specimens, prepared from an unirradiated pressure tube with hydrided region, formed at flaws with a root radius of 0.1 mm or 0.3 mm, under different hydride formation stresses and thermal histories. Crack initiation in the overload tests is detected by the acoustic emission technique. Test results indicate that the resistance to overload fracture is dependent on a variety of parameters including hydride formation stress, thermal history, hydrogen concentration, and flaw geometry.

Delayed Hydride Cracking Initiation at Notches in Zr-2.5Nb Alloys

2009 ◽  
Vol 131 (4) ◽  
Author(s):  
Jun Cui ◽  
Gordon K. Shek ◽  
D. A. Scarth ◽  
Zhirui Wang
Keyword(s):  
Hydrogen Diffusion ◽  
Process Zone ◽  
Notch Root ◽  
Threshold Value ◽  
Operating Conditions ◽  
Test Results ◽  
Pressure Tubes ◽  
Delayed Hydride Cracking ◽  
Notch Tip ◽  
Hydride Cracking

Delayed hydride cracking (DHC) is an important crack initiation and growth mechanism in Zr-2.5Nb alloy pressure tubes of CANDU nuclear reactors. DHC is a repetitive process that involves hydrogen diffusion, hydride precipitation, growth, and fracture of a hydrided region at a flaw tip. In-service flaw evaluation requires analyses to demonstrate that DHC will not initiate from the flaw. The work presented in this paper examines DHC initiation behavior from V-notches with root radii of 15 μm, 30 μm, and 100 μm, which simulate service-induced debris fretting flaws. Groups of notched cantilever beam specimens were prepared from two unirradiated pressure tubes hydrided to a nominal hydrogen concentration of 57 wt. ppm. The specimens were loaded to different stress levels that straddled the threshold value predicted by an engineering process-zone (EPZ) model, and subjected to multiple thermal cycles representative of reactor operating conditions to form hydrides at the notch tip. Threshold conditions for DHC initiation were established for the notch geometries and thermal cycling conditions used in this program. Test results indicate that the resistance to DHC initiation is dependent on notch root radius, which is shown by optical metallography and scanning electron microscopy to have a significant effect on the distribution and morphology of the notch-tip reoriented hydrides. In addition, it is observed that one tube is less resistant to DHC initiation than the other tube, which may be attributed to the differences in their microstructure and texture. There is a reasonable agreement between the test results and the predictions from the EPZ model.

Delayed Hydride Cracking Initiation at Simulated Debris Fretting Flaws in Zr-2.5Nb Alloys

2006 ◽  
Author(s):  
Jun Cui ◽  
Gordon K. Shek ◽  
Douglas A. Scarth ◽  
Zhirui Wang
Keyword(s):  
Hydrogen Diffusion ◽  
Notch Root ◽  
Threshold Value ◽  
Operating Conditions ◽  
Notch Root Radius ◽  
Pressure Tubes ◽  
Delayed Hydride Cracking ◽  
Program Test ◽  
Reactor Operating ◽  
Hydride Cracking

Flaws in Zr-2.5Nb alloy pressure tubes in CANDU nuclear reactors are susceptible to a crack initiation and growth mechanism known as Delayed Hydride Cracking (DHC), which is a repetitive process that involves hydrogen diffusion, hydride precipitation, growth and fracture of the hydrided region at the flaw-tip. In-service flaw evaluation requires an analysis to demonstrate DHC will not initiate from the flaw. The work presented in this paper examines DHC initiation behavior from simulated debris fretting flaws. Groups of cantilever beam specimens containing V-notches with root radii of 15, 30 and 100 μm were prepared from two unirradiated pressure tubes hydrided to a nominal hydrogen concentration of 57 wt. ppm. The specimens were loaded to different stress levels that straddled the threshold value predicted by an engineering model, and subjected to multiple thermal cycles relevant to reactor operating conditions to form hydrides at the flaw-tip. Threshold conditions for DHC initiation were established for the flaw geometries and thermal cycling conditions used in this program. Test results indicate that the susceptibility to DHC initiation was affected by material variability and notch root radius. The results are also compared with model predictions.

Statistical Modeling of Resistance to Crack Initiation due to Hydrided Region Overloads at Simulated Flaws in CANDU Pressure Tubes

2015 ◽  
Author(s):  
Leonid Gutkin ◽  
Douglas A. Scarth
Keyword(s):  
Crack Initiation ◽  
Stress Reduction ◽  
Process Zone ◽  
Reactor Core ◽  
Dual Process ◽  
Modeling Framework ◽  
Hydride Formation ◽  
Pressure Tubes ◽  
Delayed Hydride Cracking ◽  
Hydride Cracking

CANDU(1) Zr-2.5%Nb pressure tubes are susceptible to formation of hydrided regions at the locations of stress concentration, such as in-service flaws. Hydrided region overloads occur when the applied stress acting on a flaw with an existing hydrided region exceeds the stress at which the hydrided region has been formed. The overload events may potentially result in crack initiation and its subsequent growth by the mechanism of delayed hydride cracking. Therefore, evaluating the in-service flaws in the pressure tubes for crack initiation due to hydrided region overloads is required by the Canadian Nuclear Standards, and methodology is being developed to perform such evaluations. As part of this development, the resistance of pressure tube material to crack initiation due to hydrided region overloads was modeled statistically. In the proposed modeling framework, the overload resistance is expressed as a power-law function of the material resistance to initiation of delayed hydride cracking under constant loading. This approach fundamentally relies on the concept of a dual process zone introduced by E. Smith, as discussed in the paper. Both the overload crack initiation coefficient and the overload crack initiation exponent vary with the flaw geometry. The overload crack initiation coefficient also varies with the extent of stress reduction prior to hydride formation and with the number of non-ratcheting hydride formation thermal cycles. The developed model is suitable for use as a predictive model in probabilistic assessments of CANDU reactor core, and has been proposed for implementation into the scheduled revision (2015) of the Canadian Nuclear Standard CSA N285.8.

Delayed Hydride Cracking Initiation at Simulated Secondary Flaws in Zr-2.5 Nb Pressure Tube Material

2004 ◽  
Author(s):  
Jun Cui ◽  
Gordon K. Shek ◽  
Douglas A. Scarth ◽  
William K. Lee
Keyword(s):  
Hydrogen Diffusion ◽  
Process Zone ◽  
Pressure Tube ◽  
Experimental Program ◽  
Small Surface ◽  
Integrity Assessment ◽  
Pressure Tubes ◽  
Delayed Hydride Cracking ◽  
The Impact ◽  
Hydride Cracking

Flaws in Zr-2.5 Nb alloy pressure tubes of CANDU nuclear reactors are susceptible to a crack initiation and growth mechanism called Delayed Hydride Cracking (DHC), which is a repetitive process that involves hydrogen diffusion, hydride precipitation, growth of the hydrided region and fracture of the hydrided region at the flaw-tip. The presence of small surface irregularities, or secondary flaws, at the bottom of service-induced fretting flaws in pressure tubes requires an integrity assessment in terms of DHC initiation. Experimental data and analytical modeling are required to predict whether DHC initiation can occur from the secondary flaws. In the present work, an experimental program was carried out to examine the impact of small secondary flaws with sharp radii on DHC initiation from simulated fretting flaws. Groups of cantilever beam specimens containing blunt notches with and without secondary flaws were prepared from unirradiated pressure tube materials hydrided to a nominal concentration of 50 wt ppm hydrogen. The specimens were subjected to multiple thermal cycles to form hydrides at the flaw-tip at different applied stress levels, which straddled the threshold value for DHC initiation. The threshold conditions for DHC initiation were established for different simulated fretting and secondary flaws. The experimental results are compared with predictions from the engineering process-zone DHC initiation model.

A Probabilistic Integrity Assessment of Flaw in Zirconium Alloy Pressure Tube Considering Delayed Hydride Cracking

2003 ◽  
Vol 17 (08n09) ◽  
pp. 1587-1593 ◽  
Author(s):  
Sang Log Kwak ◽  
Joon Seong Lee ◽  
Young Jin Kim ◽  
Youn Won Park
Keyword(s):  
Probabilistic Analysis ◽  
Nuclear Reactor ◽  
Failure Criteria ◽  
Pressure Tube ◽  
Initial Surface ◽  
Tube Material ◽  
Integrity Assessment ◽  
Pressure Tubes ◽  
Delayed Hydride Cracking ◽  
Hydride Cracking

In the CANDU nuclear reactor, pressure tubes of cold-worked Zr-2.5Nb material are used in the reactor core to contain the nuclear fuel bundles and heavy water coolant. Pressure tubes are major component of nuclear reactor, but only selected samples are periodically examined due to numerous numbers of tubes. Pressure tube material gradually pick up deuterium, as such are susceptible to a crack initiation and propagation process called delayed hydride cracking (DHC), which is the characteristic of pressure tube integrity evaluation. If cracks are not detected, such a cracking mechanism could lead to unstable rupture of the pressure tube. Up to this time, integrity evaluations are performed using conventional deterministic approaches. So it is expected that the results obtained are too conservative to perform a rational evaluation of lifetime. In this respect, a probabilistic safety assessment method is more appropriate for the assessment of overall pressure tube safety. This paper describes failure criteria for probabilistic analysis and fracture mechanics analyses of the pressure tubes in consideration of DHC. Major input parameters such as initial hydrogen concentration, the depth and aspect ratio of an initial surface crack, DHC velocity and fracture toughness are considered as probabilistic variables. Failure assessment diagram of pressure tube material is proposed and applied in the probabilistic analysis. In all the analyses, failure probabilities are calculated using the Monte Carlo simulation. As a result of analysis, conservatism of deterministic failure criteria is showed.

Multi-Variable Engineering Model for Axial Delayed Hydride Cracking Growth Rate in Pre-Irradiated Zr-2.5%Nb

2009 ◽  
Author(s):  
Leonid Gutkin ◽  
Douglas A. Scarth
Keyword(s):  
Growth Rate ◽  
Regression Model ◽  
Test Temperature ◽  
Pressure Tube ◽  
Tube Length ◽  
Variable Model ◽  
Pressure Tubes ◽  
Delayed Hydride Cracking ◽  
Absolute Test ◽  
Hydride Cracking

The growth rate of postulated delayed hydride cracks in CANDU Zr-2.5%Nb pressure tubes is an important material property required for flaw evaluations and leak-before-break assessments. It is monitored using surveillance pressure tubes according to the requirements of the Canadian Standards Association (CSA) Standard N285.4 [1]. Radial growth rate and axial growth rate are used to calculate the propagation of delayed hydride cracks in the through-wall direction and along the pressure tube length, respectively. The axial delayed hydride cracking growth rate had been previously found to increase exponentially with inverse absolute test temperature. This dependence had been described by an Arrhenius-type regression model with one explanatory variable. As more experimental results were obtained from surveillance pressure tubes, it has become possible to assess whether there may be statistically significant effects of other variables, which should be incorporated into the representative relation for the axial delayed hydride cracking growth rate. In this paper, multi-variable regression analysis has been used to develop an improved representative model for the axial delayed hydride cracking growth rate of irradiated Zr-2.5%Nb pressure tube material. The developed model explains approximately 93% of overall observed variation in the experimental data, and therefore has better predictive capabilities than the reference regression model with test temperature as a sole predictor. The developed multi-variable model is proposed to be incorporated into the scheduled revision (2010 edition) of the CSA Standard N285.8 as the representative predictive model.

Statistical Assessment of Crack Initiation at Simulated Flaws due to Hydrided Region Overload in CANDU Zr-2.5%Nb Pressure Tube Material

2011 ◽  
Author(s):  
Leonid Gutkin ◽  
Douglas A. Scarth
Keyword(s):  
Stress Concentration ◽  
Crack Initiation ◽  
Applied Stress ◽  
Pressure Tube ◽  
Experimental Program ◽  
Tube Material ◽  
Statistical Assessment ◽  
Hydride Formation ◽  
Pressure Tubes ◽  
Threshold Stress Intensity Factor

CANDU Zr-2.5%Nb pressure tubes are susceptible to formation of hydrided regions at the locations of stress concentration, such as in-service flaws. When the applied stress acting on a flaw with an existing hydrided region exceeds the stress at which the hydrided region has been formed, hydrided region overload may occur. Probabilistic methodology is being developed to evaluate in-service flaws in the pressure tubes for crack initiation due to hydrided region overload. Statistical assessment of relevant experimental data on the overload resistance of Zr-2.5%Nb has been performed as part of this development. The results of this assessment indicate that the critical nominal stress for crack initiation due to hydrided region overload increases with increasing the nominal applied stress during hydrided region formation, decreasing the stress concentration factor and increasing the threshold stress intensity factor for initiation of delayed hydride cracking. These findings are consistent with our fundamental understanding of hydrided region overload, as well as with the previous modeling work by E. Smith, as referenced in the paper. The overload resistance also appears to increase with the number of thermal cycles in the course of hydride formation. The results of this assessment have been used to develop a preliminary probabilistic model to predict the critical stress for crack initiation due to hydrided region overload under ratcheting hydride formation conditions, as well as a comprehensive experimental program to further investigate the overload behavior of CANDU pressure tube material.

Cycle-Wise Process-Zone Model for Prediction of Delayed Hydride Cracking Initiation Under Flaw-Tip Hydride Ratcheting Conditions

2018 ◽  
Author(s):  
Steven X. Xu ◽  
Jun Cui ◽  
Douglas A. Scarth ◽  
David Cho
Keyword(s):  
Structural Integrity ◽  
Process Zone ◽  
Operating Conditions ◽  
Zone Model ◽  
Evaluation Procedures ◽  
Fuel Bundle ◽  
Pressure Tubes ◽  
Delayed Hydride Cracking ◽  
Technical Basis ◽  
Hydride Cracking

Flaws found during in-service inspection of Zr-2.5Nb pressure tubes in CANDU(1) reactors include fuel bundle scratches, debris fretting flaws, fuel bundle bearing pad fretting flaws and crevice corrosion flaws. These flaws are volumetric and blunt in nature. A key structural integrity concern with in-service blunt flaws is their susceptibility to delayed hydride cracking (DHC) initiation, particularly for debris fretting flaws under flaw-tip hydride ratcheting conditions. Hydride ratcheting conditions refer to situations when flaw-tip hydrides do not completely dissolve at normal operating temperature, and accumulation of flaw-tip hydrides occurs with each reactor heat-up/cool-down cycle. A significant number of in-service flaws are expected to be under hydride ratcheting conditions at late life of pressure tubes. DHC initiation evaluation procedures based on process-zone methodology for flaws under hydride ratcheting conditions are provided in CSA (Canadian Standards Association) N285.8-15. The process-zone model in CSA N285.8-15 predicts whether DHC initiation occurs or not for given flaw geometry and operating conditions, regardless of the number of reactor heat-up and cool-down cycles. There has been recent new development. Specifically, a cycle-wise process-zone model has been developed as an extension to the process-zone model in CSA N285.8-15. The cycle-wise process-zone model is able to predict whether DHC initiation occurs or not during a specific reactor heat-up and cool-down cycle under applied load. The development of the cycle-wise process-zone model was driven by the need to include flaw-tip stress relaxation due to creep in evaluation of DHC initiation. The technical basis for the development of the cycle-wise process-zone model for prediction of DHC initiation under flaw-tip hydride ratcheting conditions is described in this paper.

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