The Spent Nuclear Fuel (SNF) cladding serves as the first barrier that prevents the release of radioactive materials. It is very important to maintain cladding integrity in SNF management. It is known that the pinch load applied to the cladding can lead to Mode-3 failure and the cladding becomes more vulnerable to this failure mode with the existence of radial hydrides and other forms of mechanical defects. In this study, a numerical analysis process was proposed to scientifically and systematically evaluate the fracture resistance of cladding with reoriented hydrides under pinch load. The mechanical behavior and fracture of the irradiated cladding under pinch load can be evaluated by Ring Compression Test (RCT). Under the stress field generated by RCT, the cracks propagate more easily through radial hydrides than circumferential hydrides. The δ-hydride which form within the α-zirconium matrix causes a large expansion strain due to the volume difference and voids form at the interface between the hydride and the zirconium matrix. Chan demonstrated that the load needed to form voids and separate the hard hydride precipitates from the Zr matrix is considerably lower than that which initiates brittle fracture of hydrides using a micro-cantilever test. Therefore, we propose a microstructure crack propagation analysis method based on Continuum Damage Mechanics (CDM) that can simulate fracture of hydride, zirconium matrix, and Zr/hydride interface. CDM is possible to simulate the hydride, zirconium matrix, and interface cracking in a continuum model based on cladding deformation. The RCT simulation model was constructed from the microscopic images of irradiated cladding. A pixel-based finite element model was created by separating the hydride, zirconium matrix, and interface using the image segmentation method on a morphology operation basis. The appropriate element size was selected for the efficiency of the analysis and crack propagation using CDM. The force-displacement curves and strain energy from RCT were compared and analyzed with the simulation results of different element sizes. The finalized RCT simulation model can be used to evaluate the fracture resistance of the irradiated cladding under the quantified pinch load and to establish the failure criterion of fuel rods under pinch load. The advantages and limitations of the proposed process are discussed.

The evaluation of the damage ratio of spent nuclear fuel is a very important intermediate variable for dry storage risk assessment, which requires an interdisciplinary and comprehensive investigation. It is known that the pinch load applied to the cladding can leaded to Mode-3 failure and the cladding becomes more vulnerable to this failure mode with the existence of radial hydrides and other forms of mechanical defects. In this study, the failure resistance of Zircaloy-4 cladding against the pinch load is investigated using numerical simulations assuming the existence of radial hydrides. The simulation model is based on the microscopic images of cladding. A pixel-based finite element model was created by separating the Zircaloy-4 and hydride using the image segmentation method. The image segmentation method uses a morphology operation basis, which is a preprocessing method through erosion operation after image expansion to enable normal segmentation by emphasizing pixels corresponding to hydrides. The segmented images are converted into a finite element model by assigning node and element numbers together with corresponding material properties. Using the generated hydride cladding finite element model, several numerical methods are investigated to simulate crack propagation and cladding failure under pinch load. Using extended finite element (XFEM) models the initiation and propagation of a discrete crack along an arbitrary, solution-dependent path can be simulated without the requirement of remeshing. The applicability of fracture mechanical parameters such as stress intensity, J-integral was also investigated.

In this study, the effect of upper die type on the load characteristics of lower die and the wasted material was studied numerically. The different shapes(A-type, B-type, and C-type) of upper die were applied. Also finite element analysis method was applied for the analysis in each stage. The half of X, Y plane was analyzed due to the symmetrical shape in order to reduce the analysis time and be accurate results. The coefficient of friction was set to oil_cold conditions as refer to the system library. It was revealed that principal stress was the order in A, C, and B. A and B type have the highest value in 4 stage, and C type shows the highest value in 3 stage. In addition, Von mises stress were higher in order A, B, and C. A and B type have the highest in 4 stage, and C type shows to have about the same value in the 2 - 5 stage. The load was generally higher than C type. The load of C type was reduced in YY-direction at each stage without 2, 5, 6 stage.