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Within the last years BAM has carried out numerous drop tests with prototype casks made of ductile cast iron onto targets according to the requirements for final disposal of non-heat generating waste in the German KONRAD repository. The results have shown that the target specifications in the acceptance criteria have to be defined more accurately to get reproducible test results with high precision. Hence, a suitable test stand foundation was developed with much effort. The integrity of the upper concrete layer of this target must be preserved during a test.
Recently the geometrical properties of a tested cubic cast iron container led to a concentration of the impact forces beneath the container walls. The target was damaged strongly with the consequence of inadmissible reduction of cask stresses. For that reason the target construction was modified. However, the basic design was not changed. A prefabricated concrete slab was still joined by a mortar layer to the IAEA target of the BAM drop test facility. In the course of the optimization of the test stand foundation the concrete slab dimensions and the reinforcement were enlarged. During the drop test repetition the target kept intact. Additionally, the mechanical behavior of the cast iron container and the target was analyzed by finite element calculations.
This improved target construction is suggested as a reference target for drop tests with casks whose mass and base area are covered by the container types VI or VII respectively according to the KONRAD repository acceptance criteria.
The measurements during the drop tests with cast iron casks have provided the strains on the cask surface at selected positions. This allows the verification of finite element simulations of drop tests which show the stress distribution also inside the component. In September 2008 a drop test was carried out with a cylindrical cast iron cask containing an artificial material defect which was designed under consideration of critical stress states in the cask body. This drop test could demonstrate the safety against failure by fracture of a cask made of a special cast iron with reduced fracture toughness.
Die sicherheitstechnische Auslegung von Behältern aus duktilem Gusseisen mit erhöhten Reststoffanteilen wird untersucht. Ausgehend von den zu gewährleistenden Anforderungen an Transport- und Lagerbehälter für radioaktive Abfälle werden Referenzbeanspruchungs- situationen definiert. Für einen ausgewählten Referenzfall (bestehend aus der Kombination der Behälterbauart Gusscontainer Typ VI, einem Absturz aus 5 m Höhe auf ein hartes Endlagergestein simulierendes Betonfundament als repräsentativer Störfall und vorgegebenen Werkstoffeigenschaften) wird eine numerische Spannungsanalyse durchgeführt. Die Berechnungen erfolgen mit der Methode der finiten Elemente an dreidimensionalen Modellen, deren numerische Stabilität und Genauigkeit überprüft wird. Zur Berechnung der Behälterbeanspruchungen in Abhängigkeit vom Reststoffanteil werden dynamische Fließkurven für definiert legierte Testabgüsse angegeben.
Es werden Methoden zur sicherheitstechnischen Bewertung des mechanischen Verhaltens von Brennstabhüllrohren entwickelt, um sprödes Versagen in Belastungsszenarien nach längerfristiger trockener Zwischenlagerung zu verhindern. Unbestrahlte Brennstabhüllrohrsegmente aus der Zirkoniumlegierung ZIRLO® wurden hydriert und thermomechanischen Behandlungen unterzogen, um Hüllrohrmaterial durch Ausscheidung radialer Hydride zu verspröden. Die Proben mit radialen Hydriden wurden im Ring Compression Test (RCT) bei Raumtemperatur untersucht. Bereits bei kleinen Probenverformungen wurden abrupte Kraftabfälle mit instabiler Rissausbreitung durch das Netzwerk radialer Hydride beobachtet. Die Risslängen erreichten in einigen Fällen bis zu 90 % der Wanddicke. Der mikromechanische Versagensmechanismus ist Quasi-Spaltbruch in den Hydriden und Porenbildung, -wachstum und -vereinigung in der Zirkoniummatrix an den duktilen Brücken zwischen benachbarten Hydriden. Es wurde ein Finite-Elemente-Modell des Ring Compression Tests erstellt, um das Versagensverhalten zirkoniumbasierter Legierungen mit radialen Hydriden im RCT zu analysieren. Die Fließkurve für das elastisch-plastische Materialmodell des Matrixmaterials wurde durch eine inverse Finite-Elemente-Analyse ermittelt. Kohäsivzonenmodelle wurden benutzt, um die plötzlichen Kraftabfälle zu reproduzieren. Es wurde ein mikromechanisches Modell mit statistisch generierten Matrix-Hydrid-Verteilungen entwickelt, das zwischen sprödem Versagen entlang der Hydride und duktilem Versagen der Zirkoniummatrix in der Kohäsivzone unterscheidet. Für das jeweilige Materialverhalten wird ein lokales zweiparametriges Versagenskriterium auf Grundlage der Kohäsionsfestigkeit und der Separationsenergie bei einer festgelegten Form des Kohäsivgesetzes vorgeschlagen. Geeignete Kohäsivparameter lassen sich mit einer inversen Finite-Elemente-Analyse des Versagensverhaltens von hydrierten Proben im Ring Compression Test bestimmen. In den Simulationen lag der Schwerpunkt auf dem ersten Kraftabfall. Die Berechnungsergebnisse stimmen gut mit den RCT-Ergebnissen überein. Es konnte gezeigt werden, dass die Rissinitiierung und -ausbreitung stark von der speziellen Anordnung der radialen Hydride und Matrixbrücken in der Bruchzone abhängt. Die numerische Modellbildung wurde an Versuchen mit bestrahlten Proben aus der Zirkoniumlegierung M5® validiert.
The evaluation of cladding integrity is a major issue to be demonstrated in Germany for extended interim storage periods up to 100 years and subsequent transportation considering operational and accidental conditions with respect to reactor operation, cask drying and dry interim storage. The chemical reaction between the zirconium fuel cladding and the cooling water in water-cooled reactors produces hydrogen and zirconium oxide. Hydrogen diffuses into the cladding and precipitates as zirconium hydrides when the solubility limit is reached, preferably oriented in hoop direction. At high temperatures during vacuum drying procedures, the hydrides can dissolve. Over a succeeding period of slow cooling with existing hoop stress the hydrides precipitate again, but partly reoriented along the radial direction of the cladding. This change of microstructure in combination with a decreasing temperature (0.5...2 K/year) during (extended) interim storage and additional mechanical load by handling procedures or under accident conditions could lead to a potential cladding embrittlement and consequently increased failure probability. The current research project BRUZL (Fracture mechanical analysis of spent fuel claddings under long-term dry interim storage conditions) has been launched by BAM to investigate potential sudden brittle failure of spent fuel claddings at small deformation under long-term dry interim storage conditions and is presented.
The safety evaluation of cask components made of ductile cast iron includes investigations to prevent brittle fracture. Generally, ductile cast iron is endangered by brittle fracture especially at low temperatures (down to -40°C) and in combination with existing crack-like material defects. An applicable method is the assessment of fracture resistance using fracture mechanics according to the IAEA guidelines. The approach is based on the prevention of fracture initiation. For application of these principles for drop loads, account must be taken both of dynamic stresses within the component and dynamic material behavior. Basically, the dynamic stress intensity factor of postulated pre-existing crack-like defects is compared with the dynamic fracture toughness of the material. Applicable numerical and experimental methods for the safety assessment of cask components are demonstrated for the case of an artificially pre-cracked cylindrical cast iron cask which undergoes dynamic loading conditions as result of the hard impact between the cask and a concrete target. The proposed evaluation procedure is a combination of numerical and experimental steps. Exemplarily, the calculated stress intensity factor is compared with measured fracture toughness values from single edge notched bending specimens.
Metal gaskets in the lid system of transport and storage casks for radioactive material have to guarantee leak-tightness and safe enclosure of the radioactive inventory under normal and accident conditions during transport, in case of accidents and for the longterm interim storage. For safety assessments by nurnerical simulation of the thermomechanical behaviour of a lid system with metal gaskets, the finite element method offers three options to use: i) special gasket elements, ii) complex three-dimensional modeHing with solid elements, and iii) a simplified axisymmetric approach. Gasket elements can be adjusted by many parameters, but they give only a global representation of the experimentally observed gasket behaviour. For calculations of the entire cask including the lid system with gaskets, nonetheless this approach is recommended. To investigate the hardly measurable impact behaviour in detail or to extrapolate the long-term behaviour, a local modeHing of all parts of a gasket and their interactions with effects like elastic-plastic deformation, creep, relaxation, and friction is necessary. The three-dimensional model can describe the change of contact area between outer jacket of the gasket and flange dependent on the load conditions, what overcomes an essential limitation of special gasket elements. To simplify the problern of investigating the underlying physical effects, an axisymmetric lid system can be modelled with axisymmetric finite elements. Usually an approximation is only necessary for the helical spring of a metal gasket. This paper explains basic ideas for an adequate finite element simulation of cask lid systems with metal gaskets and their thermo-mechanical behaviour under specific load scenarios.