Severe accidents in a Light Water Reactor (LWR) have been a subject of intense research for the last three decades. The research in this area aims to reach understanding of the inherent physical phenomena and reduce the uncertainties in their quantification, with the ultimate goal of developing models that can be applied to safety analysis of nuclear reactors, and to evaluation of the proposed accident management schemes for mitigating the consequences of severe accidents.  In a hypothetical severe accident there is likelihood that the core materials will be relocated to the lower plenum and form a decay-heated debris bed (debris cake) or a melt pool. Interactions of core debris or melt with the reactor structures depend to a large extent on the debris bed or melt pool thermal hydraulics. In case of inadequate cooling, the excessive heat would drive the structures' overheating and ablation, and hence govern the vessel failure mode and timing. In turn, threats to containment integrity associated with potential ex-vessel steam explosions and ex-vessel debris uncoolability depend on the composition, superheat, and amount of molten corium available for discharge upon the vessel failure. That is why predictions of transient melt pool heat transfer in the reactor lower head, subsequent vessel failure modes and melt characteristics upon the discharge are of paramount importance for plant safety assessment.  The main purpose of the present study is to develop a method for reliable prediction of melt pool thermal hydraulics, namely to establish a computational platform for cost-effective, sufficiently-accurate numerical simulations and analyses of core Melt-Structure-Water Interactions in the LWR lower head during a postulated severe core-melting accident. To achieve the goal, an approach to efficient use of Computational Fluid Dynamics (CFD) has been proposed to guide and support the development of models suitable for accident analysis.   The CFD method, on the one hand, is indispensable for scrutinizing flow physics, on the other hand, the validated CFD method can be used to generate necessary data for validation of the accident analysis models. Given the insights gained from the CFD study, physics-based models and computationally-efficient tools are developed for multi-dimensional simulations of transient thermal-hydraulic phenomena in the lower plenum of a LWR during the late phase of an in-vessel core melt progression. To describe natural convection heat transfer in an internally heated volume, and molten metal layer heated from below and cooled from the top (and side) walls, the Effective Convectivity Models (ECM) are developed and implemented in a commercial CFD code. The ECM uses directional heat transfer characteristic velocities to transport the heat to cooled boundaries. The heat transport and interactions are represented through an energy-conservation formulation. The ECM then enables 3D heat transfer simulations of a homogeneous (and stratified) melt pool formed in the LWR lower head. In order to describe phase-change heat transfer associated with core debris or binary mixture (e.g. in a molten metal layer), a temperature-based enthalpy formulation is employed in the Phase-change ECM (so called the PECM). The PECM is capable to represent natural convection heat transfer in a mushy zone. Simple formulation of the PECM method allows implementing different models of mushy zone heat transfer for non-eutectic mixtures. For a non-eutectic binary mixture, compositional convection associated with concentration gradients can be taken into account. The developed models are validated against both existing experimental data and the CFD-generated data. ECM and PECM simulations show a superior computational efficiency compared to the CFD simulation method. The ECM and PECM methods are applied to predict thermal loads imposed on the vessel wall and Control Rod Guide Tubes (CRGTs) during core debris heatup and melting in a Boiling Water Reactor (BWR) lower plenum. It is found that during the accident progression, the CRGT cooling plays a very important role in reducing the thermal loads on the reactor vessel wall. Results of the ECM and PECM simulations suggest a high potential of the CRGT cooling to be an effective measure for severe accident management in BWRs. / <p>QC 20100812</p>

Les applications utilisant les procédés de fabrication directe par laser et projection de poudre sont en pleine expansion, en particulier, dans l'aéronautique. Néanmoins, cette technologie prometteuse fait état de quelques points durs et est confrontée aux problèmes d'instabilités du procédé. Lorsque ces phénomènes ne sont pas maîtrisés, cela conduit à des défauts (résistances mécaniques insuffisantes, porosités trop importantes, mauvais états de surface,….etc), qui, selon leur répartition et leur taille, risquent d'engendrer des non conformités, de détériorer les caractéristiques mécaniques des pièces et qui peuvent représenter un coût de post-traitement non négligeable. Par conséquent, il est primordial de maîtriser le procédé d'élaboration, afin de rendre le procédé de fabrication robuste et préserver l'intégrité structurelle de la pièce. Cela requiert la mise en place de système d'instrumentation du procède de projection laser, et par l'intermédiaire du contrôle procédé, d'avoir un système de commande temps réel permettant d'adapter les paramètres procédés en cours d'élaboration, afin de de maintenir une haute qualité de la pièce fabriquée. Dans cette perspective, nous avons développé une solution technologique (matérielle et algorithmique) à base de caméras (vision) permettant de suivre des paramètres clefs lors de la fabrication. L'application de ce système de vision a permis la mise en œuvre de méthodes innovantes, utilisant des outils de l'automatique moderne, pour surveiller l'état de pièces projetées, voire même corriger leurs défauts lors de la fabrication, en ayant un suivi et un contrôle du procédé en temps réel. De plus ce système de vision a permis à partir de mesures effectuées sur les entrées et les sorties du procédé, d'identifié un modèle dynamique qui ont conduit à la réalisation du système de contrôle procédé. / Applications using the direct metal deposition laser process have been expanded rapidly, particularly in aeronautics. However, this promising technology reported some difficult points and faced several problems, mainly the process instability. When these phenomena are not controlled, several defects was obtained (lack of mechanical strength, excessive porosity, poor surface, ... etc.). According to their distribution and size, non-conformity, deteriorate the mechanical characteristics of the parts was recorded and result in a significant cost of post-processing. Therefore, it is important to control the process, to make the process both robust and preserve the structural integrity of the piece. This requires the development of instrumentation through the control process, in order to have a real-time system able to adjust the process parameters to keep a high quality of the manufactured part. In this perspective, the studied thesis developed a technological solution (hardware and algorithms) based on cameras (vision) to monitor key parameters during manufacture. The application of this vision system has been allowed for the implementation of innovative methods by using modern automatic tools to monitor the status of the built part or even correct their defects during the manufacture parts, having a monitoring and process control in real time. Furthermore this vision system performed measurements for the inputs and outputs of the process, matched to a dynamic model that lead to the realization of the process control system.

This thesis aims to provide the thermal condition of melt pool convection by CFD simulation, which is important to the assessment of the invessel melt retention (IVR) strategy widely adopted in Generation III pressurized water reactors (PWRs). As a severe accident mitigation measure, the IVR strategy is realized through external cooling of the lower head of a reactor pressure vessel (RPV). To achieve the coolability and retention of the corium pool in the RPV lower head, the heat flux at the outer surface of the vessel should be less than the critical heat flux (CHF) of boiling around the lower head. Under such condition, the integrity of the RPV is guaranteed by the adequate thickness of the unmelted vessel wall. The thesis work starts from the selection and validation of a turbulence model in the CFD computational tool chosen (Fluent). Afterwards a numerical model is set up for estimation of melt pool heat transfer of a reference PWR with the power capacity of 1000 MWe, including a mesh sensitivity study. Based on the numerical model of a twolayer melt pool, four tasks are carried out to investigate the effects of Zr oxidation ratio, Fe content, and radiation emissivity on heat flux profiles, as well as the focus effect under extreme conditions. Selection and validation of the turbulence model are conducted by comparing the simulation results of different turbulence models with the DNS data on the convection of volumetrically heated fluid layer bounded by rigid isothermal horizontal walls at equal temperature. The internal Rayleigh numbers of the flow reach up to 10e6. The comparison shows a good agreement of the SST k-ω turbulence model results with the DNS data. The simulations with the Zr oxidation ratio of 0, 0.2 and 0.5, correspondingly, the oxide layer of 1.389m, 1.467m and 1.580m, and the metal layer of 0.705m, 0.646m and 0.561m in height, show that, the temperature of the oxide layer will increase with Zr oxidation ratio, while the temperature of the metal layer will decrease resulting in more heat transfer through the oxide layer sidewall and less top radiation. Nevertheless, the effect of the Zr oxidation ratio is not pronounced in the range of 00.5. The simulations with the Fe mass of 22t, 33t and 45t, and respective height of the metal layer of 0.462m, 0.568m and 0.646m, show that, the inner metal layer will significantly increase the temperatures of both the metal layer and the oxide layer. The percentage of heat transfer at the oxide layer sidewall will increase to supplement the reduction of that at the metal layer. The simulations with the radiation emissivity of 0.2, 0.35, 0.45 and 0.7 show that, the emissivity below 0.45 has an impact on heat transfer, and the temperatures and sidewall heat flux of both the oxide layer and the metal layer will increase with decreasing emissivity. The impact is negligible when the emissivity is above 0.45. The simulations under the hypothetically extreme conditions with either an adiabatic top boundary or a very thin metal layer show the focusing effect may occur, i.e., the heat flux through the metal sidewall is larger than that in the oxide layer. But the local high heat flux is flattened by the vessel wall with good heat conductivity. In summary, the simulations demonstrate that, except for the cases under extreme conditions, the heat fluxes of the melt pools in all other cases are significantly lower than the CHF of external cooling of the lower head. Therefore, the safety margin of the IVR strategy of the PWR chosen is seems sufficient. However, due to some limitations (e.g., simplification and assumptions) in the simulation cases and coupling of different influential factors, as indicated by the present study, the precise predictions of heat flux under all scenarios are still difficult. Therefore, the conclusions could not be generalized to the other conditions or other configurations of the molten pools. By discussing the model and simplifications/assumptions adopted in this work, the improvement directions of the numerical model and other perspectives are proposed at the end of the thesis. / Denna avhandling syftar till att tillhandahålla det termiska tillståndet för smältbassängskonvektion genom CFD-simulering, vilket är viktigt för bedömningen av IVR-strategin som allmänt antagits i tryckvattenreaktorer (PWR) i Generation III. Som en åtgärd för att mildra allvarliga olyckor realiseras IVR-strategin genom extern kylning av det nedre huvudet av ett reaktortryckkärl (RPV). För att uppnå kylbarhet och kvarhållning av koriumbassängen i det nedre RPV-huvudet bör värmeflöde vid den yttre ytan av kärlet vara mindre än det kritiska värmeflödet (CHF) som kokar runt det nedre huvudet. Under sådant tillstånd garanteras RPV: s integritet av den osmälta kärlväggens tillräckliga tjocklek. Examensarbetet startar från valet och valideringen av en turbulensmodell i det valda CFD-beräkningsverktyget (Fluent). Därefter sätts en numerisk modell upp för uppskattning av smältbassängens värmeöverföring av en referens PWR med en effektkapacitet på 1000 MWe, inklusive en nätkänslighetsstudie. Baserat på den numeriska modellen för en tvålagers smältbassäng utförs fyra uppgifter för att undersöka effekterna av Zr-oxidationsförhållande, Fe-innehåll och strålningsemissivitet på värmeflödesprofiler, liksom fokuseffekten under extrema förhållanden. Val och validering av turbulensmodellen utförs genom att jämföra simuleringsresultaten för olika turbulensmodeller med DNS-data för konvektionen av volymetriskt uppvärmt fluidskikt avgränsat av styva isoterma horisontella väggar vid lika temperatur. De interna Rayleigh-siffrorna i flödet når upp till 10e6. Jämförelsen visar att SST k-ω turbulensmodellresultaten överensstämmer med DNS-data. Simuleringarna med Zr-oxidationsförhållandet 0, 0,2 och 0,5, motsvarande oxidskiktet på 1,389 m, 1,467 m och 1,580 m, och metallskiktet på 0,705 m, 0,664 m och 0,561 m i höjd, visar att temperaturen av oxidskiktet kommer att öka med Zr-oxidationsförhållandet, medan metallskiktets temperatur kommer att minska vilket resulterar i mer värmeöverföring genom oxidskiktets sidovägg och mindre toppstrålning. Ändå är effekten av Zr-oxidationsförhållandet inte uttalad i intervallet 00,5. Simuleringarna med Fe-massan på 22t, 33t och 45t och respektive höjd av metallskiktet på 0,462m, 0,568m och 0,664m visar att det inre metallskiktet avsevärt kommer att öka temperaturerna för både metallskiktet och oxiden lager. Andelen värmeöverföring vid oxidskiktets sidovägg ökar för att komplettera minskningen av den vid metallskiktet. Simuleringarna med strålningsemissiviteten 0,2, 0,35, 0,45 och 0,7 visar att emissiviteten under 0,45 påverkar värmeöverföringen, och temperaturerna och sidoväggens värmeflöde för både oxidskiktet och metallskiktet kommer att öka med minskande emissivitet. Effekten är försumbar när strålningen är över 0,45. Simuleringarna under de hypotetiskt extrema förhållandena med antingen en adiabatisk övre gräns eller ett mycket tunt metallskikt visar att fokuseringseffekten kan uppstå, dvs. värmeflödet genom metallsidan är större än det i oxidskiktet. Men det lokala höga värmeflödet plattas ut av kärlväggen med god värmeledningsförmåga. Sammanfattningsvis visar simuleringarna att, förutom fall under extrema förhållanden, är värmeflödet från smältpoolerna i alla andra fall betydligt lägre än CHF för extern kylning av nedre huvudet. Därför verkar säkerhetsmarginalen för IVR-strategin för den valda PWR tillräcklig. På grund av vissa begränsningar (t.ex. förenkling och antaganden) i simuleringsfall och koppling av olika inflytelserika faktorer, vilket indikeras av den aktuella studien, är de exakta förutsägelserna av värmeflöde under alla scenarier fortfarande svåra. Därför kunde slutsatserna inte generaliseras till de andra förhållandena eller andra konfigurationer av de smälta poolerna. Genom att diskutera modellen och förenklingar / antaganden som antagits i detta arbete föreslås förbättringsriktningarna för den numeriska modellen och andra perspektiv i slutet av avhandlingen.

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Severe accidents in a Light Water Reactor (LWR) have been a subject of the research for the last three decades. The research in this area aims to further understanding of the inherent physical phenomena and reduce the uncertainties surrounding their quantification, with the ultimate goal of developing models that can be applied to safety analysis of nuclear reactors. The research is also focusing on evaluation of the proposed accident management schemes for mitigating the consequences of such accidents. During a hypothetical severe accident, whatever the scenario, there is likelihood that the core material will be relocated and accumulated in the lower plenum in the form of a debris bed or a melt pool. Physical phenomena involved in a severe accident progression are complex. The interactions of core debris or melt with the reactor structures depend very much on the debris bed or melt pool thermal hydraulics. That is why predictions of heat transfer during melt pool formation in the reactor lower head are important for the safety assessment. The main purpose of the present study is to advance a method for describing turbulent natural convection heat transfer of a melt pool, and to develop a computational platform for cost-effective, sufficiently-accurate numerical simulations and analyses of Core Melt-Structure-Water Interactions in the LWR lower head during a postulated severe core-melting accident. Given the insights gained from Computational Fluid Dynamics (CFD) simulations, a physics-based model and computationally-efficient tools are developed for multi-dimensional simulations of transient thermal-hydraulic phenomena in the lower plenum of a Boiling Water Reactor (BWR) during the late phase of an in-vessel core melt progression. A model is developed for the core debris bed heat up and formation of a melt pool in the lower head of the reactor vessel, and implemented in a commercial CFD code. To describe the natural convection heat transfer inside the volumetrically decay-heated melt pool, we advanced the Effective Convectivity Conductivity Model (ECCM), which was previously developed and implemented in the MVITA code. In the present study, natural convection heat transfer is accounted for by only the Effective Convectivity Model (ECM). The heat transport and interactions are represented through an energy-conservation formulation. The ECM then enables simulations of heat transfer of a high Rayleigh melt pool in 3D large dimension geometry. In order to describe the phase-change heat transfer associated with core debris, a temperature-based enthalpy formulation is employed in the ECM (the phase-change ECM or so called the PECM). The PECM is capable to represent possible convection heat transfer in a mushy zone. The simple approach of the PECM method allows implementing different models of the fluid velocity in a mushy zone for a non-eutectic mixture. The developed models are validated by a dual approach, i.e., against the existing experimental data and the CFD simulation results. The ECM and PECM methods are applied to predict thermal loads to the vessel wall and Control Rod Guide Tubes (CRGTs) during core debris heat up and melting in the BWR lower plenum. Applying the ECM and PECM to simulations of reactor-scale melt pool heat transfer, the results of the ECM and PECM calculations show an apparent effectiveness of the developed methods that enables simulations of long term accident transients. It is also found that during severe accident progression, the cooling by water flowing inside the CRGTs plays a very important role in reducing the thermal load on the reactor vessel wall. The results of the CFD, ECM and PECM simulations suggest a potential of the CRGT cooling as an effective mitigative measure during a severe accident progression. / QC 20101119

Microstructure and micro-mechanical characterization of as-built and heat-treated samples of Hastelloy X produced by laser powder bed fusion (LPBF) process has been carried out in this study. As-built LPBF blocks were solution heat-treated at 1177°C and 1220°C followed by fast cooling. The microstructure of as-built and heat-treated samples were studied by light optical microscopy, scanning electron microscopy, and electron backscatter diffraction. Instrumented indentation micro Vickers testing was performed to obtain microhardness and elastic modulus of asbuilt and heat-treated samples. Microtensile samples from as-built and heat-treated blocks were prepared and polished for mechanical characterization. Microtensile testing inside the scanning electron microscope was performed to evaluate the mechanical properties and to get information about the microstructural changes during plastic deformation. Microstructure characterization revealed disrupted epitaxial grain growth for the as-built samples whereas the two heated-treated Hastelloy X samples exhibited equiaxed grains with varying twin fractions. As-built Hastelloy X samples exhibited higher mean hardness than heat-treated samples. The yield strength of as-built samples reveals higher values as compared to conventional wrought Hastelloy X samples, whereas lower yield strength and higher elongation were observed for heat-treated samples as compared to as-built samples. Higher elongation and lower yield strength values were observed for the samples solution heat-treated at 1220°C compared to the solution heat-treated at 1177°C. Microstructural evaluation at different plastic strains during in-situ microtensile testing reveals a clear difference in dislocation density for as-built and heat-treated samples.

Additive Manufacturing (AM) is an innovative manufacturing process which offers near-net shape fabrication of complex components, directly from CAD models, without dies or substantial machining, resulting in a reduction in lead-time, waste, and cost. For example, the buy-to-fly ratio for a titanium component machined from forged billet is typically 10-20:1 compared to 5-7:1 when manufactured by AM. However, the production rates for most AM processes are relatively slow and AM is consequently largely of interest to the aerospace, automotive and biomedical industries. In addition, the solidification conditions in AM with the Ti alloy commonly lead to undesirable coarse columnar primary β grain structures in components. The present research is focused on developing a fundamental understanding of the influence of the processing conditions on microstructure and texture evolution and their resulting effect on the mechanical properties during additive manufacturing with a Ti6Al4V alloy, using three different techniques, namely; 1) Selective laser melting (SLM) process, 2) Electron beam selective melting (EBSM) process and, 3) Wire arc additive manufacturing (WAAM) process. The most important finding in this work was that all the AM processes produced columnar β-grain structures which grow by epitaxial re-growth up through each melted layer. By thermal modelling using TS4D (Thermal Simulation in 4 Dimensions), it has been shown that the melt pool size increased and the cooling rate decreased from SLM to EBSM and to the WAAM process. The prior β grain size also increased with melt pool size from a finer size in the SLM to a moderate size in EBSM and to huge grains in WAAM that can be seen by eye. However, despite the large difference in power density between the processes, they all had similar G/R (thermal gradient/growth rate) ratios, which were predicted to lie in the columnar growth region in the solidification diagram. The EBSM process showed a pronounced local heterogeneity in the microstructure in local transition areas, when there was a change in geometry; for e.g. change in wall thickness, thin to thick capping section, cross-over’s, V-transitions, etc. By reconstruction of the high temperature β microstructure, it has been shown that all the AM platforms showed primary columnar β grains with a <001>β.