The primary focus of the present work is to model the entire casting process from filling stage to complete solidification. The model takes into consideration any phase change taking place during the filling process. An implicit volume of fluid (VOF) based algorithm has been employed for simulating free surface flows during the filling process and the model for solidification is based on a fixed-grid enthalpy-based control volume approach. Solidification modelling is coupled with VOF through User Defined Functions (UDF) developed in commercial fluid dynamics (CFD) code FLUENT 6.3.26. The developed model is applied for the simultaneous filling and solidification of pure metals and binary alloy systems to study the effects of filling process on the solidification characteristics, evolution of mushy zone and the final macrosegregation pattern in the casting. The numerical results of the present analysis are compared with the conventional analysis assuming the initial conditions to be a completely filled mould cavity with uniform temperature, solute concentration and quiescent melt inside the cavity. The effects of process parameters, namely the degree of superheat, cooling temperature and filling velocity etc. are also investigated. Results show significant differences on the evolution of mushy zone and macrosegregation between the present analysis and the conventional analysis. The application of present model to simulate three dimensional sand casting is also demonstrated. The three dimensional competetive effect of filling generated residual flow and the buoyancy-induced convective flow pattern cause significant difference in macrosegregation pattern in casting.

<p>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.</p><p>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.</p><p>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.</p><p>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.</p><p>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.</p><p>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.</p>

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>

La radiographie X synchrotron ou avec une source microfocus a été appliquée pour étudier différents phénomènes dépendants du temps en relation avec la solidification directionnelle d'alliages Al-Cu. Les effets de la gravité ont été étudiés par comparaison d'expériences sur Terre et en microgravité dans le cadre du projet ESA-MAP XRMON. Les mouvements des fragments sont le sujet majeur de notre étude. Sur Terre, le mouvement des fragments est imposé par la poussée d'Archimède, avec une forte influence des effets de paroi et de la morphologie du fragment, alors qu'en microgravité, la force motrice pour le mouvement des fragments est l'écoulement du fluide interdendritique induit par la contraction du solide. L'effet d'un champ magnétique permanent sur la solidification des grains équiaxes dans un gradient de température a été également étudié. Nous avons montré qu'un couplage entre le gradient de température et le champ magnétique donne naissance à une force Thermo-électromagnétique qui agit sur les grains solides. Une bonne description a été obtenue en utilisant un modèle analytique pour une particule sphérique. Enfin, nous avons étudié l'évolution d'une zone pâteuse dans un gradient de température fixe. Trois régimes successifs ont été identifiés, suivant l'intensité de la diffusion du soluté dans la zone pâteuse et dans le bain fondu. L'analyse quantitative des radiographies par traitement d'image a clarifié le rôle de chaque phénomène de diffusion (TGZM, fermeture des canaux, murissement et diffusion du soluté dans le bain fondu). / X-ray radiography with synchrotron and microfocus sources was applied to investigate various time-dependent phenomena related to directional solidification of Al-Cu alloys. Gravity effects were investigated by a comparative study of ground and microgravity experiments in the framework of ESA-MAP XRMON project. Fragment motion was the major subject of our investigation. On Earth, fragmentation motion was imposed by buoyancy, with a strong dependency on wall influence and fragment morphology, whereas in microgravity conditions, the driving force for fragment motion is the interdendritic fluid flow induced by the solid shrinkage. The effect of a permanent magnetic field on the solidification of equiaxed grains in a temperature gradient was also studied. We have shown that a coupling between the temperature gradient and the magnetic field gives birth to a Thermo-Electro-Magnetic force that acts on the solid grains. A good description was obtained by using an analytical model for a spherical particle. Finally we studied the evolution of the mushy zone in a fixed temperature gradient. Three successive regimes were identified, depending on the relative magnitude of solute diffusion in the mushy zone and in the bulk liquid. Quantitative analysis of radiographs by image processing enlightened the role of each diffusion phenomena (TGZM, channel closure, coarsening and solute diffusion in the bulk liquid).

Heat transfer and solidification models were developed for use in a numerical model of a continuous caster to provide a means of predicting how the developing shell would react under variable operating conditions. Measurement data of the operating conditions leading up to a breakout occurrence were provided by an industrial collaborator and were used to define the model boundary conditions. Steady-state and transient simulations were conducted, using boundary conditions defined from time-averaged measurement data. The predicted shell profiles demonstrated good agreement with thickness measurements of a breakout shell segment – recovered from the quarter-width location. Further examination of the results with measurement data suggests pseudo-steady assumption may be inadequate for modeling shell and flow field transition period following sudden changes in casting speed. An adaptive mesh refinement procedure was established to increase refinement in areas of predicted shell growth and to remove excess refinement from regions containing only liquid. A control algorithm was developed and employed to automate the refinement procedure in a proof-of-concept simulation. The use of adaptive mesh refinement was found to decrease the total simulation time by approximately 11% from the control simulation – using a static mesh.

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