ICMEN 2022_Sudjadi

International Conference on Materials Eng and Nanotechnology 2022

Cladding Materials for Research Nuclear Reactors with Al-Alloy

Usman Sudjadia, Tegoh Apriyonob
a
Research Center for Nuclear Fuel and Radioactive Waste Recycling Technology, National Research and Innovation Agency ( BRIN)
PUSPIPTEK area Building 20, Serpong, Indonesia.
b
Department of Mechanical Engineering, Faculty of Engineering, Mercu Buana University, Meruya, Jakarta, Indonesia
c
Directorate of Research, Technology, and Innovation for Policy Formulation, National Research and Innovation Agency (BRIN), Jakarta,
Indonesia

Abstract

Structural or cladding materials used for nuclear fuel elements require special requirements such as good mechanical properties,
radiation resistance, corrosion resistance, adequate physical and chemical properties, and low thermal neutron absorption.
Materials that are widely used as structural materials for nuclear reactors are beryllium, magnesium, aluminum, zirconium and
their alloys. AI-alloy as alternative research reactor fuel cladding material. This study will be developed. Al- alloy
(93%Al+1%Mg+1%Fe and 1%Ni) was chosen as an alternative cladding material because it has good mechanical property. The
mixture of 97% Al+1% Mg+ 1% Ni+ 1% Fe is melted using a smelting furnace at a temperature of about 700 oC - 800oC, for 30-
60 minutes. First, the Al-Alloy sample was tested without heating and then given heat treatment (tempering) starting from 100 oC,
200 oC, 300 oC, 400 oC and 500 oC and allowed to stand for 1 hour, then the hardness test (rockwell tools) was carried out impact
testing (Charpy tools), and microstructure obseration (SEM tools). The results of testing the mechanical properties and are used
as references and considerations in the development of cladding materials for research nuclear reactors.

Keywords: Al-Alloy (93%Al+1%Mg+1%Fe and 1%Ni), fuel cladding, hardness value, microstructure, Research
Reactor.

1. Introduction

Fuel Cladding serves as a container and protector between the fuel and the environment, but neutrons can
still conduct nuclear reactions with the fuel. The selection of material for the fuel casing is based on the type of
reactor, the fuel and its operating temperature. Aluminum alloys are quite good for use as fuel cladding materials
considering the properties of aluminum which are suitable for research reactor fuel cladding materials that operate at
low temperatures. The properties of aluminum suitable for fuel cladding materials include: low neutron absorption
cross section, stable to irradiation, stable at high temperatures, high heat conductivity, corrosion resistance, easy to
fabricate, and easy to obtain [1]. Structural or cladding materials used for nuclear fuel elements require special
requirements such as good mechanical properties, radiation resistance, corrosion resistance, adequate physical and
chemical properties, and low thermal neutron absorption. Materials that are widely used as structural materials for
nuclear reactors are beryllium, magnesium, aluminum, zirconium and their alloys [2]. Nuclear fuel element cladding
serves to confine the release of fission products to the primary coolant arising from the nuclear reaction of the
uranium-based fuel used. In research reactors, aluminum alloys are used as structural materials and supporting fuel
elements. Nuclear fuel cladding materials for research reactors usually use Al-Alloy materials. Al-Alloy material is
used for low density nuclear fuel cladding.
Al-Alloy is used for cladding of nuclear fuel type U3Si2-Al with a density of 2.96 g U/cm 3 [3] Several
studies reveal that Al-Alloy material cannot be used for U3Si2-Al nuclear fuel cladding whose density is higher than
5.2 g U/cm3, the volume of the fuel element core will increase so that it affects the change in Al-Alloy cladding
thickness. This is not in accordance with the conditions of the research reactor fuel element plate fabrication because
the required thickness of the fuel cladding is a minimum of 0.25 mm and a maximum of 0.36 mm [3,4]. Al-Alloy
material is an alternative that can be used as a nuclear fuel cladding which has a high density. [ 5] Several studies
have proven that Al-Alloy has better thermal stability and thermal conductivity. In this study, we will discuss the
development of research nuclear reactor cladding materials with Al-Alloy (93%Al+1%Mg+1%Fe and 1%Ni) [3,4
6,10,11]. This can be seen from the characteristics of the Al-Alloy of samples material on the hardness of the
material, and impact ability. In this study, we will discuss the development of cladding materials for research nuclear
reactors with Al-Alloy (93% Al+1% Mg+1% Fe and 1% Ni) [3,4, 6,10,11]. This can be seen from the characteristics
of this material on the Rockwell hardness of the materia, and impact ability properties.

2. Literature Review

2.1. Research Nuclear Cladding

The fuel cladding functions as a container and a shield between the fuel and the environment, but the
neutrons can still carry out nuclear reactions with the fuel. Material selection for fuel cladding is based on reactor
type, fuel and operating temperature. Aluminum alloys are quite good for use as fuel cladding materials considering
the properties of aluminum which are suitable for research reactor fuel cladding materials that operate at low
temperatures. Nuclear fuel element cladding serves to confine the release of fission products to the primary coolant
arising from the nuclear reaction of the uranium-based fuel used. In research reactors, aluminum alloys are used as
structural materials and supporting fuel elements. The position of the fuel is in the reactor core at a certain depth
from the pool containing cooling water. This material is used because of its qualified properties such as low neutron
absorption, high corrosion resistance, easy to form, and adequate mechanical strength [2].

2.2. Nuclear Fuel Cladding/Cladding Material

The choice of materials for the nuclear reactor industry must pay attention to the properties of the materials
that are expected to best support its function in the nuclear reactor system itself. The selection of materials must take
into account certain conventional engineering properties according to their intended use, such as mechanical
strength, plasticity, ductility, structural integrity, fabricability, machinability, corrosion resistance, heat conductivity,
thermal stability, material compatibility, and of course availability in the industry. market and price.
a. General properties of cladding materials for nuclear reactors
The general properties of materials for nuclear reactors that must be considered in their selection
basically include properties commonly required for other industrial materials as shown in Table 1[7].

Table 1. General properties of cladding materials for nuclear reactors

Mechanical strength Heat transfer properties

Mechanical tenacity Thermal stability

Structural integrity Compatibility

Can be fabricated, can be molded Availability in market

by machine

Corrosion resistance Price

b. Special Properties of Materials for Nuclear Reactor

The Special properties are required for materials used in the nuclear reactor industry. The properties of
the materials used for reactor components may change when exposed to high doses of radiation. The special
properties of materials for nuclear reactor materials can be seen in Table 2[9].

Table 2. Special Properties of Materials For Nuclear Reactor

Neutronic properties Chemical interaction
Induced radioactivity Particle Interdiffusion
Irradiation stability Ease of reprocessing
2.3. Research Nuclear Reactor

A nuclear reactor is a device to control the fission chain reaction and at the same time maintain the
continuity of the reaction. A nuclear reactor is defined as "a device that uses nuclear material as its fuel". Fission
material used as fuel for example uranium, plutonium and others. Natural uranium or enriched uranium is used for
uranium. So in general a nuclear reactor is a place where a controlled nuclear reaction takes place.[8] A research
reactor is a nuclear reactor used for research, development, education and training. They produce neutrons for use in
industry, medicine, agriculture, forensics and more.[8]

2.4. Alumunium

Aluminum is a chemical element in the third periodic table that has the symbol Al and atomic number 13.
Aluminum is a metal that has a relatively low strength and is malleable. Aluminum is a light metal and has good
corrosion resistance, good electrical conductivity and other properties. Generally, aluminum is mixed with other
metals to form aluminum alloys. This material is used not only for household appliances, but also for industrial,
construction, and other purposes.
Pure aluminum is very soft and not strong, but it can be mixed with copper, magnesium, silicon,
manganese, and other elements to form beneficial properties. Aluminum has several properties that make it widely
used as an engineering material, including good electricity and heat conductors (conductors), easy fabrication
process, light weight, corrosion resistance and non-toxicity and low strength, but can be overcome with alloys from
aluminum to improve its mechanical properties.

2.5. Magnesium

Magnesium is a chemical element in the periodic table that has the symbol Mg and atomic number 12.
Magnesium (symbol Mg) is an alkaline earth metal with an oxidation number of +2. Magnesium ion has a high
solubility in water, magnesium is the third most abundant element dissolved in seawater. The free element
magnesium (metal) is not found naturally on earth, due to its highly reactive nature (although it can be produced,
magnesium is soon coated by a thin layer of its oxide, which partially protects its reactivity). Currently, magnesium
can be obtained by electrolysis of magnesium salts obtained from brine. On the other side, the primary use of this
metal as an alloy is to make aluminum-magnesium alloys, sometimes called "magnalium" or "magnelium". Because
the density of magnesium is less than that of aluminum, these alloys are valued according to their relative weight
and strength [6]. In this study will be developed Al-Alloy (93%Al+1%Mg+1%Fe and 1%Ni) [3,4 6,10,11] material
is an alternative that can be used as a nuclear fuel cladding which has a high density.[5] Several researchers have
proven that Al-Alloy (93%Al+1%Mg+1%Fe and 1%Ni) has better thermal stability and thermal conductivity [3,4
6,10,11].

3. Methodology

The mixture of 97% Al+1% Mg+ 1% Ni+ 1% Fe is melted using a smelting furnace at a temperature of
about 7000 C - 8000 C, for 30-60 minutes. Samples the smelted material was then tempered at 1000 C, 2000 C,
3000 C, 4000C and 5000 C, each for 1 hour. Then samples are tested for Rockwell hardness, Impact test (Charpy
tools ). And microstructure observation (SEM toos). The results of the smelting can be seen in Figure 1.
 Figure 1 smelted material of Al-Alloy (97% Al+1% Mg+ 1% Ni+1%Fe)

4. Result and Discussion

4.1. Rockwell Hardness Test Result of Samples

The following is the data from the measurement and testing of Rockwell hardness. The scale used is type C
with a mass of 150 kg, emphasis using a diamond cone with an angle of 1200, Superficial (E) = 100, permanent
penetration (e) = h/0.002.
HRc=E – e
E = Constanta with a value of 100 for the diamond indentor.
e = Permanent penetration depth due to main load, e=h /0,002 mm or h=e x 0,002 mm

Table 3. Rockwell hardness test results data

Rockwell Rockwell Rockwell Total

Average
Test Results1 Test Results1 Test Results1 hardness
Process Temperature hardness
(Load 150 (Load 150 (Load 150 test results
(HRc)
kg) kg) kg) (HRc)

without -
Temperin 17 16 17 50 16.67
g
Temperin 1000 C
17 16 16 49 16.33
g
0
Temperin 200 C
15 15 15 45 15
g
Temperin 3000 C
14 14 15 43 14.33
g
0
Temperin 400 C
14 15 14 43 14.33
g
0
Temperin 500 C
13 14 14 41 13.67
g
From the results of the Rockwell hardness test, data are obtained as in table 3. where each specimen was tested 3
times.
 Specimen 1 (non heat treatment) resulted from the Rockwell hardness test in the first experiment which
was 17 HRc, the second experiment was 16 HRc, and the third experiment was 17 HRc with an average
of 16.67 HRc.
 Specimen 2 (heat treatment 1000 C) the results of the first Rockwell hardness test were 17 HRc, the
second experiment was 16 HRc, and the third experiment was 16 HRc with an average of 16.33 HRc.
 Specimen 3 (heat treatment 2000 C) The results of the first Rockwell hardness test were 15 HRc, the
second experiment 15 HRc, the third experiment 15 HRc with an average of 15 HRc.
 Specimen 4 (heat treatment 3000 C) the results of the first Rockwell hardness test were 14 HRc, the
second experiment 14 HRc, the third experiment 15 HRc with an average of 14.33 HRc.
 Specimen 5 (heat treatment 4000 C) the results of the first Rockwell hardness test were 14 HRc, the
second experiment 15 HRc, the third experiment 14 HRc with an average of 14.33 HRc.
 Specimen 6 (heat treatment 5000 C) the results of the first Rockwell hardness test were 13 HRc, the
second experiment was 14 HRc, the third experiment was 14 HRc with an average of 13.67 HRc.

From Table 3 the results of the Rockwell hardness test are then entered into the graph as follows:
 45

40

35

hardness value (HRc)

30

25

20
17 16
15 14 14
15 13

10

0
0 100 200 300 400 500

Tempering 0 C

Figure 2. Graph Rockwell Test Results

The results of the Rockwell hardness test show the average hardness value for specimen 1 (non heat
treatment) with specimens 2, 3, 4, 5 and 6 (heat treatment 100 oC, 200 oC, 300oC, 400 oC dan 500 oC) decreased
hardness value. Specimen 1 (non-treated) against specimens 2, 3, 4, 5 and 6 (heat treatment 100 oC, 200 oC, 300 oC,
400 oC dan 500 oC) the hardness value decreased from 17 HRc to 16 HRc, 15 HRc, 14 HRc, 14 HRc, and 13 HRc
(see figure 2).

All tables should be numbered with Arabic numerals. Every table should have a caption. Headings should be
placed above tables, left justified. Only horizontal lines should be used within a table, to distinguish the column
headings from the body of the table, and immediately above and below the table. Tables must be embedded into the
text and not supplied separately. Below is an example which the authors may find useful.

Table 1. An example of a table.

An example of a column heading Column A (t) Column B (t)
And an entry 1 2
And another entry 3 4
And another entry 5 6

4.2. Data Impact Test Results Al-Alloy samples

Specifications, Pendulum mass 12.3 kg, Earth's gravity 9,8 m/s2, Pendulum arm length 0.75 m = 750 mm

Figure 3. Impact loading sketch

Table 4. Test Result Data for Impact Charpy Tool

Sample tempering time 1 Starting angle Final Angle Pendulum Weight Swing arm distance
hour α ß (m, kg) (L, m)

80o 7o 12,3 kg 0,75 m

o o
80 5 12,3 kg 0,75 m
Without Tempering 80o
6o
12,3 kg 0,75 m
Σm = 36,9/3 = 12,3
Σα = 240°/3 = 80° Σβ = 18°/3 = 6° ΣL = 2,25/3 = 0,75m
kg
80o 6o 12,3 kg 0,75 m

80o 4o 12,3 kg 0,75 m

sample With Tempering
0 80o
6o
12,3 kg 0,75 m
100 C
Σm = 36,9/3 = 12,3
Σα = 240°/3 = 80° Σβ = 16°/3 = 5,3° ΣL = 2,25/3 = 0,75m
kg
o o
80 7 12,3 kg 0,75 m
o o
80 6 12,3 kg 0,75 m
sample With tempering
0 80o
6o
12,3 kg 0,75 m
200 C
Σm = 36,9/3 = 12,3
Σα = 240°/3 = 80° Σβ = 19°/3 = 6,3° ΣL = 2,25/3 = 0,75m
kg
80o 8o 12,3 kg 0,75 m
80o 8o 12,3 kg 0,75 m
sample With tempering 80o 7o 12,3 kg 0,75 m
0
300 C
Σm = 36,9/3 = 12,3
Σα = 240°/3 = 80° Σβ = 23°/3 = 7,6° ΣL = 2,25/3 = 0,75m
kg
80o 7o 12,3 kg 0,75 m
80o 8o 12,3 kg 0,75 m
sample With tempering 80o 7o 12,3 kg 0,75 m
0
400 C
Σα = 240°/3 = 80° Σβ = 22°/3 = 7,3°
Σm = 36,9/3 = 12,3
ΣL = 2,25/3 = 0,75m
kg
o o
80 9 12,3 kg 0,75 m
80o 9o 12,3 kg 0,75 m
sample With tempering 80o 8o 12,3 kg 0,75 m
0
500 C
Σα = 240°/3 = 80° Σβ = 26°/3 = 8,6°
Σm = 36,9/3 = 12,3
ΣL = 2,25/3 = 0,75m
kg

a. Impact of Potential Energy

E P=m . g . L(1−cos α )
Ep : Potential Energy (joule)
m : Pendulum weight 12,3 (kg)
L : Swing arm distance 0,75 (m)
G : Earth Gravity 9,8 (m/s2)
cos α : Starting angle (o)
cos β : Final angle (o)
Impact potential energy on each heat treatment :
E P=m . g . L ¿
2 0
E P=12 , 3 kg .9 , 8 m/s .0 , 75 m(1−cos ⁡80 )
E P=90 , 40(1−0,1736)
E P=90 , 40(0,8264)
E P=74 ,71 Joule

b. Absorbed energy
W =m. g . L ¿
Absorbed energy (W) on impact Al2Mg3 Without Tempering:
2
W =12 ,3 kg .9 , 8 m/s .0 , 75 m ¿
 W =74 , 22 Joule
c. Impact Energy
W
EI =
A

EI : Impact Energy (Kg m/mm 2) = Joule/mm2

W : Absorbed energy (Joule)
A : Cross-sectional area under the notches 90 (mm2)
Energy impact Al2Mg3 Without Tampering :

74.22 joule
EI =
90 mm
EI = 0,823 joule⁄mm

Table 5 Results of Average Potential Energy, Absorbed Energy and Impact Energy
Potential energy Absorbed energy Impact energy
Sample tempering time 1 hour
(Joule) (Joule) (joule)

Sample Without Tempering 74,71 74,22 0,823

Sample tempering
0 74,71 74,32 0,826
100 C
Sample tempering
0 74,71 74,16 0,824
200 C
Sample tempering
0 74,71 73,91 0,821
300 C
Sample tempering
0 74,71 73,97 0,822
400 C
Sample tempering
0 74,71 73,69 0,820
500 C

From table 5, The average value of the impact potential energy, absorbed energy, and impact energy on
samples material in conditions without tempering and with tempering (100 oC, 200 oC, 300 oC, 400 oC dan 500oC) and
then it is made in a graph like below:

90
80 74.71 74.71 74.71 74.71 74.71 75
Impact potential energy

70
60
50
(joule)

40
30
20
10
0
0 100 200 300 400 500
Temperatur oC

Figure 4. Comparison Graph of Impact Potential Energy (Ep) with Temperature

From Table 5 and figure graph 4, the Impact test results show the average Potential Energy value for
specimen 1 (without tempering) with specimens 2, 3, 4, 5 and 6 (tempering 100 oC, 200 oC, 300 oC, 400 oC dan 500
o
C) have the same value. For specimen 1 (non-treated) for specimens 2, 3, 4, 5 and 6 (tempering 100 oC, 200 oC, 300
o
C, 400 oC and 500 oC) the value is 74,71 Joule.

90
80 74.22 74.32 74.16 73.91 73.97 73.69
70
Absorbed energy (joule)
60
50
40
30
20
10
0
0 100 200 300 400 500
Temperatur oC

Figure 5. Comparison Graph of Absorbed Energy (W) with Temperature on Impact Test

From Table 5 and figure graph 5, For the average value of energy absorbed, specimen 1 (without
tempering) is 74.22 joules, specimen 2 (tempering 1000 C) is 74.32 joules, specimen 3 (tempering 2000 C)
is 74.16 joules, specimen 4 (tempering 3000 C) is 73.91, specimen 5 (tempering 4000 C) is 73.97 joules,
specimen 6 (tempering 5000 C) is 73.69 joules.
1.0

0.9 0.823 0.826 0.824 0.820

0.821 0.822
0.8
Impact Energy (joule/mm2)

0.7

0.6

0.5

0.4

0.3

0.2

0.1

0.0
0 100 200 300 400 500

Temperatur oC

Figure 6. Comparison Graph of Impact Energy (EI) with Temperature

From Table 5 and Figure 6, The data from the Impact test results show the average Impact Energy value
for specimen 1 (without tempering) with specimen 2 (tempering 1000 C) experienced an increase in
Impact energy, which is 0.823 joules and 0.826 joules, for specimens 2 (tempering 1000 C) against
specimen 3,4 (tempering 2000 C and 3000 C) experienced a decrease in the value of Impact energy, which
is 0.824 joules and 0.821 joules, for specimen 4 to specimen 5 (tempering 3000 C and 4000 C) again
experienced an increase in the impact energy value of 0.822 joules, and a decrease in the value again
occurred in the specimen 6 (tempering 5000 C) which is 0.820 joules.
4.3. Microscope Observation Data for Al-Alloy (97% Al+ 1%Fe+ 1%Ni+1% Mg) Material. Microscope (SEM
tools) with a magnification of 500x or 50 µm.

In microstructure testing, the sample is alternately tested and measured by placing the test object
on a table located on the machine, after which the metal structure of the test material can be seen directly
on the monitor screen. Magnification was carried out 500x using a Leco microscope.

Figure 7. Al-Alloy (97% Al+ 1%Fe+ 1%Ni+1% Mg) without tempering with
Magnification 500x or 50 µm

Figure 8. Forms of Al-Alloy (97% Al+ 1%Fe+ 1%Ni+1% Mg) Tempering 300 0C
Magnification 500x or 50 µm

Al atoms dominant

Fe, Mg, Ni Atoms

Dominant

Figure 9. Form of Al-Alloy (97% Al+ 1%Fe+ 1%Ni+1% Mg) Tempering 400 0C
Magnification 500x or 50 µm
 Fe, Mg, Ni Atoms
Dominant

Al atoms dominant

Figure 10. Forms of Al-Alloy (97% Al+ 1%Fe+ 1%Ni+1% Mg) Tempering 500 0C
Magnification 500x or 50 µm

In microstructure testing, the Al-Alloy (97% Al+ 1%Fe+ 1%Ni+1% Mg) sample that was not
tempered had the same structural form as the Al-Alloy (97% Al+ 1%Fe+ 1%Ni+1% Mg) sample with
tempered 100 0C and 200 0C there was no change in the microstructure, the new Al-Alloy (97% Al+
1%Fe+ 1%Ni+1% Mg) material will experience a minimal structural change at a temperature of 300 0C.
From the test results, it can be seen that the shape of the microstructure of Al-Alloy (97% Al+ 1%Fe+
1%Ni+1% Mg) has just changed the shape of the structure after being tempered at temperatures of 300
0C, 400 0C and 500 0C (see figures 7-10). In the pictures above, it can be explained that the
microstructure of the Al-Alloy (97% Al+ 1%Fe+ 1%Ni+1% Mg) test sample without tempering the
structure is large and rough as if separated from each other, and when given a tempering (see figures 7-
10).

5. Conclusion

From the results of the research conducted, the following conclusions is:
 From the results of the Rockwell hardness test, where each specimen was tested 3 times. The average
hardness result is obtained Specimen 1 (non heat treatment) with an average of 16.67 HRc, Specimen 2
(heat treatment 100 OC) with an average of 16.33 HRc, Specimen 3 (heat treatment 200 OC) with an average
of 15 HRc, Specimen 4 (heat treatment 300 OC) with an average of 14.33 HRc, Specimen 5 (heat treatment
4000 C) with an average of 14.33 HRc, Specimen 6 (heat treatment 500 OC) with an average of 13.67 HRc.
 The Impact test results show the average Potential Energy value for specimen 1 (without tempering) with
specimens 2, 3, 4, 5 and 6 (tempering 1000 C, 200 OC, 300 OC, 400 OC dan 500 OC ) have the same value.
For specimen 1 (non-treated) for specimens 2, 3, 4, 5 and 6 (tempering 100 OC, 200 OC, 300 OC, 400 OC dan
500 OC) is 74,71 Joule.
 The average value of energy absorbed on The Impact test results, specimen 1 (without tempering) is 74.22
joules, specimen 2 (tempering 100 OC) is 74.32 joules, specimen 3 (tempering 200 OC) is 74.16 joules,
specimen 4 (tempering 300 OC) is 73.91, specimen 5 (tempering 400 OC) is 73.97 joules, specimen 6
(tempering 500 OC) is 73.69 joules.
 The data from the Impact test results show the average Impact Energy value for specimen 1 (without
tempering) is 0.823 joules, specimen 2 (tempering 1000 C) is 0.826 joules, specimen 3 (tempering 2000 C)
is 0.824 joules, specimen 4 (tempering 3000 C) is 0.821 joules, specimen 5 (tempering 4000 C) is 0.822
joules, and specimen 6 (tempering 5000 C) which is 0.820 joules.
 In microstructure observation, the Al-Alloy (97% Al+ 1%Fe+ 1%Ni+1% Mg) sample that was not
tempered had the same structural form as the Al-Alloy (97% Al+ 1%Fe+ 1%Ni+1% Mg) sample with
tempered 100 OC and 200 OC there was no change in the microstructure, the new Al-Alloy (97% Al+
1%Fe+ 1%Ni+1% Mg) material will experience a minimal structural change at a temperature of 300 OC.
Acknowledgements

Acknowledgements and Reference heading should be left justified, bold, with the first letter capitalized but have
no numbers. Text below continues as normal.

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