Outlook on Gen IV Nuclear Systems

and related Materials R&D Challenges

- Goals for innovative reactor systems
- Requirements for structural materials: generic and specific
- Synergies, crosscutting R&D areas and modelling
- Significance of international collaboration

Frank Carré and Pascal Yvon

CEA – Nuclear Energy Division
franck.carre@cea.fr
Materials for Generation IV Nuclear Reactors 1
Nuclear Energy Division Cargese, Sept. 24 – Oct. 6, 2007
Sustainable Nuclear Energy Technology Platform (SNE-TP)
Interactions between NFTP &
other TPs
SNE-TP , initiatives,
Objectives etc
& Organization

Nuclear Fission Technology Platform: SRA and Platform

Operation
LWR Innovative Materials V/HTR
Safety & and Fuels Process Heat,
Economics Electricity & H2
Simulations and Experiments:
Reactor Design, Safety, Materials
and Fuels

Strategic Research Agenda;

Platform Operation

Training and
Technical
TSO: R&D Infrastructures
Safety
Mirror Group
Organisations Geological Disposal
Fast Systems Technologies,
With Closed design, safety
Fuel Cycles
Sustainability
assessment

EU High Level Waste

Group on Nuclear Management
Safety & Security (CARD)

Kick-off meeting : September 21, 2007

Materials for Generation IV Nuclear Reactors 2
Nuclear Energy Division Cargese, Sept. 24 – Oct. 6, 2007
 Generation IV Nuclear Systems

New goals for sustainable nuclear energy

Break-throughs:
Continuous progress: Natural resources conservation
 Economically competitive Waste minimisation
 Safe and reliable Proliferation resistance

Systems marketable from 2040

onwards China Russia

France
A closed fuel cycle United
Kingdom
Canada
Members
True potential for new USA
of the Generation
IV International
EU

Applications: Hydrogen, Forum

Syn-fuel, Desalinated water, Brazil
Switzerland

Process heat
Japan
Argentina
Internationally shared R&D South Africa South Korea

Materials for Generation IV Nuclear Reactors 3

Nuclear Energy Division Cargese, Sept. 24 – Oct. 6, 2007
 Generation IV Forum: selection of six nuclear systems

Lead Fast Reactor

Sodium Fast Reactor
Gas Fast Reactor

Supercritical Water-cooled Reactor

Very High Temperature Reactor

(12-20y) R&D (~1 B€) before a 1st prototype or techno demo Molten Salt Reactor

Materials for Generation IV Nuclear Reactors 4

Nuclear Energy Division Cargese, Sept. 24 – Oct. 6, 2007
Fast Reactors & recycling for Sustainable Nuclear Power
Strategies for a flexible management of actinides
in Gen IV fast neutron systems.
 Natural resources conservation
 Waste minimisation
 Proliferation resistance (intl standards)
 Type of nuclear materials
 Detection, technical difficulty, cost, time…
Udep Udep Udep

R T FP MA R T FP R T FP
MA
U Pu U Pu U Pu MA
U & Pu Heterogeneous Homogeneous
Recycling Recycling Recycling

 Implementation depending on international standards

and national optimization criteria (economics & waste).
Materials for Generation IV Nuclear Reactors 5
Nuclear Energy Division Cargese, Sept. 24 – Oct. 6, 2007
Requirements for materials in future nuclear systems (1/2)
Technical challenges
& Leading physical phenomena
 60-year lifetime
 Fast neutron damage (fuel and core materials)
 Effect of irradiation on microstructure, phase instability, precipitation
 Swelling growth, hardening, embrittlement
 Effect on tensile properties (yield strength, UTS, elongation…)
 Irradiation creep and creep rupture properties
 Hydrogen and helium embrittlement

 High temperature resistance (SFR > 550°C, V/HTR > 850-950°C)

 Effect on tensile properties (yield strength, UTS, elongation…)
 High temperature embrittlement
 Effect on creep rupture properties
 Creep fatigue interaction
 Fracture toughness

 Corrosion resistance (primary coolant, power conversion, H2 production)

 Corrosion and stress-corrosion cracking (IGSCC, IASCC, hydrogen
cracking & chemical compatibility…)
Materials for Generation IV Nuclear Reactors 6
Nuclear Energy Division Cargese, Sept. 24 – Oct. 6, 2007
Requirements for materials in future nuclear systems (2/2)
Additional requirements

 Material availability and cost

 Fabricability, joining technology

 In service inspection
 Non destructive examination techniques

 Safety approach and licensing

 Codes and design methods
 R&D effort needed to establish or complement
mechanical design rules and standards

 Decommissioning and waste management

Materials for Generation IV Nuclear Reactors 7

Nuclear Energy Division Cargese, Sept. 24 – Oct. 6, 2007
 Structural materials for Innovative Reactor Systems

SFR GFR LFR VHTR SCWR MSR Fusion

He, Pb-
Liquid Lead He, 70 Water Molten
Coolant He, 70 bars 80 b 17Li
Na few alloys bars 280-550 salt
T (°C) 480-850 300- 480-
bars 550-800 600-1000 24 MPa 500-720
480 700

Wrapper Core Cladding &

Fuel & Target, Core First wall
F/M Graphite core
core Window structure Blanket
Core steels structures
structures Cladding Control
Structures Graphite F/M steels
Cladding rods Ni based
SiCf-SiC F/M ODS
AFMA C/C Alloys & Hastelloy
composite steels SiCf-SiC
F/M ODS SiC/SiC F/M steels
ODS
Temp. °C 390-700 600-1200 350-480 600-1600 350-620 700-800 500-625
Cladding
Cladding ~100 dpa ~ 100 dpa
Dose 200 dpa
60/90 dpa 7/25 dpa + 10 ppmHe/dpa
ADS/Target + 45 ppmH/dpa
~100 dpa
IHX or IHX or
Other turbine turbine
components
Ni alloys Ni alloys

Materials for Generation IV Nuclear Reactors 8

Nuclear Energy Division Cargese, Sept. 24 – Oct. 6, 2007
 Sodium Fast Reactor (SFR)
 A new generation of sodium cooled
Fast Reactors
 Reduced investment cost
Simplified design, system innovations
(Pool/Loop design, ISIR – SC CO2 PCS)
 Towards more passive safety features
+ Better managt of severe accidents
 Integral recycling of actinides
Remote fabrication of TRU fuel

 2009: Feasibility – 2015: Performance  2020+ : Demo SFR (FR, US, JP…)
Ste a m Ge ne ra tor
He at　 Ex cha nger

2007 Control
Rod s
Turbine Ge nerator

+ Japan Ele ctrical

Pow er

France U.S.A.
SFR Steering Hot Plenum
Conden ser

Prima ry

Committee
Sodium
（ Hot）
Russia Core
Pump

Pum p Heat Sink

Pum p Se conda ry
Sodium
Primary
Sodium
（ Cold）
Cold Ple num

Euratom South Korea

China countries

Materials for Generation IV Nuclear Reactors 9

Nuclear Energy Division Cargese, Sept. 24 – Oct. 6, 2007
 New materials for sodium fast reactors (1/2)
SFR Primary system
 New 9-12%Cr F/M steel vs Advanced Austenitic
Good physical and thermal properties, dilatation, low cost
Better creep resistance (T91, T92 (Fe-9Cr-xW-V-N…))
Compactness, mass reduction of components
 DBTT but Improved toughness
 Weldability (%Cr dependent)
Good compatibility with sodium impurities (C, O, N)
(Demonstrated in Phénix 2ry system & Steam generator
+ 150 000 h Irradiation experiments of T91 & ODS (SuperNova))

Compact component and system designs (piping, IHX…)

Potential margin for temperature increase (< 600°C)

(especially if using a gas turbine power conversion system)

Allowable departure from the negligible creep regime?


Materials for Generation IV Nuclear Reactors 10
Nuclear Energy Division Cargese, Sept. 24 – Oct. 6, 2007
 Sodium Fast Reactor structural materials: F/M Steels

Great stability of fracture properties

9% Cr Martensitic steels
Dose: 70 - 110 dpa - Phenix irradiation

F17Cr SL
300 F17Cr ST
M12Cr (HT9) SL
M12Cr (HT9) ST
M9Cr (EM10) SL
M9Cr (EM10) ST
200
DBTT (°C)

17%Cr

100
12%Cr

9%Cr
0
Unirradiated

-100
400 450 500 550 600
IRRADIATION TEMPERATURE (°C)

J.L. Séran, A. Alamo, A. Maillard, H. Touron, J.C. Brachet, P. Dubuisson, O. Rabouille J. Nucl. Mater. 212-215 (1994) 588-593.

Materials for Generation IV Nuclear Reactors 11

Nuclear Energy Division Cargese, Sept. 24 – Oct. 6, 2007
 New materials for sodium fast reactors (2/2)
Advanced fuel cladding Ferritic-ODS by HIP

 316 Ti  15-15 Ti  F/M ODS

Reduced swelling with neutron fluence
EM10 & 15-15 Ti  100 dpa @ 400-700°C
T92/HC & ODS  200 dpa @ 480 – 750/800°C
Weldability & joining techniques
Good compatibility with sodium impurities (C, O, N)

Increased fuel burnup  200 GWd/t & 200 dpa

Increased safety with low sodium content in the core & low
sodium void effect  Better prevention of severe accidents

 Research in progress on hardening of F/M steels

with micro/nano structures (dispersion / precipitates)
2nd generation ODS
F/M steels with carbo/nitride precipitates
Materials for Generation IV Nuclear Reactors 12
Nuclear Energy Division Cargese, Sept. 24 – Oct. 6, 2007
 Sodium Fast Reactor cladding material
Swelling of advanced austenitic steels
Swelling of austeniticsteels
and ferrito-martensitic Phénix
(%) claddings
used ascompare to F/M
fuel cladding materials
in Phenix
10
Average Average 15/15Ti Best lot of 15/15Ti
9
316 Ti
8
7
6
5
4
Embrittlement limit
3
Ferritic-martensitic (F/M)
2 steels, ODS included
1
0
60 70 80 90 100 110 120 130 140 150 160 170 180 190 200
dose (dpa)

Materials for Generation IV Nuclear Reactors 13

Nuclear Energy Division Cargese, Sept. 24 – Oct. 6, 2007
 Safety enhancement of Fast Reactor core
Low reactivity sodium void effect high BU
core
Large diameter fuel pin with thin spacer wire
ODS cladding for low swelling
15
V/V(Experiments in Phenix (Supernova, Matrix1&2) + in Joyo)
COEX COCA
%
10
15-15 Ti bas C

5
15-15 Ti lot CE

16-25 Ti Nb V TS2
0 15-25 Ti Nb DS5

MOX fuel fabrica-

400 450 500 550
15-25 bas Ti
12-25 Ti N9 T °C
-5 MA 957 15-25 Ti Nb DS4 MA 956
tion from co-precipita-
ted UPu solution from
Various recycling modes of minor
the COEX process
actinides in Fast Reactors:  To be first tested in
 Homogeneous (~2% MA): GACID Phenix (Copix expt)
 Heterogeneous in blanket (10-20% MA):
Curios, Amboine2-Joyo expts

Materials for Generation IV Nuclear Reactors 14

Nuclear Energy Division Cargese, Sept. 24 – Oct. 6, 2007
 Generation IV Gas Fast Reactor (GFR)
 A novel type of Gas-cooled Fast Reactor:
 an alternative to the Sodium Fast Reactor, and
 a sustainable version of the VHTR
 Robust heat resisting fuel (<1600°C)
 1200 MWe – THe ~ 850 °C - Cogeneration of electricity, H2, synfuel, process heat
 Safe management of cooling accidents
 Potential for integral recycling of Actinides

 2012 : Feasibility  ~2020 : ETDR (EU ?)

2020: Performance  2030+: GFR Prototype

GCFR
5-6 EU
France Japan
PCRD
Euratom Switzerland
countries GFR Steering
Committee
System Arrangement GFR signed Nov. 30 Nov.,2006
Project Arrangements “Fuel “ &
“Design-Safety-Integration” in 2007 U.S.A.
Materials for Generation IV Nuclear Reactors 15
Nuclear Energy Division Cargese, Sept. 24 – Oct. 6, 2007
 Gas Fast Reactor fuel designs

High density
Advanced compartmented Cladded
particles platelet pellets

HTRs

0 25 50 75 100
%vol. of actinides compound in the volume dedicated to fuel

Materials for Generation IV Nuclear Reactors 16

Nuclear Energy Division Cargese, Sept. 24 – Oct. 6, 2007
 Candidate ceramics materials for the GFR fuel
Ceramics Composite
for Gas Fast Reactor CERMET
TiC (HIP)
 Multi-layer Matrix
materials & concept
in Phénix
Mixed
10 µm CER & MET
trans-granulaire
matrices

inter-granulaire
Fibre
strenthened
Interfaces
10 µm  Investigation and modelling of phenomena
 Manufacturing and testing monolithic and
Usual low toughness
of ceramics composite ceramics (C/C, SiC/SiC)
 Characterization and optimization
Objectives: Increase ceramics ductility and toughness
Materials for Generation IV Nuclear Reactors 17
Nuclear Energy Division Cargese, Sept. 24 – Oct. 6, 2007
 2D SiC/SiC by NITE Process for GFR Fuel Pin or Plate

Goal: 3m (length) x 10mm (inner diameter)

x 1mm (wall thickness)

Nite Process
Kyoto University

Fuel Pin

5.0mm
Fuel Plate

43
.0 mm
Wall thickness: 1.0mm

Materials for Generation IV Nuclear Reactors 18

Nuclear Energy Division Cargese, Sept. 24 – Oct. 6, 2007
A few specific R&D areas on ceramics for GFR fuels
Possible applications
MAX Phases as matrix or interphase
Nano-laminate
structureTi3SiC2 in SiC/SiCf composite…
Special properties
Ti, C, Si Damage tolerant
Low density, machinable
High thermal and
electrical conductivities

Methods used to obtain large-

scale bulk Ti3SiC2
CVD, Arc melting, HIP, HP, SHS
High energy ball milling & reactive
sintering to obtain bulk Ti3SiC2 with
very fine grain

Synthesis of TiC from nano-powder

HIP without grain growth
Stable under irradiation (electrons & ions)

Materials for Generation IV Nuclear Reactors 19

Nuclear Energy Division Cargese, Sept. 24 – Oct. 6, 2007
 Generation IV Very High Temperature Reactor (V/HTR)
 A nuclear system dedicated to the production of high temperature
process heat for the industry and hydrogen
 600 MWth - THe >1000 °C
Thermal neutrons
Block or pebble core concept
 Passive safety features
 I-S Cycle or HT Electrolysis for H2

 2009: Feasibility – 2015: Performance

~ 2020: PBMR, NGNP & Other Near Term Projects

U.S.A.
France Japan

VHTR Steering
Euratom Switzerland
Committee
2007
+
South Africa South Korea
China
Materials for Generation IV Nuclear Reactors 20
Nuclear Energy Division Cargese, Sept. 24 – Oct. 6, 2007
9Cr1Mo alloy for pressure vessel of gas cooled reactors

VHTR vs PWR pressure vessel

manufacturing techniques

 Normal/off-normal service
temperatures and vessel size
dominate materials requirements VHTR
Vessel
 Up to <450/550°C at 5-9 MPa
 Up to 1 x 1019 n/cm2 fluence

 Very large vessel sizes require scale- PWR

up of ring forging & on-site joining Vessel
technologies

 Irradiation resistance to be
demonstrated for licensing

Materials for Generation IV Nuclear Reactors 21

Nuclear Energy Division Cargese, Sept. 24 – Oct. 6, 2007
 VHTR core material: Graphite & Composites
 Graphite (PCEA (UCAR), NBG 17 (SGL)…)
 Characterization: chemical, structural, thermal & mechanical
properties (20-1000°C), corrosion tests (air; water, O2, CO2…)
 Irradiation tests (T ~1050°C, 1-6 dpa G)
 Optimization for waste minimization (14C)
 Technical file for codification of design standards

 C/C & SiCf/SiC composites

 Manufacturing: 2D & 3D woven
fibres (C, Hi-Nicalon S), interphases, CVI
or pitch densification, anti-oxidation
coating (Si, B)…)
 Characterization: chemical,
structural, thermal & mechanical

500 mm
properties (20-1000°C), corrosion 60 mm
(air,water, O2, CO2), irradiation tests
 Technical file for codification of 100 mm

design standards
Materials for Generation IV Nuclear Reactors 22
Nuclear Energy Division Cargese, Sept. 24 – Oct. 6, 2007
 VHTR Intermediate Heat Exchanger
 Three IHX technologies identified:
 Plate-machined Heat Exchanger (Fig. 1)
 Plate-Fin Heat Exchanger (Fig. 2)
 Tubular concept FIG. 1

 Key issues to be addressed:

 Materials development FIG. 2
- Haynes 230
MODULE

- Inconel 617
- Ni-ODS
0.8 à 2.5 mm
Before and after

 Intermediate Heat Exchanger design 3.53 à 9.63 mm

BRAZING

- Compactness
- High thermomechanical resistance PLATES/FINS Assembly SERRATED FINS

- High thermal efficiency (95%) FIG. 3

- Low pressure drop, no leakage
 Properties required at 850°C - 950°C
- Tensile, long term creep (Fig. 3),
fatigue,creep-fatigue
- Corrosion resistance
- Fabrication and joining techniques
Creep strength: Haynes 230 and Inconel 617

Materials for Generation IV Nuclear Reactors 23

Nuclear Energy Division Cargese, Sept. 24 – Oct. 6, 2007
 Generation IV Systems related R&D Needs
Structural materials & Components
VHTR SFR GFR SCWR LFR MSR
Metals F/M steels F/M steels F/M steels Clad & Hastelloys
Mechanics, Corrosion ODS ODS ODS structures
Austenitic Ni-alloys
Ni-alloys Ni-Alloys
Steels Radiolysis

Ceramics & Graphite SiC, TiC

Composites C/C, Ceramics
SiCf/SiC

Component IHX & HX, HX, SG IHX & HX IHX & HX

mock-ups RPV (9 Cr) RPV & DHR Pump
Control rods

1ry system He test ISIR He test Heat transfer Corrosion MSalt

benches & benches & SCW Loops Purity Techno
Technology
Loops MW Loops MW Water control
Loops
chemistry

Mechanical HT Design ASME HT Design HT Design

Codification Codification Codification
Design Rules RCCM-R

Materials for Generation IV Nuclear Reactors 24

Nuclear Energy Division Cargese, Sept. 24 – Oct. 6, 2007
 Design and technology of T- breeding blanket
Fusion Power Reactor
Dual-Coolant T-Blanket
Typical Tokamak Configuration
T-Breeding Blanket: He, 80 bars Pb-17Li, ~bar
Dual Coolant Lithium Lead
0 0
300, 480 C 480-700 C
Dual-Coolant T-Blanket

0
Martensitic Steels (550 C)
0
ODS Ferritic steels (700 C)
SiCf-SiC th. & elect. insulator
0
F W: T max= 625 C
0
Channel: Tmax= 500 C
0
Insert: Tmax~1000 C
Materials for Generation IV Nuclear Reactors 25
Nuclear Energy Division Cargese, Sept. 24 – Oct. 6, 2007
 Innovative Reactor Systems
& Requirements for Structural Materials
Summary (1/2)
 Materials science and new materials are key for optimizing 2 nd & 3rd
generation LWRs as well as to meet 4th nuclear systems’ objectives :
> 2040: Fast reactors with a closed fuel cycle (SFR, GFR, LFR)
~2025-30: High temperature reactors (V/HTR) for process heat (H2…)
More prospective nuclear systems (SCWR, MSR)

 Incremental progress and breakthroughs are sought on a wide span

of structural materials for fuel claddings, core structures, reactor
cooling systems & components (RPV, IHX, SG…), power conversion
systems (electricity, H2…):
Metals: Austenitic steels, 9-12Cr F/M steels, ODS, Ni-alloys…
Ceramics & composites: Graphite, C/C, SiCf/SiC & (TiC, ZrC, Ti3SiC2…)
Fabrication, characterization, manufacturing, ND examination
Mechanical design codification: ASME, RCCM-R + extensions /
harmonization needed for fast neutrons, high temperature, lifetime…

 Synergies between materials for 4th generation nuclear systems

as well as with materials for Fusion (1st wall & blanket)
Ni-alloys, 9-12%Cr F/M steels, ODS, Ceramics (SiC…)
Materials for Generation IV Nuclear Reactors 26
Nuclear Energy Division Cargese, Sept. 24 – Oct. 6, 2007
 Innovative Reactor Systems
& Requirements for Structural Materials
Summary (2/2)
 Increased role of Materials science (analytical research and
modelling) for a more predictive R&D towards aimed materials
properties
 Metals  Ceramics  Fuels

 International cooperation to increase and share R&D work

and achieve breakthroughs for 21st century nuclear power
systems
Federate national programs into a consistent international roadmap
Enhancing R&D and technology demonstrations (Gen IV, EU FP7…)
Databases of materials properties
Multi-scale modelling of materials & fuels
Synergies between Fission and Fusion materials
Progressing towards harmonized international standards
Mechanical design rules and standards, Codification
Safety, non-proliferation, physical protection…

Materials for Generation IV Nuclear Reactors 27

Nuclear Energy Division Cargese, Sept. 24 – Oct. 6, 2007