A model for pellet-cladding interaction (PCI) fracture of light-water reactor (LWR) fuel rods is presented, the basis of which is that Zircaloy cladding fails by iodine stress corrosion cracking (SCC). Laboratory data on iodine SCC of irradiated Zircaloy provide the primary input to the model, but unirradiated Zircaloy SCC data and theoretical analyses are utilized to broaden the regime of validity to encompass the various power reactor observations.

This publication sets out the findings of an international seminar, held in Aix-en-Provence, France in March 2004, which considered recent progress in the field of pellet-clad interaction in light water reactor fuels. It also reviews current understanding of relevant phenomena and their impact on the nuclear fuel rod under the widest possible conditions, and about both uranium-oxide and mixed-oxide fuels.

The Zircaloy cladding of water reactor fuel rods is susceptible to local breach-type failure, commonly known as pellet-cladding interaction (PCI) failure, during operational and off-normal power transients after the fuel has achieved a sufficiently high burnup. An optimization of power ramp procedures or fuel rod fabrication to minimize the cladding failure would result in a significant decrease in radiation exposure of plant personnel due to background and airborne radioactivity as well as an extension of core life in terms of allowable off-gas radioactivity. As part of a program to provide a better understanding of the fuel rod faiure phenomenon and to facilitate the formulation of a better failure criterion, a mechanistic study of the deformation and fracture behavior of high-burnup spent-fuel cladding is in progress under simulated PCI conditions.

The cladding on light water reactor (LWR) fuel rods provides a stable enclosure for fuel pellets and serves as a first barrier against fission product release. Consequently, it is important to design fuel to prevent cladding failure due to mechanical interactions with fuel pellets. Cladding stresses can be effectively limited by controlling power increase rates. However, it has been shown that local geometric irregularities caused by manufacturing defects known as missing pellet surfaces (MPS) in fuel pellets can lead to elevated cladding stresses that are sufficiently high to cause cladding failure. Accurate modeling of these defects can help prevent these types of failures. Nuclear fuel performance codes commonly use a 1.5D (axisymmetric, axially-stacked, one-dimensional radial) or 2D axisymmetric representation of the fuel rod. To study the effects of MPS defects, results from 1.5D or 2D fuel performance analyses are typically mapped to thermo-mechanical models that consist of a 2D plane-strain slice or a full 3D representation of the geometry of the pellet and clad in the region of the defect. The BISON fuel performance code developed at Idaho National Laboratory employs either a 2D axisymmetric or 3D representation of the full fuel rod. This allows for a computational model of the full fuel rod to include local defects. A 3D thermo-mechanical model is used to simulate the global fuel rod behavior, and includes effects on the thermal and mechanical behavior of the fuel due to accumulation of fission products, fission gas production and release, and the effects of fission gas accumulation on thermal conductivity across the fuel-clad gap. Local defects can be modeled simply by including them in the 3D fuel rod model, without the need for mapping between two separate models. This allows for the complete set of physics used in a fuel performance analysis to be included naturally in the computational representation of the local defect, and for the effects of the local defect to be coupled with the global fuel rod model. This approach for modeling fuel with MPS defects is demonstrated and compared with alternative techniques. The effects of varying parameters of the MPS defect are studied using this technique and presented here.