Delayed hydride cracking (DHC) poses a significant integrity threat to zirconium nuclear cladding, arising from the cyclic interplay of hydrogen diffusion and hydride precipitation/dissolution, which leads to characteristic intermittent subcritical crack advance. This work develops a thermodynamically consistent variational phase-field framework that, in a unified formulation, couples hydrogen diffusion, stress- and temperature-regulated hydride evolution, thermo-elastoplasticity, and a ductile-to-brittle fracture transition. The model reproduces key experimental observations across temperatures—intermittent crack advance, DHC velocity, striation spacing, and incubation time—and quantifies how stress and temperature jointly govern hydride nucleation and cracking. Mechanistically, hydrostatic tension reduces the terminal solid solubility for precipitation/dissolution and concentrates hydrogen; ensuing precipitation relaxes and redistributes stresses, establishing a self-sustaining feedback loop that triggers hydride precipitation–fracture–dissolution–reprecipitation cycles. Parametric studies of pre-cracked cladding reveal a stress-dependent transition between diffusion-controlled and precipitation-controlled initiation. High applied stress induces pronounced thermal sensitivity via stress-assisted hydrogen accumulating, whereas low stress exhibits a weaker temperature response that manifests only above a critical hydride fraction. Beyond DHC, the framework is readily extensible to simulations of oxide–hydride synergistic delayed cracking under reactor-relevant conditions. It thus provides a physics-based foundation for mechanism identification, threshold assessment, and life prediction of zirconium cladding, and establishes a platform for future extensions to oxide–hydride interaction.
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