FCM fuel, composed of TRISO particles and SiC matrix, is a typical accident tolerant fuel that holds a promising application prospect in various advanced nuclear reactors. Optimization of the microstructure of TRISO (Tri-Structural Isotropic) particles is crucial for enhancing both the safety and economy of nuclear fuel systems. In this study, the recently published novel fission gas swelling model or volume-growth strain models for the fuel kernel and the buffer layer are involved, enabling more accurate simulation of the irradiation thermo-mechanical coupling behaviors of FCM fuel. The three-dimensional mechanical constitutive relations, stress update algorithms and consistent stiffness moduli for the points within the buffer layer and PyC layer are newly formulated, and the corresponding procedures are developed. With the fuel kernel volume fraction and SiC layer dimensions kept constant, the effects of the thicknesses of the buffer layer, IPyC layer, and OPyC layer on the safety of FCM fuel are investigated. The research findings indicate that: (1) Increasing the buffer layer thickness can effectively improve its ability to accommodate kernel swelling, thereby markedly weakening the mechanical interactions between different parts; (2) With an increase of the buffer layer thickness from 50 µm to 80 µm, the peak first principal stresses in the SiC layer and the matrix decrease by 51 % and 79 %, respectively, leading to a significantly reduced failure risk; (3) A strategic redistribution of layer thicknesses can significantly strengthen the TRISO fuel safety, particularly by increasing the buffer layer thickness while decreasing both inner and outer dense PyC layer thicknesses, without altering other microstructural parameters. This study can provide theoretical guidance and analytical tools for the advanced manufacturing and optimization design of FCM fuel.
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