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ORNL-TM-2511.txt
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h - —— — — — — = — —— — _ —
CENTRAL R
ESEARCH LI
DOCUMENT COLLECTIBC?P? i
OAK RIDGE NATIONAL LABORATORY
operated by
UNION CARBIDE CORPORATION m
NUCLEAR DIVISION
for the
U.S. ATOMIC ENERGY COMMISSION
[ g
)
-
| 445k 05
1] MATERIALS FOR MOLTEN-SALT REACTORS
| .
| H. E. McCoy W. H. Cook R. E. Gehlbach
J. R. Weir, Jr. C. R. Kennedy C. E. Sessions
R. L. Beatty A. P. Litman J. W. Koger
|
o
[s
| NOTICE This document contains information of a preliminary nature
and was preparec primarily for internal use at the Oak Ridge Mational
Laboratory. It is subject to revision or correction and therefore does
not represent a final report.
1
— LEGAL NOTICE
This repart wos prepared os an account of Government sponsared work. Neither the United States,
nor the Commission, nor any persen octing on behalf of the Commission:
A. Mokes ony waorranty or representation, expressed or implied, with respect to the occurocy,
completeness, or usefulness of the informotion contained in this report, or that the use of
any information, apparatus, method, or process disclosed in this report moy nel infringe
privately owned rights; or
B. Assumes any liabilities with respect to the use of, or for damages resulting from the use of
any information, opparatus, method, or process disclosed in this report.
As used in the above, ‘person acting on behalf of the Commission" includes any employee or
contractor of the Commission, or employee of such contracter, to the extent that such employee
or contractor of the Commission, or emplovee of such contractor prepares, disseminates, or
pravides access fo, any infermation pursuant ta his employment or contract with the Commission,
or his employment with such contractor.
ORNL-TM-2511
Contract No. W-7405-eng-26
METALS AND CERAMICS DIVISION
MATERTALS FOR MOLTEN-SALT REACTORS
H. E. McCoy W. H. Cook R. E. Gehlbach
J. R. Weir, Jr. C. R. Kennedy C. E. Sessions
R. L. Beatty A. P. Litman J. W. Koger
Paper submitted to the Journal of Nuclear Applications
MAY 1969
OAK RIDGE NATIONAL LABORATORY
Oak Ridge, Tennessee
operated by
UNION CARBIDE CORPORATION
for the
- U.S. ATOMIC ENERGY COMMISSION ' - -
| LOCKHEED MARTIN ENERGY RESEARCH LIBRARIES
t
| 3 445k 0513k7kL 9
iii
CONTENTS
Abstract . . . . . . . . .. 00 .
Introduction .
Experience With The MSRE
Development of A Modified Hastelloy N With Improved Resistance
to Irradiation Damage . . . . . . . .
Irradiation Damage in Graphite . . . . .
SUMMATY v v ¢ & o o o o o o o o o o o o o o o « o« o o«
References . .
14
35
36
MATERIALS FOR MOLTEN-SALT REACTCRS
H. .E. McCoy W. H. Cook R. E. Gehlbach
J. R. Weir, Jr. C. R. Kennedy C. E. Sessions
R. L. Beatty A. P. Litman J. W. Koger
ABSTRACT
Operating experience with the Molten-Salt Reactor
Experiment (MSRE) has demonstrated the excellent compat-
ibility of the graphite-Hastelloy N-fluoride salt system
at 650°C. Several improvements in materials are needed
for a molten-salt breeder reactor with a basic plant life
of 30 years; specifically, (1) Hastelloy N with improved
resistance to embrittlement by thermal neutrons,
(2) graphite with better dimensional stability in a fast
neutron flux, (3) graphite that is sealed to obtain a
surface permeability of less than 10”8 cm?/sec, and (4) a
secondary coolant that is inexpensive and has a melting
point of about 400°C. A brief description is given of
the materials work in progress to satisfy each of these
requirements. Our studies presently indicate that
significant improvements can likely be accomplished in
each area.
INTRODUCTION
Our presenf concept of & molten-salt breeder reactor (described
in detail by Bettis et 5;.) utilizes graphite as moderator and reflector,
Hastelloy N for the containment vessel and other metallic parts of the
system, and a liquid fluoride salt containing LiF, BeF,, UF,, and ThF,
as the fertile-fissile medium. The‘fertile-fiSSile salt will leave the
reactor vessel at a temperature of about 700°C and energy will be trans-
ferred to a coolant salt which in turn is used to produce supercritical
steam.
Our experience with the Molten-Salt Reactor Experiment (MSRE) has
demonstrated the basic compatibility of the graphite-Hastelloy N-fluoride
salt (LiF-BeF,-ZrF,-UF,) system at 650°C. However, a breeder reactor
will impose more stringent material requirements; namely, (1) the design
life of the basic plant of a breeder is 30 years at a maximum operating
temperature of 700°C, (2) the power density will be higher in a breeder
and will require the core graphite to sustain higher damaging neutron
flux and fluence, and (3) neutron economy is of utmost importance in
the breeder and the retention of fission products {particularly *°Xe)
by the core graphite must be minimized. ZEach of these factors requires
a specific improvement in the behavior of materials.
We have found that the mechanical properties of Hastelloy N
deteriorate as a result of thermal neutron exposure and must find a
method of improving the mechanical properties of this material to
ensure the desired 30-year plant life.
Similarly, we have found that graphite 1s damaged by irradiation.
Although we can replace the core graphite, we find that the allowable
fast neutron fluence for the graphite has an important infliuence on the
economics of our reactor. Thus, we have undertaken a program to learn
more about irradiation damage in graphite and to develop graphites with
improved resistance to damage.
A big factor in neutron economy is reducing the quantity of 135y%¢
that resides in the core. We will remove this gas by continuously
sparging the system with helium bubbles, but the transfer by this method
probably will not be rapid enough to prevent excessive quantities of
135Ye from being absorbed by the graphite. This can be prevented by
reducing the surface diffusivity to < 1078 cm®/sec, and we feel that
this is best accomplished by carbon impregnation by internal decomposi-
tion of a hydrocarbon.
We are also searching for a new secondary coolant that will allow
us greater latitude in operating temperature. Sodium fluoroborate has
reasonable physical properties for this application, and we'ére
evaluating the compatibility of Hastelloy N with this salt.
We shall describe our work in each of these areas in some detail.
EXPERIENCE WITH THE MSRE
Other papers in this series have elaborated on the information
ga;ned from the MSRE regarding operating experience, physics, chemistry,
and fission-product behavior. Additionally, valuable information has
been gained about the materials involved.(l_B)
We haye'a surveillance facility exposed to the salt in the core
of the reactor and one outside the reactér vessel, where the environment
is nitrogen plus about 2% 0,. Hastelloy N tensile rods and samples of
the grade CGB graphite* used in the core of the MSRE are exposed in the
core facility. The components are assembled so that portions can be
removed in a hot cell, new sémples added, and returned to the reactor.
We have removed samples after llOO,I44OO, and 9100 hr of full-power
(8 Mw) operation at 650°C. As shown in Fig. 1, the physical condition
of the graphite and metal samples was excellent; identification numbers
and machining marks were cledrly visible. The peak fast fluence
received by the graphite has been 4.8 x 1029 neutrons/cm® (> 50 keV)
and the dimensional changes are less than 0.1%. Pieces of graphite
from the MSRE have been sectioned and most of the fission products were
found to be located on the surface and within 10 mils below the surface.
*Trade name of Union Carbide Corporation for the needle-coke graphite
used in the MSRE.
W R-42962
et
Fig. 1. Graphite and Hastelloy N Surveillance Assembly Removed from
the Core of the MSRE After 72,400 Mvhr of Operation. Exposed to flowing
salt for 15,300 hr at 650°C.
However, a few of the fission products have gaseous precursors and
penetrated the graphite to greater depths. The microstructure of the
Hastelloy N near the surface was modified to a depth of about 0.001 in.,
but we found a similar modification.in samples exposed to static non-
fissioning salt for an equivalent time. We have not positively
identified the near-surface modification, but find its presenée of no
consequence. The very small changes in the amounts of chromium and
iron in the fuel salt also indicate very low corrosion rates and support
our metallographic observations.
Hastelloy N samples were removed from the surveillance facility
outside the reactor vessel after 4400 and 9100 hr of full-power operation.
This enviromment is oxidizing, and we have found that an oxide film
about 0.002 in. thick was formed on the surface after the longer exposure.
There was no evidence of nitriding, and the mechanical properties of
these samples were not affected adversely by the presence of the thin
oxide film.
Thus, our experience with the MSRE has proven in service the excel-
lent compatibility of the Hastelloy N-graphite-fluoride salt system.
DEVELOPMENT OF A MODIFIED HASTELLOY N WITH IMPROVED RESISTANCE
TO TIRRADIATION DAMAGE
Since the MSRE was constructed, we have found that Hastelloy N, as
well as most otfier iron- and nickel-base alloys, is subject to a type of
high-temperature irradiation damage that reduces the creep-rupture
strength and the fracture strain.(4_9) This effect is characterized in
Figs. 2 and 3 for a test temperature of 650°C. The rupture lives for
irradiated and unirradiated materials differ most at high stress levels
ORNL-DWG 68-4200
70
N HEAT NOS.
N o -5065
\ A-5067
' o - 5085
60 . N
' "~ PRETEST ANNEAL-IHR AT 1177°C
\\ SOLID POINTS-IRRADIATED <150°C
50 N OPEN POINTS-IRRADIATED 500—
. 650° G
* AN
o N§f . \<TYP UNIRRADIATED
o N
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7 N N
8 o Te | \\
E qe \\o o |d N
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10
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N I 10 100 1,000 10,000
RUPTURE TIME, HR
Fig. 2. Creep-Rupture Properties of Hastelloy N at 650°C After Irradiation to a
Thermal Fluence of About 5 X 10°% neutrons/cm?.
ORNL-DWG 68-4199R2
273
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/
HEAT NOS. ° [
3 0 - 5063 1
A - 5067 ¥
o -5085 ; / ¢
12 /
PRETEST ANNEAL-IHR AT1177°C . / ‘
SOLID POINTS-IRRADIATED < 150°C /
OPEN POINTS-IRRADIATED 500-650°C / o
1 ; 4
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10 ;
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Al f{"""‘%- cr/
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001 o I 1 10 100 1000
MINIMUM CREEP RATE, %/HR
Fig. 3. Fracture Strain of Hastelloy N at 65g°C After Irradiation
to a Thermal Fluence of About 5 X 10°C neutrons/em®.
and converge for stresses below 20,000 psi. The property change that
concerns us most in reactor design and operation is the reduction in
fracture strain. The postirradiation fracture strain is shown in Fig. 3
as & function of strain rate. TIn tensile tests the strain rate 1is a
controlled parameter, and for the creep tests we have used the minimum
creep rate. The data are characterized by a curve with a minimum at a
strain rate of about 0.1%/hr, with rapidly increasing fracture strain
as the strain rate is increased, and slowly increasing fracture strain
as the strain rate is decreased. Thus, under normal operating conditions
for a reactor where the stress levels (and the strain rates) are low,
the rupture life will not be affected significantly (Fig. 2), but the
fracture strain will be only 2 to 4% (Fig. 3). However, transient condi-
tions that would impose higher stresses or require that the material
absorb thermally induced strains could cause failure of the material.
Therefore, it is desirable that we have a material with improved proper-
ties in the irradiated condition and have embarked upon a program with
this as our goal.*
The changes in high-temperature properties of iron- and nickel-
base alloys during irradiation in thermal reactors have been shown
*¥Although the fast neutron flux will be quite high in the core of
our proposed breeder, the neutrons reaching the Hastelloy N vessel
will be reduced in energy by the graphite present. Thus, the fast
fluence seen by the vessel during 30 years will be less than
1 X 102! neutrons/cm?, and we do not feel that fast-neutron displace-
ment damage is of concern. Experiments will be run to confirm this
point.
rather conclusively to be related to the thermal fluence and more
specifically related to the quantity of helium produced in the metal
from the thermal °B(n,a)”Li transmutation.(lo_l2) The mechanical
properties are only affected under test conditions that produce inter-
granular fracturing of the material. Under these conditions both creep
and tensile curves for irradiated and unirradiated materials are
identical up to some strain where the irradiated material fractures and
the unirradiated material continues to deform. Thus, the main influence
of irradiation is to enhance intergranular fracture.
A logical cure for this problem would be to remove the boron from
the alloy. However, boron is present as an impurity in most refractories
used for melting, and the lowest boron concentrations obtainable by
commercial melting practice are in the range of 1 to 5 ppm. This
approach seems even more hopeless when we look carefully at the low
helium levels that have caused the creep-rupture properties to deterio-
. rate in Hastelloy N. For example, we found in some in-reactor tube
burst tests at 760°C that the rupture life was reduced by an order of
magnitude and that the fracture strain was only a few tenths of a per-
cent when the computed helium levels were in the parts-per-billion
range.(g) Thus, we have concluded that the properties of Hastelloy N
cannot be improved solely by reducing the boron level.
Another very important observation has been that the properties are
altered by irradiation at elevated temperatures only when the test tem-.
perature is high enough for grain boundary deformation to occur
10
(above about half the absolute melting temperature for meny materials).
Thus, the role of helium must be to alter the properties of the grain
boundaries so that they fracture more_easily.
The size of boron lies intermediate between the sizes of small
atoms such as carbon that occupy interstitial lattice positions and the
larger metal atoms, such as nickel and iron, that occupy the normal
lattice positions. For this reason boron concentrates in the grain
boundary regions where the atomic disorder provides holes large enough
to accommodate the boron atoms. Thus the transmuted helium will be
generated near the grain boundaries where it will have its most devas-
tating effects. We reasoned that the addition of an element that formed
stable borides would fesult in the boron being concentrated in discrete
precipitates rather than being distributed uniformly along the grain
boundaries. The transmuted helium would likely remain associated with
the precipitate and be less detrimental. Additionally, certain precipi-
tate morphologies and allbying elements are beneficial in improving the
resistance of alloys to intergranular fracture.
Following this reasoning we have made small additions of Ti, HT,
and Zr to Hastelloy N and have found the postirradiation properties to
be improved markedly.(13s14)
We have chosen the titanium-modified alloy
for development as & structural material for a molten-salt breeder
experiment (MSBE). A further modification made in the composition was
reducing the molybdenum content from 16 to 12%. This change was prompted
by the observation that the additional molybdenum was used in forming'
large carbide particles that made it difficult to control the grain size.
We also adopted the vacuum-melting practice to reduce the concentrations
of other residual elements thought to be deleterious.
11
The stress-rupture properties at 650°C of several heats of the
titanium-modified alloy (0.5% Ti) are summarized in Fig. 4. The proper-
ties in the absence of irradiation are improved over those of standard
Hastelloy N and the rupture life of the modified alloy is not reduced
more than about 10% by irradiation at 650°C to a thermal fluence of
5 x 10%° neutrons/cm®. The postirradiation fracture strains of the
titanium-modified alloy are also improved over those of the standard
alloy (Fig. 5). The modified alloy has & very well-defined ductility
minimum as a function of strain rate, but the minimum strain is about
3% compared with O.?% for the standard alloy.
Electron microscopy has shown that the titanium-modified alloy
forms very fine-grain boundary precipitates when annealed at 650°C.
These precipitates are only a few tenths of a micron in size and are
spaced along the grain boundaries at about 2-u intervals. They have a
face-centered cubic crystal structure with a lattice parameter of‘about
4.24 R and are likely complexes involving Mo, Cr, Ti, C, N, and B. This
microstructure should lead to trapping of the helium as we proposed
earlier and should also inhibit fracture along the grain boundaries.
However, further studies have shown that the precipitates which form
during long exposure at 760°C are relatively coarse MopC carbides and
thatlthe postirradiation properties of material irradiated at 760°C are
very poor. Since we planned to operate the MSBR at about 700°C, this
difference in precipitate morphology and subsgquent deterioration of
properties was of utmost concern to us. Further studies have shown that
the desirable structu;e can be stabilized by the addition of Nb, Si, or
Hf, and we are confident of having properties at least as good as those
shown in Figs. 4 and 5.
70
60
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STRESS, l?oo PS|
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20