Modeling of High-Temperature Corrosion of Zirconium Alloys Using the eXtended Finite Element Method (X-FEM)

• Published in: Corrosion science 2021-08, Vol.189 (C), p.109603, Article 109603
• Main Authors: Bailly-Salins, Louis, Borrel, Léo, Jiang, Wen, Spencer, Benjamin W., Shirvan, Koroush, Couet, Adrien
• Format: Article
• Language: English
• Subjects: Beta phase; Codes; Computational efficiency; Computing costs; Corrosion; Corrosion model; Coupling; Empirical analysis; Finite difference method; Finite element analysis; Finite element method; High temperature; High-temperature corrosion; LOCA; Mathematical models; Mechanical properties; Mechanics; Mechanics (physics); MOOSE; Nuclear fuel elements; Nuclear fuels; Operating temperature; Oxidation; Oxygen; Thickness; X-FEM; Zircaloys (trademark); Zirconium; Zirconium alloys; Zirconium base alloys
• ISSN: 0010-938X; 1879-0496
• DOI: 10.1016/j.corsci.2021.109603

•The C4 model was updated to predict corrosion kinetics at high temperature, and has been implemented in the finite-element framework MOOSE, using X-FEM.•The XFEM method was developed in MOOSE to track interfaces during corrosion modeling.•The C4 model in MOOSE was validated against empirical models and experimental data.•The C4 model can predict the oxygen concentration profile evolution in the fuel cladding, enabling evaluation of the remaining ductile thickness. Oxidation modeling in modern nuclear fuel performance codes is currently limited by the lack of coupling with mechanics, thus preventing proper description of how high-temperature oxidation impacts mechanical properties. This is mostly due to the fact that the finite difference formalism adopted in corrosion models is incompatible with the direct coupling with mechanics in the finite element modeling employed in modern nuclear fuel performance codes. In this study, a physically based zirconium alloy corrosion model called the Coupled-Current Charge Compensation (C4) model, which was initially developed for operating temperature conditions, has been updated to include high-temperature corrosion in order to provide additional critical information (e.g., oxygen concentration profile) under loss-of-coolant accident (LOCA) conditions—information lacking in existing empirical models. The C4 model was implemented in the MOOSE finite-element framework developed at Idaho National Laboratory, enabling it to be used in the BISON nuclear fuel performance code based on the MOOSE framework. To precisely track the different interfaces at a relatively low computational cost, the eXtended Finite Element Method (X-FEM) was applied in MOOSE. The model’s results were compared to those of existing empirical models as well as metallographic analysis of high-temperature oxidized Zircaloy-4 coupons. Oxygen diffusivities in the α and β phases resulting from this comparison closely agree with those found in the literature. The C4 model implemented with X-FEM in MOOSE now has the capability to accurately predict oxide, oxygen-stabilized α, and prior β phase layer growth kinetics under isothermal exposure at high temperature (1000–1500 °C). Furthermore, in contrast with the empirical models, the C4 model accounts for the finite thickness of the fuel cladding. It can predict the oxygen concentration profile evolution through the whole cladding, enabling evaluation of the remaining ductile thickness—a crucial variable for mo