CLADDING MATERIALS DEVELOPMENT FOR RESEARCH NUCLEAR

REACTORS WITH AL-Alloy

Usman Sudjadi1), Tegoh Apriyono2)

1) Research Center for Nuclear Fuel and Radioactive Waste Recycling
Technology, National Research and Innovation Agency ( BRIN)
PUSPIPTEK area Building 20, Serpong, Indonesia.
2)
Department of Mechanical Engineering, Faculty of Engineering, Mercu Buana
University, Meruya, Jakarta, Indonesia

E-mail: tegohapriyono@gmail.com

Abstract-- Structural or cladding materials used for nuclear fuel elements require special requirements
such as good mechanical properties, radiation resistance, corrosion resistance, adequate physical and
chemical properties, and low thermal neutron absorption. Materials that are widely used as structural
materials for nuclear reactors are beryllium, magnesium, aluminum, zirconium and their alloys. AI-alloy
as alternative research reactor fuel cladding material. This study will be developed. Al-
alloy(93%Al+1%Mg+1%Fe and 1%Ni) was chosen as an alternative cladding material because it has
good mechanical property. The mixture of 97% Al+1% Mg+ 1% Ni+ 1% Fe is melted using a smelting
furnace at a temperature of about 7000 C - 8000 C, for 30-60 minutes. First, the Al-Alloy sample was
tested without heating and then given heat treatment (tempering) starting from 100 0C, 200 0C, 300 0C,
400 0C and 500 0C and allowed to stand for 1 hour, then the hardness test (rockwell tools) was carried
out impact testing (Charpy tools), and microstructure obseration (SEM tools). The results of testing the
mechanical properties and are used as references and considerations in the development of cladding
materials for research nuclear reactors.

Keywords : Al-Alloy(93%Al+1%Mg+1%Fe and 1%Ni) , Fuel Cladding, Hardness Test(rockwell),

Impact Test(Charpy), microstructure, Research Reactor.

1. INTRODUCTION
Fuel Cladding serves as a container and protector between the fuel and the environment,
but neutrons can still conduct nuclear reactions with the fuel. The selection of material
for the fuel casing is based on the type of reactor, the fuel and its operating temperature.
Aluminum alloys are quite good for use as fuel cladding materials considering the
properties of aluminum which are suitable for research reactor fuel cladding materials
that operate at low temperatures. The properties of aluminum suitable for fuel cladding
materials include: low neutron absorption cross section, stable to irradiation, stable at
high temperatures, high heat conductivity, corrosion resistance, easy to fabricate, and
easy to obtain. [1]. Structural or cladding materials used for nuclear fuel elements
require special requirements such as good mechanical properties, radiation resistance,
corrosion resistance, adequate physical and chemical properties, and low thermal
neutron absorption. Materials that are widely used as structural materials for nuclear
reactors are beryllium, magnesium, aluminum, zirconium and their alloys.[2] Nuclear
fuel element cladding serves to confine the release of fission products to the primary
coolant arising from the nuclear reaction of the uranium-based fuel used. In research
reactors, aluminum alloys are used as structural materials and supporting fuel elements.
Nuclear fuel cladding materials for research reactors usually use Al-Alloy materials. Al-
Alloy material is used for low density nuclear fuel cladding. Ussually, Al-Alloy is used
for cladding of nuclear fuel type U3Si2-Al with a density of 2.96 g U/cm 3. [3] Several

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studies reveal that Al-Alloy material cannot be used for U3Si2-Al nuclear fuel cladding
whose density is higher than 5.2 g U/cm3, the volume of the fuel element core will
increase so that it affects the change in Al-Alloy cladding thickness. This is not in
accordance with the conditions of the research reactor fuel element plate fabrication
because the required thickness of the fuel cladding is a minimum of 0.25 mm and a
maximum of 0.36 mm.[3,4] Al-Alloy material is an alternative that can be used as a
nuclear fuel cladding which has a high density. [5] Several studies have proven that Al-
Alloy has better thermal stability and thermal conductivity. In this study, we will discuss
the development of research nuclear reactor cladding materials with Al-
Alloy(93%Al+1%Mg+1%Fe and 1%Ni) [3,4 6,10,11] This can be seen from the
characteristics of the Al-Alloy of samples material on the hardness of the material, and
impact ability..
In this study, we will discuss the development of cladding materials for research nuclear
reactors with Al-Alloy(93% Al+1% Mg+1% Fe and 1% Ni) [ 3,4, 6,10,11]. This can be seen
from the characteristics of this material on the Rockwell hardness of the materia, and
impact ability, properties.

2. LITERATURE REVIEW
2.1. Research Nuclear Cladding
The fuel cladding functions as a container and a shield between the fuel and the
environment, but the neutrons can still carry out nuclear reactions with the fuel. Material
selection for fuel cladding is based on reactor type, fuel and operating temperature.
Aluminum alloys are quite good for use as fuel cladding materials considering the
properties of aluminum which are suitable for research reactor fuel cladding materials
that operate at low temperatures. Nuclear fuel element cladding serves to confine the
release of fission products to the primary coolant arising from the nuclear reaction of the
uranium-based fuel used. In research reactors, aluminum alloys are used as structural
materials and supporting fuel elements. The position of the fuel is in the reactor core at a
certain depth from the pool containing cooling water. This material is used because of
its qualified properties such as low neutron absorption, high corrosion resistance, easy
to form, and adequate mechanical strength.[2]

2.2. Nuclear Fuel Cladding/Cladding Material

The choice of materials for the nuclear reactor industry must pay attention to the
properties of the materials that are expected to best support its function in the nuclear
reactor system itself. The selection of materials must take into account certain
conventional engineering properties according to their intended use, such as mechanical
strength, plasticity, ductility, structural integrity, fabricability, machinability, corrosion
resistance, heat conductivity, thermal stability, material compatibility, and of course
availability in the industry. market and price.
a. General properties of cladding materials for nuclear reactors
The general properties of materials for nuclear reactors that must be considered in
their selection basically include properties commonly required for other industrial
materials as shown in Table 1[7].

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 Table 1. General properties of cladding materials for nuclear reactors
Mechanical strength Heat transfer properties
Mechanical tenacity Thermal stability
Structural integrity Compatibility
Can be fabricated, can Availability in market
be molded by machine
Corrosion resistance Price

b. Special Properties of Materials For Nuclear Reactor

The Special properties are required for materials used in the nuclear reactor industry.
The properties of the materials used for reactor components may change when exposed
to high doses of radiation. The special properties of materials for nuclear reactor
materials can be seen in Table 2[9].
Table 2. Special Properties of Materials For Nuclear Reactor
Neutronic properties Chemical interaction
Induced radioactivity Particle Interdiffusion
Irradiation stability Ease of reprocessing

2.3. Research Nuclear Reactor

A nuclear reactor is a device to control the fission chain reaction and at the same
time maintain the continuity of the reaction. A nuclear reactor is defined as "a device
that uses nuclear material as its fuel". Fission material used as fuel for example
uranium, plutonium and others. Natural uranium or enriched uranium is used for
uranium. So in general a nuclear reactor is a place where a controlled nuclear reaction
takes place.[8] A research reactor is a nuclear reactor used for research, development,
education and training. They produce neutrons for use in industry, medicine,
agriculture, forensics and more.[8]

2.4. Aluminium
Aluminum is a chemical element in the third periodic table that has the symbol Al
and atomic number 13. Aluminum is a metal that has a relatively low strength and is
malleable. Aluminum is a light metal and has good corrosion resistance, good electrical
conductivity and other properties. Generally, aluminum is mixed with other metals to
form aluminum alloys. This material is used not only for household appliances, but also
for industrial, construction, and other purposes.
Pure aluminum is very soft and not strong, but it can be mixed with copper,
magnesium, silicon, manganese, and other elements to form beneficial properties.
Aluminum has several properties that make it widely used as an engineering material,
including good electricity and heat conductors (conductors), easy fabrication process,
light weight, corrosion resistance and non-toxicity and low strength, but can be
overcome with alloys from aluminum to improve its mechanical properties.

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2.5. Magnesium
Magnesium is a chemical element in the periodic table that has the symbol Mg and
atomic number 12. Magnesium (symbol Mg) is an alkaline earth metal with an
oxidation number of +2. Magnesium ion has a high solubility in water, magnesium is
the third most abundant element dissolved in seawater. The free element magnesium
(metal) is not found naturally on earth, due to its highly reactive nature (although it can
be produced, magnesium is soon coated by a thin layer of its oxide, which partially
protects its reactivity). Currently, magnesium can be obtained by electrolysis of
magnesium salts obtained from brine. On the other side, the primary use of this metal as
an alloy is to make aluminum-magnesium alloys, sometimes called "magnalium" or
"magnelium". Because the density of magnesium is less than that of aluminum, these
alloys are valued according to their relative weight and strength.[6]

In this study will be developed, Al-Alloy (93%Al+1%Mg+1%Fe and 1%Ni)

[3,4 6,10,11] material is an alternative that can be used as a nuclear fuel cladding which
has a high density.[5] Several researchers have proven that Al-Alloy
(93%Al+1%Mg+1%Fe and 1%Ni) [3,4 6,10,11] has better thermal stability and
thermal conductivity.

3.EXPERIMENT PROCEDURE
The mixture of 97% Al+1% Mg+ 1% Ni+ 1% Fe is melted using a smelting
furnace at a temperature of about 7000 C - 8000 C, for 30-60 minutes. Samples
the smelted material was then tempered at 100 0 C, 2000 C, 3000 C, 4000C and
5000 C, each for 1 hour. Then samples are tested for Rockwell hardness, Impact
test (Charpy tools ). And microstructure observation (SEM toos). The results of
the smelting can be seen in Figure 1.

Figure 1 smelted material of Al-Alloy (97% Al+1% Mg+ 1% Ni+1%Fe)

4. RESULTS AND DISCUSSION

4.1 Rockwell Hardness Test Result of Samples: The following is the data from the
measurement and testing of Rockwell hardness. The scale used is type C with a mass of

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150 kg, emphasis using a diamond cone with an angle of 1200, Superficial (E) = 100,
permanent penetration (e) = h/0.002.
HRc=E – e
E = Constanta with a value of 100 for the diamond indentor.
e = Permanent penetration depth due to main load, e=h /0,002 mm or
h=e x 0,002 mm
Table 3. Rockwell hardness test results data
Rockwell Rockwell Rockwell Total
Test Test Test hardness Average
Process Temperature Results1 Results1 Results1 test hardness
(Load 150 (Load 150 (Load 150 results (HRc)
kg) kg) kg) (HRc)
without -
17 16 17 50 16.67
Tempering
0
Tempering 100 C 17 16 16 49 16.33
Tempering 2000 C 15 15 15 45 15
Tempering 3000 C 14 14 15 43 14.33
Tempering 4000 C 14 15 14 43 14.33
Tempering 5000 C 13 14 14 41 13.67

From the results of the Rockwell hardness test, data are obtained as in table 3. where
each specimen was tested 3 times.
Specimen 1 (non heat treatment) resulted from the Rockwell hardness test in the first
experiment which was 17 HRc, the second experiment was 16 HRc, and the third
experiment was 17 HRc with an average of 16.67 HRc.
Specimen 2 (heat treatment 1000 C) the results of the first Rockwell hardness test were
17 HRc, the second experiment was 16 HRc, and the third experiment was 16 HRc with
an average of 16.33 HRc.
Specimen 3 (heat treatment 2000 C) The results of the first Rockwell hardness test were
15 HRc, the second experiment 15 HRc, the third experiment 15 HRc with an average
of 15 HRc.
Specimen 4 (heat treatment 3000 C) the results of the first Rockwell hardness test were
14 HRc, the second experiment 14 HRc, the third experiment 15 HRc with an average
of 14.33 HRc.
Specimen 5 (heat treatment 4000 C) the results of the first Rockwell hardness test were
14 HRc, the second experiment 15 HRc, the third experiment 14 HRc with an average
of 14.33 HRc.
Specimen 6 (heat treatment 5000 C) the results of the first Rockwell hardness test were
13 HRc, the second experiment was 14 HRc, the third experiment was 14 HRc with an
average of 13.67 HRc.

From table 3 the results of the Rockwell hardness test are then entered into the
graph as follows:

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 45

40
Rockwell hardness test
35

30
hardness value (HRc)

25

20
17 16
15 15 14 14
13
10

0
0 100 200 300 400 500
Tempering 0 C

Figure 2.: Graph Rockwell Test Results

The results of the Rockwell hardness test show the average hardness value for specimen
1 (non heat treatment) with specimens 2, 3, 4, 5 and 6 (heat treatment 100 0 C, 2000 C,
3000 C, 4000 C dan 5000 C ) decreased hardness value. Specimen 1 (non-treated) against
specimens 2, 3, 4, 5 and 6 (heat treatment 1000 C, 2000 C, 3000 C, 4000 C dan 5000 C) the
hardness value decreased from 17 HRc to 16 HRc, 15 HRc, 14 HRc, 14 HRc, and 13
HRc (see figure 2).

4.2. Data Impact Test Results Al-Alloy samples : Impact testing machine
specifications, Pendulum mass 12.3 kg, Earth's gravity 9,8 m/s2, Pendulum arm
length 0.75 m = 750 mm

Figure 3 Impact loading sketch

Table 4 Test Result Data for Impact Charpy Tool
Sample tempering Starting Final Angle Pendulum Swing arm

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 angle Weight
time 1 hour ß distance (L, m)
α (m, kg)
80o 7o 12,3 kg 0,75 m
80o 5o 12,3 kg 0,75 m
Without Tempering 80o 6o 12,3 kg 0,75 m
Σα = 240°/3 Σβ = 18°/3 = Σm = 36,9/3 ΣL = 2,25/3 =
= 80° 6° = 12,3 kg 0,75m
80o 6o 12,3 kg 0,75 m
sample With 80o 4o 12,3 kg 0,75 m
Tempering 80o 6o 12,3 kg 0,75 m
0
100 C Σα = 240°/3 Σβ = 16°/3 = Σm = 36,9/3 ΣL = 2,25/3 =
= 80° 5,3° = 12,3 kg 0,75m
80o 7o 12,3 kg 0,75 m
sample With 80o 6o 12,3 kg 0,75 m
tempering 80o 6o 12,3 kg 0,75 m
0
200 C Σα = 240°/3 Σβ = 19°/3 = Σm = 36,9/3 ΣL = 2,25/3 =
= 80° 6,3° = 12,3 kg 0,75m
80o 8o 12,3 kg 0,75 m
80o 8o 12,3 kg 0,75 m
sample With 80o 7o 12,3 kg 0,75 m
tempering3000 C Σα = 240°/3 Σβ = 23°/3 = Σm = 36,9/3 ΣL = 2,25/3 =
= 80° 7,6° = 12,3 kg 0,75m
80o 7o 12,3 kg 0,75 m
80o 8o 12,3 kg 0,75 m
sample With 80o 7o 12,3 kg 0,75 m
tempering400 0C Σα = 240°/3 Σβ = 22°/3 = Σm = 36,9/3 ΣL = 2,25/3 =
= 80° 7,3° = 12,3 kg 0,75m
80o 9o 12,3 kg 0,75 m
80o 9o 12,3 kg 0,75 m
sample With 80o 8o 12,3 kg 0,75 m
tempering5000 C Σα = 240°/3 Σβ = 26°/3 = Σm = 36,9/3 ΣL = 2,25/3 =
= 80° 8,6° = 12,3 kg 0,75m

a. Impact Potential Energy

E P=m . g . L(1−cos α )
Ep : Potential Energy (joule)
m : Pendulum weight 12,3 (kg)
L : Swing arm distance 0,75 (m)
G : Earth Gravity 9,8 (m/s2)
cos α : Starting angle (o)
cos β : Final angle (o)
Impact potential energy on each heat treatment :
E P=m . g . L ¿
2 0
E P=12 , 3 kg .9 , 8 m/s .0 , 75 m(1−cos ⁡80 )
E P=90 , 40(1−0,1736)
E P=90 , 40(0,8264)

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 E P=74 ,71Joule

b. Absorbed energy
W =m. g . L ¿
Absorbed energy (W) on impact Al2Mg3 Without Tempering:
2
W =12 ,3 kg .9 , 8 m/s .0 , 75 m ¿
W =74 , 22 Joule

c. Impact Energy
W
EI =
A
EI : Impact Energy (Kg m/mm 2) = Joule/mm2
W : Absorbed energy (Joule)
A : Cross-sectional area under the notches 90 (mm2)
Energy impact Al2Mg3 Without Tempering :
W
EI =
A
74.22 joule
EI =
90 mm
EI = 0,823 joule⁄mm

Table 5 Results of Average Potential Energy, Absorbed Energy and Impact Energy
Sample tempering Potential Absorbed Impact energy
time 1 hour energy (Joule) energy (Joule) (joule)
Sample Without
74,71 74,22 0,823
Tempering
Sample tempering
0 74,71 74,32 0,826
100 C
Sample tempering
0 74,71 74,16 0,824
200 C
Sample tempering
0 74,71 73,91 0,821
300 C
Sample tempering
0 74,71 73,97 0,822
400 C
Sample tempering
0 74,71 73,69 0,820
500 C

From table 5, The average value of the impact potential energy, absorbed energy, and
impact energy on samples material in conditions without tempering and with tempering
(1000 C, 2000 C, 3000 C, 4000 C dan 5000 C ) and then it is made in a graph like below:

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 90

80 74.71 74.71 74.71 74.71 74.71 75

Impact potential energy (joule)
70

60

50

40

30

20

10

0
0 100 200 300 400 500
Temperatur 0 C

Figure 4 Comparison Graph of Impact Potential Energy (Ep) with Temperature

From Table 5 and figure graph 4, the Impact test results show the average Potential
Energy value for specimen 1 (without tempering) with specimens 2, 3, 4, 5 and 6
(tempering 1000 C, 2000 C, 3000 C, 4000 C dan 5000 C ) have the same value. For
specimen 1 (non-treated) for specimens 2, 3, 4, 5 and 6 (tempering 1000 C, 2000 C, 3000
C, 4000 C dan 5000 C) yaitu 74,71 Joule.

90

80 74.22 74.32 74.16 73.91 73.97 73.69

70
Absorbed energy (joule)

60

50

40

30

20

10

0
0 100 200 300 400 500
Temperatur 0 C

Figure 5 Comparison Graph of Absorbed Energy (W) with Temperature on Impact Test
From Table 5 and figure graph 5, For the average value of energy absorbed, specimen 1
(without tempering) is 74.22 joules, specimen 2 (tempering 1000 C) is 74.32 joules,
specimen 3 (tempering 2000 C) is 74.16 joules, specimen 4 (tempering 3000 C) is 73.91,
specimen 5 (tempering 4000 C) is 73.97 joules, specimen 6 (tempering 5000 C) is 73.69
joules.

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 1.0
0.9 0.823 0.826 0.824 0.820
0.821 0.822
0.8
Impact Energy (joule/mm2)

0.7
0.6
0.5
0.4
0.3
0.2
0.1
0.0
0 100 200 300 400 500
Temperatur 0 C

Figure 6 Comparison Graph of Impact Energy (EI) with Temperature

From Table 5 and figure graph 6, The data from the Impact test results show the average
Impact Energy value for specimen 1 (without tempering) with specimen 2 (tempering
1000 C) experienced an increase in Impact energy, which is 0.823 joules and 0.826
joules, for specimens 2 (tempering 1000 C) against specimen 3,4 (tempering 2000 C and
3000 C) experienced a decrease in the value of Impact energy, which is 0.824 joules and
0.821 joules, for specimen 4 to specimen 5 (tempering 3000 C and 4000 C) again
experienced an increase in the impact energy value of 0.822 joules, and a decrease in
the value again occurred in the specimen 6 (tempering 5000 C) which is 0.820 joules.
4.3. Microscope Observation Data for Al-Alloy (97% Al+ 1%Fe+ 1%Ni+1%
Mg) Material. Microscope (SEM tools) with a magnification of 500x or 50 µm.
In microstructure testing, the sample is alternately tested and measured by placing the
test object on a table located on the machine, after which the metal structure of the test
material can be seen directly on the monitor screen. Magnification was carried out 500x
using a Leco microscope.

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 Fe, Mg, Ni Atoms
Al atoms dominant
Dominant

Figure 7 Form of Al-Alloy (97% Al+ 1%Fe+ 1%Ni+1% Mg) without tempering
Magnification 500x or 50 µm

v
Fe, Mg, Ni Atoms
Dominant

Al atoms
dominant

Figure 8. Forms of Al-Alloy (97% Al+ 1%Fe+ 1%Ni+1% Mg) Tempering 300 0C
Magnification 500x or 50 µm

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 Al atoms
dominant
Fe, Mg, Ni
Atoms Dominant

Figure 9. Form of Al-Alloy (97% Al+ 1%Fe+ 1%Ni+1% Mg) Tempering 400 0C
Magnification 500x or 50 µm

Fe, Mg, Ni
Al atoms Atoms
dominant Dominant

Figure 10. Forms of Al-Alloy (97% Al+ 1%Fe+ 1%Ni+1% Mg) Tempering 500 0C
Magnification 500x or 50 µm

In microstructure testing, the Al-Alloy (97% Al+ 1%Fe+ 1%Ni+1% Mg) sample that
was not tempered had the same structural form as the Al-Alloy (97% Al+ 1%Fe+
1%Ni+1% Mg) sample with tempered 100 0C and 200 0C there was no change in the

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microstructure, the new Al-Alloy (97% Al+ 1%Fe+ 1%Ni+1% Mg) material will
experience a minimal structural change at a temperature of 300 0C. From the test results,
it can be seen that the shape of the microstructure of Al-Alloy (97% Al+ 1%Fe+
1%Ni+1% Mg) has just changed the shape of the structure after being tempered at
temperatures of 300 0C, 400 0C and 500 0C (see figures 7-10).
In the pictures above, it can be explained that the microstructure of the Al-Alloy (97%
Al+ 1%Fe+ 1%Ni+1% Mg) test sample without tempering the structure is large and
rough as if separated from each other, and when given a tempering (see figures 7-10).

5. CONCLUSION
From the results of the research conducted, the following conclusions is:
1. From the results of the Rockwell hardness test, where each specimen was tested 3
times. The average hardness result is obtained Specimen 1 (non heat treatment) with
an average of 16.67 HRc, Specimen 2 (heat treatment 1000 C) with an average of
16.33 HRc, Specimen 3 (heat treatment 2000 C) with an average of 15 HRc,
Specimen 4 (heat treatment 3000 C) with an average of 14.33 HRc, Specimen 5 (heat
treatment 4000 C) with an average of 14.33 HRc, Specimen 6 (heat treatment 5000 C)
with an average of 13.67 HRc.
2. The Impact test results show the average Potential Energy value for specimen 1
(without tempering) with specimens 2, 3, 4, 5 and 6 (tempering 1000 C, 2000 C, 3000
C, 4000 C dan 5000 C ) have the same value. For specimen 1 (non-treated) for
specimens 2, 3, 4, 5 and 6 (tempering 1000 C, 2000 C, 3000 C, 4000 C dan 5000 C) is
74,71 Joule.
3. The average value of energy absorbed on The Impact test results, specimen 1
(without tempering) is 74.22 joules, specimen 2 (tempering 1000 C) is 74.32 joules,
specimen 3 (tempering 2000 C) is 74.16 joules, specimen 4 (tempering 3000 C) is
73.91, specimen 5 (tempering 4000 C) is 73.97 joules, specimen 6 (tempering 5000 C)
is 73.69 joules.
4. The data from the Impact test results show the average Impact Energy value for
specimen 1 (without tempering) is 0.823 joules, specimen 2 (tempering 1000 C) is
0.826 joules, specimen 3 (tempering 2000 C) is 0.824 joules, specimen 4 (tempering
3000 C) is 0.821 joules, specimen 5 (tempering 4000 C) is 0.822 joules, and specimen
6 (tempering 5000 C) which is 0.820 joules.
5. In microstructure observation, the Al-Alloy (97% Al+ 1%Fe+ 1%Ni+1% Mg)
sample that was not tempered had the same structural form as the Al-Alloy (97% Al+
1%Fe+ 1%Ni+1% Mg) sample with tempered 100 0C and 200 0C there was no
change in the microstructure, the new Al-Alloy (97% Al+ 1%Fe+ 1%Ni+1% Mg)
material will experience a minimal structural change at a temperature of 300 0C.

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