A study on characteristics of end plug resistance welding process in nuclear fuel rods by experiment and numerical simulation

Na, Tae-Hyung; Na, Suck-Joo; Park, Young-Whan

doi:10.1007/s00170-018-2365-3

Cited by 15 publications

(9 citation statements)

References 8 publications

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“…First of all, it is necessary to verify the reliability of simulation results of tube-cap welding tests using resistance butt welding so that the obtained simulation results can replace experimental results. The reliability of the simulation program used in the present study to simulate resistance butt welding has already been reported in previous studies [15][16][17]. In the present study, simulated and experimental crosssectional images of nuclear fuel fabricated under mass-production conditions were compared, as shown in Fig.…”

Section: Reliability Of Simulationsupporting

confidence: 57%

Simulation-based Characterization of Tube-cap Resistance Butt Welding of Nuclear Fuel for Light Water Reactors and Development of Melted-volume Prediction Models

Lee¹,

Park²,

2022

Preprint

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Tube-cap welding is a method commonly used in the production of products by sealing various materials into tubes and sealing them with caps, which are used in nuclear power to make fuel rods. Welding methods using laser and arc welding or butt welding using resistance heat are mainly used for manufacturing fuel rods by putting uranium raw materials used in nuclear power generation into tubes and welding both ends to caps. In this study, we analyzed the mechanism of welding phenomena by varying welding current, overlap length, and force, which are the main variables in the butt welding of the tube-cap used in nuclear fuel rods manufacturing thought simulation. In order to predict the melted volume of the weld, a regression model and a neural network were used to predict the amount of melt with the main process variables as input variables. The effect of each welding variable on melted volume was quantitatively determined and the correlation between two factors was analyzed.

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Section: Reliability Of Simulationsupporting

confidence: 57%

Simulation-based Characterization of Tube-cap Resistance Butt Welding of Nuclear Fuel for Light Water Reactors and Development of Melted-volume Prediction Models

Lee¹,

Park²,

2022

Preprint

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“…At this stage, the length of the cladding tube protruding from the CT electrode is referred to as the overlapping length (O.L), and it forms the welded joint as it joins with the end plug. Following the welding process, external reinforcement (bead) is generated based on the shape of the tube electrode, and this section is then machined to remove the reinforcement [15][16][17][18].…”

Section: Tube-cap Welding For Nuclear Fuel Rodmentioning

confidence: 99%

“…The contact area between objects obtained from the mechanical model is applied again as an input value of current density, and the coupling process for the three models is repeated until the analysis is completed. In this study, the time step of each iteration was applied to 10 µs or less so that the analysis result of the resistance welding applying the AC welding current of 60 Hz could be well converged [11][12][13][14][15][16].…”

Section: Simulation Processmentioning

confidence: 99%

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Analysis of Foreign Substance Flow within the Weld Joint through Simulation in Pressurized Water Reactor Nuclear Fuel Rods

Kim

2023

Applied Sciences

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The welding of end plugs to cladding tubes is a critical process in the manufacture of pressurized water reactor (PWR) nuclear fuel rods. The resistance butt welding method is commonly used for this purpose in production. In this paper, we present an analysis of the flow of foreign substances within the weld joint during the tube-cap welding process of PWR nuclear fuel rods, using SORPAS 2D software. The welding process generates foreign substances such as oxide scales, welding fumes, and spatters, which can negatively impact the quality of the weld. Additionally, carbide-based ceramic materials with higher melting temperatures than the base metal have been found within the weld joint in some cases, which can also affect the quality of the weld. To simulate the intrusion of foreign substances with higher melting temperatures than the base material (zirconium alloy) during welding, we conducted a simulation and analyzed the flow of foreign substances. Based on this study, we expected to enhance the reliability and stability of the tube-cap welding process of PWR nuclear fuel rods.

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“…the analysis of the weld in terms of shear strength, deliberately ignoring the thermal cycle. Numerous researchers use numerical modelling for the analysis of resistance welding process, detailed analysis of processes taking place during welding and optimization of the welding process [6][7][8][9][10][11]. Many authors attempt to achieve the optimal, i.e.…”

Section: The Ideal Weldmentioning

confidence: 99%

The investigation on the ideal spot weld numerical model in resistance welding

Mikno

Grzesik

Stępień

2020

Int J Adv Manuf Technol

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The paper presents investigation on the ideal spot weld numerical model. The weld discussed in the paper was made by the resistance spot welding of two overlapping steel sheets. The ideal weld contained three parts, i.e. two welded steel sheets and an intermediate component (connector) made of the same material. The connector was placed between the sheets, assembled mechanically and fixed. A numerical model of the ideal weld enables the elimination of all welding imperfections, including, among other things, an indent left by the electrode as well as stresses and deformations of materials present in the actual welded joint. The ideal weld was intentionally not subjected to the thermal cycle. As a result, the heat-affected zone and the molten nugget were eliminated from the model (welding area). Consequently, the entire tested (analysed) weld specimen only had the properties of the base material. The analysis presented in the paper is based on 3D FEM numerical modelling and experimental validation. The numerical model of the ideal weld (nugget surface) was investigated in relation to various shapes of the nugget (e.g. circular, square and rectangular) as well as in relation to different dimensions. The research also involved the performance of a comparative analysis including various welding conditions. The analysis was carried out to determine the highest possible value of shear force generated during a static tensile test. The results of the numerical tests were compared with the results of selected laboratory tests.

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A study on characteristics of end plug resistance welding process in nuclear fuel rods by experiment and numerical simulation

Cited by 15 publications

References 8 publications

Simulation-based Characterization of Tube-cap Resistance Butt Welding of Nuclear Fuel for Light Water Reactors and Development of Melted-volume Prediction Models

Simulation-based Characterization of Tube-cap Resistance Butt Welding of Nuclear Fuel for Light Water Reactors and Development of Melted-volume Prediction Models

Analysis of Foreign Substance Flow within the Weld Joint through Simulation in Pressurized Water Reactor Nuclear Fuel Rods

The investigation on the ideal spot weld numerical model in resistance welding

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