PSI - Issue 46

Available online at www.sciencedirect.com Available online at www.sciencedirect.com ScienceDirect Structural Integrity Procedia 00 (2020) 000–000

www.elsevier.com/locate/procedia

ScienceDirect

Procedia Structural Integrity 46 (2023) 149–154

© 2023 The Authors. Published by Elsevier B.V. This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0) Peer-review under responsibility of ICSID 2021 Organizers Abstract Zirconium alloy has been extensively used as a cladding material in nuclear power reactors due to its low neutron absorption cross section, excellent tensile properties, fracture strength, and corrosion resistance. The influence of swaging parameters such as feed rate (0.7, 1.25, 2 m/min), die angle (2 o to 10 o ), and deformation (0% to 40%) on residual stress induced in Zirconium alloys was investigated numerically in the present work. A 3D finite element model based on plastic and elastic-plastic formulation is developed using the commercial finite element software DEFORM 3D to analyse the residual stress in zircaloy-4 (Zr-4 alloy). The residual stress in swaged Zirconium alloys at different die angles (2 o to 10 o ) was estimated using DEFORM-3D. The residual stress was found to be first decreasing with increasing die angle, and after reaching 4 o , it has increased again. The optimum swaging parameters (die angle and feed rate) were proposed for improving production, achieving better mechanical properties, and lower residual stresses. © 2021 The Authors. Published by ELSEVIER B.V. This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0) Peer-review under responsibility of ICSID 2021 Organizers. Keywords: Die design; Residual Stress; Zr-4; Defoem 3D 1. Introduction Zirconium alloy has been extensively used as a cladding material in nuclear power reactors due to its low neutron absorption cross-section, excellent tensile properties, fracture strength, and corrosion resistance. Rotary swaging is an 5th International Conference on Structural Integrity and Durability, ICSID 2021 The effect of die design on residual stresses of Zr-4 alloy processed by swaging Gaurav Singh a *, Roshan Raj a , Vishnu Narayanan K I b , U.K. Arora b , R. Jayaganthan a a Department of Engineering Design, IIT Madras, Chennai, 600036, India b Nuclear Fiel Complex Hyderabad, Hyderabad, 503301, India

* Corresponding author. Tel.: +919453057049; +91 44 2257 4735; fax: +91 44 2257 4735. E-mail address: pankaj.gaurav.singh@gmail.com, edjay@iitm.ac.in

2452-3216 © 2021 The Authors. Published by ELSEVIER B.V. This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0) Peer-review under responsibility of ICSID 2021 Organizers.

2452-3216 © 2023 The Authors. Published by ELSEVIER B.V. This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0) Peer-review under responsibility of ICSID 2021 Organizers 10.1016/j.prostr.2023.06.025