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Thesis/Dissertation
Date
2025-08
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Mechanical Engineering
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https://doi.org/10.34944/r62e-8d77
Abstract
This dissertation presents a comprehensive investigation into the failure mechanisms and mechanical behavior of two advanced material systems: zirconium-based fuel cladding used in nuclear reactors and lightweight, elastic carbon composites produced through additive manufacturing. By integrating experimental data with multiscale numerical simulations, the research explores material degradation and performance under varying environmental and operational conditions, offering insights critical to the design and application of high-performance materials.In the context of nuclear fuel cladding, the study focuses on the effects of hydrogen embrittlement and hydride reorientation in zirconium alloys, particularly Zircaloy. Hydrogen accumulation over time leads to the formation of brittle zirconium hydrides, which compromise the cladding’s structural integrity. The research reveals that radial hydrides, which form due to operational stresses and temperature variations, significantly reduce the ductility and strength of the cladding, making it more prone to fracture. Computational models, validated by experimental data, show that hydride orientation plays a critical role in material failure, with radial hydrides contributing to earlier crack initiation compared to circumferential hydrides. These findings underscore the importance of hydride management to ensure the durability of nuclear fuel cladding during reactor operation and dry storage.
The study also explores the additive manufacturing (AM) of lightweight and elastic carbon composites using polypropylene with carbon fibers (PP-CF). The composites are produced through sulfonation-induced crosslinking and carbonization, allowing for the control of porosity and mechanical properties by adjusting the crosslinking time. The research demonstrates that shorter crosslinking times result in more compressible, elastic materials, while longer crosslinking times yield stiffer, load-bearing structures. This tunability makes the carbon composites suitable for a range of applications, from energy storage to wearable electronics. The study’s multiscale simulation framework, integrating gyroid structures and mesoscale representative volume elements (RVEs), accurately captures the mechanical performance of the composites and provides valuable design insights.
Overall, this research advances the understanding of failure mechanisms in nuclear fuel cladding and the design of carbon-based composites with tunable properties. The findings contribute to improving the safety and reliability of nuclear reactor materials and offer scalable methods for producing high-performance carbon composites using additive manufacturing techniques.
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