On the interaction of grain-scale and hydride-scale stresses in hydrogen enriched zirconium alloy nuclear cladding via combined discrete dislocation plasticity and crystal plasticity finite element modelling

The interaction of Zircaloy fuel cladding components with coolant water in a nuclear reactor leads to embrittlement and potentially delayed hydride cracking (DHC). We explore rate controlling mechanisms for the detrimental DHC process via Discrete Dislocation Plasticity (DDP) modelling of an intragranular -hydride, informed by Crystal Plasticity Finite Element (CPFE) analysis of a notched Zircaloy-4 (Zr-4) polycrystal. It is believed that nano-hydride plasticity occurs under a background (polycrystalline) stress state that depends on the grain-scale stress re-distribution associated with plastic deformation at a notch. We find that depending on grain size the background stresses can enhance plasticity during hydride growth (cooling), enhancing the residual hydrostatic stresses on hydride dissolution (heating), which encourages local hydrogen accumulation and re-precipitation. This ‘memory effect’ can be enhanced further by obstacles preventing dislocations from gliding backwards and annihilating during dissolution, highlighting that the discrete nature of plasticity can play important role in the DHC process. Our analysis provides a stepping-stone to modelling interacting nano-hydrides and irradiation effects for supporting the design of better nuclear materials.