AbstractA proposed fuel freezing mechanism for molten UO2fuel penetrating a steel channel was investigated in the course of liquid-metal-cooled fast breeder reactor hypothetical core disruptive accident safety studies. The fuel crust deposited on an underlying melting steel wall was analyzed as being subjected to two stresses, one due to the pressure difference between the flowing fuel and the stagnant molten steel layer, and the other resulting from the temperature variation through the crust thickness. Analyses based on the proposed freezing mechanism and comparisons with fuel freezing experiments confirmed that fuel freezing occurs in three modes. For initially low steel wall temperatures, the fuel crust was stable and grew to occlude the channel. At high steel wall temperatures (above 1070 K), instantaneous wall melting leading to steel entrainment was calculated to occur with final penetration depending on the refreezing of the entrained steel. Between these two extremes, the stress developed within the crust at the steel melting front exceeds the critical buckling value, the crust ruptures, and steel is injected into the fuel flow. Freezing is dominated by the fuel/steel mixture. The theoretical penetration distances and freezing times were in good agreement with the experimental results with no more than 20% error involved.