Linking Buffer Microstructure to TRISO Nuclear Fuel Thermo-Mechanical Integrity: A Multiscale Modeling Study

Reliable performance of TRISO (tristructural isotropic) nuclear fuel depends on the interplay between its multilayer architecture and the buffer-layer microstructure, which are difficult to isolate experimentally. We implement a multiscale, multiphysics model in the open-source MOOSE (Multiphysics Object-Oriented Simulation Environment) framework that couples particle-scale thermo-mechanical finite-element analysis with mesoscale phase-field fracture to link microstructure to effective stiffness and strength. The model resolves the combined influence of pore volume fraction, size, and aspect ratio and explicitly separates the effects of reduced load-bearing capacity from stress concentrations in the porous buffer. Simulations reveal substantial hoop stresses across coating layers under nominal thermal conditions due to material property mismatches and temperature gradients. In the buffer, stiffness and strength decrease with porosity; morphology is decisive: as aspect ratio decreases, strength degrades far more rapidly than stiffness, consistent with crack-like pores that amplify local stresses. The framework reproduces logarithmic trends with aspect ratio and explains the higher sensitivity of strength, providing parameters that can inform design and acceptance criteria (e.g., limits on pore elongation and porosity gradients). Implemented within MOOSE, the approach is readily extensible to irradiation-dependent kinetics, interface debonding, and uncertainty-quantified 3D analyses to support risk-informed TRISO fuel development.