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DOE OSTI2023

Fission gas retention of densely packed uranium carbonitride tristructural-isotropic fuel particles in a 3D printed SiC matrix

The Transformational Challenge Reactor (TCR) fuel form was designed to contain large, densely packed uranium carbonitride (UCN) tristructural-isotropic (TRISO) fuel particles within a 3D printed SiC matrix, increasing the uranium density compared to conventional TRISO fuel forms and offering full geometric freedom for core design. Here, this work summarizes initial low-burnup, high-power irradiation testing of TCR fuel materials, including loose UCN TRISO particles and integral fuel compacts with ~55% TRISO particles by volume, to evaluate fission gas retention. Fission gasses were fully retained in all loose particle tests and in integral compacts irradiated at low (<250 °C) surface temperatures. Initial testing at higher (~700–750 °C) fuel surface temperatures showed fission gas release (FGR) and complete fracture of three compacts, but no FGR was observed in later high temperature tests (~300–750 °C) of both fueled compacts and loose TRISO particles. Calculated thermal stresses in the failed compacts were far less than the measured strength of the SiC matrix and the stresses in some failed compacts were less than those in compacts that did not show FGR. Thermal stress-induced matrix cracks also would not cause complete fracture because the tensile stresses transition to compression in the higher temperature regions. Therefore, fuel failure was likely not caused by thermal stresses and may have been related to leakage currents from the electrical heaters and erratic fuel surface temperatures that were only observed in the test for which failure was observed. In any case, the matrix cracks propagated through the coatings of TRISO particles located in the high-density matrix regions on the peripheries of the compacts, resulting in measurable fission gas release. The discussion focuses on the importance of understanding matrix density distributions and the particle-matrix interface properties to prevent matrix cracks from causing TRISO particle failures.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2026

HIGHER EFFICIENCY FISSION COUNTER FOR NEUTRON DETECTION

Fission chambers containing 235U have been used for detection of neutrons for many decades. In these chambers 235U is electroplated on a metal which is one plate of an ionization chamber. Since the range of fission products from induced fission in the chamber is extremely short, these deposits from electroplating are so thin that the amount of 235U results in low neutron detection efficiency and the chamber needs high internal 235U surface area to increase efficiency. A typical ~8 in. long, ~2 in. diameter fission counter only contains < 2 g of 235U total, resulting in very low detection efficiency per incident neutron impinging on the outer surface of the detector. However, because of their large electronic pulses from fission products compared to gamma rays it is very easy to discriminate against gamma rays impinging on the detector. These types of chambers are produced commercially and are used worldwide in nuclear research and nuclear power reactors. ORNL has made a higher efficiency fission ionization chamber by using many thin concentric annuli to increase the area. A higher efficiency fission counter would be useful and can be made by incorporating 235U into a glass or ceramic scintillator. For nearly 100 years the green color in antique glass was produced by incorporation of depleted uranium (up to 20 wt. %) into a glass. The concept for this scintillation-optical-based fission detector is to dope a scintillator (either ceramic or glass) with 235U. Glass scintillators are commercially available doped with as much as 8 wt. % 6Li for neutron detection. In the 235U doped scintillator the fission product pulses would be double the size of those in an ion chamber since all fission products produce light in the scintillator whereas in the ionization chamber half do not go into the ionizing gas volume. These higher efficiency fission chambers would be very useful for a wide variety of research, nuclear research, and nuclear power reactor applications. Because of their smaller size and weight, they should be useful for space application such as monitoring of space nuclear power reactors. This report reviews existing fission chamber technology and suggests the development of these small high-efficiency fission chambers. Other fission isotopes could be used for other research applications.

Mihalczo, John [ORNL] (ORCID:0000000254292681)↗

NASA NTRS1972

Post impact behavior of mobile reactor core containment systems

The reactor core containment vessel temperatures after impact, and the design variables that affect the post impact survival of the system are analyzed. The heat transfer analysis includes conduction, radiation, and convection in addition to the core material heats of fusion and vaporization under partially burial conditions. Also, included is the fact that fission products vaporize and transport radially outward and condense outward and condense on cooler surfaces, resulting in a moving heat source. A computer program entitled Executive Subroutines for Afterheat Temperature Analysis (ESATA) was written to consider this complex heat transfer analysis. Seven cases were calculated of a reactor power system capable of delivering up to 300 MW of thermal power to a nuclear airplane.

Puthoff, R. L.↗

DOE OSTI2020

Mechanical failure of fresh nuclear grade iron–chromium–aluminum (FeCrAl) cladding under simulated hot zero power reactivity initiated accident conditions

The reactivity initiated accident (RIA) is a postulated accident in light water reactors initiated by a rapid increase in reactivity which causes an increase in fission rate and fuel temperature. One potential mode of fuel system failure during RIA is pellet cladding mechanical interaction (PCMI) due to the rapid thermal expansion of the fuel pellet. Simulated PCMI experiments were performed by rapidly pressurizing iron-chromium-aluminum (FeCrAl) cladding tube samples using a hydraulic modified burst test system, causing the specimens to burst under a biaxial loading path. Deformation and rupture of the specimens were tracked with a telecentric lens and high-speed camera system. Outer surface strains were calculated using digital image correlation (DIC) on speckle patterns painted on the specimens’ outer surfaces. Experiments were conducted at approximately 275 °C, representative of hot zero power RIA conditions. The failure hoop strain was DIC-calculated between approximately 1.8–3.4%, corresponding to quasi-static energy depositions of approximately 110–260 calories per gram UO 2 assuming initial pellet-cladding contact. These conditions are very similar to the proposed energy deposition limit of 150 calories per gram UO 2 for unirradiated zirconium-based cladding in US Nuclear Regulatory Commission (NRC) Draft Regulatory Guide 1327. A very small strain rate dependence was observed in the data, with the magnitude of the failure hoop strain decreasing slightly with increasing strain rate. This observed dependence may be relevant because the FeCrAl cladding strain rate will be approximately 20% higher than in zirconium-based cladding due to the harder neutron spectrum and resultant shorter neutron generation time.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

NASA NTRS1992

Fusion energy from the Moon for the twenty-first century

It is shown in this paper that the D-He-3 fusion fuel cycle is not only credible from a physics standpoint, but that its breakeven and ignition characteristics could be developed on roughly the same time schedule as the DT cycle. It was also shown that the extremely low fraction of power in neutrons, the lack of significant radioactivity in the reactants, and the potential for very high conversion efficiencies, can result in definite advantages for the D-He-3 cycle with respect to DT fusion and fission reactors in the twenty-first century. More specifically, the D-He-3 cycle can accomplish the following: (1) eliminate the need for deep geologic waste burial facilities and the wastes can qualify for Class A, near-surface land burial; (2) allow 'inherently safe' reactors to be built that, under the worst conceivable accident, cannot cause a civilian fatality or result in a significant (greater than 100 mrem) exposure to a member of the public; (3) reduce the radiation damage levels to a point where no scheduled replacement of reactor structural components is required, i.e., full reactor lifetimes (approximately 30 FPY) can be credibly claimed; (4) increase the reliability and availability of fusion reactors compared to DT systems because of the greatly reduced radioactivity, the low neutron damage, and the elimination of T breeding; and (5) greatly reduce the capital costs of fusion power plants (compared to DT systems) by as much as 50 percent and present the potential for a significant reduction on the COE. The concepts presented in this paper tie together two of the most ambitious high-technology endeavors of the twentieth century: the development of controlled thermonuclear fusion for civilian power applications and the utilization of outer space for the benefit of mankind on Earth.

Kulcinski, G. L.↗

NASA NTRS2007

Optimization of Crew Shielding Requirement in Reactor-Powered Lunar Surface Missions

On the surface of the moon -and not only during heightened solar activities- the radiation environment As such that crew protection will be required for missions lasting in excess of six months. This study focuses on estimating the optimized crew shielding requirement for lunar surface missions with a nuclear option. Simple, transport-simulation based dose-depth relations of the three (galactic, solar, and fission) radiation sources am employed in a 1-dimensional optimization scheme. The scheme is developed to estimate the total required mass of lunar-regolith separating reactor from crew. The scheme was applied to both solar maximum and minimum conditions. It is shown that savings of up to 30% in regolith mass can be realized. It is argued, however, that inherent variation and uncertainty -mainly in lunar regolith attenuation properties in addition to the radiation quality factor- can easily defeat this and similar optimization schemes.

Barghouty, Abdulnasser F.↗

NASA NTRS2007

Optimization of Crew Shielding Requirement in Reactor-Powered Lunar Surface Missions

On the surface of the moon and not only during heightened solar activities the radiation environment is such that crew protection will be required for missions lasting in excess of six months. This study focuses on estimating the optimized crew shielding requirement for lunar surface missions with a nuclear option. Simple, transport-simulation based dose-depth relations of the three radiation sources (galactic, solar, and fission) are employed in a one-dimensional optimization scheme. The scheme is developed to estimate the total required mass of lunar regolith separating reactor from crew. The scheme was applied to both solar maximum and minimum conditions. It is shown that savings of up to 30% in regolith mass can be realized. It is argued, however, that inherent variation and uncertainty mainly in lunar regolith attenuation properties in addition to the radiation quality factor can easily defeat this and similar optimization schemes.

Barghouty, A. F.↗

NASA NTRS2003

Design concept for a nuclear reactor-powered Mars Rover

This paper describes the unique design challenges encountered in the development of this mission architecture and incorporation of the fission power system in the rover, and presents a detailed description of the final design of this innovative concept for providing long range, long duration mobility on Mars.

nuclear↗

NASA NTRS2022

Recent Concept Study for Cryogenic Fluid Management to Support Opposition Class Crewed Missions to Mars

NASA recently completed a mission concept study to evaluate the feasibility and propulsion technology development requirements for reduced travel duration crewed missions to Mars. A high-level goal of the study was to minimize the health impact on the crew caused by the space environment. This was implemented in the study by limiting the crew to a total of approximately-two years of in-space operations and travel time. For the initial mission, the crew would stay about 30 days on the Martian surface. The propulsive demands of such a mission are immense, and the study identified two advanced propulsion options with the potential to meet the mission requirements—both options rely on nuclear fission to provide efficient propulsive energy. One propulsion option was a nuclear electric propulsion (NEP)/Chem Hybrid, with a reactor and energy conversion system powering xenon propellant ion thrusters to provide an efficient, but lower-thrust, push for most of the mission duration. This concept also relied on a liquid oxygen/liquid methane (LO2/LCH4) chemical propulsion stage to provide high thrust for maneuvers while near the Earth and Mars. The second propulsion option was nuclear thermal propulsion (NTP), in which the reactor heats liquid hydrogen (LH2) propellant to expand through a nozzle for thrust at about twice the efficiency of the best chemical propulsion systems. Both vehicle concepts rely on storing large amounts of cryogenic propellant (either LO2/LCH4 or LH2) for multiple years in space without loss, far exceeding state-of-the-art capability. To enable this new capability, the team assumed the use of several advanced cryogenic fluid management (CFM) technologies and analyzed the integrated system performance. This included considering the vehicle-level effects of the size, mass, and power requirements of these CFM elements. Further, the team evaluated the development required to enable such a mission in the mid-2030 s and determined that it was feasible. The paper elaborates on the assumed CFM technologies, provides key analysis results, and illustrates the feasibility of technology development for the proposed solutions to the CFM challenges for each propulsion concept.

cryogenic propellant↗

NASA NTRS2017

Orbital Space Solar Power Option for a Lunar Village

One of the most significant challenges to the implementation of a continuously manned lunar base is power. During the lunar day (14 Earth days), it is conceptually simple to deploy solar arrays to generate the estimated 35 kilowatts of continuous power required. However, generating this level of power during the lunar night (also 14 Earth days) has been an extremely difficult problem to solve. Conventional solutions range from the requirement that the base be located at the lunar south pole so as to take advantage of the continuous sunshine available there to developing a space-qualified nuclear reactor and power plant to generate the needed energy. There is a third option: Use the soon-to-be-available Space Launch System to place a space based solar power station in lunar orbit that would beam the needed energy to the lunar base. Several detailed studies have been performed by NASA, universities and others looking at the lunar south pole for locating the base. The results are encouraging: by taking advantage of the moon's orbital tilt, large solar arrays can be deployed there to track the sun continuously and generate the power needed to sustain the base. The problem with this approach is inherent to its design: it will only work at the lunar south pole. There is no other site on the Moon with geometry favorable to generating continuous solar power. NASA has also considered the development of a compact fission reactor and power plant to generate the needed power, allowing the base to be sited anywhere on the Moon. The problem with this approach is that there are no space fission reactors available, none are being planned and the cost of developing one is prohibitively expensive. Using an orbiting space based solar power station to generate electrical power and beam it to a base sited anywhere on the moon should therefore be considered. The technology to collect sunlight, generate greater than the estimated 35 kilowatts of power, and beam it to the surface using microwaves is available today. The problem with this concept in the past would have been the mass and packaging volume (for launch) required to put such a system in place in lunar orbit. This problem is potentially solved with the advent of the Space Launch System (SLS). The SLS, with its 70 mT launch capacity, it more than capable of placing such a system into lunar orbit in a single launch. This paper will examine the potential use of an SLS-launched, space solar power system in lunar orbit as the primary power source for a first-generation, continuously-occupied lunar base and compare it with the other power generation and storage options previously considered.

Johnson, Les↗

NASA NTRS2018

Polar Volatiles Exploration in Peary Crater Enabled by NASA's Kilopower Project

For more than 50 years, scientists have discussed the possibility of the existence of water ice and other frozen volatiles at the lunar poles [1]. However, it was not until the 1990s when the polar orbiting spacecraft Clementine and Lunar Prospector collected data supporting these hypotheses [2]. Subsequent missions, including the Lunar Reconnaissance Orbiter (LRO) mission [3], and the Lunar Crater Observation and Sensing Satellite (LCROSS) mission [4], provided further evidence that supports the existence of water ice deposits at the lunar poles. During NASA's Constellation Program, several areas at both lunar poles polar were included in 50 Regions of Interest (ROI) for intensive study by the Lunar Reconnaissance Orbiter Camera (LROC) [5]. These polar ROI focused on peaks and craters rims that received high amounts of solar illumination, assuming initial missions back to the lunar surface would utilize solar arrays to generate electricity. Recently, the successful demonstration of NASA's Kilopower Project at the National Nuclear Security Administration (NNSA) Nevada National Security Site makes it possible to consider lunar polar missions at locations other than highly illuminated regions. The Kilopower Project was initiated in 2015 to demonstrate subsystem-level technology readiness of a small space fission power system [6]. This abstract describes the science objectives and operations for a mission concept developed at NASA Glenn Research Center's COMPASS Concurrent Engineering Team for a 1-year exploration of Peary Crater focused on prospecting for lunar polar volatiles.

Gruener, J. E.↗

NASA NTRS2007

Stainless Steel NaK-Cooled Circuit (SNaKC) Fabrication and Assembly

An actively pumped Stainless Steel NaK Circuit (SNaKC) has been designed and fabricated by the Early Flight Fission Test Facility (EFF-TF) team at NASA's Marshall Space Flight Center. This circuit uses the eutectic mixture of sodium and potassium (NaK) as the working fluid building upon the experience and accomplishments of the SNAP reactor program from the late 1960's The SNaKC enables valuable experience and liquid metal test capability to be gained toward the goal of designing and building an affordable surface power reactor. The basic circuit components include a simulated reactor core a NaK to gas heat exchanger, an electromagnetic (EM) liquid metal pump, a liquid metal flow meter, an expansion reservoir and a drain/fill reservoir To maintain an oxygen free environment in the presence of NaK, an argon system is utilized. A helium and nitrogen system are utilized for core, pump, and heat exchanger operation. An additional rest section is available to enable special component testing m an elevated temperature actively pumped liquid metal environment. This paper summarizes the physical build of the SNaKC the gas and pressurization systems, vacuum systems, as well as instrumentation and control methods.

Godfroy, Thomas J.↗

DOE OSTI2020

The use of U3Si2/Al dispersion fuel for high power research reactors

In order to investigate the irradiation performance of U3Si2/Al dispersion fuel at relatively aggressive reactor conditions, compared to how this fuel is typically used in a research or test reactor, post irradiation examination was performed on two fuel plates that were irradiated at ~270 W/cm2 average surface heat flux and to a maximum local burnup greater than 8 × 1021 fissions/cm3 in the Advanced Test Reactor as part of the RERTR-8 experiment. As part of the non-destructive examinations that were performed on both fuel plates, detailed thickness measurements using a high-fidelity measurement bench were performed on one fuel plate and a segment of the second fuel plate. This paper provides the first reported results of such high-resolution thickness measurements for U3Si2/Al dispersion fuel plates, containing primarily the U3Si2 fuel phase, irradiated at such power levels to high burnup. For destructive examination using optical metallography, samples were generated from both irradiated plates. Localized regions of high swelling (characteristic of internal blistering) were observed on the surface of both fuel plates, suggesting that the performance limits had been reached for each plate. Destructive examinations showed that the fuel particles that are primarily U3Si2, which become amorphous during irradiation, in both plates contained relatively large fission gas bubbles with evidence of fission gas bubble interconnection.

Wachs, Daniel M.↗

NASA NTRS2010

Progress Towards the Development of a Long-Lived Venus Lander Duplex System

NASA has begun the development of a combined Stirling cycle power and cooling system (duplex) to enable the long-lived surface exploration of Venus and other harsh environments in the solar system. The duplex system will operate from the heat provided by decaying radioisotope plutonium-238 or its substitute. Since the surface of Venus has a thick, hot, and corrosive atmosphere, it is a challenging proposition to maintain sensitive lander electronics under survivable conditions. This development effort requires the integration of: a radioisotope or fission heat source; heat pipes; high-temperature, corrosion-resistant material; multistage cooling; a novel free-displacer Stirling convertor for the lander; and a minimal vibration thermoacoustic Stirling convertor for the seismometer. The first year effort includes conceptual system design and control studies, materials development, and prototype hardware testing. A summary of these findings and test results is presented in this report.

Dyson, Roger W.↗

NASA NTRS2011

Progress Towards the Development of a Long-Lived Venus Lander Duplex System

Dyson, Rodger, W.↗

DOE OSTI2022

Evaluation of mitigation strategies for radioactive fission gases in fluoride-salt-cooled high-temperature reactors

Here, the Fluoride-salt-cooled High-temperature Reactor (FHR) is a promising Generation IV nuclear reactor due to its improved safety design, near atmospheric working pressure, and high electric power conversion efficiency. However, control of radioactive fission gases, such as tritium, is a critical issue in FHRs due to the significantly larger production rate and potentially larger leakage rate of tritium compared to those in Light Water Reactors (LWRs). Therefore, this study proposes two mitigation strategies for tritium in FHRs: Double-Wall Heat eXchanger with a Tritium Carrier (DWHX-TC) option and Single-Wall Heat eXchanger with a Tritium Barrier (SWHX-TB) option. For the DWHX-TC option, two tube surface configurations, i.e., plain and fluted tubes, and four tritium carriers, i.e., helium, FLiBe, FLiNaK, and KF-ZrF 4 , are initially considered, among which the best tube configuration and promising tritium carrier are then selected and used for design optimization of the DWHX. For the SWHX-TB option, two cases, tritium barriers with and without cracks, are investigated in this study. In addition, the two mitigation strategies are evaluated by an in-house, one-dimensional, coupled HEat and MAss Transfer (HEMAT) code developed to predict the leakage rate of tritium in nuclear systems. Our analysis shows that (1) a double-wall configuration using fluted tubes as both the inner and outer tubes is better than other double-wall configurations investigated; (2) helium, as a tritium carrier, is superior to other candidates, including FLiBe, FLiNaK, and KF-ZrF 4 ; (3) the leakage rate of tritium (into the atmosphere) is reduced from 3400 Ci/day, taking the Advanced High-Temperature Reactor (AHTR) as a reference, to 4.0 Ci/day for an optimum design of the DWHX-TC option using helium as the tritium carrier and 1.7 Ci/day for an optimum design of the SWHX-TB option using 30-µm thick silicon carbide (SiC) as the tritium barrier (no cracks); and (4) potential cracks in tritium barriers may significantly deteriorate mass transfer performance of the SWHX-TB option. For example, a cracking rate of 0.1% leads to an increase of 694.1% in the leakage rate under the conditions investigated.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2022

BISON validation of FeCrAl cladding mechanical failure during simulated reactivity-initiated accident conditions*

Here, a reactivity-initiated accident (RIA) is a postulated design basis accident in light water reactors (LWRs) in which a rapid reactivity insertion induces a fission rate increase and a fuel pellet temperature rise. During RIA, the fuel pellet thermally expands and may cause pellet-cladding mechanical interaction (PCMI). Separate effects PCMI tests were performed on C26M FeCrAl cladding tube samples, introducing biaxial stress via a well understood modified burst test (MBT) system. A high-speed camera in the MBT system captured the projections, covering a 360° view of the cladding deformation and enabling a digital image correlation (DIC) method to quantify the surface strains with high fidelity. Representative hot zero-power RIA mechanical loading conditions were applied to the sample, and the test duration ranged from 20 to 500 ms at an average temperature of 573 K. BISON finite element–based fuel performance code modeling was performed against the high-fidelity DIC data produced from the MBTs. Validation calculations were conducted with 2D models and systematically compared with test data of the burst time, burst pressure, burst hoop strains, and hoop strain rates. Based on the behaviors from the separate effects test, BISON calculations satisfactorily predicted the cladding deformation behaviors. Sensitivity analysis was conducted to identify highly influential mechanical properties responsible for the cladding failure behavior during the MBT experiments. The results highlight the significance of the cladding's mechanical strength in governing cladding strain, followed by the significance of the mechanical interactions between the pellet and the cladding.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2023

Integrated simulation of U-10Mo monolithic fuel swelling behavior

Here, a separate computational branch has been implemented within the DART (Dispersion Analysis Research Tool) computational code to simulate the swelling behavior of U-10Mo monolithic fuel under the operating conditions of high-power research and test reactors (RTRs). The monolithic branch of the DART code implements a mechanistic rate-theory-based fission-gas-behavior model for the calculation of fission gas swelling, as well as a suite of thermal, physical, and mechanical models to take into account various processes occurring in RTR fuels during irradiation. In order to accurately simulate and eventually predict U-10Mo monolithic fuel irradiation behavior, the code uses materials properties calculated with lower length-scale computational methods, such as gas atom diffusivity and U-Mo surface energy from atomic simulations and grain-morphology-specific recrystallization kinetics (recrystallized fuel volume fractions vs. fission density) predicted using the phase-field method. The remainder of fission gas behavior parameters used in the model were calibrated with measured intergranular bubble size distributions. With this integrated simulation approach, the swelling behavior of U-10Mo monolithic fuel was simulated for various initial grain sizes at different operating conditions and compared with measured data. Furthermore, because limited experimental data exist for parameter calibration detailed sensitivity studies for the important parameters used in the fission gas behavior model were performed in order to examine their impact on both intergranular gas bubble morphology at low fission density, and on total porosity at high fission density.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗