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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 235 records · Page 13
All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

Microstructural Development in Inconel 718 Nickel-Based Superalloy Additively Manufactured by Laser Powder Bed Fusion

Excellent weldability and high temperature stability make Inconel 718 (IN718) one of the most popular alloys to be produced by additive manufacturing. Here in this study, we investigated the effects of laser powder bed fusion (LPBF) parameters on the microstructure and relative density of IN718. The samples were fabricated with independently varied laser power (125 - 350W), laser scan speed (200 - 2200 mm/s), and laser scan rotation (0° - 90°). Archimedes’ method, optical microscopy, and scanning electron microscopy were employed to assess the influence of LPBF parameters on the relative density and microstructure. Optimal processing windows were identified for a wide range of processing parameters and relative density greater than 99.5% was achieved using volumetric energy density between 50 and 100 J/mm3. Microstructural features including melt pool geometry, lack of fusion defect, keyhole porosity, and sub-grain cellular microstructure were examined and quantified to correlate to LPBF parameters. A simple empirical model was postulated to relate relative sample density and LPBF volumetric energy density. Melt pool dimensions were quantitatively measured and compared to estimations based on Rosenthal solution, which yielded a good agreement with the width, but underestimated the depth, particularly at high energy input, due to lack of consideration for keyhole mode. In addition, the sub-grain cellular-dendritic microstructure in the as-built samples was observed to decrease with increasing laser scan speed. Quantification of the sub-micron cellular-dendritic microstructure yielded estimated cooling rate in the order of 10 5 – 10 7 K/s.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2025

Chlorine gas and anion radical reactivity in molten salts and the link to chlorobasicity

Next-generation nuclear power plants may include exciting novel designs in which molten salts are the coolant or a combination of the coolant and fuel. Whereas it is straightforward to see why having a low volatility coolant can be advantageous for safety, much is not understood about the production of volatile halogen gases as a result of radiation and even less is known about the distribution of these species at and away from interfaces. Using first principles molecular dynamics simulations, we investigate the product of the disproportionation reaction between chlorine anion radicals (nominally Cl 2 ˙ − ) in the bulk and slab configurations. We find that the product depends on the chlorobasicity of the medium. For example, in ZnCl 2 , Cl 2 forms, but in a eutectic mixture of LiCl and KCl, Cl 3 − is formed as a product. We also find that Cl 3 − prefers to form at the vapor interface and this may have implications for corrosion and reactivity. Furthermore, the mechanisms of the mobility of Cl 2 and Cl 3 − are radically different, the first one being vehicular and the second Grotthus-like. Chlorobasicity is linked to the electronic structure of the host melt; ZnCl 2 forms extended networks along which metal ions and anionic counterions have significant electronic orbital overlap forming long, linear, molecular-like constructs; the opposite is true for the alkali metal eutectic salt.

Nguyen, Hung H. [Univ. of Iowa, Iowa City, IA (Uni↗
DOE OSTI2021

Catalysts by pyrolysis: Direct observation of chemical and morphological transformations leading to transition metal-nitrogen-carbon materials

Transition metal-nitrogen-carbon materials (M-N-C catalysts) are promising electrocatalysts in polymer electrolyte fuel cells (PEFCs) and electrolyzer applications. High temperature treatment in inert atmosphere (pyrolysis) is the essential, most common method for the synthesis of M-N-C catalysts and critical to achieve high electrocatalytic activity and electronic conductivity. To this day, despite many uses and successful implementations in materials manufacturing, pyrolysis has been an entirely empirical technology, with process control and optimization relying exclusively on “Edisonian” approach. The knowledge gap in the mechanism about how the precursor is being transformed into catalysts hinders further development of the M-N-C catalysts regardless of the precursor class and processing protocols. In this work, we probed the morphological evolution and chemical transformation of a nitrogen-containing charge transfer organic salt, mixed with transition metal (iron) salt and amorphous silica powder (precursor) during the pyrolysis process via a combination of in situ synchrotron and laboratory-based diagnostic techniques. The pyrolysis process is found to be divided into three stages. During a controlled temperature ramp, the selected organic N-C precursor (nicarbazin) began melting and decomposing just below 400 °C, forming a certain number of micrometer-scale pores and pathways. With increase in temperature from 400 °C to 900 °C, amorphous carbon domains started forming, and reduced (metallic) iron nanoclusters appeared, being dispersed uniformly throughout the carbonaceous matrix. When temperature advanced above 900 °C, graphitization of carbon commenced, associated with appearance and evolution of atomically dispersed metal-nitrogen moieties in the carbonaceous matrix. As the graphitization advanced further, a secondary process of agglomeration of metal nanoparticles occurred. Multi-analytical technique observations conducted here provide a base for rational design and optimization of M-N-C electrocatalysts via pyrolysis.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Novel Synthesis and Characterization of Uranium-Zirconium Carbonitride by Direct Casting

UZrCN has exhibited thermophysical properties beneficial to high temperature reactor applications such as nuclear thermal rockets. The present work investigates a novel liquid phase synthesis method involving the admission of nitrogen gas during arc melting of uranium, zirconium, and carbon. Initial microstructural examinations using SEM indicated that the samples remain heterogenous with zirconium-rich cores in a uranium-rich matrix. Heterogeneity resulted from large differences in melting temperature of the major constituents and rapid solidification. Additional EDS, combustion analysis, and inert gas fusion analysis proved that the core regions have both uranium and zirconium and establish that carbon and nitrogen are retained during the fabrication process. XRD clarifies that the light elements did not form compounds with the uranium matrix but rather incorporated into the core region forming a sub-stoichiometric UZrCN. Heat treatment performed on equimolar U-Zr-C resulted in an increase in the homogenous phase present with an XRD pattern reflecting a ternary UZrCN despite small amounts of segregation in the final button.

36 - MATERIALS SCIENCE↗
DOE OSTI2020

Calculating Potential Radiological Emissions for Waste Management Activities at INL - 20068

At Idaho National Laboratory (INL), work involving radionuclides is evaluated for potential emissions from a project in order to comply with the National Emission Standards for Hazardous Air Pollutants (NESHAP) regulations, 40 CFR 61 Subpart H. Emission calculations are documented in an Air Permitting Applicability Determination (APAD) to analyze unmitigated and mitigated emissions and determine if an Application to Construct (ATC) or continuous monitoring is required. To calculate the unmitigated and mitigated emissions, a spreadsheet was developed to provide ease in determining potential emissions by providing the maximum operating temperature and the material being used. The spreadsheet aids in determining the potential emissions for research projects and waste management activities at Materials and Fuels Complex (MFC) and other locations across the INL site. Furthermore, it can also be used for periodic confirmatory measurements (PCM) to justify low emissions. Elements that factor into the unmitigated and mitigated calculations include the amount of each radionuclide used (in curies or grams), specific activity (if amount is given in grams), the temperature the material is heated to in Celsius, the dose conversion factor which is derived from Clean Air Act Assessment Package - 1988 (CAP-88) modeling, and the number of HEPA filters used for mitigated measures. The main drivers for calculating the unmitigated emissions for a project are the amount used per radionuclide, the maximum operating temperature, and the location of the work. The maximum operating temperature determines the airborne release factor which is dependent on the physical state of the radionuclide. Prior to October 2017, if the radionuclide was heated to greater than 100 deg. C, the radionuclide was assumed to be a gas, which has the highest airborne release factor. This assumption would be overly conservative for radionuclides with high melting and boiling points, which provided a challenge to demonstrate low emissions. In October 2017, the Environmental Protection Agency (EPA) approved an alternative method for INL. This method allows the airborne release factor to be determined by using the melting point and 90% of the boiling point of the radionuclide. This methodology was included in the spreadsheet to allow unmitigated emission calculations for APADs to be completed more efficiently and effectively. Results show a reduction in time completing air emission calculations as well as lower total emissions across all facilities at INL. MFC annual emissions were reduced by 62% from the previous year and Research and Education Campus (REC) facilities were reduced by 38% due to implementation of the approved alternative method. Time spent on APADs, PCMs, and documentation for the annual NESHAP report was also reduced significantly. The spreadsheet provided in Table I provides the potential emission calculations for the 'Advanced Retrieval and Disposition Techniques for Remote Handled Mixed Low Level Waste (RH MLLW) at the Radioactive Scrap and Waste Facility (RSWF)' project. Calculations show the Potential Effective Dose Equivalent (PEDE) at RSWF to be 7.27 E-04 mrem/yr (7.27 E-09 Sv/yr) which is well below the 0.1 mrem/yr threshold. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2020

A Discrete Dendrite Dynamics Model for Epitaxial Columnar Grain Growth in Metal Additive Manufacturing with Application to Inconel

Epitaxial columnar grain growth is a prevalent microstructural feature in the additive manufacturing (AM) of metal components such as Inconel, with cubic unit cell crystal lattice structure (face centered cubic (FCC) or body centered cubic (BCC)). These columnar grains evolve from the partly molten grains in the substrate or the solidified metal. This work proposes an efficient model to simulate the competitive growth of epitaxial columnar dendritic grains. The proposed model tracks the dynamic changes in the dendrites emanating from discrete points along the solid/liquid interface of a quasi-steady melt pool (MP). These dynamic changes include convergence and divergence of growing dendrites. The model is extended to predict the microstructure of large 3D parts and experimentally validated by comparing the simulation results for laser powder bed fusion (L-PBF) and wire-arc additive manufacturing (WAAM) processes. The microstructure and pole figures are predicted for Inconel 718 samples produced by L-PBF and Inconel 740H samples produced by WAAM processes. Finally, the model predictions compare well with the observed microstructure and pole figures results for both the L-PBF and WAAM processes.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2023

Integrated Circular Economy Model System for Direct Lithium Extraction: From Minerals to Batteries Utilizing Aluminum Hydroxide

Aluminum hydroxide, an abundant mineral found in nature, exists in four polymorphs: gibbsite, bayerite, nordstrandite, and doyleite. Among these polymorphs gibbsite, bayerite, and commercially synthesized amorphous aluminum hydroxide have been investigated as sorbent materials for lithium extraction from sulfate solutions. The amorphous form of Al(OH) 3 exhibits a reactivity higher than that of the naturally occurring crystalline polymorphs in terms of extracting Li + ions. This study employed high-temperature oxide melt solution calorimetry to explore the energetics of the sorbent polymorphs. The enthalpic stability order was measured to be gibbsite > bayerite > amorphous Al(OH) 3 . The least stable form, amorphous Al(OH) 3 , undergoes a spontaneous reaction with lithium, resulting in the formation of a stable layered double hydroxide phase. Consequently, amorphous Al(OH) 3 shows promise as a sorbent material for selectively extracting lithium from clay mineral leachate solutions. Further, this research demonstrates the selective direct extraction of Li + ions using amorphous aluminum hydroxide through a liquid–solid lithiation reaction, followed by acid-free delithiation and relithiation processes, achieving an extraction efficiency of 86%, and the maximum capacity was 37.86 mg·g –1 in a single step during lithiation. With high selectivity during lithiation and nearly complete recoverability of the sorbent material during delithiation, this method presents a circular economy model. Furthermore, a life cycle analysis was conducted to illustrate the environmental advantages of replacing the conventional soda ash-based precipitation process with this method, along with a simple operational cost analysis to evaluate reagent and fuel expenses.

25 ENERGY STORAGE↗
DOE OSTI2023

Analysis of iron-chromium-aluminum samples exposed to accident conditions followed by quench in the QUENCH-19 experiment

The QUENCH-19 experiment was a first-of-its-kind full-bundle test simulating accident conditions followed by water quench on accident-tolerant fuel (ATF) cladding. Here, a type of FeCrAl(Y) alloy, B136Y3, was developed at Oak Ridge National Laboratory and tested at the Karlsruhe Institute of Technology using Kanthal APM corner rods, a shroud, and Kanthal AF spacer grids. Testing conditions were similar to those in QUENCH-15—which tested ZIRLO cladding behavior—so that B136Y3 and ZIRLO cladding could be compared. QUENCH-19 consisted of an initial pre-oxidation heating followed by a transient. Then, a maximum power hold, which was not present in QUENCH-15, was executed to extend the heating period for the FeCrAl(Y) rods. Finally, a rapid water quench was executed that was similar to emergency core coolant system (ECCS) actuation. Compared with the ZIRLO rods in QUENCH-15, the bundle in QUENCH-19 released significantly less H 2 (9.2 g vs. 47.6 g) and achieved a much lower maximum temperature (1455°C vs. 1880°C). Furthermore, no breakaway oxidation was observed in QUENCH-19. Metallographic mounts revealed that despite the symmetry of the setup, at elevations near the maximum temperature, cladding and thermocouples were heavily damaged, substantial melting and oxidation occurred, and the cladding underwent chemical interaction with the thermocouple sheaths. Additionally, the ZrO 2 spacers detrimentally interacted with the cladding, leading to mixed oxide debris and the full destruction of some rods. Additional failure was found in certain cooler rods that may have risen due to the high thermal expansion coefficient of FeCrAl alloys. This paper presents an analysis of this work, which suggests that FeCrAl cladding can chemically survive anticipated loss-of-coolant accident events followed by rapid ECCS quench if the correct geometry and core design are present.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Technology Strategy Assessment: Findings from Storage Innovations 2030 Thermal Energy Storage

The concept of thermal energy storage (TES) can be traced back to early 19th century, with the invention of the ice box to prevent butter from melting. Modern TES development began with building heating and cooling and concentrated solar thermal technologies for power generation in the early 1900s and late 1970s, respectively. TES systems provide many advantages compared with other long-duration energy storage (LDES) technologies, which include low costs, long operational lives, high energy density, synchronous power generation capability with inertia that inherently stabilizes the grid, and the ability to output both heat and electricity. TES Use Cases TES technologies can couple with most renewable energy systems, including wind, photovoltaic, and concentrated solar thermal energy, and can be used for heat-to-heat, heat-to-electricity, electricity-to-heat, and electricity-to-electricity (bidirectional electricity) applications. The three types of TES that have heat as an input or output are grouped together for the purposes of this report. Retrofitting retired thermal power plants can be a potential cost-effective option for TES with electricity output because they both use a similar thermal-to-electricity type of conversion. Additionally, TES can directly serve heat demand for buildings and industrial processes, displacing fossil fuels to achieve broad decarbonization. Bidirectional Electricity Figure 1 shows a bidirectional electricity TES (ETES) architecture that is emerging as a prime technology for LDES at a grid scale. The ETES technology can utilize existing TES technology infrastructures, has no geological limitations (such as mountains and water for pumped storage hydro, underground natural caverns for compressed-air energy storage, etc.), and is capable of deployment anywhere in the United States and the world for broad uses. Particularly, ETES technology can be placed at retired fossil-fueled thermal power plants to reuse decommissioned assets, protect job security in associated communities, and provide resilient and high-inertia (i.e., spinning) power to the grid. Heat Input and Output There also are many ways to integrate TES within heat-to-electricity, heat-to-heat, and electricity-to-heat applications, such as those used in concentrating solar power (CSP), buildings, district heating, and industry process heat applications. These categories can be further classified for low- and high-temperature applications. High-temperature thermal energy storage (HTTES) heat-to-electricity TES applications are currently associated with CSP deployments for power generation. TES with CSP has been deployed in the Southwestern United States with rich solar resources and has proved its value to the electric grid. Electricity-to-heat and heat-to-heat HTTES applications present great potential for decarbonizing energy-intensive industrial process heat applications [8, 9], such as iron ore processing, iron smelting, cement production, glass manufacturing, mineral processing, and chemical production. Some industrial processes require process heat at temperatures > 1,400°C, so HTTES can be utilized to reduce fuel consumption in those processes through fuel, oxidizer, and process material pre-heating. Thermal energy storage for augmenting existing industrial process heat applications makes a much more attractive economic case because the energy penalty due to thermal-to-electric conversion is eliminated. Co-located applications of power production and heat also can add to the value stacking of integrating utility-scale TES; however, these scenarios are very case specific and not practically possible in many cases. These constraints are primarily attributed to the existing infrastructure being designed, developed, and constructed for many decades around the most economically feasible technologies, such as electricity and a selection of fossil fuels for heat input. Low-temperature TES can be utilized for building and district heating and cooling, as well as some process heat applications in electricity-to-heat and heat-to-heat configurations. Lower temperature TES (LTTES) can be added to heat pump equipment (electric input), either directly interacting with the refrigerant in the condenser or evaporator, or through a secondary heat transfer fluid. It also can be integrated in the building envelope or within the ducts of the heating, ventilation, and air conditioning (HVAC) system. Cost-effective integration of TES into buildings adds significant cost, and it is one of the key barriers preventing the commercialization and deployment of TES. The optimal strategy for integrating TES with buildings has yet to be determined for various applications of TES. Nevertheless, thermal storage materials are far less costly per unit of energy stored than electricity storage materials. This means that thermal storage has the potential to reduce the cost to society of energy storage.

25 ENERGY STORAGE↗
DOE OSTI2025

Compatibility of molten plutonium with wrought and additively manufactured metal crucibles

Understanding plutonium’s interaction with metals is crucial for optimizing pyrochemical operations, nuclear fuel containment, and various actinide processing techniques. Traditionally, tantalum crucibles are employed for plutonium processing due to their high durability, excellent temperature stability, and low solubility in plutonium. However, tantalum faces challenges such as plutonium wetting and diffusion, making surface coatings particularly important for crucibles in pyrochemical applications to enhance corrosion resistance against plutonium. Tantalum is also expensive and difficult to machine, prompting the need for advanced manufacturing techniques to address these challenges. Here, in this work, we investigate the interaction of Pu with tantalum and titanium crucibles fabricated using both traditional machining methods and laser powder bed fusion (LPBF) additive manufacturing (AM). LPBF-AM is an advanced technique that allows for the creation of complex geometries from traditionally difficult-to-machine metals by using a high-powered laser to build parts. Previous studies of conventional manufactured tantalum have utilized oxidation and carburization of the surface to mitigate plutonium wetting; however, no studies of surface modified LPBF-AM material have been undertaken. These studies are crucial, given the typical differences in the grain structure between conventional and LPBF-AM materials. All crucibles underwent differential scanning calorimetry to confirm the melting of plutonium. Subsequently, the crucibles were sectioned and mounted in epoxy for microstructural analysis using optical microscopy and scanning electron microscopy. This investigation, comparing the performance of wrought vs AM metal crucibles, provides a basis for future tooling applications in actinide processing techniques and can address the challenges associated with traditional machining, particularly in pyrochemical applications.

Actinides↗
DOE OSTI2021

Neutron Dosimetry for the GE Hitachi 16-10393 Irradiation in ATR

PNNL project 74242 involves the analysis of neutron fluence monitors and melt wires irradiated in the Advanced Test Reactor (ATR) at Idaho National Laboratory in accordance with MPO 00236287 and Statement of Work (SOW) No. 17370, Rev. 0, PNNL Analysis of NSUF Flux and Melt Wire Capsules. This report is for the GE Hitachi 16-10393 irradiation which was conducted in positions B11 of the ATR. Three other irradiations included in the SOW will be reported separately. The neutron fluence monitors were prepared by PNNL and loaded into the GE Hitachi assemblies prior to irradiation. Following irradiation, the capsules were returned to PNNL for analysis. The neutron dosimetry capsules were opened, the flux wires were removed for gamma analysis. The measured activities were used to determine the activation rates for various activation products. Following suitable corrections, the measured activation rates were used to adjust calculated neutron spectra at each fluence monitor location. The adjusted neutron spectra were then used to determine displacement per atom (dpa) and gas production for irradiated materials.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2022

A systematic method for selecting molecular descriptors as features when training models for predicting physiochemical properties

Machine learning has proven to be a powerful tool for accelerating biofuel development. Although numerous models are available to predict a range of properties using chemical descriptors, there is a trade-off between interpretability and performance. Neural networks provide predictive models with high accuracy at the expense of some interpretability, while simpler models such as linear regression often lack in accuracy. In addition to model architecture, feature selection is also critical for developing interpretable and accurate predictive models. We present a method for systematically selecting molecular descriptor features and developing interpretable machine learning models without sacrificing accuracy. Our method simplifies the process of selecting features by reducing feature multicollinearity and enables discoveries of new relationships between global properties and molecular descriptors. To demonstrate our approach, we developed models for predicting melting point, boiling point, flash point, yield sooting index, and net heat of combustion with the help of the Tree-based Pipeline Optimization Tool (TPOT). For training, we used publicly available experimental data for up to 8351 molecules. Our models accurately predict various molecular properties for organic molecules (mean absolute percent error (MAPE) ranges from 3.3% to 10.5%) and provide a set of features that are well-correlated to the property. This method enables researchers to explore sets of features that significantly contribute to the prediction of the property, offering new scientific insights. To help accelerate early stage biofuel research and development, we also integrated the data and models into a open-source, interactive web tool.

09 BIOMASS FUELS↗
DOE OSTI2021

Synthesis, antibiotic structure–activity relationships, and cellulose dissolution studies of new room-temperature ionic liquids derived from lignin

Ionic liquids (ILs) are promising pretreatment solvents for lignocellulosic biomass, but are largely prepared from petroleum precursors. Benzaldehydes from depolymerized lignin, such as vanillin, syringaldehyde, and 4-methoxy benzaldehyde, represent renewable feedstocks for the synthesis of ionic liquids. We herein report syntheses of novel lignin-derived ionic liquids, with extended N -alkyl chains, and examine their melting points, cellulose dissolution capacities, and toxicity profiles against Daphnia magna and E. coli strain 1A1. The latter organism has been engineered to produce isoprenol, a drop-in biofuel and precursor for commodity chemicals. The new N,N -diethyl and N,N -dipropyl methyl benzylammonium ILs were liquids at room temperature, showing 75–100 °C decreased melting points as compared to their N,N,N -trimethyl benzylammonium analog. Extension of N -alkyl chains also increased antibacterial activity threefold, while ionic liquids prepared from vanillin showed 2- to 4-fold lower toxicity as compared to those prepared from syringaldehyde and 4-methoxybenzaldehyde. The trend of antibacterial activity for anions of lignin-derived ILs was found to be methanesulfonate < acetate < hydroxide. Microcrystalline cellulose dissolution, from 2 to 4 wt% after 20 min at 100 °C, was observed in all new ILs using light microscopy and IR spectroscopy. Ionic liquids prepared from H-, S- and G-lignin oxidation products provided differential cytotoxic activity against E. coli and D. magna , suggesting these compounds could be tailored for application specificity within a biorefinery.

09 BIOMASS FUELS↗
DOE OSTI2023

Elucidation of Structure and Physical Properties of Pyrolytic Sugar Oligomers Derived from Cellulose Depolymerization/Dehydration Reactions: A Density Functional Theory Study

Fast pyrolysis of lignocellulosic materials is a promising research area to produce renewable fuels and chemicals. Dehydration is known to be among the most important reaction families during cellulose pyrolysis; water is the most important product. Together with water, dehydration reactions also form a range of poorly known oligomer species of varying molecular sizes, often collected as part of bio-oil water-soluble (WS) fraction. In this work, we used electronic structure calculations to evaluate the relative thermodynamic stabilities of several oligomer species resulting from up to three consecutive dehydration events from cellulose depolymerization intermediates. A library of the thermodynamically favored candidate molecular structures was compiled. Results revealed that most of the water molecules are eliminated from the non-reducing end, forming thermodynamically more stable conjugated compounds. This is consistent with results reported by other researchers in literature where dehydration reactions occur preferably at the non-reducing ends of oligomers. The physical-chemical properties of the proposed structures were estimated using quantitative structure-property relationships (QSPRs) and quantitative property-property relationships (QPPRs). The anhydro-sugars derived from cellulose are often blamed for coke formation during bio-oil hydrotreatment. Understanding their chemical structure could help to develop rational strategies to mitigate coke formation. Furthermore, the thermo-physical properties reported (boiling point, melting point, Gibb’s free energy of formation, enthalpy of formation, and solubility parameters among others) are also fundamental to conducting first principle engineering calculations to design and analyze new pyrolysis reactors and bio-oil up-grading units.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2021

Neutron Dosimetry for the Colorado School of Mines (CSM 16-10584) Irradiation in ATR

PNNL project 74242 involves the analysis of neutron fluence monitors irradiated in the Advanced Test Reactor (ATR) at Idaho National Laboratory in accordance with MPO 00236287 and Statement of Work No. 17370, Rev. 0, PNNL Analysis of NSUF Flux and Melt Wire Capsules. This report is for the Colorado School of Mines (CSM 16-10584) experiment which was conducted in position B5 of the ATR. Three other irradiations included in the scope of work are reported separately. The neutron fluence monitors were prepared by PNNL and loaded into the CSM assemblies at INL prior to irradiation. Following irradiation, the capsules were returned to PNNL for analysis. The neutron dosimetry capsules were opened, the flux wires were removed for gamma analysis, and the measured activities were used to determine the activation rates for various activation products. Following suitable corrections, the measured activation rates were used to adjust calculated neutron spectra at 12 fluence monitor locations. The adjusted neutron spectra were then used to determine displacement per atom (dpa) and gas production for irradiated materials.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2021

Neutron Dosimetry for the University of Central Florida (UCF3) Irradiation in ATR

PNNL project 74242 involves the analysis of neutron fluence monitors irradiated in the Advanced Test Reactor (ATR) at Idaho National Laboratory in accordance with MPO 00236287 and Statement of Work No. 17370, Rev. 0, PNNL Analysis of NSUF Flux and Melt Wire Capsules. This report is for the University of Central Florida (UCF)-3 third stage experiment which was conducted in position B8 of the ATR. Three other irradiations included in the scope of work are reported separately. The neutron fluence monitors were prepared by PNNL and loaded into the UCF-3 assemblies at INL prior to irradiation. Following irradiation, the capsules were returned to PNNL for analysis. The neutron dosimetry capsules were opened, the flux wires were removed for gamma analysis, and the measured activities were used to determine the activation rates for various activation products. Following suitable corrections, the measured activation rates were used to adjust calculated neutron spectra at 8 fluence monitor locations. The adjusted neutron spectra were then used to determine displacement per atom (dpa) and gas production for irradiated materials.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2023

Corrosion testing needs and considerations for additively manufactured materials in nuclear reactors

Metal additive manufacturing holds significant promise as an enabling technology for the 21st century nuclear energy industry. Metal additive manufacturing (MAM) can allow the fabrication of novel materials and innovative component designs that are not achievable through conventional manufacturing. Due to its very different fabrication methods, as-fabricated MAM components are characteristically different from conventionally manufactured components. MAM materials exhibit very different microstructures from conventional cast or wrought materials. For example, austenitic stainless steels fabricated by laser powder bed fusion exhibit columnar grain structures, dislocation cell structures, and melt pool fingerprints. In addition, MAM fabrication may result in defects such as porosity, incomplete processing of the feedstock (e.g., lack of fusion in melt-based methods), and oxide inclusions. Heat treatments may further evolve the microstructure, microsegregation, and stresses within the component. Furthermore, MAM components have a rough surface with feature sizes on the order of the feedstock material, as opposed to smooth surfaces resulting from conventional machining and forming operations. As a result, the corrosion behavior of MAM components will likely be significantly different from that of conventionally formed components. Corrosive environments for structural materials within advanced reactor environments include molten fluoride and chloride salts, liquid sodium and lead-bismuth, and high-temperature helium. The Advanced Materials and Manufacturing Technologies program within the Department of Nuclear Energy in the United States Department of Energy is assessing the unique concerns of MAM component corrosion and testing methodologies in advanced nuclear reactor environments. We discuss these concerns and testing strategies in this paper.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2024

High Temperature Additive Architectures for 65% Efficiency (Final Technical Report)

This project aimed to develop advanced high-temperature additive components that contribute towards the DOE’s goal for advanced gas turbines that are capable of at least 65% efficiency in combined cycle application. The objective was to leverage state-of-the-art additive manufacturing to develop an innovative stage 1 turbine nozzle (S1N) that can provide cooling flow savings while maintaining the component durability expected in today’s gas turbines. The program had two phases. Phase I was a conceptual phase for novel advanced cooling designs enabled by additive manufacturing, as well as proposals for validation. Phase II included execution of the Phase I conceptual design, including manufacturing of prototype hardware and validation within an environment that is similar to engine operation. During Phase I of the program, the team devised a concept to reduce cooling air usage. The cooling air used in the side walls is filmed out along the side walls, while the cooling air used in the airfoil is eventually directed to near-wall channels and exits holes along the airfoil trailing end. During this program, the team performed additive trials to analyze the geometric limitations of additive manufacturing. This helped the team understand minimum wall thicknesses, hole sizes, and cooling channel dimensions among other limits. Phase II of this program pushed GE Vernova beyond its previous experience of designing and manufacturing an additively manufactured hot gas path component. Modern hot gas path components utilize material chemistries that are traditionally hard to weld, such as cast Renè 108, and exhibit solidification cracking when additively manufactured using Direct Metal Laser Melting (DMLM). Note that AM108 is a powder form of Renè 108. A S1N with advanced cooling is larger and more complex than parts previously built by additive manufacturing and required new learnings to resolve risks around solidification cracking. Finally, the team validated the design in a combustion rig that replicated operation in a gas turbine. In order to properly quantify the benefits of the new additive design, a baseline was also tested in the rig and operated under the same conditions. In addition, an uncertainty analysis was done to quantify any sources of error that could impact the results. At the end of the validation effort, it was determined that the additive nozzle exceeded the 15% reduction in cooling flow goal even with the worst-case assumptions for uncertainty.

03 NATURAL GAS↗