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All sourcesNASA NTRSDOE OSTI
DOE OSTI2021

Pulsed Thermal Tomography Nondestructive Examination of Additively Manufactured Reactor Materials and Components. Third Annual Progress Report

Additive manufacturing (AM) of high-strength corrosion resistance alloys for nuclear energy applications, such as stainless steel and Inconel, is currently based on laser powder bed fusion (LPBF) process. Some of the challenges with using LPBF method for nuclear manufacturing include the possibility of introducing pores into metallic structures. Probability of crack initiation at the pore depends on size, shape, and orientation of the defect. Pulsed Infrared Thermography Imaging (PIT) provides a capability for non-destructive evaluation (NDE) of sub-surface defects in arbitrary size structures. The PIT method is based on recording material surface temperature transients with infrared (IR) camera following thermal pulse delivered on material surface with flash light. The PIT method has advantages for NDE of actual AM structures because the method involves one-sided non-contact measurements and fast processing of large sample areas captured in one image. Following initial qualification of an AM component for deployment in a nuclear reactor, a PIT system can also be used for in-service nondestructive evaluation (NDE) applications. In this report, we describe recent progress in enhancing PIT capabilities in detecting microscopic subsurface defects in metals, and classifying shapes and orientation of pores in thermal images. For detection of microscopic defects in PIT imaging data, we have developed Spatial Temporal Denoised Thermal Source Separation (STDTSS) unsupervised machine learning (ML) image processing algorithm. We show that flat bottom hole (FBH) defects as small as 200µm in SS316 and IN718 specimens, can be detected with STDTSS algorithm. To the best of our knowledge, these are the smallest detected defects which are reported in literature. For classification of defects shapes, we have previously developed thermal tomography (TT) algorithm to obtain depth reconstructions of material defects from data cube of sequentially recorded surface temperatures. However, interpretation of TT images is non-trivial because of blurring with increasing depth. To address this challenge, we have developed a deep learning convolutional neural network (CNN) to classify size and orientation subsurface defects in simulated TT images.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2023

Phase Field Modeling of Corrosion for Design of Next-Generation Magnesium-Aluminum Vehicle Joints

In this study, WPI and its partners sought to understand galvanic corrosion in Mg-Al friction stir weld (FSW) joints. Unlike fusion welds, FSW is done in the solid state. This limits (but does not eliminate) the formation of brittle Al-Mg intermetallics, resulting in better joint strength and corrosion resistance. This study aimed to understand corrosion behavior of Mg-Al FSW joints by using a Cahn-Hilliard phase field electrochemistry model based on the work of Pongsaksawad et al. Its context challenge problem was an ultra-light door designed by Magna with 6061-Al sheet outer and ZEK100-Mg sheet inner panels, joined by an adhesive and FSW. Unlike most FSW joints, which weld through the softer material into the harder one, the Al sheet’s hem joint around Mg required the FSW tool to through the harder Al into the softer Mg, which was itself a challenge. Despite this challenge, PNNL succeeded in consistently making very strong FSW lap joints, by using a triflute tool and power control. Characterization showed mostly separate Al and Mg regions in the weld, usually with a hook protruding from Al into Mg, which likely contributed to high joint strength. Nanohardness mapping showed higher hardness in thin Mg swirls into the Al nugget, likely due to the intermetallics. The study used the industry standard SAE J2334 Cyclic Corrosion Test (CCT) to simulate corrosion conditions over the life of a vehicle, as well as linear polarization testing and ASTM G71 pitting corrosion testing. Corrosion reactions were: H 2 O + ½O 2 + 2e - → 2OH - at the Al cathode, and either Mg → Mg 2+ + 2e - or Mg + 2OH - → Mg(OH) 2 + 2e - at the Mg anode, with electron transfer through the joint. Mass loss increased with Al section length, supporting the hypothesis that galvanic corrosion in Al-Mg joints is limited by the cathodic reaction. Both pitting corrosion (first anode reaction) and hydroxide film formation (second reaction) were observed. The J2334 CCT test method was slightly modified, adding a chromium solution cleaning step after each week of corrosion testing, in order to remove Mg oxides and hydroxides and accurately measure mass loss over time. That said, FSW joints treated in this way did not did not exhibit significant reduction in lap shear strength of the joints vs. newly welded samples which had not undergone corrosion. Corrosion appeared to consist mainly of pitting in Mg in a way which did not directly affect the bond between the materials where the joints failed. A Cahn-Hilliard phase field model coupled with electrical potential described the electronically mediated galvanic corrosion electrochemical reactions described above in the four-component Al-Mg-H 2 O-(H 2 O+½O 2 ) system. This 2-D model successfully predicted Mg(OH)₂ formation at the anode in some circumstances, and Mg pitting corrosion in others, and showed the correct electric field directions in both cases. The model predicted Mg pit corrosion depth within a factor of two of measured pits.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2025

WRPS Hanford Update [Slides]

The purpose of this report is to coordinate with the staff from WRPS, the current contract holder for operations at the Hanford site to better inform design decisions for the Autonomous systems for Hanford waste tank handling project. The project goals are to support risk reduction associated with monitoring, inspection and mapping of Hanford tank underground pits and includes: 1. A pit mock-up demonstration of Idaho National Laboratory’s (INL) Autonomous Pit Exploration System (APES) technology, which has two configurations: A. The Autonomous Robotic Arm, which is a proposed collaboration with Florida International University (FIU) and has capabilities to visually inspect, monitor, map and conduct simple tool manipulation tasks in the tank pits, and B. The robotic crawler configuration, which has capabilities to deploy to the bottom of the pits and conduct closer and bottom-up visual inspections. 2. An Implementation Plan that identifies Hanford site-wide application of the INL remote robotics technologies to enhance the performance of the tank farm systems and the characterization of the waste they contain to mitigate risk and optimize the overall waste mission. 3. A first-of-a-kind environmental digital twin will be produced. Digital twins to date require permanently installed sensors in order to produce asset specific predictions. This project will use the intermittent signals during inspections from deployed sensors on robotic systems to produce the data sets used by AI/ML to enable predictions of issues on tanks.

42 - ENGINEERING↗
DOE OSTI2018

Aging Hanford Nuclear Waste Using Carbon Dioxide to Evaluate Corrosion at Lower pH Limits - 18467

Samples of Hanford Nuclear Reservation (HNR) tank waste and simulated Hanford tank waste were exposed to carbon dioxide gas (CO{sub 2}) in the laboratory in order to decrease the pH of the solution. Sodium hydroxide is required to be added to some tanks according to waste handling specifications to keep tanks protected from pitting corrosion, but the maximum-allowed volume in some tanks is currently approaching capacity. Decreasing the pH of tank solutions using CO{sub 2} gas mimics the environmental exposure chemistry, does not add sodium, and allows for testing on solutions currently categorized as out-of-specification according to technical waste handling documents. Legacy alloy A537 Class 1 carbon steel was used to construct the AN tanks on the HNR and was utilized for this testing. The planned testing of three solutions included a simulant for feasibility and a waste solution from Tank 241-AN-102 (AN-102), taken in 2013, which was run in duplicate. The solutions were evaluated for corrosion potential using cyclic potentiodynamic polarization (CPP) scans to determine the propensity for stress corrosion cracking and pitting corrosion. Results in all solutions showed that pitting potential was low when the pH was above 11 and temperatures were below 40 deg. C. As solution pHs dipped into the 10- 10.5 range, there were mixed results. CPP scans were initially run at the higher temperature of 50 deg. C, accelerating corrosion rates. Solution pHs that did not indicate corrosion were further exposed to CO{sub 2}. Solutions with mixed or positive pitting results were rerun at 40 deg. C. The first failed run on the tank solution was seen when testing the duplicate sample at 50 deg. C and a pH of 13.01. When this solution was retested at 40 deg. C, the CPP scan did not show corrosion. A mixed corrosion result was obtained from a scan run at the final pH of 10 when tested at 50 deg. C. Upon completion of testing a visual inspection of the coupon did not show corrosion products on its surface. These results provide assurance that tanks containing slightly reduced pHs are still protected from pitting corrosion. Tank integrity assurance at a lower pH limit in Tank AN-102 could slow sodium addition and the rising volume of hazardous waste. Other benefits of reducing the pH specification would be reduced costs associated with retrieving and storing smaller volumes of hazardous waste, a reduced number of radiation exposure events (required for pH modification of tank waste), and a potential for a decreased volume required to be immobilized for long-term storage in a vitrified (glass) phase. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2016

Chloride-Induced Stress Corrosion Cracking Characteristics of the Used Nuclear Fuel Canister Material

The used nuclear fuel (UNF) dry storage systems are located in the coastal and lake/river-side regions, the service time of which is 60 years and more. One type of dry storage systems is composite of a thin-walled austenitic stainless steel (SS) welded canister and a concrete overpack. The air flows through the canister surface and brings away the decay heat. Meanwhile, the air brings the salt species into the canister and make them deposit on the surface. The salt deposit will be deliquescent when absorbing the moisture air, being corrosive to the surface. NRC and other programs claimed that chloride induced stress corrosion cracking (CISCC) would lead to the canister failure, being one of the major technical gaps for extended dry storage systems. CISCC is induced by the combined influence of the aggressive environment (chloride ions in our case) and tensile stresses (residual stresses in our case) on the susceptible materials (the austenitic SS in our case). Chrome (Cr), as one of the chemical compositions of SSs, plays an important role in the corrosion resistance. It can form a chrome-rich inner barrier oxide layer to prevent the SS from corrosion. However, chloride ions can easily break down the barrier and accelerate dissolution of the underlying metal, the phenomena of which is pitting corrosion. Pitting is the precursor to CISCC as which provides the combination of a local aggressive solution chemistry and a stress concentrating feature. Accordingly, CISCC invariably originates from the pits, and cracks that have nucleated on pit walls can grow around the pit and coalesce to form a complete through-crack. Significant tensile residual stresses, caused by the welding process, exist throughout the thickness of the canister wall. Enos and Bryan found that large residual stresses were in the full-scale mockup container simulating a canister, which supports the SCC propagation. It is therefore interesting to achieve a good knowledge about the effect of welding on the durability of SSs, especially in the corrosive environment. In order to understand the fundamental of the cracking behaviors, it's vital to elucidate the microstructure and microchemistry of cracking. This study focused on observing the CISCC characteristics of the UNF canister material exposed to the humid environment with salt deposit. Extensive micro-characteristics have been achieved by the techniques include focused ion beam/ scanning electron microscope (FIB/SEM), transmission electron microscopy (TEM), energy dispersive spectroscopy (EDS), and optical profiler. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2022

Improving Abundance Estimates of Spring–Summer Snake River Chinook Salmon for Fisheries Management

Abstract The Columbia River basin is home to a run of spring–summer Chinook Salmon Oncorhynchus tshawytscha that returns to the Snake River drainage of Idaho, Oregon, and Washington in the Pacific Northwest. Historically, the run was one of the more productive throughout the Columbia River basin. However, Snake River spring–summer Chinook Salmon have experienced declines in abundance due to overfishing, habitat degradation, and dams. Several stocks are listed as threatened under the U.S. Endangered Species Act and are supported by mitigation hatcheries funded by Idaho Power Company, the Lower Snake River Compensation Plan, and the Bonneville Power Administration. To maximize tribal and state harvest of returning hatchery adults, minimize impacts on wild fish, and ensure that enough hatchery fish return to meet broodstock needs, careful fisheries management is required. Since 2008, managers have used hatchery adults, PIT-tagged as juveniles and detected at Lower Granite Dam, to generate adult abundance estimates. In season, these estimates inform state and tribal harvest shares and ensure that broodstock needs are met. Postseason, they provide smolt-to-adult survival and return rates. Since 2012, parentage-based tagging (PBT) has provided an alternative method to estimate stock- and age-specific returns at Lower Granite Dam, since returning hatchery adults sampled at Lower Granite Dam can be assigned to their parents. We compared stock-specific abundance estimates between PIT- and PBT-derived methodologies for return years 2016–2019. Across all years, PIT tag estimates accounted for 65% of the PBT-based estimates at Lower Granite Dam across all age-groups and release sites combined. This underrepresentation across all groups equated to 49,833 fish that were not accounted for in PIT tag abundance estimates. It is clear that PBT-based estimates should aide in-season harvest management and postseason run reconstruction to avoid the known bias of estimates from PIT tags, especially during years of low returns when increased accuracy is critical.

Coykendall, D. Katharine (ORCID:0000000211482397)↗
DOE OSTI2019

Mechanical and Corrosion Properties of Additively Manufactured CoCrFeMnNi High Entropy Alloy

Here, this study investigates the mechanical and corrosion properties of as-built and annealed equiatomic CoCrFeMnNi alloy produced by laser-based directed energy deposition (DED) Additive Manufacturing (AM). The high cooling rates of DED produced a single-phase, cellular microstructure with cells on the order of 4 μm in diameter and inter-cellular regions that were enriched in Mn and Ni. Annealing created a chemically homogeneous recrystallized microstructure with a high density of annealing twins. The average yield strength of the as-built condition was 424 MPa and exceeded the annealed condition (232 MPa), however; the strain hardening rate was lower for the as-built material stemming from higher dislocation density associated with DED parts and the fine cell size. In general, the yield strength, ultimate tensile strength, and elongation-to-failure for the as-built material exceeded values from previous studies that explored other AM techniques to produce the CoCrFeMnNi alloy. Ductile fracture occurred for all specimens with dimple initiation associated with nanoscale oxide inclusions. The breakdown potential (onset of pitting corrosion) was similar for the as-built and annealed conditions at 0.40 V Ag/AgCl when immersed in 0.6 M NaCl. Pit morphology/propagation for the as-built condition exhibited preferential corrosion of inter-cellular Ni/Mn regions leading to a tortuous pit bottom and cover, while the annealed conditions pits resembled lacy pits similar to 304 L steel. Lastly, a passive oxide film depleted in Cr cations with substantial incorporation of Mn cations is proposed as the primary mechanism for local corrosion susceptibility of the CoCrFeMnNi alloy.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Modeling of Diffusivity for 2D Vacancy Nanopits and Comparison with 2D Adatom Nanoislands on Metal(100) Surfaces Including Analysis for Ag(100)

Diffusion coefficients, D N , for 2D vacancy nanopits are compared with those for 2D homoepitaxial adatom nanoislands on metal(100) surfaces, focusing on the variation of DN with size, N. Here, N is measured in missing atoms for pits and adatoms for islands. Analysis of D N is based on kinetic Monte Carlo simulations of a tailored stochastic lattice-gas model, where pit and island diffusion are mediated by periphery diffusion, i.e., by edge atom hopping. Precise determination of D N versus N for typical parameters reveals a cyclical variation with an overall decrease in magnitude for increasing moderate O(10 2 ) ≤ N ≤ O(10 3 ). Monotonic decay, D N ~ N -β , is found for N ≥ O(10 2 ) with effective exponents, β = β eff , for both pits and islands, both well below the macroscopic value of βmacro = 3/2. D N values for vacancy pits are significantly lower (higher) than for adatom islands for moderate N in the case of low (high) kink rounding barrier. However, D N values for pits and islands slowly merge, and β eff → 3/2 for sufficiently large N. The latter feature is expected from continuum Langevin formulations appropriate for large sizes. Finally, we compare predictions from our model incorporating appropriate energetic parameters for Ag(100) with different sets of experimental data for diffusivity at 300 K, including assessment of β eff , for experimentally observed sizes N from ~100 to ~1000.

36 MATERIALS SCIENCE↗
DOE OSTI2022

A subdermal tagging technique for juvenile sturgeon using a new self-powered acoustic tag

Abstract Background A new technology for a self-powered acoustic tag (SPT) was developed for active tracking of juvenile fish, intended to avoid the typical battery life constraints associated with active telemetry technology. We performed a laboratory study to evaluate a subdermal tagging technique for the SPT and effects of the tag on survival, tag retention, and growth in juvenile white sturgeon ( Acipenser transmontanus ). Results Survival was associated with tag retention. White sturgeon implanted with the SPT ( n = 30) had 93% survival and tag retention by day 28, 67% by day 101, and 38% by day 595 post-tagging. Sturgeon implanted with a passive integrated transponder (PIT) tag only (control group) had 96% survival and tag retention by day 28, and through day 101 post-tagging. Fish in the PIT group were repurposed after day 101, so no comparisons with this group were made at day 595 post-tagging. Specific growth rate (SGR) for fork length was a median of 0.25% day −1 by day 28 for the SPT group, which was significantly lower than the PIT group (median: 0.42% day −1 ; n = 27). The SPT and PIT groups had similar SGR fork length by day 101 post-tagging (0.22 and 0.25% day −1 , respectively). SGR weight was also lower for the SPT group compared to the PIT group on day 28 (1.39 and 2.11% day −1 , respectively), but the difference again dissipated by day 101 (0.79 and 0.88% day −1 , respectively). Conclusion The tagging technique and placement of the SPT allowed the tag to remain upright along the flank of the sturgeon to ensure maximum battery output of the SPT; however, retention rates of the SPT were not ideal. We provided suggestions to improve the tagging technique. Suggestions included tagging fish that are > 400 mm FL, moving the incision location to extend the cavity and create a pocket for the placement of the SPT, and performing a quantitative wound-healing evaluation. Future studies are therefore recommended to evaluate these suggestions.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2016

Uncertainty quantification methodologies development for stress corrosion cracking of canister welds

This letter report presents a probabilistic performance assessment model to evaluate the probability of canister failure (through-wall penetration) by SCC. The model first assesses whether environmental conditions for SCC – the presence of an aqueous film – are present at canister weld locations (where tensile stresses are likely to occur) on the canister surface. Geometry-specific storage system thermal models and weather data sets representative of U.S. spent nuclear fuel (SNF) storage sites are implemented to evaluate location-specific canister surface temperature and relative humidity (RH). As the canister cools and aqueous conditions become possible, the occurrence of corrosion is evaluated. Corrosion is modeled as a two-step process: first, pitting is initiated, and the extent and depth of pitting is a function of the chloride surface load and the environmental conditions (temperature and RH). Second, as corrosion penetration increases, the pit eventually transitions to a SCC crack, with crack initiation becoming more likely with increasing pit depth. Once pits convert to cracks, a crack growth model is implemented. The SCC growth model includes rate dependencies on both temperature and crack tip stress intensity factor, and crack growth only occurs in time steps when aqueous conditions are predicted. The model suggests that SCC is likely to occur over potential SNF interim storage intervals; however, this result is based on many modeling assumptions. Sensitivity analyses provide information on the model assumptions and parameter values that have the greatest impact on predicted storage canister performance, and provide guidance for further research to reduce uncertainties.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2020

Hanford Double Shell Waste Tank Corrosion Studies (Final Report FY2019)

During fiscal year (FY) 2019, the Savannah River National Laboratory (SRNL) focused on four primary tasks for Hanford Double Shell Tanks (DSTs) corrosion studies. The first task, New Limits, was a continuation from the electrochemical work started in FY16, to expand electrochemical testing to elevated temperatures and elevated hydroxide concentrations and evaluate how these factors will influence pitting corrosion. Using the pitting factor (PF) equation, these new conditions were validated to provide a conservative estimate for the susceptibility of pitting corrosion on legacy carbon steel. The second task, Secondary Liner Corrosion, focused on Vapor Space Corrosion (VSC) and immersion testing studies using two commercially available vapor corrosion inhibitors (VCIs). For this FY, the VCI strategy was applied mid-experiment to determine performance on weathered coupons. The third task, Long-Term Open Circuit Potential (OCP) Drift, was performed using simplified simulated chemistries to evaluate change in pitting corrosion risk due to evolution of corrosion potential for mill-scale and freshly polished 600-grit surfaces. Finally, the fourth task, Microbiologically-Influenced Corrosion (MIC) studies, was focused on the study of leak detection pit (LDP) water sent from the Hanford tank farm for determination of bacteria that can be conducive to corrosion using commercially available kits: BART TM and MICkit® 5. In addition, this FY, a secondary task was added which was a continuation of the study of the Quartz-enhanced Photoacoustic Spectroscopy (QEPAS) system. Work was started but was ultimately not pursued. A summary of each task performed is presented below.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2025

Pulsed Infrared Thermography Nondestructive Imaging of SiC-SiC f Composite Cladding Architectures; Understanding the Performance of SiC-SiC f Composite Cladding Architectures with Cr Coating in Normal Operating and Accident Conditions in LWRs and Advanced Reactors

SiC-SiC f composites, consisting of silicon carbide fibers embedded in a silicon carbide matrix, are advanced materials with high thermal conductivity, temperature stability, and resistance to radiation damage. Traditional methods for quality control of fabricated SiC-SiC f composites involve nondestructive evaluation (NDE) with X-ray computed tomography (XCT). However, XCT imaging of typical SiC-SiC f structures for cladding applications can involve several hours. In this project, we investigate an alternative approach to NDE of SiC-SiC f composites that involves rapid (on the order of seconds) imaging with Pulsed infrared thermography (PIT). PIT images of a planar SiC-SiC f specimen show the structure of the surface monolith layer and internal SiC f structures. The capability of PIT imaging in visualizing SiC f structures is qualitatively confirmed by observing similarity in the PIT and X-ray transmission images of the same specimen. Computer vision analysis of defects in the PIT image of the monolith was performed with thresholding followed by topological structural analysis that computed geometric descriptors, including major/minor axes of fitted ellipses, area, perimeter, Feret diameter, circularity, roundness, and solidity.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2026

Determining Drying Conditions to Mitigate Hanford Double Shell Storage Tank Underside Corrosion — Phase 1

The Hanford Site in Washington State has legacy radiological waste that is being retrieved from single shell tanks (SSTs) and transferred to newer, double shell tanks (DSTs) for eventual closure of the SSTs. The waste is maintained in the DSTs until eventual immobilization can be performed at the Waste Treatment and Immobilization Plant (WTP), currently under construction. Until full immobilization is complete, extended service of the DSTs must be ensured by mitigating corrosion of the steel tank walls and buried steel pipelines. A Pit Air Supply System has been developed to mitigate corrosion of the leak detection pits connected to the concrete foundations of the DSTs. The objectives for the present study are: (i) to corrode steel specimens in an electrolytic simulant to form artificial pits with specific pit depths, and (ii) to determine the temperature and humidity levels that will mitigate further pit growth. Experimental work and results will be presented to evaluate conditions associated with the PASS system and predict corrosion rates when the PASS is operating.

Atmospheric Corrosion↗
DOE OSTI2020

Cryo-based Structural Characterization and Growth Model of Salt Film on Metal

Metal salt films play a critical role in high rate dissolution processes such as within an active pit. However, structural and compositional characterization of salt films is challenging owing to the dynamic nature of the dissolving interface. Here, the salt film formed on SS304 one-dimensional artificial pit surface was directly characterized using flash freezing and cryo-based focused ion beam/scanning electron microscopy. The salt film exhibits a porous structure. Ni is co-located with Fe in the salt film, indicating the formation of co-precipitated salt containing Fe2+ and Ni2+. Additionally, a salt film growth model is presented based on ion transport.

Salt film, Pitting corrosion, Cryogenic, Cryo-FIB/↗
DOE OSTI2019

Innovative Approach to SCC Inspection and Evaluation of Canister in Dry Storage

This final report is summarized four years of work of awarded project number DE-NE0008442\IRP-15-9318, title as: “Innovative Approach to SCC Inspection and Evaluation of Canister in Dry” supported by Nuclear Energy University Program\Integrated Research Program, NEUP\IRP, where last year is an extension of no cost project. This research work is focused on the possible degradation of dry storage canister holding used nuclear fuel (UNF), due to exposure of marine atmospheric environment. The canister usually designed from a welded austenitic stainless-steel of types 304 or 316, encased in a concrete shell known as an overpack. This canister designed and licensed for 20 years with an extension period need to be determined, in addition 20 years or more. These casks are located throughout the country in Independent Spent Fuel Storage Installations (IFSFIs) often on the site close to nuclear power plants, that are often located in coastal or lake-side regions where a marine atmospheric salt air environment exist. As a result of several recent decisions, such as not pursuing Yucca Mountain as a long-term geologic repository storage facility for UNF and the cancellation of the construction of a reprocessing facility in the 1980s due to proliferation risks, interim dry storage facilities for long-term storage are vital option for the immediate future of nuclear energy technology. One of the primary concerns with respect to the long-term performance of the storage casks is the potential for corrosion initiation due to deliquescence of salts deposited on the canister surface as aerosols; in regions of high residual weld stresses, this may lead to localized stress corrosion cracking (SCC). Dust and aerosols in the air being drawn though ventilation openings in the overpacks of passively ventilated dry canister storage systems may be deposited on the stainless-steel canister outer surfaces. Under these conditions, localized corrosion attack can occur. Chlorides ions deliquescence on the canister surface, a process by which the salts essentially pull moisture out of the air, creating a concentrated salt brine on the canister surface. Chloride-induced stress corrosion cracking (CISCC) of welded zones is of special concern, as it a well-documented mode of attack for austenitic stainless steels marine environments, and many independent spent fuel storage installations (ISFSIs) are located in coastal areas. Recent canister inspections have shown that chloride salts are present on the surface of in-service canisters at near-marine settings. However, canister surface inspections of satisfactory resolution to detect SCC have never been carried out in details, because access to the canister surfaces through vents in the overpacks is extremely limited, and high radiation fields make removal of the canisters from the overpacks undesirable. Although no significant corrosion damage has not been detected up to date, there is concern that this may lead to pitting corrosion, which could in turn develop into stress corrosion cracking, causing canister structural failure. The initiation and propagation of pitting corrosion has been widely studied in full immersion conditions, but limited studies have been done on marine atmospheric conditions, which is a focus of this work, these includes laboratory and field experimentally and propagation rate modeling of pitting and transition to crack, and crack propagation rate. It is known, however, that the rate of atmospheric corrosion can be affected by variations in relative humidity (RH), salt density, salt type, droplet area, temperature and stainless-steel microstructure and residual stress particularly in welded zones of canisters. The integrated research program has identified potential deterioration mechanisms for the stainless-steel canisters containing the UNF in dry storage that require detailed research and investigation and will have an impact on the performance of long-term interim storage under the normal and extreme environmental conditions experienced during the duration of this storage. The prediction and monitoring of canister corrosion processes while in storage can provide important data for the assessment of interim storage performance and the safety to the public. This report comprises of mainly the published results in different journals and covering a wide range spectrum from susceptible stainless-steel types 304\316 microstructural analysis through the implant test at atmospheric environment, residual stress analysis of mockup canister and simulation, inspection methodology includes nonlinear ultrasound and vibro-thermography and stochastic modeling and simulation of pits propagation rates and transition to cracks. Description of field specimens installed at ISFSI of Main Yankee is given in the following chapters and will be analyzed in the coming future and serves as an important data for a stochastic analysis as it was drawn from the publications and reports described in this report. The purpose of this report is to bring together the project efforts that includes improving in our understanding of structural aging performance at current dry storage casks fleet at ISFSIs in the context of remedial maintenance and inspection applications technologies.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2019

Corrosion Behavior of Pipeline Steel with Different Microstructures Under AC Interference in Acid Soil Simulation Solution

Corrosion behavior of X65 pipeline steels with different microstructures under alternating current (AC) interference was investigated in acid soil simulation solution by potentiodynamic polarization curve, potentiostatic polarization curve and immersion test. The results show that superimposed AC causes a sharp increase in corrosion current density of X65 steel. With the increase in i{sub AC}, the corrosion current densities of steels with various microstructures increase, especially at high i{sub AC}. Hot-rolled steel mainly experiences uniform corrosion, with very slight pit corrosion. Serious corrosion degrees with intensive corrosion pits can be observed on the surfaces of normalized and quenched microstructure steels. The annealed steel exhibits the feature of non-uniform corrosion with some pitting. The steels with various microstructures applied with AC have different corrosion resistance. The normalized steel shows the worst corrosion resistance, then the quenched microstructure, and the hot-rolled steel displays the optimum corrosion resistance. The difference in the microstructure can result in difference in corrosion degree and occurrence position of pitting corrosion of X65 steel. The normalized microstructure composed of polygonal ferrite and a large amount of pearlite and bainite is the most susceptible to AC corrosion.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Surfactant inhibition mechanisms of carbonate mineral dissolution in shale

Surfactants are common additives to hydraulic fracturing and enhanced oil recovery (EOR) fluids, and are under consideration for amendment to supercritical carbon dioxide for geological carbon sequestration (GCS). The effect of a common anionic surfactant, internal olefin sulfonate (IOS), on mineral dissolution from shale into brine was evaluated. When added to brine at concentrations exceeding the critical micelle concentration (94 mg/L), IOS inhibited carbonate mineral dissolution in an Eagle Ford shale, as well as dissolution of optical quality calcite (the dominant carbonate in the shale). Laser profilometry images provide spatial resolution across > 3 orders of magnitude, and indicate that IOS addition to brine both enhances the formation of new etch pits in calcite, and impedes their further growth. Time-of-flight secondary ion mass spectrometry surface profiles show for the first time that IOS preferentially adsorbs at calcite pit edges versus flat calcite surfaces (i.e., terraces). Surface pressure calculations, sulfur K-edge near edge X-ray absorption fine structure (NEXAFS) spectroscopy results, and density functional theory (DFT) calculations support this observation; the DFT results indicate that the sulfonate head group of the IOS molecule binds strongly to the calcite step site as compared to the terrace site. The S K-edge NEXAFS results indicate that IOS adsorbed more to etched calcite surfaces compared to smooth calcite surfaces. Overall, the results indicate that weak adsorption on flat calcite surfaces (i.e., terraces) disrupts water structure and enhances mass transfer of dissolution, while strong adsorption on calcite pit edges displaces adsorbed water and inhibits further etch pit growth. This work provides the first direct evidence of preferential adsorption of IOS to etched calcite surfaces and links it to macroscopic dissolution kinetics. Finally, this work has implications for surfactant-containing fluids used in hydraulic fracturing, EOR and potentially GCS for subsurface injection into carbonate rich reservoirs.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Electrochemical metrics for corrosion resistant alloys

Abstract Corrosion is an electrochemical phenomenon. It can occur via different modes of attack, each having its own mechanisms, and therefore there are multiple metrics for evaluating corrosion resistance. In corrosion resistant alloys (CRAs), the rate of localized corrosion can exceed that of uniform corrosion by orders of magnitude. Therefore, instead of uniform corrosion rate, more complex electrochemical parameters are required to capture the salient features of corrosion phenomena. Here, we collect a database with an emphasis on metrics related to localized corrosion. The six sections of the database include data on various metal alloys with measurements of (1) pitting potential, E pit , (2) repassivation potential, E rp , (3) crevice corrosion potential, E crev , (4) pitting temperature, T pit , (5) crevice corrosion temperature, T crev , and (6) corrosion potential, E corr , corrosion current density, i corr , passivation current density, i pass , and corrosion rate. The experimental data were collected from 85 publications and include Al- and Fe-based alloys, high entropy alloys (HEAs), and a Ni-Cr-Mo ternary system. This dataset could be used in the design of highly corrosion resistant alloys.

36 MATERIALS SCIENCE↗