Search NASA⌕ Search

SEARCH · Search NASA

Results for “Non-Destructive Evaluation”

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.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

251 records · Page 14
All sourcesNASA NTRSDOE OSTI
NASA NTRS2010

X-Ray Computed Tomography Inspection of the Stardust Heat Shield

The "Stardust" heat shield, composed of a PICA (Phenolic Impregnated Carbon Ablator) Thermal Protection System (TPS), bonded to a composite aeroshell, contains important features which chronicle its time in space as well as re-entry. To guide the further study of the Stardust heat shield, NASA reviewed a number of techniques for inspection of the article. The goals of the inspection were: 1) to establish the material characteristics of the shield and shield components, 2) record the dimensions of shield components and assembly as compared with the pre-flight condition, 3) provide flight infonnation for validation and verification of the FIAT ablation code and PICA material property model and 4) through the evaluation of the shield material provide input to future missions which employ similar materials. Industrial X-Ray Computed Tomography (CT) is a 3D inspection technology which can provide infonnation on material integrity, material properties (density) and dimensional measurements of the heat shield components. Computed tomographic volumetric inspections can generate a dimensionally correct, quantitatively accurate volume of the shield assembly. Because of the capabilities offered by X-ray CT, NASA chose to use this method to evaluate the Stardust heat shield. Personnel at NASA Johnson Space Center (JSC) and Lawrence Livermore National Labs (LLNL) recently performed a full scan of the Stardust heat shield using a newly installed X-ray CT system at JSC. This paper briefly discusses the technology used and then presents the following results: 1. CT scans derived dimensions and their comparisons with as-built dimensions anchored with data obtained from samples cut from the heat shield; 2. Measured density variation, char layer thickness, recession and bond line (the adhesive layer between the PICA and the aeroshell) integrity; 3. FIAT predicted recession, density and char layer profiles as well as bondline temperatures Finally suggestions are made as to future uses of this technology as a tool for non-destructively inspecting and verifying both pre and post flight heat shields.

McNamara, Karen M.↗
NASA NTRS2005

Lunar and Planetary Science XXXVI, Part 13

Contents include the following: A Fast, Non-Destructive Method for Classifying Ordinary Chondrite Falls Using Density and Magnetic Susceptibility. An Update on Results from the Magnetic Properties Experiments on the Mars Exploration Rovers, Spirit and Opportunity. Measurement Protocols for In Situ Analysis of Organic Compounds at Mars and Comets. Piping Structures on Earth and Possibly Mars: Astrobiological Implications. Uranium and Lead in the Early Planetary Core Formation: New Insights Given by High Pressure and Temperature Experiments. The Mast Cameras and Mars Descent Imager (MARDI) for the 2009 Mars Science Laboratory. MGS MOC: First Views of Mars at Sub-Meter Resolution from Orbit. Analysis of Candor Chasma Interior Layered Deposits from OMEGA/MEX Spectra. Analysis of Valley Networks on Valles Marineris Plateau Using HRSC/MEX Data. Solar Abundance of Elements from Neutron-Capture Cross Sections. Preliminary Evaluation of the Secondary Ion/Accelerator Mass Spectrometer, MegaSIMS. Equilibrium Landforms in the Dry Valleys of Antarctica: Implications for Landscape Evolution and Climate Change on Mars. Continued Study of Ba Isotopic Compositions of Presolar Silicon Carbide Grains from Supernovae. Paleoenviromental Evolution of the Holden-Uzboi Area. Stability of Magnesium Sulfate Minerals in Martian Environments. Tungsten Isotopic Constraints on the Formation and Evolution of Iron Meteorite Parent Bodies. Migration of Dust Particles and Volatiles Delivery to the Inner Planets. On the Sitting of Trapped Noble Gases in Insoluble Organic Matter of Primitive Meteorites. Trapping of Xenon Upon Evaporation-Condensation of Organic Matter Under UV Irradiation: Isotopic Fractionation and Electron Paramagnetic Resonance Analysis. Stability of Water on Mars. A Didactic Activity. Analysis of Coronae in the Parga Chasma Region, Venus. Photometric and Compositional Surface Properties of the Gusev Crater Region, Mars, as Derived from Multi-Angle, Multi-Spectral Investigation of Mars Express HRSC Data. Mapping Compositional Diversity on Mars: Spatial Distribution and Geological Implications. A New Simulation Chamber for Studying Planetary Environments. Folded Structure in Terra Sirenum. Mars. Nitrogen-Noble Gas Static Mass Spectrometry of Genesis Collector Materials. Neon Isotope Heterogeneity in the Terrestrial Mantle: Implication for the Acquisition of Volatile Elements in Terrestrial Planets. The Cosmic Clock, the Cycle of Terrestrial Mass Extinctions.

Source record↗
DOE OSTI2025

Monte Carlo N-Particle Transport Performance of Predicting Digital Radiographic IQI Inspection

The identification of porosity, geometric noncompliance, and other defect types are critical to the qualification of materials and components. X-ray radiographic nondestructive testing is a common industrial inspection method for process quality control and component qualification and certification. Digital radiography provides a quick and efficient alternative when compared to traditional film-based inspection. The quality of radiographic inspection is dependent on equipment specifications, such as the source spot size and detector pixel size, and the specific parameters selected for use for the radiographic technique. To evaluate if an x-ray system and technique is sufficient for a given requirement, a radiographic image quality indicator (IQI) can be used. Radiographic IQIs in hard to machine materials or hard to manufacture defects can be time consuming and expensive to manufacture. This study was conducted to evaluate current Savannah River National Laboratory (SRNL) x-ray imaging systems with a custom tantalum IQI and using Monte Carlo simulations to predict the performance of future systems. The tantalum IQI was tested using a Siefert Isovolt 420 keV x-ray tube with a Perkin Elmer XRD 1611 flat panel with 100-micron pixels. Using the Monte Carlo N-Particle transport software, the radiographic tally was used to simulate the photon flux through an identical tantalum IQI. These simulations provided a benchmark as to the best theoretical identification on a given system using our tantalum IQI. The simulations were refined to match SRNL’s current systems’ noise levels, leading to confidence in their ability to predict the performance of other systems that may be purchased and deployed in the future at the Savannah River Site. Future studies will be conducted to prove this research can be extended to artificially evaluate the ability for systems to identify critical defect sizes through x-ray radiographic inspection, drastically reducing the cost and time burdens of producing high-fidelity radiographic test articles.

digital X-ray radiography↗
DOE OSTI2026

Self-supervised and multi-fidelity learning for extended predictive soil spectroscopy

Infrared spectroscopy is a cost-effective, non-destructive, and environmentally benign technology that is increasingly recognized as an important solution for meeting the global demand for soil data. While both near-infrared (NIR) and mid-infrared (MIR) diffuse reflectance spectroscopy enable rapid estimation of soil properties, they present a significant trade-off: NIR offers superior scalability and lower operational costs, whereas MIR provides higher analytical fidelity by capturing fundamental molecular vibrations. In this study, we propose a self-supervised, multi-fidelity learning framework designed to bridge this gap. Our approach leverages large-scale MIR spectral libraries to learn a compact, transferable latent representation, into which NIR spectra are subsequently aligned for downstream prediction. The workflow consists of pretraining a latent model on a large MIR library, adapting the representation using a smaller paired NIR–MIR dataset, and evaluating generalization on an independent external test set. Across a range of chemical and physical soil properties, we found that MIR-derived embeddings improved prediction accuracy relative to baseline models that used raw MIR inputs. Predictions derived from the spectrum conversion (NIR to MIR) task did not match the performance of the original MIR spectra but were similar or superior to predictive performance of NIR-only models, suggesting the unified spectral latent space can effectively leverage the larger and more diverse MIR dataset for prediction of soil properties not well represented in current NIR libraries.

54 ENVIRONMENTAL SCIENCES↗
NASA NTRSDate not supplied

A Study of the Curation Protocol by Sample Analysis Working Team (SAWT) in Martian Moons eXploration (MMX) Project

Japan Aerospace Exploration Agency (JAXA) will launch a spacecraft in 2024 for a sample return mission from Phobos (Martian Moons eXploration: MMX). The major scientific goals of MMX are to constrain (1) the origin of Phobos and Deimos and (2) the evolution of the Mars-moon system [1]. The touchdown operations are planned to be performed twice at different landing sites on the Phobos surface to collect > 10 g of the surface materials [2]. After the return to the Earth, the Phobos samples will be collected from the individual sample canisters and introduced to the clean chamber installed at ISAS (Institute of Space and Astronautical Science). The Sample Analysis Working Team (SAWT) of MMX designed the procedure of Phobos sample analysis mainly conducted by the initial analysis teams [3]. For the next step, the SAWT will define the procedure of the curation process (mostly non-destructive analysis) of the Phobos samples, which will be presented here. The protocols of the Phobos sample curation is illustrated in figure 1. First, the headspace gas from the sample container will be collected during the Quick Analysis phase. The Quick Analysis will be operated by the sampler and curation teams in ISAS/JAXA. The terrestrial leak and contamination from the sampling systems will be tested using a quadrupole mass spectrometer equipped with a gas sampling system. Second, the bulk Phobos sample will be observed in the clean chamber under purified-N2 gas with an ambient condition (Pre-basic Characterization). This phase will be operated by the curation team in ISAS/JAXA and the instrument team of the MMX mission. The consistency between the data from the instruments in the clean chamber and the spacecraft will then be evaluated. Subsequently, the curation will distribute the small amount of Phobos samples to the Initial analysis team of MMX to conduct the "Preliminary Examination". The objectives of the preliminary examination are to provide (1) feedback on the subsequent sample allocation process, (2) preliminary scientific results that will address parts of MMX mission goals, and (3) evaluation of the sampling system and terrestrial alteration on Phobos samples. Because multiple models are proposed for the origin of Phobos [1] (e.g., giant impact, the capture of asteroids), the chemical and mineralogical characteristics of Phobos must be assessed before the allocation of the samples to the individual initial analysis teams. Simultaneously, the curation team in JAXA will observe the individual grains and aliquots of the samples in the clean chamber (Basic Characterization).

R Fukai↗
DOE OSTI2025

Characterizing leaf-scale fluorescence with spectral invariants

Sun-induced chlorophyll fluorescence (SIF) is increasingly recognized as a non-destructive probe for tracking terrestrial photosynthesis. Emerging developments in spectral invariants theory provide an innovative and efficient approach for representing SIF radiative transfer processes at the canopy scale. However, modeling leaf-scale fluorescence based on the spectral invariants properties (SIP) remains underexplored. In this study, the spectral invariants theory is employed for the first time to model the leaf-scale total, backward and forward fluorescence (leaf-SIP SIF). The leaf-SIP SIF model separates the leaf-scale radiative transfer process into two distinct components: the wavelength-dependent one associated with leaf biochemical properties, and the wavelength-independent component linked to leaf structural characteristics. The leaf structure-related effects are characterized by two spectrally invariant parameters: the photon recollision probability (p) and the scattering asymmetry parameter (q), which are parameterized using the directly measurable leaf dry matter. Evaluation against field measurements shows that the proposed leaf-SIP SIF model has a good performance, with coefficient of determination (R 2 ) of 0.89, 0.89, 0.90 and root mean squared errors (RMSE) of 1.28, 0.69, 0.74 Wm -2 µm -1 sr -1 , respectively for the total, backward, and forward fluorescence (660–800 nm). The leaf-SIP SIF model with a more concise formulation demonstrates comparable performance with the widely used Fluspect model. Further, the leaf-SIP SIF model provides a simple and efficient approach for simulating leaf-scale fluorescence, with the potential to be integrated into a unified SIP-based model framework for simulating the radiative transfer processes across the soil-leaf-canopy-atmosphere continuum.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2024

Towards in-situ certification of additively manufactured parts: the vital roles of physics-based and data-driven models

Certifying additively manufactured (AM) parts in-situ at the completion of a build is an enticing prospect, as it can help reduce the high costs associated with post-build testing and evaluation. However, achieving this goal presents significant challenges that may keep it aspirational for the foreseeable future. Nonetheless, incremental progress can pave the way forward. A critical aspect of in-situ certification involves continuous quality checking due to the random nature of the AM process and the difficulties in detecting defects or anomalies once layers are built over. While real-time in-situ monitoring strategies assisted by machine learning (ML) play a pivotal role in auditing part quality, they must ideally be supported by real-time (or near real-time) adaptive process control enabled by ML-assisted decision-making. By analyzing in-situ monitoring data in real-time (or near real- time) to dynamically adjust manufacturing parameters, such intervention can ensure AM parts are built to meet stringent certification standards. This can be achieved virtually by using high-fidelity performance models for the physical testing and evaluation tasks. In this short editorial, we discuss the key contributions made by data-driven and physics-based models in providing intelligence to the monitoring and process control tasks underpinning in-situ certification and in the simulation of the build’s performance under test and service conditions. While our focus lies in metal AM, the concepts discussed here are also relevant to other AM processes.

: In-situ monitoring↗
NASA NTRS2010

NASA MUST Paper: Infrared Thermography of Graphite/Epoxy

The focus of this project is to use Infrared Thermography, a non-destructive test, to detect detrimental cracks and voids beneath the surface of materials used in the space program. This project will consist of developing a simulation model of the Infrared Thermography inspection of the Graphite/Epoxy specimen. The simulation entails finding the correct physical properties for this specimen as well as programming the model for thick voids or flat bottom holes. After the simulation is completed, an Infrared Thermography inspection of the actual specimen will be made. Upon acquiring the experimental test data, an analysis of the data for the actual experiment will occur, which includes analyzing images, graphical analysis, and analyzing numerical data received from the infrared camera. The simulation will then be corrected for any discrepancies between it and the actual experiment. The optimized simulation material property inputs can then be used for new simulation for thin voids. The comparison of the two simulations, the simulation for the thick void and the simulation for the thin void, provides a correlation between the peak contrast ratio and peak time ratio. This correlation is used in the evaluation of flash thermography data during the evaluation of delaminations.

Comeaux, Kayla↗
NASA NTRS1990

Use of high-dimensional spectral data to evaluate organic matter, reflectance relationships in soils

Recent breakthroughs in remote sensing technology have led to the development of a spaceborne high spectral resolution imaging sensor, HIRIS, to be launched in the mid-1990s for observation of earth surface features. The effects of organic carbon content on soil reflectance over the spectral range of HIRIS, and to examine the contributions of humic and fulvic acid fractions to soil reflectance was evaluated. Organic matter from four Indiana agricultural soils was extracted, fractionated, and purified, and six individual components of each soil were isolated and prepared for spectral analysis. The four soils, ranging in organic carbon content from 0.99 percent, represented various combinations of genetic parameters such as parent material, age, drainage, and native vegetation. An experimental procedure was developed to measure reflectance of very small soil and organic component samples in the laboratory, simulating the spectral coverage and resolution of the HIRIS sensor. Reflectance in 210 narrow (10 nm) bands was measured using the CARY 17D spectrophotometer over the 400 to 2500 nm wavelength range. Reflectance data were analyzed statistically to determine the regions of the reflective spectrum which provided useful information about soil organic matter content and composition. Wavebands providing significant information about soil organic carbon content were located in all three major regions of the reflective spectrum: visible, near infrared, and middle infrared. The purified humic acid fractions of the four soils were separable in six bands in the 1600 to 2400 nm range, suggesting that longwave middle infrared reflectance may be useful as a non-destructive laboratory technique for humic acid characterization.

Henderson, T. L.↗
NASA NTRS2010

Measurement of Insulation Compaction in the Cryogenic Fuel Tanks at Kennedy Space Center by Fast/Thermal Neutron Techniques

The liquid hydrogen and oxygen cryogenic storage tanks at John F. Kennedy Space Center (KSC) use expanded perlite as thermal insulation. Th ere is evidence that some of the perlite has compacted over time, com promising the thermal performance and possibly also structural integr ity of the tanks. Therefore an Non-destructive Testing (NDT) method for measuring the perlite density or void fraction is urgently needed. Methods based on neutrons are good candidates because they can readil y penetrate through the 1.75 cm outer steel shell and through the ent ire 120 cm thickness of the perlite zone. Neutrons interact with the nuclei of materials to produce characteristic gamma rays which are the n detected. The gamma ray signal strength is proportional to the atom ic number density. Consequently, if the perlite is compacted then the count rates in the individual peaks in the gamma ray spectrum will i ncrease. Perlite is a feldspathic volcanic rock made up of the major elements Si, AI, Na, K and 0 along with some water. With commercially available portable neutron generators it is possible to produce simul taneously fluxes of neutrons in two energy ranges: fast (14 MeV) and thermal (25 meV). Fast neutrons produce gamma rays by inelastic scatt ering which is sensitive to Fe and O. Thermal neutrons produce gamma rays by radiative capture in prompt gamma neutron activation (PGNA) and this is sensitive to Si, AI, Na, Kand H. Thus the two energy ranges produce complementary information. The R&D program has three phases: numerical simulations of neutron and gamma ray transport with MCNP s oftware, evaluation of the system in the laboratory on test articles and finally mapping of the perlite density in the cryogenic tanks at KSC. The preliminary MCNP calculations have shown that the fast/therma l neutron NDT method is capable of distinguishing between expanded an d compacted perlite with excellent statistics.

Livingston, R. A.↗
DOE OSTI2026

A Bayesian inferencing framework for ultrasound wave speed measurements in metal additive manufacturing

Process-related changes during metal additive manufacturing introduce microstructural variability in the material properties of printed parts, directly affecting component reliability. Accurate estimation of these property variations with part performance are essential for quality assurance. Ultrasound testing offers a non-destructive means to estimate mechanical properties and detect defects; however, conventional analysis methods often neglect the influence of microstructural variability, limiting their effectiveness. Here, this research presents a Bayesian inference technique for quantifying wave speed uncertainty from ultrasound measurements of metal additive manufactured parts. By integrating prior ultrasound data with a Bayesian model, the proposed approach generates posterior density estimates of wave speed that systematically account for manufacturing-induced variability and uncertainty. The novelty of this research lies in applying a Bayesian framework to analyze experimental ultrasound measurements within the context of metal additive manufacturing variability. The method enhances the accuracy of wave speed estimation by 64%, defect position by 50% and increases confidence associated with wave speed variance by 30% across different porosity levels, thereby providing a robust foundation for improved decision-making and increased reliability in additively manufactured components.

Additive manufacturing↗
DOE OSTI2025

Variance Preserving Spectral Subsampling

Generating statistically faithful short-duration gamma-ray spectra from a single long measurement is essential in nuclear safeguards, supporting tasks such as algorithm development and machine-learning applications, especially when list-mode data are unavailable. Existing subsampling methods often distort the statistical characteristics of genuine short-duration measurements, leading to biased or unreliable analytical outcomes and thereby undermining downstream tasks. In this work, we compare five subsampling approaches using a benchmark set of 156 genuine replicate spectra collected with a high-purity germanium detector. We evaluate each method with respect to run-to-run variance, channel-to-channel variance, and preservation of total counts (losslessness). Across a wide range of subsampling ratios, only binomial subsampling without replacement consistently reproduces the statistical properties of genuine short-duration spectra, maintaining proper dispersion even in sparse spectral regions and perfectly preserving total counts. These results provide a mathematically principled and practically validated framework for generating synthetically shortened spectra when true short-duration measurements are unavailable.

98 NUCLEAR DISARMAMENT, SAFEGUARDS, AND PHYSICAL P↗
DOE OSTI2024

First Phase Consensus Roadmap for Development of Condition-Based Cable Reliability Assurance

The objective of this work was to develop a first phase consensus roadmap for condition-based qualification (CBQ) of electrical cables. With CBQ, qualification of Class 1E electrical cables moves from a time-based approach to a condition-based approach, which is anticipated to be safer in terms of reliability and conservatism, and more cost effective in the long run. However, due to barriers, the CBQ approach has not yet been adopted by U.S. nuclear power plants (NPPs). Based upon a review of current work evaluating CBQ, the limitation of available condition monitoring technology seems to be the largest barrier. The importance of condition monitoring, or more specifically selecting appropriate condition indicators, during CBQ cannot be understated. However, selecting appropriate condition indicators is challenged by techniques that are destructive and only evaluate cable degradation locally. Further, arguably, no one identified condition indicator fully establishes cable condition. Thus, additional work is necessary to evaluate potential condition indicators towards CBQ. In addition to the requirements of IEC/IEEE Std. 60780-323, ideal condition indicators should include a) both destructive and non-destructive approaches, b) both local and global measurements, c) real-time (i.e., online) monitoring that trends with degradation, d) enable correlation with qualified levels of degradation, and e) be established within a repository of condition indicators with applicable materials and/or components and their acceptance criteria. Additional work is needed in development of technology and methodology prior to adoption of CBQ, especially for extending qualified life of installed components. Education and early experience by the industry and regulators will be required for this change in approach as an alternative to re-analysis. A series of workshops that bring together stakeholders to identify and address gaps will be needed. The longstanding cooperative working group of cable researchers from the U.S. Department of Energy, the Electric Power Research Institute, and the Nuclear Regulatory Commission forms a valuable starting point for development of a consensus roadmap to condition-based qualification approach as a viable options for qualification of cable systems in U.S. light water reactors.

42 ENGINEERING↗
NASA NTRS1991

Quantitative nondestructive evaluation of materials and structures

An experimental investigation was undertaken to quantify damage tolerance and resistance in composite materials impacted using the drop-weight method. Tests were conducted on laminates of several different carbon-fiber composite systems, such as epoxies, modified epoxies, and amorphous and semicrystalline thermoplastics. Impacted composite specimens were examined using destructive and non-destructive techniques to establish the characteristic damage states. Specifically, optical microscopy, ultrasonic, and scanning electron microscopy techniques were used to identify impact induced damage mechanisms. Damage propagation during post impact compression was also studied.

Smith, Barry T.↗
NASA NTRS1994

Root growth and development in response to CO2 enrichment

A non-destructive technique (minirhizotron observation tubes) was used to assess the effects of CO2 enrichment on root growth and development in experimental plots in a scrub oak-palmetto community at the Kennedy Space Center. Potential effects of CO2 enrichment on plants have a global significance in light of concerns over increasing CO2 concentrations in the Earth's atmosphere. The study at Kennedy Space Center focused on aboveground physiological responses (photosynthetic efficiency and water use efficiency), effects on process rates (litter decomposition and nutrient turnover), and belowground responses of the plants. Belowground dynamics are an exceptionally important component of total plant response but are frequently ignored due to methodological difficulties. Most methods used to examine root growth and development are destructive and, therefore, severely compromise results. Minirhizotrons allow nondestructive observation and quantification of the same soil volume and roots through time. Root length density and root phenology were evaluated for CO2 effects with this nondestructive technique.

Day, Frank P., Jr.↗
NASA NTRSDate not supplied

Assessing Degradation of Advanced Coatings for Carbon/Carbon Composites

Carbon/carbon (C/C) composites are a well-utilized material system for hot structures to enable hypersonic flight. However, C/C materials are susceptible to attack by environmental degradation mechanisms, notably oxidation, which can limit the durability of components resulting in premature failure. Environmental barrier coatings (EBCs) have been developed to mitigate deleterious oxidation. Coating compositions based on silicon carbide (SiC) offer promise as a protective coating material for C/C composites. Under particular hypersonic flight conditions, a passivating silica scale can form at the surface of the EBC, acting as a barrier that can protect the underlying coating and substrate. However, the transition from passive to active oxidation, which varies with temperature and pressure, causes the formation of gaseous SiO that volatilizes leading to detrimental consumption of the SiC coating. In this work, arc-jet testing of SiC-based coatings developed to protect Advanced C/C-6 (ACC-6) was performed under a range of conditions to replicate varying oxidation conditions. In-situ optical emission spectroscopic measurements of the gas-surface interactions were collected and evaluated to render compositional degradation of the coating and underlying composite during arc-jet testing. Specimens were evaluated before, during and after arc-jet testing using destructive and non-destructive materials characterization methods, including optical and scanning electron microscopy and energy dispersive spectroscopy.

Coatings, Hypersonics, Composites↗
DOE OSTI2025

Assessing High Burnup U-19Pu-10Zr Fuel Performance against Historical and Modeled Behavior

Advancing the deployment of sodium-cooled fast reactors (SFRs) requires thorough testing of metallic fuel pins under accident conditions to establish safe operational limits of high burnup fuel. To conduct transient testing, a comprehensive understanding of steady-state fuel behavior obtained through both experimental characterization and accurate predictive capabilities is needed. This study comparatively assesses the steady-state irradiation performance of two high burnup U-19Pu-10Zr fuel pins, DP-36 and DP-40, irradiated under prototypic fast reactor conditions in preparation for planned safety testing at the Transient Reactor Test Facility. Since DP-40 was designated for use in the test and DP-36 serves as its sibling pin, non-destructive, engineering-scale post-irradiation examinations (PIE) were conducted on both pins while destructive examinations were performed exclusively on DP-36. The results were then assessed against historical performance data from similar fuel pins irradiated in the Experimental Breeder Reactor-II. Additionally, the steady-state irradiation of each pin was modeled using the BISON fuel performance code to assess the accuracy of current modeling capabilities in predicting the baseline irradiation behavior. Non-destructive examinations included neutron radiography to measure fuel column elongation, gamma scanning to verify pin integrity and fission product migration, and profilometry to assess dimensional changes. Benchmarking against existing PIE data revealed consistent patterns in axial fuel column growth and cladding diametral strain, though both pins exhibited longer low-density “fluff” structures, which can have implications for core reactivity and source term calculations. Destructive examinations on DP-36 included fission gas release analysis and sectioning for optical microscopy, which showed more complex constituent redistribution patterns than the traditionally accepted 3-ring model. The axial evolution of fractional areas and porosities of each of the redistributed zones were quantified and presented. Modeling comparisons showed agreement in fractional fission gas release but consistently overestimated axial and radial swelling and disagreed with measured axial porosity patterns. These conservative overpredictions suggested that the pins would appear closer to failure or operational limits at the start of transient tests, potentially leading to higher strain accumulation during the transient. While conservative estimates provide safety margins, they can negatively impact fuel economics. A review of the swelling models identified areas for improvement in the gaseous swelling, solid swelling, and fuel hot-pressing models when applied to ternary fuel. The results of this study highlight the critical importance of conducting pre-test characterization on both test and sibling pins to accurately capture steady-state fuel behavior, providing a precise baseline for post-test evaluations and essential inputs for transient modeling of the planned experiments. The analysis also revealed significant data gaps that require further investigation to enhance the understanding and prediction of fuel swelling and pore dynamics. Collecting comprehensive data across different irradiation conditions, burnup levels, and fuel compositions are essential for refining existing models and developing mechanistic models for both binary and ternary metallic fuels, ultimately improving the integration of modeling and experimental approaches in accident testing.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗