Advanced Manufactured Sensors: Feedstock Development, Fabrication and Process Control
Advanced Manufactured Sensors Project Summary
46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
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Broadband electromagnetic sensors for aircraft lightning research
A set of electromagnetic sensors, or electrically-small antennas, is described. The sensors are designed for installation on an F-106 research aircraft for the measurement of electric and magnetic fields and currents during a lightning strike. The electric and magnetic field sensors mount on the aircraft skin. The current sensor mounts between the nose boom and the fuselage. The sensors are all on the order of 10 cm in size and should produce up to about 100 V for the estimated lightning fields. The basic designs are the same as those developed for nuclear electromagnetic pulse studies. The most important electrical parameters of the sensors are the sensitivity, or equivalent area, and the bandwidth (or rise time). Calibration of sensors with simple geometries is reliably accomplished by a geometric analysis; all the sensors discussed possess geometries for which the sensitivities have been calculated. For the calibration of sensors with more complex geometries and for general testing of all sensors, two transmission lines were constructed to transmit known pulsed fields and currents over the sensors.
Trost, T. F.↗
Retractable Sensor for Reactor Experiments
This presentation is to orient a mechanical or nuclear engineering senior design team so that they can help solve an instrumentation problem found in high power test reactors. Test reactors such as the Advanced Test Reactor (ATR) at the Idaho National Laboratory are used to irradiate nuclear fuels and materials to evaluate performance after high levels of exposure to a reactor in-pile environment. The purpose of the experiments is to determine property changes as the materials or fuels are bombarded with fast neutrons (and thermal (slow) neutrons as well). Typically, the irradiation must take place at a very specific temperature. Sometimes other parameters are monitored as well as properties such as creep, or gas composition, etc. However, the fast neutrons cause changes in not only the materials, but also in the transducers that are placed in the neutron flux, e.g., thermocouples or optical fibers. This task will be limited to considering temperature measurements. Thermocouples experience decalibration from not only the neutron flux, but also from the very high temperatures that are sometimes measured. Optical fibers darken in a neutron or gamma flux. However, it takes quite a few hours, or days for these changes to manifest. High power test reactors typically run at a constant power and so the temperature in an experiment is fairly stable over time. Because the changes are typically very slow, even a single temperature measurement per day, would provide 95% of a perfect data set. The basic concept of this effort is to push a very small diameter thermocouple or optical fiber into the location to be measured, leave it for 30 seconds or so for it to come to equilibrium, and transmit the signal, and then pull it up and away from the high neutron flux and high temperature region. The distance the thermocouple or fiber would need to move is on the order of 50 – 100 cm. By doing this, the thermocouple junction or optical fiber would spend only a few hours in the high flux/high temperature environment over the life of the irradiation.
46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
A Data-driven approach to Core Power distribution reconstruction in a Nuclear Reactor
This report presents the initial development of a data-driven approach for reconstructing the core power distribution in a nuclear reactor (power shape synthesis) using ex-core sensors. Traditional techniques rely on deploying a large number of detectors throughout the reactor core. However, this approach is not feasible for innovative reactor concepts like Advanced Reactors and Microreactors. First, the tight lattice pitch, designed to maximize power density, limits the space available for sensors. Secondly, the harsh operating conditions are not compatible with commercially available detectors. The method proposed in this work integrates high-fidelity modeling with data-driven techniques to accurately reconstruct power distribution across various reactor types, thereby reducing the reliance on in-core sensors. Purdue University Reactor One (PUR-1) was selected as the test case. The CAD model representing the latest configuration of the PUR-1 core was imported into the OpenMC simulation framework, and the model was built. Additionally, the previously developed MCNP6 model was updated. The two models were assessed against the data collected during an experimental campaign conducted in July 2024. Thirty gold foils were placed in three Irradiation Assemblies in PUR-1 core. Using the measured activity of the irradiated foils, the neutron flux at different core locations was estimated.
22 GENERAL STUDIES OF NUCLEAR REACTORS↗
Wireless Sensing and Communication Capability from In-Core to a Monitoring Center
Significant cost savings can be made if electrical cables can be replaced by wireless technology in current Nuclear Power Plants (NPP) and in advance reactor designs. Wireless technology can also provide in-core opportunities by significantly reducing the number of penetrations in the pressure vessel, cost and complexity of sensor installation and by increasing the efficiency of current and advanced reactors. Unlike other deployment scenarios for an industrial environment, operators need to have centralized control over all the networks. Centralized control will reduce implementation costs, provide single point control and enable monitoring of network devices, improve security, and enhance connectivity. Micro-sensors that can simultaneously monitor temperature and pressure within a fuel rod inside nuclear reactors will enable preventative actions during abnormal operating conditions. This ability could avert accidents and enable the expedient development of accident tolerant fuels. A novel micro-sensor suite (~ mm) to simultaneously measure multiple parameters such as temperature, strain, pressure, and neutron/gamma flux inside a fuel rod is being developed for use in reactors. The necessary communication architecture is also being developed to transmit measurement signals from the core to the plant's data cloud or control room. A three three-tier strategy has been developed to support wireless transmission of in-core measurements to the control room or to a secure cloud platform for control, analytics, and decision-making purposes. 1. In-core: data signal from in-core to outside of the pressure vessel within the containment building 2. Containment building: data signal from inside to the outside of the containment building and into the balance of the plant network 3. Balance of the plant network: information transmitted to the data cloud and control room This plan presents a wireless sensing and communication system for use within a reactor core and elsewhere. The communication technology is advantageous to compensate for network equipment failures and adverse data transmission conditions. Wireless technology will significantly increase the resiliency of the plants network system. The wireless system naturally provides multiple transmission path capability and data redundancy.
46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
Development of selenium imaging detectors toward a definitive search for neutrinoless ββ decay
Imaging sensors made from an ionization target layer of amorphous selenium (aSe) coupled to a silicon complementary metal-oxide-semiconductor (CMOS) active pixel array for charge readout are a promising technology for neutrino physics. The high spatial resolution in a solid-state target provides unparalleled rejection of backgrounds from natural radioactivity in the search for the neutrinoless ββ decay of 82 Se. With this grant, we experimentally determined two crucial factors necessary for the realization of this novel technology: i) the intrinsic energy response of aSe to ionizing electrons, and ii) the feasibility to couple a target layer of aSe to a CMOS active pixel sensor to image electron tracks.
46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
Assembly and Functional Test of NRAD Heated Instrumentation Rig
This is a technical report (TEV-4296) which documents the configuration and materials of construction for a heated sensor test conducted in the NRAD reactor. It is being reviewed for external release so that operators of university reactors can evaluate whether this level of documentation will be acceptable for similar tests conducted in their reactors. The Objective section of this TEV is reproduced below. The purpose of this TEV is to document assembly and functional testing of a device which is designed to allow advanced sensors to be temporarily placed at the periphery of the NRAD reactor. While in this location, the operational characteristics of the sensors can be evaluated while they are exposed to a neutron flux. This device (or “rig”) consists of a cartridge heater surrounded by six guide tubes, which are in turn surrounded by insulation and an aluminum dry tube. The heater allows for the sensors to be tested while at elevated temperature.
46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
Structural Health Monitoring of Microreactor Safety Systems Using Convolutional Neural Networks
Microreactors, a class of modular reactors with net power output of less than 20 MWth, have innovative applications in nuclear and nonnuclear industries due to their portability, reliability, resilience, and high capacity factors. In order to operate microreactors on a wider scale, it is essential to bring down maintenance life-cycle costs while ensuring the integrity of operating such systems. Autonomous operations in microreactors using augmented digital-twin (DT) technology can serve as a cost-effective solution by increasing awareness about the system’s health. Structural health monitoring (SHM) is a key component of nuclear DT frameworks. Artificial neural networks can be beneficial to detect degradation in the nuclear safety systems, such as piping equipment systems, by monitoring the sensor data obtained from the plant and its corresponding structures, systems and components. In this report, an SHM methodology is presented which uses convolutional neural networks to determine degraded locations and their corresponding degradation-severity levels at various locations of nuclear piping equipment systems. A simple pipe system, subjected to seismic loads, is selected to design the post-hazard SHM framework. The effectiveness of the proposed SHM methodology is demonstrated by obtaining high accuracy in detecting degraded locations as well as the severity levels.
21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
Substrate-controlled dynamics of spin qubits in low dimensional van der Waals materials
We report a theoretical study of the coherence dynamics of spin qubits in two-dimensional materials (2DMs) and van der Waals heterostructures, as a function of the host thickness and the composition of the surrounding environment. We focus on MoS2 and WS2, two promising systems for quantum technology applications, and we consider the decoherence arising from the interaction of the spin qubit with nuclear spins. We show that the Hahn-echo coherence time is determined by a complex interplay between the source of decoherence in the qubit host and in the environment, which in turn determines whether the noise evolution is in a classical or quantum mechanical regime. We suggest that the composition and thickness of van der Waals heterostructures encapsulating a qubit host can be engineered to maximize coherence times. Finally, we discuss how quantum sensors may be able to probe the dynamics of the nuclear bath in 2DMs.
Onizhuk, Mykyta (ORCID:0000000304344575)↗
Augmented Monitoring and Condition Assessment Program (AMCAP) - Proof-of-Principle (POP) Mockup for Non-Aluminum Spent Nuclear Fuel Container In-Situ Examinations
A disciplined engineering approach is being followed to develop an engineered system of tooling and sensors, characterization techniques, and deployment subsystems for in-situ inspection of the several container types used for the storage of non-aluminum spent nuclear fuel (NASNF) in L Basin under the Augmented Monitoring and Condition Assessment Program (AMCAP). Inspecting the containers to provide information on their structural condition helps ensure the safe handling and storage of the NASNF containers pending final disposition. This report describes the work performed in the initial two phases of this developmental work, namely the bench scale and proof-of-principle (POP) scale, which focus on sensor selection and the tooling design and fabrication for two remote non-destructive examination (NDE) methods. These methods include visual testing (VT) for a visual examination of the container surfaces and ultrasonic testing (UT) for a n examination to characterize container wall material thickness and flaws.
11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
Demonstration of Embedded Sensors in Ceramic Structures
The Transformational Challenge Reactor (TCR) program seeks to demonstrate an advanced 3D printed nuclear reactor core. A binder jet additive manufacturing process is used to fabricate the complex SiC ceramic components of the TCR core. After printing, the components are densified via chemical vapor infiltration (CVI). This process allows complex cavities to be created in which sensors can be placed at strategic locations. Inserting the sensors during the CVI process allows the sensors to be embedded within the component as it is infiltrated. The primary challenge for embedding the sensors is identifying the sensors and sensor sheath materials that can survive the temperatures (>1,000°C) and chemical exposure to H 2 and HCl during CVI. The embedded sensors that are being investigated for use during TCR operation include thermocouples, self-powered neutron detectors, and spatially distributed fiber-optic temperature sensors. This report describes the CVI materials compatibility tests and initial trials for embedding functional sensors. Mo is identified as the most suitable sensor sheath material based on its availability in small diameter tubing, relatively low neutron absorption cross section, and compatibility with H 2 , HCl, and the surrounding SiC matrix at the process temperatures. Amorphous SiO2 fiber-optic samples with Au and Cu metal coatings were successfully embedded in SiC along with bare fibers, although the metal coatings showed some evidence of localized melting during CVI. Initial experiments attempting to embed functional sensors showed that the sensors can be embedded in 3D printed SiC parts, but there are still challenges that must be overcome to ensure that the sensors and sensor sheaths do not fail during CVI. In particular, Nb-sheathed Mo-Nb thermocouples failed at temperatures far lower than expected despite thermodynamic calculations and materials compatibility tests that show the Nb sheath to be compatible with the CVI environment. One potential explanation for the large expansion of the Nb sheath could be related to hydride formation in the lower temperature region of the sheath. Future work will focus on Mo-sheathed thermocouples instead of Nb. The fiberoptic sensors tested during the instrumented experiment broke due to the lack of mechanical protection after their polymer-based coatings were vaporized. Future instrumented experiments will use metal-coated optical fibers for strain sensing to provide additional mechanical protection. However, custom coatings with higher melting points than commercially available Au and Cu might be required. Regardless, fiber-optic sensors are still candidates for spatially distributed temperature measurements since they can be inserted into an embedded metal sheath after CVI.
22 GENERAL STUDIES OF NUCLEAR REACTORS↗
Embedded Aluminum Nitride Sensors for Advanced Reactors
This project aims to manipulate the of growth of aluminum nitride (AlN) inclusions in an iron-chromium-aluminum (FeCrAl) alloy, using the principle of powder metallurgy and heat treatment methods. to promote the formation of AlN phase within FeCrAl for embedded sensing. This effort seeks to fill in a gap with respect to robust sensor hardware for ubiquitous structural health monitoring of advanced nuclear reactors. A systematic evaluation of various solid-state methods will be performed to understand the influence of process conditions on AlN growth and to promote the growth of desirable AlN phase. Fabricated specimens will be analyzed to investigate the AlN structures that are formed using a suite of tools to characterize the concentration, morphology, and distribution of AlN within the FeCrAl substrate.
22 GENERAL STUDIES OF NUCLEAR REACTORS↗
Technology - The basis for the past, the key to the future
The relationship between new technology and space missions, and the objectives of the Civil Space Technology Initiative (CSTI) are studied. The CSTI is concerned with technologies for safe and efficient access to space, earth-orbiting operations, and future science missions. The initiative focuses on research in the areas of propulsion, vehicles, information systems, large space structures and their control, power, and automation and robotics. Consideration is given to the development of high-performance engines for next-generation vehicles, booster technology for hybrid and pressure-fed propulsion systems, and a space OTV based on the aerobrake concept. Research involved with the application of automation and robotics to earth-orbiting operations are discussed. The control of flexible structure flight experiment, the use of nuclear systems for space propulsion, and the development of sensor devices and high-rate, high-capacity data systems are examined.
Harris, Leonard A.↗
Science, engineering and enabling technologies for exploration of the universe
This report by NASA's Office of Aeronautics, Exploration, and Technology identifies a list of critical technologies needed to support the exploration of the universe. The concept of the Integrated Technology Plan (ITP) is introduced with specific attention given to the strategic planning framework for NASA and other participants involved in the development of space technologies. The required technologies are identified for the Mission to Planet Earth, the Space Exploration Initiative, information systems, spacecraft advancement, and critical astrophysics issues. The ITP presents the basis for strategically planning the development of such technologies as observation systems, on-board processing, EVA systems, aerobraking, nuclear propulsion, scientific information acquisition, and high-energy sensors. The ITP is a significant step towards the planned and prioritized advancement of critical technologies related to the exploration of the universe.
Reck, Gregory M.↗
A Photo-Realistic 3-D Mapping System for Extreme Nuclear Environments: Chornobyl
We present a novel stereoscopic mapping system for use in nuclear accident settings. First we discuss a radiation shielded sensor array desigtned to tolerate 10(sup 6)R of cumulative dose. Next we give procedures to ensure timely, accurate range estimation using trinocular stereo. Finally, we review the implementation of a system for the integration of range information into a 3-D, textured, metrically accurate surface mesh.
3-D mapping Chornobyl robot Pioneer robot Pioneer ↗
Phenomenology and node-level processing of MASINT sensor data across distributed sensor networks, STL-016-19, Year 3 of 3
Presentation to be presented during the Site-Directed Research and Development (SDRD) program FY 2021 review meeting (Webex), September 22–23, 2021.
46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
Neutron irradiation and electrical characterisation of the first 8” silicon pad sensor prototypes for the CMS calorimeter endcap upgrade
As part of its HL-LHC upgrade program, the CMS collaboration is replacing its existing endcap calorimeters with a high-granularity calorimeter (CE). The new calorimeter is a sampling calorimeter with unprecedented transverse and longitudinal readout for both electromagnetic and hadronic compartments. Due to its compactness, intrinsic time resolution, and radiation hardness, silicon has been chosen as active material for the regions exposed to higher radiation levels. The silicon sensors are fabricated as 20 cm (8”) wide hexagonal wafers and are segmented into several hundred pads which are read out individually. As part of the sensor qualification strategy, 8” sensor irradiation with neutrons has been conducted at the Rhode Island Nuclear Science Center (RINSC) and followed by their electrical characterisation in 2020-21. The completion of this important milestone in the CE's R&D program is documented in this paper and it provides detailed account of the associated infrastructure and procedures.The results on the electrical properties of the irradiated CE silicon sensors are presented.
46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
Magnetostrictive EMAT for Nuclear Spent Fuel Canisters
One approach for mitigation of stainless steel (SS) spent fuel canisters (SFCs) is to coat the welds or even the entire SFC with a cold-sprayed nickel coating. The coating can serve as a magnetostrictive interface between an electromagnetic acoustic transducer (EMAT) and the SS plate material. The EMAT can send ultrasound into the canister and “listen” for reflections caused by chloride-initiated stress corrosion cracking (CISCC) or other damage mechanisms that may lead to leaks if undetected and unmitigated. Here, this project outlines an approach for monitoring the integrity of SFCs using magnetostrictive EMAT sensors, which emit and detect discontinuity-initiated reflections indicative of pits or cracks likely arising from CISCC. Flat 13 mm SS plates with welds similar to actual canister welds were prepared, with flat-bottom holes 3 mm and 6 mm deep and 6 mm in diameter placed within the weld heat-affected zone (HAZ). The most effective sensor configurations were able to detect critical discontinuities more than 2 m away. Although a single sensor could be robotically deployed, the large volume covered by each sensor could support a small number of permanently mounted sensors, equipped with an external connector for periodic interrogation. The HAZ of a hypothetical SFC cylindrical surface could be effectively monitored with just 16 sensors.
12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗