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

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At least 271 records · Page 15
All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Hanford Waste Treatment Plant Low Activity Waste Facility Stack Effluent Monitoring: Sampling Probe Location Qualification Evaluation (Rev.1)

The Hanford Tank Waste Treatment and Immobilization Plant Low Activity Waste (LAW) facility stack monitor locations were qualified using scale model stacks to mitigate the risk of discovering that sampling locations do not meet the qualification criteria on the full-scale stacks. As required by the American National Standards Institute/Health Physics Society (ANSI/HPS) N13.1-1999 standard, the scale model and its sampling location were geometrically similar to the actual stack and the Reynolds numbers for both the actual and model stacks were >10,000. An additional criterion is that the product of the hydraulic diameter and mean velocity (DV) of the full-scale stack must be between 1/6 DV and 6 DV of the scale model stack tests. Verification tests of the LAW stacks were performed at normal operating conditions. The minimum 1/6 DV value, along with the maximum 6 DV value from the scale model testing, determines the range of stack flow rates for which the full-scale stack may be operated and remain in compliance with the stack verification criterion. For this analysis, the range of qualified flow rates listed is conservatively based on the average DV through 6 DV for LV-S1, LV-S2, and LV-C2, and 1/3 DV to 3 DV for LV-S3. Table S1 lists the operating flow rates along with the conservative lower and upper qualified stack flow rates for each of the LAW facility stacks. For each stack, the operating flow is below the upper qualified stack.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2024

Results of Long-Term Analyses of the Salt (Macro) Batch 11 Tank 21H Qualification Sample

Savannah River National Laboratory (SRNL) analyzed samples from Tank 21H in support of qualification of Salt Waste Processing Facility (SWPF) Salt Batch 11. This document reports the long-term results of the analyses of the sample of Tank 21H. Analysis of this sample indicates that the material does not display any unusual characteristics or observations, such as visually apparent solids. However, the sample was dark colored. This report satisfies Deliverable 3 of the Technical Task Request (TTR).

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2023

Preliminary results addressing material qualification using combined ion irradiation and modeling data

Additively-manufactured (AM) materials have attracted increasing attention in recent years as a new method to make novel and customized components. While AM and conventionally produced materials are compositionally similar, they do possess different microstructures, necessitating assessment of materials produced via AM for their behavior in reactor environments. Some microstructures unique to AM materials, such as compositional micro-inhomogeneity and dislocation cell structures, are of particular importance since they may lead to different radiation performance. The performance of AM materials for advanced nuclear reactor applications is of interest to the Advanced Materials and Manufacturing Technologies (AMMT) program under the Department of Energy Office of Nuclear Energy. The AMMT program aims to demonstrate its new accelerated development and qualification methods via laser powder bed fusion (LPBF) 316 stainless steel (SS). Focusing on material bearing both 316L and 316H specifications, we integrate ion irradiation and modeling. This year, we focus on answering foundational questions related to process variability, alloy chemistry variation, and microchemical segregation. Experimental results provide information and motivate questions to the modeling effort, which aims to develop the ability to model radiation-driven microstructural evolution in additively-manufactured 316 stainless steel under a variety of advanced reactor conditions, including different temperatures, neutron spectra, and fluxes, in a sort of "virtual experiment". We perform in-situ and ex-situ ion irradiations and microstructural characterizations to support the development of AM materials for reactor applications, develop a phase field model of radiation-induced segregation in additively manufactured material with high angle grain boundaries and dislocation cells, and investigate the effect of carbon and chromium content on point defect behavior.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2024

Results of Long-Term Analyses of the Salt (Macro) Batch 11 Tank 21H Qualification Sample

Savannah River National Laboratory (SRNL) analyzed samples from Tank 21H in support of qualification of Salt Waste Processing Facility (SWPF) Salt Batch 11. This document reports the long-term results of the analyses of the sample of Tank 21H. Analysis of this sample indicates that the material does not display any unusual characteristics or observations, such as visually apparent solids. However, the sample was dark colored. This report satisfies Deliverable 3 of the Technical Task Request (TTR). This revision adds a further triplicate analysis for 129 I content.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2024

Fuels Irradiation and Physics Database (FIPD) Development and Data Qualification FY24 Updates

The DOE-NE Advanced Reactor Technologies program has supported efforts to recover and preserve metallic fuel data generated throughout the past fast reactor R&D programs. Those efforts are currently focused on establishing databases for information from the experiments conducted during the Integral Fast Reactor program including data generated at EBR-II, FFTF, and TREAT reactors, as well as out of pile transient testing data. These databases are essential for future-licensing activities of metallic fuel based advanced fast reactors. This report describes the Metallic Fuels Irradiation & Physics Database (FIPD) development, content updates, data qualification status, and user support in FY24. Future plans are also provided.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2024

Results of Long-Term Analyses of the Salt (Macro) Batch 13 Tank 42H Qualification Sample

Savannah River National Laboratory (SRNL) analyzed samples from Tank 42H in support of qualification of Salt Waste Processing Facility (SWPF) Salt Batch 13. This document reports the long-term results of the analyses of the sample of Tank 42H. Analysis of this sample indicates that the material does not display any unusual characteristics or observations, such as visually apparent solids. This report satisfies Deliverable 3 of the Technical Task Request (TTR).

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2024

Feature Based Qualification (FBQ) of Wire Arc Additively Manufactured (WAAM) 17-4PH Martensitic Stainless Steels

The Department of Defense (DOD) programs of records desire to reduce the time and cost of the development and delivery loop in metal additive manufacturing (AM), including establishing forwarded AM capabilities. The success of these efforts relies on a robust and qualified process. To achieve this, the United States Army Combat Capabilities Development Command Ground Vehicle Systems Center Materials Engineering (GVME) needs to be able to quickly evaluate, test, and develop feedstocks, processes, and parts. This report is directed towards demonstrating the need for a framework for metal AM processes, defining and exploring geometries for metal AM process qualification, testing resultant deposition, and delivering actionable data.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Assessment and Usage of In-Situ Monitoring Data for American Society of Mechanical Engineers Part Qualification

In-situ monitoring and anomaly detection are important components for qualification of directed energy deposition (DED) additive manufacturing (AM) processes and components. The use of in-situ monitoring requires an understanding of anomalies that can be identified during the process and how those anomalies correlate to mechanical properties of the component post-production. There is also a need to qualify the algorithms and software used to interpret the process signals for DED AM. There is no single process signal that can be used with a single algorithm that will identify all anomalies that will translate to a defect in a process. The process signals are affected by changes in material, location, resolution, acquisition rate, component geometry, and the machine itself. It is observed that multiple process signals are required to identify relevant features that can be correlated to mechanical properties.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Model-based quantification of margins and uncertainties in metal additive manufacturing for process design and qualification

Laser powder bed fusion (LPBF) Additive Manufacturing (AM) has the potential to enable the production of components with novel designs and material properties unachievable otherwise. However, process repeatability is a challenge, making qualification ill-defined and greatly reducing the utility of what could be an important manufacturing technology. In this work, a combination of modeling, uncertainty quantification (UQ), and experimentation are used in an effort to predict and bound the range of possible outcomes of the LPBF process. Quantities of interest predicted are melt pool dimensions, microstructure features, and mechanical distortions. A combination of high fidelity thermal-fluid models, microstructure growth models, and reduced fidelity, rapid thermal and mechanical models are used. Uncertainty propagation techniques are used to predict probability distributions of quantities of interest from estimates of process uncertainties. Repeated experiments are done to quantify observed probability distributions and compared to predicted distributions to determine if predictions are precise and accurate. Novel modeling methods are microstrucutre characterization techniques are also discussed. It is found that high fidelity models do a generally good job bounding experimentally observed melt pool morphologies for both bead-on-plate and powder bed cases. Microstructure models are able to bound a number of experimentally observed microstructure statistics, but with low precision due to challenges with calibrating the microstructure growth model parameters. A developed modified inherent strain distortion model does not accurately predict observed distortions. A lumped laser distortion model shows promise in being both accurately and precisely bounding observed outcomes from the deflection comb build, but requires further evaluation on more builds and geometries.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Development and Qualification of Advanced Alloys Used in High Helium and Displacement Damage Service for Fusion Energy Applications

This document represents a final report on the Department of Energy (DOE) Office of Science, Office of Fusion Energy Science (OFES) Grant Entitled “Development and Qualification of Advanced Alloys Used in High Helium and Displacement Damage Service for Fusion Energy Applications” (DE-FG02-94ER54275). This grant has been funded since 1994, by a series of five and three-year renewals. We express our deep appreciation for the long-standing support by OFES for our fusion materials research. The latest three-year renewal was awarded in 2019. This renewal subsequently received a 1- year no-cost extension, followed by another funded 1-year phaseout period. Here, we focus on this five-year effort. The final report is composed of 35 Fusion Semiannual Reports covering the period from 2019 to 2024. In addition, Appendix A lists 158 fusion materials papers published since 1994, with the partial, or full, support of the OFES program. We note that, as metrics of their high impact, these papers have received a total of 8582 citations, with an average of 54 per paper.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Results of Long-Term Analyses of the Salt (Macro) Batch 14 Tank 21H Qualification Sample

Savannah River National Laboratory (SRNL) analyzed samples from Tank 21H in support of qualification of Salt Waste Processing Facility (SWPF) Salt Batch 14. This document reports the long-term results of the analyses of the sample of Tank 21H. Analysis of this sample indicates that the material does not display any unusual characteristics or observations, such as visually apparent solids. This report satisfies Deliverable 3 of the Technical Task Request (TTR).

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

Qualification of Digitized Legacy Fast Reactor Data

The Integral Fast Reactor (IFR) fuel compatibility test program (1984-1994) included a variety of fuel pin examinations conducted at the Hot Fuel Examination Facility (HFEF) and the Alpha-Gamma Hot Cell Facility (AGHCF). Hard copy data records of these examinations have been recovered, scanned, and preserved in PDF format. Many hard copy records are now qualified in accordance with an NRC-approved Quality Assurance Program Plan (QAPP), and there is an ongoing effort to qualify additional legacy records. This legacy fuel performance data is vital to support design and licensing of fast reactors with validation of state-of-the-art codes and advanced methods for design and analysis. Stakeholders can most easily utilize this data when the PDF scans have been converted into digital data tables. However, qualification of the scanned hard copy data does not qualify the digital data file resulting from the digitization of the data contained in the record; the subject matter expert (SME) must make a review of the digitized data table as well before it can be designated as qualified. This report outlines a peer review process to qualify the digital data file(s), typically in CSV format, corresponding to hard copy records in accordance with the existing QAPP.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2025

Demonstrating Advanced Sensors for In-Situ Monitoring Towards Qualification of Nuclear Relevant Components

The U.S. Department of Energy’s Office of Nuclear Energy Advanced Materials and Manufacturing Technologies (AMMT) program is pursuing qualification of laser powder bed fusion (LPBF) components for nuclear applications. A major focus of this effort is the use of in situ process monitoring and machine learning–based tools to establish real-time quality assurance. The primary objective of this report is to identify and evaluate the most relevant in situ sensor systems for LPBF, and to document the deployment of these systems across platforms critical to the AMMT program. This work demonstrates how in situ monitoring can detect process anomalies, track geometry-dependent flaws, and identify limiting combinations of processing parameters—particularly those related to energy density and complex geometries (e.g., overhanging structures). To support this goal, a diverse suite of sensor modalities was evaluated across LPBF platforms, including visible and near-infrared (NIR) imaging, fringe projection profilometry, long-wavelength infrared (LWIR) thermography, and high-speed photodiode/pyrometry systems. These sensor streams were integrated with Peregrine, a machine-agnostic software platform that, among other capabilities, can generate real-time process anomaly classification. This report documents sensor deployments on multiple AMMT flagship platforms, including the Concept Laser M2 and Renishaw AM400/AM250 systems. Calibration builds with complex, flaw-prone geometries such as unsupported overhangs, stepped features, and thin walls, were used to evaluate how well Peregrine and its associated sensors could detect process anomalies and other instabilities under varied energy densities. It will be shown how Peregrine reliably identifies common process anomalies such as recoater streaking, superelevation, etc., and can be used in post-build analysis for anomaly spatial distributions throughout the build height to better understand the impact of geometry and processing parameter choice on the build. This work demonstrates measurable progress toward the vision that components can be born-qualified by establishing a real-time monitoring framework, identifying limiting process conditions, and laying the foundation for sensor fusion–enabled prediction pipelines that are scalable across platforms and applicable to nuclear-relevant components.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2025

Preparation and Qualification of Preproduction SSR2 Jacketed Cavities for PIP-II

The qualification of 325 MHz Single Spoke Resonators type 2 (SSR2) jacketed cavities to meet technical requirements represents a significant milestone in the development of the SSR2 cryomodules for the PIP-II Project at Fermilab. This poster reports the procedures and lessons learned in processing and preparing these cavities for horizontal cold testing prior to integration into a cavity string assembly, with a focus on addressing the field emission issues observed during the cold testing. A comprehensive root cause analysis identified critical fabrication, processing, and handling factors impacting field emission onset. New techniques were successfully developed and implemented to achieve field emission-free SSR2 cavities, and efforts were made to correlate radiation levels measured at the test stand with expected levels in the LINAC tunnel. Additionally, the evolution of field emission through assembly steps was thoroughly investigated, leading to a reassessment of design choices and enhancing our understanding of their effects on cavity performance.

Grassellino, L. [Fermilab]↗
DOE OSTI2025

Alloy 625 Qualification Pathway for ASME Section III Division 5 Class A construction

The American Society of Mechanical Engineers Boiler and Pressure Vessel Code Section III Division 5 provides construction and inspection rules to ensure the safety of nuclear components operating at elevated temperatures, defined as those operating above 700°F (370°C) or 800°F (425°C), depending on the material type. At present, there are six materials approved for Class A (high safety significance) component construction under ASME BPVC Section III Division 5. Out of these six materials, five materials are steels or iron-based alloys and one material, Alloy 617, is a nickel alloy. Nickel alloys are stronger than steels; however, Alloy 617 consists of 10-15% cobalt, and activation is a concern under irradiation. Therefore, there is a need to qualify new nickel alloy with lower cobalt content. Alloy 625 is one candidate which has similar mechanical properties at elevated temperature compared to Alloy 617 and has a maximum of 1% cobalt. Although Alloy 625 material properties have been developed in the past to support allowable stress development under ASME Section II, new test results would be needed to qualify this material for elevated temperature component construction under ASME Section III Division 5. The purpose of this report is to describe a path towards developing a Nuclear Code Case to qualify Alloy 625 (UNS N06625; Grade 1 and Grade 2) for elevated temperature nuclear use in accordance with the ASME BPVC rules. This report reviews the existing database on Alloy 625, presents proposed test campaign, and discusses potential paths for accelerating the accelerated material qualification process.

36 - MATERIALS SCIENCE↗
DOE OSTI2026

Progress Report on SFR Metallic Fuel Data Qualification

This report summarizes the progress of SFR metallic fuel qualification related activities, which are focused on providing quality assurance relevant information applicable to experiments irradiated during the Integral Fast Reactor (IFR) program. An overview of the metallic fuel performance data and the associated databases, including the EBR-II Fuels Irradiation & Physics Database (FIPD), Out-of-Pile Transient Database (OPTD), and TREAT Experimental Relational Database (TREXR) is included. The legacy data in the databases, including as-built, post-irradiation examination (PIE), operating parameters, and out-of-pile experiment post-test data are introduced. The SFR metallic fuel Quality Assurance Program Plan (QAPP) and its implementation to qualify these legacy data is described in detail. Important PIE data QA documents and the specifications of seven types of PIE measurements (contact profilometry, laser profilometry, neutron radiography, gamma scan, fission gas release fission gas chemistry, and metallography) are provided. Examples of the implementation of the QAPP to qualify each of those types of PIE data are provided.

Mo, Kun [Argonne National Laboratory (ANL), Argonn↗
DOE OSTI2024

Evaluation of the Mechanical Properties of Cast and Wrought CF8C-Plus Relevant to ASME Code Case Qualification

The mechanical behavior of a cast form of an advanced austenitic stainless steel, CF8C-Plus, is compared with that of its wrought equivalent in terms of both tensile and creep-rupture properties and estimated allowable stress values for pressurized service at temperatures up to about 850°C. A traditional Larson-Miller parametric model is used to analyze the creep-rupture data and to predict long-term lifetimes for comparison of the two alloy types. The cast CF8C-Plus exhibited lower yield and tensile strengths, but higher creep strength compared to its wrought counterpart. Two welding methods, shielded-metal-arc welding (SMAW) and gas-metal-arc welding, met the weld qualification acceptance criteria in ASME BPVC Section IX for the cast CF8C-Plus. However, for the wrought CF8C-Plus, while SMAW and gas-tungsten-arc welding passed the tensile acceptance criteria, they failed the side bend tests due to lack of fusion or weld metal discontinuities.

Chen, Xiang↗