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DOE OSTI2025

Determination of Scale Bar for AGHCF Metallography Data

The DOE Nuclear Energy Advanced Reactor Technologies (ART) Fast Reactor Program (FRP) has supported the development of several databases containing information on the safety performance of fast reactors, components, and fuels. This growing collection of legacy experimental data, operating data, and analysis is available online to registered users. Metallography data represents one of the most critical types of post-irradiation examination (PIE) data being collected, organized, and archived in several ART Fast Reactor Databases (https://frdb.ne.anl.gov), including the Metallic Fuels Irradiation & Physics Database (FIPD), Out-of-Pile Transient Database (OPTD), and TREAT (the Transient Reactor Test Facility) Experimental Relational Database (TREXR). These databases contain three principal sets of metallography data. The first set comprises metallography data from Experimental Breeder Reactor-II (EBR-II) and Fast Flux Test Facility (FFTF) irradiated fuel pins examined in the Hot Fuel Examination Facility (HFEF). The second set consists of metallography data from EBR-II irradiated fuel pins examined in the Alpha-Gamma Hot Cell Facility (AGHCF). The third set includes metallography data from transient-tested fuel pins (including both out-of-pile furnace tests and TREAT tests) examined in AGHCF. Since both the second and third sets were generated in AGHCF, they are governed by identical specifications. The metallography data in the databases consist of digital images scanned from either positive or negative photographic films. To analyze the microstructure of a fuel pin, a series of preparatory steps are required, including sectioning, epoxy mounting, mechanical grinding and polishing, and etching. Following sample preparation, specimens are transferred for metallographic examination. The AGHCF and HFEF metallography data were generated using optical microscopes manufactured by Leitz and Bausch and Lomb (B&L). Images were recorded on Polaroid film at preset magnifications. Magnification verification for the Leitz and B&L metallographs was conducted every two months prior to 1989 and at least every six months from 1989 through the conclusion of the IFR program. Magnifications determined from imaging of microslide standards were compared to the instrument settings for magnifications ranging from 50× to 500×. If the magnifications determined from standards deviated from the instrument settings, adjustments were made to the bellows extension until agreement was achieved. The specifications for AGHCF and HFEF legacy metallography data have been established based on available hard-copy and digital records, most of which have been incorporated into the data repositories associated with FIPD, OPTD, and TREXR. Detailed specifications including hard-copy records, digitized records, cutting diagrams and sectioning schemes, high-magnification photographs, photomosaics (composites), information tags, scale bars, and magnification verification procedures can be found in a separate report.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2025

Degradation of Be 2 C at conditions expected in molten salt environments

This technical report is in submission of completion of the Level 4 milestone number M4AT-25OR1101021, titled “Degradation of Be 2 C at conditions expected in molten salt environments”, for the AT-25OR110102 “Beryllium Carbide as moderator for MSRs—ORNL” WBS number 2.04.11.01 within the larger Advanced Reactor Technologies program at Oak Ridge National Laboratory. This effort is an initial study of the viability of Be 2 C as a future neutron moderator for molten salt reactors and other high-temperature reactors. The research was awarded funding in September 2022, and this Level 4 milestone presents the work that completed by the end of July 2025. This work is a collaboration between Oak Ridge National Laboratory and the University of Michigan.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2025

Progress on the US-Japan Source Term Benchmark Analysis Collaboration

There has been a resurgence in global interest in advanced reactor technology, with a variety of innovative concepts being proposed and developed. Sodium-cooled Fast Reactors (SFRs) have garnered considerable attention given their beneficial characteristics and extensive historical development programs and operating experience. Central to the licensing of non-light water reactor (non-LWR) technology is the characterization of the safety case. At its basics, reactor safety focuses on the prevention and mitigation of the release of radioactive material to the environment.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2025

An In Situ Feed Monitoring System for Molten Salt Reactors with Fast Neutron Energy Spectrum Molten Salt Reactor Applications

Molten salt reactors (MSRs) are one of the six promising advanced reactor technologies selected for further research and development by the Generation IV International Forum. More than twenty MSR designs are actively being developed around the world. Several of these designs are liquid-fueled and intended for operation within the fast neutron energy spectrum.1 National regulations will require liquid-fueled MSRs to control and account for nuclear material within licensed facilities. Additionally, states with comprehensive safeguards agreements with the International Atomic Energy Agency (IAEA) are obligated to declare nuclear material quantities within facilities. In return, the IAEA Department of Safeguards independently verifies these quantities and provides assurance that the nuclear material and facility are being used only for peaceful purposes. One key distinction of liquid-fueled MSRs compared with other types of reactors is that in portions of the facility, the nuclear material is in bulk form rather than discrete items. Traditional nuclear material accounting techniques such as physical item counting and verification of serial numbers on fresh fuel assemblies do not translate directly to all process streams within liquid-fueled reactors. Liquid-fueled MSRs are typically designed with low excess reactivity. This feature provides safety benefits but also means that most MSRs require the addition of makeup fuel salt while a reactor is operational. The nuclear material in the initial fuel salt and in any makeup fuel salt must be quantified. Additionally, distinct nuclear material diversion and reactor misuse scenarios form the basis of the detection methods and monitoring systems developed for liquid-fueled MSRs. For example, the IAEA provides assurance that fuel salt containing nuclear material is not being diverted from the system, that the feed salt matches the reported actinide concentrations and uranium enrichment, and that no additional fertile material is being introduced into the system. Measurement systems currently used for nuclear material control and accounting are not directly applicable to achieving MSR safeguards goals. This paper concerns a system being designed to account for the nuclear material added to liquid-fueled MSRs and monitor for diversion and misuse scenarios related to MSR feed systems.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2026

Status on Microstructural Studies of Nuclear Graphite

This report documents the completion of the Advanced Reactor Technologies (ART) Level 3 Milestone (M3AT-26OR0605054), “Provide status on microstructural studies of nuclear graphite,” due May 1, 2026. The contents of this report summarize recent progress in the development of the Nuclear Graphite Microstructure Library, including datasets that have been generated, curated, and submitted for publication, as part of the broader effort to establish and integrate the library within the NDMAS platform.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2025

Worst Case Sabotage Consequence Modeling for Advanced Reactors

Under proposed rulemaking by the United States Nuclear Regulatory Commission, advanced reactor licensees may qualify for a reduction in onsite responders if the consequences from a sabotage attack do not exceed 25 rem at the reactor site boundary 2 hours after a release occurs. This work presents a preliminary assessment of the feasibility of meeting the 25 rem at the site boundary criteria. Using advanced reactor radionuclide inventories radiological release estimates created by collaborators at Oak Ridge National Laboratory, the MACCS consequence analysis code was used to investigate the distance at the dose from hypothetical sabotage events reaches 25 rem for different advanced reactor technologies. It was found that the distance to 25 rem depended heavily on sampled weather conditions and sabotage release fractions, and further refinement of release fractions and MACCS modeling parameters is recommended.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2024

Cradle to grave: the importance of the fuel cycle to molten salt reactor sustainability

Advanced reactor technologies are being considered for the next-generation of nuclear power plants. These plants are designed to have a smaller footprint, run more efficiently at higher temperatures, have the flexibility to meet specific power or heating needs, and have lower construction costs. This paper offers a perspective on molten salt reactors, promoted as having a flexible fuel cycle and close-to-ambient pressure operation. A complexity introduced by reducing the reactor footprint is that it may require low-enriched fuel for efficient operation, available from enrichment of the feed salt or by reusing actinides from existing used nuclear fuel (UNF). Recycling UNF has the potential to reduce high-level waste, if done correctly. Release limits from UNF processing are stringent, and processes for waste reduction, fission gas trapping, and stable waste-form generation are not yet ready for commercial deployment. These complex processes are expensive to develop and troubleshoot because the feed is highly radioactive. Thus, fuel production and supply chain development must keep abreast of reactor technology development. Another aspect of reactor sustainability is the non-fuel waste streams that will be generated during operation and decommissioning. Some molten salt reactor designs are projected to have much shorter operational lifetimes than light-water reactors: less than a decade. A goal of the reactor sustainability effort is to divert these materials from a high-level waste repository. However, processing of reactor components should only be undertaken if it reduces waste. Economic and environmental aspects of sustainability are also important, but are not included in this perspective.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2023

Digital Twin Framework for the Resilient Remote Monitoring and Operation of Nuclear Microreactors

The nuclear industry is developing new advanced reactor technologies, and many companies are conceptualizing designs for microreactors, a class of nuclear reactor with a sub-20 MWth power output designed to be factory fabricated, easily transportable, and simple to control. Microreactors offer promising solutions to several use cases for which large-scale plants would not be suitable, and conventional power generation means, notably diesel electric generators, are expensive and logistically difficult. Many of the potential use cases are in isolated locations such as arctic communities, remote mines, and military installations. Therefore, the cost of microreactor deployment and traditional onsite operations pose a challenge that requires new technical solutions to address. One solution that has the potential to greatly improve economics is to operate and monitor microreactors remotely from a centralized location. Remote monitoring and operation are novel concepts to the nuclear industry and will greatly alter the tasks and responsibilities associated with current commercial nuclear power plant operators. As such, it is important to perform research on potential technological solutions and the impacts those solutions have on operations with end-goal of defining a safe and effective remote concept of operations. This paper proposes a framework for resilient remote operation of microreactors enabled by a novel digital twin implementation.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2016

Benchmark Simulations of the Thermal-Hydraulic Responses during EBR-II Inherent Safety Tests using SAM

An advanced system analysis tool SAM is being developed for fast-running, improved-fidelity, and whole-plant transient analyses at Argonne National Laboratory under DOE-NE’s Nuclear Energy Advanced Modeling and Simulation (NEAMS) program. As an important part of code development, companion validation activities are being conducted to ensure the performance and validity of the SAM code. This paper presents the benchmark simulations of two EBR-II tests, SHRT-45R and BOP-302R, whose data are available through the support of DOE-NE’s Advanced Reactor Technology (ART) program. The code predictions of major primary coolant system parameter are compared with the test results. Additionally, the SAS4A/SASSYS-1 code simulation results are also included for a code-to-code comparison.

Hu, Rui↗
DOE OSTI2016

FFTF Passive Safety Test Data for Benchmarks for New LMR Designs

Liquid Metal Reactors (LMRs) continue to be considered as an attractive concept for advanced reactor design. Software packages such as SASSYS are being used to im-prove new LMR designs and operating characteristics. Significant cost and safety im-provements can be realized in advanced liquid metal reactor designs by emphasizing inherent or passive safety through crediting the beneficial reactivity feedbacks associ-ated with core and structural movement. This passive safety approach was adopted for the Fast Flux Test Facility (FFTF), and an experimental program was conducted to characterize the structural reactivity feedback. The FFTF passive safety testing pro-gram was developed to examine how specific design elements influenced dynamic re-activity feedback in response to a reactivity input and to demonstrate the scalability of reactivity feedback results to reactors of current interest. The U.S. Department of En-ergy, Office of Nuclear Energy Advanced Reactor Technology program is in the pro-cess of preserving, protecting, securing, and placing in electronic format information and data from the FFTF, including the core configurations and data collected during the passive safety tests. Benchmarks based on empirical data gathered during operation of the Fast Flux Test Facility (FFTF) as well as design documents and post-irradiation examination will aid in the validation of these software packages and the models and calculations they produce. Evaluation of these actual test data could provide insight to improve analytical methods which may be used to support future licensing applications for LMRs

Wootan, David W.↗
DOE OSTI2016

Comparisons of RELAP5-3D Analyses to Experimental Data from the Natural Convection Shutdown Heat Removal Test Facility

The Reactor Cavity Cooling System (RCCS) is an important passive safety system being incorporated into the overall safety strategy for high temperature advanced reactor concepts such as the High Temperature Gas- Cooled Reactors (HTGR). The Natural Convection Shutdown Heat Removal Test Facility (NSTF) at Argonne National Laboratory (Argonne) reflects a 1/2-scale model of the primary features of one conceptual air-cooled RCCS design. The project conducts ex-vessel, passive heat removal experiments in support of Department of Energy Office of Nuclear Energy’s Advanced Reactor Technology (ART) program, while also generating data for code validation purposes. While experiments are being conducted at the NSTF to evaluate the feasibility of the passive RCCS, parallel modeling and simulation efforts are ongoing to support the design, fabrication, and operation of these natural convection systems. Both system-level and high fidelity computational fluid dynamics (CFD) analyses were performed to gain a complete understanding of the complex flow and heat transfer phenomena in natural convection systems. This paper provides a summary of the RELAP5-3D NSTF model development efforts and provides comparisons between simulation results and experimental data from the NSTF. Overall, the simulation results compared favorably to the experimental data, however, further analyses need to be conducted to investigate any identified differences.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2016

Progress In Developing An In-Pile Acoustically Telemetered Sensor Infrastructure

A salient grand challenge for a number of Department of Energy programs such as Fuels Cycle Research and Development ( includes Accident Tolerant Fuel research and the Transient Reactor Test Facility Restart experiments), Light Water Sustainability, and Advanced Reactor Technologies is to enhance our fundamental understanding of fuel and materials behavior under irradiation. Robust and accurate in-pile measurements will be instrumental to develop and validate a computationally predictive multi-scale understanding of nuclear fuel and materials. This sensing technology will enable the linking of fundamental micro-structural evolution mechanisms to the macroscopic degradation of fuels and materials. The in situ sensors and measurement systems will monitor local environmental parameters as well as characterize microstructure evolution during irradiation. One of the major road blocks in developing practical robust, and cost effective in-pile sensor systems, are instrument leads. If a wireless telemetry infrastructure can be developed for in-pile use, in-core measurements would become more attractive and effective. Thus to be successful in accomplishing effective in-pile sensing and microstructure characterization an interdisciplinary measurement infrastructure needs to be developed in parallel with key sensing technology. For the discussion in this research, infrastructure is defined as systems, technology, techniques, and algorithms that may be necessary in the delivery of beneficial and robust data from in-pile devices. The architecture of a system’s infrastructure determines how well it operates and how flexible it is to meet future requirements. The limiting path for the effective deployment of the salient sensing technology will not be the sensors themselves but the infrastructure that is necessary to communicate data from in-pile to the outside world in a non-intrusive and reliable manner. This article gives a high level overview of a promising telemetry infrastructure based on acoustic wireless transmission of data that is being developed and tested by the INL, Penn State and Westinghouse.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2018

Support for Fuel Fabrication and Characterization

Oak Ridge National Laboratory (ORNL) has participated in the Advanced Gas Reactor (AGR) program for the Next Generation Nuclear Plant (NGNP) and the transition to the Idaho National Laboratory (INL) Advanced Reactor Technologies (ART) Technology Development Office (TDO) since the inception of the program. In this effort, ORNL has fabricated tristructural isotropic (TRISO) fuel and fuel compacts for AGR-1, AGR-2, and AGR-3/4 experiments, provided matrix only components for AGC-2, AGC-4, and AGR 3/4 experiments and for university studies, and provided characterization, coating, and compaction support for INL and BWX Technologies Nuclear Operations Group (BWXT). In fiscal year (FY) 2017, the activities for the INL ART TDO fuel development are focused on preparations for the AGR-5/6/7 experiments and technical support to the Generation-IV International Forum (GIF) pre-irradiation leach-burn-leach (LBL) round robin effort with China and South Korea. With the successful transfer of fuel fabrication technology to BWXT, ORNL’s involvement has shifted toward transferring fuel characterization methods, providing technical support, verification of BWXT laboratory results, and fabricating surrogate fuel materials for university collaborations. ORNL will also provide analytical support to BWXT and INL for uranium dispersion analysis and confirmatory fuel characterization analyses as needed.

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DOE OSTI2018

Dose Uncertainty Quantification in AGC Experiment

This memorandum formally documents completion of the Advanced Reactor Technologies Level 3 Milestone (M3NT-18IN060504037), “Interoffice Memorandum detailing status of the AGC irradiation uncertainty analysis” due SeptemberAugust 30, 2018. This memorandum details the progress made toward the issuance of a final report detailing the AGC uncertainty analysis including the proposed methodology, progress on activities, and explanation of how the data will be used. Radiation damage estimation is an important component of the post-irradiation analysis of the AGC experiments. It depends primarily on the fast fluence, which is determined using well-established methods of spectral adjustments. These are based on best estimates from models (e.g. MCNP). Input cross-sections, and measured activities from flux wires in the experiment, propagate uncertainties in each of these. While the methods of propagating uncertainty are well-established, the final uncertainty estimates they provide are only as good as the estimates of uncertainty in the inputs on which they are based. The purpose of this work is to implement a method that eliminates some deficiencies in the ways input uncertainties are presently estimated. The rRadiation damage estimates for the AGC experiments are ostensibly based on experimental data in the form of flux wire activation measurements; each AGC experiment has been instrumented with flux wires at various locations along the axial length to provide this data. However, the estimatesy also depend on the results of MCNP calculations. To understand why, consider that the objective of the analysis is to estimate some number of parameters (the energy group fluences ?_i) that best reproduce the observations (the measured activities of the flux wires a_i).

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2019

Fuel Loading Optimization and Planning for the Versatile Test Reactor

The Versatile Test Reactor (VTR) mission is to enable accelerated testing of advanced reactor fuels and materials required for advanced reactor technologies. In service of this duty, the goal of the design is to maximize the peak fast flux and the experimental volume exposed to a fast flux above 4.0 × 1015n/cms s. Delivering the desired neutron fluence for each experiment requires the capability to optimize the fuel loading to achieve a specified cycle length and flux, while also satisfying other criteria such as thermal hydraulic design constraints. To achieve the desired conditions and cycle length, several measures may be taken, including optimization of the fuel loading pattern, moving partially-burned assemblies back and forth between the core and the in-vessel storage, and potentially shuffling fuel within the core. Optimizing in a "brute-force" manner by solving a wholecore transport equation for hundreds of configurations would be inefficient. A sufficiently refined DIF3D-VARIANT solution for the whole core requires on the order of 1 hour. Instead, we seek an approximate evaluation of the parameters for many variations on a base core configuration without directly solving a diffusion or transport equation for each.

fuel loading optimization↗
DOE OSTI2019

Assessment of Low Enriched Uranium Fueled Core Configurations for the Versatile Test Reactor

The Versatile Test Reactor (VTR) Program was initiated in FY-2017. This multi-laboratory effort supported by the U.S. Department of Energy has the long-term objective of completing a Versatile Test Reactor concept with associated cost and schedule estimate that enables a fully informed DOE decision within 3 years, to have a fully operating VTR by 2026 if acquisition is authorized, and to enable accelerated testing of advanced reactor fuels and materials required for advanced reactor technologies. The VTR concept uses sodium as coolant, features a core power of 300 MWth, and employs reactor-grade plutonium as fissile material in a U-Pu-10Zr fuel alloy. The reference core layout provides 10 assembly locations for high-flux irradiation testing with peak fast flux in excess of 4x1015 n/cm2-s. In order to establish a comparison point with other types of fuel, alternative core configurations were investigated using Low Enriched Uranium (LEU) fuel. The objective of this study was to modify the reference VTR core such as to use LEU fuel and assess the performance tradeoff, while retaining the same core envelope.

Stauff, Nicolas E.↗
DOE OSTI2018

Support for Fuel Fabrication and Characterization

Oak Ridge National Laboratory (ORNL) has participated in the Advanced Gas Reactor (AGR) program for the Next Generation Nuclear Plant (NGNP) and the transition to the Idaho National Laboratory (INL) Advanced Reactor Technologies (ART) Technology Development Office (TDO) since the inception of the program. In this effort, ORNL has fabricated tristructural isotropic (TRISO) fuel and fuel compacts for AGR-1, AGR-2, and AGR-3/4 experiments, provided matrix only components for AGC-2, AGC-4, and AGR 3/4 experiments and for university studies, and provided characterization, coating, and compaction support for INL and BWX Technologies Nuclear Operations Group (BWXT). In fiscal year (FY) 2017, the activities for the INL ART TDO fuel development are focused on preparations for the AGR-5/6/7 experiments and technical support to the Generation IV (GenIV) pre-irradiation leach-burn-leach round robin effort with China and South Korea. With the successful transfer of fuel fabrication technology to BWXT, ORNL’s involvement has shifted toward transferring fuel characterization methods, providing technical support, verification of BWXT laboratory results, and fabricating surrogate fuel materials for university collaborations. ORNL will also provide analytical support to BWXT and INL for uranium dispersion analysis and confirmatory fuel characterization analyses as needed.

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DOE OSTI2017

Support for Fuel Fabrication and Characterization

Oak Ridge National Laboratory (ORNL) has participated in the Advanced Gas Reactor (AGR) program for the Next Generation Nuclear Plant (NGNP) and the transition to the Idaho National Laboratory (INL) Advanced Reactor Technologies (ART) Technology Development Office (TDO) since the inception of the program. In this effort, ORNL has fabricated tristructural isotropic (TRISO) fuel and fuel compacts for AGR-1, AGR-2, and AGR-3/4 experiments, provided matrix only components for AGC-2, AGC-4, and AGR 3/4 experiments and for university studies, and provided characterization, coating, and compaction support for INL and BWX Technologies Nuclear Operations Group (BWXT). In fiscal year (FY) 2018, the activities for the INL ART TDO fuel development are focused on final characterization to support the AGR-5/6/7 experiments and technical support to the Generation-IV International Forum (GIF) pre-irradiation leach-burn-leach (LBL) round robin effort with China and South Korea.

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