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DOE OSTI2022

Westinghouse Accident Tolerant Fuel Phase 2B with Higher Enriched and Higher Burnup Add-On Project Final Technical Report Deliverable Volume 2

The Westinghouse Electric Company LLC (Westinghouse) accident tolerant fuel (ATF) program funded by Westinghouse and the US Department of Energy (DOE) utilized chromium (Cr) coated zirconium alloy cladding with doped UO 2 (ADOPT(TM)) and uranium silicide (U 3 Si 2 ) high density/high thermal conductivity fuel for its lead test rod (LTR) program with irradiation beginning in 2019. ADOPT is a Cr 2 O 3 +Al 2 O 3 doped UO 2 pellet with increased oxidation resistance and density, and increased resistance to fission gas release. Due to the issues with U 3 Si 2 fuel reaction in pressurized water reactor (PWR) environments, uranium nitride (U 15 N) has been substituted for U 3 Si 2 as a long-term fuel option. Cr coated cladding with ADOPT fuel is the near-term Westinghouse EnCore ® fuel product. The long-term EnCore fuel product is SiGA ® SiC/SiC composite cladding with high density/high thermal conductivity UN fuel. In 2020, the higher burnup and higher enriched and (HBHE) program was integrated into the ATF program. The objective of this expanded program is to extend ATF burnups to at least 75 MWd/kgU to economically facilitate 24-month cycles in PWRs. The ATF program now includes ADOPT fuel with enrichments >5% 235 U. Over the past several years, Westinghouse has tested the Cr coated zirconium (Zr) and silicon carbide (SiC) claddings in Westinghouse Churchill autoclaves and the Massachusetts Institute of Technology (MIT) reactor. Additionally, the Cr coated cladding has been tested in the Advanced Test Reactor (ATR) at Idaho National Laboratory (INL) and in LTR programs at the Doel 4 and Bryon 2 commercial reactors. High temperature tests at the state-of-the-art Westinghouse facilities in Churchill, PA and at Karlsruhe Institute of Technology (KIT) have been carried out to determine the time and temperature limits for the Cr coated zirconium claddings. These tests indicate that Cr coated Zr cladding can take temperatures up to about 1500°C for short periods of time without becoming totally oxidized. The main issue is the formation of the Cr-Zr eutectic at 1333°C resulting in the migration of this eutectic inward with the formation of ZrCr 2 which rapidly oxidizes to ZrO 2 on the outside of the tube. The Cr coated Zr cladding also delays the bursting of the tube, reduces the burst area, and reduces hydriding and embrittlement of the Zr which is a major benefit for reducing fuel fragmentation, redistribution, and dispersal (FFRD), the major licensing issue faced by HBHE. The manufacturing parameters for the SiC have been found to have a significant effect on the corrosion rate of the SiC in light water reactor (LWR) conditions and significant improvements have been made in the yield, quality, and oxidation resistance of the SiC cladding by identifying and tightening manufacturing process parameters. Current autoclave results for SiC composite claddings indicate that a corrosion rate of fewer than 2 micrometers per year can be achieved which meets corrosion requirements under normal operating conditions. High temperature steam oxidation tests at the state-of-the-art Westinghouse facilities in Churchill, PA and at Karlsruhe Institute of Technology (KIT) have been carried and determined that SiC cladding can withstand temperatures up to about 1800°C to 1900°C before excessive corrosion reactions begin, and that the SiC will not balloon and burst. ADOPT fuel pellets were incorporated into the Westinghouse ATF program because of their increased density and oxidation resistance. A topical report supporting the use of ADOPT pellets has been submitted to the NRC and will be approved shortly. ADOPT pellets have been a product in Europe for over 15 years. The additives work to make larger grain sizes which appear to reduce fission gas release during transients as well as increase the density of the pellet. Fuel rod and assembly design in preparation for the lead test rod (LTR) and lead test assembly (LTA) programs is underway as well as licensing efforts with the Nuclear Regulatory Commission (NRC). Finally, accident analyses coupled with economic evaluations for both operating savings as well as fuel savings have been initiated. Modular Accident Analysis Program 5 (MAAP5) calculations indicate that both Cr coated cladding and SiC composite cladding can increase the time to fuel rod loss of geometry for up to two hours longer than current Zr based cladding in a station blackout scenario. This additional time is due to the much higher oxidation resistance of the SiC and Cr coated cladding. These two hours can be used to implement additional response options instituted through the Diverse and Flexible Mitigation Capability (FLEX) program by reactor operators. Both ATF cladding options also reduce hydrogen production which dramatically reduces primary system and containment pressure and the risk of fission product release beyond containment in the unlikely event of an accident. The lower pressure in the system allows more time to feed cooling water to the core, resulting in the avoidance of fuel melting. The coping time is extended indefinitely if the modest water flow provided by FLEX continues. Experimental work on methods to rapidly fabricate SiC composite structures with high density and reduce the fabrication price of SiC fibers while maintaining a high level of performance is needed. Methods for mitigating or stopping the Cr-Zr eutectic are also needed to further improve the oxidation resistance of Cr coated Zr. Minimal (<1%) swelling of U 3 Si 2 and subsequent fission gas release has been demonstrated up to 20 MWd/kgU. Irradiation experiments with U 3 Si 2 fuel in ATR to determine these properties at 40 MWd/kgU were completed but post irradiation examinations were not done since U 3 Si 2 has been replaced by UN. UN has three issues that are being addressed. The first is increasing the oxidation resistance so that there is not excessive reaction up to ~1500°C. While UN increases the pellet density and additives to the UN postponed the temperature at which rapid oxidation occurred by ~100°C to 200°C, this is not enough, and pellet coating options are now being pursued. The second is developing a method to manufacture that does not require the multi-step process of UF 6 to UO 2 to UC to UN. Efforts are underway looking at UF 6 to UN 2 to UN and UF 6 to UF 4 to UN 2 to UN reactions. Finally, an economically acceptable process for potentially enriching the 15 N content of the nitrogen used to make UN to >95% 15 N was identified though not experimentally validated. In addition to the work supported by the DOE, research and testing activities are being carried on in a world-wide effort funded by many countries such as Sweden, United Kingdom, Belgium, Netherlands, Spain, Germany, Japan, and France. This work is being facilitated through the Westinghouse led Collaboration for Advanced Research on Accident Tolerant Fuel (CARAT) program. Annual meetings were organized in 2018 and 2019 by Westinghouse as a venue for presentation of this work and to provide for the cross-fertilization of ideas among the many outstanding researchers in the ATF area. No meetings were held in 2020 and 2021 due to the COVID-19 related restrictions on traveling and gatherings. Since SiC, coated cladding, and high-density fuel options are not currently used in the nuclear industry; support from the government and industry members is needed to further the significant effort of setting new standards. The same is true for the Nuclear Regulatory Commission (NRC) which must review and approve the commercial use of these new fuels since all current regulations are oriented toward Zr/UO 2 fuel. Several meetings have been held with the NRC to generate a fast-track approach to licensing ATF using a combination of atomic modeling, in-rod sensors, and in-reactor testing. This approach was memorialized in an “Accelerated Fuel Qualification White Paper” prepared by the Accelerated Fuel Qualification Working Group lead by General Atomics.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2026

ROADRUNNER uranium nitride MiniFuel: Experimental design, fabrication and pre-irradiation baseline characterization for accelerated burnup testing

Uranium nitride (UN) is a promising fuel candidate for advanced reactor systems owing to its high uranium density and thermal conductivity; however, its qualification remains constrained by the scarcity of well-controlled irradiation performance data. Here, to address this limitation, the ROADRUNNER (Research On ADvancing the peRformance of UraNium Nitrides in Extreme enviRonments) campaign employs the MiniFuel platform in the High Flux Isotope Reactor (HFIR) to enable accelerated burnup irradiation testing under tightly controlled and largely isothermal conditions. This paper presents the experimental design, fuel fabrication, and pre-irradiation baseline characterization of the ROADRUNNER UN MiniFuel campaign. Thirty-six UN minidisc specimens were fabricated with systematically varied as-fabricated density (86–96% of theoretical density), carbon impurity content (961–5240 ppm), oxygen content (≤ ∼2000 ppm), and grain size (2.5–24 μm). The irradiation matrix spans nominal fuel temperatures of 873 K, 1173 K, and 1473 K and target burnups of 3.75%, 6.0%, and 7.5% fissions per initial metal atom (FIMA). Neutronic and thermal analyses were performed to define specimen-specific burnup accumulation and temperature histories, establishing the boundary conditions for subsequent in-pile behavior. Comprehensive pre-irradiation characterization—including dimensional metrology, density verification, impurity analysis, X-ray diffraction, Raman spectroscopy, scanning electron microscopy, X-ray computed tomography, and confocal profilometry—provides a detailed baseline for post-irradiation examination. Pre-irradiation data were further used to generate predictive estimates of fission gas release and swelling using existing empirical correlations. This quantitative comparison reveals substantial inter-model divergence at intermediate and elevated temperatures that exceeds propagated input uncertainties, highlighting structural gaps in the historical irradiation database. The ROADRUNNER irradiation campaign is currently underway in HFIR, with initial firs cycle completed in late 2025 and remaining targets scheduled through 2027. The experimental design and baseline dataset presented here establish the framework needed to interpret forthcoming post-irradiation measurements and to provide discriminating data for the validation and refinement of physics-based UN fuel performance models.

Lopes, Denise Adorno [Oak Ridge National Laborator↗
DOE OSTI2024

Source term analysis of FeCrAl accident tolerant fuel using MELCOR

It has been established that incremental improvements in beyond design basis accident performance can be achieved through accident tolerant fuel (ATF). However, they have the potential to recover margin with respect to conventional fuel and therefore enhance plant economics through uprate or cycle length increase. To realize this potential, it is necessary to quantify the reduction in source term due to use of ATF, and correspondingly how this is affected by increasing the cycle length and/or burnup. This requires development of a risk informed analysis methodology for ATF under high burnup conditions, which is being developed within LWRS. To this end, a MELCOR simulation of FeCrAl ATF in a recovered Large Break LOCA (LBLOCA) scenario has been developed, using a model based on the Zion Pressurized Water Reactor (PWR). The new user defined material capability, along with the inclusion of detailed neutronics- and depletion-derived parameters such as core power distribution, decay heat behavior, and fission product inventories, allows a more detailed simulation of FeCrAl clad material properties and behavior than has previously been possible using MELCOR. These detailed FeCrAl results were compared with a zircaloy clad model to investigate the differences between the two clad types and quantify the benefits of FeCrAl ATF with an 18-month cycle. Next, the fuel cycle with ATF was extended to 24 months, to determine whether any additional safety margin provided by FeCrAl ATF could be leveraged to implement high burnup FeCrAl-clad fuel while retaining the same operating and safety limits as current zircaloy-clad fuel. For the particular scenario analyzed, the delay to fuel failure from using ATF was of the same order as the LOCA recovery time, and hence significant in reducing fission product release, with the 24-month FeCrAl core performing better than the 18-month zircaloy core. It is noted that for other transients, the reduction in release due to using FeCrAl may be less significant. Furthermore, the material model developed here can be used in such further studies in support of determining the overall source term.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2022

Evaluation of Mechanistic and Empirical Models against Existing FFRD and LOCA Experimental Databases

The desire of the nuclear industry to improve the economics of existing nuclear power plants has necessitated research into the potential of a phenomenon known as fuel fragmentation, relocation, and dispersal (FFRD). This phenomenon is possible during a loss-of-coolant accident (LOCA) at relatively high burnup. The Nuclear Energy Advanced Modeling and Simulation program has been developing simulation capabilities for FFRD and LOCA in the BISON fuel performance code for multiple years. This year, the effort has been focused on evaluating new lower length scale informed pulverization thresholds as well as updating and adding new empirical models for various phenomena. Models added or updated this year include a preliminary transient fission gas release model, new high-temperature Zircaloy creep models, a Zircaloy rupture opening area model, and a temperature-dependent emissivity during radiation from the fuel rod to the surrounding atmosphere. The models are verified through implementation tests to demonstrate code correctness after addition to BISON. The models are then assessed against a subset of the existing BISON validation suite for LOCA and FFRD cases. Two new cases, Studsvik Rods 192 and 193, have been added. The results indicate that the inclusion of a bubble pressure evolution model in the bubbles in the high-burnup structure has the largest impact compared to the 3D fracture criterion on reducing the calculated amount of pulverized fuel.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2023

Advanced Drying Cycle Simulator Thermal Response to Commercial Drying Conditions

The purpose of this report is to document updates on testing of the apparatus built to simulate commercial drying procedures for spent nuclear fuel at the Nuclear Energy Work Complex at Sandia National Laboratories. Validation of the extent of water removal in a dry spent nuclear fuel storage system based on drying procedures used at nuclear power plants is needed to close existing technical gaps. Operational conditions leading to incomplete drying may have potential impacts on the fuel, cladding, and other components in the system during subsequent storage and disposal. A general lack of data suitable for model validation of commercial nuclear canister drying processes necessitates well-designed investigations of drying process efficacy and water retention that incorporate relevant physics and well-controlled boundary conditions. This report documents testing updates for the Advanced Drying Cycle Simulator (ADCS). This apparatus was built to simulate commercial drying procedures and quantify the amount of residual water remaining in a pressurized water reactor (PWR) fuel assembly after drying. The ADCS was constructed with a prototypic 17×17 PWR fuel skeleton and waterproof heater rods to simulate decay heat. These waterproof heaters are the next generation design to heater rods developed and tested at Sandia National Laboratories in FY20. This report describes preliminary testing of the ADCS through measurement and analysis of the thermal response of the system to a subset of commercial drying conditions that exclude the introduction of water, namely simulated decay heats and pressures relevant to commercial drying. This test series, referred to as a “dry” test series in this report, spans three uniform waterproof heater rod powers (representing spent fuel decay heats), four helium fill pressures, and six vacuum levels. This test series was conducted to cover the range of expected ADCS testing conditions for upcoming “wet” testing, where water will be introduced and a simulated commercial drying cycle will be performed. The dry test conditions were derived from the commercial drying conditions seen in the High Burnup Demonstration and the vacuum drying conditions chosen for a smaller scale Dashpot Drying Apparatus tested at Sandia National Laboratories in FY22. For a given uniform power and pressure/vacuum level, the ADCS was operated at constant power and pressure and allowed to reach steady state conditions. The thermal data obtained from these tests were analyzed, and the results can inform computational models built to simulate commercial drying processes by providing baseline thermal data prior to the introduction of water. Following the preliminary dry tests, a test plan for the ADCS will be developed to implement a drying procedure that begins with the introduction of water to the system and is based on measurements from the drying process used for the High Burnup Demonstration Project. While applying power to the simulated fuel rods, this procedure is expected to consist of filling the ADCS vessel with water, draining the water with applied pressure and multiple helium blowdowns, evacuating additional water with a vacuum drying sequence at successively lower pressures, and backfilling the vessel with helium. Additional investigations are expected to feature failed fuel rod simulators with engineered cladding defects and guide tubes with obstructed dashpots to challenge the drying system with multiple water retention sites. The data from these investigations is expected to inform the efficacy of commercial drying operations through the quantification of residual water in a prototypic-length dry storage canister.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2022

The need for speed – Burnup determination of spent nuclear fuel

Here we present the application of a novel analytical approach for high-speed evaluation of burn-up in spent nuclear fuel. This automated online separation–direct analysis method, which simultaneously measures the isotopic compositions and concentrations of Nd, Pu, and U using isotope dilution-inductively coupled plasma mass spectrometry, enables the determination of burnup in as little as 4.5 h per sample with expanded uncertainties as low as 1.2% using as little as 1µg of fuel. We compare the determined burn-up values, sample requirements, and analysis times with an ultra-high precision, in-house developed, methodology which employs multiple analytical techniques to measure the isotopic compositions and concentrations of Nd, Pu, and U yielding burn-up values with expanded uncertainties as low as 0.49% at the 95% confidence level, the lowest reported to date.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2022

Update on the Investigation of Commercial Drying Cycles Using the Advanced Drying Cycle Simulator

The purpose of this report is to document updates on the apparatus to simulate commercial vacuum drying procedures at the Nuclear Energy Work Complex at Sandia National Laboratories. Validation of the extent of water removal in a dry spent nuclear fuel storage system based on drying procedures used at nuclear power plants is needed to close existing technical gaps. Operational conditions leading to incomplete drying may have potential impacts on the fuel, cladding, and other components in the system during subsequent storage and disposal. A general lack of data suitable for model validation of commercial nuclear canister drying processes necessitates well-designed investigations of drying process efficacy and water retention. Scaled tests that incorporate relevant physics and well-controlled boundary conditions are essential to provide insight and guidance to the simulation of prototypic systems undergoing drying processes. This report documents a new test apparatus, the Advanced Drying Cycle Simulator (ADCS). This apparatus was built to simulate commercial drying procedures and quantify the amount of residual water remaining in a pressurized water reactor (PWR) fuel assembly after drying. The ADCS was constructed with a prototypic 17×17 PWR fuel skeleton and waterproof heater rods to simulate decay heat. These waterproof heaters are the next generation design to heater rods developed and tested at Sandia National Laboratories in FY20. This report describes the ADCS vessel build that was completed late in FY22, including the receipt of the prototypic length waterproof heater rods and construction of the fuel basket and the pressure vessel components. In addition, installations of thermocouples, emissivity coupons, pressure and vacuum lines, pressure transducers, and electrical connections were completed. Preliminary power functionality testing was conducted to demonstrate the capabilities of the ADCS. In FY23, a test plan for the ADCS will be developed to implement a drying procedure based on measurements from the process used for the High Burnup Demonstration Project. While applying power to the simulated fuel rods, this procedure is expected to consist of filling the ADCS vessel with water, draining the water with applied pressure and multiple helium blowdowns, evacuating additional water with a vacuum drying sequence at successively lower pressures, and backfilling the vessel with helium. Additional investigations are expected to feature failed fuel rod simulators with engineered cladding defects and guide tubes with obstructed dashpots to challenge the drying system with multiple water retention sites.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2024

Path to Automated Validation of ENDF/B-VIII.1 [Slides]

We need to expand the variety of applications to rigorously test libraries. Advanced reactors: – Decreasing reactivity for 8.1b2 compared to 8.0, some unexpected nuclides causing major differences (F-19, Cr), no clear performance difference when compared to experiment. Depletion RCA: – High impact isotopes closer to 7.1 – Small improvement on average (U-5, Pu-9, BC FPs), worse for Am and Cm. Fuel reactivity: – 8.1b2 is higher reactivity at high burnups than 8.0, but likely under predicting k eff for PWRs at high burnup.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2023

SATS Enhanced Capabilities and Demonstration of Improved Ramp Rates for In-Cell Testing

This report presents the development of the second-generation Severe Accident Test Station, referred to as SATS 2.0. SATS 2.0 represents a major advancement in addressing critical research needs for the United States nuclear industry, particularly in relation to fuel fragmentation, relocation, and dispersal (FFRD) concerns associated with the nuclear industry’s goal to extend fuel burnup beyond a peak rod average of 62 GWd/tU. The central objective of SATS 2.0 was the deployment a new furnace capable of achieving heating rates up to 100°C/s. This achievement addresses critical capability gaps, enabling assessment of prioritized research objectives established by the Electric Power Research Institute’s (EPRI) Collaborative Research on Advanced Fuel Technologies (CRAFT) working group. These research objectives are directly related to high-burnup loss-of-coolant accident (LOCA) conditions and the effects of prolonged exposure to elevated temperatures, both of which are crucial to enhancing nuclear safety and efficiency. The SATS 2.0 system builds upon prior experience with the original SATS system, which focused on evaluating accident-tolerant fuel (ATF) cladding concepts during accident conditions. However, the new system not only expands upon prior core capabilities by achieving higher heating rates with a better furnace but also plans to incorporate novel auxiliary systems to create a versatile platform for addressing current research needs. For example, a system was developed for the quantification and characterization of fission gas released during high-temperature transients. Additionally, in situ measurement capabilities were developed, such as digital image correlation which enabled the real-time capture of strain related to balloon and burst events and fiber-optic sensors that allowed for high-fidelity characterization of temperature gradients. Demonstration tests of the new 12-lamp furnace achieved heating rates up to 120°C/s. Notably, SATS 2.0 demonstrated its capacity to simulate LOCA burst tests at different pressures, yielding burst data that align with historical empirical models. Moreover, the system exhibited its capability to simulate complex conditions observed in anticipated operational occurrences, while effectively mitigating temperature overshoots. These accomplishments mark significant progress toward overcoming FFRD challenges and advancing the United States nuclear industry's safety basis and technical capabilities for extended burnup.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
NASA NTRS2007

Testing in Support of Fission Surface Power System Qualification

The strategy for qualifying a FSP system could have a significant programmatic impact. The US has not qualified a space fission power system since launch of the SNAP-10A in 1965. This paper explores cost-effective options for obtaining data that would be needed for flight qualification of a fission system. Qualification data could be obtained from both nuclear and non-nuclear testing. The ability to perform highly realistic nonnuclear testing has advanced significantly throughout the past four decades. Instrumented thermal simulators were developed during the 1970s and 1980s to assist in the development, operation, and assessment of terrestrial fission systems. Instrumented thermal simulators optimized for assisting in the development, operation, and assessment of modern FSP systems have been under development (and utilized) since 1998. These thermal simulators enable heat from fission to be closely mimicked (axial power profile, radial power profile, temperature, heat flux, etc.) and extensive data to be taken from the core region. For transient testing, pin power during a transient is calculated based on the reactivity feedback that would occur given measured values of test article temperature and/or dimensional changes. The reactivity feedback coefficients needed for the test are either calculated or measured using cold/warm zero-power criticals. In this way non-nuclear testing can be used to provide very realistic information related to nuclear operation. Non-nuclear testing can be used at all levels, including component, subsystem, and integrated system testing. FSP fuels and materials are typically chosen to ensure very high confidence in operation at design burnups, fluences, and temperatures. However, facilities exist (e.g. ATR, HFIR) for affordably performing in-pile fuel and materials irradiations, if such testing is desired. Ex-core materials and components (such as alternator materials, control drum drives, etc.) could be irradiated in university or DOE reactors to ensure adequate radiation resistance. Facilities also exist for performing warm and cold zero-power criticals.

Houts, Mike↗
DOE OSTI2021

Evaluation of BISON's Transient Fission Gas Release Model on High-Burnup UO 2 MiniFuel

BISON's fission gas release (FGR) model has been evaluated and tested over several hypothetical thermal transient cases at high burnup and validated against FGR experimental data from an annealing test at high burnup. Diffusion-controlled FGR is accounted for in the model by including several physical mechanisms such as the diffusion of fission gas to grain faces, grain boundary sweeping, grain growth, and intergranular bubble growth. Under temperature variations, FGR is increased due to the development of micro-cracks at grain faces. This existing transient capability, however, was developed based on transient fuel behavior during power ramps and the associated micro-cracking process. Nevertheless, a fraction of the FGR during temperature transients such as LOCA can ensue from different mechanisms (in particular, fuel fragmentation) and present an important dependency on local burnup and high burnup structure formation. It follows that the performance and necessary developments of the existing BISON fission gas model for the analysis of LOCA-type transients need to be investigated through a systematic assessment study. Such a study is performed in this work. The model shows an overall good qualitative agreement with experimental observations on FGR during annealing tests with different temperature conditions. It also accounts well for microstructural effects on FGR. When quantitatively compared to FGR data from previously irradiated 103 MWd/kgU UO 2 discs under thermal annealing, the model shows a less satisfactory agreement with the experimental data.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2022

Fast ignition inertial fusion energy using laser-driven ion beams

Ion fast ignition (IFI), or fusion fast ignition initiated by a laser-driven ion beam, is a promising path to high-gain inertial fusion energy (IFE). In IFI, cold, dense deuterium-tritium (DT) fuel is first assembled using lasers or pulsed power drivers. Then, a high-power ion beam is focused onto a small volume within the fuel (the hot spot), heating the fuel rapidly to conditions where fusion ignition takes place. Fusion burn in this hot spot propagates to the fuel surrounding the hot spot, leading to burnup of a significant fraction of this fuel and the possibility of high gain (G~100), as needed for inertial fusion energy. IFI uses separate drivers for the two basic elements, fuel compression and ignition, allowing maximum control and optimization of each. On the other hand, conventional laser fusion uses multiple beams of the same driver to compress the fuel and shock-heat its very center to ignite a burn wave. Despite impressive progress in conventional laser fusion, the precise spatial symmetry, temporal pulse shaping and timing required for high gain and IFE remain a serious unmet challenge.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗
DOE OSTI2025

Considerations for Thermal Annealing of Zr-Alloy Cladding During Dry Storage

In January 2025, the U.S. Department of Energy (DOE) sponsored a technical workshop with fuel vendors that provided a forum for increased collaboration on backend fuel cycle research. The workshop reviewed observations of thermal annealing of irradiated zirconium alloys in simulated dry storage conditions and discussed implications to the industry’s interest in reducing wet storage to optimize operational flexibility and the expected trend of increasing discharge burnup (and decay heats), which could lead to an increase in dry storage temperatures. One approach to accommodate increased decay heats in dry storage is to increase the regulatory temperature limit during dry storage, which is now 400°C. However, this could lead to thermal annealing of the cladding, which will tend to increase creep rates, creep strains, and ductility while decreasing yield strength. These considerations are compounded by bonding between the pellet and cladding at high burnup, which results in the pellet carrying more load during fuel rod deformations, especially in bending, which is the dominant deformation phenomenon in canister drop analyses. Because the U.S. Nuclear Regulatory Commission (NRC) recommends yield strength as a primary failure criterion for accident analyses in storage and transportation, particularly for canister drop scenarios, the purpose of the workshop was to develop options for alternative failure criterion that could replace yield strength in canister drop analyses. Topics discussed were (1) the regulatory framework, (2) the effect of thermal annealing on microhardness and tensile properties of cladding materials, (3) the effect of thermal annealing on fuel rod failure during bending, bending fatigue, and pinch loading, and (4) an alternative failure criterion for canister drop analyses. This paper provides a summary of the key discussions and outcomes of the workshop

Cantonwine, Paul [ORNL] (ORCID:0009000522247033)↗
DOE OSTI2025

Assessment of Deep Burnup HALEU Fuel Impact and Requirements

This report explores advancements in nuclear fuel technology, focusing on once-through high-assay low-enriched uranium (HALEU) fuels. It examines the potential for increased fuel residence time in reactors and the fuel cost implications. The study highlights the differences between fast and thermal reactors in terms of fuel enrichment and burnup, emphasizing the complex relationship in fast reactors in which increased core size and fuel density can lead to lower enrichment requirements. Various advances in fuel technologies for light-water reactors (LWR) and sodium-cooled fast reactors (SFR) are presented in this report to provide more comprehensive analysis.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2022

Specimen Size Artifacts Associated with a Glovebox Deployable Laser Flash Diffusivity Measurement System

To accelerate nuclear fuel qualification and deployment efforts, Oak Ridge National Laboratory has led the world in developing vehicles for accelerating burnup accumulation in nuclear fuel by testing miniature samples in the High Flux Isotope Reactor. However, a challenge remains to establish parity between post irradiation characterization methods for miniature fuel specimens in comparison to conventional fuel elements. This work aims to identify artifacts associated with the thermal analysis of miniature disk specimens in comparison to samples of standardized dimensions through a combination of experimental and computational tools. Using a newly procured Netzsch 427 laser flash diffusivity system, preliminary data on mild steel specimens were collected, and finite element techniques were used to model heat transfer using 1D conditions to assess issues associated with pulse width and data collection frequency effects. These preliminary investigations found that significant variability in measured thermal diffusivity exist within datasets. These variations are not necessarily attributed to limitations with respect to data collection rate; nor are they associated with limitations on pulse width. Instead, these artifacts may be a result of limitations in detector intensity. Future work aims to design a focusing lens to better measure the smaller surface area of miniature specimens analyzed using the laser flash analysis system.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2022

Nuclide Inventory Benchmark for BWR Spent Nuclear Fuel: Challenges in Evaluation of Modeling Data Assumptions and Uncertainties

This work discusses challenges and approaches to uncertainty analyses associated with the development of a nuclide inventory benchmark for fuel irradiated in a boiling water reactor. The benchmark under consideration is being developed based on experimental data from the SFCOMPO international database. The focus herein is on how to address missing data in fuel design and operating conditions that are important for adequately simulating the time-dependent changes in fuel during irradiation in the reactor. The effects of modeling assumptions and uncertainties in modeling parameters on the calculated nuclide inventory were analyzed and quantified through computational models developed using capabilities in the SCALE code system. Particular attention was given to the impact of the power history and water coolant density on the calculated nuclide inventory, as well as to the effect of geometry modeling considerations not usually addressed in a nuclide inventory benchmark. These considerations include gap closure, channel bow, and channel corner radius, which do not usually apply to regular reactor operation but are relevant for assessing impacts of potential anomalous operating scenarios.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2022

Phase-field simulations to inform nuclear fuel performance modeling

Software tools to simulate nuclear fuel performance at the engineering scale, such as Idaho National Laboratory (INL)’s BISON code, are increasingly relied upon in regulatory and economic decision-making. However, accurate results from these tools depends on the availability of materials parameters that are used as input. In recent years, atomistic and mesoscale simulation methods have emerged as a cost-effective, expedient means to obtain such input parameters. Phase-field simulations using INL’s Marmot application have been used to obtain microstructure-level parameters and to improve material models for fuel performance modeling using BISON. In this talk, recent examples of this process are given, including applications in UO2, U3Si2, and UZr fuel.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗