Materials technology program for a compact fast reactor for space power
Production engineering and compatibility tests of Ta-8W-2Hf clad UN nuclear fuel element for use in lithium cooled space power unit reactors
Gluyas, R. E.↗
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Rapid Screening of Cladding Materials for Generation IV Nuclear Reactors.
Abstract Not Provided
Hattar, Khalid Mikhiel↗
ASNF Engineering Scale Drying Experiment Acceptance Criteria for Fabricated Items
This document specifies the acceptance criteria for items fabricated by Holtec International under the scope of INL Contract # 215725, consistent with the parameters described in INL/EXT-19-56017, Aluminum-clad Spent Nuclear Fuel Engineering Scale Drying Experiment Design. Verification is confirmed with initials (or the need for remediation may be identified) along with the date of inspection for each requirement. Verification may be performed by independent proxy (University of South Carolina participant, under INL Contract Number 207046) or by an INL employee, remotely by camera images.
12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
ASNF Engineering Scale Drying Experiment System Operability Functional Requirements
This checklist specifies the functional requirements for the drying system installed at Holtec International under the scope of INL Contract # 215725, in collaboration with University of South Carolina under INL Contract Number 207046, consistent with the parameters described in INL/EXT-19-56017, Aluminum-clad Spent Nuclear Fuel Engineering Scale Drying Experiment Design. Completion of the ASNF Engineering Scale Drying Experiment Acceptance Criteria for Fabricated Items, INL/MIS-20-58551, is a prerequisite.
36 MATERIALS SCIENCE↗
Milestone 2.7: Evaluation of Techniques for the Measurement of Molecular Hydrogen Gas in Helium Matrices
Published data by Task 2 (Oxyhydroxide Layer Radiolytic Gas Generation Resolution) for Technical Considerations and Challenges for Extended (>50 yrs) Dry Storage of Aluminum Cladded Spent Nuclear Fuel (ASNF), demonstrated that radiolytic molecular hydrogen (H2) production from gamma irradiated aluminum alloy 1100 (Al-1100) coupons exhibited significant dependence on backfill gaseous environment conditions: air, due to the presence of oxygen, completely inhibited H2 production; nitrogen promoted H2 production; and argon yielded more H2 than nitrogen environments. The concern here is that helium has been proposed as the backfill gas for extended storage and is more inert than argon, which may translate into significantly more H2 production than current Task 3 argon-based models predict. However, the measurement of H2 in helium media was not possible using the previously establish gas chromatography (GC) flame ionization detector, due to similarities in thermal conductivity. This milestone was initiated to evaluate an alternative GC approach that employed a mercuric oxide (HgO) reduction gas detector (RGD). Using the HgO RGD setup, H2 was successfully calibrated in the presence of a helium carrier gas, and then subsequently measured in control and irradiated crush-tube sample vials, consistent with previous sample measurements. Overall, the HgO RGD approach was found to be sufficient for future helium environment irradiations.
38 RADIATION CHEMISTRY, RADIOCHEMISTRY, AND NUCLEA↗
Milestone 1.2.13: Preliminary Measurements of Radiolytic Nitric Acid Formation to Support Predictive Model Validation
Predictive computational models have been developed to support the technical basis for extended dry storage of aluminum-clad spent nuclear fuel (ASNF) in helium-backfilled cannisters. To date, these models have been optimized on a variety of irradiation experiments designed to elucidate the radiation-induced formation of molecular hydrogen gas, a radiolysis product that is potentially problematic for the safe storage of ASNF. However, the yield of nitric acid (HNO3) has not been determined, despite conservative predictions of its formation (300–4000 ppm) in 1% residual air environments irradiated in contact with ASNF. HNO3, another problematic radiolysis product, can lead to enhanced corrosion and potentially compromise storage canister integrity. Thus, to support the validation of predictive computer models, we report the measurement and quantification of HNO3 from the gamma irradiation of aluminum alloy coupons in humid air.
38 RADIATION CHEMISTRY, RADIOCHEMISTRY, AND NUCLEA↗
Milestone 1.2.14: Surface Characterization of Irradiated Surrogate Non-Native Corrosion Plumes on Aluminum 6061-T6 Specimens
The United States Department of Energy is seeking to evaluate the feasibility of extended dry storage of aluminum-clad spent nuclear fuel (ASNF) in helium-backfilled cannisters. A significant research effort has been devoted to determining the amount of radiation-induced molecular hydrogen generation from corrosion layers that would be present on the fuel assembly surfaces. However, to date, no evidence of radiation-induced changes in the microstructure of the corroded aluminum surfaces have been reported. This report provides surface characterization, in terms of corrosion layer composition and morphology, for aluminum alloy 6061-T6 “plume” samples subjected to one of three potential ASNF drying techniques—“vacuum only”, “vacuum + 4 hours at 100 oC”, and “vacuum + 4 hours at 220 oC”—and gamma irradiated (= 53 MGy) in the presence of helium gas with ~0% added relative humidity. At these high absorbed gamma doses, for the first time ever, radiation-induced circular defects were found on the sample surface, regardless of the drying regime employed. Additionally, large cracks that penetrated through the corrosion layer to expose bare aluminum metal were observed in irradiated “plume” specimens subjected to drying conditions of “vacuum + 4 hours at 220 oC”. The nature and implications of these defects on the extended dry storage of ASNF is unclear, requiring further study.
38 RADIATION CHEMISTRY, RADIOCHEMISTRY, AND NUCLEA↗
DISSOLUTION OF SURROGATE U-Zr FUEL USING ALNIFLEX CONDITIONS
Non-aluminum clad spent nuclear fuel (NASNF) stored in L Basin at the Savannah River Site (SRS) is widely varied in fuel composition, design, packaging, and physical condition. The complexity of the NASNF inventory presents significant challenges, and technology development is necessary for successful disposition. One such fuel in the inventory is metallic uranium-zirconium (U-Zr) alloy fuel, the focus of this study. Electrolytic or nitric acid only dissolution of metallic U-Zr alloy can form insoluble zirconium oxide, which results in up to 52% loss of U to insoluble solids, and can be subject to potentially uncontrolled oxidation reactions [1, 2]. The AlNiflex process was determined to be a viable dissolution flowsheet for the U-Zr alloy fuel. Under a narrow set of solution concentrations, a combination of hydrofluoric acid (HF), nitric acid (HNO3), aluminum nitrate (Al(NO3)3), and hexavalent chromium can safely dissolve U-Zr intermetallic alloys, keep Zr soluble, and not significantly corrode stainless steel (SS) vessels [3, 4.
Gogolski, Jarrod M. [Savannah River National Labor↗
Prioritizing Nuclear Materials for SAM-3 Neutron Irradiation Campaign: Structural and Cladding Materials Candidates
This report outlines a framework for selecting structural and cladding materials for the Nuclear Science User Facilities (NSUF) SAM-3 neutron irradiation campaign to support the advancement of nuclear energy technologies. The document begins with an introduction that provides background context, highlights the motivations for launching a new irradiation campaign, and defines the overall objectives. The core of the report describes the design considerations for the irradiation campaign, including capsule configurations, irradiation temperature ranges, and target dose levels (defined by displacements per atom, or dpa). The material recommendation was guided by the Specimen Identification and Prioritization (SIP) Working Group, a multidisciplinary team of experts representing national laboratories, academia, industry, federal government and agency. This group played a central role in identifying candidate materials, evaluating technical justifications, and ensuring alignment with boarder programmatic goals. A detailed set of criteria for material prioritization is then presented, taking into account reactor relevance, performance gaps, advanced manufacturing methods, and emerging material classes. Based on the input of SIP working group, specific materials were selected and justified for inclusion in the irradiation campaign by the NSUF leadership and its U.S. Department of Energy (DOE)-Office of Nuclear Energy (NE) management. The final section provides recommended capsule designs, summarizing critical parameters such as material type, fabrication method, sample geometry, irradiation conditions, and specimen quantities. This report serves as a foundation for executing a focused and high-impact neutron irradiation campaign aimed at addressing key materials challenges for both existing and advanced nuclear reactors.
36 - MATERIALS SCIENCE↗
Development of Non-Concentrated Alloys for Nuclear Applications
This presentation summarizes the fabrication and characterization of non-concentrated alloys for the preparation of slides for the project review meeting.
36 - MATERIALS SCIENCE↗
Laser-based characterization of nuclear fuel plates
Ensuring the integrity of fuel-clad and clad-clad bonding in nuclear fuels is important for safe reactor operation and assessment of fuel performance, yet the measurement of bond strengths in actual fuels has proved challenging. The laser shockwave technique (LST) originally developed to characterize structural adhesion in composites is being employed to characterize interface strength in a new type of plate fuel being developed at Idaho National Laboratory (INL). LST is a non-contact method that uses lasers for the generation and detection of large-amplitude acoustic waves and is well suited for application to both fresh and irradiated nuclear-fuel plates. This paper will report on initial characterization results obtained from fresh fuel plates manufactured by different processes, including hot isostatic pressing, friction stir welding, and hot rolling.
21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
Laser-Based Characterization of Nuclear Fuel Plates
Ensuring the integrity of fuel-clad and clad-clad bonding in nuclear fuels is important for safe reactor operation and assessment of fuel performance, yet the measurement of bond strengths in actual fuels has proved challenging. The laser shockwave technique (LST) originally developed to characterize structural adhesion in composites is being employed to characterize interface strength in a new type of plate fuel being developed at Idaho National Laboratory (INL). LST is a non-contact method that uses lasers for the generation and detection of large-amplitude acoustic waves and is well suited for application to both fresh and irradiated nuclear-fuel plates. This paper will report on initial characterization results obtained from fresh fuel plates manufactured by different processes, including hot isostatic pressing, friction stir welding, and hot rolling.
11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
Draft of M2 Report on Integration of the Hybrid Hydride Model into INL's MBM Framework for Review
This report documents the development, demonstration and validation of a mesoscale, microstructural evolution model for simulation of zirconium hydride {delta}-ZrH{sub 1.5} precipitation in the cladding of used nuclear fuels that may occur during long-term dry storage. While the Zr-based claddings are manufactured free of any hydrogen, they absorb hydrogen during service, in the reactor by a process commonly termed ‘hydrogen pick-up’. The precipitation and growth of zirconium hydrides during dry storage is one of the most likely fuel rod integrity failure mechanisms either by embrittlement or delayed hydride cracking of the cladding. While the phenomenon is well documented and identified as a potential key failure mechanism during long-term dry storage (NUREG/CR-7116), the ability to actually predict the formation of hydrides is poor. The model being documented in this work is a computational capability for the prediction of hydride formation in different claddings of used nuclear fuels. This work supports the Used Fuel Disposition Research and Development Campaign in assessing the structural engineering performance of the cladding during and after long-term dry storage. This document demonstrates a basic hydride precipitation model that is built on a recently developed hybrid Potts-phase field model that combines elements of Potts-Monte Carlo and the phase-field models. The model capabilities are demonstrated along with the incorporation of the starting microstructure, thermodynamics of the Zr-H system and the hydride formation mechanism.
11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
Adsorption of Chlorine on Zr(0001) Surface: First-Principles Predictions
The adsorption of atomic and gaseous chlorine on Zr (0001) surface has been investigated using state-of-the-art density functional theory calculations as part of an effort to gain fundamental understanding of chlorination processes occurring in fuel cladding materials. Zirconium alloys, including Zircaloy-4, Zircaloy-2 and Zr-Nb alloys (Zirlo{sup TM} and Zr-2.5Nb) are the most common fuel cladding materials in nuclear light water reactors (LWRs) due to their favorable mechanical properties, corrosion resistance, low thermal-neutron capture cross section and criticality. The United States produces a large amount of cladding material from used nuclear fuel, which could approach 1,000 MT/year in the next 50 years. In nuclear fuel recycling, spent nuclear fuel assemblies are disassembled and the cladding hulls are separated from the U oxide spent fuel. Zr can be recovered from Zr cladding using the chlorination method. However the presence of impurities in the recovered ZrCl{sub 4} was reported, including Sn, Cr and Fe. Thus, further efforts are necessary to improve the purification process significantly. This requires fundamental understanding of chlorination processes in cladding materials. Most of the material properties are expected to be similar between the pure zirconium and its alloys due to the fact that the alloy composition consists of more than 95 weight-percent zirconium and less than 2% of tin, niobium, iron, chromium, nickel and other metals. Therefore, while the overarching goal is to understand the chlorination process occurring in complex fuel cladding materials, chlorination of pure zirconium was used as an initial system for the modeling and simulation efforts in this study.
11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
Oak Ridge National Laboratory Fission Product Hydrochlorination
This work supports the recovery of high-assay low-enriched uranium (HALEU, uranium enriched in 235 U to >5% and <20%) from used nuclear fuel through a process based on the zirconium extraction (ZIRCEX) process. The ZIRCEX process starts with the dry head-end removal of zirconium or aluminum cladding from the nuclear fuel via chlorination or hydrochlorination, which results in the separation of cladding from the fuel as the metal chloride (e.g., aluminum trichloride or zirconium tetrachloride). The hydrochlorination process is included in the Material Recovery Pilot Plant (MRPP), a ZIRCEX-based demonstration plant at Idaho National Laboratory (INL). The experiments outlined in this report assessed fission product (FP) volatility and transport under the hydrochlorination conditions used to separate cladding from used nuclear fuel.
11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
Model for determining rupture area in Zircaloy cladding under LOCA conditions
The dispersal of nuclear fuel through a cladding rupture opening during a transient event is the primary safety concern preventing the United States nuclear industry from extending burnup beyond a peak rod average burnup of 62 GWd/tU. The majority of research thus far has prioritized understanding, or at a minimum prioritized quantifying, fuel fragmentation and pulverization as a function of burnup and to a lesser extent onset temperature. Early high burnup loss-of-coolant accident tests performed at the Halden Boiling Water Reactor evaluated the impact of relocation on cladding temperature, whereas historical and recent cladding burst tests focused primarily on generating data related to cladding balloon and burst timing. However, very little effort has been put forth to develop a relationship for determining the rupture opening dimensions for Zircaloy cladding tubes bursting during a simulated light water reactor loss-of-coolant accident. This is significant because high burnup loss-of-coolant accident data suggest dispersal could be limited by the size of the rupture opening or rupture dimensions, thereby minimizing the safety concern. Therefore, the purpose of this research is to build a database composed of all simulated loss-of-coolant accident data to develop an empirical model that conservatively captures the rupture opening dimensions and translates those dimensions to rupture area. Analysis of the experimental data indicates the rupture dimensions are strongly correlated to the peak balloon strain. This relationship is leveraged to develop a rupture length empirical correlation as a function of peak balloon strain and a rupture width empirical correlation as a function of rupture length. Outliers in the experimental data are identified and discussed. Finally, the rupture opening empirical model is presented in such a way for general implementation into high fidelity fuel performance codes or fuel performance codes used for safety analyses.
22 GENERAL STUDIES OF NUCLEAR REACTORS↗
Simplified analysis of nuclear fuel pin swelling
Effect of fuel swelling on strains in cladding of cylindrical nuclear fuel elements
Lietzke, A. F.↗
Engineered Zircaloy Cladding Modifications for Improved Accident Tolerance of LWR Nuclear Fuel
The DOE NEUP sponsored IRP on accident tolerant fuel (ATF) entitled Engineered Zircaloy Cladding Modifications for Improved Accident Tolerance of LWR Nuclear Fuel involved three academic institutions, Idaho National Laboratory (INL), and ATI Materials (ATI). Detailed descriptions of the work at the University of Illinois (UIUC, prime), the University of Florida (UF), the University of Michigan (UMich), and INL are included in this document as separate sections. This summary provides a synopsis of the work performed across the IRP team. Two ATF solution pathways were initially proposed, coatings on monolithic Zr-based LWR cladding material and selfhealing modifications of Zr-based alloys. The coating pathway was extensively investigated, both experimentally and in computations. Experimental activities related to ATF coatings were centered at UIUC, UF, and UMich and involved coating development and testing, and ion irradiation. Neutronic and thermal hydraulic aspects of ATF coatings were the focus of computational work at UIUC and UMich, while materials science aspects were the focus of computational work at UF and INL. ATI provided monolithic Zircaloy 2 and 4 material and a binary Zr-Y alloy material. The selfhealing pathway was investigated with advanced computations only. Beryllium was identified as a valid self-healing additive early in this work. However, all attempts to fabricate a Zr-Be alloy failed. Several avenues of fabrication were explored. ATI ultimately declined our fabrication request over health concerns associated with Be (we note that Be was not part of the original work scope and the ATI SOW). Likewise, Ames Laboratory declined our fabrication request, citing known litigation dating to the 1980s and 1990s involving the U.S. Federal government and U.S. National Laboratory employees involving the use of Be. Materion (formerly, Brush Wellman) also declined our fabrication request, citing the difficulty in working with a highly reactive Zr and Be. International fabrication options were explored in Europe and Asia, but this proved to be impractical, if not impossible. Consequently, experimental investigation of the Zr-Be binary system was dropped and exploration binary Zr-Y binary system was initiated. The motivation behind the Zr-Y system is the known thermodynamic stability of yttria over zirconia.
11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗