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DOE OSTI2025

An integrated approach to examine fuel-cladding chemical interaction in HT9/U-10Zr metallic fast reactor fuels: Coupling machine learning with electron microscopy and local mechanical properties analysis

The metallic U-Zr nuclear fuel alloy has garnered renewed interest as a promising candidate for next-generation sodium-cooled fast reactors. Recent studies and technology assessments have identified several areas requiring improvements, enhanced knowledge, and reliable data to strengthen the U-Zr fuel design basis for qualification and commercial applications. One of the most challenging phenomena impacting this fuel system’s performance is fuel-cladding chemical interaction (FCCI). This work aimed to harvest FCCI data by examining selected HT9/U-10Zr (wt. %) fuel samples of prototypic full-length fuel pins through an integrated approach. This approach integrated scanning electron microscopy (SEM) microstructure characterization with localized mechanical properties examination to deepen understanding of FCCI phenomenon in HT9/U-10Zr fuel system. Particularly, this study focused on MFF fuel pins irradiated at Fast Flux Test Facility (FFTF), which aimed to qualify metallic fuel as a driver fuel for FFTF and to assess its viability for larger-scale fast reactors. Electron microscopy provided high confidence in detecting and distinguishing the different FCCI layers, while small-scale mechanical testing (SSMT) probed the mechanical properties of these layers. SEM examination of a MFF-2 pin 192167, with a time averaged inner cladding temperature (TICT) slightly over 500°C, revealed minimal cladding-side FCCI (cladding wastage). In contrast, significantly thicker cladding wastage comprising two distinct sublayers was observed in samples from the thermally hot MFF-3 pin 193045 and MFF-5 pin 195011 where the TICT ranged from 610-635°C. SSMT indicated complete embrittlement in the sublayer adjacent to the fuel and a tendency toward embrittlement in the other sublayer. Additionally, a new machine learning method was developed, validated, and used to quantify cladding wastage thickness. The machine learning method reliably predicted the wastage thickness across various fuel pins and sample cross-sections. Furthermore, the available cladding wastage data from HT9/U-10Zr fuel system demonstrated a strong temperature dependency. However, the dataset remains small, and ongoing research activities are essential to further understand the FCCI phenomenon and develop a reliable FCCI model for enhanced fuel performance simulation under various conditions.

36 - MATERIALS SCIENCE↗

DOE OSTI2025

Disassembly and Initial Post-Irradiation Examination of the Mini99 Experiment

The Miniature Fuel Molybdenum-99 (Mini99) experiment is a first-of-a-kind experiment in the High Flux Isotope Reactor. Mini99 is the first MiniFuel irradiation experiment to use liquid metal inside the MiniFuel subcapsule for additional temperature control. In this work, the initial post-irradiation examination is reported. As-built simulations were conducted and compared with designs, and physical post-irradiation examinations were conducted to determine actual test temperatures via SiC thermometry samples, to evaluate the extent of fission gas release from the samples, and to remove the fuel from the subcapsules. As-built simulations compared well with experiment designs and were in reasonable agreement with the measured temperatures inferred from the passive SiC thermometers. Additionally, fission gas release values were relatively small (on the order of 3%); one sample reached approximately 8%. Although some of this behavior is attributable to recoil, most of the gas release was likely caused by the physics of the fuel behavior during the test. Finally, disassembly showed that at least four of the fuel samples degraded into small components and granules at some point during the test, with the state of the other two samples unproven. Additional work is planned for further examination of these samples via various microscopy techniques.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2025

Postirradiation Examination of HFIR-Irradiated Yttrium Hydrides

The US Department of Energy Microreactor Program is developing compact, high-temperature microreactors that require robust neutron moderators. Known for its high hydrogen retention and structural stability, YH x is a leading candidate for this purpose. As part of an ongoing evaluation, Oak Ridge National Laboratory conducted post-irradiation examinations on YH x specimens irradiated in the High Flux Isotope Reactor under the legacy Transformational Challenge Reactor program, focusing on their structural integrity, hydrogen retention, and thermal properties. The post-irradiation examination campaign primarily examined specimens from two irradiation campaigns, covering a range of hydrogen-to-yttrium atomic ratios (H/Y), neutron damage levels (0.1–2 displacements per atom), and targeted irradiation temperature of 600°C. The investigations included electron microscopy, high-energy x-ray diffraction, laser flash analysis, differential scanning calorimetry, and SiC thermometry analysis.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2026

U.S. Efforts in Support of Examinations at Fukushima Daiichi - November 2025 Meeting Notes

Fifteen years have passed since the March 11, 2011, the Great East Japan Earthquake (GEJE) triggered a tsunami that inundated the Fukushima Daiichi Nuclear Power Station (Daiichi or 1F) and led to severe accidents in multiple units at the plant. During these fifteen years since these events, Daiichi forensics examinations and evaluations have revealed many insights for enhancing the safety of nuclear power plants worldwide. However, uncertainties remain regarding the events after the GEJE. Additional Daiichi forensics information is required to inform future Decontamination and Decommissioning (D&D) activi- ties conducted by the plant owner, Tokyo Electric Power Company Holdings, Incorporated (TEPCO Hold- ings). This forensics information also has important implications for the safety and operation of U.S. commercial nuclear power plants. A collaborative U.S. and Japanese effort, which includes approximately 50 experts in reactor safety and plant operations, was initiated in 2014 by the Department of Energy Office of Nuclear Energy (U.S. DOE-NE) to identify Daiichi examination needs and evaluate recent Daiichi examination data to address these needs. This collaborative effort, which is beneficial to the U.S. and Japan, continues as Japan moves forward with D&D activities.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2026

Postirradiation Examination of WIRE-21 Experiment Irradiated in the High Flux Isotope Reactor

Westinghouse Electric Company is developing wireless sensors to monitor the centerline temperature and internal pressure of commercial light-water reactor fuel rods during irradiation. Oak Ridge National Laboratory and Westinghouse Electric Company developed the Wireless Instrumented RB Experiment 2021 (WIRE-21) to test wireless temperature and pressure sensor technologies in a removable beryllium position in the High Flux Isotope Reactor. The experiment was irradiated for a total of 75 days, at temperatures ranging from approximately 150°C to 400°C, resulting in a peak fast (energy > 0.1 MeV) neutron fluence of about 3 × 10 21 n/cm 2 . The temperature was intentionally cycled multiple times to compare the response of the wireless temperature sensor to collocated thermocouples. Similarly, the pressure sensor was actuated in multiple steps to compare the response of the wireless measurement to excore pressure transducers (Petrie et al., 2023). After irradiation, the experiment was disassembled in the Irradiated Fuels Examination Laboratory (IFEL) hot cell at Oak Ridge National Laboratory with the intent to recover sensor and dosimetry components, document the as-irradiated condition of the hardware, and investigate possible causes of the sensor behavior observed during irradiation. The postirradiation examination successfully recovered and preserved key WIRE-21 components. After the housing was removed using a milling machine, the internal experiment sections were examined. All eight fiber-optic sensors were recovered, cut, and stored. The silicon carbide thermometry, temperature sensor, pressure sensor, lower spacer, and selected pressure and temperature cable sections were also removed and stored. The metal bellows of the pressure sensor was found to be plastically deformed, indicating that it had been properly pressurized during irradiation and generally behaved as expected. X-ray diffraction analysis of a section of one of the irradiated inductor cores within the pressure sensor was performed and confirmed the presence of phase-pure alpha ferrite (i.e., no unexpected phase transformations). Inductance testing was performed on the irradiated pressure sensor cores using an unirradiated test coil, and DC resistance measurements of the transceiver coils were also performed. The measurements with irradiated inductor cores assembled inside unirradiated coils showed slightly reduced inductance compared to measurements made with unirradiated cores, but the difference was not sufficient to explain the more significant reductions in inductance that were observed in-pile. Therefore, it is suspected that degradation of the inductor coils (specifically the wire wrapping) is responsible for the reduced inductance observed in-pile.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

NASA NTRS1973

Examination of oxide scales in the SEM using backscattered electron images

The complementary use of the scanning electron microscope in the backscattered electron mode with the more usual secondary electron mode results in a significant increase in the versatility of the instrument, since regions of different chemical composition can be readily detected, and their morphology examined. The use of this technique to examine complex oxide scales formed on heat-resistant alloys is described, and in particular the location of thoria particles in the scale formed on a Ni-20 wt pct Cr-2.3 wt pct ThO2 alloy, and the examination of the behavior of yttrium during the high-temperature oxidation of a Co-Cr-Al-Y alloy are discussed.

Price, C. W.↗

NASA NTRS1979

Results of the examination of the Skylab/Apollo windows for micrometeroid impacts

Examination of the Command Module windows of the Skylab/Apollo 3 and 4 spacecraft at 5x magnification resulted in the detection of 18 micrometeroid craters 80 microns and larger in diameter for an accumulated exposure time of 144 days. A 20x magnification examination of the windows of the Skylab/Apollo 4 spacecraft identified 6 such craters between 20 and 70 microns in diameter for 84 days exposure. As the Skylab was oriented such that its solar panels faced the sun continuously, the three windows examined had a fixed orientation also. The six small craters were all found on the window that faced in the solar direction. A cumulative flux per square centimeter per year is given for pit and spall diameters.

Cour-Palais, B. G.↗

NASA NTRS1986

Examination of design options for 35 Ah ambient temperature Li-TiS sub 2 cells

The Jet Propulsion Laboratory is actively engaged in the development of ambient temperature rechargable lithium cells for future NASA geosynchronous Earth orbit (GEO) missions. To achieve these ambitious goals, Li-TiS2, Li-MoS3, and Li-V6O13 systems were examined in detail. Among these three, the Li-TiS2 system has shown the longest life cycle and highest rate capability. Experimental Li-TiS2 batteries (10.5 V, 0.4 Ah) developed in-house have completed eight simulated and accelerated GEO seasons successfully. Inview of the encouraging results, the design options were examined for a scaled-up Li-TiS2 cell. It is hoped that the results of these studies will provide guidelines for prioritizing the research efforts and guiding the selection of optimized materials. Designs for 35 Ah Li-TiS2 cell were examined because present day geosynchronous satellites are powered by batteries of 35 Ah capacity. A computer program was developed to evaluate the influence of various design parameters on the specific energy and the rate capability of the cells.

Shen, D. H.↗

NASA NTRS1999

A Heuristic Approach to Examining Volatile Equilibrium at Titan's Surface

R. D. Lorenz, J. I. Lunine, and C. P. McKay have shown in a manuscript accepted for publication that, for a given ethane abundance and surface temperature, the nitrogen and methane abundances in Titan's atmosphere can be calculated, yielding a surface pressure that can be compared with the observed value. This is potentially a very valuable tool for examining the evolution of Titan's climatology. Its validity does depend on two important assumptions, however: 1) that the atmosphere of Titan is in global radiative equilibrium, and 2) that volatiles present are in vapor equilibrium with the surface. The former assumption has been shown to be likely, but the latter has not. Water vapor in the Earth's atmosphere, in fact, is generally not very close to equilibrium in a global sense. In the present work a heuristic approach is used to examine the likelihood that methane vapor is in equilibrium with Titan's surface. Plausible climate scenerios are examined that are consistent with methane vapor abundances derived from Voyager IRIS data. Simple precipitation and surface diffusion models are incorporated into the analysis. It is tentatively inferred that methane may be in surface equilibrium near the poles, but that equilibrium at low latitudes is more difficult to establish.

Samuelson, Robert E.↗

NASA NTRS2004

Genesis Preliminary Examination Plans

The purpose of preliminary examination of the Genesis sample collectors is to provide information on the condition and availability of collector materials to the science community as a basis for allocation requests. Similarly, the information will be used by the Genesis Sample Allocation sub-committee of CAPTEM to determine the optimum allocation scheme, and by the Genesis Curator to determine the processing sequence for allocation production. The plan includes a decision process and detailed examination and documentation protocol for whole arrays and individual collectors (wafers, concentrator targets, bulk metallic glass, gold foil, and polished aluminum). It also includes a plan for communicating the information obtained to the scientific community. The plan does not include a detailed plan for preliminary examination of the SRC lid foil collectors, the process for removal of individual collectors from their frames, or for the subsequent subdivision of collector materials for allocation.

K M McNamara↗

NASA NTRS2011

Preliminary Examination of Particles Recovered from the Surface of the Asteroid Itokawa by the Hayabusa Mission

The Hayabusa spacecraft arrived at S-type Asteroid 25143 Itokawa in November 2006, and reveal astounding features of the small asteroid (535 x 294 x 209 m). Near-infrared spectral shape indicates that the surface of this body has an olivinerich mineral assemblage potentially similar to that of LL5 or LL6 chondrites with different degrees of space weathering. Based on the surface morphological features observed in high-resolution images of Itokawa s surface, two major types of boulders were distinguished: rounded and angular boulders. Rounded boulders seem to be breccias, while angular boulders seem to have severe impact origin. Although the sample collection did not be made by normal operations, it was considered that some amount of samples, probably small particles of regolith, was collected from MUSES-C regio on the Itokawa s surface. The sample capsule was successfully recovered on the earth on June 13, 2010, and was opened at curation facility of JAXA (Japan Aerospace Exploration Agency), Sagamihara, Japan. A large number of small particles were found in the sample container. Preliminary analysis with SEM/EDX at the curation facility showed that at least more than 1500 grains were identified as rocky particles, and most of them were judged to be of extraterrestrial origin, and definitely from Asteroid Itokawa. Minerals (olivine, low-Ca pyroxene, high-Ca pyroxene, plagioclase, Fe sulfide, Fe-Ni metal, chromite, Ca phosphate), roughly estimated mode the minerals and rough measurement of the chemical compositions of the silicates show that these particles are roughly similar to LL chondrites. Although their size are mostly less than 10 m, some larger particles of about 100 m or larger were also identified. A part of the sample (probably several tens particles) will be selected by Hayabusa sample curation team and examined preliminary in Japan within one year after the sample recovery in prior to detailed analysis phase. Hayabusa Asteroidal Sample Preliminary Examination Team (HASPET) has been preparing for the preliminary examination with close cooperation with the curation team.

Tsuchiyama, A.↗

NASA NTRS2011

Examination of Relationship Between Photonic Signatures and Fracture Strength of Fused Silica Used in Orbiter Windows

A commercially available grey-field polariscope (GFP) instrument for photoelastic examination is used to assess impact damage inflicted upon the outermost pane of the orbiter windows. Four categories of damage: hyper-velocity impacts that occur during space-flight (HVI); hypervelocity impacts artificially made at the Hypervelocity Impact Technology Facility (HIT-F); impacts made by larger objects falling onto the pane surface to simulate dropped items on the window during service/storage of vehicle (Bruises); and light scratches from dull objects designed to mimic those that might occur by dragging a dull object across the glass surface (Chatter Checks) are examined. The damage sites are cored from fused silica window carcasses, examined with the GFP and other methodologies, and broken using the ASTM Standard C1499-09 to measure the fracture strength. A correlation is made between the fracture strength and damage-site measurements including geometrical measurements and GFP measurements of photoelastic retardation (stress patterns) surrounding the damage sites. An analytical damage model to predict fracture strength from photoelastic retardation measurements is presented and compared with experimental results.

Yost, William T.↗

NASA NTRS2016

Wind Tunnel Test of a Risk-Reduction Wing/Fuselage Model to Examine Juncture-Flow Phenomena

A wing/fuselage wind-tunnel model was tested in the Langley 14- by 22-foot Subsonic Wind Tunnel in preparation for a highly-instrumented Juncture Flow Experiment to be conducted in the same facility. This test, which was sponsored by the NASA Transformational Tool and Technologies Project, is part of a comprehensive set of experimental and computational research activities to develop revolutionary, physics-based aeronautics analysis and design capability. The objectives of this particular test were to examine the surface and off-body flow on a generic wing/body combination to: 1) choose a final wing for a future, highly instrumented model, 2) use the results to facilitate unsteady pressure sensor placement on the model, 3) determine the area to be surveyed with an embedded laser-doppler velocimetry (LDV) system, 4) investigate the primary juncture corner- flow separation region using particle image velocimetry (PIV) to see if the particle seeding is adequately entrained and to examine the structure in the separated region, and 5) to determine the similarity of observed flow features with those predicted by computational fluid dynamics (CFD). This report documents the results of the above experiment that specifically address the first three goals. Multiple wing configurations were tested at a chord Reynolds number of 2.4 million. Flow patterns on the surface of the wings and in the region of the wing/fuselage juncture were examined using oil- flow visualization and infrared thermography. A limited number of unsteady pressure sensors on the fuselage around the wing leading and trailing edges were used to identify any dynamic effects of the horseshoe vortex on the flow field. The area of separated flow in the wing/fuselage juncture near the wing trailing edge was observed for all wing configurations at various angles of attack. All of the test objectives were met. The staff of the 14- by 22-foot Subsonic Wind Tunnel provided outstanding support and delivered exceptional value to the experiment, which exceeded expectations. The results of this test will directly inform the planning for the first of a series of instrumented-model tests at the same Reynolds number. These tests will be performed on a slightly larger-scale model with the selected wing, and will include off-body measurements with LDV and PIV, steady and unsteady pressure measurements, and the flow-visualization techniques that are discussed in this report.

Kegerise, Michael A.↗

NASA NTRS2020

Examining Biases in Diurnally-Integrated Shortwave Irradiances due to Two- and Four-Stream Approximations in Cloudy Atmosphere

Shortwave irradiance biases due to two- and four-stream approximations have been studied for the last couple of decades, but biases in estimating Earth’s radiation budget have not been examined in earlier studies. In order to quantify biases in diurnally-averaged irradiances, we integrate the two- and four-stream biases using realistic diurnal variations of cloud properties from Clouds and the Earth’s Radiant Energy System (CERES) synoptic (SYN) hourly product. Three approximations are examined in this study, delta-two-stream-Eddington (D2strEdd), delta- two-stream-quadrature (D2strQuad), and delta-four-stream-quadrature (D4strQuad). Irradiances computed by the Discrete Ordinates Radiative Transfer (DISORT) and Monte Carlo (MC) methods are used as references. The MC noises are further examined by comparing with DISORT results. When the biases are integrated with a one-day of solar zenith angle variation, regional biases of D2strEdd and D2strQuad reach up to 8 W/sq.m, while biases of D4strQuad reach up to 2 W/sq.m. When the biases are further averaged monthly or annually, regional biases of D2strEdd and D2strQuad can reach –1.5 W/sq.m in SW top-of-atmosphere (TOA) upward irradiances and +3 W/sq.m in surface downward irradiances. In contrast, regional biases of D4strQuad are within +0.9 for TOA irradiances and –1.2 W/sq.m for surface irradiances. Except for polar regions, monthly and annual global mean biases are similar, suggesting that the biases are nearly independent to season. Biases in SW heating rate profiles are up to –0.008 K/d for D2strEdd and –0.016 K/d for D2strQuad, while the biases of the D4strQuad method are negligible.

Ham, Seung-Hee↗

NASA NTRSDate not supplied

Examination of L-Band Brightness Temperature Forecasts in the SMAP Level-4 Soil Moisture Analysis

The NASA Soil Moisture Active Passive (SMAP) mission [4] has been providing L-band (1.4 GHz) passive microwave brightness temperature (Tb) observations since April 2015. By assimilating the Tb observations into the NASA Catchment land surface model [5] using a spatially distributed ensemble Kalman filter, the NASA Global Modeling and Assimilation Office generates the SMAP Level-4 Soil Moisture (L4_SM) product, which provides global, 3-hourly, 9-km resolution estimates of surface (0-5 cm) and root-zone (0-100 cm) soil moisture with ~2.5-day latency for use in research and applications [6]. The L4_SM product also includes estimates of soil temperature, land surface fluxes, and assimilation diagnostics such as the model forecast and observed Tb values [7]. The output from the L4_SM system is routinely monitored by the L4_SM team. Such monitoring provides valuable information; instances of unusually large Tb observation-minus-forecast (O-F) residuals can indicate events during which soil moisture conditions are poorly described in the land modeling system [7,8]. For example, repeated occurrences of very large Tb O-F values in central Australia were traced back to deficiencies in the gauge-based precipitation product used in the land modeling system through L4_SM Version 5; this discovery prompted the use, beginning in Version 6, of satellite- and gauge-based precipitation observations outside of North America [9]. Recently, a statistical analysis of the Tb O-F residuals revealed systematic errors in the “tau-omega” L-band radiative transfer model that converts the land-model simulated soil moisture and temperature into the forecast Tb prior to the L4_SM analysis. The L4_SM analysis is built on the ensemble Kalman filter and assumes unbiased forecast errors. The presence of systematic Tb forecast errors could thus adversely impact the quality of the analyzed soil moisture. In this paper, we examine the Tb O-F residuals of the latest Version 7 L4_SM data (Science Version ID Vv7030 and Vv7032) [10,11,12]. In the L4_SM Version 7 algorithm, key parameters of the L-band radiative transfer model, including soil roughness, scattering albedo, and a (seasonally varying) climatology of vegetation opacity, are obtained from the SMAP Level-2 Radiometer retrieval product (Version 5) [1]. Additionally, we also use ground measurements of surface soil moisture and soil temperature from the SMAP core validation sites as in situ reference of soil conditions [2,3]. As part of the L4_SM system calibration, the seasonally-varying bias between the model forecast Tb and the observed values is removed prior to the assimilation of the SMAP Tb observations [7]. That is, the L4_SM system is designed to only correct errors in synoptic-scale and interannual variations from the long-term mean seasonal cycle while maintaining the model’s (potentially erroneous) climatology. The Tb O-F residuals examined here are thus computed using SMAP Tb observations after they are rescaled to the mean seasonal cycle of Tb from the modeling system without SMAP data assimilation. Consequently, the long-term average of the Tb O-F residuals has a global mean of only 0.13 K and locally small values, ranging from -1 to 3 K. Despite the small time-average values of the Tb O-F residuals, the model forecast Tb was nevertheless found to exhibit undesirable systematic errors. At some locations, the time-average Tb O-F values strongly depend on surface soil moisture (SM). At the Yanco SMAP core validation site, for example, the Tb O-F residuals typically range from 5 to 15 K under dry soil moisture conditions (SM < 0.15 m3 m-3) yet are predominantly negative under wet soil moisture conditions (SM > 0.25 m3 m-3), with values ranging from 0 to -40 K. This results in soil moisture analysis increments that persistently make the soil drier under dry SM conditions and persistently make the soil wetter under wet SM conditions, suggesting an error in the dynamic range of the simulated Tb, soil moisture or soil temperature. In this paper, we describe the higher-order systematic Tb forecast errors in more detail, examine their impact on the L4_SM product quality, and explore potential avenues to further improve the L4_SM algorithm.

Rolf Reichle↗

DOE OSTI2024

AGC-4 Specimen Post-Irradiation Examination Data Interim Report

This interim report documents preliminary results of the post-irradiation examination material property testing from the fourth advanced graphite creep (AGC), AGC 4, capsule specimens. This is the fourth of a series of six irradiation test trains planned as part of the AGC experiment to fully characterize the neutron irradiation effects and radiation creep behavior of current nuclear graphite grades to moderate dose levels (=7 dpa). The AGC 4 capsule was irradiated in the Idaho National Laboratory Advanced Test Reactor at a nominal temperature of 800°C and to a peak dose of 8 dpa. Half of the AGC-4 specimens were subjected to compressive stresses to induce irradiation creep. Post-irradiation testing and measurement results are reported with the exception of thermal testing, which is still in progress, and irradiation mechanical strength testing. Additionally, some specimens initially deemed too hot to be examined in the ART Graphite laboratory may still be measured. The data reported includes specimen dimensions for both stressed and unstressed specimens to establish the irradiation creep rates, mass and dimensional data necessary to derive density, elastic constants (Young?s modulus, shear modulus, and Poisson?s ratio) from ultrasonic time of flight velocity measurements, Young?s modulus from the fundamental frequency of vibration, and electrical resistivity. A more complete evaluation of trends in the material property changes, as well as irradiation-induced creep due to the irradiation environment and applied load on the specimens, will be discussed later in AGC 4 post-irradiation examination analysis reports.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2025

AGC-4 Specimen Post-Irradiation Examination Data Interim Report

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2025

Comparative post-irradiation examination of high burnup U-19Pu-10Zr: Assessing steady-state irradiation behavior against historical and modeled fuel performance

Here, the development of next-generation sodium-cooled fast reactors necessitates comprehensive research on metallic fuels to maximize economic performance while ensuring safe operation. In this study, we investigated the steady-state irradiation behavior of two high burnup U-19Pu-10Zr fuel pins, DP-36 and DP-40, in preparation for planned safety testing. Post-irradiation examination (PIE) was performed to quantify fuel column elongation, regions of low-density at the top of the fuel column, pin deformation, fission product distribution, fractional fission gas release, microstructural evolution, and fuel constituent redistribution. Benchmarking against existing PIE data from U-19Pu-10Zr fuel pins irradiated in EBR-II revealed consistent patterns in fuel column elongation and cladding diametral strain. However, both pins exhibited longer low-density structures, and destructive examination of DP-36 revealed more complex constituent redistribution patterns compared to previously reported data for ternary fuel pins. The steady-state irradiation of both pins was also modeled using BISON. Comparisons of PIE results with modeled predictions showed overall agreement in fractional fission gas release but consistent overestimation of axial and radial swelling due to gaseous and solid swelling models. These findings underscore the critical importance of pre-test characterization on test and sibling pins to accurately capture steady-state fuel behavior ahead of transient testing, thus establishing a baseline for post-test comparison. Additionally, these analyses identified key data gaps that warrant further investigation to improve the understanding and prediction of fuel swelling, thereby enhancing the synergy between modeling and experimental efforts in supporting accident testing.

BISON↗