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At least 37 records · Page 2

Development of High-Temperature Emissivity Measurement Capabilities for Molten Salts at PNNL

In this study, an emissivity measurement system for a liquid molten salt was developed on the bases on the Stefan Boltzmann Law. A prototype device operating in ambient atmosphere was constructed an initial result compared well with available literature. The diffuse emissivity of NaCl-KCl system (NaCl, 51mol% NaCl – 49mol% KCl and KCl) was measured from 550 to 850 °C at a wavelength of 1.3 µm. The system appears to be relatively invariant with composition but a clear trend of decreasing emissivity values from ~0.9 at 550 °C to 0.75 at 850 °C was observed. A schematic for an enclosed system for inert atmosphere and actinide salts was drafted. Several of the components for fabrication of this device, improved laser system, furnace, nickel for capsule construction, have been purchased and are ready for assembly. The new laser system will have an improved measurement range of 275-1000 °C. The clam shell furnace has a maximum temperature of 1200 °C and will support the hermetically sealed inert encapsulation vessels. Nickel plate and tubing will create a relatively corrosion resistance capsule for testing that can withstand temperature up to 1000 °C. Emissivity measurements are important for a larger effort to understand radiative heat transfer within molten salts at elevated temperatures (600-1000 °C). Literature review of optical salt properties and radiative heat transfer models indicated that systems within elevated temperature regimes could see upwards of 20% or more of their total heat transferred through photonic mechanisms. Ultimately, future work will measure the total thermal conductivity and break down the molecular and radiative portions. Thermal conductivity, along with other thermal properties of molten salts, both coolant and fuel, are fundamental to modeling and simulations that support MSR design. The results presented here and ongoing work at PNNL will be useful in selecting optimal salt compositions, designing reactor systems, and optimizing heat transfer within a MSR power plant.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

First-principles Study of the Tritium Species Diffusion Across Ni-Zircaloy-4 Getter Interface

Tritium is a critical fuel component for experimental nuclear fusion reactors (like tokamaks), typically used in combination with deuterium. In tritium-producing burnable absorber rods (TPBARs), due to its high lithium density, LiAlO2 is used in the form of an annular ceramic pellet enriched with the Li_6 isotope located between the Zircaloy-4 liner and nickel-plated Zircaloy-4 tritium getter. Employing DFT, we explored the tritium diffusion across the pellet and getter.

36 MATERIALS SCIENCE↗

Nanostructured Black Nickel Coating as Replacement for Black Cr(VI) Finish

This work compares different electrodeposition procedures to produce nickel black coatings as greener and less toxic alternatives to Cr(VI)-based coatings used in different applications. Nickel and nickel-plated brass served as substrates in studies with a Hull cell and polarization curves. After a set of comparative experiments, the best electrodeposition procedure was further studied and optimized. Optimal conditions were found with a bath consisting of 75 g/L NiCl2·6H2O + 30 g/L NaCl and a current density of 0.143 A dm−2 applied for 5 min at room temperature. Furthermore, a pre-treatment with 18.5 vol.% of hydrochloric acid in water was found to be necessary to warrant good coating adhesion to the substrate. The black color is attributed to the development of a nanostructured surface that absorbs the incident light. Corrosion testing was performed in 0.5 M NaCl aqueous solution using electrochemical impedance spectroscopy (EIS) and polarization tests.

Mennucci, Marina M. (ORCID:0000000171886804)↗

ENVIRONMENTAL DEGRADATION OF HARD AND SOFT MAGNETIC MATERIALS IN GASEOUS AND SUPERCRITICAL CO2 ENVIRONMENTS

It may be beneficial to use hermetic designs for supercritical CO2 (sCO2) cycles machinery as they would eliminate CO2 leakage through shaft end seals. This would reduce CO2 emissions and operating costs for makeup of lost process fluid. Those designs may replace traditional oil-lubricated bearings with actively controlled magnetic bearings operating at high temperatures in the process fluid environment (to reduce the need for active cooling). This paper investigates the material degradation of various types of magnets in CO2. Included are several permanent and soft magnetic materials (Alnico 9C, Alnico 5-7C, and 18-T550 grade SmCo, and Hiperco 50) with or without coatings (nickel plating or C5 coating). The materials were exposed to: (1) flowing gaseous CO2 at 1,022 °F (550 °C) and atmospheric pressure in a furnace and (2) sCO2 at 842 °F (450 °C) and 1,500 psi (103 bar) in an autoclave. The preliminary mass change measured after total exposures of 1,000 hours and 2,000 hours are included.

supercritical CO2, magnetic material↗

Alternative All-Metal Scroll Pump Design

In tritium process systems, vacuum pumps are typically used to evacuate volumes and piping, as well as transfer gas to other parts of the process. This was done using the combination of an all-metal scroll pump with a metal bellows backing pump. The all-metal scroll pump, manufactured by Normetex, has been unavailable since 2012, and efforts continue to find a suitable replacement. The main obstacle is finding a pump that has no oils or polymer components, which degrade when exposed to tritium and introduce corrosive and/or hazardous impurities into the process. There have been development efforts to design an all-metal scroll pump design alternative to the Normetex style. The first generation was fabricated out of machined stainless steel, but the thermal management and increased weight were not ideal. To mitigate the weight, an aluminum version was designed. The tritium holdup on untreated aluminum surfaces can be greater than stainless steel, so the wetted aluminum surfaces were electroless plated in nickel and then electroplated in gold. The development effort outlined in this report details the design of an improved version of the stainless steel version.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Integral Experiment Final Design for Thermal/Epithermal eXperiments (TEX) Plutonium Additional Mixed Spectrum Configurations

This report presents the final design (CED-2) for three additional mixed-spectra configurations for plutonium Thermal/Epithermal eXperiments (TEX) to target the intermediate energy region (IER-553). The baseline cases of IER-184 (PU-MET-MIXED-002 [2]) spanned the entire fission energy spectrum. Case 3, which had a median fission energy (MFE) of approximately 6E-5 MeV and had a fission fraction of about 42% in the intermediate energy range, resulted in a $k_{eff}$ overestimation of 1.1%. Compared to 749 previous ICSBEP plutonium benchmarks, the baseline cases accurately predicted the experiments in the thermal and fast regions where the majority of benchmarks inhabit. The benchmarks in the intermediate energy region to date are sparse and overestimate $k_{eff}$ with an average C/E between 1.02 and 1.03. The additional proposed configurations span the whole of the intermediate energy region. The experimental design utilizes the plutonium/aluminum metal alloy Zero Power Physics Reactor (ZPPR) Plutonium-Aluminum No-Nickel (PANN) plates with varying polyethylene moderator thicknesses to span the intermediate fission energy region. Each of the cases have varying fractions of thermal, intermediate, and fast fissions. The designs were chosen to maximize the intermediate energy fraction. The experiment will take place on the universal critical assembly machine, Planet. The layers will be split as equally as possible between the lower platen and the upper stationary platform of Planet. The upper half of the experimental configuration will also have an upper reflector of polyethylene of specified thicknesses to achieve criticality when the lower platen is raised fully. The previous IER-184 configurations, specifically Case 3, were used to determine the configurations for the additional experiments and neutronics calculations were used to fine-tune the configurations to ensure criticality. The quadrature sum uncertainty in Δ$k_{eff}$ for Case 3 in PU-MET-MIXED-002 was found to be 0.00219. Section 3.8 gives a detailed description of the uncertainties calculated. The additional configurations, which are based directly on Case 3, are expected to have similar uncertainties. However, it is possible to reduce the overall uncertainty of Δ$k_{eff}$ for the additional configurations using the knowledge obtained from the calculations in the benchmark.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗

Efficient Hydrogen Delivery for Microbial Electrosynthesis via 3D-Printed Cathodes

The efficient delivery of electrochemically in situ produced H 2 can be a key advantage of microbial electrosynthesis over traditional gas fermentation. However, the technical details of how to supply large amounts of electric current per volume in a biocompatible manner remain unresolved. Here, we explored for the first time the flexibility of complex 3D-printed custom electrodes to fine tune H 2 delivery during microbial electrosynthesis. Using a model system for H 2 -mediated electromethanogenesis comprised of 3D fabricated carbon aerogel cathodes plated with nickel-molybdenum and Methanococcus maripaludis, we showed that novel 3D-printed cathodes facilitated sustained and efficient electromethanogenesis from electricity and CO 2 at an unprecedented volumetric production rate of 2.2 L CH4 /L catholyte /day and at a coulombic efficiency of 99%. Importantly, our experiments revealed that the efficiency of this process strongly depends on the current density. At identical total current supplied, larger surface area cathodes enabled higher methane production and minimized escape of H 2 . Specifically, low current density (<1 mA/cm 2 ) enabled by high surface area cathodes was found to be critical for fast start-up times of the microbial culture, stable steady state performance, and high coulombic efficiencies. Our data demonstrate that 3D-printing of electrodes presents a promising design tool to mitigate effects of bubble formation and local pH gradients within the boundary layer and, thus, resolve key critical limitations for in situ electron delivery in microbial electrosynthesis.

03 NATURAL GAS↗

Benchmark of the Chlorine Worth Study Experiments in Support of Chlorine Nuclear Data Validation for Nuclear Criticality Safety

The Chlorine Worth Study (CWS) was a critical experiment to address an urgent need for thermal chlorine nuclear data validation in plutonium systems. This urgent need is tied directly to plutonium recycle and recovery operations in the plutonium facility at Los Alamos National Laboratory, where exceptionally conservative criticality safety limits are used because no credit is taken for the neutron capture by chlorine. The experiment used weapons-grade plutonium metal plates clad in stainless steel, known as the PANN (plutonium aluminum no nickel) ZPPR (zero power physics reactor) plates. The plutonium was reflected and moderated by high-density polyethylene and included combinations of polyvinyl chloride (PVC) and chlorinated polyvinyl chloride (CPVC) as absorbers. The experiment and benchmark included three configurations mimicking 30 g 239 Pu/L plutonium, 300 g 239 Pu/L plutonium, and 600 g 239 Pu/L plutonium in an aqueous chloride solution. Uncertainties in the benchmark included five broad categories: (1) criticality measurement, (2) mass and density, (3) dimensions, (4) material compositions, and (5) positioning. The largest contribution to the overall uncertainties for all three cases came from the material compositions, in particular the PVC and CPVC absorber compositions. A detailed model was created to be a near match (that is within expectations of transport code users) and a simplified model was created to minimize offset dimensions and expedite modeling for code validation. Sample calculations were completed in MCNP6.3 with ENDF/B-VIII.0 and ENDF/B-VII.1 nuclear data. For the detailed and simplified models, the average difference between the computed and experimental k eff was 951 pcm. CWS will serve as the key validation experiment for nuclear criticality safety in support of aqueous chloride operations. The sensitivity to the chlorine capture cross section is orders of magnitude greater than other existing benchmarks. The current limits, as defined by nuclear criticality safety, are 520 g Pu per batch, i.e. the minimum critical mass of the Pu solution infinitely reflected by water [Criticality Handbook: Volume II, (1969)]. This extremely conservative critical mass limit does not credit any neutron capture by chlorine (in particular neutron capture by 35 Cl) and greatly impedes the throughput required for current and future operations.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗

Experimental Evaluation of Interfacial Bonding Strength Between 304 Stainless Steel Substrate and Electrodeposited Nickel Coating Using Mesoscale Mechanical Testing Methods

Electrodeposition is a commonly used method for depositing a metal layer on a metallic substrate, to provide a decorative finish or for functional purposes including wear and corrosion resistance. The interfacial bonding strength is a critical factor in determining the quality of electrodeposition, as it ensures the adhesion of the deposited layer to the substrate. Despite its importance, there has not previously been a suitable mechanical testing method to quantitatively characterize the bonding strength between the electrodeposited layers and the substrate, due to the high strength of the materials and to restrictions imposed by the geometry (due to the small thickness of the plating layer) to manufacture tensile bars. In this study, we introduce a novel mesoscale mechanical testing method to overcome these limitations. This technique was applied to assess the bonding strength between a 304 stainless steel (SS) substrate and electrodeposited nickel with three different plating formulae (nickel sulfamate, Watts bath, and hard nickel). The thickness of the pure nickel coatings achieved for each of the three electrolyte solutions was approximately 1 mm on each side of the substrate. Mesoscale tensile bars of 1 mm length were manufactured by a femtosecond laser, with the material interface at the center of the gauge section, and then tensile-tested with digital image correlation. Further, the results proved that the electrodeposition technique is able to produce a very high bonding strength that is close to the yield strength of both the substrate material and the electrodeposited nickel layer. Additionally, in the case of the Watts bath formula, the interfacial bonding strength between the SS 304 and electrodeposited nickel can exceed that of the nickel layer. This method is expected to be useful for quantifying the interfacial bonding strength in numerous applications.

36 MATERIALS SCIENCE↗

Preliminary Plan for Evaluation of Reactor Pressure Vessel Surveillance Materials from Palisades Nuclear Generating Station

The Palisades Nuclear Generating Station (PNGS), located in Michigan, is owned and operated by Entergy. It is a Combustion Engineering 2-loop pressurized water reactor (PWR) producing 805 MWe (2,565 MWth). The PNGS was built between 1967 and 1970, with approval to operate at full power in 1973; the plant’s original license was due to expire on March 24, 2011. An application for 20-year extension was filed in 2005 with the Nuclear Regulatory Commission and was granted on January 18, 2007. Although the plant was scheduled for decommissioning by 2031, Entergy currently plans to close the PNGS in 2022. The PNGS included in its reactor pressure vessel (RPV) surveillance program a capsule, designated A-60, containing specimens of one of the vessel plates and a weld metal with nickel content of about 1.36 wt% and copper content of about 0.20 wt%. This capsule was irradiated to a fluence of 1.8 x 10 20 n/cm 2 . The capsule was removed from its surveillance position in 1995 and has been resident in the spent fuel pool since that time. The material is also of special interest because of its very high nickel content and because of the potential for development of NiMnSi (nickel-manganese-silicon) precipitates, dubbed “late blooming phases.” The surveillance program also includes a capsule, designated T-150, dedicated specifically for thermal aging, which would provide results for at least 33 effective full power years, which is beyond the current thermal-aging database for such materials. Given that license extensions to 60 years of operation have been approved by the US Nuclear Regulatory Commission for most of the currently operating light water reactors in the United States, and that the first extension to 80 years was recently approved, there exists the probability that some RPVs will reach and possibly exceed a fast neutron fluence (> 1 MeV) of 1 x 10 20 n/cm 2 . This is a fluence regime with no US surveillance data and very little test reactor data, except for the Light Water Reactor Sustainability Program–sponsored University of California Santa Barbara Advanced Test Reactor (ATR) ATR-2 project. Thus, the materials in the A-60 capsule represent a valuable resource for directly exploring the effects of commercial surveillance irradiation on a typical plate and a high-nickel weld with similar materials irradiated in the ATR-2 test reactor project. This report provides background information for the surveillance program, previous results of surveillance materials testing, the preliminary plan for capsule retrieval and disassembly, and the plan for testing and microstructural examination of the mechanical test specimens of these unique materials to assess the features induced by very high irradiation fluence or very long thermal aging time

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Sensitivity of Thermal Predictions to Uncertain Surface Tension Data in Laser Additive Manufacturing

To understand the process-microstructure relationships in additive manufacturing (AM), it is necessary to predict the solidification characteristics in the melt pool. This study investigates the influence of Marangoni driven fluid flow on the predicted melt pool geometry and solidification conditions using a continuum finite volume model. A calibrated laser absorptivity was determined by comparing the model predictions (neglecting fluid flow) against melt pool dimensions obtained from single laser melt experiments on a nickel super alloy 625 (IN625) plate. Using this calibrated efficiency, predicted melt pool geometries agree well with experiments across a range of process conditions. When fluid mechanics is considered, a surface tension gradient recommended for IN625 tends to overpredict the influence of convective heat transfer, but the use of an intermediate value reported from experimental measurements of a similar nickel super alloy produces excellent experimental agreement. Despite its significant effect on the melt pool geometry predictions, fluid flow was found to have a small effect on the predicted solidification conditions compared to processing conditions. We find that this result suggests that under certain circumstances, a model only considering conductive heat transfer is sufficient for approximating process-microstructure relationships in laser AM. Extending the model to multiple laser passes further showed that fluid flow also has a small effect on the solidification conditions compared to the transient variations in the process. Furthermore, limitations of the current model and areas of improvement, including uncertainties associated with the phenomenological model inputs are discussed.

36 MATERIALS SCIENCE↗

Pool Boiling Reliability Tests and Degradation Mechanisms of Microporous Copper Inverse Opal (CuIOs) Structures

The rising power density in electronic systems requires thermal management solutions that are both high-performing and reliable. Porous materials such as Copper Inverse Opal (CuIOs) have unique structural features, including high permeability and high thermal conductivity, to enhance pool boiling performance. However, there is little understanding of the degradation mechanism of such porous materials under pool boiling conditions. In this study, samples of 10 ..mu..m thick CuIOs with 4.8 ..mu..m diameter, covering silicon substrate of area 11 mm x 11 mm, with various heated areas ranging from 2.5 mm x 2.5 mm to 10 mm x 10 mm, were tested in 100 degrees C deionized water at a constant heat flux of 110 Wcm -2 for 3-to-7 days. The combined effect of erosion and corrosion caused structural degradation of the CuIOs. The directly heated area had the most severe degradation while the edge of the heater and the unheated area showed progressively less degradation, maintaining some CuIOs structure even after the 7-day reliability test. Among all the tested samples with various heater sizes, the 2.5 mm x 2.5 mm heater sample - in which the heater size was designed to be comparable to the water bubble characteristic length - had the largest critical heat flux (CHF) up to 300 Wcm -2 with a superheat ~ 13 degrees C. Additionally, CuIOs with a smaller heated area performed better in terms of reliability. This study offers preliminary insights into CuIOs degradation mechanisms, contributing to the development of more robust thermal management solutions. We expect that electroless plating of CuIOs with gold (Au), nickel (Ni), and atomic layer deposition (ALD) aluminum oxide (Al 2 O 3 ) in combination with appropriate application-specific coolants will further improve the reliability and lifetime of the CuIOs.

boiling-induced degradation↗

Pool Boiling Reliability Tests and Degradation Mechanisms of Microporous Copper Inverse Opal (CuIOs) Structures: Preprint

The rising power density in electronic systems requires thermal management solutions that are both high-performing and reliable. Porous materials such as Copper Inverse Opals (CuIOs) have unique structural features, including high permeability and high thermal conductivity, to enhance pool boiling performance. However, there is little understanding of the degradation mechanism of such porous materials under pool boiling conditions. In this study, samples of 10-micrometer-thick CuIOs with 4.8-micrometer diameter, covering silicon substrate of area 11-mm by 11-mm, with various heated areas ranging from 2.5-mm by 2.5-mm to 10-mm by 10-mm, were tested in 100 degrees C deionized water at a constant heat flux of 110 watts per square cm for 3-7 days. The combined effect of erosion and corrosion caused structural degradation of the CuIOs. The directly heated area had the most severe degradation while the edge of the heater and the unheated area showed progressively less degradation, maintaining some CuIOs structure even after the 7-day reliability test. Among all the tested samples with various heater sizes, the 2.5-mm by 2.5-mm heater sample - in which the heater size was designed to be comparable to the water bubble characteristic length - had the largest critical heat flux (CHF) up to 300 watts per square cm with a superheat of approximately 13 degrees C. Additionally, CuIOs with a smaller heated area performed better in terms of reliability. This study offers preliminary insights into CuIOs degradation mechanisms, contributing to the development of more robust thermal management solutions. We expect that electroless plating of CuIOs with gold (Au), nickel (Ni), and atomic layer deposition of aluminum oxide in combination with appropriate application-specific coolants will further improve the reliability and lifetime of the CuIOs.

boiling-induced degradation↗

Electrochemical Formation of Li-M-(M')-Si Phases Using Multivalent Electrolyte Salt Additives

Lithium-rich silicides (Li 15 Si 4 ), formed during the electrochemical lithiation of silicon, show high reactivity with electrolyte components that contribute to capacity decay, formal lithium loss, and low coulombic efficiency. Recently, the reactivity of lithium silicides was found to be suppressed by substituting a multivalent cation (i.e. Mg, Ca) for lithium that results in the room temperature formation of a ternary Li-M-Si phase. In this study, we explored a range of multivalent electrolyte salt additives (M = Ni, Cu, La, Ce, Sr, Ba, and Ca-Mg mixed salt) in a lithium-ion cell configuration and identified a room temperature electrochemical route to the formation of new ternary and quaternary lithium silicides. Using this method, both nickel and copper salts were found to plate onto the silicon electrode surface upon lithiation. Further, based on refined synchrotron XRD data, multivalent cations with an ionic radius similar to Na (~1.03 Å) or smaller can be inserted electrochemically into a formally cation-deficient Li 15 Si 4 host lattice to form new ternary (or quartenary) phases. The electrochemical synthesis of a new quaternary Li-M-M’-Si phase represents a facile route to preparing and scaling materials isostructural to the Heusler phase and electron-precise Li 14 MgSi 4 phase that results in enhanced cycling and calendar life performance.

25 ENERGY STORAGE↗

IER 519 Experiment Execution Report: TEX Hanford

The TEX-Hanford experiments were performed at the National Criticality Experiments Research Center (NCERC) at the Device Assembly Facility (DAF) at the Nevada Nuclear Security Site (NNSS). Three configurations were measured, with the measurements occurring in December 2025 and January 2026. The Fe-14 configuration was executed in December 2025; the Fe-11 configuration began its handstack on the Planet critical assembly machine in December 2025, but was taken critical in January 2026; the Fe-16 configuration was executed entirely in January 2026. The TEX-Hanford experiments were performed on the Planet critical assembly machine utilizing using PANN (Plutonium Aluminum No Nickel) ZPPR (Zero Power Physics Reactor) plutonium plates as fuel. The configurations were moderated with varying thicknesses of HDPE and iron absorber. This document details the configurations that were measured, preliminary reactivity measurements of the measured configurations, data files from the neutron detection systems, and results from the coordinate-measuring machine (CMM) measurements of the final stack height measurements each configuration.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

Fast charging of Li-ion cells: Effect of separator membranes and mapping of “safe lines” to avoid Li plating

An experimental method is introduced that uses microprobe Li/Cu reference electrodes to map "safe" charging regimes to avoid Li metal plating on graphite anodes at rates to 8C. With this method, a Li-ion cell closely approaches the Li plating condition but avoids descending into this regime. This "safe" approach is used to demonstrate effects of the microporous separator on Li plating in cells consisting of a layered nickel-manganese -cobalt oxide cathode and graphite anode. We argue that most of the difference in behaviors for different separators arises from time delayed Li + ion percolation through the membrane. In conclusion, our study suggests that explicitly treating kinetics of phase transitions in the lithiated graphite anode is essential for electrochemical models predicting "safe" lines for fast charging cells.

25 ENERGY STORAGE↗

Radiation Effects Related to Repaired BWR Core Shrouds

The material properties of the core shroud and supporting tie rod components are important factors for Boiling Water Reactor (BWR) life extension considerations. Given the variability of nickel and boron content found in 304 stainless steel shroud plates, and XM-19 and Inconel X-750 tie rod materials, this paper combines the latest spectral information in the vicinity of the core shroud to calculate hydrogen and helium gas production limits as well as atomic displacement damage spanning 80 full-power years (FPY) using the SPECTER code. Results indicate that, whereas boron has little effect on the atomic displacement damage, helium production from boron can be important and must be included in weldability assessments. Since the boron concentration is uncertain, helium generation is calculated assuming a composition range based on specifications and reported measurements. The results show that helium production caused by transmutations in the 304 SS shroud material are dominated by the concentration of boron and will have a significant impact on weldability after only a few years of service. For tie rods, the susceptibility to irradiation-assisted stress corrosion cracking (IASCC) has been assessed by determining helium production in Inconel X-750 IASCC specimens irradiated in the Advanced Test Reactor (ATR) reactor and correlating with the helium produced in a BWR. As a tie rod material in a high thermal neutron flux environment, Inconel X-750 is more likely to be IASCC sensitive during service in a BWR due to helium than the XM-19 stainless steel alloy because of a greater nickel content and boron concentration. Weldability of the core shroud plate material, IASCC of the tie rod materials, and the gamma photon contribution to radiation damage are discussed.

radiation damage in materials, BWR↗