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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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DOE OSTI2026

Validation Studies of RELAP5-3D for High-Temperature Gas-Cooled Reactor Analysis Using a Refined RELAP5-3D Model of the High Temperature Test Facility

RELAP5-3D has been used extensively for high-temperature gas-cooled reactor (HTGR) analysis, but such analysis lies outside the validation basis for the code. Oregon State University (OSU) and the United States Department of Energy’s (DOE) Advanced Reactor Technologies (ART) – Gas-cooled reactor campaign worked together to design and operate the High Temperature Test Facility (HTTF) at OSU to provide validation data for prismatic HTGR thermal hydraulics analysis. Work using a previous RELAP5-3D model of HTTF demonstrated the ability to reproduce trends in HTTF data but an inability to reproduce the values measured in multiple experiments within the uncertainty. It was hypothesized that a new model with a finer radial nodalization would perform better for HTTF analysis. In this paper, we present the development of that more refined model and analyze HTTF experiments PG-27 and PG-29, a pressurized (PCC) and depressurized conduction cooldown (DCC) transient. Comparing PG-27 results to experimental data shows a better prediction of steady state and transient temperatures; however, a deeper dive reveals that better transient temperature predictions are a result of better initial conditions. The transient temperature rise in the core is comparable between the two models, but the legacy model predicts temperatures in the reflectors better. The new model demonstrates the ability to predict unique temperatures in each sector of the core during PG-29, capturing the azimuthal asymmetry; however, the temperature predictions still differ from measured temperatures. One hypothesis is that differences between the assumed and actual power distribution leads to the underprediction of the individual block temperatures. These results suggest that gaps and uncertainties in the measured boundary conditions for the HTTF tests do not allow to fully validate RELAP5-3D for prismatic HTGR analyses. The authors suspect that some of the differences between predicted and measured temperatures may be a result of uncertainties associated with HTTF itself rather than RELAP5-3D. We demonstrated improved validation for steady-state analysis, but significantly improved transient performance has yet to be recognized.

22 - GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2024

Code Benchmark of Depressurized Conduction Cooldown Transient in the High Temperature Test Facility

This paper presents results from modeling of a depressurized conduction cooldown (DCC) transient at the High Temperature Test Facility (HTTF) as part of the OECD-NEA Thermal Hydraulics Code Validation Benchmark for High-Temperature Gas-Cooled Reactors using HTTF Data . This paper briefly describes the benchmark and the models being used. It then presents a comparison of steady state and transient results based on the Problem 2 Exercise 1A and 1B definitions. We compare block and helium temperature distributions, mass flow distribution, and energy balance in steady state. All models show comparable mass flow distributions and energy balances. The temperatures within the core and outer regions are comparable in all models too, but inner reflector temperatures can vary significantly. Despite that, we find that the models are in good agreement for the full-power steady state. In the DCC, we look at block temperature at the core midplane and RCCS water exit temperature. The INL and ANL models are found to be in excellent agreement with one another on block temperature over time, while the agreement when the KAERI and NRG models are added into consideration is good. Differences in the transient heat removal from the RCCS cause the differences in block temperature over time in these models. The CNL models show similar trends to the INL, ANL, KAERI, and NRG models, but the temperatures are high because the volumes used in calculating the average temperature include the heater rods in the CNL models only. The HUN-REN model shows results that suggest significantly lower heat removal in the RCCS which merit further investigation.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2026

Representativity error scaling of models of the high temperature test facility

Error scaling is a critical step toward the validation of modeling capabilities for high-temperature gas-cooled reactors (HTGRs). Extensive effort is being made to bring HTGRs into the validation basis of numerous thermal-hydraulics codes. Here, this paper demonstrates how systems-level codes can be leveraged to perform error scaling analyses between an experimental facility and a plant-to-be facility. Specifically, we focus on two conduction cooldown experiments from the High Temperature Test Facility (HTTF) and the General Atomics 350 MW th modular high-temperature gas-cooled reactor (MHTGR-350). The error scaling methodology employed in this study is representativity, which in the context of this work was used to quantify how well experiments captured the physics of the plant facility by comparing sensitivity vectors between the two facilities. In addition, two different RELAP5–3D models of the HTTF were included in the comparison to determine if modeling methodologies notably impact the representativity results. The key figures of merit are the maximum block temperature and the coolant outlet temperature. The time-dependent maximum block temperature had a low representativity of below 0.1 for both models across both transients. The coolant outlet temperature had a higher representativity of around 0.6 for both models during the pressurized conduction cooldown, but it was below 0.2 for the depressurized conduction cooldown. Overall, the HTTF experiments were not representative of the transients in the MHTGR-350. However, these results can play a significant role in informing future potential experiments for HTGR systems that iterate on what the HTTF accomplished.

22 - GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2024

DOE’s National Solar Thermal Test Facility Operations and Maintenance

This report details operations and maintenance (O&M) activities performed across Fiscal Years 2022 through 2024 in support of the continued capabilities of the National Solar Thermal Testing Facility (NSTTF) at Sandia National Laboratories. The NSTTF O&M project is funded by the U.S. Department of Energy Solar Energy Technologies Office (SETO) to support research activities and testing on behalf of external customers at the facility under award number CPS 38491. During the project period, the NSTTF made progress in the areas of site metrics, site maintenance and utilization tracking, and customer engagement. The O&M project also supported special initiatives including procurement of a heat exchanger for particle concentrating solar thermal processes and a scoping and cost study for refurbishment and repair of component in the NSTTF heliostat field.

14 SOLAR ENERGY↗
DOE OSTI2025

RAVEN Template for Dynamic Representativity Analysis of the High Temperature Test Facility

These slides present a walkthrough of the template that has been developed for using RAVEN to perform representativity analysis using models of the High Temperature Test Facility and the General Atomics Modular High Temperature Gas-cooled Reactor. The presentation provides participants in the HTTF benchmark with a walkthrough on how to use RAVEN for their sensitivity analysis and how to read results from the MHTGR-350 to perform representativity

22 - GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2026

Fuel-Cladding Eutectic Study of Legacy Fast Flux Test Facility (FFTF) MFF HT9/U-10Zr Metallic Fuel

This report presents the first systematic investigation of fuel-cladding eutectic interaction (FCEI) in irradiated HT9/U-10Zr metallic fuel from the Fast Flux Test Facility (FFTF) Materials Fuels Form (MFF) program, using differential scanning calorimetry (DSC) coupled with scanning electron microscopy (SEM) and energy dispersive X-ray spectroscopy (EDS). Two irradiated fuel cross-sections, MNT07H (9.5 at% burnup, x/L = 0.78) and MNT08H (7.0 at% burnup, x/L = 0.93), were subjected to three successive isothermal annealing rounds (R1–R3) at 820°C for 20 minutes each, yielding a cumulative transient duration of one hour. This study directly addresses a recognized gap in the existing FCEI database, which previously lacked irradiated HT9/U-10Zr data at burnup levels above 8 at%. Two principal findings emerge from the study. First, for both samples, FCEI remained spatially confined within the pre-existing fuel-cladding chemical interaction (FCCI) zone boundaries after R3, with no measurable eutectic penetration into unaffected cladding beyond the original FCCI layer. This self-limiting behavior is consistent with historical Fuel Behavior Test Apparatus (FBTA) results and is attributed to the near-eutectic phase composition of the FCCI zone, which rapidly absorb the available eutectic-forming constituents and then stall penetration once the FCCI zone is consumed. A comparison with unirradiated surrogate data further supports this mechanism: whereas a U–34 at.% Fe sample would be expected to show ~176 µm of iron penetration under comparable conditions, the irradiated samples exhibited only ~20 µm, a discrepancy attributed to irradiation-induced interfacial porosity and pre-existing FCCI composition gradients. Second, for MNT08H, FCEI was observed exclusively on the half of the cladding circumference where pre-existing steady-state FCCI was present, with no detectable FCEI on the opposite half. Three hypotheses are proposed to explain this asymmetry: the inhibiting role of a zirconium-rich rind at the fuel-cladding interface; the chemical sequestration of iron by redistributed zirconium within the fuel matrix; and the persistence of fuel-cladding gaps on the FCEI-free half that preclude direct contact. All three hypotheses require further experimental investigation. The results extend the empirical FCEI database into higher-burnup territory and demonstrate the viability of DSC-based testing as a substitute for the no-longer-available FBTA apparatus. Future work will include additional cross-section testing, compilation of the full FCEI dataset, model evaluation, and DSC testing of ternary fuel compositions to broaden the experimental basis for safety assessment of sodium-cooled fast reactor systems.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2024

Development and demonstration of a BISON–Griffin modeling framework for the design of targeted TRISO transient experiments in the Transient Reactor Test Facility

Uranium oxycarbide (UCO)-bearing tri-structural isotropic (TRISO) particle fuels are expected to be used in numerous U.S. commercial reactor applications within the next decade. Here, in this work, we reviewed historical particle fuel transient experiments to identify gaps in TRISO fuel performance transient testing. A BISON–Griffin modeling framework was then developed to conduct preliminary TRISO transient analyses and begin to address these gaps. The framework was demonstrated using limiting-case transient conditions from a prototypic high-temperature gas-cooled reactor (HTGR). It was then applied to develop a matrix of experiments that could be performed in the Transient Reactor Test Facility (TREAT) to (1) evaluate UCO-fueled particle performance at moderate and high heat rates, (2) assess whether historical testing involving UO 2 -fueled particles is applicable to modern UCO-fueled particles, (3) deconvolute the impacts of temperature and heat rate on particle transient response, and (4) collect the data needed for fuel performance model validation and/or further development.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2024

Development of 250 kW Ammonia and Hydrogen Industrial Burner Test Facility at the National Energy Technology Laboratory

In an effort to investigate the viability of ammonia and hydrogen as fuels in the industrial heating sector, the Department of Energy’s National Energy Technology Laboratory is developing a 250 kW burner test facility. The pursuit of a decarbonized industrial heating sector requires innovative approaches to convert existing assets to alternative fuels while maintaining adequate radiative heat transfer and limiting NOx. This new capability will leverage NETL’s experience and prior investments in ammonia and hydrogen combustion, to advance atmospheric pressure industrial combustion systems for industries such as cement kilns and glass factories. The intention in coming years is to collaborate with burner manufacturers and heavy industry partners to study, develop, and validate strategies for converting existing hardware from carbon-based fuels to next-generation clean ammonia and hydrogen technologies.

May, Kristyn Johnson↗
DOE OSTI2024

Status Report on Fast Flux Test Facility Mechanistic Fuel Failure Experiment Analysis with BISON for Post Irradiation Examination Support

The renewed interest in metallic U-Zr nuclear fuel alloy has led to a drive for deeper understanding of the mechanisms driving the phenomena observed under irradiation conditions. The Department of Energy Advanced Fuel Campaign has developed infrastructure to support metallic fuel development, including Post Irradiation Examination (PIE) of legacy Fast Flux Test Facility (FFTF) Mechanistic Fuel Failure (MFF) experiments. The PIE performed on legacy FFTF MFF experiments gives insight on metallic fuel performance and can address the lack of knowledge and scarcity of reliable data identified in several studies over recent years. Unfortunately, PIE efforts can cost significant time and resources which can impede the progress of metallic U-Zr fuel development. Metallic U-Zr fuel performance modeling can be used to inform PIE efforts on regions of interest for relevant investigations and can help understand phenomena observed in PIE. This report demonstrates the current progress of FFTF MFF fuel performance simulations using the BISON fuel performance code and discusses the support provided by simulation to PIE efforts. Progress in temperature, profilometry, fission gas release, plenum pressure, and zirconium redistribution simulation results have been demonstrated.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2025

The Design of a Multiphase CO2 Turbine Test Facility

As the energy market continues to evolve with increased renewables, such as solar and wind energy, the need to balance energy demand with its availability has become increasingly more challenging. The country’s aggressive decarbonization goals in the upcoming decades will increase renewable energy market penetration, thus exacerbating the disparity between energy demand and renewable resource availability. Long-duration energy storage technologies, such as pumped thermal energy storage (PTES), are potential solutions to this challenge with high potential round-trip efficiency (RTE), no geological or geographical constraints, and low safety risks. The charge mode of a PTES system operates a heat pump cycle, converting input power to thermal energy in hot and cold reservoirs. Fundamentally, heat pumps are commonly used in daily life, but the operating conditions required by high RTE PTES systems are outside the design experience of these systems. The low-pressure side of the cycle for a supercritical CO2 (sCO2) PTES operates just above the vapor-dome and potentially drives the turbine to expand into the dome, resulting in multiphase operation in the rear stages of the turbine. This paper presents the design of the test facility for an advanced multiphase-tolerant sCO2 turbine for the heat pump of a PTES system. Heat rejection and pressure loss estimations for the multiphase sections of the test loop presented unforeseen challenges.

25 ENERGY STORAGE↗
DOE OSTI2025

The Dual-Axis Radiographic Hydrodynamic Test Facility Capability eXpansion (DCX) Strategy

This document details the strategy proposed to meet the National Nuclear Security Administration (NNSA) requirement for the Dual-Axis Radiographic Hydrodynamic Test (DARHT) Facility Sustainment and Modernization projects identified in multiple NNSA Stockpile Stewardship and Management Plan (SSMP) reports to Congress [NNSA, 2020; 2021; 2022; 2023; 2024]. DARHT has become indispensable for the certification of the primaries of U.S. nuclear weapons since the current U.S. moratorium halted underground nuclear testing more than 30 years ago. However, aging facilities, evolving technology, and other issues are limiting or threatening the capability of DARHT to meet NNSA’s expanding mission needs now and into the future. This DARHT Capability eXpansion (DCX) strategy was developed to address NNSA needs by extending DARHT’s reliability and resilience, increasing the quality and quantity of DARHT data, and enabling hydrodynamic measurements in complex environments. The strategy can be implemented through integration of line-item projects, acquisition of major items of equipment, and other actions coordinated with the execution of the SSMP. This strategy document is intended for U.S. Government officials, particularly authorizers, appropriators, and program leaders. It may also be furnished to DARHT users, customers, collaborators, stakeholders, and visitors as needed

45 MILITARY TECHNOLOGY, WEAPONRY, AND NATIONAL DEF↗
DOE OSTI2025

Progress Towards the Validation of a new RELAP5-3D model of the High Temperature Test Facility

Validation is a key step in the development of any type of systems model. As the next generation of reactors approaches, the need for codes that have been validated for these new types of systems continues to grow. An example of a prominent option is the Reactor Excursion Leak Analysis Program (RELAP5-3D), developed by Idaho National Laboratory. This code was developed for the purpose of systems level thermal-hydraulic modeling of light water reactors (LWRS) and postulated transients that can occur in LWRS.RELAP5-3D has been substantially validated against LWR data. Due to its long history as a reactor safety analysis tool, there has been an effort to adapt RELAP5-3D for the purposes of advanced reactor concepts such as prismatic high-temperature gas-cooled reactors (HTGRs). However, RELAP5-3D has not nearly been validated and verified for HTGRs to the degree of LWRs, warranting verification and validation opportunities with computational benchmarks and existing experimental facilities. Examples of such facilities include the modular high-temperature gas-cooled reactor (MHTGR) 350 and the high temperature engineering test reactor (HTTR) from Japan. The MHTGR 350 is a benchmark design concept for code-to-code verification purposes; therefore, it does not provide any experimental data for validation opportunities The HTTR provides useful multiphysics validation data but does not have the in-core instruments to generate thermal-hydraulic experimental data to help with RELAP5-3D validation. Consequently, a facility that could provide key in-core temperatures for thermal-hydraulic validation was still needed. The High Temperature Test Facility (HTTF) is an integral effects facility for HTGR thermal hydraulics developed and operated by Oregon State University. HTTF represents ¼ length scale of the General Atomics MHTGR and is rated for a total power of 2.2 MW. Axially, the core consists of an upper and lower reflector and 10 blocks, numbered from bottom to top (Block 1 is right above lower reflector). The core is heated via graphite resistive heater rods, with respective channels distributed throughout the core. The primary coolant is helium and heat can radiate out of the core to the reactor cavity cooling system (RCCS), which is cooled by water. The primary purpose of the facility is to investigate pressurized conduction cooldown (PCC) and depressurized conduction cooldown (DCC) transients, which are also referred to as the pressurized and depressurized loss of forced cooling respectively. Two experiments were chosen to perform the validation study with a RELAP5-3D model of HTTF. These experiments are PG-27 (PCC) and PG-29 (DCC). These were chosen based off of the quality of available experimental data before and during the experiment which led to their inclusion in the HTGR Thermal Hydraulics Benchmark.

22 - GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2025

The Transient Reactor Test Facility (TREAT)

TREAT operated from 1959-1994, later refurbished & resumed operation in 2017 to support fuel safety testing Zircaloy-clad graphite/fuel blocks comprise core Virtually any power history possible within ~2000 MJ core transient energy capacity From milliseconds to minutes: Pulses, Ramps, LOCA Fuel motion monitoring system “hodoscope” observes fast neutrons emitted from specimens to track fuel relocation in real time Reactor also can be a neutron source to adjacent radiography facility Experiment vehicle does everything else Safety containment, specimen environment, and instrumentation

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2024

Monitoring Helium Cryogen Usage with iFix Software at IB1 Test Facility

At the IB1 facility of the Applied Physics and Superconducting Technology Directorate within the Cryogenic Division at Fermilab, Liquid Helium is essential to the testing activities. The test stands require large amounts of Helium to test the thermal and superconducting cavities and magnets. The Liquid Helium that enters the test stand is monitored through a series of valves and controls to determine the start and stop for monitoring time. There are 3 phases of cryogen usage that must be considered for each stand, cooldown, warming and overnight mode. With a new system in place, cold hour tracking will be more objective and precise within each test stand ensuring better calculations for User s fees which are charged to various groups that employ the facility and aid replenishment of Helium and continual operation at IB1.

Trillo, Angelica↗
DOE OSTI2025

Operational Experience of the NML Cryogenic Plant at the FAST Test Facility

The NML cryogenic plant cools two individually cryostated superconducting radio frequency (SRF) capture cavities and one prototype ILC cryomodule with eight SRF cavities. This complex accelerates electrons at 150 MeV for the Integrable Optics Test Accelerator (IOTA) ring, located at the Fermilab Accelerator Science and Technology (FAST) facility. The cryogenic plant is composed of two nitrogen precooled Tevatron satellite refrigerators, two Mycom 2016C compressors, a cryogenic distribution system, a Frick purifier compressor, two charcoal bed adsorber purifiers, and a liquid ring vacuum pump with a roots booster. The SRF cavities are immersed in a 2.0 K liquid helium bath, shielded with a 5 K gaseous helium shield and a liquid nitrogen cooled thermal shield. Since 2019, this R&D accelerator complex has gone through four science runs with an average duration of 12 months. Operational experience for each run, availability metrics, performance data and common outages are presented in this paper.

Wallace, Timothy [Fermilab] (ORCID:000900051589302↗
DOE OSTI2025

Operational Experience of the NML Cryogenic Plant at the FAST Test Facility

The New Muon Laboratory (NML) cools two individually cryostated superconducting radio frequency (SRF) capture cavities (CC) and one prototype ILC cryomodule (CM) with eight SRF cavities. This complex accelerates electrons at 150 MeV for the Integrable Optics Test Accelerator (IOTA) ring, located at the Fermilab Accelerator Science and Technology (FAST) facility. Since 2019, this R&D accelerator complex has gone through four science runs.

Wallace, T. [Fermilab]↗
DOE OSTI2024

Monitoring Helium Cryogen Usage with iFix Software at IB1 Test Facility

At the IB1 facility of the Applied Physics and Superconducting Technology Directorate within the Cryogenic Division at Fermilab, liquid helium is essential to the testing activities. The test stands used require large amounts of Helium to test the thermal and superconducting cavities and magnets. The liquid helium that enters the test stand is monitored through a series of valves and controls to determine the start and stop for monitoring time. There are 3 phases of cryogen usage that must be considered for each stand, cooldown, warming and overnight mode. With a new system in place, cold hour tracking will be more objective and precise within each test stand ensuring better calculations for user s fees that will provide funding for the replenishment of helium and continual operation at IB1.

Trillo, Angelica↗
DOE OSTI2026

Ultra-High Operation Temperature SiC-matrix Solar Thermal Air Receiver (HOTSSTAR) enabled by additive manufacturing: Test Facility & Performance Evaluations

Solar Heat for Industrial Processes (SHIP) cavity receivers are capable of generating electricity or industrial process heat by absorbing thermal energy from solar radiation, focused on a small area. The concentration of solar radiation on the small area of the receiver enables the achievement of high temperatures (ranging from 400°C to 1,100°C) of a working fluid, thus making the SHIP technology thermodynamically comparable with conventional power plants. A volumetric receiver consists of a porous structure-generally made of silicon carbide or metal, which absorbs solar radiation and converts it into heat energy. Heat energy from the porous materials is then transferred to the fluid following through them. A volumetric receiver acts as a convective heat exchanger, transferring heat to the fluid through convection. Open-loop volumetric receivers work with air at atmospheric pressure and are suitable for single-cycle or multi-cycle energy plants. A Model Based Systems Engineering (MBSE) approach was used to develop a test bed at Sandia national Laboratories (SNL) capable of demonstrating an open-loop volumetric air receiver developed by General Electric Aerospace (GE Aerospace). This paper presents the development of the various MBSE methods, test bed, and testing operations for the GE air receiver, which was experimentally demonstrated to achieve 1,350°C for over 3 hours of operation and an approximate 70% receiver efficiency. By being able to achieve such high temperatures >1,000°C, this work provides the potential to support many SHIP industrial use cases.

14 SOLAR ENERGY↗