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Results for “Fuel Fabrication”

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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At least 361 records · Page 20
All sourcesNASA NTRSDOE OSTI
DOE OSTI2021

Direct Integration of Strained-Pt Catalysts into Proton-Exchange-Membrane Fuel Cells with Atomic Layer Deposition

The design and fabrication of lattice-strained platinum catalysts achieved by removing a soluble core from a platinum shell synthesized via atomic layer deposition, is reported. The remarkable catalytic performance for the oxygen reduction reaction (ORR), measured in both half-cell and full-cell configurations, is attributed to the observed lattice strain. By further optimizing the nanoparticle geometry and ionomer/carbon interactions, mass activity close to 0.8 A mg Pt -1 @0.9 V iR-free is achievable in the membrane electrode assembly. Nevertheless, active catalysts with high ORR activity do not necessarily lead to high performance in the high-current-density (HCD) region. More attention shall be directed toward HCD performance for enabling high-power-density hydrogen fuel cells.

25 ENERGY STORAGE↗
DOE OSTI2020

Method for measurement of TRISO kernel and layer volumes by X-ray computed tomography

Layer dimensions are key parameters for as-fabricated tristructural-isotropic (TRISO) particle fuel as well as for post-irradiation examination of particle performance. Layer thicknesses are typically measured by optical microscopy of the particle cross section near mid-plane, while layer volumes are estimated with serial sectioning and microscopy. This method for measuring layer volumes is limited due to the resolution limit imposed by slice thickness and the effect of the polishing process on delicate irradiated particle microstructures. In this study, image processing software has been developed to segregate the three-dimensional (3D) TRISO particle images provided by x-ray computed tomography (XCT) into high-resolution volumetric data for the kernel, all particle layers, and any internal voids introduced during irradiation. These data can be used to analyze key in-reactor behaviors of TRISO particles such as kernel swelling or buffer shrinkage, which are important inputs for fuel performance modeling.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Rapid quantitative analysis of trace elements in plutonium alloys using a handheld laser-induced breakdown spectroscopy (LIBS) device coupled with chemometrics and machine learning

Here, we present the first reported quantification of trace elements in plutonium via a portable laser-induced breakdown spectroscopy (LIBS) device and demonstrate the use of chemometric analysis to enhance the handheld device's sensitivity and precision. Quantification of trace elements such as iron and nickel in plutonium metal via LIBS is a challenging problem due to the complex nature of the plutonium optical emission spectra. While rapid analysis of plutonium alloys has been demonstrated using portable LIBS devices, such as the SciAps Z300, their detection limits for trace elements are severely constrained by their achievable pulse power and length, light collection optics, and detectors. In this paper, analytical methods are evaluated as a means to circumvent the detection constraints. Three chemometric methods often used in analytical spectroscopy are evaluated; principal component regression, partial least-squares regression, and artificial neural networks. These models are evaluated based on goodness-of-fit metrics, root mean-squared error, and their achievable limits of detection (LoDs). Partial least squares proved superior for determining content of iron and nickel in plutonium metal, yielding LoDs of 15 and 20 ppm, respectively. These results of identifying the undesirable trace elements in plutonium components are critical for applications such as fabricating radioisotope thermoelectric generators or nuclear fuel.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2021

Performance of Embedded Sensors in 3D Printed SiC

This report summarizes recent advances in embedding sensors in 3D printed silicon carbide (SiC) ceramic components under the Transformational Challenge Reactor (TCR) program. The additive manufacturing technologies developed under this program will enable fabrication of complex structures with embedded fuels and sensors. The sensors will be capable of characterizing fuel performance using spatially distributed measurements at the most strategic locations that would be otherwise inaccessible using conventional manufacturing techniques. While previous programmatic updates describe initial concepts for embedding sensors, materials selection, and initial characterization of the embedded sensors, the technology requires further demonstration, and quality-significant procedures must be established before the embedding technology is ready for adoption by industry. To this end, this report describes the most effective techniques that have been used to embed functional sensors in 3D printed components using a combination of binder-jet additive manufacturing and chemical vapor infiltration (CVI). A detailed procedure describes each step in the process and is available upon request. Molybdenum (Mo)-sheathed thermocouples have been successfully embedded in complex SiC components, and temperatures were monitored in situ during the embedding process. Post-embedding measurements showed no significant hysteresis, and characterization of the interface revealed qualitatively strong bonding around the entire perimeter of the sensor sheath. Distributed fiber-optic temperature sensors were able to briefly measure temperature profiles during CVI, but they ultimately failed prior to completion of the CVI run. The failure appears to be related to the fiber coating at temperatures close to 1,000°C. Future work will focus on irradiation testing of embedded thermocouples and other sheathed electrical sensors, as well as the identification of fiber-optic sensor coatings that can survive CVI.

42 ENGINEERING↗
DOE OSTI2026

Free-Piston Expander for Hydrogen Cooling

This final report details work done by GTI Energy, in partnership with University of Texas at Austin – Center for Electromechanics (UTCEM), Argonne National Laboratory (ANL), and Quantum Fuel Solutions (Quantum) to successfully design, fabricate, and test a linear free-piston hydrogen expander controlled by linear motors which also generates electrical power during the process.

03 NATURAL GAS↗
DOE OSTI2020

Global Security & Strategic Partnership Programs

Long, proud history of expertise in uranium, lithium, high explosives, assembly/disassembly, and nuclear security and a vital part of today’s nuclear security enterprise Integral role in sustaining U.S. nuclear deterrent and reducing global nuclear threats with unique security and nonproliferation research capabilities NN and GSP Missions Bring Fresh Ideas and Solves Important National Security Problems NN and GSP Missions Keep Our Technology and People Sharp and Ready for New Challenges

98 NUCLEAR DISARMAMENT, SAFEGUARDS, AND PHYSICAL P↗
DOE OSTI2022

FY2022 Progress Report for Advanced Re-fabrication/Re-instrumentation Capability Development

In support of performing follow-on irradiation experiments with previously irradiated materials, the Halden Reactor Project developed unique and state of the art capabilities to refabricate and re-instrument previously irradiated materials. Such materials were used in in-pile tests at the Halden reactor, and out-of-pile tests for example using furnaces as a heat source. The decision to close the Halden Reactor Project results in the loss of this refabrication and re-instrumentation capability. As a result, the United States (U.S.) Department of Energy (DOE) has determined to develop refabrication and re-instrumentation capability at the unique shielded facilities at Idaho National Laboratory (INL). The development of refabrication capability has been completed and demonstrated. This report focuses on the complementary aspects of reinstrumentation and the progress to-date. Halden spent nearly 30 years developing both refabrication and re-instrumentation. Collaboration with Halden is allowing Idaho National Laboratory (INL) to develop this capability much more rapidly. In FY-21 the results include development of the capability to drill annular center holes in ceramic UO2 fuel pellets, development of fuel rod end caps with feedthroughs for centerline instrumentation inside the rodlet, The procurement of both fuel drilling and welding demonstration equipment from Halden, evaluation of surface thermocouple attachments to support better understanding of temperature measurement uncertainties, and finally, the conceptual design of a new shielded enclosure where advanced refabrication and re-instrumentation equipment can be housed. In FY-22, the results include; Completing set up of the drilling and welding modules procured from Halden, and early experimental trials using that equipment.; Completing set up of an out-of-cell circumferential weld system to allow for further weld development to take place and support fabrication of fuel for fresh fuel experiments.; Evaluation of the Hot Fuel Examination Facility (HFEF) infrastructure to support future installation of advanced re-fabrication/re-instrumentation equipment, specifically related to necessary infrastructure for cryo-drilling.; Developments in dry-drilling alternative. Including experimental studies showing cordierite is the most suitable surrogate for UO 2 for performing drilling studies. That drilling performance is enhanced when a fuel-clad bonding condition is simulated.; Conceptual design completed for attaching surface thermocouples to irradiated fuel in support of TWIST capsule experiments. The authors would like to thank the numerous colleagues at INL and Halden who provided support in accomplishing this work. Their support both material and intellectual is invaluable in advancing the state of the art and establishing the capabilities for refabrication and re-instrumentation at INL.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2019

Advanced Fuels Campaign 2019 Accomplishments

The mission of the Advanced Fuels Campaign (AFC) is to perform or support research, development, and demonstration (RD&D) activities to identify and mature innovative fuels and cladding materials and associated technologies with the potential to improve the performance and safety of current and future reactors; increase the efficient utilization of nuclear energy resources; contribute to enhancing proliferation resistance of the nuclear fuel cycle; and address challenges related to waste management and ultimate disposal. AFC pursues its mission objectives using a goal-oriented, science-based approach that seeks to establish a fundamental understanding of fuel and cladding behaviors under conditions that arise during fabrication, normal steady-state irradiation, off-normal transient scenarios, and storage/disposal. This approach includes advancing the theoretical understanding of fuel behavior, conducting fundamental and integral experiments, and supporting the mechanistic, multi-scale modeling of nuclear fuels to inform and guide fuel development projects, advance the technological readiness of promising fuel candidates, and ultimately support fuel qualification and licensing initiatives. In the area of advanced tools for the modeling and simulation of nuclear fuels, the AFC works in close partnership with the Nuclear Energy Advanced Modeling and Simulation (NEAMS) program, participating with NEAMS in developing mechanistic fuel behavior models and providing experimental data to inform and validate its most advanced tools. Specifically, AFC objectives in thecoming five year horizon include: 1. support the industry-led development of Accident Tolerant Fuel (ATF) technologies with improved reliability and performance under normal operations and enhanced tolerance during hypothetical accident scenarios, with implementation of lead test rods/assemblies of one or more ATF concepts in commercial reactor(s) by or before 2022 and batch reloads of near-term concept(s) in the 2023-2026 timeframe; 2. lead research and development on innovative fuel and cladding technologies for applications to future advanced reactors, especially fast-spectrum reactors, including reactors that utilize both once-through and recycle scenarios; 3. continue the development and demonstration of a multi-scale,science-based approach to fuel development and testing, andcontribute to the establishment of a state-of-the-art R&D infrastructure necessary to accelerate the development of new fuel concepts; and collaborate with NEAMS on the development and validation of multi-scale, multi-physics, and increasingly predictive fuel performance models and codes. 4. collaborate with NEAMS on the development and validation of multi-scale, multi-physics, and increasingly predictive fuel performance models and codes.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2023

Designing Nuclear Fuels with a Multi-Principal Element Alloying Approach

Previous research has shown that multi-principal element alloys (MPEAs) using chromium, molybdenum, niobium, tantalum, titanium, vanadium, and zirconium can form stable body-centered-cubic (BCC) structures across a large temperature region (25°C to 1000°C). This is the same crystal structure as γ-uranium (U), which has shown desirable thermal and irradiation behavior in previous alloy fuel research. It is hypothesized then that the MPEA alloying approach can be used to produce a stable BCC uranium-bearing alloy and to retain its stability throughout anticipated operating regimes of power-producing reactors. Candidate elements were assessed using Monte Carlo N-Particle (MCNP) analysis to determine uranium densities necessary to make the alloy an economically viable fuel compared to conventional fuel forms. Following neutronic considerations, materials property databases and empirical predictors were used to determine the compositions with a high potential to form a BCC solid solution alloy. The final four alloys were MoNbTaU 2 , MoNbTiU 2 , NbTaTiU 2 , and NbTaVU 2 , which were cast using arc melting of raw elemental foils and chunks. Characterization of the fabricated alloys included scanning electron microscopy, X-ray diffraction, energy dispersive X-ray spectroscopy, and transmission electron microscopy. The results showed a two-phase system with a U-rich matrix phase surrounding the refractory precipitates. The U phase was found to contain varying concentrations of the alloying elements and was a BCC γ-U phase. These results warrant further research to identify ideal compositions for use as an advanced alloy fuel.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2025

Fracture toughness measurement of ceramics with fuel pellet geometry

The crack initiation of nuclear fuel pellets, driven by extreme temperature gradients, is a critical factor impacting reactor performance. Although this fact is widely acknowledged, there is limited fracture toughness data for specimens with representative geometry and fabricated using relevant processing methods. Here, to address this, a new chevron-notched short-rod specimen configuration with diameter and length both equal to 10 mm, representative of a conventional fuel pellet and tested in tension, was developed in an attempt to validly measure Mode I fracture toughness, K Ic . Test calibration was carried out by testing polycrystalline ZrO 2 , SiC, and Si 3 N 4 ceramics fabricated with conventional fuel pellet geometry and known fracture toughnesses. The results suggest that the method described in this paper produces valid K Ic measurements using conventional ceramic fuel pellets.

Ceramics↗
DOE OSTI2024

Nanofabrication and inspection of fuel capsules for inertial confinement fusion

3D nanofabrication via Two-Photon Polymerization (TPP) provides a unique capability of flexibly fabricating complex structures over 1D-3D dimensions and µm-cm scales with resolutions below 100 nm. In the past years, the Laser-Assisted Nano Engineering (LANE) Group at the University of Nebraska-Lincoln (UNL) has been working closely with the Laboratory of Laser Energetics (LLE) in developing practical TPP approaches to fabricating various target structures for Inertial Confinement Fusion (ICF). At the same time, fuel capsules for ICF experiments should be inspected for surface and wall-embedded defects. Plastics materials [e.g., for example polystyrene (PS)] are the common materials used to make fuel capsules. However, during their manufacturing, capsules usually contain defects (vacuoles) embedded inside the shell walls, which may distort the implosion processes and influence the ICF performance of the capsules. The size of vacuoles is usually in a range from 100 to 2000 nm. Coherent anti-Stokes Raman scattering (CARS) microscope offers the capabilities of inspecting and characterizing the capsule defects. Furthermore, cryo-CARS microscopy was developed to explore how fuel isotope distributed inside target when icing that could not be diagnosed before.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Nuclear Materials Production [Slides]

This presentation covers the basics of the nuclear fuel cycle, mining and milling, enrichment technologies and processes, uranium fabrication, plutonium production, and basics of nuclear reactors.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2025

Impact of U-10Mo HALEU Fuel Element Tolerances on the Massachusetts Institute of Technology Reactor safety and operational performance – Neutronics

The U.S. is coordinating efforts for the conversion of six U.S. high performance research reactors (USHPRR), including one critical assembly from highly enriched uranium (HEU) to low-enriched uranium (LEU). In order to continue the mission of these reactors, including the Massachusetts Institute of Technology Reactor (MITR), and achieve similar performance, high assay low-enriched uranium (HALEU) with a high-density metallic alloy of uranium with 10 wt% molybdenum (U-10Mo) is being considered. Following the preliminary design of the proposed MITR LEU fuel elements using the U-10Mo monolithic alloy, the impact of the fabrication specification was assessed. This work focuses on the analysis of select neutronics characteristics of the MITR LEU core as a function of the variation of the relevant fuel specification parameters (e.g., U-10Mo composition, fuel plate thickness, etc.). A separate article submitted to this journal addresses the impact on the thermal hydraulic performance. The analyses in these works are performed based on an all-LEU conversion management plan identified in previous work, in which only the proposed elements are utilized for achieving the conversion of MITR. The variations of two main neutronics characteristics are assessed as a function of the variability of the specification parameters resulting from the fabrication process: the MITR LEU core reactivity and the fuel cycle length. The main findings of this work show that the MITR core can meet the operational requirements during the LEU transition plan under the limiting fabrication parameter combinations considered. In addition, the analyses show that the dependency of the core neutronics characteristics on the specification parameters is highly linear within the specification tolerances. The rates of variation are reported in detail for each parameter and can serve as a powerful tool for future MITR fuel management in cases such as when HALEU supply is established that may allow additional cycle length or other operational benefits.

Conversion↗
DOE OSTI2021

Ammonia-fed reversible protonic ceramic fuel cells with Ru-based catalyst

Abstract The intermediate operating temperatures (~400–600 °C) of reversible protonic ceramic fuel cells (RePCFC) permit the potential use of ammonia as a carbon-neutral high energy density fuel and energy storage medium. Here we show fabrication of anode-supported RePCFC with an ultra-dense (~100%) and thin (4 μm) protonic ceramic electrolyte layer. When coupled to a novel Ru-(BaO) 2 (CaO)(Al 2 O 3 ) (Ru-B2CA) reversible ammonia catalyst, maximum fuel-cell power generation reaches 877 mW cm −2 at 650 °C under ammonia fuel. We report relatively stable operation at 600 °C for up to 1250 h under ammonia fuel. In fuel production mode, ammonia rates exceed 1.2 × 10 −8 NH 3 mol cm −2 s −1 at ambient pressure with H 2 from electrolysis only, and 2.1 × 10 −6 mol NH 3 cm −2 s −1 at 12.5 bar with H 2 from both electrolysis and simulated recycling gas.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2025

SPC-3184 Rev 7 MARVEL Reactor Structures Build to Print Fabrication Specification

Idaho National Laboratory (INL) is developing a microreactor to produce electrical power utilizing a small nuclear core and under the Microreactor Application Research Validation and Evaluation (MARVEL) program. This procurement specification defines the requirements for fabrication of the MARVEL Primary Coolant System (PCS), Fuel and Core System (FCS), and Reactor Sub-Structure Assemblies, including the Upper Confinement Structure.

21 - SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLAN↗
DOE OSTI2024

Design of Mini-Plate-1 Irradiation Test for Qualification of High-Density, Low-Enriched U-10Mo Monolithic Fuel

The United States High Performance Research Reactor project is tasked with fuel development and qualification leading to conversion of higher power research and test reactors in the US from high-enriched uranium (HEU) to low-enriched uranium (LEU) fuels. Here, this manuscript identifies the functional and operational design requirements of the first miniature test plate (mini-plate [MP]) irradiation campaign (MP-1) of commercially fabricated LEU U-10Mo monolithic plate-type fuel and is the precursor to a large parametric mini-plate test (MP-2) aimed at producing the data to support regulatory qualification of the LEU U-10Mo monolithic fuel. The manuscript (1) provides a general description of the selected U-10Mo LEU fuel and (2) defines the overall experiment design and functional requirements to accomplish the specific test objective of MP-1, which is to confirm that the commercially manufactured LEU U-10Mo monolithic fuel meets the established requirements of geometric stability, mechanical integrity and stable and predictable behavior. The fuel testing parameters are established by the need to bound performance behavior within the operational envelope of the reactors being converted.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2025

Renewable Activated Carbon Sorbent for the Desulfurization of Liquid Fuels

In recent years, significant efforts have been devoted to the reduction of sulfur levels in transportation fuels in order to reach regulatory limits and reduce the emission of harmful SO x into the atmosphere. In particular, adsorptive desulfurization (ADS) has the potential to produce zero-sulfur fuels without the need for a high energy intensity process, high H 2 pressure, and long process times as in the case of other technologies such as hydrodesulfurization. In this work, we have demonstrated the effectiveness of renewable activated carbons derived from food waste (FWAC) for the ADS of model jet and diesel fuels. The optimal FWAC materials were those fabricated to maximize the micropore volume, providing available sites for the adsorption of dibenzothiophene (DBT) and dimethyldibenzothiophene (DMDBT). The FWAC had a greater sulfur adsorption capacity than commercial AC, Y zeolite sorbents, and AC derived from other biomass sources including miscanthus, coconut shell, and walnut shell. Elemental analysis suggests that the inorganic impurities inherent in food waste, notably K, Ca, P, and Na, may contribute to its improved sulfur adsorption compared to other AC materials. Microscopy and X-ray diffraction studies further demonstrated the presence of inorganic species on FWAC that may provide active sites for the chemisorption of sulfur molecules.

Adsorption↗