Search NASA⌕ Search

SEARCH · Search NASA

Results for “Cladding design”

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.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 451 records · Page 25

Nitride Fuel Potential for Power Uprates

This work presents the methodology and current results for design analysis of grid supported pressurized water reactor cores using uranium nitride (UN) fuel in square arrays. Uranium nitride has a higher theoretical density and higher thermal conductivity than uranium oxide, allowing for lower fuel temperatures, longer cycle length and higher power densities with similar enrichment. In order to avoid the UN and high temperature water reaction, silicon carbide cladding has been proposed in place of Zircaloy cladding. The analysis aims at finding the maximum thermal power over a range of bundle geometries (rod diameter and pitch). The same methodology is applied to the design of UO{sub 2} oxide fueled cores to provide a fair comparison of the achievable power rating between the two fuel types. Steady-state limits are considered, including fuel bundle pressure drop, minimum departure from nucleate boiling ratio (MDNBR), fuel temperature, fuel rod vibrations and pin fretting and sliding wear. Transients such as loss of flow and overpower accident will be considered. A steady state analysis was undertaken to determine the maximum achievable power that can be sustained by square array fuel assemblies loaded with nitride and oxide fuels with same or better safety performances as the reference design. Steady-state design limits were applied including MDNBR, fuel bundle pressure drop, fuel temperature, cumulative sliding and fretting wear. The major conclusions of this study are as follows: 1) It is possible to achieve significant power increase for UN and UO{sub 2} compared to the reference core power output of 3400 MWth with smaller but more numerous rods and higher pitch over diameter ratios. A power uprate of 25% can be reached according to the VIPRE-MATLAB interface for full core analysis with the same number of spacer grids, and 32% according to the new MATLAB script for single hot channel analysis, with five more spacer grids. For this latter core, a higher enrichment would be required. 2) The nitride fuel temperature constraint from dissociation doesn't influence steady state performances as other design constraints such as MDNBR and pressure loss are more restrictive. The oxide fuel temperature constraint from fission gas release is reached in part of the study domain, but not in the region that allows for possible uprates. 3) As a result, the thermal hydraulic performance of UN and UO{sub 2} are similar. Differences in possible power uprates will arise from fretting and sliding wear. Wear depends of the time spent by the fuel in the core, which depends on burnup and heavy metal inventory. UN being denser, it can allow for power uprates or increased cycle length. There is a trade off between power uprates and cycle length with regards to fuel pin wear. Reducing fuel pin wear by reducing cycle length can allow for higher thermal power. This affects the plants' economics as well. This work will be completed by a transient analysis using CASMO4E, SIMULATE3 and SIMULATE3k to model the neutronics of a nitride fueled core. The transient performances will be used to determine the maximum power uprates while performing as well or better during transients as the reference design. (authors)

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

Irradiation damage and IASCC of printed 316L for use as fuel cladding

Additive manufacturing is an area of increasing interest to the nuclear industry. It offers a number of benefits over traditional manufacturing methods, such as the ability to create complex geometries without the need for welds. In addition to the potential for creating nuclear structural components, additive manufacturing may be used to create novel fuel/cladding designs. However, printed steel behaves differently than traditional wrought material. A number of industries are already studying the effects of the printed microstructures on mechanical properties. For cladding material and some structural nuclear components, however, the nuclear industry must also understand the material response to irradiation. This work examines the irradiation damage and the irradiation assisted stress corrosion cracking behavior of both proton irradiated (1 and 5 dpa) printed 316L steel and wrought 316L steel that were irradiated side by side at the Michigan Ion Beam Laboratory. As orientation with respect to the build direction can affect the mechanical properties of printed metal, specimens were taken from multiple orientations within the printed steel. For the IASCC testing, specimens were strained to 4% in simulated BWR NWC water (288°C, 0.2 µS/cm). TEM, SEM and X-ray microCT were used to examine coupons of the material as well as tensile bars used in the IASCC testing. This paper will show the key findings from this work, namely the IASCC response of printed metal (as compared to wrought), as well as the effects of the printed microstructure (such as the pre-existing voids) on the irradiation damage.

36 MATERIALS SCIENCE↗

BISON Validation to In-Situ Cladding Burst Test and High Burnup LOCA Experiments

The process to develop and qualify nuclear fuels for commercial nuclear application requires fundamental material development, characterization, and design; out-of-pile testing on unirradiated materials; integral fuel rod irradiations, testing, and post irradiation examinations (PIEs); and transient analyses. The historical approach depends on the generation of large empirical datasets and series of integral fuel rod irradiations, and this approach ultimately takes approximately 20 years—or sometimes longer—to acquire data through extensive sequential testing. Thus, the qualification and eventual deployment of new fuel systems constitute a long and drawn-out process. However, recent technological advancements have provided researchers the opportunity to perform out-of-cell, in-situ measurements to assess material performance for the duration of the experiment. One such example of this capability is the use of digital image coordination and thermal imaging to assess Zircaloy cladding performance under a simulated loss-of-coolant accident (LOCA) transient condition. In general, the in-situ measurements provide high-fidelity strain, strain rates, and temperature surface maps. This is critical for the United States nuclear industry, which is actively developing a technical basis to support extending the peak rod average burnup from 62 to ~75 GWd/tU and the deployment of accident-tolerant fuel. However, the Nuclear Regulatory Commission, through their research information letter, outlined a number of technical issues for the industry to address before extending burnup. One topic of specific interest is understanding the cladding balloon and rupture geometry during the LOCA heatup phase. Leveraging these advanced in-situ capabilities, this work intends to use insitu data generated from a simulated LOCA in the Severe Accident Test Station at Oak Ridge National Laboratory to better understand high-temperature creep and its impact on Zircaloy balloon and rupture performance. This work used the BISON fuel performance code to compare BISON’s high-temperature creep model predictions to in-situ data and identify limitations and gaps within the model. Additionally, BISON will subsequently be used to simulate relevant high-burnup LOCA tests. The results will be analyzed and compared to the available post-test data in a manner consistent with the approach outlined in the Nuclear Regulatory Commission research information letter.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Establishment of the roadmap for chlorination process development for zirconium recovery and recycle

Process development studies are being conducted to recover, purify, and reuse the zirconium (about 98.5% by mass) in used nuclear fuel (UNF) zirconium alloy cladding. Feasibility studies began in FY 2010 using empty cladding hulls that were left after fuel dissolution or after oxidation to a finely divided oxide powder (voloxidation). In FY 2012, two industrial teams (AREVA and Shaw-Westinghouse) were contracted by the Department of Energy Office of Nuclear Energy (NE) to provide technical assistance to the project. In FY 2013, the NE Fuel Cycle Research and Development Program requested development of a technology development roadmap to guide future work. The first step in the roadmap development was to assess the starting point, that is, the current state of the technology and the end goal. Based on previous test results, future work is to be focused on first using chlorine as the chlorinating agent and secondly on the use of a process design that utilizes a chlorination reactor and dual ZrCl{sub 4} product salt condensers. The likely need for a secondary purification step was recognized. Completion of feasibility testing required an experiment on the chemical decladding flowsheet option. This was done during April 2013. The roadmap for process development will continue through process chemistry optimization studies, the chlorinated reactor design configuration, product salt condensers, and the off-gas trapping of tritium or other volatile fission products from the off-gas stream. (authors)

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Irradiation Embritlement in Alloy HT-­9

HT-9 steel is a candidate structural and cladding material for high temperature lead-bismuth cooled fast reactors. In typical advanced fast reactor designs fuel elements will be irradiated for an extended period of time, reaching up to 5-7 years.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

ATF Neutron Irradiation Program Technical Plan

The Japan Atomic Energy Agency (JAEA) under the Civil Nuclear Energy Working Group (CNWG) is engaged in a cooperative research effort with the U.S. Department of Energy (DOE) to explore issues related to nuclear energy, including research on accident-tolerant fuels and materials for use in light water reactors. This work develops a draft technical plan for a neutron irradiation program on the candidate accident-tolerant fuel cladding materials and elements using the High Flux Isotope Reactor (HFIR). The research program requires the design of a detailed experiment, development of test vehicles, irradiation of test specimens, possible post-irradiation examination and characterization of irradiated materials and the shipment of irradiated materials to JAEA in Japan. This report discusses the technical plan of the experimental study.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Capture of Tritium Released from Cladding in the Zirconium Recycle Process

Zirconium may be recovered from the Zircaloy® cladding of used nuclear fuel (UNF) for recycle or to reduce the quantities of high-level waste destined for a geologic repository. Recovery of zirconium using a chlorination process is currently under development at the Oak Ridge National Laboratory. The approach is to treat the cladding with chlorine gas to convert the zirconium in the alloy (~98 wt % of the alloy mass) to zirconium tetrachloride. A significant fraction of the tritium (0–96%) produced in nuclear fuel during irradiation may be found in zirconium-based cladding and could be released from the cladding when the solid matrix is destroyed by the chlorination reaction. To prevent uncontrolled release of radioactive tritium to other parts of the plant or to the environment, a method to recover the tritium may be required. The focus of this effort was to (1) identify potential methods for the recovery of tritium from the off-gas of the zirconium recycle process, (2) perform scoping tests on selected recovery methods using nonradioactive gas simulants, and (3) select a process design appropriate for testing on radioactive gas streams generated by the engineering-scale zirconium recycle demonstrations on radioactive used cladding.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Analysis of Operating Strategies Using Different Target Designs For 238Pu Production

An engineering effort is underway to re-establish capability to produce 238Pu oxide at the kilogram scale in the United States. A multi-step batch process is being developed to produce this important material. Recently, a portion of this process was studied using discrete-event simulation tools to determine whether the conceptual process might achieve its yearly production goal. The study showed the conceptual process can meet the yearly production goal under some circumstances, but process improvements would be needed to ensure greater likelihood of success. This study extends the work performed previously by examining the effects of changing the reactor target design on the yearly process output. Two new reactor target configurations are considered an aluminum-clad reactor target containing 50% greater 237Np oxide content than the original target, and a zirconium alloy-clad target using no aluminum. The results indicate that use of the new aluminum-clad target configuration may allow the process to achieve the same yearly production goal in less time using fewer targets. If the zirconium alloy-clad target is used, then even fewer targets would be needed to reach the production goal, but some process changes would be required to handle the zirconium cladding. The number of days needed to process a target batch to completion, and the steady state 238Pu oxide production rate, for each configuration are compared to the results from the initial simulation study.

campaign↗

Thermo-physical Properties of U-10Mo Monolithic Fuel

Monolithic fuel is a candidate fuel form that is being considered for the conversion of high-performance research reactors. This plate-type fuel consists of a high-density, U-Mo fuel in a monolithic form that is sandwiched between zirconium diffusion barriers and encapsulated in an aluminum cladding. To date, many plates were irradiated with a satisfactory irradiation performance, demonstrating that the conceptual design works. The program is now moving to the qualification phase, a predecessor to the timely conversion of the target reactors. To qualify this fuel system, the program must show that the fuel plates have predictable behavior, meet the safety standards, and perform well in reactors. The requirement of a satisfactory irradiation performance under normal operating conditions is primarily demonstrated by a successful testing. To demonstrate that the fuel system has a predictable behavior, the several key material properties should be quantified accurately since these properties are needed to estimate the thermal and mechanical behavior of the fuel system. Although, there is a large set of thermophysical property data available for unirradiated material, the property data for irradiated fuel is scarce. Since irradiation causes drastic effects in material, a significant change in material properties occurs. Consequently, using representative degradation models becomes essential for accurate performance assessments. This work examines thermal conductivity of U-10Mo, by evaluating recent experimental data from the literature and available theoretical models. The study has discovered inconsistencies in the literature data, revealing that previously developed theoretical models fail to predict the thermal conductivity of irradiated fuel.

42 ENGINEERING↗

Pre-Transient Characterization of Historic EBR-II Pins for Transient Testing

Current interest in sodium-cooled fast reactor (SFR) designs, such as TerraPower’s Natrium Reactor, has highlighted the need for advanced reactor fuel technology development. Modern U-Zr and U- Pu-Zr pin designs are primary candidates to fuel SFRs and boast high fuel utilization capacity, increased fuel-cladding compatibility, and improved safety through inherent feedback mechanisms. Despite over 60 years of metallic fuel irradiation, uncertainties exist in the performance of the fuel system, particularly under transient overpower (TOP) and loss of flow (LOF) scenarios. Throughout historical testing within the Experimental Breeder Reactor II (EBR-II) and the Fast Flux Test Facility (FFTF), fuel behavior has demonstrated benign response to transient reactor conditions; however, accurate predictions of failure thresholds to inform operational limitations rely heavily on fuel composition, burnup, and irradiation history. In expanding TOP and LOF testing, the Transient Heat sink Overpower Response (THOR) Capsule will be used to test modern fuel technologies in a static sodium environment in the Transient Reactor Test (TREAT) Facility. The THOR capsule is highly instrumented and will provide time-dependent thermal behavior of SFR fuel pins subjected to accident conditions within TREAT. The THOR-Metallic (THOR- M) campaign aims to validate and expand historical TOP and LOF testing on high burnup U-Zr and U-Pu- Zr fuel alloys previously irradiated in EBR-II by running the rods to failure. This contribution focuses primarily on the pre-transient engineering-scale destructive and non- destructive characterization that has been conducted on both the test and sibling pins used for the TOP and LOF tests. All pins underwent visual examination, neutron radiography, element contact profilometry, and precise gamma scan. The sibling pins used for each test were further analyzed using gas assay, sampling, and recharge analysis (GASR), and optical microscopy. The results from each technique confirmed that the fuel pins were intact and devoid of any atypical developments when compared to historical data. Additionally, the analyzed measurements establish a baseline for comparison to post-transient analysis. Key fuel behaviors quanitifed include axial elongation of the fuel column, diametral strain of the pin, patterns in fluff structure geometry, changes in axial isotope distribution, evolution of constituent redistribution, porosity, and fission gas release. The pre-transient measurements and changes attributed to transient behavior from post-transient measurement will be compared to historical data to capture the behavioral dependence on composition, burnup, and irradiation history. Results from this work advance the initiatives of the THOR-M campaign, which aid in informing fuel performance models and establishing safety criteria for SFR operational limits. The novel combination of test environment, in-situ instrumentation, and comprehensive suite of characterization methods provides greater understanding of transient fuel behavior. Overall, information on the time and condition of pin failure for high burnup U-Pu-Zr will greatly expand the limited existing TOP and LOF test data.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Pre-Transient Characterization of Historic EBR-II Pins for Transient Testing

Current interest in sodium-cooled fast reactor (SFR) designs, such as TerraPower’s Natrium Reactor, has highlighted the need for advanced reactor fuel technology development. Modern U-Zr and U- Pu-Zr pin designs are primary candidates to fuel SFRs and boast high fuel utilization capacity, increased fuel-cladding compatibility, and improved safety through inherent feedback mechanisms. Despite over 60 years of metallic fuel irradiation, uncertainties exist in the performance of the fuel system, particularly under transient overpower (TOP) and loss of flow (LOF) scenarios. Throughout historical testing within the Experimental Breeder Reactor II (EBR-II) and the Fast Flux Test Facility (FFTF), fuel behavior has demonstrated benign response to transient reactor conditions; however, accurate predictions of failure thresholds to inform operational limitations rely heavily on fuel composition, burnup, and irradiation history. In expanding TOP and LOF testing, the Transient Heat sink Overpower Response (THOR) Capsule will be used to test modern fuel technologies in a static sodium environment in the Transient Reactor Test (TREAT) Facility. The THOR capsule is highly instrumented and will provide time-dependent thermal behavior of SFR fuel pins subjected to accident conditions within TREAT. The THOR-Metallic (THOR- M) campaign aims to validate and expand historical TOP and LOF testing on high burnup U-Zr and U-Pu- Zr fuel alloys previously irradiated in EBR-II by running the rods to failure. This contribution focuses primarily on the pre-transient engineering-scale destructive and non- destructive characterization that has been conducted on both the test and sibling pins used for the TOP and LOF tests. All pins underwent visual examination, neutron radiography, element contact profilometry, and precise gamma scan. The sibling pins used for each test were further analyzed using gas assay, sampling, and recharge analysis (GASR), and optical microscopy. The results from each technique confirmed that the fuel pins were intact and devoid of any atypical developments when compared to historical data. Additionally, the analyzed measurements establish a baseline for comparison to post-transient analysis. Key fuel behaviors quanitifed include axial elongation of the fuel column, diametral strain of the pin, patterns in fluff structure geometry, changes in axial isotope distribution, evolution of constituent redistribution, porosity, and fission gas release. The pre-transient measurements and changes attributed to transient behavior from post-transient measurement will be compared to historical data to capture the behavioral dependence on composition, burnup, and irradiation history. Results from this work advance the initiatives of the THOR-M campaign, which aid in informing fuel performance models and establishing safety criteria for SFR operational limits. The novel combination of test environment, in-situ instrumentation, and comprehensive suite of characterization methods provides greater understanding of transient fuel behavior. Overall, information on the time and condition of pin failure for high burnup U-Pu-Zr will greatly expand the limited existing TOP and LOF test data.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

ROD INTERNAL PRESSURE QUANTIFICATION AND DISTRIBUTION ANALYSIS USING FRAPCON

The discharge rod internal pressure (RIP) and cladding hoop stress (CHS) distributions are quantified forWatts BarNuclearUnit 1 (WBN1) fuel rods by modeling core cycle design data, intercycle assembly movements, operation data (including modeling significant trips and downpowers), and as-built fuel enrichments and densities of each fuel rod in FRAPCON-3.5. An alternate model for the amount of helium released from zirconium diboride (ZrB2) integral fuel burnable absorber (IFBA) layers is derived and applied to FRAPCON output data to quantify the RIP and CHS for these fuel rods. SCALE/Polaris is used to quantify fuel rod-specific spectral quantities and the amount of gaseous fission products produced in the fuel for use in FRAPCON inputs. Fuel rods with ZrB2 IFBA layers (i.e., IFBA rods) are determined to have RIP predictions that are elevated when compared to fuel rod without IFBA layers (i.e., standard rods) despite the fact that IFBA rods often have reduced fill pressures and annular fuel blankets. Cumulative distribution functions (CDFs) are prepared from the distribution of RIP predictions for all standard and IFBA rods. The provided CDFs allow for the determination of the portion of WBN1 fuel rods that exceed a specified RIP limit. Lastly, improvements to the computational methodology of FRAPCON are proposed.

cladding hoop stress↗

Capture of Tritium Released from Cladding in the Zirconium Recycle Process

This report is issued as the first revision to FCRD-MRWFD-2016-000297. Zirconium may be recovered from the Zircaloy® cladding of used nuclear fuel (UNF) for recycle or to reduce the quantities of high-level waste destined for a geologic repository. Recovery of zirconium using a chlorination process is currently under development at the Oak Ridge National Laboratory. The approach is to treat the cladding with chlorine gas to convert the zirconium in the alloy (~98 wt % of the alloy mass) to zirconium tetrachloride. A significant fraction of the tritium (0–96%) produced in nuclear fuel during irradiation may be found in zirconium-based cladding and could be released from the cladding when the solid matrix is destroyed by the chlorination reaction. To prevent uncontrolled release of radioactive tritium to other parts of the plant or to the environment, a method to recover the tritium may be required. The focus of this effort was to (1) identify potential methods for the recovery of tritium from the off-gas of the zirconium recycle process, (2) perform scoping tests on selected recovery methods using non-radioactive gas simulants, and (3) select a process design appropriate for testing on radioactive gas streams generated by the engineering-scale zirconium recycle demonstrations on radioactive used cladding.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Coupled 3D-neutronics / thermal-hydraulics analysis of an unprotected loss-of-flow accident for a 3600 MWth SFR core

The core behaviour of a large (3600 MWth) sodium-cooled fast reactor (SFR) is investigated in this paper with the use of a coupled TRACE/PARCS model. The SFR neutron spectrum is characterized by several performance advantages, but also leads to one dominating neutronics drawback - a positive sodium void reactivity. This implies a positive reactivity effect when sodium coolant is removed from the core. In order to evaluate such feedback in terms of the dynamics, a representative unprotected loss-of-flow (ULOF) transient, i.e. flow run-down without SCRAM in which sodium boiling occurs, is analyzed. Although analysis of a single transient cannot allow general conclusions to be drawn, it does allow better understanding of the underlying physics and can lead to proposals for improving the core response during such an accident. The starting point of this study is the reference core design considered in the framework of the Collaborative Project on the European Sodium Fast Reactor (CP-ESFR). To reduce the void effect, the core has been modified by introducing an upper sodium plenum (along with a boron layer) and by reducing the core height-to-diameter ratio. For the ULOF considered, a sharp increase in core power results in melting of the fuel in the case of the reference core. In the modified core, a large dryout leads to melting of the clad. It seems that, for the hypothetical event considered, fuel failure cannot be avoided with just improvement of the neutronics design; therefore, thermal-hydraulics optimization has been considered. An innovative assembly design is proposed to prevent sodium vapour blocking the fuel channel. This results in preventing a downward propagation of the sodium boiling to the core center, thus limiting it to the upper region. Such a void map introduces a negative coolant density reactivity feedback, which dominates the total reactivity change. As a result, the power level and the fuel temperature are effectively reduced, and a large dryout is prevented. As a next step, the classical sodium plenum is replaced by a fission gas plenum (with lower sodium fraction), thus improving flow stability. Stable boiling at a steady power level is achieved in this final configuration. (authors)

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

BISON validation to in situ cladding burst test and high-burnup LOCA experiments

The process for developing and qualifying nuclear fuels for commercial nuclear application requires fundamental material development, characterization, and design; out-of-pile testing on unirradiated materials; integral fuel rod irradiations, testing, and postirradiation examinations; and transient analyses. The historical approach depends on the generation of large empirical datasets and series of integral fuel rod irradiations, and this approach ultimately takes ~20 years—or sometimes longer—to acquire data through extensive sequential testing. Thus, the qualification and eventual deployment of new fuel systems constitute a long process. However, recent technological advancements have provided researchers the opportunity to perform out-of-cell, in situ measurements to assess material performance for the duration of the experiment. One such example of this capability is the use of digital image coordination and thermal imaging to assess Zircaloy cladding performance under a simulated loss-of-coolant accident (LOCA) transient condition. In situ measurements generally provide high-fidelity strain, strain rates, and temperature surface maps. This is critical for the US nuclear industry, which is actively developing a technical basis to support extending the peak rod average burnup from 62 to ~75 GWd/tU and the deployment of accident-tolerant fuel. However, the US Nuclear Regulatory Commission (NRC) outlined in its research information letter several technical issues that the industry must address before extending burnup. One topic of specific interest is understanding the cladding balloon and rupture geometry during the LOCA heat-up phase. By leveraging these advanced in situ capabilities, this work used in situ data generated from a simulated LOCA to better understand high-temperature creep and its effect on Zircaloy balloon and rupture performance. Here, this work used the BISON fuel performance code to assess the high-temperature creep model predictions with in situ data.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Design Studies for the Optimization of 238 Pu Production in NpO 2 Targets Irradiated at the High Flux Isotope Reactor

Efforts to reestablish a domestic 238 Pu production capability in support of National Aeronautics and Space Administration mission objectives are ongoing throughout the U.S. Department of Energy complex. The Plutonium-238 Supply Project (PSP) was initiated in response to a report published by the National Research Council in 2011 stating that “without a restart of 238 Pu production, it will be impossible for the United States, or any other country, to conduct certain important types of planetary missions after this decade.” The PSP is targeting a sustained, constant production rate of 1.5 kg/year of heat source PuO 2 for several years. Design and optimization studies of 237 Np-bearing targets are underway at Oak Ridge National Laboratory (ORNL). It is anticipated that targets will be irradiated in ORNL’s High Flux Isotope Reactor (HFIR) and in the Advanced Test Reactor (ATR) at Idaho National Laboratory. A variety of target materials, containments, arrangements, and irradiation histories have been analyzed, and the results indicate that a sufficient quantity of 238 Pu can be produced in HFIR and ATR to fulfill the PSP’s constant production rate target. This paper focuses on the design and optimization of new target configurations containing pellets that are (1) ~93% of the theoretical density of NpO 2 , (2) loaded into pins of cladding materials that can be handled as solid waste following postirradiation 238 Pu recovery operations, (3) irradiated in various vertical experiment facility (VXF) locations in the HFIR permanent beryllium reflector, and (4) rotated within and/or moved to another VXF location following each HFIR operational cycle to maximize 238Pu production and minimize peak heat generation rates.

07 ISOTOPE AND RADIATION SOURCES↗

Application of Directed Energy Deposition for Transformational Challenge Reactor Core

The following report focuses on utilizing directed energy deposition (DED) for constructing the Transformational Challenge Reactor core. Multiple additive manufacturing processes are under investigation to evaluate the advantages and viability of each process for direct manufacturing of complex structures needed for future nuclear reactors. Technologies under investigation include binder jet, laser powder bed (LPB) fusion, electron beam powder bed fusion, and DED. Each process has advantages and disadvantages. For the core design, the current manufacturing approach consists of integrating LPB with DED. This hybrid manufacturing approach uses LPB for the core’s top and bottom manifold (where complexity is high) and DED for the manufacture of the cladding, where complexity is still high but geometric variability, size, and speed are better suited for DED. Research has focused on processing parameter development, evaluation of toolpath generation algorithms, core designs suitable for DED, manufacturing tolerances for integration of fuel elements, and seamless calibration and integration of LPB components into a DED build volume to create monolithic structures based on integrating these technologies. The following report highlights reactor core design as it relates to DED and experimental validation of test components necessary for finalizing the core design.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

An innovative accident tolerant LWR fuel rod design based on uranium-molybdenum metal alloy

The US Department of Energy is developing a uranium-molybdenum metal alloy Enhanced Accident Tolerant Fuel concept for Light Water Reactor applications that provides improved fuel performance during normal operation, anticipated operational occurrences, and postulated accidents. The paper is organized as follows. First, an overview of the design features of the U-Mo fuel concept is summarized, including the key attributes and technical challenges to be addressed through the research and development program. Second, recent results are provided on the triple extrusion of a depleted U-Mo fuel rodlet with a niobium liner and SS-316 cladding. A status is presented next on the high temperature water corrosion testing of short samples with pre-drilled cladding defects. Lastly, an assessment of the enhanced accident tolerance features is discussed that highlights the key performance attributes of the U-Mo fuel rod design. Scoping calculations have identified that the reduced stored energy of the U-Mo fuel at the initiation of a LOCA event may reduce core temperatures below 500-600 Celsius degrees during the early phase of the LOCA event. These preliminary evaluations find that the U-10Mo fuel design concept has many beneficial features that can meet or improve conventional LWR fuel performance requirements under normal operation, anticipated operational occurrences (AOOs) and postulated accidents.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗