Materials technology program for a compact fast reactor for space power
Production engineering and compatibility tests of Ta-8W-2Hf clad UN nuclear fuel element for use in lithium cooled space power unit reactors
Gluyas, R. E.↗
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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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Employing MACS/ViBRANT as a Surrogate MARVEL Reactor for Startup Reactivity Tuning and Supervisory Control Processes
Advanced nuclear reactors are a key part of the future of nuclear energy both in the United States and globally. They offer unique benefits for various energy-demanding applications, including use in remote locations, compact size, modular manufacturing, remote monitoring, low and/or variable power rating operation, and reliance on novel technologies to enhance operational safety. To achieve economic feasibility, advanced reactors must significantly reduce their workforces in comparison with the current fleet. Achieving this reduction will occur through reducing staff workloads using technology to achieve autonomous or semi-autonomous operations, demonstrated by comprehensive testing and validation activities. These operations will require both software and hardware platforms during the design and testing phases. While simulations are useful during the design phase, their performance can significantly deviate during actual deployment on hardware. This report presents the outcomes of a collaborative technical initiative between the U.S. Department of Energy (DOE) Microreactor Program (MRP) and Advanced Sensors and Instrumentation (ASI) Program. The collaboration utilized the Microreactor Automated Control System (MACS) hardware platform to bridge the gap between theoretical reactor design and actual startup and control operations. Two key use cases were investigated: facilitating the startup testing period and demonstrating supervisory control. The first use case details the key Microreactor Applications Research Validation and Evaluation (MARVEL) reactor startup physics testing activities conducted using the MACS platform. These activities included drum worth measurements, shutdown margin assessment, temperature feedback analysis, and scram time evaluation, as well as unique testing that would apply to the MARVEL reactor to demonstrate the testing methodologies in a low-risk environment. The MACS platform, serving as a surrogate representation of the MARVEL reactor, proved instrumental in performing these tests. The exercise revealed aspects that led to optimized processes, refined hardware design, and enhanced base software capabilities. By maturing methods and technologies in this manner, the initiative promises to reduce wasted time in the actual on-site reactor deployment effort, thereby saving significant time and resources. The second use case focuses on the development and implementation of supervisory control methods aimed at managing core tilt, which can result from asymmetrical operations or manufacturing imperfections in fuel rods or reactivity control devices. A key objective was to assess and compare the use of artificial intelligence (AI) for supervisory control. The effort aimed to define the role of supervisory control to enhance performance without risking control instability. This effort explored three distinct approaches: rules-based (RB) methods, optimization techniques, and reinforcement learning (RL) algorithms. Each approach was evaluated for its ease of implementation, its usability, and its effectiveness in responding to asymmetries in neutron flux. Comparative analysis of these approaches provided valuable insights into their applicability and effectiveness, offering a robust framework for advanced reactor operations. Together, these two use cases highlight the potential of hardware test beds to help streamline the design, operation, and control of advanced nuclear reactors. This collaborative effort underscores the importance of continued innovation and experimentation in achieving the next generation of safe, reliable, and economically viable nuclear energy solutions.
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Literature Review and Previous Flood Barrier Tests - Slide Package [Slides]
This presentation is prepared for NRC Flood Barrier Testing Workshop. The presentation covers an introduction of literature review, plant-specific flood barrier types and performance, and examples of previous flood barrier tests.
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AGC-2 Specimen Post Irradiation Data Package Report
This report documents results of the post-irradiation examination material property testing of the creep, control, and piggyback specimens from the irradiation creep capsule Advanced Graphite Creep (AGC)-2 are reported. This is the second of a series of six irradiation test trains planned as part of the AGC experiment to fully characterize the neutron irradiation effects and radiation creep behavior of current nuclear graphite grades. The AGC-2 capsule was irradiated in the Idaho National Laboratory Advanced Test Reactor at a nominal temperature of 600°C and to a peak dose of 5 dpa (displacements per atom). One half of the creep specimens were subjected to mechanical stresses (an applied stress of either 13.8, 17.2, or 20.7 MPa) to induce irradiation creep. All post-irradiation testing and measurement results are reported with the exception of the irradiation mechanical strength testing, which is the last destructive testing stage of the irradiation testing program. Material property tests were conducted on specimens from 15 nuclear graphite grades using a similar loading configuration as the first AGC capsule (AGC-1) to provide easy comparison between the two capsules. However, AGC-2 contained an increased number of specimens (i.e., 487 total specimens irradiated) and replaced specimens of the minor grade 2020 with the newer grade 2114. The data reported include specimen dimensions for both stressed and unstressed specimens to establish the irradiation creep rates, mass and volume data necessary to derive density, elastic constants (Young’s modulus, shear modulus, and Poisson’s ratio) from ultrasonic time of flight velocity measurements, Young’s modulus from the fundamental frequency of vibration, electrical resistivity, and thermal diffusivity and thermal expansion data from 100–500°C. No data outliers were determined after all measurements were completed. A brief statistical analysis was performed on the irradiated data and a limited comparison between pre- and post-irradiation properties is presented. A more complete evaluation of trends in the material property changes, as well as irradiation-induced creep due to irradiation, temperature, and applied load on specimens will be discussed in later AGC-2 post-irradiation examination analysis reports.
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Upcoming irradiation of ultrasonic and fiber optic sensors in the MITR - 361
Fiber optic and ultrasonic technologies offer the potential for high accuracy and resolution in-pile measurement of a range of parameters, including geometry changes, temperature, crack initiation and growth, gas pressure and composition, and microstructural changes. These technologies, which have performed successfully in out-of-pile tests, have not been well qualified in a test reactor environment. The uncertainty of successful operation of instruments at this level of development has typically been a significant barrier to in-core deployment. Many Department of Energy-Office of Nuclear Energy (DOE-NE) programs are exploring the use of these technologies to provide enhanced sensors for irradiation testing. For example, the ability of small diameter ultrasonic thermometers (UTs) to provide a temperature profile in candidate metallic and oxide fuel would provide much needed data for validating new fuel performance models. The National Scientific User Facility (NSUF) is sponsoring a project to evaluate the performance of promising temperature sensors based on ultrasound and on fiber optics during an upcoming irradiation test in the Massachusetts Institute of Technology Research Reactor (MITR). Several types of thin-wire metallic waveguide ultrasonic thermometers will be tested along with fiber optic temperature sensors using regenerated Fiber-Bragg Grating technology. Additionally, samples of several new optical materials which are potentially much more radiation tolerant than commonly used fiber materials, such as silica, will be included and analyzed post-irradiation. The irradiation is a collaborative effort between researchers from Idaho National Laboratory, the French Alternative Energies and Atomic Energy Commission, the University of Pittsburgh, the Massachusetts Institute of Technology, and AFO Research, Inc. (authors)
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Methodology for Stress-Controlled Fatigue Test Under In-Air and Pressurized Water Reactor Coolant Water Condition and to Evaluate the Effect of Pressurized Water Reactor Water and Loading Rate on Ratcheting [Methodology for Stress-Controlled Fatigue Test Under In-Air and PWR Coolant Water Condition and to Evaluate the Effect of PWR Water and Loading Rate on Ratcheting]
Here, this work investigates the behavior of 316 stainless steel (SS) under stress-controlled low cycle fatigue loading. Several fatigue experiments are conducted under different environment such as in air at 300°C and primary loop water conditions for a pressurized water reactor (PWR). Two different loading conditions are also employed to examine the effect of stress rate on material hardening and ratcheting. During PWR water test, actuator position measurements are used to determine the strain of the specimen. Under PWR environment, 316 SS is found to ratchet to a significantly greater degree compared with in air. At slow stress rate, higher amount of cyclic hardening is observed in 316 SS, and slow stress rate increases the rate of ratcheting. Results also indicate that 316 SS exhibits asymptotic strain response at higher stress loading which can cause material to behave very differently under same stress cyclic loading.
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Scaling methodologies and similarity analysis for thermal hydraulics test facility development for water-cooled small modular reactor
Small modular reactors (SMRs) represent a promising option for providing clean and sustainable energy due to their potential for enhanced safety, reduced capital costs, and increased siting flexibility. However, new reactor systems require the development and operation of representative scaled-down test facilities to support the verification and validation of system computer codes and models. Here this study reviews the research on scaling methodologies and similarity principles pivotal in developing non-nuclear integral effects test and separate effects test facilities for water-cooled SMRs. The study focuses on a review of the scaling methods, similarity approaches, and possible challenges posed by the unique and compact design features of integral-pressurized water reactor-type SMRs, and their representative test facilities. This study also reviews previous research related to scaling and similarity methodologies and provides insights into design considerations for achieving prototypic conditions in test facilities. The findings and recommendations emphasize the broader impact of appropriate scaling and similarity principles to ensure meaningful and transferable results from non-nuclear test facilities to accelerate the safe and efficient deployment of next-generation water-cooled SMRs.
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The Use of Acoustic Cavitation to Recovery High-Assay Low-Enriched Uranium (HALEU) form TRISO Fuel Particles
Recent interest in advanced nuclear reactor concepts such as small modular reactor (SMR), micro reactor or versatile test reactor (VTR) has increased the demand for high-assay, low-enriched uranium (HALEU). The sustainable management of this resource is integral to successful resurgence of nuclear energy in the United States. The High Temperature Gas-Cooled Reactor (HTGR) concept is a prime candidate for deployment of the new fleet of SMRs, and it will become very important to have a simple and cost-effective technology to recover HALEU from short-burned, defective, or off-specification TRISO fuel particles. We have attempted to harness the high energetics of sonochemistry to penetrate the TRISO fuel particles and recover HALEU via acidic leaching. While the TRISO fuel particle design is inherently “bulletproof,” (due to the silicon carbide (SiC) layer), ultrasonic irradiation may hold the key to convenient access to its valuable contents. Sonochemistry is a field of chemistry based on acoustic cavitation, which is the formation, growth, and collapse of bubbles in liquid media.1,2 The oscillating bubble formation is produced by irradiation of a liquid media with sound waves. Literature reports indicate that collapsing bubbles induced by cavitation produces intense local heating, high pressures, and short lifetimes.1 These localized hot spots reach temperatures of ˜5000 K, pressures approaching 500 atm, and heating and cooling rates exceeding 100 K/s.1 The large temperature and pressure differentials deliver high-energy heating and microscopic explosive shock waves to a liquid media or liquid/solid interface. Cavitation at the surface of a solid in solution induces a deformation in the bubble cavity upon collapse. This deformation reinforces the bubble structure and sends a fast-moving stream of liquid through the cavity at the surface with velocities greater than 100 m/s.3 These energetic impacts have demonstrated an ability to penetrate or simply destroy the SiC shell surrounding the uranium fuel kernel during prolonged exposures to the high-power acoustic waves. Some preliminary results demonstrating HALEU recovery using sonochemistry techniques will be reported.
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Transient Testing of Nuclear Fuels Performed in the Original Operation of TREAT (First Edition)
This report provides summary information on a selected set of key historic experiment series which were performed in the Transient Reactor Test Facility (TREAT) during its original operation from 1959-1994. The selected experiments are intended to illustrate the diversity in experiments which have been performed, and the range in capabilities of the TREAT reactor. Knowledge of those prior experiments provides a foundation for qualification and safety evaluation of numerous fuel forms already tested in TREAT, planning and designing new future tests, and for future TREAT operation.
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Accelerated Irradiation Testing and Post-Irradiation Characterization: U.S.-Based Capabilities for Advanced Nuclear Systems and Radioisotope Production
Irradiation experiments and post-irradiation examinations, together referred to as irradiation testing (IRT), are prerequisites for nuclear fuel and material qualification for the deployment of new and advanced reactors, as well as radioisotope production, thereby ensuring regulatory compliance. Qualified research and test reactors (RTRs) and testing facilities are essential to enable IRT to verify performance and safety under prototypical reactor conditions. In the past, qualification of new fuels or structural materials required about 20 years. Synergist strategies, advanced tools, and qualified methods are needed to greatly reduce this timeframe of IRT and radioisotope production. This study, termed accelerated-IRT, focuses on identifying gaps and leveraging U.S.-based RTRs and material testing capabilities, leveraging the preliminary evaluation and qualification of selected RTRs to provide a generic as well as specific-case solution paths forward, ensuring adherence to stringent regulatory standards. Furthermore, IRT and radioisotope production utilizing qualified RTRs necessarily includes modeling and simulation to support the design (i.e. neutronics, thermal, and structural aspects) and manufacturing of irradiation test specimens, vehicles, capsules, apparatuses, and flow loops. In addition, IRT can be improved by applying advanced manufacturing techniques and in-pile sensors and instrumentation, as discussed in this study.
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Confirmatory LBL Analysis of AGR-5/6/7 Compacts and Over-Coated Particles BWXT Batches 11034, 14154C, 14156C, AND 14156D
Fuel for the Advanced Gas Reactor Fuel Development and Qualification (AGR) Program’s AGR-5/6/7 irradiation test in the Idaho National Laboratory (INL) Advanced Test Reactor (ATR) was produced by BWX Technologies (BWXT) Nuclear Operations Group in Lynchburg, Virginia. Tristructural isotropic (TRISO) coatings were deposited using a 150-mm-diameter production-scale fluidized-bed chemical vapor deposition (CVD) furnace on 425-μm-nominal-diameter spherical kernels from Lot J52R-16-69317 containing a mixture of 15.5% 235U low-enriched uranium carbide and uranium oxide (UCO). The TRISO coatings consisted of four consecutive CVD layers: a ~50% dense carbon buffer layer with 100-μmnominal thickness, a dense inner pyrolytic carbon (IPyC) layer with 40-μm-nominal thickness, a silicon carbide (SiC) layer with 35-μm-nominal thickness, and a dense outer pyrolytic carbon (OPyC) layer with 40-μm-nominal thickness. TRISO-coated particle Lot J52R-16-98005 was over-coated with a graphite/resin blend and these over-coated particles were pressed in half-inch-diameter, one-inch-long cylindrical compacts. Two packing fractions (PF) were produced, 40%PF and 25%PF, where the TRISO particle volume made up approximately 40% and 25% of the total compact volume, respectively. The AGR-5/6/7 Fuel Specification, SPC-1352 [Marshall 2016], provides the requirements necessary for acceptance of the fuel manufactured for the AGR-5/6/7 irradiation test. Quality control (QC) acceptance testing for all AGR-5/6/7 composited lots and single batches was performed by BWXT, with the exception of pyrolytic carbon (PyC) anisotropy and defective IPyC fraction in the TRISO candidate batches and final composite, which were measured at the Oak Ridge National Laboratory (ORNL) and reported in ORNL/TM-2017/036 [Hunn et al. 2017] and ORNL/TM-2017/037 [Helmreich et al. 2017a].
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FY2021 July Monthly Status Report for the Versatile Test Reactor
FY2021 July Monthly Status Report for the Versatile Test Reactor
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Update on Development of a U.S. Rail Transport Capability for Spent Nuclear Fuel and High-Level Waste - 18518
The U.S. Department of Energy, Office of Nuclear Energy (DOE-NE) is laying the groundwork for implementing an integrated nuclear waste management system. This includes preparing for future large-scale transport of spent nuclear fuel (SNF) and high-level radioactive waste (HLW) since transport will be a necessary component of an integrated waste management system. This paper provides an overview of the progress to date, and discussion of the path forward related to designing, fabricating and testing prototype railcars for rail transport of SNF from commercial nuclear power reactor sites when a receiving site becomes operational. (authors)
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Chemistry and Reactivity of Oxide Films on Aluminum Clad Test Reactor Fuels - 19294
This paper describes recent work performed to assess the degradation of aluminum spent nuclear fuel (ASNF) as part of an ongoing Department of Energy project. As part of a multi-task effort, this paper specifically describes efforts initiated in 2018 to better understand chemical phenomena and degradation in ASNF). In this paper experimental and modeling activities are described. The modeling effort presents initial results in two areas potentially influencing stability. Using an established electrolyte model based on experimental data, the solubility of aluminum as a function of temperature and pH was examined. This work describes interesting results for the minimum pH providing relevant data that was not available from the literature. It was found that solubility increases with temperature and that the minimum pH shifts to low pH with increase in temperature. The second area involves understanding the metallurgy of aluminum alloys during fuel drying. In this study, the temperature range from 100 deg. C to 300 deg. C was analyzed. Thermodynamic models predict that AA1100 will not experience significant phase changes while the more highly alloyed AA6061 and AA5052 may experience significant phase changes. These thermodynamic measurements establish a potential for phase changes during drying, however they do not predict the kinetics for such processes. Phase 1 of the experimental program has initiated and results are forthcoming. The test program will examine aluminum oxidation under anticipated dry storage conditions (temperature and humidity). Examination of localized corrosion due to tight crevices and galvanic contact (with stainless steel) will be included. Finally, water deliquescence will be assessed using thermogravimetric analysis with dynamic humidity profiles. (authors)
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MARVEL Reactor Fuel Performance Report
The Microreactor Applications Research Validation and EvaLuation (MARVEL) project is producing a high temperature liquid metal-cooled nuclear test bed at Idaho National Laboratory (INL) to ultimately improve the integration of microreactors to end-user applications. This ambitious effort seeks to design, authorize, construct, test, and operate the reactor within five years. In order to construct and operate the MARVEL reactor in a timely manner, the system will utilize materials and component designs which have already been used, qualified, or licensed from previous reactors. The MARVEL reactor will be located at the INL Transient Reactor Test (TREAT) facility in the north high-bay equipment pit and will use the existing 304 stainless steel-clad U-ZrH1.6 pin-type fuel system developed by General Atomics and purchased from TRIGA International. This fuel has been previously qualified under the United States Department of Energy’s (US DOE) Reduced Enrichment for Research and Test Reactors (RERTR) Program. Even though the regulator of the MARVEL reactor is the US DOE, the standards and overall approach recommended by the Nuclear Regulatory Commission is well-defined and utilized here. Following NUREG-1537 regulatory guidance, this report documents the authorization case for the MARVEL fuel system’s application to MARVEL and establishes stable and predictable fuel performance during the most thermophysically unfavorable conditions achievable in the MARVEL reactor. To that end, this report provides a comprehensive survey of the known thermophysical properties, performance, and quantitative relationships associated with the MARVEL reactor fuel element and uses this information to determine its mechanical integrity and risk of reaching unacceptable conditions during the most extreme accident scenarios predicted for the reactor using the most conservative assumptions available. The information contained herein is compiled from a combination of historical reports and peer reviewed scientific publication manuscripts. Known mechanisms under which the fuel is susceptible to failure are highlighted and compared to conditions that could exist in the MARVEL reactor during an unanticipated transient or accident scenario. The two scenarios considered for analysis in this report are (1) an unprotected loss of flow accident and (2) a hypothetical unprotected loss of coolant accident during the loss of flow accident. Preliminary 2D steady-state analyses herein indicate that both fuel-cladding chemical interactions and fuel-cladding mechanical interactions are negligible throughout the fuel’s operational cycle under both normal and high temperature accident scenario conditions. Although higher fidelity 3D time-dependent modeling and simulations are planned, the following may be concluded presently. The MARVEL fuel element maintains its geometric stability and structural integrity during the most extreme accident scenarios predicted for the MARVEL reactor. The hoop stress during the unprotected loss of flow accident reaches about -1.27 MPa; this negative stress indicates that it is compressive rather than tensile. The compressive stress is a result of the NaK pressure on the outside of the fuel element, caused by the restricted thermal expansion of the NaK coolant, exceeding the internal pressures generated inside of the fuel element. The hoop stress generated in the cladding during the unprotected loss of coolant accident reaches a maximum of about approximately 10 MPa, which is nearly an order of magnitude less than the predicted yield strength of the cladding under high-temperature accident scenario conditions. Calculations were compared with results from high performance computational simulations using BISON and are in very close agreement. A conservative MARVEL fuel meat peak temperature limit of 900 °C is recommended presently, which is about 180 °C higher than the peak fuel temperature predicted to occur during the most extreme accident. Based on the known properties and behavior of the MARVEL fuel element, the fuel successfully meets its design and safety requirements under normal and most extreme accident conditions with a large safety margin.
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Neutron fluxes in test reactors
Communicate the fact that high-power water-cooled test reactors such as the Advanced Test Reactor (ATR), the High Flux Isotope Reactor (HFIR) or the Jules Horowitz Reactor (JHR) cannot provide fast flux levels as high as sodium-cooled fast test reactors. The memo first presents some basics physics considerations about neutron fluxes in test reactors and then uses ATR, HFIR and JHR as an illustration of the performance of modern high-power water-cooled test reactors.
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Neutronic Consideration of TREAT Facility Fuel SiC Recladding
The Transient Reactor Test (TREAT) Facility is an air-cooled reactor composed of graphite-urania fuel encapsulated in zirconium alloy canisters and surrounded by ~2 ft (~61 cm) of nuclear grade graphite. The primary role of TREAT is to provide in-pile nuclear-heated safety research via transient testing [1]. Benchmark efforts have demonstrated sensitivity of TREAT neutronics models to graphite cross section data and key neutron poisons found in the fuel assemblies [2]. During fabrication of TREAT fuel assemblies, a small concentration of boron was inadvertently introduced with variable concentration into the aggregate of fuel blocks prepared for TREAT use. The concentration of boron, and its respective uncertainty, represent the most sensitive component in a neutronics study; unfortunately, nothing can be done to reduce or otherwise mitigate its impact. Hydrogen in the fuel blocks reduces the mean free path of the core and its true quantity and uncertainty is approximated. The hydrogen remains from pitch binder used in the fuel fabrication process and was not completely released due to incomplete fuel graphitization. Destructive fuel testing is necessary to quantify the actual hydrogen content and to improve benchmark model quality. A third neutron poison of some significance is the hafnium impurity in the Zircaloy-3 (Zry-3) assembly cladding. The quantity of hafnium is expected to be within nominal manufacturing limits for nuclear grade zircaloy. Recladding the fuel assemblies with material that is less neutron absorbing is expected to benefit reactor neutron economy. Moreover, TREAT’s total transient energy is restricted based on the rate of Zry-3 oxidation in TREAT’s air coolant environment. Hence, cladding with more benign air reaction kinetics could dramatically uprate the facility’s experimental capability. Silicon carbide (SiC) has been proposed as a candidate material for recladding TREAT assemblies, as SiC/SiC demonstrate favorable properties within nuclear environments [3]. The current operational limits of TREAT are restricted by the oxidation of Zry-3. Change of the cladding to SiC could feasibly double the current temperature limitation. Recladding opportunities allow for previously damaged fuel assemblies to be returned to service, as Zry-3 is not commercially available. The initial effort required to consider proceeding with any recladding effort is to neutronically characterize key reactor parameters while replacing Zry-3 with SiC. A characterization summary, with respective results, is provided herein.
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MCNP Analysis fo the Aqua-SETH Experiment in TREAT
The versatile Transient Reactor Test (TREAT) Facility’s capability to deliver customized transient nuclear power excursions gives researchers and developers a multitude of specialized testing options. In conjunction with reactorprescribed delivery of neutron flux, experiment design requires specimen packaging to meet TREAT safety containment requirements and experimenter test objectives. These objectives may range from the very simple separate effects tests (generally dry capsule) to the more complex integral scale testing wherein prototypic boundary or specimen reactor environment conditions are created. The historic MARK-III sodium flow loop that achieved thermalhydraulic prototypic test conditions serves as an example of the more complex experiment design package.
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