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All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

Multilayer Architecture Barriers for High Temperature Nuclear Applications

Innovative thin film multilayer metal/ceramic barrier coatings have been developed by Argonne National Laboratory to protect fuel cladding against different phenomena that can be encountered under the harsh operating conditions of advanced nuclear reactors. One phenomenon is Fuel-Cladding Chemical Interaction (FCCI), which can represent a challenge to the performance of steel-clad metallic fuels in sodium-cooled fast reactors (SFRs), especially when operating to high burnups at elevated cladding temperatures, and long fuel residence time. Another phenomenon is the corrosion of zirconium-based cladding under prototypic boiling water reactor (BWR) conditions and associated cladding during off normal conditions, including loss of coolant accidents (LOCA). This work provides details of the development and testing of a thin film (few microns) multilayer metal/ceramic (CrY/Y 2 O 3 ) coatings on steel cladding and its performance against FCCI. The coating architecture evolved through systematic mechanical testing, radiation tolerance assessments, and high-temperature diffusion studies from a preliminary multilayer concept to an optimized high-performance design. The optimized structure leverages stoichiometric Y 2 O 3 for its exceptional radiation stability, chemical inertness, and ultra-low fission product diffusivity (e.g., Ce diffusivity ~10 -20 m 2 /s in irradiated Y 2 O 3 at 650 °C). This is paired with ductile chromium-rich interlayers (Cr 95 Y 5 ), which significantly enhance fracture toughness and mechanical resilience. Design refinements, including increased ceramic layer thickness and optimized Cr–Y interlayer composition, eliminated fracture propagation and preserved coating integrity under extreme mechanical stress (>10× typical reactor conditions) and prolonged radiation exposure (~300 dpa). Those conditions are well beyond expected conditions during normal operations in SFR, and cover some of the transient conditions as well. In addition, the coating deposition was demonstrated to be applied uniformly to the inner surface of steel tubes representing prototypic SFR cladding. Another phenomenon under consideration in this work is the corrosion of zirconium-based cladding under prototypic boiling water reactor (BWR) conditions and associated off normal conditions including loss of coolant accident (LOCA). Another multilayer thin film coating is considered for mitigation of this phenomenon, where a coating of yttrium aluminum and yttrium aluminum ceramic/metal thin film coating. Preliminary results on the coating performance during high temperature thermal cycling (up to 1000 C) have shown promising performance of the coating. On-going optimization of the coating will continue in FY26.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2020

A Critical Review of High Burnup Fuel Fragmentation, Relocation, and Dispersal under Loss-Of-Coolant Accident Conditions

High burnup fuel in excess of ~6268 GWd/MTU has been observed to severely fragment when subjected to temperature transient conditions as in a loss-of-coolant accident. In the event of cladding failure, the severely fragmented fuel can relocate into the balloon region and potentially disperse through the burst opening into the reactor’s primary system. This observation has led to implementation of several independent test programs designed to focus on various aspects of fuel fragmentation, relocation, and dispersal. The purpose of this review is to perform a critical, holistic assessment of fuel fragmentation, relocation, and dispersal under loss-of-coolant conditions to identify data gaps in the experimental data base. Phenomena have been identified and well defined through the various testing programs, and general agreement regarding the governing parameters (temperature, burnup, heating rate, cladding deformation, etc.) has been established. However, there is a significant data gap connecting research to commercial application. Furthermore, previous research attempted to evaluate the problem holistically, but has yet to provide a comprehensive understanding of the problem. Major identified data gaps consist of (1) a comprehensive understanding of pretransient fuel rod conditions (fuel temperature, fuel stress, rod internal pressures, microstructure, etc.), (2) definition of prototypic loss-of-coolant accident conditions (heating rate, fuel temperatures, fuel stress), (3) identification of the differences between nuclear and electrical integral loss-of-coolant accident tests, and connection of fuel rod performance (cladding ballooning, burst opening, potential relocation, fragmentation susceptibility, etc.) to fuel fragmentation, relocation, and dispersal severity. Finally, the content of this manuscript provides a clear path for connecting testing and data acquisition to commercial application by providing concrete means for filling data gaps and prioritized testing regimes.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2015

PRELIMINARY EVALUATION OF FeCrAl CLADDING AND U-Si FUEL FOR ACCIDENT TOLERANT FUEL CONCEPTS

Since the accident at the Fukushima Daiichi Nuclear Power Station, enhancing the accident tolerance of light water reactors (LWRs) has become an important research topic. In particular, the community is actively developing enhanced fuels and cladding for LWRs to improve safety in the event of accidents in the reactor or spent fuel pools. Fuels with enhanced accident tolerance are those that, in comparison with the standard UO2-zirconium alloy system, can tolerate loss of active cooling in the reactor core for a considerably longer time period during design-basis and beyond design-basis events while maintaining or improving the fuel performance during normal operations and operational transients. This paper presents early work in developing thermal and mechanical models for two materials that may have promise: U-Si for fuel, and FeCrAl for cladding. These materials would not necessarily be used together in the same fuel system, but individually have promising characteristics. BISON, the finite element-based fuel performance code in development at Idaho National Laboratory, was used to compare results from normal operation conditions with Zr-4/UO2 behavior. In addition, sensitivity studies are presented for evaluating the relative importance of material parameters such as ductility and thermal conductivity in FeCrAl and U-Si in order to provide guidance on future experiments for these materials.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2025

Topological photonic crystal fiber

Photonic crystal fibers (PCFs) provide a versatile platform for various applications, thanks to the flexibility with which light guiding can be customized by modifying the fiber geometry. We realize a PCF with guided modes produced by photonic band structure topology rather than conventional mode-trapping mechanisms. The design, which is compatible with the stack-and-draw fabrication process, consists of a cross-sectional photonic topological crystalline insulator with a disclination. A bulk-defect correspondence produces degenerate topological modes, lying below the cladding light line. We use various theoretical methods to confirm their topological origins, including a spectral localizer that makes minimal assumptions about the band structure. Our experiments on the fabricated fiber show it transmitting visible to near-infrared light with low losses of 10 to 20 decibels per kilometer, which do not increase substantially when the fiber is bent. A comparable solid-core PCF of conventional design exhibits substantially higher bending losses. Optical fibers based on topological modes hold promise for improved performance and versatile functionalities.

Zhu, Bofeng [Nanyang Technological Univ. (Singapor↗
DOE OSTI2018

Thermally-Conductive and Mechanically-Robust Graphene Nanoplatelet Reinforced UO 2 Composite Nuclear Fuels

Low thermal transport behavior along the radial direction of nuclear fuel pellets and pellet-cladding mechanical interaction significantly impact fuel performance and the safety of current nuclear energy systems. Here we report a new strategy of advanced fuel design in which highly thermally-conductive and mechanically-robust graphene nanoplatelets are incorporated into UO 2 fuel matrix to improve fuel thermal-mechanical properties. The 2D geometry of the graphene nanoplatelets enables a unique lamellar structure upon fuel consolidation by spark plasma sintering. The thermal conductivity along the radial direction of the sintered fuel pellets at room temperature reaches 12.7 and 19.1 wm –1 K –1 at 1 wt.% and 5 wt.% loadings of the graphene nanoplatelets, respectively, representing at least 74% and 162% enhancements as compared to pure UO 2 fuel pellets. Indentation testing suggests great capability of the 2D graphene nanoplatelets to deflect and pin crack propagation, drastically improving the crack propagation resistance of fuel matrix. Here, the estimated indentation fracture toughness reaches 3.5 MPa·m 1/2 by 1 wt.% loading of graphene nano-platelets, representing a 150% improvement over 1.4 MPa·m 1/2 for pure UO 2 fuel pellets. Isothermal annealing of the composite fuel indicates that the graphene nano-platelet is able to retain its structure and properties against reaction with UO 2 matrix up to 1150 °C.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2023

The Complex, Unique, and Powerful Imaging Instrument for Dynamics (CUPI 2 D) at the Spallation Neutron Source (invited)

The Oak Ridge National Laboratory is planning to build the Second Target Station (STS) at the Spallation Neutron Source (SNS). STS will host a suite of novel instruments that complement the First Target Station’s beamline capabilities by offering an increased flux for cold neutrons and a broader wavelength bandwidth. A novel neutron imaging beamline, named the Complex, Unique, and Powerful Imaging Instrument for Dynamics (CUPI 2 D), is among the first eight instruments that will be commissioned at STS as part of the construction project. CUPI 2 D is designed for a broad range of neutron imaging scientific applications, such as energy storage and conversion (batteries and fuel cells), materials science and engineering (additive manufacturing, superalloys, and archaeometry), nuclear materials (novel cladding materials, nuclear fuel, and moderators), cementitious materials, biology/medical/dental applications (regenerative medicine and cancer), and life sciences (plant–soil interactions and nutrient dynamics). The innovation of this instrument lies in the utilization of a high flux of wavelength-separated cold neutrons to perform real time in situ neutron grating interferometry and Bragg edge imaging—with a wavelength resolution of δλ/λ ≈ 0.3%—simultaneously when required, across a broad range of length and time scales. This manuscript briefly describes the science enabled at CUPI 2 D based on its unique capabilities. The preliminary beamline performance, a design concept, and future development requirements are also presented.

47 OTHER INSTRUMENTATION↗
DOE OSTI2016

Summary of BISON Development and Validation Activities - NEAMS FY16 Report

This summary report contains an overview of work performed under the work package en- titled “FY2016 NEAMS INL-Engineering Scale Fuel Performance (BISON)” A first chapter identifies the specific FY-16 milestones, providing a basic description of the associated work and references to related detailed documentation. Where applicable, a representative technical result is provided. A second chapter summarizes major additional accomplishments, which in- clude: 1) publication of a journal article on solution verification and validation of BISON for LWR fuel, 2) publication of a journal article on 3D Missing Pellet Surface (MPS) analysis of BWR fuel, 3) use of BISON to design a unique 3D MPS validation experiment for future in- stallation in the Halden research reactor, 4) participation in an OECD benchmark on Pellet Clad Mechanical Interaction (PCMI), 5) participation in an OECD benchmark on Reactivity Insertion Accident (RIA) analysis, 6) participation in an OECD activity on uncertainity quantification and sensitivity analysis in nuclear fuel modeling and 7) major improvements to BISON’s fission gas behavior models. A final chapter outlines FY-17 future work.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2018

Zr Recycle Installation of Out-of-Cell Accessory Facilities

Design, fabrication, and installation of the out-of-cell accessory equipment for the Zr Recycle Project tests with actual used nuclear fuel (UNF) cladding was completed on September 9, 2016, shortly before installation of the hot cell equipment. As indicated in Figures 1 and 2, the out -of- cell equipment includes (1) a gas cabinet for a chlorine cylinder, (2) piping and valves, (3) flow control valves, and (4) two shielded plugs in the hot cell walls, one for gas flow piping from the Charging Area and one for electric power and thermocouple instrumentation from the Operating Area. In addition, wiring for flow control signals and piping for Argon gas transfer were run through the existing pass-through tube underneath the hot cell to enable operation of flow controller signals in the Operating Area to the control valves and piping located in the Charging Area. The shielded plug from the Charging Area into the hot cell contains spare lines that can be used in the future for transferring off-gas from the test equipment to tritium traps located in the Charging Area, and then back into the hot cell for caustic scrubbing and venting.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2021

Thermal analyses of high-power advanced thermoacoustic radioisotope power system for future space exploration missions

This paper presents the results of 3-D thermal analyses of the heat source assembly of a 440 We advanced radioisotope power system (RPS) for future space exploration missions. This high thermal efficiency RPS employs a heat source assembly of eight Step 2 General Purpose Heat Source (GPHS) modules and four Thermoacoustic Power Converter (TAPC) units. Each unit is thermally coupled to two GPHS modules. Here, the analyses investigated the temperatures of the Iridium (Ir) alloy cladding of the 238 PuO 2 fuel pellets and the surface of the Fine Weave Pierced Fabric (FWPF) aeroshell in the GPHS modules to ensure reliable operation and safety in case of an unlikely reentry. Conductive coupling of the GPHS modules to the heater heads of the TAPC units produces relatively uniform axial and azimuthal distributions of heat flux and temperature. However, for this case the temperature of the Ir alloy cladding is lower than the desired values of 1173 K to maintain sufficient ductility. Adding a 5 mm wide He filled gap and decreasing the thickness of the graphite sleeve to 10 mm increased Ir cladding temperature to 1197–1174 K, which are in the desired range. The maximum surface temperatures of the FWPF graphite aeroshell of 1022–1131 K is well below the NASA specified limit of 1373 K. In addition, the total mass of the heat source assembly decreased by 19.6 kg, ~43% saving compared to original design.

42 ENGINEERING↗
DOE OSTI2012

Fuel and cladding nano-technologies based solutions for long life heat-pipe based reactors

A novel nuclear reactor concept, unifying the fuel pipe with fuel tube functionality has been developed. The structure is a quasi-spherical modular reactor, designed for a very long life. The reactor module unifies the fuel tube with the heat pipe and a graphite beryllium reflector. It also uses a micro-hetero-structure that allows the fission products to be removed in the heat pipe flow and deposited in a getter area in the cold zone of the heat pipe, but outside the neutron flux. The reactor operates as a breed and burn reactor - it contains the fuel pipe with a variable enrichment, starting from the hot-end of the pipe, meant to assure the initial criticality, and reactor start-up followed by area with depleted uranium or thorium that get enriched during the consumption of the first part of the enriched uranium. (authors)

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2017

Modeling the Transient Reactor Test Loop in TRACE for PWR Critical Heat Flux Benchmarking

Understanding transient critical heat flux (CHF) resulting from a Reactivity Insertion Accident (RIA) in nuclear systems is an extremely undeveloped field. Though many experiments have been done for CHF, remarkably few have been done for rods at PWR operating temperature and pressure (300 deg. C, 2200 psia) with a short time constant ramp in power. This leads to many concerns regarding understanding how RIA scenarios develop and evolve in commercial nuclear reactors. With a limited understanding of the phenomenology governing transient CHF, there is little hope in being able to accurately model these scenarios using today's thermal hydraulic codes. The Accident Tolerant Fuels (ATF) Program established by the Department of Energy (DOE) is seeking out new fuel and cladding systems that can be used to reduce the probability and consequences of severe accidents. To better understand this phenomenon, the DOE is restarting the Transient Reactor Test (TREAT) Facility at the Idaho National Laboratory (INL). TREAT will be able to provide representative neutronic boundary conditions for testing coupled thermal hydraulics on the Transient Water Environment Recirculating Loop (TWERL) to study transient CHF with the best representation possible. To support this task, Oregon State University (OSU) is designing and building a representative flow loop that will be able to mimic the conditions of TWERL (sans the neutronic boundary conditions) to create a benchmark study for existing lumped parameter thermal-hydraulic codes such as RELAP5 and TRACE. This flow loop, the Transient Reactor Test Facility (TRTL), will support the ATF program by providing much needed NQA-1 data for transient CHF at operating temperature and pressure.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2025

Tantalum Experiments in Fully-Reflected Water-Moderated Triangular-Pitched U(6.90)O 2 Fuel Rod Lattices (1.02 cm Pitch)

The United States (US) Department of Energy (DOE) Nuclear Energy Research Initiative funded the design and construction of the Seven Percent Critical Experiment (7uPCX) at Sandia National Laboratories (SNL). The start-up of the experiment facility and the execution of the experiments described here were funded by the DOE Nuclear Criticality Safety Program. The 7uPCX is designed to investigate critical systems with fuel for light water reactors in the enrichment range above 5 % 235 U. The 7uPCX assembly is a water moderated and — reflected array of aluminum-clad U(6.90 %)O 2 fuel rods. Other critical experiments performed in the 7uPCX assembly are documented in LEU-COMP-THERM-078, LEU-COMP-THERM-080, LEU-COMP-THERM 096, LEU- COMP-THERM-097, LEU-COMP-THERM-101, LEU-COMP-THERM-102, and LEU-COMP-THERM-111. Applied interests in neutron-absorbing elements at epithermal and intermediate neutron energy ranges at DOE’s Hanford Site and Savannah River Site were identified through DOE Office of Environmental Management (EM) workshops and needs surveys performed in conjunction with the National Nuclear Security Administration/Nuclear Criticality Safety Program. In response, a team lead by Oak Ridge National Laboratory (ORNL) performed a study evaluating the use of 7uPCX for testing the epithermal cross sections of materials at SNL. This marked the inception of the set of experiments described here. The purpose of these experiments was to measure the effects of tantalum in nearly-critical systems. The tantalum was introduced into the fuel arrays as experiment rods within a central test region. The central test region was designed to target the epithermal neutron energy range by providing a dry cylindrical cavity constructed of aluminum and lined with 0.04 in (0.1016 cm) thick cadmium sheet. The central test region has an outer diameter of 3.75 in (9.525 cm) length of 31 in (78.74 cm) and can hold 85 tantalum rods nominally 0.25 in (0.635 cm) outside diameter and 31.25 in (79.375 cm) long. The critical experiments were done using a set of triangular-pitched grid plates fabricated for these experiments. The grid plate set accommodated a fuel array of a total of 2016 fuel rod positions on a pitch of 0.4 in (1.016 cm) in a series of 21 hexagonal rings positioned around the central test region. The fuel used in these experiments was fabricated using unirradiated 6.90 % enriched UO 2 fuel pellets from fuel elements designed to be used in the internal nuclear superheater section of the Pathfinder boiling water reactor operated in South Dakota by the Northern States Power Company in the 1960s. The fuel elements were obtained from The Pennsylvania State University where they had been stored for many years. The fuel pellets in those fuel elements were removed from the original Incoloy cladding and reclad in 3003 aluminum tubes and end caps for use in the experiments reported here. The eight cases in this experiment series were performed in 2024 in the Sandia Critical Experiments (SCX) at the Sandia Pulsed Reactor Facility by varying the number of fuel rods in the critical assembly. The personnel involved in conducting these experiments included David Ames, Elijah Lutz, Beth Hanson, Patrick Ward, Jason Soares, and Augie Chapa from SNL, as well as Mathieu Dupont and B.J. Marshall from ORNL. Case 1 had no tantalum experiment rods. Case 2 had seven tantalum rods in the center of the central test region. Case 3 had 18 tantalum rods in the third hexagonal ring of the central test region. Case 4 had 19 tantalum rods in the center of the central test region. Case 5 had 30 tantalum rods in the outer most positions of the central test region. Case 6 had 37 tantalum rods in the center of the central test region. Case 7 had 61 tantalum rods in the center of the central test region. Case 8 had 85 tantalum rods filling all positions in the central test region. All eight critical experiments are judged to be acceptable as benchmark experiments.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗
DOE OSTI2025

Status Report on Design of In-situ Thermomechanical Testing at LANSCE

Nuclear fuel encounters severe thermomechanical environments in which its mechanical response is determined by its microstructure, temperature and stress level histories. Simulating the response of such microstructures is crucial for predicting both performance and transient fuel mechanical responses and experimental verification of such predictions is therefore of great interest. While most of the deformation in a nuclear fuel rod occurs in the cladding, deformation of the fuel itself is still of interest with deformation mechanisms at operating temperature and above including creep, swelling, cracking as well as pellet-clad interaction. Characterization of these properties and understanding of the underlying deformation phenomena at operating or excursion temperatures is therefore of great importance for development and ultimately licensing of improved and novel nuclear fuel forms. Diffraction techniques offer unique insight on the atomistic (e.g. crystal structure) and microstructure (e.g. phase transformations, texture, defects) length scales and have a long history of providing unique data to inform relevant deformation models that enable the required predictive capabilities. For example, dislocations lead to diffraction peak broadening that can be characterized to estimate the dislocation density and study the role of dislocations on the deformation while measuring lattice strains allows to studie load sharing in two phase materials. In this report the requirements for a sample environment for high temperature deformation of nuclear fuels are defined. The HIPPO neutron time-of-flight diffractometer at LANSCE will host this sample environment and is also described. This instrument covers diffraction angles from 140° to 40° and is also equipped with an event-mode neutron imaging detector system, enabling energy-resolved neutron imaging in parallel with the diffraction that could measure sample temperature from Doppler broadening of neutron absorption resonances or measure pore densities from changes in the attenuation. Designs of devices to characterize thermomechanical properties of nuclear fuel without diffraction are also considered to guide the design. While this report is focused on applications for nuclear fuels, the device can also characterize cladding, moderator or structural materials and therefore contribute to other fields of research and development for advanced reactors. The temperatures planned to be reached are above 2000℃, thus enabling characterization of LWR reactor fuels under accident scenarios but also reaching temperatures of fuels developed for nuclear thermal propulsion and providing opportunities to characterize those. In conjunction with the energy-resolved neutron imaging detector, this setup would allow to measure neutron cross-sections at high temperatures, filling a gap towards development of reactors operating at high temperatures.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2022

MAGNETICALLY SUSPENDED CANNED ROTOR PUMPS FOR THE INTEGRAL MOLTEN SALT REACTOR

This project developed a molten salt pump design for small modular reactors, concentrated solar, and Gen IV nuclear reactors with a magnetically levitated rotor that can operate at temperatures of up to 700 °C. This eliminates the need for rotating seals and roller element bearings which require maintenance and are prone to failure. The pump design is also more compact than existing molten salt pump designs which require long shafts to thermally isolate the electric motor. The aims of the project are to: 1) design and test the molten salt pump, 2) develop and test a high temperature position sensor needed for magnetic bearing control, and 3) develop and test high temperature coil fabrication methods for electric motor and magnetic bearing fabrication. To develop the high temperature coils, conductor materials were analyzed for oxidation, diffusion, cladding, and resistivity. Of the candidate conductor materials that met the requirements, silver was chosen. The long-term impact of radiation on silver resistivity was analyzed by developing a model of a generic molten salt fast reactor to model the conductor irradiation in worst case scenarios. The analysis showed that increased resistivity due to transmutation of silver decreases exponentially with the reactor reflector thickness. Different electrical insulation materials were tested and the final high temperature coils developed were able to withstand conductor to ground voltages up to 1800 V before insulation breakdown. Magnetic bearings require high-precision high-speed measurements of the rotor position to operate. Current commercial position sensors can only operate up to 550 °C so a novel position sensor was developed that can operate up to 800 °C. These sensors were also designed to measure the position of the metallic rotor through a thin metallic corrosion barrier that protects that coils, insulation, and magnetic cores so that the salt containment barrier does not have any penetrations. The high-temperature sensor was tested and had comparable performance to commercially available inductive position sensors. The sensor design and signal processing has led to several invention disclosures. The magnetically levitated molten salt pump design was completed and analyzed. The chloride salt test loop at Oak Ridge National Laboratory was chosen to test the pump and the pump hydraulics and power were designed for the test loop flow and pressure requirements. Classes of motor designs that do not utilize permanent magnetic were considered for the high-temperature motor. After extensive analysis of their performance, a synchronous reluctance motor was chosen for the pump. The design was refined and analyzed to optimize performance. The magnetic bearings were designed to meet the force and frequency requirements necessary to levitate the rotor and reject disturbances from rotor imbalance, motor forces, and hydraulic forces. Compliant mounts for the position sensors were designed that would not damage the ceramic sensor components and maintain sensor alignment over a wide temperature range. A thermal hydraulic analysis of the molten salt coolant flow used to cool the rotor and stator was performed to ensure that the maximum temperature in the rotor and stator will not exceed 725 °C. The corrosion barrier and casing were designed to maintain the salt fluid boundary by using compliant features to absorb large expansion mismatches due to different coefficients of thermal expansion (CTE). Finally, the salt drain and fill systems were designed along with the pump support structure, integration with the test loop, and thermal insulation and heating. Corrosion barrier fabrication experiments were performed to assess using laser cladding to apply a sub-millimeter corrosion barrier to the surface of a Fe-Co-V magnetic core material. The cladding method showed minimal mixing between materials at their interface and withstood temperature cycling without damage to the cladding. The technology commercialization is focused on the high-temperature position sensors and there has been significant interest from the nuclear industry in utilizing these sensors along with some interest from the aerospace industry. The project also led to a research collaboration with a fusion energy industrial partner to study barriers to scaling the pump design from the kW size to the MW size. This research collaboration will also study methods to create high-temperature coils that have conductor to ground breakdown voltages above 5 kV. The successful development of high-temperature electromagnetic coils and high-temperature position sensors greatly increases the temperature limits for electromagnetic devices that don’t rely on permanent magnets. This includes electric motors, magnetic bearings, linear actuators, rotary position and velocity sensing, actuated valves, and generators to name a few. This will fill a current need in molten salt reactors, concentrated solar, and fusion energy for these critical peripheral devices needed for practical reactor designs that do not currently have commercial solutions.

Hines, J Wesley↗
DOE OSTI2020

Investigation of Process Emissions during Thermal Cutting of Clad Metals from the Nuclear Sector - 20183

Typically, reactor pressure vessels as well as steam generators comprising low alloyed steel with a cladding of stainless steel. Recently the permissible values for Cr (VI) in the air of the working areas have been reduced in Germany from 100 μg/m{sup 3} to 1 μg/m{sup 3} air. This results in the danger that even with low-alloy steel with claddings these limit values would be exceeded when using flame cutting technologies. In order to ensure compliance with the permissible limit values, exhaust gas systems with gas cleaning measures are provided. The process emission test shall replace the assumptions required for the design of these systems with measured values. NUKEM Technologies Engineering Services GmbH (NUKEM) has chosen autogenous flame cutting as an example of a thermal cutting system for process emission testing, as there are no proven values in the literature for the Cr (VI) and NiOx emissions produced. The autogenous flame cutting can be used for a variety of cutting tasks within decommissioning projects. In order to simulate the material to be cut, mock ups were generated and cut from information about the material specification for the reactor pressure vessel from existing nuclear power plants including possible claddings. The cutting length needed for analysis in the test will be maximum 100 mm. The airborne emissions from the thermal cutting process will be captured and analyzed as follows: - Dust emission: The generated particles will be collected by a hood equipped with strong suction device and suitable filter elements. The resulting filter is gravimetrically measured before and after the tests. - Particle Size Distribution: The airborne particle size distribution measurement will result in figures for the size and number of particles arising from the thermal cutting process. - Gas Analysis: The gas analysis enables the determination of e.g. CO{sub 2}, CO, O{sub 3}, NO, NO{sub 2}. - Cr (VI) and NiOx Analysis: For the Cr (VI) and NiOx analysis, samples of the filter residue will be taken. As a result Cr (VI) in relation to total Cr as well as the Ni content will be determined by ICP-optically emission spectroscopy and put in relation to the total dust amount. The process emissions test itself as well as the necessary gas analyses and spectroscopic analyses were carried out at the Institute of Materials Science (IW) of Leibniz Universitaet Hannover (LUH). The results of the process emission tests are used to confirm the design of the gas cleaning systems. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2016

Characterization of Ion Implantation and Irradiation Effects in Interface-Dominated Metallic Composites

The candidate structural and fuel cladding materials for the next-generation nuclear power reactors must possess excellent irradiation damage tolerance, and high mechanical and thermal stability that present a challenge for materials design. Here we report an approach to engineer interphase boundaries in metallic composites to achieve superior resistance to void swelling and prevent loss of plastic deformability after irradiation. Model composite systems of face-centered-cubic (Cu) and body-centered-cubic (Nb, Mo or V) metals are used to elucidate the effects of boundary structure and spacing on the damage accumulation and mechanical properties after irradiation. Transmission electron microscopy (TEM) and nano-mechanical testing are used to characterize the irradiation response. A recent development in in situ straining in high-resolution TEM to measure lattice strains and thereby estimate local stresses corresponding to dislocation nucleation and migration is discussed as a capability that in future can enable quantitative characterization of defect interactions in irradiated materials. (authors)

36 MATERIALS SCIENCE↗
DOE OSTI2020

Milestone 2.8: Preliminary Radiolytic Gas Generation Measurements from Helium-Backfilled Samples

The Department of Energy (DOE) is currently managing nearly 13 metric tons of aluminum-clad spent nuclear fuel (ASNF) with the intention of extended (> 50 years) dry storage in helium-backfilled canisters. Due to in-reactor and cooling pond conditions, oxyhydroxide corrosion layers have formed on the surface of the ASNF elements. These corrosion layers are susceptible to radiolysis and the formation of molecular hydrogen gas (H 2 ) due to the fuel’s inherent radiation field. Consequently, a rigorous evaluation of the effect of helium gas on radiolytic H 2 production is necessary to support the Technical Considerations and Challenges for Extended (> 50 yrs) Dry Storage of ASNF program, especially as previous Task 2 - Oxyhydroxide Layer Radiolytic Gas Generation Resolution work demonstrated a significant effect of gas composition on the radiolytic yield (G-value) of H 2 . Here we report preliminary G-values for the radiolytic formation of H 2 from the gamma irradiation of pre-corroded aluminum alloy 1100 coupons flame sealed in helium environments. Irradiations yielded G(H 2 ) values of (5.1 ± 0.5) x 10 –4 and (9.4 ± 0.9) x 10 –4 µmol J –1 for pristine coupons, and (10.1 ± 0.4) x 10 –4 and (15.1 ± 1.2) x 10 –4 µmol J –1 for pre-corroded coupons for 0% and 50% relative humidity, respectively. These helium environment G(H 2 ) values are between 28% and 58% higher than previously reported values for argon environments. This enhancement is attributed to the significant difference in first ionization energy between helium (24.59 eV) and argon (15.76) facilitating additional processes, e.g., Penning ionization. These new preliminary helium environment G(H 2 ) values will be employed by Task 3 - Sealed and Vented System Episodic Breathing and Gas Generation Prediction to model the effect of radiolytic H 2 accumulation in helium environments to evaluate the practicality of the extended storage standard canister design.

38 RADIATION CHEMISTRY, RADIOCHEMISTRY, AND NUCLEA↗
DOE OSTI2015

Performance of low smeared density sodium-cooled fast reactor metal fuel

An experiment was performed in the Experimental Breeder Rector-II (EBR-II) in the 1990s to show that metallic fast reactor fuel could be used in reactors with a single, once-through core. To prove the long duration, high burnup, high neutron exposure capability an experiment where the fuel pin was designed with a very large fission gas plenum and very low fuel smeared density (SD). The experiment, X496, operated to only 8.3 at. % burnup because the EBR-II reactor was scheduled for shut-down at that time. Many of the examinations of the fuel pins only funded recently with the resurgence of reactor designs using very high-burnup fuel. The results showed that, despite the low smeared density of 59% the fuel swelled radially to contact the cladding, fission gas release appeared to be slightly higher than demonstrated in conventional 75%SD fuel tests and axial growth was about the same as 75% SD fuel. There were axial positions in some of the fuel pins which showed evidence of fuel restructuring and an absence of fission products with low metaling points and gaseous precursors (Cs and Rb). Lastly, a model to investigate whether these areas may have overheated due to a loss of bond sodium indicates that it is a possible explanation for the fuel restructuring and something to be considered for fuel performance modeling of low SD fuel.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗