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Legacy Metallic Fuel U(Pu)Zr Data Qualification

The Metallic Fuels Irradiation and Physics Database (FIPD) is an organized collection of legacy metallic fuel U(Pu)Zr data, measurements, and reactor conditions from the Experimental Breeder Reactor II (EBR-II) and the Fast Flux Test Facility (FFTF). The database provides a wealth of information and is easily accessed and utilized by the U.S. nuclear industry and the Nuclear Regulatory Commission (NRC). The database contains three categories of data. The first category covers fuel pin fabrication specifications, including fuel slug diameter and length, cladding diameter, smeared density, etc. The second consists of operational conditions, which include axial distributions of power, temperature, fluence, burnup, isotopic density, etc. The third category contains post-irradiation examination (PIE) results, largely collected at facilities now part of the Idaho National Laboratory (INL), formerly part of Argonne National Laboratory -West (ANL-W) and at the Alpha-Gamma Hot Cell Facility (AGHCF) at Argonne National Laboratory, comprising fission gas release and chemistry analysis, profilometry measurements, neutron radiography data, etc. All these data have been organized and preserved in FIPD.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Applying U.S. metal fuel experience to new fuel designs for fast reactors

With the increasing interest in small modular reactors or microreactors, developers are working to design and submit licensing approval requests of U–10Zr-fueled fast reactors. The developers and their proponents cite prior metal fuel experience (worldwide, but U.S. experience in particular for many developers) as the motivation and justification for their reactor concepts. The experience with metal fuel deployment in sodium-cooled fast reactors as well as the underlying irradiation testing database, provide a suitable basis for analytically justifying the use of metal fuel in new reactors. The evolution of metal fuel design and capability illustrates the importance of key fuel design parameters to consider in new applications of the prior experience: fuel smeared density, plenum-to-fuel volume ratio, the ratio of cladding radius to thickness, fuel composition, and cladding and duct materials. In-service operating and deployment conditions to be considered include fuel linear heat generation rate, fuel temperature, cladding temperature, peak burnup and peak fast fluence. Fuel designs and in-service conditions that are bounded by the database and experience are most easily addressed, but deviations from those previous parameters and conditions can be addressed by considering impacts on previously established behavior and applying other mitigating conservatisms, as appropriate. Here, the authors recommend any new deployment proceed with fuel surveillance and monitoring to mitigate risk, application of conservative measures to address uncertainties, and a fuel qualification program that addresses a range of in-service operating conditions with production fuel. The work reported should be of interest to students and regulators unfamiliar with metal fuel in fast reactors.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Initial Assessment of CTF for Time-at-Temperature Applications

The US nuclear industry is interested in improving the economics of their fleet of light-water reactors (LWRs) by uprating US plants. One option being considered is to regain lost margin from overly conservative fuel safety limits. The current limit requires avoidance of critical heat flux (CHF) and prevents further operation of fuel that experiences a dry-out in boiling water reactors (BWRs) or departure from nucleate boiling (DNB) in pressurized water reactors (PWRs); however, it has been shown that temporary, mild dry-out of the fuel does not necessarily increase the risk of fuel failure during its normal anticipated operating life. Such mild dry-out or DNB events may occur during a plant anticipated operational occurrence (AOO), such as a locked rotor in a PWR or a pump trip in a BWR. The time-at-temperature (TAT) approach to regulating fuel operation aims to demonstrate that the fuel rod’s integrity is not challenged during such a mild transient that leads to CHF in which the fuel operates at an elevated temperature for a brief period of time. However, implementing this approach will require extensive fuel material experimental data, as well as supporting modeling and simulation (M&S) predictions, to ensure that the predicted fuel response during AOOs, with all applicable uncertainty considered, will not threaten the safety of the fuel during the transient or the remainder of its anticipated lifecycle. To address this need, a comprehensive effort is being proposed that includes generating cladding material data under TAT conditions, assessment of available code capabilities for TAT conditions, development of new mechanistic models, and demonstration of the M&S capabilities for AOOs of interest. This will require a joint effort between the Nuclear Energy Advanced Modeling and Simulation (NEAMS) and Advanced Fuels Campaign (AFC) programs, as well as close collaboration with nuclear industry stakeholders. The outcome of this collaboration will result in development and assessment of capabilities that can be used by the nuclear industry to support qualification of a TAT-based fuel failure criteria safety limit. This report focuses on the thermal hydraulics (T/H) modeling capabilities and summarizes currently available data for validating the T/H subchannel code CTF for TAT conditions, as well as preliminary assessment results of the code. The initial assessment also resulted in implementation of an alternative post-CHF heat transfer package, which has been shown to significantly improve accuracy. This report is not a final assessment and does not consider all available validation data; it is intended that a future assessment will more fully validate the code for this application.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

Fabrication of U-10 wt.%Zr Metallic Fuel Rodlets for Irradiation Test in BOR-60 Fast Reactor

The fabrication technology for metallic fuel has been developed to produce the driver fuel in a PGSFR in Korea since 2007. In order to evaluate the irradiation integrity and validate the in-reactor of the starting metallic fuel with FMS cladding for the loading of the metallic fuel, U-10 wt.%Zr fuel rodlets were fabricated and evaluated for a verification of the starting driver fuel through an irradiation test in the BOR-60 fast reactor. The injection casting method was applied to U-10 wt.%Zr fuel slugs with a diameter of 5.5 mm. Consequently, fuel slugs per melting batch without casting defects were fabricated through the development of advanced casting technology and evaluation tests. The optimal GTAW welding conditions were also established through a number of experiments. In addition, a qualification test was carried out to prove the weld quality of the end plug welding of the metallic fuel rodlets. The wire wrapping of metallic fuel rodlets was successfully accomplished for the irradiation test. Thus, PGSFR fuel rodlets have been soundly fabricated for the irradiation test in a BOR-60 fast reactor.

Kim, Ki-Hwan↗

The advanced characterization, post-irradiation examination, and materials informatics for the development of ultra high-burnup annular U-10Zr metallic fuel

U-Zr metallic fuel is a promising fuel candidate for Gen Ⅳ fast spectrum reactors. Previous experimental irradiation campaigns showed that the sodium thermal bonded U-10Zr fuel design can achieve a burnup of 10% fissions per initial heavy metal atom (FIMA). Advanced metallic fuel designs are pushing the burnup limit to 20% or even 30% FIMA. To achieve the higher burnup and eliminate the pyrophoric sodium, a prototypical annular fuel has been designed, fabricated, clad with HT-9 in the Materials and Fuels Complex, and irradiated in the Advanced Test Reactors of Idaho National Laboratory (INL) to a peak burnup of 3.3% FIMA. During irradiation, the mechanical contact between fuel and cladding acts as a thermal bond. The irradiation lasted for 132 days in the reactor. Recently, the archived fresh and irradiated fuel samples were characterized using advanced characterization capabilities in the Irradiated Materials Characterization Laboratory (IMCL) of INL. This article summarizes the results of advanced characterization and computer vision-based materials informatics to reveal the irradiation effects on U-Zr metallic fuel. Future work will focus on further implementation of advanced characterization and statistical data mining to improve the fidelity of fuel performance modeling and support U-Zr metallic fuel qualification for fast spectrum reactors.

Yao, Tiankai↗

Thermal Model for Horizontal In-Water and In-Air Mini-Plate Experiments in the Advanced Test Reactor

Mini-Plate (MP) irradiation tests are a fueled experiment designed for irradiation in multiple test locations in the Advanced Test Reactor (ATR) at the Idaho National Laboratory (INL). MP experiments are considered a non-instrumented drop-in test where small aluminum-clad fuel plate samples are cooled directly by the ATR Primary Coolant System (PCS) water. These fueled experiments contain aluminum-clad fuel mini plates consisting of monolithic U-10Mo. Previous thermal analyses have been documented concerning oxide growth[1] and thermal safety margin[2] for the MP-2 experiment. A thermal analysis has been performed on the MP-2 experiment using a new technique for calculating the necessary time after the experiment has been irradiated and reactor shutdown necessary to not exceed the 95% lower bound blister threshold temperature for the fuel in a horizontal in air configuration. A horizontal in water model has also been analyzed and will be discussed. After the experiment is irradiated in the ATR, it is necessary to calculate the fuel meat temperatures at 12 hours after shutdown. This is done to assure that at the 12 hour mark, if this experiment is removed from the reactor and accidentally dropped onto the working tray and is in the most severe geometrical configuration of horizontal (minimum heat transfer) that fission products will not be released. The blister threshold temperature is considered this safety limit. The horizontal in air analysis is also performed considering that the experiment is horizontal in a drained canal and filled with air and natural convection heat transfer with air on the outside. The initial mini-plate testing campaign known as MP-1 [3] has been irradiated and its purpose was to form the base fuel specimens fabricated by various processes so that a single process can be down-selected for qualification. MP-2 will then serve to populate a comprehensive fuel performance data set for the down-selected fabrication process. The MP-2 experiment will be irradiated in several locations of the ATR as shown in Figure 1. The fuel plate thickness and geometry is identical to the MP-1 experiment [3], with the only variable being the fuel meat thickness. This model of the B-12 position is treated as encompassing the I-21, I-24, and B-9 positions since it has more fuel and higher total heat than the other positions. Since the blister threshold temperature is a function of fission density, a series of fission densities is calculated for the B-12 position to cover the other three positions. The B 12 position specifically uses fuel meat that is 0.016 in thick by 3.25 in long and 0.75 in tall. The total plate thickness is 0.050 in. Aluminum cladding forms the barrier between the PCS and the fuel meat. The purpose of this paper is to demonstrate this new technique developed to calculate the necessary decay time after shutdown for a series of fission densities using the ABAQUS [4] finite element and heat transfer code.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Start-up of Silo 130 Waste Retrieval at La Hague: first Step Towards Reducing Legacy Inventory - 20020

On June 25, 2019, the first grapple of waste and debris was lifted from Silo 130, one of the most challenging legacy waste storage silos at La Hague. This was the achievement of more than ten years of studies and efforts focused on solving some very unique technical and safety challenges, and on designing an innovative, efficient solution. The waste is from de-cladding materials from past Gas-Cooled Reactor fuel reprocessing operations. It is an unsorted mixture of magnesium cladding pieces, graphite debris, and various other metallic waste types. These materials can be chemically reactive and therefore need specific dispositions for handling and storing. The building is more than 40 years old and does not meet modern standards. French safety authorities have required the silo to be emptied. After about three years of operation, the bulk of this waste will be removed and placed in safe storage, pending the selection of a final conditioning solution. Removal of bottom debris will then be possible. When finished, this operation will bring a conclusion to a significant legacy-related hazard on the site. The silo will then be available for final cleaning and de-activation. This paper will describe the technical, safety, and economical challenges, and the various decisions and optimizations that led to the definition of the process and technology to be implemented. Several innovative features were developed and implemented, in all sections of the project: project organization, progressive approach for the waste disposition strategy, light building design, customized and robust retrieval technology, processing technologies involving the most modern robotic and sorting techniques, storage method... Several of these first-of-a-kind innovative features have been developed and qualified specifically for this application, using the detailed qualification procedure specified for all La Hague projects. The facility was built in less than five years, overcoming various difficulties along the line. Commissioning is now finished with the combined efforts of the project, engineering, start-up, and operating teams assisted by dedicated suppliers. The facility is now ramping-up. The paper will also report on the commissioning and start-up of the facility and describe the first operational results. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

Research Needs for Uranium-Zirconium- Based Metallic Fuels

The purpose of this report is to summarize the needs and present recommendations related to the future direction for U-Zr-based metallic fuel research (including binary U-Zr and ternary U-Pu-Zr alloys). These needs and recommendations were determined by subject matter experts from various institutions during a two-day workshop held at the University of Florida in November, 2019. During open-floor discussions, the highest priority gaps in our understanding of U-Zr-based fuels were down-selected, and near- and long-term needs that directly impact the implementation of these metallic fuels were identified. The identified near-term needs include investigation of the following phenomena: i) swelling and fission gas release, ii) fuel-cladding chemical interaction, iii) phase evolution/constituent redistribution, and iv) thermal properties of the fuels. The long-term needs are: i) investigation of fuel creep and plasticity and ii) fission product (lanthanide) transport. In addition, there was general agreement that all institutions and subject matter experts would benefit from an open-source metallic fuels database with thermophysical property and microstructural data, along with fuel operation/irradiation history, which should be regularly updated with vetted information from new experimental and computational investigations and used to advance metallic fuels research and development. Finally, we recommend that metallic fuel research should be ongoing and that fuel qualification and fuel optimization should be equally prioritized; research combining experiments with modeling and simulation has the largest potential impact.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Final CRADA Report: Accelerated Burn-up Accumulation Test of Clean Core Thorium Energy Designated ANEEL Fuel

Clean Core Thorium Energy (CCTE), LLC, located in Oak Brook, Illinois, is committed to the development of alternative nuclear fuels. CCTE is focused on leveraging the inherent benefits of thorium to create a novel nuclear fuel solution for our worlds growing power demand. Unlike some other fuel cycles proposing to use thorium in advanced reactors, CCTE is focused on deploying solid fuel designs (ceramic pellets in metallic cladding) in existing pressurized heavy-water reactors (PHWRs) and Canada deuterium uranium (CANDU) reactors. CCTE’s fuel design, referred to as Advanced Nuclear Energy for Enriched Life (ANEEL), uses mixed thorium-uranium oxide ((Th,U)O2) to enhance reactor operational strategies while producing significantly low attractiveness material in terms of nuclear proliferation. The overall project objective is to investigate the performance of high burnup ANEEL fuel via an irradiation experiment to be performed in the Advanced Test Reactor (ATR) at the Idaho National Laboratory (INL). The scope of work for this CRADA was specifically aimed at performing conceptual design and analysis to support development of an irradiation test rig, development of a fuel fabrication process for the experiment pellets, fabrication and qualification of the pellets, and shipment of the pellets to INL so they can be used to construct experiment rodlets.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Understanding Fission Gas Bubble Distribution and Zirconium Redistribution in Neutron-irradiated U-Zr Metallic Fuel Using Machine Learning

U-10wt.% Zr (U-10Zr) based metallic fuel is the leading candidate for next-generation sodium cooled fast reactor in United States. Currently, Idaho National Laboratory (INL) has been the leading national laboratory for research, development, and demonstration (RD&D) on metallic fuel. Advanced post-irradiation characterization will help to understand fuel microstructure and property change during irradiation, benefiting fuel qualification for commercial application. Characterization capabilities ranging from sub-nanometer to micrometer, such as scanning electron microscopy (SEM), focused ion beam (FIB) sampling, transmission electron microscopy (TEM) characterization, and local thermal conductivity microscopy (TCM), have been utilized recently on irradiated U-10Zr fuel samples to gain a better understanding of nuclear fuel microstructure and property evolution inside a reactor. The FIB/SEM coupled with energy dispersive X-ray spectroscopy (EDS) can capture the essential information to achieve better understanding of fuel behaviors. Inside a nuclear reactor, the phase and microstructure of U-10Zr is constantly changing under neutron bombardment. For example, the gaseous fission product atoms have a limited solubility inside fuel matrix and tend to precipitate out in bubble form, which not only contribute to fuel thermal conductivity degradation but also provide a shortcut for movement of fission products, i.e. lanthanides. The resultant deposition of lanthanides at the cladding inner surface will potentially trigger a chemical reaction/interaction between nuclear fuel and cladding at reactor operational conditions, threatening fuel integrity and safety. FIB/SEM coupled with EDS can provide the fission bubble information as well as probe into phase separation or Zr redistribution, which is fundamental to predict the fuel performance. With high velocity image data generating method, such as FIB/SEM, an automatic way to extract the microstructural information quantitively can better serve the needs from post irradiation characterization. A trained machine learning model, named Decision Tree, is employed to generate a bubble classifier and to categorize bubbles into three categories: isolated bubble, connected without lanthanides, and connected with lanthanides bubbles[3]. This work presents a showcase of this approach on six regions of a fuel cross-section along the radial temperature gradient. We obtained distributions of bubble categories and porosity rates along the six regions. Moreover, a secondary phase U-Zr2 was determined and found on regions 5 and 6. The secondary phase fraction was increasing from 15.61% in region 5 to 34.79% in region 6 based on this approach . This quantitative data offers insights into the lanthanide migration and potentially thermal conductivity degradation. This information from machine learning will be fed into fuel design code for better prediction of fuel performance.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

EDS Analysis of FCCI in AFC-FAST Fuel Pins

The Advanced Fuel Campaign’s Fission Accelerated Steady-state Testing (FAST) program uses metallic fuel pins with small diameters to reach a desired burnup more quickly. This enables accelerated testing of advanced fuel designs and decreases the time between idea conception and commercial usage. Post-irradiation examination is critical in this process, especially with respect to the fuel-cladding chemical interactions (FCCI). In this work, energy dispersive X-ray spectroscopy (EDS) is used to track how elements from the fuel and fission products have diffused through the cladding. Elemental redistribution along the fuel-cladding interface is mapped and FCCI region thicknesses are measured. The correlations between geometry, temperature, burnup, and FCCI thickness are presented.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Demonstrate new plasticity models for doped UO 2 that capture dislocation mechanisms

In light water reactors, fuel vendors are investigating the use of dopants to modify the properties of UO 2 pellets, with the goal of improving pellet-cladding mechanical interactions during operation. Dopants are expected to ‘soften’ the pellets; that is, the doped pellets have higher plastic deformation than conventional UO 2 . This leads to a reduction in the severity of mechanical pellet-cladding interactions, helping to reduce the hoop strain on the cladding. By minimizing the strain exerted by the pellet on the cladding, it is anticipated that cladding performance under accident conditions can be enhanced (i.e., lowering the risk of burst during a LOCA). Dopants such as chromium (Cr) promote grain growth during pellet fabrication, leading to larger grains; therefore, understanding the link between chemistry, microstructure and mechanical deformation (enhanced creep rates) behavior of UO 2 is critical to helping operators further substantiate the benefits of doping UO 2 . Historically, the nuclear energy industry has relied on empirical models to make assessments of performance. Compared to empirical models, mechanistic physics-based models provide benefits, such as, fewer data points for validation and better extrapolation where experimental data is scarce or non-existent. In this report, Bayesian inference techniques have been applied to a previously developed lower length-scale-informed diffusional creep model. The objective is to i) infer lower-length-scale parameter distributions from available experiment and then ii) determine the uncertainties in the measurable quantity (in this case creep rates) after propagating the inferred lower length scale parameter uncertainties. The approach requires many evaluations of the model, which becomes computationally insurmountable; therefore, a neural-network model is trained to data obtained by sampling the full model over the most important parameters. This neural-network is then used in the Bayesian inference approach to determine probability distributions in the parameter values that represent the uncertainty in the model given what is known from the experiments (posterior). A significant reduction compared to conservative initial (prior) uncertainties is achieved through inference against the experimental data, demonstrating the efficacy of this approach. Furthermore, by accounting for uncertainties in the experimental conditions and sample non-stoichiometry, it is possible to resolve apparent discrepancies in experimental measurements within a self-consistent grain boundary (Coble) creep model that is sensitive to chemistry. This work has been written up and submitted to Nuclear Technology for a special issue on accelerated fuel qualification (AFQ). This uncertainty quantification (UQ) work not only improves the diffusional model, while accounting for uncertainty, but also establishes a framework which can readily be applied to the mechanistic models of dislocation deformation developed in this study. The most likely values from the Bayesian analysis are incorporated into our UO 2 diffusional creep model and a lower length scale-informed irradiation UO 2 creep mechanistic model to generate a dataset. This dataset has been provided to our INL collaborators for training an artificial neural network surrogate model, which will be implemented in the BISON fuel performance code to assess how the results differ from those currently obtained using a fully empirical model and that of using the nominal (uncalibrated) atomic scale parameters in our mechanistic model. Plastic deformation (creep and glide) in UO 2 is a complex phenomenon, governed by multiple underlying processes such as local defect concentrations, applied stresses, and microstructural characteristics. Consequently, there is a need for a meso-scale model with polycrystalline resolution capable of extrapolating to large grain sizes applicable to doped UO 2 , where data is limited and the model can help bridge the knowledge gap. By integrating atomistic data into the polycrystal LApx code, it becomes possible to predict dislocation climb and glide plasticity that simple analytical models cannot accurately represent. The application of atomic-scale data within LApx demonstrated the importance of climb and glide mechanisms in reproducing high-stress UO 2 behavior. Behaviors such as this are crucial to capture and implement in BISON, as parts of the fuel pellet can reach temperatures where glide can occur before pellet cracking. This model which captures dislocation based mechanisms for UO 2 is then used to stand up the doped model accounting for larger grain sizes. It was found that larger grain sizes can lead to enhanced deformation rates in the glide regime, and therefore can help with the pellet cladding mechanical interaction. Therefore if the fuel pellet reaches conditions (stress/temperature) where glide is active, the enhanced creep rates for larger grains in the glide regime (doped UO 2 ) can help with pellet cladding mechanical interactions. Plastic deformation in UO 2 involves multiple mechanisms, including diffusional creep, dislocation climb, and glide. This milestone contains two parts: (1) UQ of a pre-existing lower length scale informed mechanistic diffusional creep model, and (2) development of a new LApx based model for dislocation-mediated creep mechanisms in UO 2 , with application to large-grain doped UO 2 .

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

R&D Roadmap for Enhanced Resilient Plant Systems, Metrics, Scenarios, Risk Analysis, and Modeling and Simulation

The nuclear industry and the U.S. Department of Energy are jointly developing accident tolerant fuel (ATF) which has the potential to greatly improve the safety and economic performance of the current fleet of NPPs. The combination of ATF with the optimal use of FLEX equipment (deployed as an industry response to the Fukushima Daiichi Nuclear Power Plant (NPP) accident in 2012), enhancements on plant components and systems, incorporation of augmented cooling systems or new passive cooling systems, and improvements in fuel cycle efficiency, have the potential to render the NPPs more efficient and resilient to events (both internally and externally initiated) that have the potential to challenge the integrity of the fuel or plant containment. In this report, combinations of these plant improvements are called Enhanced Resilient Plant Systems. In order to accelerate the development and deployment of the components that comprise Enhanced Resilient Plant Systems, a well-integrated toolkit that is fuel/clad-, fuel cycle-, systems-, and scenario-centric is required to provide a ready platform for the analysis of the advanced ATF fuel and cladding materials that are being developed, as well as plant systems modifications to achieve enhanced resiliency. Since the deployment of these enhancements will comprise a risk/benefit tradeoff of their impacts on plant safety and economics, the envisioned toolkit will need to be capable to characterizing the multidimensional aspects associated with these evaluations and provide decision-makers with information that can optimize the technological, economic, and safety benefits that are to be obtained. The Risk-Informed Systems Analysis (RISA) Pathway of the DOE Light Water Reactor Sustainability (LWRS) Program initiated several research tasks to develop analytical capabilities to support the industry in the transition to the ATF and Enhanced Resilient Plant Systems. The general idea behind the initiative is the development of an integrated evaluation approach which combines the plant probabilistic risk assessment (PRA) models with Multi-Physics Best Estimate Plus Uncertainty (MP-BEPU) analyses in a seamless fashion. The integrated evaluation framework aims at enabling plant system configuration variations to be studied with speed and precision, including detailed risk and benefit assessments of introducing ATF and Enhanced Resilient Plant Systems into current LWR plants to achieve both safety and operational performance enhancements. The focus of this report is to present an integrated research and development (R&D) roadmap to identify and perform high value evaluations of proposed ATF and Enhanced Resilient Plant Systems concepts to identify both the technical (e.g. benefits to risk, safety, and operational margins) and the economic (i.e. business and cost) elements associated with industry adoption of the technology. The integrated evaluation approach will be developed to support the development, testing, qualification, licensing, and deployment of ATF and Enhanced Resilient Plant Systems technology that is capable of achieving substantial safety and economic improvements as well as timely widespread adoption by the US nuclear industry.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

Wireless Instrumented RB Experiment Preliminary Design and Analysis

The ability to deploy new nuclear fuels for current or future reactor concepts requires carefully designed experiments to generate data to support fuel qualification. Ideally these experiments would include state of-the-art sensing to maximize the amount of in situ data that can be collected during operation. Furthermore, advanced reactor systems can take advantage of integrated in-core sensing technologies to maximize fuel utilization, reduce unnecessary conservativism in design margins, and improve operator’s understanding of limiting peaking factors. Before any novel sensing technologies can be readily adopted for nuclear applications, they must first demonstrate acceptable performance in test reactors. This report summarizes the preliminary design and analysis of the most highly instrumented irradiation experiment ever performed in the removable beryllium (RB) positions of the High Flux Isotope Reactor (HFIR) at Oak Ridge National Laboratory (ORNL). The Wireless Instrumented RB Experiment 2021 (WIRE-21) will test a wide range of sensors including wireless sensors being developed by Westinghouse Electric Company (WEC) that could provide in situ measurements of peak fuel temperatures and fuel rod pressurization due to fission gas release. The ability to wirelessly transmit a signal through the fuel rod’s cladding is critical to improving fuel monitoring capabilities without requiring signal penetrations through the cladding pressure boundary, which would significantly impact fuel fabrication, handling, and operation. Other sensors that will be tested in WIRE-21 include an array of thermocouples, self-powered neutron detectors (SPNDs), and spatially distributed fiber-optic temperature sensors. More generally, WIRE-21 will establish a flexible irradiation vehicle design to allow accelerated, economical testing of advanced sensor technologies while leveraging the extremely high neutron flux that is available in HFIR. This report summarizes the mechanical design for WIRE-21, the experimental test matrix, initial neutronic and thermal design analyses, and the active monitoring and control system enhancements necessary to support testing of advanced sensor technologies. The containment for WIRE-21 is similar to previous RB irradiation vehicles but includes a few modifications, most notably the use of integrated compression seals to pass a larger number of sensor leads through the experiment’s pressure boundary. In addition to the sensor leads, inert gas lines are passed into the experiment to enable active temperature control and the ability to pneumatically actuate a bellows-driven pressure sensor. WIRE-21 is targeting temperatures (300–350°C) and neutron fluence levels (~10 22 n/cm 2 ) relevant to light water reactors (LWRs), but the flexible design of the experiment vehicle allows much higher operating temperatures (>1,100°C). Neutronic calculations determine the neutron flux conditions as well as the nuclear heating within the experiments. These results are used as inputs to detailed thermal finite element calculations, which are required to evaluate the complex, three-dimensional heat transfer that occurs within WEC’s wireless sensor enclosures. Initial results show that the temperatures of the sensors’ enclosures and the metal bellows can be operated near the temperature range of LWR coolants and cladding while simultaneously increasing the temperature of a surrogate fuel material to values in the range of 800–1200°C to simulate centerline fuel temperatures during LWR operation.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Development of Advanced Instrumentation for Transient Testing

A fuel safety research program centered on in-pile transient testing experiments is being developed to support assessment and qualification of advanced nuclear fuel systems using the recently restarted Transient Reactor Test (TREAT) facility at the Idaho National Laboratory (INL). While resumption of transient testing at TREAT is crucial to enable these programs, full recovery and cutting-edge transient testing capability also requires a well-coordinated and innovative instrumentation development and qualification program to support near-term and future objectives. This paper summarizes the experimental approach of transient testing to focus on measuring the response of nuclear fuel to off-normal (or power-cooling mismatch) conditions for modern and advanced reactor environments requiring capabilities extending over wide measurement and environment conditions. It also highlights unique attributes of transient testing of importance to in-pile instruments including relatively low total neutron fluence, high gamma heating, and the need for well-defined and possibly short time response. Historical approaches to instrumentation for transient testing are also reviewed to provide context to the modern instrument strategy. The instrumentation needs of a modern transient testing are detailed while summarizing several ongoing R&D activities are supporting the development of state-of-the-art and ‘advanced’ measurement technologies that will provide baseline capability for Light Water Reactor (LWR) and Sodium-Cooled Fast Reactor (SFR) experiment objectives, while extending to other advanced reactor needs and advanced sensing technology opportunities. Examples of specific sensors planned for near-term deployment with ongoing development includes prompt-response self-powered neutron detectors (SPND), miniature fission chambers, optical-fiber-coupled infrared pyrometer, cladding surface thermocouples, electrical-impedance based boiling detector, and Linear Variable Differential Transformer (LVDT) based sensors for fuel elongation and pressure measurement.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Qualification and Quantification of Porosity at the Top of the Fuel Pins in Metallic Fuels Using Image Processing

Approximately 130,000 metal fuel pins were irradiated in the Experimental Breeder Reactor II (EBR-II) during its 30 years of operation to develop and characterize existing and prospective fuels. For many of the metal fuel irradiation experiments, neutron radiography imaging was performed to characterize fuel behavior, such as fuel axial expansion. While several fuel expansion results obtained from neutron radiography imaging have been published, the analysis of neutron radiography for the purpose of describing statistical properties of porous matter formed on top of the fuel pins, also referred to as fluff in previous publications, is significantly less represented in the literature with just a single paper so far. This study aims to validate and augment results reported in previous publications using automated image processing. The paper describes the statistical properties of the porous matter in terms of nine parameters derived from radiography images and correlates those parameters with such fuel properties as composition, expansion, temperature, and burnup. The reported results are based on 1097 fuel pins of eight different fuel compositions. For three major fuel types, U-10Zr, U-8Pu-10Zr, and U-19Pu-10Zr, a clear negative correlation is found between the Pu content and five parameters describing the amount of porous matter generated. The parameters describing granularity properties, however, showed either negative correlation or nonlinear dependency from fuel composition. The parameters describing the amount showed a positive correlation with fuel axial expansion, while granularity parameters showed a negative correlation with axial expansion. The dependency on cladding temperature was found to be weak. A positive correlation is demonstrated for volume parameters and fuel burnup. In general, reported results confirm and validate findings published in previous studies using a much larger number of pins and automated processing techniques, which easily lend themselves to reproducibility, thus avoiding subjective bias.

36 MATERIALS SCIENCE↗

Prospects for additive manufacturing of nuclear fuel forms

Additive manufacturing (AM) is viewed as a critical enabling technology for achieving superior performance and improved economics across many sectors. Although the past decade has seen increased application of AM methods to nuclear reactor cladding and structural materials, exploration of AM as applied to the uranium-bearing nuclear fuel forms has been limited. The two major families of nuclear fuel forms (monolithic, particle/dispersion) are utilized with their own set of core objectives in mind, and their differences require distinct fabrication infrastructures. These reference fabrication methods impose many limitations on nuclear fuels. Further, both currently operating reactors and future concepts have the potential for improved performance if these accepted limitations are relaxed or removed entirely. The primary limitations of reference fabrication processes for the common nuclear fuel forms are outlined in this paper. This groundwork is then used to identify avenues of fuel performance specific to each of these fuel architectures that could be exploited if the restrictions of conventional fuel fabrication are removed. Moreover, multiple targets for AM studies are laid out for each of the major nuclear fuel variants. Finally, key strategic components to guide research activities in AM of nuclear fuels are outlined, with an emphasis on use of modeling and simulation to motivate research aims and embrace of an accelerated testing methodology to screen and quality new fuel forms.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Advanced Autonomous Welding for Refabrication and Follow-On Testing of Previously Irradiated Nuclear Fuel

The performance of follow-on experiments using irradiated nuclear fuel at any point in its lifecycle is a critical step in understanding phenomena and behavior. Transient experiments with high-burnup fuel can deepen the understanding of fuel fragmentation, relocations, and dispersal under loss-of-coolant accidents. An advanced autonomous welding process to refabricate commercial fuel rods inside a hot cell was created and tested to enable flexible experiment approaches on fuels irradiated in commercial and test reactors. Irradiated light water reactor fuel test pins from experiments performed at the Advanced Test Reactor (ATR) at Idaho National Laboratory were used to demonstrate the refabrication process. The welding process was found to be sensitive to welding parameters but flexible such that multiple passes could be performed on the same location until a hermetic weld was obtained. The refabrication of rodlets and successful welds was also found to be sensitive to the preparation of the irradiated cladding and endcaps. Thorough defueling of the fuel at the weld location and proper sizing of the endcaps and backing material mitigated these issues. The use of strategically located heat sinks in contact with the cladding and endcap materials also increased welding and refabrication success. For this work, the test pins were sectioned to remove the original endcaps and fuel was removed from both ends of each rodlet. The reassembly of the rodlets was then completed in four steps, which included the press fitting of new endcaps, the circumferential welding of rodlet endcaps to the cladding, rodlet pressurization in a pressure chamber, and seal welding the rodlet under pressure. The integrity of the refabricated rodlets was then verified via helium leak checking inside a vacuum chamber. The advanced welding system is capable of refabricating rodlets up to 380 mm in length, and repressurizing them up to 15 500 kPa. The refabricated lengths of the rodlets used in this work ranged from 149 to 165 mm and the refabricated fuel stack heights ranged from 70.4 to 79.8 mm. Here, the rodlets were pressurized with argon to an average pressure of 3617 kPa, and the average leak rate after refabrication was 6.7 • 10 -8 cm 3 • s -1 .

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗