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DOE OSTI2015

Studies of EMP generation using a Lienard-Wiechert formulation, and progress toward a 3-D EMP code

Here, we describe studies of the generation of electro-magnetic pulse (EMP) fields under the idealized conditions of a delta-function gamma pulse, a spherical cap of Compton electrons located at a common radius from the burst, and the absence of the conduction current. Various processes (geomagnetic rotation, drag, and scattering) contribute to the time derivative of the Compton current density, which appears as the source term in the Lienard–Wiechert expression for the radiation field. These processes are considered separately and in combination, and their influences on the waveform of the EMP assessed. Using a separate computational approach, different numerical models of multiple scattering are tested, in an effort to assess the validity of existing codes and earlier results. We also describe plans for and progress toward a comprehensive 3-D EMP code, which is to employ recently developed numerical methods and is to offer a variety of models, including the Lienard–Wiechert formulation described here.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2024

Development of spectroscopy apparatus for molten salt reactor safeguards and material characterization

A molten salt reactor (MSR) produces nuclear fission energy using mixture of fissile and non-fissile salts. Salt in the reactor functions as the nuclear material and the coolant allowing for a safer design. International nuclear safeguards is the monitoring of nuclear reactors, nuclear fuel, and irradiated material to prevent the proliferation of nuclear weapon grade material in hostile foreign nations. The mixture of salt creates a proliferation risk as it generates a conglomeration of fuel, daughter nuclei, and corrosive material. A method to monitor and measure the materials present in the reactor is essential to the scalable deployment of MSRs. The objective of this project was to design a spectroscopy apparatus for aqueous salt so it can be measured and collected consistently in the aerosol phase.

98 NUCLEAR DISARMAMENT, SAFEGUARDS, AND PHYSICAL P↗

DOE OSTI2021

Accelerate Nuclear Research and Development by Reducing Time and Cost Spend in the Pre-conceptual Design Phase of Advanced Reactor Experiments

The design process of every new concept, such as advanced nuclear reactors or associated experiments, starts with the pre-conceptual design phase. In this phase, the viability of a wide range of design options needs to be assessed quickly, to understand the operating envelope and its feasibility. A variety of physics models (thermal-hydraulics, neutronics, mechanical design, etc.) has to be considered at this very first design stage and optimum component sizes and materials (e.g. heat exchangers, piping, turbomachinery, coolant type, etc.) have to be chosen for a given set of boundary conditions (e.g. heat source, heat sink, flow rate, etc.). Detailed solutions such as provided by high fidelity methods like computational fluid dynamics (CFD), Monte Carlo methods, etc. and even lower fidelity tools such as system or subchannel codes, etc. are usually not used during the pre-conceptual design due to the relatively long time needed to create input models, the computational time to obtain a solution and the lack of flexibility to quickly investigate different combinations of components, individual component sizes and material properties. High fidelity tools are usually only employed in the conceptual design and later phases once a base concept has been identified during the pre-conceptual design stage. The current practice during the pre-conceptual design stage is that analysts collect the needed equations, material properties, closure laws, etc. and create ad-hoc solutions form scratch for every new problem. There clearly is a lack of a flexible scoping tool that can be used during pre-conceptional design before higher fidelity tools (as described above) come into play. To reduce user errors in ad-hoc solutions and increase fidelity and efficiency, this project aims to investigate and develop a user-friendly scoping tool to address the thermal-hydraulic designing needs during preconceptual experiment design, i.e. Thermal-hydraulic Research Universal Scoping Tool (TRUST). The success of TRUST will provide the nuclear engineers with an easy-to-use and affordable calculator for early reactor system design and optimization.

42 ENGINEERING↗

DOE OSTI2026

Ceramic Composite Experimental Testing Status

Over recent years, ceramic matrix materials such as SiC–SiC and C–C have been gaining interest for use in fusion reactors, light water reactors (LWRs), and high-temperature reactors (HTRs). These materials are good candidates to operate in very high temperature and moderate to high radiation environments. The evaluation of composite materials, in general, is challenging because of variations in precursor materials, variations in the fabrication process across fabricators, and the wide range of potential fiber architectures, to name a few. However, the need to evaluate neutron-irradiated properties adds another layer of complexity, which includes cost, timeline, and specimen size limitations (often associated with irradiation testing). A qualification methodology for the use of ceramic composites is provided in the American Society of Mechanical Engineers (ASME) Boiler and Pressure Vessel Code Section III-5-HHB. The methodology is supported by ASTM International (ASTM) guides, which provide a pathway to accomplish this effort. Part of the qualification strategy is for the designer to collect material property data on environmental conditions representative of its design envelope. These data include irradiation effects. This report presents an experimental study and test campaign developed to partially address this gap by providing initial mechanical and physical property data required for design. A variety of different materials using different manufacturing techniques are considered as part of this campaign. The test plan suggests performing a screening or partial irradiation study to assist the designer during the material selection process. The designer can then perform a more comprehensive qualification study if the material performance is promising. This work focuses on the status of the specimen preparations (machining of samples), the current test methods and failure analysis as well as the preparation of irradiation vehicles for the irradiation campaign. The irradiation will be performed at Oak Ridge National Laboratory (ORNL) in the High Flux Isotope Reactor (HFIR) and at Idaho National Laboratory (INL) in the Advanced Test Reactor (ATR).

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2014

AUTOMATED, HIGHLY ACCURATE VERIFICATION OF RELAP5-3D

Computer programs that analyze light water reactor safety solve complex systems of governing, closure and special process equations to model the underlying physics. In addition, these programs incorporate many other features and are quite large. RELAP5-3D[1] has over 300,000 lines of coding for physics, input, output, data management, user-interaction, and post-processing. For software quality assurance, the code must be verified and validated before being released to users. Verification ensures that a program is built right by checking that it meets its design specifications. Recently, there has been an increased importance on the development of automated verification processes that compare coding against its documented algorithms and equations and compares its calculations against analytical solutions and the method of manufactured solutions[2]. For the first time, the ability exists to ensure that the data transfer operations associated with timestep advancement/repeating and writing/reading a solution to a file have no unintended consequences. To ensure that the code performs as intended over its extensive list of applications, an automated and highly accurate verification method has been modified and applied to RELAP5-3D. Furthermore, mathematical analysis of the adequacy of the checks used in the comparisons is provided.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2023

Polarized fusion and potential in situ tests of fuel polarization survival in a tokamak plasma

Abstract The use of spin-polarized fusion fuels would provide a significant boost towards the ignition of a burning plasma. The cross section for D + T → α + n, would be increased by 1.5 if the fuels were injected with parallel polarization. Furthermore, our simulations demonstrate additional non-linear power gains in large-scale machines such as ITER, due to increased alpha heating. Such benefits require the survival of spin polarizations for periods comparable to the particle confinement time. During the 1980s, calculations predicted that polarizations could survive a plasma environment, although concerns persisted regarding the cumulative impacts of wall recycling. In that era, technical challenges prevented direct tests and left the large scale fueling of a power reactor beyond reach. Over the last decades, this situation has changed dramatically. Detailed simulations of ITER have predicted negligible wall recycling in a high-power reactor, and recent advances in laser-driven sources project the capability of producing large quantities of ∼100% polarized D and T. The remaining crucial step is an in-situ demonstration of polarization survival in a plasma. For this, we outline a measurement strategy using the isospin-mirror reaction, D + 3 He → α + p. Polarized 3 He avoids the complexities of handling tritium, while encompassing the same spin-physics. We evaluate two methods of delivering deuterium, using dynamically polarized Lithium-Deuteride (with vector polarization P V D of 70%) or frozen-spin Hydrogen-Deuteride (with P V D of 40%), together with a method of injecting optically-pumped 3 He (with 65% polarization). Pellets of these materials all have long polarization decay times (∼6 min for LiD at 2 K, ∼2 months for HD at 2 K, and ∼3 d for 3 He at 77 K), all far greater than a plasma shot in a research tokamak such as DIII-D (∼20 s). Both species can be propelled from a single cryogenic injection gun. We review plasma requirements and strategies for detecting polarization survival. Polarization alters both fusion yields and the angular distribution of fusion products, and each of these provides a potential signal. In this paper we simulate a selection of shots with similar characteristics in a future high-T ion H plasma, and find ratios of yields from shots with fuel spins parallel and antiparallel reaching 1.3 (HD + 3 He) to 1.6 (LiD + 3 He) over a wide range of poloidal angles. (A companion paper finds sensitivity to fusion product angular distributions as reflected in the pitch angles of protons and alphas reaching the plasma facing wall.)

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2025

Decayheatml

This code is designed to predict and analyze the decay heat generated in molten salt reactors (MSRs) using a hybrid approach that combines machine learning and segmented polynomial fitting. The accurate prediction of decay heat is essential for reactor safety and the optimization of spent fuel storage. The code operates through several key components: 1) Data Architecture: It incorporates a modular data architecture that handles various MSR-specific operational parameters such as power density, humidity content, and air ingress. These parameters are sampled using Sobol sequences to ensure comprehensive coverage of operational uncertainties. 2) Machine Learning Framework: The code employs a diverse set of machine learning models, including polynomial regression, decision trees, random forests, gradient boosting, support vector regression, k-nearest neighbors, multi-layer perceptrons, and symbolic regression. These models are trained to predict decay heat over a wide temporal range, from immediate shutdown up to 10,000 years. 3) Region-Optimized Training: The temporal domain is divided into multiple regions, each modeled separately to capture distinct decay heat characteristics across different time scales. This approach significantly improves the accuracy and interpretability of predictions. 4) Segmented Polynomial Interpretation (SPI): The SPI method translates machine learning predictions into piecewise polynomial equations. These equations are physically interpretable and can be directly integrated into existing engineering workflows and safety analyses. 5) Front-End Interfaces: The code includes both a Jupyter notebook interface for research development and a Streamlit web application for operational deployment. These interfaces allow users to interactively explore decay heat predictions, adjust operational parameters, and visualize results in real-time. 6) Applications: The framework supports various applications, including safety system validation and spent fuel container optimization. It enables real-time evaluation of worst-case decay heat scenarios, informing the design of passive safety systems and optimizing container designs for long-term storage. Overall, this code provides a robust, accurate, and user-friendly tool for predicting decay heat in MSRs, enhancing reactor safety, and optimizing spent fuel management.

Retamales, Mauricio Eduardo Tano [Idaho National L↗

DOE OSTI2022

Demonstration of photoreactor platform for on-sun unassisted photoelectrochemical hydrogen generation with tandem III–V photoelectrodes

Photoelectrochemical (PEC) water splitting is a direct solar-driven technology that converts solar energy to storable chemical energy in the form of hydrogen. In addition to semiconductor and catalyst development for improved photoelectrodes, designing reactors for testing and operation of PEC systems under inherently dynamic outdoor solar illumination is necessary to further the commercial viability of PEC technology. Herein, we present a versatile photoreactor system mounted on a solar tracker for outdoor PEC testing and demonstrate unassisted PEC water splitting under real world on-sun conditions. GaInP 2 /GaAs tandem absorber photoelectrodes with a MoS 2 catalyst were fabricated and exhibit >8% solar-to-hydrogen efficiency. On-sun efficiency and stability of the photoelectrodes were characterized on both sunny and partly cloudy days with continuous monitoring of insolation and weather conditions. Furthermore, the versatile photoreactor and outdoor PEC testing capabilities and methods presented here can accelerate the development of other solar fuel generating systems and technologies.

solar fuels↗

DOE OSTI2020

DOE-NE LWRS Integrated Program Plan - Physical Security Pathway

Domestic nuclear power is facing increased financial pressures from a variety of areas and there is pressure on these utilities to reduce their cost of operation. Currently, about 20%-30% of all on-site personnel are related to physical security. The LWRS Program recognized that R&D related to physical security could play a role in providing nuclear utilities technical and staffing efficiency options to meet their physical security commitments, but utilities often lack the technical basis or the ability to create the technical basis to realize or implement these efficiencies; towards this end, the LWRS Program created the Physical Security Pathway in September 2019. The pathway performs R&D to develop methods, tools, and technologies to optimize and modernize a nuclear power facility’s security posture. The pathway will: (1) conduct research on risk-informed techniques for physical security that account for a dynamic adversary; (2) apply advanced modeling and simulation tools to better inform physical-security scenarios and reduce uncertainties in force-on-force modeling; (3) assess benefits from proposed enhancements and novel mitigation strategies and explore changes to best practices, guides, or regulation to enable modernization; and (4) enhance and provide the technical basis for stakeholders to employ new security methods, tools, and technologies.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2017

Treatment of Nonuniform Temperature Distribution by Subgroup Method

The subgroup method divides an energy group into several subgroups according to the magnitude of the cross section. The subgroup fixed source equation is formulated on the energy range of a subgroup, the ratio of which to the energy range of an energy group is defined as subgroup probability. Typically the physical probability table or the mathematical probability table is applied. However, both of the tables are not guaranteed to share the same set of subgroup probabilities for a resonant nuclide at different temperatures. This means that the subgroup fixed source equation cannot be formulated and the subgroup method will not work when the temperature distribution is nonuniform. To overcome this defect, the subgroup method based on partial cross section fit scheme (PXSFS) and the simplified partial cross section fit scheme (SPXSFS) are proposed. These methods fit the cross sections at different temperatures as partial cross sections to share a same set of subgroup probabilities. The new methods is compared to the conventional subgroup method (CSM) based on physical probability table and the preexisting methods: the correlation model (CM), the subgroup level adjustment scheme (SLAS) and the number density adjustment scheme (NDAS). The numerical results show that the new methods can better predict the spatial dependent reaction rate than preexisting methods. Within these two methods, the simplified scheme consumes less time.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2016

Ab initio generation of thermal neutron scattering law for uranium dioxide

Neutronic analysis of moderated nuclear fission systems, e.g. nuclear reactors, relies upon an accurate prediction of the thermal neutron spectrum. Thermal neutrons have wavelengths on the order of the interatomic spacing between atoms in matter. Consequently, the scattering cross-sections of these neutrons are affected by the scattering law of the material (i.e. S(α,β), where α and β are dimensionless momentum and energy transfer variables), which describes the atomic structure and thermodynamic motion of the atomic nuclei. Uranium-dioxide (UO{sub 2}) is the primary fuel source for nuclear power reactors moderated by light water. In such systems (e.g. nuclear power reactors, spent fuel pools, etc.) the nuclear fuel comprises a large fraction of the system volume, approximately 1/3 in light-water reactors. Therefore, the scattering law of the fuel material may impact the thermal neutron spectrum and criticality of these systems. In this work previously established ab initio lattice dynamics (AILD) methods were utilized to calculate the phonon density of states (DOS), which acts as a fundamental input to the scattering law. Subsequently, the S(α,β) of UO{sub 2} was generated for publication as an ENDF thermal scattering library (TSL), which will be available for use in standard neutronics computer applications. (authors)

07 ISOTOPE AND RADIATION SOURCES↗

DOE OSTI2026

Subplane Decusping for BWRs in MPACT

Control blade cusping can introduce significant error in boiling water reactor (BWR) calculations with MPACT when blade tips fall partway within an axial method of characteristics (MOC) plane, requiring homogenization of controlled and uncontrolled regions. This work implements subplane decusping for BWRs in MPACT by enabling BWR-compatible subplane coarse mesh finite difference (CMFD) and extending the existing decusping framework to represent between-assembly control blades that insert from the bottom of the core. The method resolves axial heterogeneity on a refined subplane mesh in the low-order solve and uses the resulting subplane flux shape to form flux-volume homogenized transport cross sections for the partially rodded MOC plane. The capability is evaluated using a single physics General Electric (GE)-14 assembly and a multiphysics Peach Bottom Unit 2 Type 1 assembly (PB2T1A) with thermal hydraulic feedback. In both cases, coarse axial meshes with and without subplane decusping are compared against fine mesh reference solutions over the full range of blade withdrawal positions. Subplane decusping reduces maximum/average eigenvalue errors from 3,369/220 pcm to 303/36 pcm for GE-14 and from 6,689/585 pcm to 1,582/109 pcm for PB2T1A. Additionally, it reduces pin power root mean square errors from 5.2%/0.8% to 1.8%/0.2% for GE-14 and from 6.9%/0.6% to 2.3%/0.1% for PB2T1A. These results demonstrate an effective, practical correction for BWR blade cusping in VERA-MPACT.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2017

Roadmap for the Application of Ion Beam Technologies to Challenges for the Advancement and Implementation of Nuclear Energy Technologies

The use of ion beams in interrogating materials performance for nuclear energy applications is advancing at a rapid rate. Ion irradiations have been proven to produce radiation effects data that are of direct relevance for understanding neutron-induced displacement damage. This development reflects significant and continued investment in infrastructure by the U.S. Department of Energy (DOE) as well as support of science and engineering research at universities and national laboratories. Application of ion beam irradiation methods to enhance the deployment of materials in reactors is in the spirit of the Gateway for Accelerated Innovation in Nuclear (GAIN) initiative sponsored by DOE to accelerate the deployment of innovation in the U.S. nuclear industry. Ion beam irradiation shows considerable promise for assisting in down selecting candidate materials for use in both current and advanced nuclear energy systems. Ion beams allow rapid achievement of materials damage levels not accessible by neutron irradiation in test reactors due to cost and time constraints. Ion beam studies provide data on the effects of irradiation under very specific conditions of temperature, radiation dose, and radiation dose rate that are difficult or impossible to achieve via reactor irradiation experiments. This data can be used to develop and validate detailed predictive radiation effects models for use in reactor materials research and development. Despite the current high state of the art and the maturity of quality assurance, there are still challenges to the deployment of ion beam data in support of reactor materials qualification. For the most part, these challenges arise from the lack of a detailed mechanistic understanding of potential difference between ion induced and neutron induced materials damage, which is exacerbated by difficulties in obtaining bulk physical and mechanical properties data from the micron-scale heavy ion irradiation depths. In particular, improved understanding of dose rate effects, as a function of temperature, are needed. This document offers a roadmap for the development and enhancement of current U.S. ion beam irradiation technologies within university and national laboratory settings, and especially for the deployment of new highly controlled in situ interrogation of materials during irradiation to provide dynamic and mechanistic data for model development. The status and capabilities of relevant U.S. ion beam facilities are summarized and recommended “best practices” for performing ion irradiations are described. The potential role of ion beam irradiations to assist the development and deployment of reactor materials is outlined. Key principles include developing methods for rapid and cost-effective materials selection and development, characterizing fundamental material response under irradiation, and developing a robust mechanistic understanding of microstructure evolution under irradiation (including development and validation of reliable predictive models for microstructure evolution).

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

DOE OSTI2016

Ceramic oxygen transport membrane array reactor and reforming method

A commercially viable modular ceramic oxygen transport membrane reforming reactor for producing a synthesis gas that improves the thermal coupling of reactively-driven oxygen transport membrane tubes and catalyst reforming tubes required to efficiently and effectively produce synthesis gas.

03 NATURAL GAS↗

DOE OSTI2020

Sulfur Pellets Responses to a Bare and Steel Reflected Pulse of the Oak Ridge National Laboratory Health Physics Research Reactor

The experiments analyzed in this report were conducted at the Health Physics Research Reactor (HPRR), also known as the $\textit{Fast Burst Reactor}$. The reactor was designed and built at Oak Ridge National Laboratory (ORNL) in 1961. The HPRR was an unmoderated, unshielded fast reactor that used highly enriched uranium and molybdenum alloy as fuel. The reactor was initially sent to the Nevada Test Site in 1962, where it was used to evaluate radiation doses received as a result of the Hiroshima and Nagasaki bombings during World War II. A few years later, the reactor was sent back to ORNL to be part of the Dosimetry Application Research (DOSAR) facility shown in Figure 1, which included a reactor building shown on the left (west) of the picture and a control and laboratory building in the upper right corner (northeast). The critical assembly was used for numerous technical studies, including systems calibration, dosimetry, radiobiology of plants and animals, testing of radiation alarms, as well as teaching and training in radiation dosimetry and nuclear engineering. Between 1963 and 1987, the HPRR was operated for thousands of hours, achieving criticality close to 10,000 times and motivating many publications. The HPRR was decommissioned in 1987. The goal of this effort was to use historical data from operation of the HPRR to create a criticality accident alarm system (CAAS) benchmark to be included in the $\textit{International Handbook of Evaluated Criticality Safety Benchmark Experiments}$ (ICSBEP Handbook). A thorough inspection was performed of all available documentation and information available. The most promising experiments that were selected for evaluation were those described in the 1987 ORNL report entitled $\textit{Health Physics Research Reactor Reference Dosimetry}$, ORNL-6240. The report includes reference dosimetry results of the shielded and unshielded configurations of the HPRR after burst operations. Because of changes to the reactor positioning and storage systems that were made in 1985, the previous dosimetry reports became obsolete, and the newly designed experiments were needed to create the HPRR’s adjusted dosimetry data. The various results reported in ORNL-6240 include reference doses and dose equivalents from different conventions at different distances and elevations as determined using the detected neutron fluence and conversion factors. The HPRR neutron fluence was obtained through different methods, including sulfur pellet analysis and threshold detector unit data. Information about the HPRR spectrum was also obtained through Bonner sphere measurements. This benchmark is focused on a part of the measured sulfur fluences reported in Appendix H of ORNL-6240. Standard commercial sulfur pellets were placed at different distances from the HPRR centerline during burst operation and were activated due to the 32 S(n,p) 32 P reaction. The resulting 32 P activity was then measured and the information about the corresponding sulfur fluence and/or neutron dose could be extracted. Many of those measurements have 7 been performed with the HPRR in its bare configuration or with different shields (combinations of Lucite, concrete, steel). All the necessary, precise information about material and/or dimensions of the different shields was not found, so it was decided to focus only on the unshielded and steel-shielded configurations to minimize the benchmark uncertainty. A total of 31 cases (24 unshielded and 7 shielded cases at different positions) of sulfur fluence were selected before evaluation to develop the benchmark.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2018

On the Heating of Ions in Noncylindrical Z-Pinches

The method proposed here for analyzing processes in a hot plasma of noncylindrical Z-pinches is based on separation of the group of high-energy ions into a special fraction. Such ions constitute an insignificant fraction (~10%) of the total volume of the Z-pinch plasma, but these ions contribute the most to the formation of conditions in which the pinch becomes a source of nuclear fusion products and X-ray radiation. The method allows a quite correct approach to obtaining quantitative estimates of the plasma parameters, the nuclear fusion energy yield, and the features of neutron fluxes in experiments with Z-pinches.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2022

Development of a high fidelity model of the CROCUS experimental reactor

Measurements of scalar flux distributions with fine spatial and energy resolutions are needed to remedy one of the validation shortcomings of the novel neutronics full core solvers, such as MPACT and nTRACER. While a very detailed resolution of the flux can be calculated with such codes, only a limited experimental data set is available to check their accuracy. Such type of measurements are on-going at the zero power reactor CROCUS, operated at the Laboratory for Reactor Physics and System Behaviours of the EPFL, thanks to the development of advanced miniature neutron detection systems. This kind of experimental data would provide the community with a suitable benchmark for the validation of high fidelity neutronics solvers. In parallel, a multi-physics solver for steady-state and transient analysis of nuclear reactors, named GeN-Foam, has been developed. Based on the finite-volume OpenFOAM library, GeN-Foam provides us with enough flexibility to analyze non-conventional reactor geometries such as that of CROCUS. While CROCUS heterogeneities cannot be modeled by MPACT and nTRACER for the moment, GeN-Foam offers a unique opportunity to build a high fidelity model which mimics these codes' method to reach sub-pin simulation resolution. This document aims at describing the work achieved to get from the existing GeN-Foam model of the CROCUS reactor based on a structured mesh and using the neutron diffusion, the first high-fidelity model using discrete ordinates method as an approximation to neutron transport and an unstructured mesh for inter lattice water gap description and sub-pin heterogeneous modeling. (authors)

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2016

Examination of Hybrid Metal Coatings for Mitigation of Fission Product Release and Corrosion Protection of LWR SiC/SiC

There is a need to increase the safety margins of current and future light water reactors (LWRs) due to the unfortunate events at Fukushima Daiichi Nuclear Plant. Safety is crucial to restore public confidence in nuclear energy, acknowledged as an economical, high-density energy solution to climate change. The development of accident-tolerant fuel (ATF) concepts is crucial to this endeavor. The objective of ATF is to delay the consequences of accident progression, being inset in high temperature steam and maintaining high thermomechanical strength for radionuclide retention. The use of advanced SiCf-SiC composite as a substitute for zircaloy-based cladding is being considered. However, at normal operations, SiC is vulnerable to the reactor coolant and may corrode at an unacceptable rate. As a ceramic-matrix composite material, it is likely to undergo microcracking operation, which may compromise the ability to contain gaseous fission products. A proposed solution to both issues is the application of mitigation coatings for use in normal operations. At Oak Ridge National Laboratory (ORNL), three coating technologies have been investigated with industry collaborators and vendors. These are electrochemical deposition, cathodic arc physical vapor deposition (PVD hereafter) and vacuum plasma spray (VPS). The objective of this document is to summarize these processing technologies, the resultant as-processed microstructures and properties of the coatings. In all processes, substrate constraint resulted in substantial tensile stresses within the coating layer. Each technology must mitigate this tensile stress. Electrochemical coatings use chromium as the coolant facing material, and are deposited on a nickel or carbon “bond coat”. This is economical but suffers microcracking in the chromium layer. PVD-based coatings use chromium and titanium in both metallic form and nitrides, and can be deposited defense-in-depth as multilayers. This vapor method eliminated tensile stress during processing and coatings were up to ~30 μm thick without microcracking. VPS produced coatings based on Zircaloy-2, which has a proven reactor-compatibility. The tensile stresses appearred to be partially mitigated by annealing. Analysis showed that VPS coatings required further optimizations to prevent adverse reactions with the substrate and need a minimum thickness of ~50 μm. In addition, development of coatings are constrained by neutronic depletion analysis, which clearly indicated enrichment as an issue if the coating is too thick. Based on the present work, the cathodic arc PVD technology was considered ready for the extensive testing and evaluation on cladding materials due to their ability to mitigate the excessive tensile stresses and the reasonable coating quality achieved. The VPS Zircaloy-2 coating technology required additional development toward mitigation of issues related to the substrate reaction and porosity. In the future, PVD and VPS will have be scaled upon successful development and demonstration. Electrochemical coatings, which are proven scalability, currently require development to mitigate issues related to the tensile stress after deposition.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗