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DOE OSTI2025

In-Situ TEM Ion Irradiation Investigations on U3Si2 at LWR Temperatures

The radiation-induced amorphization of U3Si2 was investigated by in-situ transmission electron microscopy ion irradiation. Both arc-melted and sintered U3Si2 specimens were irradiated at room temperature to confirm the similarity in their responsesto radiation. The sintered specimens were then irradiated at 350◦C and 550◦C to examine their amorphization behavior under light water reactor (LWR) conditions. U3Si2 maintains its crystalline structure under irradiation at LWR temperatures. Oxidation of the material was observed at high irradiation doses.

Miaoa, Yinbin↗

DOE OSTI2021

Propagation of radio frequency waves through turbulent plasmas

The practical and economic viability of tokamak fusion reactors depends, in a significant way, on the efficiency of radio frequency (RF) waves to deliver energy and momentum to the plasma in the core of the reactor. The RF electromagnetic waves, excited by antenna structures placed near the wall of a tokamak, have to propagate through the turbulent edge plasma along their path to the core of the fusion device. In present day experiments, the radial width of the edge region and scrape-off layer is of the order of a few centimeters. In ITER, and in future fusion reactors, this width will be of the order of tens of centimeters. Any effects on RF waves due to plasma turbulence have to be properly understood in order to optimize the delivery of RF energy and momentum into the core. This paper is on a multi-pronged, theoretical and computational, approach that is being pursued to quantify the effect of edge plasma turbulence on the propagation of RF waves. The theoretical and analytical models are based on solutions of the Faraday-Ampere equation in a magnetized plasma and on the Kirchhoff tangent plane approximation. An effective medium approach has been developed so as to approximate the permittivity of a turbulent plasma by analytical expressions. The computations are being carried out with a newly developed code ScaRF that is based on the finite difference finite domain technique for solving Maxwell's equations. The plasma permittivity can be assigned as desired. The code is being used to validate the analytical and theoretical models and to evaluate their limitations.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2017

Microstructural evolution in Fe-20Cr-25Ni austenitic alloys under proton irradiation at 670 ºC

Austenitic stainless steels (SSs) are widely used in different components of nuclear plants. The NF709 (20Cr-25Ni-1.5MoTiNb) class of alloy was recently selected for development as a candidate structural material for sodium-cooled fast reactors due to its improved creep and corrosion resistance compared with 300-series austenitic SSs. This requires new understanding of the radiation response of the 709 class alloys. In this study, we correlated the mechanical changes with the proton-induced microstructural and chemical evolutions of a 20Cr-25Ni model alloy M709 and a 20Cr-25Ni-1.5MoNb alloy A709. The irradiation was conducted using 2 MeV protons at 670 ± 20 ºC to achieve 1.5 displacements per atom (dpa) at the middle of the proton project range. Sample characterization was achieved using nanoindentation, focused ion beam (FIB), scanning electron microscopy (SEM), energy-dispersive X-ray spectroscopy (EDS) and transmission electron microscopy techniques (TEM).

Chen, Tianyi↗

DOE OSTI2020

Estimated Diffusion Out of a TRISO Particle Under Ambient Conditions

Many analyses performing diffusion calculations for tri-structural isotropic (TRISO) fuel focus on either reactor conditions or accident scenarios, both instances of elevated temperatures. However, it is worthwhile to understand the diffusion of different elements out of a TRISO particle at ambient atmospheric temperatures, i.e. atmospheric temperatures that are common on the Earth’s surface. This report will outline the thermal analysis and diffusion calculations and then present the results of a generic TRISO particle.

Ivanusa, Pavlo↗

DOE OSTI2022

Updates and Validation for the n+ 63,65 Cu Cross Sections [Abstract]

The neutron induced total, elastic, and capture cross sections of 63,65 Cu isotopes were selected for evaluation in the resolved and unresolved resonance energy ranges by the National Criticality Safety Program to resolve discrepancies related to benchmark performance. This is especially evident for the series of ZEUS benchmarks in which copper is used as a reflector. Because copper is also used as structural material in both fission and fusion reactors, the need to address benchmark discrepancies linked to nuclear data deficiencies is a task of primary importance. The aim of this work is to describe the steps of evaluation work towards a consistent improvement of the benchmark performance. The R-matrix analysis with the SAMMY code focused on the 63 Cu(n,γ) reaction channel between 100-300 keV coupled to unresolved resonance region parameters up to 650 keV to fit average cross section data from a recent experiment. Due to the high sensitivity of many benchmarks to elastic scattering angular distribution data, especially for the 65 Cu isotope, the impact of these data was tested by generating Legendre coefficients from both resonance parameters and the Hauser-Feshbach model. Guided by the findings of Shaw et al., the performance of the current evaluation for 65 Cu was compared to that of ENDF/B-VII.1 and ENDF/B-VIII.0 by testing the reactivity coefficients corresponding to the validation suite of experimental criticality benchmarks for thermal, intermediate, and fast systems taken from the International Criticality Safety Benchmark Experiments Project Handbook. The benchmark performance is especially sensitive to 63 Cu(n,γ) and 65 Cu elastic scattering for neutron energies in the 100–500 keV region, whereas 100 keV is the upper limit of the resolved resonance region in the ENDF/B-VIII.0 evaluations for 63,65 Cu. The results highlight the need to handle the transition from the resolved resonance region to the high energy region carefully.

07 ISOTOPE AND RADIATION SOURCES↗

DOE OSTI2016

Evaluating alternate test techniques to characterize mechanical properties in nuclear-grade graphites - 18421

The deployment of graphite as a core structural material in the very high temperature reactor (VHTR) design presents a number of challenges with regard to accurate property and performance assessments. In the United States Advanced Reactor Technologies (ART) program, candidate VHTR graphite grades are being evaluated not only with respect to irradiated property values, but also with a focus on comprehensive data sets that explicate the property variability inherent to nuclear-grade graphites. The large data sets being compiled on baseline physical and mechanical properties provide a means not only to quantify variability within and between major graphite grades, but also to evaluate test techniques utilized on irradiated specimens that are severely limited in size and geometry. Detailed appraisals of emerging mechanical test techniques that either (a) fall outside of the prescribed test size and configuration constraints in order to be assembled into irradiation capsule such as the three-point bend test on sub-sized cylinders or (b) are not yet fully evaluated and standardized by ASTM International such as the Brazilian disc splitting tensile strength test can be more accurately generated when a broad comparison is possible that leverages multiple mechanical tests on full-size specimens using approved standards. (authors)

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2023

Preliminary NBSR Design-Demonstration Element Thermal-Hydraulics and Structural Analyses

1.1 OBJECTIVE The United State High Performance Research Reactor (USHPRR) program aims to eliminate more than 200kg of High Enriched Uranium (HEU) from commerce annually by converting five U.S. high-performance research reactors and one associated critical assembly to Low Enriched Uranium (LEU) fuel using a high-density alloy of uranium-10 wt% molybdenum (U-10Mo). The National Bureau of Standards Reactor (NBSR) is one of five research reactors selected for this program. The objective of this report is to provide preliminary thermal-hydraulic and mechanical analyses of the hydrodynamic effects in the NBSR Design Demonstration Element (DDE) under conservative approximations for the plate power distribution. This report provides details on the modeling approach and the simulation results obtained, including pressure, flow velocity, temperature, and oxide layer over the design demonstration experiment for the irradiation cycles in the Belgian Reactor (BR)-2.

42 ENGINEERING↗

DOE OSTI2025

Impact of Irradiation on Microstructure and Mechanical Properties of Materials Produced by Advanced Manufacturing

Advanced non-light water reactor designs, known as Generation IV (Gen IV) reactors, typically operate at higher temperatures and under more extreme radiation conditions than conventional light water reactors. A critical aspect of the successful deployment and advancement of Gen IV reactor designs is the selection of appropriate structural materials for specific applications, which necessitates the timely development of new materials and manufacturing processes. Advanced manufacturing (AM) offers numerous opportunities for innovative designs, enabling the production of high-performance components with potentially shorter development cycles compared to traditional manufacturing methods. However, a significant challenge in deploying AM technologies in the nuclear energy sector is the current lack of data on the irradiation performance of AM-produced components. This presentation will discuss neutron and ion irradiation results of AM materials, including stainless steel 316L, Grade 91, SA508, Inconel 718, and Inconel 625 materials. The materials were manufactured by AM, such as Powder Metallurgy Hot Isostatic Pressing (PM HIP), Laser Powder Bed Fusion (LPBF) and Directed Energy Deposition (DED). The effects of neutron irradiation on microstructure (e.g., dislocations, loops, and nanoclusters), tensile properties (e.g., strength and ductility), and ion irradiation on Irradiation-Assisted Stress Corrosion Cracking (IASCC) will be explored. Results are collected from several projects supported by the Nuclear Science User Facilities (NSUF) program.

36 - MATERIALS SCIENCE↗

DOE OSTI2020

A hybrid porous model for full reactor core scale CFD investigation of a prismatic HTGR

Three-dimensional (3-D) Computational Fluid Dynamics (CFD) analysis of a whole nuclear reactor core is a tremendous challenge due to the large geometric volume and complex structures. Here, this research presents a hybrid porous (HP) model to simplify a prismatic High Temperature Gas-cooled Reactor (HTGR) core, so 3-D CFD investigation can be performed on a full reactor core scale. In the HP model, the prototypic small coolant channels in the nuclear fuel blocks are lumped together to form multiple equivalent large coolant channels, and then the porous medium flow model is applied to each of them. Therefore, heat transfer in fuel blocks is computed by a hybrid combination of solid energy and porous flow energy equations. The similarity between the HP model and prototypic model is achieved by deriving the porous flow permeability, inertial resistance factor, and artificial thermophysical properties. Compared with the widely used whole porous (WP) flow model, the HP model preserves more realistic geometric structures, and therefore more accurate physical processes. The General Atomics' Modular High Temperature Gas-cooled Reactor (MHTGR) design was chosen as a prototype to demonstrate the methodology. Simulations were performed using the prototypic CFD model and HP model at steady-state forced circulation, steady-state natural circulation, and transient conditions that correspond to normal operation, extended period of pressurized cool down, and short-term transients after reactor shutdown, respectively. The comparison shows good agreement between the HP model and prototypic model in the maximum fuel temperature, average solid temperature, and helium flow rate, which demonstrates the potential applicability of the HP model for a full reactor core scale simulation in the future. As a benefit, the HP model reduces the mesh quantity by a factor of 50 from a prototypic model. Correspondingly, the computation time was reduced by a factor of at least 30.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2021

Performance Validation of Pulsed Thermal Imaging System for In-Service Applications

Additive manufacturing (AM) is an emerging method for cost-efficient fabrication of complex topology nuclear reactor parts from high-strength corrosion resistance alloys, such as stainless steel and Inconel. AM of metallic structures for nuclear energy applications is currently based on laser powder bed fusion (LPBF) process, which has the capability of melting metallic powder and net shaping the structures with relatively high precision. Some of the challenges with using LPBF method for nuclear manufacturing include the possibility of introducing pores into metallic structures. Integrity of AM structures needs to be evaluated nondestructively because material flaws could lead to premature failures in high temperature nuclear reactor environment. Currently, there exist limited capabilities to evaluate actual AM structures non-destructively. Pulsed Thermography Imaging (PTI) provides a capability for non-destructive evaluation (NDE) of subsurface defects in arbitrary size structures. The PTI method is based on recording material surface temperature transients with infrared (IR) camera following thermal pulse delivered on material surface with flash light. The PTI method has advantages for NDE of actual AM structures because the method involves one-sided non-contact measurements and fast processing of large sample areas captured in one image. Following initial qualification of an AM component for deployment in a nuclear reactor, a PTI system can also be used for in-service nondestructive evaluation (NDE) applications. In this report, we describe recent progress in enhancing PTI capabilities in detecting microscopic defects in metallic specimens. SS316 and IN718 specimens were developed with a pattern of subsurface calibrated flat bottom hole (FBH) defects with diameters from 500µm to 200µm. FBH’s were created with EDM (electron discharge machining) drill. PTI imaging data was processed Spatial Temporal Denoised Thermal Source Separation (STDTSS) unsupervised machine learning (ML) algorithm. We show that defects as small as 200µm in SS316 and IN718 can be detected with STDTSS algorithm. To the best of our knowledge, these are the smallest detected defects which are reported in literature.

42 ENGINEERING↗

DOE OSTI2015

3D toroidal physics: Testing the boundaries of symmetry breaking

Toroidal symmetry is an important concept for plasma confinement; it allows the existence of nested flux surface MHD equilibria and conserved invariants for particle motion. However, perfect symmetry is unachievable in realistic toroidal plasma devices. For example, tokamaks have toroidal ripple due to discrete field coils, optimized stellarators do not achieve exact quasi-symmetry, the plasma itself continually seeks lower energy states through helical 3D deformations, and reactors will likely have non-uniform distributions of ferritic steel near the plasma. Also, some level of designed-in 3D magnetic field structure is now anticipated for most concepts in order to provide the plasma control needed for a stable, steady-state fusion reactor. Such planned 3D field structures can take many forms, ranging from tokamaks with weak 3D edge localized mode suppression fields to stellarators with more dominant 3D field structures. This motivates the development of physics models that are applicable across the full range of 3D devices. Ultimately, the questions of how much symmetry breaking can be tolerated and how to optimize its design must be addressed for all fusion concepts. A closely coupled program of simulation, experimental validation, and design optimization is required to determine what forms and amplitudes of 3D shaping and symmetry breaking will be compatible with the requirements of future fusion reactors.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2015

Reactor Pressure Vessel Integrity Assessments with the Grizzly Aging Simulation Code

Grizzly is a simulation tool being developed at Idaho National Laboratory (INL) as part of the US Department of Energy’s Light Water Reactor Sustainability program to provide improved safety assessments of systems, components, and structures in nuclear power plants subjected to age-related degradation. Its goal is to provide an improved scientific basis for decisions surrounding license renewal, which would permit operation of commercial nuclear power plants beyond 60 years. Grizzly is based on INL’s MOOSE framework, which enables multiphysics simulations in a parallel computing environment. It will address a wide variety of aging issues in nuclear power plant systems, components, and structures, modelling both the aging processes and the ability of age-degraded components to perform safely. The reactor pressure vessel (RPV) was chosen as the initial application for Grizzly. Grizzly solves tightly coupled equations of heat conduction and solid mechanics to simulate the global response of the RPV to accident conditions, and uses submodels to represent regions with pre-existing flaws. Domain integrals are used to calculate stress intensity factors on those flaws. A physically based empirical model is used to evaluate material embrittlement, and is used to evaluate whether crack growth would occur. Grizzly can represent the RPV in 2D or 3D, allowing it to evaluate effects that require higher dimensionality models to capture. Work is underway to use lower length scale models of material evolution to inform engineering models of embrittlement. This paper demonstrates an application of Grizzly to RPV failure assessment, and summarizes on-going work.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2022

Fast Modular Reactor Nuclear Design Parameters of Fuel Cycle and Power Distributions

This paper describes conceptual design of a 112 MW thermal (50 MW electric) Fast Modular Reactor (FMR) system operating at 7 MPa with inlet/outlet temperatures of 509/800 ºC. The reactor system includes the reactor core, fuel assemblies, fuel rods, reactor internals, reflector, neutron control system, flow control, and structural components. The nuclear design and analysis were conducted to search for a baseline core with a cycle length greater than 8-year and the power peaking factor less than 1.5 by adjusting the fuel assembly, reactor core, and reflector configurations. The neutronics calculations of the baseline core showed that a refueling interval of 9-year is achieved with a total peaking factor of 1.47 and a fuel rod average linear power of 3.6 kW/m.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2022

Fast modular reactor nuclear design parameters of fuel cycle and power distributions

This paper describes conceptual design of a 112 MW thermal (50 MW electric) Fast Modular Reactor (FMR) system operating at 7 MPa with inlet/outlet temperatures of 509/800 Celsius degrees. The reactor system includes the reactor core, fuel assemblies, fuel rods, reactor internals, reflector, neutron control system, flow control, and structural components. The nuclear design and analysis were conducted to search for a baseline core with a cycle length greater than 8-year and the power peaking factor less than 1.5 by adjusting the fuel assembly, reactor core, and reflector configurations. The neutron transport calculations of the baseline core showed that a refueling interval of 9-year is achieved with a total peaking factor of 1.47 and a fuel rod average linear power of 3.6 kW/m. (authors)

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2022

High volume packing fraction TRISO-based fuel in light water reactors

We report that for a decade, fully ceramic microencapsulated (FCM) fuel, containing tri-structural isotropic (TRISO) fuel particles in a silicon carbide (SiC) matrix, has been investigated as an accident-tolerant fuel for light water reactors (LWRs). Other examples exist of TRISO-based concepts for LWR fuels with different matrix materials. Previous studies assumed TRISO particle volume packing of approximately 0.44 in SiC (or another) matrix, the highest realistic packing fractions possible with conventional manufacturing. Recent advances in advanced manufacturing have yielded the development and demonstration of a fuel form that consists of conventionally manufactured TRISO particles in a 3D-printed SiC matrix with significantly higher possible TRISO packing fractions (0.5–0.7). This increased uranium loading enhances the viability of using TRISO-based particle fuel forms in LWRs. The viability of high-packing-fraction TRISO-based particle fuel forms in LWRs is assessed from the perspective of fuel cycle length, achievable fuel burnup, reactivity coefficients, and fuel cycle performance. Higher-packing-fraction TRISO-based fuel enables either longer cycle lengths (by ~25% at a packing fraction of 0.55 relative to 0.44) at a constant enrichment or decreased enrichments (by ~25% at a packing fraction of 0.55 relative to 0.44) at a constant cycle length. Studies of different fuel kernel types (uranium nitride, uranium oxycarbide, and uranium carbide) yield similar results, although the cycle length of uranium oxycarbide is shorter than for uranium nitride or uranium carbide (due to the lower density of uranium oxide). This work also characterized the production of 14 C resulting from neutron absorption in 14 N during operation for uranium mononitride fuel kernels; the ratio of 14 C/N was 1–2 at. % at discharge. For the fuel cycle evaluation, the activity of spent nuclear fuel and high-level waste at 100 and 100,000 years was lower for high-packing-fraction fuels than for conventional LWR fuel. Environmental impact metrics were similar overall, but higher on the front end of the fuel cycle and lower on the back end of the fuel cycle. Reactivity coefficients of higher-packing-fraction TRISO-based fuel were reasonable compared with those of conventional fuels.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2014

The Development of an INL Capability for High Temperature Flow, Heat Transfer, and Thermal Energy Storage with Applications in Advanced Small Modular Reactors, High Temperature Heat Exchangers, Hybrid Energy Systems, and Dynamic Grid Energy Storage C

The overall goal of this project is to support Idaho National Laboratory in developing a new advanced high temperature multi fluid multi loop test facility that is aimed at investigating fluid flow and heat transfer, material corrosion, heat exchanger characteristics and instrumentation performance, among others, for nuclear applications. Specifically, preliminary research has been performed at The Ohio State University in the following areas: 1. A review of fluoride molten salts’ characteristics in thermal, corrosive, and compatibility performances. A recommendation for a salt selection is provided. Material candidates for both molten salt and helium flow loop have been identified. 2. A conceptual facility design that satisfies the multi loop (two coolant loops [i.e., fluoride molten salts and helium]) multi purpose (two operation modes [i.e., forced and natural circulation]) requirements. Schematic models are presented. The thermal hydraulic performances in a preliminary printed circuit heat exchanger (PCHE) design have been estimated. 3. An introduction of computational methods and models for pipe heat loss analysis and cases studies. Recommendations on insulation material selection have been provided. 4. An analysis of pipe pressure rating and sizing. Preliminary recommendations on pipe size selection have been provided. 5. A review of molten fluoride salt preparation and chemistry control. An introduction to the experience from the Molten Salt Reactor Experiment at Oak Ridge National Laboratory has been provided. 6. A review of some instruments and components to be used in the facility. Flowmeters and Grayloc connectors have been included. This report primarily presents the conclusions drawn from the extensive review of literatures in material selections and the facility design progress at the current stage. It provides some useful guidelines in insulation material and pipe size selection, as well as an introductory review of facility process and components.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2017

NRC ARDC Guidance Support Status Report

This report provides a summary that reflects the progress and status of proposed regulatory design criteria for advanced non-light water reactor (LWR) designs in accordance with the Level 3 milestone M3AT-17IN2001013 in work package AT-17IN200101. These criteria have been designated as advanced reactor design criteria (ARDC) and they provide guidance to future applicants for addressing the general design criteria (GDC) that are currently applied specifically to LWR designs. This report provides a summary of Phase 2 activities related to the various tasks associated with ARDC development and the subsequent development of ARDC regulatory guidance for sodium fast reactor (SFR) and modular high-temperature gas-cooled reactor (HTGR) designs. Status Report Organization: Section 2 discusses the origin of the GDC and their application to LWRs. Section 3 addresses the objective of this initiative and how it benefits the advanced non-LWR reactor vendors. Section 4 discusses the scope and structure of the initiative. Section 5 provides background on the U.S. Department of Energy (DOE) ARDC team’s original development of the proposed ARDC that were submitted to the NRC for consideration. Section 6 provides a summary of recent ARDC Phase 2 activities. Appendices A through E document the DOE ARDC team’s public comments on various sections of the NRC’s draft regulatory guide DG–1330, “Guidance for Developing Principal Design Criteria for Non-Light Water Reactors.”

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2020

Light Water Reactor Sustainability Program Materials Research Pathway Technical Program Plan

The Materials Research (MR) Pathway within the Light Water Reactor Sustainability (LWRS) Program is charged with performing the research and development (R&D) to develop the scientific basis for understanding and predicting long-term environmental degradation behavior of materials in nuclear reactors. Furthermore, it is essential to use the mechanistic understanding of degradation phenomena in materials to develop mitigation, repair, and new material alternatives for existing components. The work will provide data and methods to assess performance of systems, structures, and components (SSCs) essential to safe and sustained reactor operations. The R&D products developed from the LWRS Program will be used by utilities, industry groups, and regulators to inform operational and regulatory requirements for materials in reactor SSCs subjected to long-term operation conditions, providing key input to both regulators and industry. The intent of this research is to help in reducing the operating costs, which may be in the form of offset maintenance costs due to better predictive models for component lifetimes, improved analysis of materials through nondestructive evaluation, reduced costs for repairs, or extended performance of plants through the selection of improved replacement materials. To best achieve this, industry experience and guidance are important as is their role in coordinated or collaborative research projects. The objectives of this report are to describe the motivation and organization of the MR Pathway within the LWRS Program, provide details on the individual research tasks within the MR Pathway, describe the outcomes and deliverables of the MR Pathway, including recent technical highlights and progress, and list the requirements for performing the research.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗