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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 883 records · Page 49
All sourcesNASA NTRSDOE OSTI
DOE OSTI2018

Evaluation of Neutron-induced Cross Sections and their Related Covariances with Physical Constraints

Nuclear data, along with numerical methods and the associated calculation schemes, continue to play a key role in reactor design, reactor core operating parameters calculations, fuel cycle management and criticality safety calculations. Due to the intensive use of Monte-Carlo calculations reducing numerical biases, the final accuracy of neutronic calculations increasingly depends on the quality of nuclear data used. This paper gives a broad picture of all ingredients treated by nuclear data evaluators during their analyses. After giving an introduction to nuclear data evaluation, we present implications of using the Bayesian inference to obtain evaluated cross sections and related uncertainties. In particular, a focus is made on systematic uncertainties appearing in the analysis of differential measurements as well as advantages and drawbacks one may encounter by analyzing integral experiments. The evaluation work is in general done independently in the resonance and in the continuum energy ranges giving rise to inconsistencies in evaluated files. For future evaluations on the whole energy range, we call attention to two innovative methods used to analyze several nuclear reaction models and impose constraints. Finally, we discuss suggestions for possible improvements in the evaluation process to master the quantification of uncertainties. These are associated with experiments (microscopic and integral), nuclear reaction theories and the Bayesian inference.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗
DOE OSTI2017

Modelling I and C systems with relays for simulation, adapting CIM standards - 243

As the nuclear power plants are in operation for many years, a main issue is to integrate simulation activities in parallel to the present I and C design process in order to limit impacts on current operating I and C engineering process and commissioning activities. The objective is to keep the existing I and C data and diagrams format. EDF chose to build an intermediate file independent of the tool used for simulation to exchange and store data. This file has been created adapting CIM standards (IEC 61968-13 and IEC 61970-301). It is an XML file built according to an RDF schema. CIM standards are intended to model transport or distribution electrical networks and used to facilitate system integration and information exchanges. We chose to adapt CIM to model EDF electromechanical relay circuitries in order to re-use all methods and tools developed around CIM standards such as RDF schema and RiseClipse, an open source tool developed by EDF and SUPELEC engineering school that will be used to verify exported I and C data according to a data model and to EDF engineering rules. This paper will describe the ongoing project on simulation in parallel to current I and C design process, focusing on how I and C electromechanical relays data are modelled based on CIM standards, and what benefits that model provides to I and C Verification and Validation activities. (authors)

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2021

Development of Digital Twin Predictive Model for PWR Components: Updates on Multi Times Series Temperature Prediction Using Recurrent Neural Network, DMW Fatigue Tests, System Level Thermal-Mechanical-Stress Analysis

The long-term operation (LTO) of nuclear power plant (NPP) beyond their original design life of 40 years, can lead to more material damage associated with cyclic fatigue under thermal-mechanical loading cycles and associated long-term exposure of reactor material to the deleterious reactor-coolant environments. However, under this LTO condition the reactor components can still safely operate but may require more frequent Nondestructive Evaluation (NDE) of reactor components. Frequent NDE requirement may lead to frequent shutdown of the NPP. This in turn can lead to power outage and additional NDE-inspection-cost related economic loss. The economic loss can be minimized by reducing uncertainty in life estimation of safety-critical pressure boundary components and by implementing more digital approach such as by using upcoming digital-twin (DT) technology for predicting the structural states (e.g., time and location dependent inside/outside thickness temperature, stress, strain, plastic deformation, etc.) and associated fatigue life of a component in real time. Towards this goal Argonne National Laboratory (ANL) with the sponsorship of DOE Light Water Reactor Sustainability (LWRS) program is working on the development of a DT framework that can be used for real time environmental fatigue prediction of reactor components. The DT framework is based on limited experiment-data, Artificial-intelligence (AI) – Machine-Learning (ML) - Deep-Learning (DL) based techniques and Multiphysics-computational-mechanics such as finite element (FE) based modeling tools. Towards this overall goal, following are some of the major contributions made during the FY21: 1) Multiple 82/182 dissimilar metal weld (DMW) specimens (both solid-weld and joint-weld representing the actual reactor multi-metal nozzles) were fatigue tested. The resulting fatigue lives were compared to the NUREG-6909 based best-fit and design fatigue curves. Additionally, the results of 52/152 DMW fatigue specimens (which were recently tested at Republic of Korea under the sponsorship of International Nuclear Energy Research Initiative - INERI program) were compared to the NUREG-6909 based best-fit and design fatigue curves. From the comparison of 82/182 and 52/152 DMW test data with NUREG-6909 best-fit curve, most of the reported test data fall way away from the NUREG-6909 suggested best-fit or mean curve. The NUREG-6909 suggested best-fit curve is the best-fit curve of austenitic stainless steel and due to lack of enough data on Nickel-based welds, this is currently being used for predicting the life of Nickel-alloy-based welded components. However, the above observation may require higher scaling factor (e.g., ASME suggested factor of 20 on cycles rather than the current NUREG-6909 suggested factor of 12 on cycles) for scaling the austenitic-stainless-steel best-fit-curve for estimating the design or safe-life of a welded component. Accordingly, for example, if a DMW component experience a strain amplitude of 0.6% the PWR-water life of the component would be 52 cycles instead of 85 cycles. However, more DMW tests are required to further ascertain the above-mentioned observations. 2) A system level CAD and finite element model were developed which consists of reactor pressure vessel (RPV), part of steam generator (SG), part of pressurizer (PRZ), hot leg (HL), and surge line (SL). This is with detailed nozzle geometry and thermal-mechanical material properties of different metals to simulate realistic thermal-mechanical stress under connected system global thermal-mechanical boundary conditions. 3) Different system level heat transfer analyses were performed with estimation of relevant heat transfer coefficients. The resulting data were used in subsequent system level thermal-mechanical stress analysis and for generating spatial-temporal training and validation data for a system level digital-twin based temperature predictor. Transient heat transfer analyses were performed considering thermal boundary condition under design-basis (DB) loading and EDF (Électricité de France) data-based grid-load-following (EDF-GLF) loading cycles. 4) System level thermal-mechanical stress analysis was performed for identifying damage-prone hotspots and for future extension of the model for cyclic state prediction. From the system-level model simulation under DB loading cycle it is found that HL and the SL nozzle that connect to the HL can experience significant stress and strain and could be one of the weakest links in the overall reactor coolant system (RCS). 5) An AI/ML based DT model was developed for multi-time-series temperature prediction at any inside/outside thickness locations of PWR pressure boundary components. This is by using Recurrent-neural-network (RNN) and keras machine learning libraries. The RNN model was validated against two laboratory test-based data sets with one obtained through ANL’s in-air fatigue test system and other through PWR-water test loop. The experimentally validated DT model further validated against FE model results to predict thermal scarification related spatialtemporal temperatures at random locations of a component. The well validated DT model was then used for demonstrating spatial-temporal temperature prediction under 100+ years of reactor operation subjected to combined DB, EDF-GLF and randomized grid-load-following (RANDOMGLF) loading Cycles. The expert-elicitation DT model framework was developed assuming field/input/process measurements can be available from a few existing plant sensors and can readily be used by the NPP operators. The above temperature prediction model will feed to the next-step stress analysis model based on which the life of a component can be predicted in realtime, which is one of our future works.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
NASA NTRS1997

Predictive Modeling in Plasma Reactor and Process Design

Research continues toward the improvement and increased understanding of high-density plasma tools. Such reactor systems are lauded for their independent control of ion flux and energy enabling high etch rates with low ion damage and for their improved ion velocity anisotropy resulting from thin collisionless sheaths and low neutral pressures. Still, with the transition to 300 mm processing, achieving etch uniformity and high etch rates concurrently may be a formidable task for such large diameter wafers for which computational modeling can play an important role in successful reactor and process design. The inductively coupled plasma (ICP) reactor is the focus of the present investigation. The present work attempts to understand the fundamental physical phenomena of such systems through computational modeling. Simulations will be presented using both computational fluid dynamics (CFD) techniques and the direct simulation Monte Carlo (DSMC) method for argon and chlorine discharges. ICP reactors generally operate at pressures on the order of 1 to 10 mTorr. At such low pressures, rarefaction can be significant to the degree that the constitutive relations used in typical CFD techniques become invalid and a particle simulation must be employed. This work will assess the extent to which CFD can be applied and evaluate the degree to which accuracy is lost in prediction of the phenomenon of interest; i.e., etch rate. If the CFD approach is found reasonably accurate and bench-marked with DSMC and experimental results, it has the potential to serve as a design tool due to the rapid time relative to DSMC. The continuum CFD simulation solves the governing equations for plasma flow using a finite difference technique with an implicit Gauss-Seidel Line Relaxation method for time marching toward a converged solution. The equation set consists of mass conservation for each species, separate energy equations for the electrons and heavy species, and momentum equations for the gas. The sheath is modeled by imposing the Bohm velocity to the ions near the walls. The DSMC method simulates each constituent of the gas as a separate species which would be analogous in CFD to employing separate species mass, momentum, and energy equations. All particles including electrons are moved and allowed to collide with one another with the stipulation that the electrons remain tied to the ions consistent with the concept of ambipolar diffusion. The velocities of the electrons are allowed to be modified during collisions and are not confined to a Maxwellian distribution. These benefits come at a price in terms of computational time and memory. The DSMC and CFD are made as consistent as possible by using similar chemistry and power deposition models. Although the comparison of CFD and DSMC is interesting, the main goal of this work is the increased understanding of high-density plasma flowfields that can then direct improvements in both techniques. This work is unique in the level of the physical models employed in both the DSMC and CFD for high-density plasma reactor applications. For example, the electrons are simulated in the present DSMC work which has not been done before for low temperature plasma processing problems. In the CFD approach, for the first time, the charged particle transport (discharge physics) has been self-consistently coupled to the gas flow and heat transfer.

Hash, D. B.↗
DOE OSTI2022

Pronghorn Porous Media Model Validation with Pressure Drop Measurements

The verification and validation (V&V) of Pronghorn is imperative to assert its accuracy when predicting the fluid velocity, temperature, and pressure in high temperature gas-cooled reactors. Pronghorn is a coarse-mesh, intermediate-fidelity, and multidimensional thermal-hydraulics (TH) code developed by the Idaho National Laboratory (INL). New pebble bed experiments are used to observe the details of the fluid motion and pressure drop in the porous bed under the reactor normal operation. This paper focuses on the validation of the Pronghorn compressible and incompressible Navier-Stokes equations using the pressure drop measurements performed at the engineering-scale pebble bed facility at the Texas A&M university (TAMU). Various pressure drop correlations and porosity functions are implemented in both Pronghorn and STAR-CCM+ to compare the pressure drop due to the combined viscous and inertial resistances in the porous bed. The correlations accounting for the near-wall effect are also utilized to observe if the pressure drop estimates can be improved. Pronghorn porous media models predict the pressure drop well relative to the STAR-CCM+ simulation results and 1D correlations, and both the finite element method (FEM) and finite volume method (FVM) perform accurately. Pronghorn models are also validated with the experimental measurements given the different Reynolds number ranges and specific aspect ratios. The likelihood of the statistical significance between the pressure drop measurements and specific correlations or simulations is low provided that the overlap of their confidence intervals is more than the half of a single arm. Several validation metrics are reasonable in regard to the similar studies from other literature. The precise average pebble bed porosity estimation has much impact on the pressure drop, and the Foumeny and Montillet (dense packing) models carry out the accurate pressure drop prediction by considering the near-wall effect.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2017

Determining appropriate data analytics for transformer health monitoring - 107

Transformers are vital assets for the safe, reliable and cost-effective operation of nuclear power plants. The unexpected failure of a transformer can lead to different consequences ranging from a lack of export capability, with the corresponding economic penalties, to catastrophic failure, with the associated health, safety and economic effects. Condition monitoring techniques examine the health of the transformer periodically, with the aim to identify early indicators of anomalies. However, many transformer failures occur because diagnostic and monitoring models do not identify degraded conditions in time. Therefore, health monitoring is an essential component to transformer life cycle management. Existing tools for transformer health monitoring use traditional dissolved gas analysis based diagnostics techniques. With the advance of prognostics and health management (PHM) applications, we can enhance traditional transformer health monitoring techniques using PHM analytics. The design of an appropriate data analytics system requires a multi-stage design process including: (i) specification of engineering requirements; (ii) characterization of existing data sources and analytics to identify complementary techniques; (iii) development of the functional specification of the analytics suite to formalize its behavior, and finally (iv) deployment, validation, and verification of the functional requirements in the final platform. Accordingly, in this paper we propose a transformer analytics suite which incorporates anomaly detection, diagnostics, and prognostics modules in order to complement existing tools for transformer health monitoring. (authors)

42 ENGINEERING↗
DOE OSTI2019

Plasma Jet Driven Magneto-Inertial Fusion (PJMIF)

We report that PJMIF is the only embodiment of magneto-inertial fusion that has the unique combination of standoff implosion and high implosion velocity (50 km/s - 150 km/s). It uses inexpensive plasma guns for all plasma formation and implosion. It has potential for relatively high repetition rate from 1 to 2 Hz. Its configuration is compatible with the use of a thick liquid wall that doubles as a tritium breeding blanket as well as a coolant for extracting the heat out of the fusion reactor. Its operational parameter space allows for the possibility of using a suffciently dense target plasma for the target plasma to have a high beta. If such a high beta plasma could be realized, it would help to suppress micro and MHD instabilities, giving its target plasma classical transport and energy confinement characteristics. Its open geometry and moderate time and spatial scales provide convenient diagnostics access. Diagnostics accessibility, high shot rate and low cost per shot should enable quick resolution of technical issues during development, thus the potential for enabling rapid R&D of PJMIF. There are a number of challenges, however, for PJMIF including being at a very early stage of development, developing the required plasma guns, dealing with potential liner non-uniformities, clearing the chamber of residual high-Z gas between shots, and developing the repetitive pulsed power component technologies. Over the last three years, the development of the Plasma Liner Formation Experiment (PLX-alpha) have been undertaken to explore the physics and demonstrate the formation of a spherical liner by the merging of a spherical array of plasma jets. Two- and three- jet merging experiments have been conducted to study the interactions of the jets. Lastly, six- and seven-jet experiments have been performed to form a piece of the plasma liner. A brief status report on this development is provided in this paper.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2018

Encapsulation of Defective Fuel Rods for Transport and Dry Storage - 18190

Removing of the whole inventory of fissile and non-fissile material out of the spent fuel pool is performed when the power plant is about to start its last operation phases or may occur during the extended operating life cycle due to plant storage space limitation. Removal of defective spent fuel is then definitely required for emptying the pool and may in addition also be performed in the course of plant operation for reducing pool contamination. Depending on the general used fuel management solution chosen for post-storage pool operations, specific management of a defective fuel assembly (DFA) and/or a defective fuel rod (DFR) should be implemented accordingly to the regulation requirements to be followed. For meeting these DFA and/or DFR management needs, Framatome together with New AREVA offer wide portfolio of solutions with flexibility and adaptability advantages: - from simple to advanced technologies; - for several types of fuel assemblies and/or defective rods; - for suitable and compatible cask designs; - for compatible solution with both used fuel final management strategies (closed and open fuel cycles). For instance, a technology is jointly proposed and developed by New AREVA and Framatome for implementing dry storage of DFR. It consists in: - encapsulating each DFR by loading the fuel rod in a respective capsule, drying the fuel rod using a process which allows to physically verify with high accuracy the dryness inside the DFR, and seal welding the capsule - assembling the capsules in a capsule canister (a skeleton with external dimensions similar to a respective fuel assembly) and - transferring the capsule canister along with intact spent fuel assemblies in an associated dry transport and storage (dual purpose) cask. Such a project is currently being implemented in Belgium. After successfully obtaining the cask transport and storage license extensions for including the encapsulated DFR content, the first encapsulation campaign has been started in 2017. The purpose of the paper is to present the industrial solutions proposed by Framatome and New AREVA together, for management of DFR, notably the one related to dry storage of encapsulated DFR implemented in Belgium and the perspectives opened by this successful project. The paper presents: - the available solutions for management of DFA and/or DFR depending on applicable requirements - the drying method, welding of a capsule and associated cask as the state of art technology for dry storage of DFR and/or DFA; - lessons learned from project management and encapsulation campaign performed in Belgium; - perspectives for management of DFR and/or DFA. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2021

Development of a Reconstruction Methodology Based on X-Ray Computed Tomography to Generate Realistic 3D Concrete Microstructures in MOSAIC

Despite being passive components, concrete structures represent a major capital investment in nuclear power plants. However, some concrete components are critical for the safety and long-term operation of the reactors: the concrete containment building protects the reactors from external aggression. The concrete biological shield (CBS) contains the radiation exiting the reactor to protect equipment and personnel. Depending on the design, the CBS also has a function for supporting the reactor’s systems. This function needs to be ensured in-service and during accident scenarios. After several decades of use, the CBS is exposed to high-energy irradiation over an extended operation time, exceeding the fluence level currently considered detrimental for the concrete’s structural properties. Such conditions occur at different times depending on the reactor’s operation and design. Nevertheless, from the perspective of subsequent license application, it is mandatory to assess the potential effects of prolonged irradiation on concrete. Unlike steel components, concrete structures are built with local constituents (cement, sand, and coarse aggregates) to avoid prohibitive transportation costs. Thus, concrete performance is determined by the tolerance or the susceptibility of its constituents against any aging mechanism. The tolerance against irradiation of the CBSs may vary greatly among the 56 nuclear power plants and 93 nuclear power reactors that form the current US light-water reactor fleet. Irradiation-induced degradation is mainly a result of amorphization-induced expansions of the silicated minerals present in the aggregates. The neutron irradiation–induced expansion varies from one rock-forming mineral to another: well framework–structured silicates (e.g., quartz and feldspars) exhibit higher swelling than chained (e.g., pyroxene) or isolated silicates (e.g., garnet). Silicates make up nearly 90% of the Earth’s crust. Other common minerals present in construction aggregates are carbonates found, for example, in limestone. Irradiated carbonates exhibit only very minor expansions.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2017

{sup 14}C Entry into the Atmosphere

{sup 14}C enters the atmosphere in amounts equivalent to 1.4 PBq/yr with total accumulation 140 PBq via cosmic radiation. As a result of nuclear explosions (1950–1969), its activity in the atmosphere exceeded 200 PBq. At present, {sup 14}C has been completely removed into bottom waters and sedimentary rocks in the ocean. The activity of the {sup 14}C entering the atmosphere from all operating nuclear reactors equals ~0.3 PBq/yr and the amount from all spent fuel reprocessing facilities equals ~0.06 PBq/yr. The admissible levels of {sup 14}C emissions must not exceed levels corresponding to peroral intake dose 10 μSv/yr. This is can be accomplished by means of a system of measures: reduction of the volume of technogenic gases and their {sup 12}CO{sub 2} content, combining high-efficiency purification with dispersion through high exhaust-stacks, and developing new technologies and reagents binding {sup 14}C in compact forms.

38 RADIATION CHEMISTRY, RADIOCHEMISTRY, AND NUCLEA↗
DOE OSTI2020

Advancing Fusion with Machine Learning Research Needs Workshop Report

Abstract Machine learning and artificial intelligence (ML/AI) methods have been used successfully in recent years to solve problems in many areas, including image recognition, unsupervised and supervised classification, game-playing, system identification and prediction, and autonomous vehicle control. Data-driven machine learning methods have also been applied to fusion energy research for over 2 decades, including significant advances in the areas of disruption prediction, surrogate model generation, and experimental planning. The advent of powerful and dedicated computers specialized for large-scale parallel computation, as well as advances in statistical inference algorithms, have greatly enhanced the capabilities of these computational approaches to extract scientific knowledge and bridge gaps between theoretical models and practical implementations. Large-scale commercial success of various ML/AI applications in recent years, including robotics, industrial processes, online image recognition, financial system prediction, and autonomous vehicles, have further demonstrated the potential for data-driven methods to produce dramatic transformations in many fields. These advances, along with the urgency of need to bridge key gaps in knowledge for design and operation of reactors such as ITER, have driven planned expansion of efforts in ML/AI within the US government and around the world. The Department of Energy (DOE) Office of Science programs in Fusion Energy Sciences (FES) and Advanced Scientific Computing Research (ASCR) have organized several activities to identify best strategies and approaches for applying ML/AI methods to fusion energy research. This paper describes the results of a joint FES/ASCR DOE-sponsored Research Needs Workshop on Advancing Fusion with Machine Learning, held April 30–May 2, 2019, in Gaithersburg, MD (full report available at https://science.osti.gov/-/media/fes/pdf/workshop-reports/FES_ASCR_Machine_Learning_Report.pdf ). The workshop drew on broad representation from both FES and ASCR scientific communities, and identified seven Priority Research Opportunities (PRO’s) with high potential for advancing fusion energy. In addition to the PRO topics themselves, the workshop identified research guidelines to maximize the effectiveness of ML/AI methods in fusion energy science, which include focusing on uncertainty quantification, methods for quantifying regions of validity of models and algorithms, and applying highly integrated teams of ML/AI mathematicians, computer scientists, and fusion energy scientists with domain expertise in the relevant areas.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2025

Advancing nuclear forensics competencies at the National Nuclear Center of the Republic of Kazakhstan and conceptual development of a National Nuclear Forensics Library

Since 2021, the National Nuclear Center (NNC) of the Republic of Kazakhstan has been successfully developing a project dedicated to nuclear forensics. The relevance of this project is underscored by Kazakhstan’s leading position in the global uranium mining and export market. The country operates research reactors and is involved in the production of experimental nuclear fuel. The nuclear forensics project is being implemented in several key areas: the project will develop competencies in laboratory research of samples, interpretation of results, and develop a prototype concept for the National Nuclear Forensics Library. In implementing these challenges, the NNC experts draw on the experience of colleagues from world-leading scientific and research centers. Designing a prototype National Nuclear Forensics Library (NNFL) is a challenging project. In conclusion, the solution to this task is based on the IAEA’s approaches, recommendations, and the experience gained from the construction of similar systems in other countries.

and nuclear chemistry↗
DOE OSTI2019

Intermediate temperature corrosion behaviour of Fe-12Cr-6Al-2Mo-0.2Si-0.03Y alloy (C26M) at 300–600 °C

Iron-chromium-aluminium alloys are of interest to the nuclear materials community due to their resistance to high temperature steam oxidation and good mechanical properties under irradiation. The present work investigates oxide formation on Fe-12Cr-6Al-2Mo-0.2Si-0.03Y alloy at temperatures relevant to light water reactor cladding operation following extended aging to assess growth kinetics, chemical composition, and oxide microstructure. Oxide growth follows a logarithmic time dependence. Here, when the oxidization temperature is 400 °C or below, the oxide is amorphous. At 500 °C or above, crystalline α-Al 2 O 3 oxide film develops and the correlated logarithmic rate constant decreases significantly, indicating enhanced oxidation resistance of the formed oxide film.

36 MATERIALS SCIENCE↗
DOE OSTI2020

The Material Plasma Exposure eXperiment: Mission and conceptual design

Mastering Plasma Material Interactions (PMI) is key for obtaining a high performance, high duty-cycle and safe operating fusion reactor. Numerous gaps exist in PMI which have to be addressed before a reactor can be built. In particular the lack of data at high ion fluence, fusion reactor divertor relevant plasma conditions and neutron displacement damage requires new experimental devices to be able to develop plasma facing materials and components. This has been recognized in the community and the U.S. fusion program is addressing this need with a new linear plasma device—the Material Plasma Exposure eXperiment (MPEX). MPEX will be a superconducting linear plasma device with magnetic fields of up to 2.5 T. The plasma source is a high-power helicon source (200 kW, 13.56 MHz). The electrons will be heated via Electron Bernstein Waves with microwaves using multiple 70 GHz gyrotrons (up to 600 kW in total). Ions will be heated via ion cyclotron heating in the so-called “magnetic beach heating” scheme in the frequency range of 6–9 MHz (up to 400 kW in total). An overview of the conceptual design and the project/design requirements is given in this paper.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2020

Mechanical and chemical properties of PVD and cold spray Cr-coatings on Zircaloy-4

In this paper, accident-tolerant fuel (ATF) cladding materials aim to improve fuel reliability and safety during accident scenarios in water-cooled reactors. These ATF cladding should also perform comparable or better than the current zirconium alloy cladding under reactor normal operating conditions. Surface-modified Zircaloy-4 was produced by depositing a protective coating of chromium by two different coating techniques, Physical Vapor Deposition (PVD) and Cold Spray (CS). The coating thickness, structure, composition, and mechanical properties of the coated Zircaloy were assessed with advanced materials characterization techniques. Results showed a strengthening effect of the Cr-coating, along with ~83% higher hardness compared to that of the Zircaloy-4 substrate. Surface topography and surface chemistry of the Cr-coated Zircaloy-4 were assessed with contact profilometry, atomic force microscopy, contact angle goniometry, and X-ray photoelectron spectroscopy. Deposited Cr-coating significantly improved surface wettability compared to the substrate Zircaloy-4. The formation of surface oxides on the coatings by prolonged exposure to ambient air showed a further increase in the hydrophobic behavior. Surface parameters and surface chemistry after flow boiling critical heat flux tests, conducted at atmospheric pressure, evidenced a slight increase in surface roughness with notable changes in wettability associated with the formation of surface oxides.

36 MATERIALS SCIENCE↗