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DOE OSTI2024

Elucidating the degradation mechanisms of Pt-free anode anion-exchange membrane fuel cells after durability testing

The development of anion-exchange membrane fuel cells (AEMFCs) has recently accelerated due to synergistic improvements yielding highly conductive membranes, stable ionomers, and enhanced alkaline electrocatalysts. However, cell durability, especially under realistic conditions, still poses a major challenge. Herein, we employ low-loadings of Pt-free Pd-based catalysts in the anode of AEMFCs and elucidate potential degradation mechanisms impacting long-term performance under conditions analogous to the real-world (high current density, H 2 –air (albeit CO 2 -free), and intermittent operation). Our high-performing AEMFCs achieve impressive performance with power densities approaching 1 W cm —2 and current densities up to 3.5 A cm —2 . Over a 200 h period of continuous operation in H 2 –air at a current density of 600 mA cm —2 , our model Pd/C–CeO 2 anode cell exhibits record stability (~30 μV h —1 degradation) compared to the literature and up to 6× better stability than our Pd/C and commercial Pt/C anode cells. Following an 8 h shutdown, the Pd/C–CeO 2 anode cell was restarted and continued for an additional 300 h with a higher degradation rate of ~600 μV h —1 . Thorough in situ evaluations and post-stability analyses provide insights into potential degradation mechanisms to be expected during extended operation under more realistic conditions and provide mitigation strategies to enable the widespread development of highly durable AEMFCs.

08 HYDROGEN↗

DOE OSTI2023

In-Rod Sensor System Overview, Benefits and Recent Irradiation Test Results

Westinghouse is developing an In-Rod Sensor (IRS) System capable of measuring critical fuel rod parameters such as center-line fuel temperature, rod internal pressure and axial fuel pellet stack elongation without having penetrations to the fuel rod. The technology is similar to the Halden Reactor instrumentation, but the IRS system focuses on commercial fuel rod instrumentation. Both systems circumvent fuel rod penetrations, however the IRS system overcomes unique geometric challenges found in commercial fuel rod assemblies. The IRS could also play a key role in accelerated fuel qualification by allowing real-time measurements during separate effects tests, integral fuel testing or during irradiation of lead test rods or lead test assemblies. Combining these measurements with data acquired from targeted separate effects testing and multi-scale modelling could significantly reduce the time required to qualify new fuel and reduce the safety margin uncertainty of operating plants. The IRS is actively in development for Light Water Reactors (LWR) based fuel assemblies but can also be applied to Gen IV reactor designs with minimal modifications.

Carvajal, Jorge↗

DOE OSTI2019

Advanced Fuels Campaign 2019 Accomplishments

The mission of the Advanced Fuels Campaign (AFC) is to perform or support research, development, and demonstration (RD&D) activities to identify and mature innovative fuels and cladding materials and associated technologies with the potential to improve the performance and safety of current and future reactors; increase the efficient utilization of nuclear energy resources; contribute to enhancing proliferation resistance of the nuclear fuel cycle; and address challenges related to waste management and ultimate disposal. AFC pursues its mission objectives using a goal-oriented, science-based approach that seeks to establish a fundamental understanding of fuel and cladding behaviors under conditions that arise during fabrication, normal steady-state irradiation, off-normal transient scenarios, and storage/disposal. This approach includes advancing the theoretical understanding of fuel behavior, conducting fundamental and integral experiments, and supporting the mechanistic, multi-scale modeling of nuclear fuels to inform and guide fuel development projects, advance the technological readiness of promising fuel candidates, and ultimately support fuel qualification and licensing initiatives. In the area of advanced tools for the modeling and simulation of nuclear fuels, the AFC works in close partnership with the Nuclear Energy Advanced Modeling and Simulation (NEAMS) program, participating with NEAMS in developing mechanistic fuel behavior models and providing experimental data to inform and validate its most advanced tools. Specifically, AFC objectives in thecoming five year horizon include: 1. support the industry-led development of Accident Tolerant Fuel (ATF) technologies with improved reliability and performance under normal operations and enhanced tolerance during hypothetical accident scenarios, with implementation of lead test rods/assemblies of one or more ATF concepts in commercial reactor(s) by or before 2022 and batch reloads of near-term concept(s) in the 2023-2026 timeframe; 2. lead research and development on innovative fuel and cladding technologies for applications to future advanced reactors, especially fast-spectrum reactors, including reactors that utilize both once-through and recycle scenarios; 3. continue the development and demonstration of a multi-scale,science-based approach to fuel development and testing, andcontribute to the establishment of a state-of-the-art R&D infrastructure necessary to accelerate the development of new fuel concepts; and collaborate with NEAMS on the development and validation of multi-scale, multi-physics, and increasingly predictive fuel performance models and codes. 4. collaborate with NEAMS on the development and validation of multi-scale, multi-physics, and increasingly predictive fuel performance models and codes.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2025

IMPACT-01 Assembly Overview [Slides]

The Irradiated Material Properties Accelerated Characterization Test (IMPACT) series of experiments will irradiate three metallic fuel alloy specimens with embedded thermal conductivity probes in the Advanced Test Reactor (ATR). Metallic fuel alloys have long been under investigation for use in advanced reactors on account of their high thermal conductivity. Metallic fuel undergoes dramatic microstructural changes early in life due to fission gas swelling until ~2-3 at% burnup when pores interconnect, thus allowing fission gas to escape into the fuel pin plenum and swelling effectively ceases. The evolution of metallic fuel thermal conductivity during this early phase has never been successfully measured in situ. This experiment will be designed to use advances in measurement sciences to characterize how thermal transport properties evolve while in reactor. The IMPACT experiment consists of three metallic fuel rodlets with thermal conductivity probes axially centered within the fuel specimen. This presentation is an overview of the IMPACT-01 assembly process with a focus MFC fuel fabrication and experiment assembly steps.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

NASA NTRS2003

Durability of Membrane Electrode Assemblies (MEAs) in PEM Fuel Cells Operated on Pure Hydrogen and Oxygen

Proton exchange membrane (PEM) fuel cells are energy sources that have the potential to replace alkaline fuel cells for space programs. Broad power ranges, high peak-to-nominal power capabilities, low maintenance costs, and the promise of increased life are the major advantages of PEM technology in comparison to alkaline technology. The probability of PEM fuel cells replacing alkaline fuel cells for space applications will increase if the promise of increased life is verified by achieving a minimum of 10,000 hours of operating life. Durability plays an important role in the process of evaluation and selection of MEAs for Teledyne s Phase I contract with the NASA Glenn Research Center entitled Proton Exchange Membrane Fuel cell (PEMFC) Power Plant Technology Development for 2nd Generation Reusable Launch Vehicles (RLVs). For this contract, MEAs that are typically used for H2/air operation were selected as potential candidates for H2/O2 PEM fuel cells because their catalysts have properties suitable for O2 operation. They were purchased from several well-established MEA manufacturers who are world leaders in the manufacturing of diverse products and have committed extensive resources in an attempt to develop and fully commercialize MEA technology. A total of twelve MEAs used in H2/air operation were initially identified from these manufacturers. Based on the manufacturers specifications, nine of these were selected for evaluation. Since 10,000 hours is almost equivalent to 14 months, it was not possible to perform continuous testing with each MEA selected during Phase I of the contract. Because of the lack of time, a screening test on each MEA was performed for 400 hours under accelerated test conditions. The major criterion for an MEA pass or fail of the screening test was the gas crossover rate. If the gas crossover rate was higher than the membrane intrinsic permeability after 400 hours of testing, it was considered that the MEA had failed the test. Three types of MEAs out of the nine total membranes failed the test. The evaluation results showed that fuel cell operating conditions (current, pressure, stoichiometric flow rates) were the parameters that influenced the durability of MEAs. In addition, the durability test results indicated that the type of membrane was also an important parameter for MEA durability. At accelerated test conditions, the MEAs with casted membranes failed during the 400 hour test. However, the MEAs prepared from the casted membrane with support as well as extruded membranes, both passed the 400h durability test at accelerated operating test conditions. As a result of the MEA accelerated durability tests, four MEAs were selected for further endurance testing. These tests are being carried out with four-cell stacks under nominal fuel cell operating conditions.

Stanic, Vesna↗

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 OSTI2023

Coaxial Nanowire Electrodes Enable Exceptional Fuel Cell Durability

Polymer-electrolyte-membrane fuel cells (PEMFCs) hold great promise for applications in clean energy conversion, but cost and durability continue to limit commercialization. This work presents a new class of catalyst/electrode architecture that does not rely on Pt particles or carbon supports, eliminating the primary degradation mechanisms in conventional electrodes, and thereby enabling transformative durability improvements. The coaxial nanowire electrode (CANE) architecture consists of an array of vertically aligned nanowires, each comprising an ionomer core encapsulated by a nanoscale Pt film. This unique design eliminates the triple-phase boundary and replaces it with two double-phase boundaries, increasing Pt utilization. It also eliminates the need for carbon support and ionomer binder, enabling improved durability and faster mass transport. Fuel cell membrane electrode assemblies based on CANEs demonstrate extraordinary durability in accelerated stress tests (ASTs), with only 2% and 5% loss in performance after 5000 support AST cycles and 30000 catalysts AST cycles, respectively. The high-power density and extremely high durability provided by CANEs can enable a paradigm shift from random electrodes based on unstable platinum nanoparticles dispersed on carbon to ordered electrodes based on durable Pt nanofilms, facilitating rapid deployment of fuel cells in transportation and other clean energy applications.

25 ENERGY STORAGE↗

DOE OSTI2022

Quantifying deformation during Zry-4 burst testing: a comparison of BISON and a combined in-situ digital image correlation and infrared thermography method

The development and verification of nuclear fuel-cladding performance codes require extensive testing to establish empirical correlations, necessitating more accelerated testing methods that can replace large validation studies. Here, in the present work, a technique was developed and implemented to experimentally quantify the relationship between temperature, cladding internal pressure, and strain in-situ during a burst test, with the specific aim of generating data for code validation and model refinement. Digital image correlation was used to measure hoop, axial, and radial strain, and infrared thermography to quantify axial temperature gradients. Several key experimental modifications to traditional LOCA burst testing were necessary, but are shown to effectively have little impact on burst temperatures. The time/temperature dependent pressure and time/spatially dependent thermal gradient data were used with BISON to simulate cladding burst and strain rates. Although the measured DIC strains reach appreciable amounts at slightly lower temperatures than BISON simulated strains, there is good agreement between the measured and simulated strains in terms of magnitude and rates leading up to burst. However, in the few seconds prior to and during burst, the BISON simulated strains are significantly lower than the measured strains, indicating the potential for model improvement. The combined experiment and simulation technique may be applied to any new cladding concept to accelerate fuel qualification.

36 MATERIALS SCIENCE↗

NASA NTRS1976

Vibration testing of the JE-M-604-4-IUE rocket motor (Thiokol P/N E 28639-03)

The NASA International Ultraviolet Explorer (IUE) rocket motor (TE-M-604-4), a solid fuel, spherical rocket motor, was vibration tested in the Impact, Vibration, and Acceleration (IVA) Test Unit of the von Karman Gas Dynamics Facility (VKF). The objective of the test program was to subject the motor to qualification levels of sinusoidal and random vibration prior to the altitude firing of the motor in the Propulsion Development Test Cell (T-3), Engine Test Facility (ETF), AEDC. The vibration testing consisted of a low level sine survey from 5 to 2,000 Hz, followed by a qualification level sine sweep and qualification level random vibration. A second low level sine survey followed the qualification level testing. This sequence of testing was accomplished in each of three orthogonal axes. No motor problems were observed due to the imposition of these dynamic environments.

Alt, R. E.↗

NASA NTRS1972

Flowing gas, non-nuclear experiments on the gas core reactor

Flow tests were conducted on models of the gas core (cavity) reactor. Variations in cavity wall and injection configurations were aimed at establishing flow patterns that give a maximum of the nuclear criticality eigenvalue. Correlation with the nuclear effect was made using multigroup diffusion theory normalized by previous benchmark critical experiments. Air was used to simulate the hydrogen propellant in the flow tests, and smoked air, argon, or freon to simulate the central nuclear fuel gas. All tests were run in the down-firing direction so that gravitational effects simulated the acceleration effect of a rocket. Results show that acceptable flow patterns with high volume fraction for the simulated nuclear fuel gas and high flow rate ratios of propellant to fuel can be obtained. Using a point injector for the fuel, good flow patterns are obtained by directing the outer gas at high velocity along the cavity wall, using louvered or oblique-angle-honeycomb injection schemes.

Kunze, J. F.↗

NASA NTRS1992

Early aerospaceplane propulsion research: Marquardt Corporation: ca 1956-1963

A brief summary is presented of the very early days of aerospaceplane propulsion and concept research, from a viewpoint based in the Astro Division of Marquardt Aircraft Co. in the years listed, with some view into later times that were on Bill Escher's watch and others. Other groups who were pursuing the same goals by various routes are discussed by some following speakers. The chief purpose is to bring out background information that may be of value to members of the workshop and future workers in the field. The state of engine and airframe technology at those times must be understood to make sense of the effort. Operational kerosene fueled ramjets were routinely flying Mach 2 to 3 in the Bomarc and Talos interceptors. One Marquardt ramjet had accelerated a Lockheed X-7 test vehicle to about Mach 4.7 in an all-out test, holding it at nearly 1 'G' until the fuel ran out. Development of further research at Marquardt is outlined.

Lindley, Charles A.↗

DOE OSTI2025

Accelerated Irradiation Testing and Post-Irradiation Characterization: U.S.-Based Capabilities for Advanced Nuclear Systems and Radioisotope Production

Irradiation experiments and post-irradiation examinations, together referred to as irradiation testing (IRT), are prerequisites for nuclear fuel and material qualification for the deployment of new and advanced reactors, as well as radioisotope production, thereby ensuring regulatory compliance. Qualified research and test reactors (RTRs) and testing facilities are essential to enable IRT to verify performance and safety under prototypical reactor conditions. In the past, qualification of new fuels or structural materials required about 20 years. Synergist strategies, advanced tools, and qualified methods are needed to greatly reduce this timeframe of IRT and radioisotope production. This study, termed accelerated-IRT, focuses on identifying gaps and leveraging U.S.-based RTRs and material testing capabilities, leveraging the preliminary evaluation and qualification of selected RTRs to provide a generic as well as specific-case solution paths forward, ensuring adherence to stringent regulatory standards. Furthermore, IRT and radioisotope production utilizing qualified RTRs necessarily includes modeling and simulation to support the design (i.e. neutronics, thermal, and structural aspects) and manufacturing of irradiation test specimens, vehicles, capsules, apparatuses, and flow loops. In addition, IRT can be improved by applying advanced manufacturing techniques and in-pile sensors and instrumentation, as discussed in this study.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2024

ROADRUNNER MiniFuel Experiment: Irradiation Target Design and Sample Characterization

High-density uranium nitride (UN) is a fuel candidate for several advanced nuclear reactor designs currently under development. Because there are limited UN performance data relative to fuel fabrication impurity and density variation, an irradiation campaign has been developed as part of a collaborative effort among the University of Texas at San Antonio (UTSA), Westinghouse Electric Company, Oak Ridge National Laboratory (ORNL), and Los Alamos National Laboratory (LANL) under the Nuclear Science User Facilities program. This project, entitled ROADRUNNER, or Research On ADvancing the peRformance of UraNium Nitrides in Extreme enviRonments, aimsto support UN fuel qualification for advanced reactors by investigating the impact of density and impurity variations on UN performance as a function of irradiation temperature and burnup. The MiniFuel experiment vehicle developed by ORNL, which leverages the High Flux Isotope Reactor, was selected to perform this accelerated separate-effects irradiation testing. The experiment test matrix consists of six MiniFuel targets containing miniature UN fuel disks, and targets three distinct burnup levels (37.5, 60, and 75 MWd/kg U) and three distinct temperatures (600, 900, and 1200°C). Neutronics and thermal analyses were performed to determine the experimental parameters needed to meet the desired irradiation conditions and to predict the experiment components temperatures. UN pellets were fabricated at LANL with tightly controlled parameters to produce specimens with three distinct densities and three levels of carbon content. The pellets were then thinned down by UTSA to the experiment-required thickness. The pre-characterization of the specimens includes density measurements, carbon and oxygen contents, microstructure analysis, and x-ray computed tomography. The selected specimens will be assembled into the MiniFuel experiment, and the first ROADRUNNER MiniFuel targets are intended for HFIR insertion during the Fall of 2024. After irradiation, the targets will be shipped to ORNL’s hot cell facility for disassembly. The post-irradiation examination on the fuel specimens includes fission gas release measurements, visual inspection, fuel swelling measurements, gamma spectroscopy, and microstructure analysis. The data collected post-irradiation will be used to develop fuel performance models.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

NASA NTRS2012

On Shaft Data Acquisition System (OSDAS)

On Shaft Data Acquisition System (OSDAS) is a rugged, compact, multiple-channel data acquisition computer system that is designed to record data from instrumentation while operating under extreme rotational centrifugal or gravitational acceleration forces. This system, which was developed for the Heritage Fuel Air Turbine Test (HFATT) program, addresses the problem of recording multiple channels of high-sample-rate data on most any rotating test article by mounting the entire acquisition computer onboard with the turbine test article. With the limited availability of slip ring wires for power and communication, OSDAS utilizes its own resources to provide independent power and amplification for each instrument. Since OSDAS utilizes standard PC technology as well as shared code interfaces with the next-generation, real-time health monitoring system (SPARTAA Scalable Parallel Architecture for Real Time Analysis and Acquisition), this system could be expanded beyond its current capabilities, such as providing advanced health monitoring capabilities for the test article. High-conductor-count slip rings are expensive to purchase and maintain, yet only provide a limited number of conductors for routing instrumentation off the article and to a stationary data acquisition system. In addition to being limited to a small number of instruments, slip rings are prone to wear quickly, and introduce noise and other undesirable characteristics to the signal data. This led to the development of a system capable of recording high-density instrumentation, at high sample rates, on the test article itself, all while under extreme rotational stress. OSDAS is a fully functional PC-based system with 48 channels of 24-bit, high-sample-rate input channels, phase synchronized, with an onboard storage capacity of over 1/2-terabyte of solid-state storage. This recording system takes a novel approach to the problem of recording multiple channels of instrumentation, integrated with the test article itself, packaged in a compact/rugged form factor, consuming limited power, all while rotating at high turbine speeds.

Pedings, Marc↗

NASA NTRS2004

Crash Simulation of a Boeing 737 Fuselage Section Vertical Drop Test

A 30-ft/s vertical drop test of a fuselage section of a Boeing 737 aircraft was conducted in October of 1999 at the FAA Technical Center in Atlantic City, NJ. This test was performed to evaluate the structural integrity of a conformable auxiliary fuel tank mounted beneath the floor and to determine its effect on the impact response of the airframe structure and the occupants. The test data were used to compare with a finite element simulation of the fuselage structure and to gain a better understanding of the impact physics through analytical/experimental correlation. To perform this simulation, a full-scale 3-dimensional finite element model of the fuselage section was developed using the explicit, nonlinear transient-dynamic finite element code, MSC.Dytran. The emphasis of the simulation was to predict the structural deformation and floor-level acceleration responses obtained from the drop test of the B737 fuselage section with the auxiliary fuel tank.

Fasanella, Edwin L.↗

DOE OSTI2026

Sparsely Dispersed CeO x ‑Stabilized Pt Nanoparticles Overcome Pt Loading–Durability Trade-Off for Highly Durable Heavy-Duty Fuel Cells

Proton-exchange-membrane fuel cells (PEMFCs) are clean and sustainable mobile power sources for transportation. Recently, their deployment in heavy-duty vehicles (HDVs) has attracted growing interest owing to their high energy scalability and lower infrastructure requirements. However, to meet the stringent requirements for efficiency and long-term durability for HDV applications, PEMFCs typically employ a relatively high platinum group metal (PGM) loading (>0.2 mg PGM /cm 2 ). This elevated PGM loading significantly increases the stack and system costs, surpassing the U.S. Department of Energy (DOE) target of $\$ 60$/kW for commercial viability. Reducing PGM loading while maintaining performance and durability remains a central challenge for HDV fuel cells. Here we exploit metal oxide–Pt interactions and utilize the strong CeO x –Pt interaction to design a CeO x @Pt catalyst structure with exceptional durability. At a low total PGM loading (0.1 mg PGM /cm 2 ), the CeO x @Pt/C catalyst demonstrates high fuel cell performance (8.8 kW/g PGM ) and stability (power retention >90%) after the challenging HDV durability testing (90,000 accelerated-stress-test cycles). With the CeO x @Pt/C catalyst, we showcase over 70% reduction in Pt cost from the M2FCT target (to $\$ 9$/kW), highlighting its promising potential for enabling stable and cost-effective fuel cell systems for heavy-duty applications.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

NASA NTRS1981

Deposit formation in liquid fuels. II - The effect of selected compounds on the storage stability of Jet A turbine fuel

The influence of substituted pyridines, pyrroles, indoles, and quinolines on the storage stability of conventional Jet A turbine fuel is evaluated. Significant increases in the amount of deposit formed in accelerated storage tests are found upon addition of these compounds at levels as low as one ppm nitrogen. While the effect is correlated with basicity of the nitrogen compound within a given compound class, the correlation does not hold between classes (pyridines, quinolines, etc.). Steric hindrance at the nitrogen atom greatly inhibits deposit promotion. The characteristics, but not the elemental composition, of deposits vary with the identity of the added nitrogen compound and with deposition temperature.

Worstell, J. H.↗

DOE OSTI2025

AFC FAST Status Report Fiscal Year 2025

The Fission Accelerated Steady-state Test (FAST) methodology has been used to test several innovative metallic fuel designs for use in Sodium?cooled Fast Reactors (SFRs). The FAST method utilizes geometrically scaled fuel pins to produce improved burnup rates for fuels while maintaining semi-prototypic thermal conditions. This report provides a summary description of the test matrix and test objectives for the AFC FAST irradiation campaign as well as details of the as-built conditions for all rodlets. This report also include status update on the irradiation conditions for the rodlets as well as post-irradiation examination (PIE) results on low to mid?range burnup fuel rodlets and a summary power history for those rodlets. A brief discussion provides some early interpretation of the results and whether or not FAST is producing results typical of metallic fuels. Lastly, an outlook for the work expected to be completed in fiscal year (FY) 2026 is also included.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗