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At least 91 records · Page 5

Non-Nuclear Testing of Compact Reactor Technologies at NASA MSFC

Safe, reliable, compact, autonomous, long-life fission systems have numerous potential applications, both terrestrially and in space. Technologies and facilities developed in support of these systems could be useful to a variety of concepts. At moderate power levels, fission systems can be designed to operate for decades without the need for refueling. In addition, fast neutron damage to cladding and structural materials can be maintained at an acceptable level. Nuclear design codes have advanced to the stage where high confidence in the behavior and performance of a system can be achieved prior to initial testing. To help ensure reactor affordability, an optimal strategy must be devised for development and qualification. That strategy typically involves a combination of non-nuclear and nuclear testing. Non-nuclear testing is particularly useful for concepts in which nuclear operating characteristics are well understood and nuclear effects such as burnup and radiation damage are not likely to be significant. To be mass efficient, a SFPS must operate at higher coolant temperatures and use different types of power conversion than typical terrestrial reactors. The primary reason is the difficulty in rejecting excess heat to space. Although many options exist, NASA s current reference SFPS uses a fast spectrum, pumped-NaK cooled reactor coupled to a Stirling power conversion subsystem. The reference system uses technology with significant terrestrial heritage while still providing excellent performance. In addition, technologies from the SFPS system could be applicable to compact terrestrial systems. Recent non-nuclear testing at NASA s Early Flight Fission Test Facility (EFF-TF) has helped assess the viability of the reference SFPS and evaluate methods for system integration. In July, 2011 an Annular Linear Induction Pump (ALIP) provided by Idaho National Laboratory was tested at the EFF-TF to assess performance and verify suitability for use in a10 kWe technology demonstration unit (TDU). In November, 2011 testing of a 37-pin core simulator (designed in conjunction with Los Alamos National Laboratory) for use with the TDU will occur. Previous testing at the EFFTF has included the thermal and mechanical coupling of a pumped NaK loop to Stirling engines (provided by GRC). Testing related to heat pipe cooled systems, gas cooled systems, heat exchangers, and other technologies has also been performed. Integrated TDU testing will begin at GRC in 2013. Thermal simulators developed at the EFF-TF are capable of operating over the temperature and power range typically of interest to compact reactors. Small and large diameter simulators have been developed, and simulators (coupled with the facility) are able to closely match the axial and radial power profile of all potential systems of interest. A photograph of the TDU core simulator during assembly is provided in Figure 2.

Houts, Michael G.↗

Benefits of using multiple Raman laser wavelengths for characterizing defects in a UO 2 matrix

Abstract Raman spectroscopy is one of the most useful techniques for studying the structure of UO 2 and changes due to specific defects caused by doping, changes in stoichiometry, irradiation, or heating under oxidizing conditions. In this paper, we illustrate several aspects of the application of Raman techniques to the study of UO 2 , including the use of wavelength‐dependent excitation (455, 532, and 785 nm) to assess the effects of doping (Nd, Th, and Zr), ion irradiation, and in situ heating and oxidation (UO 2 to U 3 O 8 ). Additionally, we show examples of how correlative microscopy is possible using electron backscatter diffraction combined with Raman maps of specific vibration bands or of laser‐induced luminescence generated by rare‐earth dopants in the matrix. For each of these applications, we suggest optimal excitation wavelengths that vary depending on the desired data. Blue (455 nm) excitation tends to promote oxidation even at low powers, but because Raman spectra change little with doping, irradiation‐induced changes are easier to observe. Green (532 nm) excitation is optimal for observing electron–phonon resonance effects in UO 2 and offers a good compromise for high‐temperature oxidation experiments, delivering high‐quality spectra for both UO 2 and U 3 O 8 . Infrared (785 nm) excitation is best for observing “defect” bands associated with doping in UO 2 , as changes with irradiation are small. Raman spectroscopy is particularly suited for studying the stability of UO 2 towards oxidation in the presence of dopants simulating fission products, where electron–phonon resonant effects, dopant ion luminescence, and mapping can be used together to investigate structural rearrangement as a function of temperature. These techniques can offer insight into microstructural changes in UO 2 fuels at higher burnups envisioned in future reactors.

42 ENGINEERING↗

Comparative post-irradiation examination of high burnup U-19Pu-10Zr: Assessing steady-state irradiation behavior against historical and modeled fuel performance

Here, the development of next-generation sodium-cooled fast reactors necessitates comprehensive research on metallic fuels to maximize economic performance while ensuring safe operation. In this study, we investigated the steady-state irradiation behavior of two high burnup U-19Pu-10Zr fuel pins, DP-36 and DP-40, in preparation for planned safety testing. Post-irradiation examination (PIE) was performed to quantify fuel column elongation, regions of low-density at the top of the fuel column, pin deformation, fission product distribution, fractional fission gas release, microstructural evolution, and fuel constituent redistribution. Benchmarking against existing PIE data from U-19Pu-10Zr fuel pins irradiated in EBR-II revealed consistent patterns in fuel column elongation and cladding diametral strain. However, both pins exhibited longer low-density structures, and destructive examination of DP-36 revealed more complex constituent redistribution patterns compared to previously reported data for ternary fuel pins. The steady-state irradiation of both pins was also modeled using BISON. Comparisons of PIE results with modeled predictions showed overall agreement in fractional fission gas release but consistent overestimation of axial and radial swelling due to gaseous and solid swelling models. These findings underscore the critical importance of pre-test characterization on test and sibling pins to accurately capture steady-state fuel behavior ahead of transient testing, thus establishing a baseline for post-test comparison. Additionally, these analyses identified key data gaps that warrant further investigation to improve the understanding and prediction of fuel swelling, thereby enhancing the synergy between modeling and experimental efforts in supporting accident testing.

BISON↗

Evaluation of PBR Spent Fuel Criticality and Dose Rate Compliance for Storage and Transportation

Spent tri-structural isotropic (TRISO)–based fuels have a strong track record in storage and transportation without documented incidents. This work seeks to reduce uncertainty to aid in more informed spent fuel management of TRISO-based fuels by modeling both fresh and spent pebble bed reactor (PBR) fuel and comparing the results to the regulatory standards from 10 CFR 71. SCALE was used for all modeling due to it having fast and accurate methods for handling PBR fuel modeling, as well as having an efficient method for shielding calculations in monaco with automated variance reduction using importance calculations (MAVRIC), which utilizes the consistent adjoint-driven importance sampling (CADIS) and the forward-weighted consistent adjoint-driven importance sampling (FW-CADIS) methods. KENO-VI was used for all criticality calculations, TSUNAMI was used for uncertainty quantification on k-effective, TRITON and the Oak Ridge isotope generation code (ORIGEN) were both used for depletion of the fuel, and MAVRIC was used for shielding calculations. For criticality assessments, this study focused on the requirement that the value of the neutron multiplication factor, k-effective (k-eff), would not exceed a peak value of 0.95, including uncertainty, with 95% confidence. Criticality was initially examined by modeling fresh fuel from three different designs—HTR-10 fuel, PBMR-400 fuel, and demonstration fuel representative of a TRISO-fueled modern high-temperature gas reactor (HTGR) design, henceforth referred to as Demo HTGR—and placing them into various sized containers with conditions described in 10 CFR 71 to quantify the peak k-eff state. When the peak value of 0.95 k-eff was exceeded, mitigation methods were examined in those scenarios. Burnup credit, pebble displacement in areas of strong neutron multiplication, and random pebble replacement using pebbles of various compositions and replacement fractions were examined. In summary, the criticality of PBR fuels can be well accounted for by restricting container size, taking credit for burnup, or by displacing/replacing pebbles. Uncertainty of the k-eff due to nuclear data uncertainties was recorded at ~0.6644%Δk/k, or roughly 664% mil (pcm). The nuclear data–induced uncertainty was relatively small and should not require significant modification in the design to be accounted for. Revisions to the evaluated nuclear data file values have been shown to have a larger impact than nuclear data–induced uncertainty. For dose rate aspects, U.S. Nuclear Regulatory Commission regulations require a maximum dose rate of 10 millirem per hour (mrem/h) at 2 meters. In examining the dose rate behavior of spent PBR fuel, the representative Demo HTGR fuel was modeled exclusively due to it possessing the highest target burnup of the examined fuels. Equilibrium cycle modeling methods were used to produce a higher-fidelity discharge isotopic composition than simple assumptions, such as reflected pebbles. The discharge composition was used as a source term in the fixed-source transport shielding calculations, and dose rates were calculated at 2 m for the shortest possible cooling time. The low concentration of fuel material led to dose rates that were in line with regulatory limits, despite the high burnup when compared to traditional light water reactor fuels. In conclusion, the methods employed in this study would require more work to further verify and validate and are limited to the criticality and dose rate analyses performed.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Multilayer Architecture Barriers for High Temperature Nuclear Applications

Innovative thin film multilayer metal/ceramic barrier coatings have been developed by Argonne National Laboratory to protect fuel cladding against different phenomena that can be encountered under the harsh operating conditions of advanced nuclear reactors. One phenomenon is Fuel-Cladding Chemical Interaction (FCCI), which can represent a challenge to the performance of steel-clad metallic fuels in sodium-cooled fast reactors (SFRs), especially when operating to high burnups at elevated cladding temperatures, and long fuel residence time. Another phenomenon is the corrosion of zirconium-based cladding under prototypic boiling water reactor (BWR) conditions and associated cladding during off normal conditions, including loss of coolant accidents (LOCA). This work provides details of the development and testing of a thin film (few microns) multilayer metal/ceramic (CrY/Y 2 O 3 ) coatings on steel cladding and its performance against FCCI. The coating architecture evolved through systematic mechanical testing, radiation tolerance assessments, and high-temperature diffusion studies from a preliminary multilayer concept to an optimized high-performance design. The optimized structure leverages stoichiometric Y 2 O 3 for its exceptional radiation stability, chemical inertness, and ultra-low fission product diffusivity (e.g., Ce diffusivity ~10 -20 m 2 /s in irradiated Y 2 O 3 at 650 °C). This is paired with ductile chromium-rich interlayers (Cr 95 Y 5 ), which significantly enhance fracture toughness and mechanical resilience. Design refinements, including increased ceramic layer thickness and optimized Cr–Y interlayer composition, eliminated fracture propagation and preserved coating integrity under extreme mechanical stress (>10× typical reactor conditions) and prolonged radiation exposure (~300 dpa). Those conditions are well beyond expected conditions during normal operations in SFR, and cover some of the transient conditions as well. In addition, the coating deposition was demonstrated to be applied uniformly to the inner surface of steel tubes representing prototypic SFR cladding. Another phenomenon under consideration in this work is the corrosion of zirconium-based cladding under prototypic boiling water reactor (BWR) conditions and associated off normal conditions including loss of coolant accident (LOCA). Another multilayer thin film coating is considered for mitigation of this phenomenon, where a coating of yttrium aluminum and yttrium aluminum ceramic/metal thin film coating. Preliminary results on the coating performance during high temperature thermal cycling (up to 1000 C) have shown promising performance of the coating. On-going optimization of the coating will continue in FY26.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

Nuclear concepts/propulsion

Nuclear thermal and nuclear electric propulsion systems will enable and/or enhance important space exploration missions to the moon and Mars. Current efforts are addressing certain research areas, although NASA and DOE still have much work yet to do. Relative to chemical systems, nuclear thermal propulsion offers the potential of reduced vehicle weight, wider launch windows. and shorter transit times, even without aerobrakes. This would improve crew safety by reducing their exposure to cosmic radiation. Advanced materials and structures will be an important resource in responding to the challenges posed by safety and test facility requirements, environmental concerns, high temperature fuels and the high radiation, hot hydrogen environment within nuclear thermal propulsion systems. Nuclear electric propulsion (NEP) has its own distinct set of advantages relative to chemical systems. These include low resupply mass, the availability of large amounts of onboard electric power for other uses besides propulsion, improved launch windows, and the ability to share technology with surface power systems. Development efforts for NEP reactors will emphasize long life operation of compact designs. This will require designs that provide high fuel burnup and high temperature operation along with personnel and environmental safety.

Miller, Thomas J.↗

Sample Preparation for 3D Characterization of Irradiated Fuel

Thorough characterization of nuclear fuel is essential when striving to understand its microstructural evolution in response to varying irradiation conditions. A detailed understanding of the microstructural evolution of irradiated fuel can be useful when predicting the fuel’s response to off-normal conditions and related phenomena such as high burnup fuel fragmentation (HBFF) and fission gas release. This sort of characterization and the study of complex phenomena like HBFF that are related to fuel performance are an important part of the US Department of Energy Office of Nuclear Energy’s Advanced Fuels Campaign (AFC). Multiple characterization techniques are commonly used to perform post-irradiation examination (PIE) analysis on an irradiated fuel sample, but many of these techniques are limited to the 2D surface analysis of the fuel pellet. Although there is a lot of useful information to be gained by analyzing the fuel pellet surface, a 2D analysis provides only an approximation of the nature of the material’s features, such as porosity and grain structure. Therefore, it is critical to analyze the 3D structure of the material, as materials exist and respond to conditions in all three dimensions.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Validation of MFUEL Metal Fuel Performance Models of SAS4A/SASSYS-1

The fuel characterization models of SAS4A/SASSYS-1 (SAS) have recently been extended to include a new U-Pu-Zr metal fuel model, MFUEL. MFUEL is equipped with mechanistic physics based models to predict the pre-transient characterization and transient response of metal fuel, with emphasis on fuel melting, cladding failure, and the metal fuel’s impact on core reactivity. The MFUEL model will be available in the full version of SAS4A/SASSYS-1 5.7, which is scheduled to be released in June 2023. Fast reactor fuel pins that operated in EBR-II and FFTF with low smear density U-Zr and U-Pu-Zr metal fuels and irradiation resistant ferritic-martensitic cladding showed significant advantages in achieving high burnups and assuring inherent safety characteristics during anticipated transients, design basis events, and beyond design basis events. For safety analysis, a fuel performance model must be able to predict (1) Fuel pin mechanics and compositional and dimensional changes, (2) Clad failure, and (3) Fuel pin thermal resistance. Achieving these high level goals accurately is strongly related to the model performance of individual physical processes taking place within a fuel pin during its lifetime. Metal fuels typically operate above the mid-point temperature of melting during normal, as well as off-normal, conditions. At these elevated temperatures, the availability of thermal activation provides a driving force for various diffusional processes leading to complex phase transformations, micro-structure evolution, significant amounts of fuel swelling, interconnected porosity formation, excessive amounts of fission gas release, and fuel clad chemical interactions. Clad failure in fast reactors primarily occurs as a result of creep rupture augmented by clad wastage formation. The reaction is driven by thermal creep induced dislocation motion, grain boundary cavity nucleation, growth and breakup of grain boundaries. The high level complexity and limited available data requires introducing physics-based modeling approaches to gain extrapolation ability and sensitivity with respect to various conditions. The objective of this report is to perform validation of MFUEL using the experimental data for (1) Normal operation EBR-II fuel behavior, (2) Normal operation PHENIX fuel behavior, (3) HT9 Pressure tube ramp-and-hold creep rupture tests, (4) Whole Pin Furnace (WPF) creep strain, creep rupture and eutectic tests, (5) Fuel Behavior Test Apparatus (FBTA) eutectic tests, and (6) TREAT M5-7 OverPower tests up to clad failure. Section-2 includes a brief description of the MFUEL models. A detailed description of the MFUEL physics-based, semi-empirical models will be presented in the SAS V 5.7 theory manual. Section-3, 4, and 5 describes the validation effort for the pre-transient irradiation, furnace transients, and TREAT M-Series transients, respectively.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Neutronic design and fuel cycle analysis of a fluoride salt-cooled High Temperature Reactor (FHR)

The Fluoride salt-cooled High temperature Reactor (FHR) is a new Gen IV reactor concept that can operate under near atmospheric pressure circumstances and further enhance the inherent safety. In this study, an FHR core design with 165 megawatts of thermal output (MWth) is proposed. The reactor core employs tri-structural-isotropic (TRISO) particle fuel within prismatic graphite blocks as the basic fuel form, FLiBe (2 {sup 7}LiF-BeF{sub 2}) as the primary coolant, and a three-batch fuel cycle scheme. Sensitivity analyses on various parameters were performed to optimize the cycle length and neutronic parameters. The fuel cycle of this core design was evaluated in detail from 4 aspects: cycle length, power peaking factor (PPF), discharge burnup, and temperature coefficient. It was found that larger fuel channel pitch (FCP) would have a relatively harder neutron spectrum, and yield relatively longer cycle length, lower, better fuel temperature coefficient (FTC), and moderator temperature coefficient (MTC). In addition, burnable poison (BP), Er{sub 2}O{sub 3}, can effectively reduce PPF, hold down the multiplication factor, and more importantly it can improve the MTC. (authors)

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

SERPENT 2 and TRIPOLI-4 neutronics benchmarking of the Jules Horowitz reactor

Jules Horowitz Reactor (JHR) is a future center for nuclear material testing in Europe, currently under construction at CEA Cadarache in southern France. It has been modelled extensively with CEA's HORUS3D/N neutron calculation package, that includes a Monte-Carlo neutron transport code TRIPOLI-4. In order to support the future computational analyses on the reactor core physics, VTT's Monte Carlo neutronics code SERPENT 2 has been used to create an alternative model of the JHR, taking advantage of the pre-existing Constructive Solid Geometry (CSG) structures on which the TRIPOLI-4 model was built. This work describes a benchmark, in which two JHR core configurations were analyzed using both of these models. The first configuration is a fresh fuel core at the beginning of life, in which aluminum based dummy-devices are installed in the reactor test positions. The second configuration represents the end-of-cycle equilibrium core with a heterogeneous burnup distribution, in which CALIPSO devices containing cladding material samples are installed at the in-core experimental positions, while the reflector positions are occupied by DEN-REP devices containing UO{sub 2} fuel. Neutron flux spectra and heat deposition are the parameters of interest in this study, due to their high importance in creating the desired experimental irradiation environment. The impact of delayed gamma energy deposition will be studied in detail, since the two models account for it with different methods. This work aims to establish a SERPENT 2 model of JHR, understanding its differences and agreements with TRIPOLI-4, and discussing its potential future applications. (authors)

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

Evaluation of Hydrogen Generation in High Burnup Demonstration Dry Storage Cask

This report provides a best-estimate evaluation of residual water content (post-dry out) in the High Burnup (HBU) LWR Spent Fuel Demonstration project TN-32 cask, and evaluates the radiolysis of the residual free water, and the physisorbed and chemisorbed waters on the surfaces of the fuel and cask internal contents. The evaluation of radiolytic breakdown of those waters with gamma radiation causing the generation of hydrogen gas (H 2 ) is made using available literature data and models. This evaluation is part of the overall materials performance evaluation of the SNF-in-canister system, and is part of the technical bases for their continued safe dry storage. The TN-32 cask contents included 32 HBU LWR spent fuel assemblies each with 264 fuel rods clad in zirconium alloys, aluminum neutron absorber components, and aluminum and stainless steel structural components. The residual free and surface (physisorbed/chemisorbed) waters are ascribed to water vapor in the free volume and to components’ surfaces, respectively. The total potential radiolytic hydrogen inventory from the water vapor and from waters ascribed to surfaces has been calculated assuming all the water produced molecular H 2 . The residual water that is chemically incorporated into the bulk of a hydrated oxide, i.e., chemisorbed water, and its total potential hydrogen inventory has been calculated. These calculations are at the physical limit of material available and are used for a bounding assessment purpose only.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Beyond interpolation: Physics-inspired gating transformers for extrapolating irradiation conditions to novel nuclear fuels

The qualification of advanced nuclear fuels relies on irradiation experiments in test reactors that emulate commercial conditions. Designing these tests requires accurate prediction of key irradiation quantities, particularly heat generation rate and burnup, yet obtaining them typically involves computationally expensive multi-step simulation workflows. We propose a physics-inspired gating transformer (PIGT) that integrates an inverse-square, distance-based attenuation into the encoder representation to bias attention toward physically relevant spatial relationships while retaining data-driven flexibility. Using MiniFuel irradiation data from the High Flux Isotope Reactor at Oak Ridge National Laboratory, we benchmark against ensemble methods, feedforward and recurrent networks, convolutional models, and standard transformers. While baseline models perform well under interpolation, they exhibit a pronounced generalization gap when evaluated on fuels not included in the training set. The proposed model consistently improves extrapolative accuracy and stability, yielding the strongest performance on unseen fuel configurations. These results indicate that a lightweight physics structure embedded within attention mechanisms can substantially improve robustness, enabling more reliable surrogate predictions to accelerate the design of nuclear fuel irradiation experiments.

Fuel qualification↗

Fundamental Studies of Tritium Diffusivity in Pure and Defective Zircaloy-4 Getters (Tritium Science Program FY2020 Report)

Zirconium (Zr) alloys are extensively used as tritium (T) getters in nuclear reactors due to their low absorption cross section to thermal neutron, good mechanical properties at high temperature and resistant to corrosion in different environmental conditions. Zr alloys have better thermal properties than many other refractory alloys including stainless steel. The nuclear characteristic is simulated, and T is produced in tritium-producing burnable absorber rods (TPBAR) by the irradiation of neutron flux in pressurized water reactor (PWR). T thus produced diffuses through the pellets and is captured by the getter where it chemically reacts with Zr to form metal hydride (ZrTx). These hydrides are brittle and affect adversely the mechanical properties of alloys. In addition to that, mismatch in the lattice structures after hydride formation creates a stress which needs to be considered in component design and their life evaluation. Therefore, understanding the behavior of T and its species becomes significant as fuel burnup is increased, which leads to increase in hydrogen pickup and oxide formation. The transport of T and its species in pure Zr alloys, and in alloys with certain alloying elements and defects are important to understand in order to enhance the performance of the materials.

36 MATERIALS SCIENCE↗

Transformational challenge reactor design characteristics

The Transformational Challenge Reactor (TCR) program was conceived with the goal to reduce costs and time frames associated with advanced reactor deployment by leveraging developments in advanced manufacturing, advanced materials, data science, and rapid prototyping and testing. The final deliverable of the TCR program was to be an operational test of a novel reactor design. The TCR core design incorporates a dense tri-structural-isotropic/SiC fuel form and volumetrically efficient yttrium hydride moderator, both of which were manufactured and characterized under the TCR program. The TCR is a 3 MW{sub th} He-cooled experimental nuclear reactor designed to reach a total integrated burnup of less than 24 effective full-power hours to keep the radioactive source term to a very low level. TCR design process revealed a positive moderator coefficient; however, the negative doppler coefficients for the fuel and thermal expansion of fuel, moderator, and core support plate yield an overall negative reactivity coefficient. Calculated fuel element temperatures and stresses are well within safety margins. The maximum hypothetical accident (i.e., de-pressurized loss of forced cooling) yields only a modest increase in reactor temperatures that are all within safety margins. This paper summarizes the high-level TCR design characteristics, which were derived from neutronics, thermohydraulics, thermomechanics, and safety analyses.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

An analysis of fluff formation in metallic fuel via data analyzes from EBR-II experiments and BISON fuel code modeling

During the operation of EBR-II, it was found that a highly porous structure (over 40% area fraction) formed at the top of several fuel columns. Previous work has shown that this structure, designated fluff in this paper, contains a significant fraction of fuel elements (e.g., U and Pu) which could potentially impact neutronics. This work aims in analyzing the formation mechanism of this microstructure so its impact can be incorporated into future metallic fuel modeling codes and algorithms. This paper details a preliminary examination into the formation mechanisms of fluff by performing qualitative and statistical analysis of EBR-II experimental data. Additionally, the operating conditions that have the greatest impact on fluff formation were determined based on this data set. Also, BISON fuel code simulations were used to help postulate potential fluff formation mechanisms. From this analysis it was found that the largest contributors to fluff formation were fuel burnup and composition, with fluff formation exhibiting a roughly linear positive correlation with increasing burnup and a negative correlation with increasing Pu content. It was also found that higher pin operating temperatures decreased fluff formation but only for U-10Zr fuels.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

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↗

Feasibility of Recycling Discharged Microreactor Heavy Metal in Light Water and Sodium-Cooled Fast Reactors: A Neutronics Analysis

Nuclear microreactors (MRs) offer unique advantages, such as rapid deployment, potability, low maintenance requirements, and operational flexibility. Their compact size makes them a promising solution for decentralized power generation, particularly in remote areas, military bases, and disaster-stricken regions. However, MRs face challenges, including unutilized fissile material at the end of life, economic inefficiency, increased heavy metal (HM) waste complicating disposal, and the accumulation of plutonium (Pu) with high 239 Pu concentrations raising proliferation risks. Here, this study investigated the neutronics feasibility of a novel three-stage fuel cycle where discharged HM from MRs is recycled and burned in light water reactors and sodium-cooled fast reactors. This approach converts discharged HM into valuable fuel, enhancing the efficiency of MR deployments while improving the safeguardability of their final waste products. Neutronics analysis demonstrated that the safety characteristics of reactor designs in each stage were minimally impacted by the proposed cycle. For two representative MR designs, a fast-spectrum MR with solid pellet fuel and a thermal-spectrum MR with TRISO (TRi-structural-ISOtropic) fuel compacts, the proposed fuel cycle reduced the uranium disposal mass flow rate by ~60%, decreased the 235 U enrichment of the discharge fuel to ~1 wt%, eliminated plutonium disposal, and increased the cumulative fuel burnup to ~580 gigawatt-day per metric ton of initial heavy metal (GWd/t-iHM) or 60% fissions per initial metal atom. Despite the significant differences between the two MR designs, the performance and infrastructure requirements of the developed fuel cycles were remarkably similar, indicating its generalizability to a broader class of MRs.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

A study on texture stability and the biaxial creep behavior of as-hydrided CWSR Zircaloy-4 cladding at the effective stresses from 55 MPa to 65 MPa and temperatures from 300°C to 400°C

The creep rupture of high burnup used nuclear fuel (> 45 GWD/MTU) cladding is regarded as one of the failure mechanisms during long-term dry storage. A high amount of zirconium hydride in the cladding matrix would degrade the mechanical properties of the cladding especially leading to delayed hydride cracking. To better understand the influence of zirconium hydride on the biaxial thermal creep performance and the crystalline texture stability of Zircaloy-4 cladding, the pressurized tube technique is applied to test the durability of the as-hydrided material. Tests were performed on as-received Zircaloy-4 tubular specimens as well as-hydrided ones with targeted 300 wt parts per million (wppm) or 750 wppm hydrogen. The biaxial creep experiments were conducted at temperatures from 300 degrees C to 400 degrees C and at equivalent stresses at mid-wall from 55 MPa to 65 MPa. The hydridation process prior to creep tests induces the formation of FCC delta-hydride platelets along the circumferential direction of the tube. This alignment and phase structure of hydride show no significant change after biaxial creep tests. The creep strain-rate negatively depends on the hydrogen content. The synchrotron wide-angle X-ray diffraction (WAXD) technique and electron backscatter diffraction (EBSD) analysis were applied for the study of the crystallographic orientation relationship. zirconium-to-hydride grain orientation follows Shoji-Nishiyama crystallographic relationship. This relationship is stable before and after creep deformation. These results of creep performance and texture stability of Zircaloy-4 claddings can help support the design basis of interim and long-term dry storage facilities.

creep↗