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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 91 records · Page 5
All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

Control rod damping system

A damping area or “dash pot” on the upper ends of control rods absorb energy from dropped control rod assemblies without narrowing the diameter of guide tubes. As a result, coolant can freely flow through the guide tubes reducing boiling water issues. The dampening area reduces a separation distance between an outside surface of the control rod and an inside surface of the guide tubes decelerating the control rods when entering a top end of the guide tubes. In another example, the dampening area may be located on a drive shaft. The dampening area may have a larger diameter than an opening in a drive shaft support member that decelerates the drive shaft when dropped by a drive mechanism.

Snuggerud, Ross Douglas↗
DOE OSTI2025

Fuel Bonding and its Impact on Axial Gas Communication Behavior in Light-Water Reactor Fuel Rods

Axial gas communication concerns the flow along the axial axis of nuclear fuel rods during ramp and loss of coolant accident (LOCA) conditions. During power ramps, the higher linear heat generation rate may cause fuel-to-clad gap closure that may prevent transport of released fission gases to the plenum. Upon reduction in power the gas then can communicate to the plenum. This phenomenon has been experimentally observed by short power dips during ramp experiments completed at the Risø reactor. At higher burnups it is observed that the UO2 fuel and Zircaloy cladding forms a chemical bond. This bond results in complete closure of the gap. When these high burnup rods are subjected to a LOCA, the bond has implications on both the mechanical response (i.e., ballooning) of the cladding and subsequent fuel relocation and axial gas communication. In the LOCA scenario, gas communication is of interest in two different regimes: 1) pre-rupture communication from the plenum towards the lower pressure ballooning area and 2) the post-rupture depressurization of the plenum to the external system pressure. In both regimes the presence of a fuel-to-cladding bond will impact the rate of depressurization. In this work we present a fuel-to-clad bonding model that is coupled to an existing axial gas communication model framework in the BISON fuel performance code. The effect of considering the bond on fuel performance modeling predictions is presented through comparisons to existing experimental data. Experiments considered include several rods from the Halden IFA-650 test series. An evaluation on a full-length rod that explores the combined effect of plenum size and bonding status on axial gas communication behavior is also presented.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2026

Assessment of multi-stage telescopic control rods in a pebble bed reactor. Part II: corrosion and wear performance

To support High-Temperature Gas-Cooled Reactor designs, the effects of corrosion and wear on a SS316L telescopic control rod prototype were investigated in helium at 775 °C with up to 5 ppm oxygen for durations up to 500 h. Three deployment conditions were tested to assess their impact on wear and oxide formation: severe cycles, daily cycles, and gravity-driven deployments. Here, a chromium-rich oxide layer developed on regions exposed to the helium flow, reaching up to 2 µm in the most affected areas. No carburization or decarburization was observed. Oxide breakthrough occurred mainly at grooves and contact points during severe cycling of the telescopic rod, while in the other tests it was limited to contact points. Friction forces increased due to oxide growth and thermal expansion, the latter being the dominant factor, but never enough to hinder rod deployment significantly. Coaxial misalignment of stages was identified as the main potential risk to reliable operation under normal conditions.

Control rod↗
DOE OSTI2024

Complex Phase Transitions of Fully Rigid Sphere–Rod Amphiphiles Induced by Solvent Polarity in Dilute Solutions

Here we report complex macrophase and microphase transitions of rigid amphiphiles with spherical Keggin molecular clusters as the solvophilic block and rod-like rigid oligofluorene (OF) as the solvophobic block in mixed solvents of water and polar organic solvent. By properly adjusting the solvent polarity, the amphiphiles are found to respond accordingly by self-assembling into multilayered incomplete onion-like structures (10–25 vol % THF), single-layered vesicular structures (60 vol % THF), and an unexpected macrophase separation in the middle (40–50 vol % THF), which is due to the anomalous trends in Keggin solubility as a result of the nature of TBA + counterions. The rigidity of the OF block prevents the amphiphile from assembling by following the rule of packing parameters; instead, interdigitation among different rods leads to the formation of the solvophobic domain to achieve self-assembly. The incomplete onion structures are controlled by the interdigitation of rigid rods for the number of layers and the electrostatic interaction among Keggin head groups for the interlayer distance. When the degree of interdigitation becomes lower, the self-assembly process shows a trend that can be explained by the traditional rule of packing parameter. This study demonstrates the formation of different self-assembled structures by rigid amphiphiles and their transitions induced by solvent composition. The self-assembly (microphase separation) of rigid amphiphiles in a dilute solution could indeed represent a broad area containing complicated, uncharted rules.

36 MATERIALS SCIENCE↗
DOE OSTI2020

DEMONSTRATION OF MULTI-PHYSICS EVALUATION OF FUEL ROD BURST PROBABILITY WITH BURNUP EXTENSION UNDER LBLOCA CONDITIONS

Extending the fuel discharge burnup level, e.g., from the current limit of rod averaged discharge burnup limit of 62 GWD/MT to a proposed new limit of 75 GWD/MT, can provide significant economic benefits to the current fleet of operating light water reactors (LWRs). It allows for longer operating cycles and improved resource utilization. The major economic gain of longer operating cycles is attributable to the increased capacity factor resulting from decreased refueling time as a fraction of total operating time, as well as fewer assemblies to be discharged for a given amount of energy produced. The main licensing challenges for higher burnup fuel are to ensure fuel rod safety under design basis accident conditions, especially under large-break loss-of-coolant accident (LBLOCA) and reactivity insertion accident (RIA). In this work, two-year cycle core design for a typical 4-loop pressurized water reactor (PWR) is performed with enrichment increased up to 6% and burnup extended to 75 GWD/MT. The fuel rod burst potential evaluations under large-break loss-of-coolant accident (LBLOCA) conditions are subsequently performed using the multi-physics best estimate plus uncertainty analysis framework LOTUS (LOCA Toolkit for the U.S. LWRs) and the preliminary results are presented.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2023

Rational Design and Reticulation of Infinite qbe Rod Secondary Building Units into Metal–Organic Frameworks through a Global Desymmetrization Approach for Inverse C 3 H 8 /C 3 H 6 Separation

Abstract The development of reticular chemistry has enabled the construction of a large array of metal–organic frameworks (MOFs) with diverse net topologies and functions. However, dominating this class of materials are those built from discrete/finite secondary building units (SBUs), yet the designed synthesis of frameworks involving infinite rod‐shaped SBUs remain underdeveloped. Here, by virtue of a global linker desymmetrization approach, we successfully targeted a novel Cu‐MOF (Cu‐ASY) incorporating infinite Cu‐carboxylate rod SBUs with its structure determined by micro electron diffraction (MicroED) crystallography. Interestingly, the rod SBU can be simplified as a unique cylindric sphere packingqbetubule made of [4 3 .6 2 ] tiles, which further connect the tritopic linkers to give a newly discovered 3,5‐connectedgfcnet. Cu‐ASY is a permanent ultramicroporous material featuring 1D channels with highly inert surfaces and shows a preferential adsorption of propane (C 3 H 8 ) over propene (C 3 H 6 ). The efficiency of C 3 H 8 selective Cu‐ASY is validated by multicycle breakthrough experiments, giving C 3 H 6 productivity of 2.2 L/kg. Density functional theory (DFT) calculations reveal that C 3 H 8 molecules form multiple C−H⋅⋅⋅π and atypical C−H⋅⋅⋅ H−C van der Waals interactions with the inner nonpolar surfaces. This work therefore highlights the linker desymmetrization as an encouraging and intriguing strategy for achieving unique MOF structures and properties.

Chemistry↗
DOE OSTI2023

Effects of transient fission gas release on rod balloon burst behavior during a loss-of-coolant accident

The US nuclear energy industry is investigating strategies to increase the reactor operating cycle to 24 months, which would result in rod average burnups exceeding the current limit of 62 GWd/tU. To support this goal, multiphysics simulations tools and methodologies are being developed to predict the effects of this change during transient events such as loss-of-coolant accidents (LOCAs). In this work, two cladding burst correlations were used to predict cladding failure. Here, these were coupled with three transient fission gas release (tFGR) models and were implemented in the BISON fuel performance code to quantify any changes in cladding burst behavior during a large-break LOCA. First, a simple linear model was used to perform a sensitivity analysis of a single fuel rod. Second, a tFGR model available in BISON was applied to 281 fuel rods throughout the core. The third model examined was an empirical correlation based on data from the literature.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2026

Structural uniformity and compositional homogeneity of solid-phase alloyed rod

Solid-phase processes have emerged as an alternative to fusion-based alloying to avoid coarse microstructures, undesirable phase formation, and high energy consumption. However, achieving uniform distribution of alloying elements during friction-based processing remains challenging due to highly heterogeneous thermomechanical conditions. This work evaluates the structural uniformity and compositional homogeneity of Al–Cu–Zn alloyed rods produced by friction extrusion (FE) and establishes the role of the rotational speed to feed rate ratio (N/V) on alloying effectiveness. A systematic matrix of FE experiments was conducted at constant extrusion ratio with N/V values ranging from 3.7 to 300. Compositional uniformity was assessed along the rod length (ICP-OES), in three dimensions (X-ray computed tomography), and at the microscale (SEM–EDS), supported by a gray-level co-occurrence matrix (GLCM)–based homogeneity metric. Smoothed particle hydrodynamics (SPH) simulations were used to reveal material flow and thermomechanical fields. Results show that N/V = 100 produces a high-shear mixing zone that eliminates the unmixed core and enables near-full dissolution and dispersion of Cu and Zn. At lower N/V, a laminar flow region persists at the rod center, causing segregation and large composition gradients. The combined experimental–computational analysis provides mechanistic insight into the transition from fragmented particle dispersion to thermomechanically assisted metallurgical mixing. This study establishes processing–structure relationships for solid-phase alloying and provides guidance for achieving homogenized compositions comparable to wrought alloys via rapid, scalable FE processing.

Aluminum↗
DOE OSTI2025

Porous Flow Modeling of Axial Gas Redistribution in Fragmented LWR Fuel Rods using MOOSE

Understanding how gas axially redistributes within fragmented fuel pellets is crucial for predicting the behavior of Light Water Reactor (LWR) fuel rods, particularly during transient and accidental scenarios. The time scale of this phenomenon plays a fundamental role in determining the progression and hazard of a Loss Of Coolant Accident (LOCA), especially when high burn-up fuel in a severe state of fragmentation is involved. Here, this study presents a Computational Fluid Dynamics (CFD) model developed within the Multiphysics Object-Oriented Simulation Environment (MOOSE) to predict the time-scale of plenum depressurization in Light-Water Reactor (LWR) fuel rods driven by axial gas transport through fragmented pellets. The model examines the effects of incorporating non-linearities in the friction term by comparing the results with experimental data. The experiment employed surrogate fuel rods containing pellets subjected to mechanical and/or thermal loadings to simulate various severity of cracking, and aimed at studying the influence of fuel conditions on axial gas redistribution. The results of this analysis indicate that under certain flow regime conditions - determined by the value of an equivalent Reynolds number - accounting for the non-linear friction term in Navier-Stokes equations guarantees better predictions for the time-scale of plenum depressurization. Also, the model enabled the simulation of the pressure decay by assigning distinct permeability values to each pellet instead of a single uniform value. Multiple simulations were run across all possible pellet position combinations, having each pellet assigned with values of permeability extracted from the experimental data. This allows to quantify the impact of the considering various non-uniform distributions of permeability on the dynamics of axial gas redistribution. The present work findings enhance the understanding of axial gas transport, and provide valuable insights for the integration of a model for predicting the axial gas redistribution during a LOCA scenario into the BISON fuel performance code.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2022

Microgap breakdown with floating metal rod perturbations

Here, we report the characterization of microgap breakdown with perturbations from a metal rod floating between anode and cathode electrodes. The effects of the metal rod on the electric field distribution and the field enhancement factor are evaluated by numerical simulation and the conformal mapping method, and they indicate that the field emission regime is not reached. The breakdown voltages in the Townsend discharge regime are determined based on the voltage–current characteristics, which are obtained from two-dimensional fluid simulations. It is found that the breakdown characteristics can be significantly modulated by the floating metal rod, and the breakdown curve (breakdown voltage vs the net gap distance) is no longer U-shaped, which deviates from the conventional Paschen's law. The underlying physical mechanisms are related to the electric field enhancement, curved breakdown path, and nonuniform ion flux caused by the electric shielding effect. The results provide insights into breakdown characteristics in microscale discharges, which may promote conventional investigation of simplified clean gaps toward more complex conditions (e.g., with floating microparticles) in miniaturized plasma devices.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
DOE OSTI2023

Flow field characteristics of a 127-pin rod bundle with hexagonal spacer grids

A determination of nominal flow phenomena in liquid metal fast reactor (LMFR) fuel assemblies is critical toward generation-IV reactor development. Axially positioned spacer grids are used to maintain the geometry of hexagonal rod bundles and simultaneously introduce perturbations in the flow. Three-dimensional (3D) printed asymmetric honeycomb spacer grids were installed in a prototypical 127-pin LMFR fuel assembly model to study complex fluid dynamics interactions induced by the spacer grid and rods. To characterize flow dynamics in this intricate geometry, time-resolved particle image velocimetry (TR-PIV) using the matched-index-of-refraction method was employed to obtain non-intrusive velocity measurements for three axial planes (one near-wall and two interior planes) at a Reynolds number of 6000. The statistical TR-PIV results compared sub-channel-dependent normalized time-averaged velocity, velocity fluctuations, Reynolds stress, vorticity, and turbulence kinetic energy distributions. TR-PIV line profiles characterized downstream spacer grid flow dynamics. Two-point spatial and spatial–temporal cross-correlation fields revealed local coherent structures and quantified convection velocities of traveling vortices. Spatial–temporal decomposition using dynamic mode decomposition (DMD) applied to the near-wall vorticity fields extracted turbulent structures and flow instabilities in the wake region of the spacer grid, along with their decay and frequency rates. Reduced-order velocity fields from DMD reconstructions identified the most energy-containing coherent structures persistent in the near-wall region. This research provides experimental data sets and analyses of flow behavior in rod bundles with hexagonal spacer grids. In conclusion, the results are critical toward LMFR design and geometry optimization, crucial for the validation of computational fluid dynamics and reduced-order flow models.

42 ENGINEERING↗
DOE OSTI2025

Rotation of electrothermal-instability-driven overheating structure due to helically oriented surface magnetic field on a high-current-density aluminum rod

Experiments on the 1-MA, 100-ns-rise-time Mykonos Facility demonstrate rotation of electrothermal instability (ETI)-driven overheating structure on 1.00-mm-diameter, 10-nm-surface roughness, 99.999%-pure aluminum rods, which are pulsed with helically polarized surface magnetic field. Rods are machined to include pairs of 10-micron-scale quasi-hemispherical voids or “engineered defects (ED)” which provide the dominant current density perturbation from which ETI grows most rapidly. Experiments include an axial magnetic field component through the addition of a helically wound return-current electrode or “helical return can (HRC).” For a given HRC design, azimuthal field (B ɵ ) and axial field (B z ) components rise at a prescribed and fixed ratio, driving an increasing magnetic field of constant polarization at the rod's surface; most experiments generated surface magnetic field at a 15-degree field polarization angle (from horizontal) defined as ɸ B = arctan(B z /B ɵ ). ETI-driven emission patterns from individual ED are observed to rotate along ɸ B , while emission patterns from dielectric-coated ED pairs are shown to elongate and preferentially merge along ɸ B , in qualitative agreement with 3D-magnetohydrodynamic simulations. These data strongly support that for a randomized distribution of current density perturbations on a high-current density conductor, nearby perturbations will favorably merge about ɸ B , with the degree of merging increasing with current. Such observations offer fundamental new understanding of the seeding mechanisms of the helical magneto-Rayleigh Taylor (MRT) instabilities observed from axially magnetized magnetically driven imploding liners.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2020

Technology of thin-rod Yb : YAG amplifiers with a high pulse energy and average power

Technology for producing thin-rod Yb : YAG laser amplifiers is improved, which is aimed at increasing the output pulse energy and includes the development of a new method for mounting active elements into a cooling system and employment of more persistent dielectric coatings of rod ends. An influence of a thermal lens on the beam size in an active element is theoretically studied and the parameters are found, which provide equal beam sizes at input and output rod ends. The output pulse energy of 4 mJ is obtained without optical breakdown of the output end, which substantially exceeds the previously obtained results. The amplifier demonstrates an average power of 60 W and maintains a high beam quality. (paper)

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
DOE OSTI2022

Eddy current flow meter model validation with a moving solid rod*

We report that the eddy current flow meter (ECFM) has been used to measure velocities and temperatures of conductive flows, such as liquid metal flows in a nuclear fission reactor. The goal of this paper is to develop a finite element electromagnetic model that can characterize the ECFM sensor performance and validate this finite element model with detailed velocity measurements of a controlled, well-characterized moving conductive solid rod. Both measurements and modeling were performed for various parameters that are important for ECFM performance such as rod velocity, rod material, ECFM sensor coil length, number of sensor coils, applied alternating current (AC) current amplitude, and applied ECFM AC frequency. For all parametric scans, the measurement and modeling agree well in both magnitude and trend. The normalized root-mean-square error between measurement and modeling is less than 10% for all cases. These results suggest that electromagnetic modeling could eventually be used to cost-effectively design future ECFM sensors in arbitrary geometry for more challenging applications such as liquid metal nuclear fission reactors.

47 OTHER INSTRUMENTATION↗
DOE OSTI2023

Radius of Contact During Friction Surfacing of Stainless Steel 304L: Effect of Spindle Speed and Rod Diameter

Abstract The “radius of contact” or the “real-rotational contact plane,” has been increasingly mentioned terminology in friction surfacing. However, the fundamental understanding of the flow dynamics behind this phenomenon is still very limited. The goal of this study was to understand the influence of spindle speed and consumable rod diameter on the flow dynamics and the radius of contact during friction surfacing of 304L stainless steel over a substrate of the same material. Friction surfacing was performed using consumable rods with diameters of 4.76 mm, 9.52 mm, and 12.7 mm while using spindle speeds from 1500 rpm to 20,000 rpm. The impact of spindle speed on deposition morphology, including the radius of contact, was studied. The radius of contact was calculated empirically and was found to be inversely proportional to the tangential velocity of the rod. The coupling between flow stresses and localized forces is hypothesized to be the key factor behind the variation of the radius of contact with processing conditions.

Engineering↗
DOE OSTI2020

Pitch Variation Experiments in Water-Moderated Square-Pitched U(6.90)O 2 Fuel Rod Lattices with Fuel to Water Volume Ratios Spanning 0.08 to 0.67

The US Department of Energy (DOE) Nuclear Energy Research Initiative funded the design and construction of the Seven Percent Critical Experiment (7uPCX) at Sandia National Laboratories. The start-up of the experiment facility and the execution of the experiments described here were funded by the DOE Nuclear Criticality Safety Program. The 7uPCX is designed to investigate critical systems with fuel for light water reactors in the enrichment range above 5 % 235 U. The 7uPCX assembly is a water-moderated and -reflected array of aluminum-clad square-pitched U(6.90 %)O 2 fuel rods. Other critical experiments performed in the 7uPCX assembly are documented in LEU-COMP-THERM-078, LEU-COMP-THERM-080, LEU-COMPTHERM- 096, LEU-COMP-THERM-097, and LEU-COMP-THERM-101. The fuel used in these experiments was fabricated using unirradiated 6.90 % enriched UO 2 fuel pellets from fuel elements designed to be used in the internal nuclear superheater section of the Pathfinder boiling water reactor operated in South Dakota by the Northern States Power Company in the 1960s. The fuel elements were obtained from The Pennsylvania State University where they had been stored for many years. The fuel pellets in those fuel elements were removed from the original Incoloy cladding and reclad in 3003 aluminum tubes and end caps for use in the experiments reported here. The purpose of these experiments was to measure the effects of decreasing the fuel-to-water volume ratio on the critical array size. This was accomplished by removing fuel rods from fully fueled configurations, effectively increasing the pitch of the fuel arrays in the assembly. The fuel rod pitch variations provided assembly configurations that ranged from strongly undermoderated to slightly overmoderated.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2026

Mitigation of Cu-Induced Grain Boundary Sensitization in Steel Wire Rods Through a Desensitization Heat Treatment

Steel wire rods are essential for manufacturing high-strength steel tire cords. Yet, the presence of residual copper (Cu) in recycled steel can cause grain-boundary sensitization, embrittlement, and deterioration of the mechanical performance of the final product. This study introduces a desensitization heat treatment step designed to redistribute Cu away from austenite grain boundaries after sensitization occurs. The treatment consists of a 10 min dwell at 1000 °C in a 5%H 2 -Ar reducing atmosphere followed by quench. The temperature and hold time were selected based on diffusion calculations to promote solid-state back diffusion of Cu without altering grain morphology. Experimental validation showed that the dwell step reduced the length of Cu-rich sensitized zones of steel wire rod samples containing 0.21 wt.% Cu by approximately 89% and restored the mechanical properties to nearly 95–98% relative to low-Cu baseline steel (0.01 wt.% Cu). Compared with sensitized and as-obtained samples, these results highlight the effectiveness of the proposed method in improving both the microstructure and tensile performance of recycled steel wire rods, enabling their potential application in tire manufacturing.

copper↗
DOE OSTI2025

Analysis of Fuel Rod Arrays

Brief presentation on recent work to enable analysis of arrays of fuel rods in Bison. Mesh generation is available in the input file. Simplified syntax is available to ease descriptions common to all fuel rods. The capability allows contact between neighboring rods.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗