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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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DOE OSTI2021

Design Optimization for Printed Melt Wire Arrays Encapsulation

As part of the Nuclear Energy Enabling Technology (NEET) Advanced Sensor and Instrumentation (ASI) Program, Idaho National Laboratory (INL) has recently established in-house capabilities to fabricate and test new advanced-manufactured sensors for measuring peak irradiation temperature within a nuclear test reactor. Although methods of real-time temperature monitoring, such as thermocouples, may be used, the complexity of feedthroughs and attachments to collect real-time measurements greatly increases the cost of the experiment. Instead, passive monitoring techniques may be used for peak- temperature measurement that exploit the melting point of well-characterized materials (standard melt wires) to infer peak reactor temperatures. However, limited available space for instrumentation during experiments introduces an additional challenge. To accommodate this, INL has expanded its temperature- detection instrumentation capabilities to include advanced manufactured (AM) melt wires for peak irradiation temperature measurements. These melt wires can determine peak temperatures while also accommodate space limitations in irradiation experiments. In an effort to improve performance reliability of AM meltwire capabilities, a process was developed and tested to identify the significance of entrapping a high purity inert atmosphere within the packaging of printed melt wire arrays. The materials used in this study were aluminum, zinc, and tin encapsulated in high purity helium within a stainless steel (SS) 316 container. Tin, with a low melting point of approximately 230°C, Zn with a mid-melting point of approximately 420°C, and Al with a high melting point of approximately 660°C. This report describes the design, fabrication process, furnace testing and X-ray Computed Tomography (XCT) evaluation. Results show a successful outcome in creating an inert gas encapsulation and high-resolution evaluation methods.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2021

Molten Salt Reactor Signatures and Modeling Study

Molten salt reactor (MSR) technologies, either liquid fueled and cooled or only liquid cooled, pose specific, unique challenges for safeguards of the special nuclear material during the operation, fueling, and maintenance of the reactor. MSRs are one type of Generation IV technologies being invested in and considered for U.S. domestic fabrication primarily for electricity and process heat production. These designs have generated growing commercial interest for several reasons, including high (≈40%) thermal efficiency, ease of fueling, improved use of uranium fuel, potential utilization of thorium fuel, and proposed inherent safety features. U.S. companies have several planned designs that differ in fuel, cooling, and neutron energy spectrum. Driven by commercial interest and the intent of licensing MSRs, the U.S. Nuclear Regulatory Commission (NRC) has developed a vision and strategy to accommodate non-light water reactors (LWR), which include MSRs (U.S. Nuclear Regulatory Commission 2019). In addition, the Department of Energy (DOE) through the Office of Nuclear Energy (NE) Office of Advanced Reactor Technologies (ART), …sponsors research, development and deployment (RD&D) activities through its Next Generation Nuclear Plant (NGNP), Advanced Reactor Concepts (ARC), and Advanced Small Modular Reactor (aSMR) programs to promote safety, technical, economical, and environmental advancements of innovative Generation IV nuclear energy technologies. Reactor types considering the use of salts, liquid metals, or gases for coolant fall under both ARC and aSMR. Therefore, Research Design & Development is being pursued by DOE-NE through national laboratories, universities, and international and industrial collaborations. Additionally, the U.S. is a member of the Gen IV International Forum (GIF). The GIF is a cooperative, multinational organization to guide and carry out research and development needed for the GEN IV reactor systems (Forum 2018). GIF evaluated numerous reactor concepts and down-selected to the six most feasible advanced reactor technologies: gas-cooled fast reactor (GFR), lead-cooled fast reactor (LFR), MSR, supercritical watercooled reactor (SCWR), sodium-cooled fast reactor (SFR), and very high temperature reactor (VHTR). In support of the growing interest domestically and internationally, the Materials Protection, Accounting, and Control Technologies (MPACT) campaign, under the DOE-NE Fuel Cycle Technologies (FCT) program, engages in R&D activities by developing advanced instrumentation and analysis for safeguards and security of modern, advanced nuclear fuel cycle (non-LWR) facilities. Because of the historic experience in the operation of the Aircraft Reactor Experiment (ARE) and the Molten Salt Reactor Experiment (MSRE) (Robertson, MSRE Design and Operations Report Part I 1965), Oak Ridge National Laboratory (ORNL) is heavily engaged in the various R&D activities through the DOE complex related to MSRs including national technical leadership of the DOE-NE MSR campaign. This report discusses and presents the outcomes of the FY19 MPACT MSR Safeguards task. The challenges presented by MSRs for nuclear material accountancy and control (NMAC) and associated safeguards will be investigated. The objective of this research is to explore and compile the safeguards requirements and identify measurement signatures through an initial high-level MSR design and develop complementary advanced simulation and modeling capabilities. A high-level ORNL-developed MSR design called the Molten Salt Demonstration Reactor (MSDR) (Bettis, Alexander and Watts 1972) was used as the target reactor design for this research. The MSDR model incorporates technology from the MSRE and the Molten Salt Breeder Reactor (Robertson, Conceptual Design of a Single-Fluid Molten-Salt Breeder Reactor 1971). But the MSDR is a 750 MWth graphite moderated liquid fueled (low-enriched uranium) MSR compared to the MSRE’s of 7.5 MWth. The focus of this report is to discuss the evaluation of novel signatures, correlations, and indicators to understand the applicability of current safeguards instrumentation to MSRs using the modeling results from the MSDR.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2022

FORCE Development Status Update: Vertical Integration and Benchmarking of System Dynamics

Recent efforts to establish effective models for grid energy analysis, especially given the increase in variable renewable energy (VRE) sources and the economic challenges faced by traditional nuclear energy, have generated new technological considerations. One effort to improve the economic viability of nuclear power involves investigating integrated energy systems (IES) which include secondary energy systems that introduce flexibility and secondary market possibilities to existing and perceived future nuclear energy generation technologies. To analyze the technical and economic potential of IES, the Framework for Optimization of Resources and Economics (FORCE) tool suite was developed through a collaboration among national laboratories. Within the FORCE tool suite, the Holistic Energy Resource Optimization Network (HERON) provides algorithms for analyzing the long-term viability of potential IES technologies, while HYBRID provides algorithms and models to achieve high-resolution analysis of coupling physics over a short time period. Continued maturing of the FORCE tool suite requires further interconnections between the various tools in the suite in order to ensure consistent analysis. Analyses performed by applying HYBRID to transient process modeling should be easily harvestable as inputs to HERON analyses. The first item in this status update is a demonstration of an automated data pipeline for loading data from HYBRID into HERON analyses. Application of HYBRID results to HERON, as part of using the FORCE tool suite, relies on robust modeling assumptions for the various models included in HYBRID. The second result of this status update is the benchmarking and validation of cost and operational data, with a particular focus on natural gas energy generators. These generators are benchmarked with a focus on contrasting them with proposed thermal energy storage (TES) technologies.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2021

Laser-based Adhesion Strength Measurements for Advanced Manufactured Sensor Adhesion Characterization

As part of the advanced manufacturing (AM) focus of the Nuclear Energy Enabling Technologies (NEET) Advanced Sensors and Instrumentation (ASI) Program, new in-house capabilities to fabricate and test novel active and passive in-pile sensors are being developed at the Idaho National Laboratory (INL). These advanced-manufactured sensors, such as peak temperature monitors and strain gauges, must be miniaturized and be able to provide real-time feedback, all while withstanding the coupled extremes of temperature and radiation typically observed in the environment of a nuclear test reactor. Fabricating durable and robust in-pile sensors with high fidelity requires a fundamental understanding of the optimal process parameters required in the AM technique, as well as the effect of deviations from optimal process parameters on the sensor-substrate adhesion and the ultimate robustness of the sensor. This report presents the use of a laser-based, non-contact approach for characterizing the adhesion of sensors manufactured using aerosol jet printing (AJP) that comprise of silver nanoparticle inks deposited and sintered on austenitic stainless steel (SS) 316L substrates. The effect of substrate surface roughness, surface energy, ink sintering time and sintering temperature on the printed sensor topography and the sensor-substrate adhesion has been systematically investigated. The sensor-substrate interfacial adhesion strength was determined from the critical laser pulse energy required to ablate/ detach the printed sensor from the substrate. Measurements of the sensor topography using optical profilometry revealed that post-deposition sintering at 400°C for 60 minutes resulted in a reduced sensor thickness, while plasma treating the substrate prior to printing yielded sensors with uniform thickness profiles transverse to the print direction. Sintering temperature and time were found to be the dominant parameters that affected sensor-substrate adhesion, followed by substrate surface roughness. The laser-based and locally-destructive approach for adhesion strength measurements shows promise in overcoming the challenges and limitations of current standardized peel tests and can be developed into a post-fabrication process control protocol for evaluating the durability of AM printed sensors in a high throughput fashion. Future studies will investigate the use of laser-induced spallation techniques as well as non-destructive laser ultrasonic methods for sensor-substrate adhesion characterization on sensors manufactured using AJP and other AM techniques such as plasma jet printing (PJP).

42 ENGINEERING↗
DOE OSTI2022

Regulatory Considerations for Nuclear Energy Applications of Digital Twin Technologies

Digital twins (DTs) in complex industrial and engineering applications have potential benefits that include increased operational efficiencies, enhanced safety and reliability, improved security engineering, reduced errors, faster information sharing, and better predictions. The interest in DT technologies continues to grow, and many of these advanced technologies are expected to experience rapid and wide industry adoption in the near future. Some of the potential application areas for DTs in the nuclear industry are design, licensing, plant construction, training simulators, predictive operations and maintenance, autonomous operation and control, failure and degradation prediction, physical protection modeling and simulation, and safety and reliability analyses. The Office of Nuclear Regulatory Research at the U.S. Nuclear Regulatory Commission (NRC) has initiated a future-focused research project to assess the regulatory viability of DTs for nuclear power plants and other NRC-regulated activities, such as fuel cycle facilities and operations. This report explores the potential impact of DT technologies in nuclear applications on NRC-regulated activities of interest. This report describes a nuclear DT system and its capabilities for nuclear power plant applications, followed by identification and discussion of some regulated activities that merit special consideration and present opportunities in implementing DT-enabling technologies and capabilities.

99 GENERAL AND MISCELLANEOUS↗
DOE OSTI2021

High Temperature Irradiation-Resistant Thermocouple Qualification (Test Results Report)

This is a qualification report for the high-temperature irradiation-resistant thermocouple (HTIR-TC) developed by Nuclear Energy Enabling Technologies Advanced Sensors and Instrumentation program. Utilizing the Advanced Gas Reactor (AGR) 5/6/7 test conducted in the Advanced Test Reactor (ATR) at Idaho National Laboratory, the HTIR-TCs measured temperatures upwards of 1500°C during accident conditions. The HTIR TCs are thus qualified to perform and withstand an 18-month refueling cycle typical of nuclear power plants at the normal operating temperature, with a drift of less than ±1%. The HTIR-TC is also qualified for incorporating into a test fixture during new fuels tests.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2023

Advanced Sensors and Instrumentation 2022 Summary of Accomplishments

The Advanced Sensors and Instrumentation (ASI) program is the element of the Nuclear Energy Enabling Technologies (NEET) initiative dedicated to Instrumentation and Control (I&C) technology. This document collects in the form of summaries the research accomplishments presented at the program 2022 Annual Review meeting, which was held virtually between October 24 and October 27, 2022.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2025

Advanced Sensors & Instrumentation FY24 Summary of Accomplishments

The Advanced Sensors and Instrumentation (ASI) program is the element of the Nuclear Energy Enabling Technologies (NEET) initiative dedicated to Instrumentation and Control (I&C) technology. This document collects in the form of summaries the research accomplishments presented at the program 2024 Annual Review meeting, which was held virtually between November 4 & 6-7, 2024.

46 - INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AN↗
DOE OSTI2023

Creating a Simulation Platform for Research and Development of Advanced Control Methods

Advanced nuclear reactors are essential to meet the changing energy requirements throughout both the United States and the rest of world. In addition to other features, they are designed to enable deployment in remote locations and operate in a fully (or near-fully) autonomous manner, which will require a new control paradigm. To realize autonomously operating reactors, the U.S. Department of Energy’s Nuclear Energy Enabling Technologies Advanced Sensors and Instrumentation (NEET ASI) program conducts research and development into the enabling technologies and methods needed, including digital twins, machine learning, and risk modeling, in addition to various types of control methods. These technologies and methods are the key foundations needed to achieve fully autonomous systems. To develop and evaluate the technologies and methods necessary for achieving autonomous operations, it is critical to identify a software tool capable of integrating all the required elements. In surveying the available solutions, no software platforms were identified that could accomplish what was needed without introducing drawbacks. This challenge was the motivation for the current effort: to develop a software platform that can seamlessly integrate autonomouscontrol-enabling technologies and methods, allowing for accelerated research and development and transfer of ideas. The resulting platform, known as the Control and Optimization Modular Modeling Application for Nuclear Deployment (COMMAND), is Python-based, and leverages open-source tools to provide flexibility and facilitate building upon prior research. It is designed to enable advanced reactor developers to deploy and test advanced control technologies and methods coupled with their own models, solutions, and hardware. Given the substantial undertaking of developing such a platform, the current effort focused on laying down scalable, flexible software foundations and infrastructure, then demonstrating the platform via a use case. These foundations included developing generic modules, which contain the base variable and system blocks (the information and functional building blocks, respectively, that can be used to design a simulation) and the data handling and storage blocks needed to exchange information between the various blocks; as well as enablingtechnology-specific modules. This platform was evaluated via a use case, which was to simulate and control a process for the Microreactor Automated Control System (MACS) test bed. While MACS is not currently directly coupled to any specific microreactor physics, it was initially developed in concert with the Microreactor Applications Research Validation and Evaluation (MARVEL) microreactor, and so the MARVEL physics are used here. As part of this use case, several enabling-technology-specific blocks within COMMAND were integrated, including a proportional integral derivative (PID) control block, a Reactor Excursion and Leak Analysis Program (RELAP5-3D) block, and an anomaly detection block. The COMMAND software platform was successfully demonstrated to achieve the scalability and flexibility objectives of this effort and will be leveraged by the program’s research efforts to advance state of the art control methodologies towards autonomous operations of advanced reactors. As new use cases are created and implemented, it is anticipated that COMMAND will continue to grow and evolve to meet new requirements.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2024

Identification and time evolution of thionyl chloride (SOCl 2 ) radiolysis products

In this study, innovative solutions are needed to reduce the amount of high-level waste generated by used nuclear fuel recycling strategies to support the widespread adoption of sustainable nuclear fission energy technologies. To this end, a new sulfur chloride-based process has been developed to recycle zirconium alloy-based materials, which make up a significant fraction of high-level radioactive waste. To support the continued development of this process, we present new data on the potential reaction pathways over time of the products arising from the gamma and electron beam radiolysis of neat thionyl chloride (SOCl 2 ). Interrogation of the gamma irradiated liquid by Raman spectroscopy provided more conclusive identification of the SOCl 2 degradation products, specifically sulfur dichloride (SCl 2 ), molecular chlorine (Cl 2 ), sulfur dioxide (SO 2 ), and sulfuryl chloride (SO 2 Cl 2 ). In comparison, the high dose rate (~10 7 Gy s -1 ) electron beam irradiations formed significantly more degradation products. For both cobalt-60 gamma and electron beam irradiations, the observed degradation products were found to evolve as a function of time post-irradiation via the same reaction pathways, with indication of a solvent regeneration mechanism. These findings are fortuitous for process development, as such a mechanism would be beneficial for process longevity and cost effectiveness.

38 RADIATION CHEMISTRY, RADIOCHEMISTRY, AND NUCLEA↗
DOE OSTI2023

Fluid-phase helium: Shock-compression experiments, quantum molecular dynamics simulations, and development of an equation of state

Helium (He) plays a critical role in numerous areas ranging from the study of celestial objects like brown dwarfs and gas giants to modern-day technologies like nuclear energy and rocket propulsion. For many of these applications, it is essential to have a reliable equation of state (EOS) for He that yields an accurate representation of its thermodynamic behavior. To help constrain and develop such EOS models, we have performed a series of shock-compression experiments on cryogenic liquid He to pressures exceeding 100 GPa using a magnetically accelerated flyer plate on Sandia National Laboratories' Z-machine. We have also performed quantum molecular dynamics simulations that are consistent with our shock measurements. None of the previously available EOSs agree with our experimental and simulation results, motivating the development of a fluid-phase He EOS that we present in this study. Here, we show that our EOS yields good agreement with published data that span temperatures and pressures encountered across a diverse array of applications.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2020

FY20 Report for Instrumentation Development for the Transient Testing Program

This yearly report provides a summary of accomplishments carried out under funding from the Department of Energy (DOE) Nuclear Technology Research and Development (NTRD) program for in-pile instrumentation supporting the transient testing program in FY20. These activities were performed in support of cross-cutting transient testing experiment objective. In this year, specific instrument R&D has been a lesser priority to years past, with complementary instrumentation R&D being ramped up under the DOE Advanced Sensors and Instrumentation Program. The primary focus of the work in FY20 pertain to defining a process and system, developed over the past several years, for developing, qualifying, and deploying instrumentation in in-pile experiments. The purpose of this report is to provide a summary of these outcomes and be a reference for researchers that are interested in developing in-pile instrumentation, with a particular emphasis on the Transient Reactor Test (TREAT) facility for deployment.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2020

Post-Irradiation Examinations of the ATF Experiments - 2020 Status

This report contains the results of post-irradiation examination (PIE) of both Accident Tolerant Fuels-1 (ATF-1) rodlets and ATF-2 rodlets irradiated in the Advanced Test Reactor (ATR). The experiment is part of the U.S. Department of Energy (DOE) Nuclear Technology Research and Development (NTRD) program’s Advanced Fuels Campaign (AFC). The ATF-1 PIE focused on the continuation of the analyses of five rodlets, one containing U 3 Si 2 fuel, two containing UN-U 3 Si 5 composites, and two with UN-U 3 Si 2 composites. The non-destructive examinations of the U 3 Si 2 rodlet showed results comparable to the previously investigated rodlets. The profilometry of the UN-U 3 Si 2 composites highlighted permanent deformation of the cladding at the pellet-pellet interface, suggesting that hourglassing of the composite pellet occurred during irradiation, causing increased localized stresses on the Zirlo cladding tube due to Pellet-Cladding Mechanical Interaction (PCMI). The UN-U 3 Si 5 rodlets, which were contained in Kanthal cladding, did not show enhanced cladding deformation at the pellet interfaces; however, it is to be noted that the initial gap of these two rodlets was larger than typical light water reactor (LWR) gaps. The larger gap might have been sufficient to accommodate the fuel swelling without having contact between the fuel and cladding, explaining the absence of PCMI. Regarding the fission products, no axial redistribution of the major gamma emitters was observed in any of the composite rodlets. Fission gas measurements on the UN-U 3 Si 5 rodlets also has been performed. The estimated fission gas release, based on the calculated fission product inventory, remains limited, with a higher fission gas release for the rodlet that experienced a higher power.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2021

Materials Scorecards, Phase 1: Advanced Materials and Manufacturing Technology

This report presents preliminary material score cards (Phase 1) based on a survey of industry experts and the limited literature available on the state of advanced manufacturing of materials for nuclear applications. Seven reactor types were considered, and the data is presented in tabular form. The caveat is that the scores are based on limited data and expert judgement. Considerable work remains to be done to prioritize materials for advanced manufacturing to support existing and advanced reactors. A central database of processing conditions, resulting microstructure, post processing, properties, and performance of these materials is needed to support the accelerated adoption of advanced manufacturing by the industry.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Solving the Pulsed-Power Driven Inertial Fusion Energy Standoff Problem (Abbreviated Final Report)

The standoff problem in pulsed-power driven IFE (Inertial Fusion Energy) refers to the problem of electrically connecting a fusion target with the driver in a way that preserves the driver/target interface in the presence of a large fusion energy release (100’s of megajoules to 1000 megajoules). High yield fusion drivers for stockpile stewardship applications have similar concerns, but without the complication of the high repetition rate needed for energy production. All proposed IFE or high yield systems have the challenge of protecting the reactor vessel and driver from the energy release, but pulsed power drivers have the additional challenge of establishing an electrical connection in a way that does not create excessive debris or require costly/massive structures that must be expendable. Fortunately, there are conceptual solutions in the form of very low mass transmission lines, usually in the form of wires or foils, since very little mass is needed to overcome the magnetic forces driving the transmission lines apart or provide a low resistance pathway given the short pulse duration of the driver. Several important aspects of the standoff problem were analyzed in the course of this LDRD project. Conceptual means of introducing the low mass transmission lines into the reactor chamber were proposed, including analysis of methods to retain the power flow gap between the electrodes in the presence of the chamber environment. The energy losses due to ohmic dissipation and magnetic acceleration of the low mass transmission lines were evaluated for candidate driver pulses and different transmission line masses, and the fluence of x-ray and neutron energy on the persistent power flow structures that must survive the pulse of energy were evaluated. Finally, means of rapidly pumping down the chamber were explored as a way to return the system to low pressure following the multi-atmosphere post-pulse pressure rise. The overall conclusion from the analysis is that, while the reactor environment creates stressful conditions for a low mass transmission line standoff system, there are concepts expending 10 kg or less of electrode mass each pulse with the potential to mitigate the stresses and successfully drive fusion targets. Whether such a system could lead to a practical and economical fusion reactor would require extensive research and development beyond the scope of the feasibility study.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2021

Fuel Design and Fabrication: TRISO Particle Fuel

Tristructural-isotropic (TRISO) particle fuel is an advanced, mature technology for nuclear energy generation. Inherent containment of radionuclides within the fuel obviates the need for expensive reactor containment buildings; however, this benefit comes at the cost of increased complexity in fabrication relative to other nuclear fuel forms. In addition, rigorous fuel characterization and quality control efforts are required to ensure that the credited radionuclide containment within the fuel is realized.

Helmreich, Grant↗
DOE OSTI2023

Road Map for the Development of Commercial Maritime Applications of Advanced Nuclear Technology

The U.S. Department of Energy (DOE) is making significant investments in advanced nuclear reactor development and demonstration programs such as the Advanced Reactor Demonstration Program (ARDP). The innovations in advanced nuclear reactor technologies (defined in Section 1.4.1), including concepts of microreactors and small modular reactors (SMRs), have opened the door to a wide range of applications beyond land-based power stations providing electricity to the grid. Applications for transportation and industrial operations could offer reliable carbon-free energy to achieve decarbonization goals by supporting energy-intensive activities such as alternative fuel production, water desalinization, and local power supply. The DOE recognizes the transformational power of these technologies and is investing in foundational research and development as well as reactor demonstration projects. However, unique and significant challenges exist in each application domain to bring projects into reality beyond just the underlying reactor technology maturation.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2021

2021 ATR Strategic Plan

Collaborative development of nuclear energy science and technology by three major sectors—academia, the commercial nuclear power industry, and the federal government—is key to meeting the challenges of nuclear energy. All three share a common need for experimental capabilities, whether for basic science investigations, applied research in nuclear fuels and materials, or validation of data. The Advanced Test Reactor (ATR) provides the unique irradiation capabilities to support the need.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗