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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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All sourcesNASA NTRSDOE OSTI
DOE OSTI2020

Carburization of metals by a chemical mechanism of carbon transport through molten fluoride salts

Carburization of structural alloys used in Fluoride Cooled High Temperature Reactors (FHR) can result from the interaction between the metal and graphite components and cause changes in alloy properties. However, carburization requires transport of carbon from graphite to alloy surfaces through the molten fluoride coolant. This work introduces an alternative to previously proposed carbon transport mechanisms. The new mechanism is based on the generation of carbonate ions (CO 3 2- ) by oxide impurities in the salt reacting with graphite. CO 3 2- is then reduced on metal surfaces to deposit carbon. This work demonstrates the reduction of dissolved CO 3 2- on pure Fe, Ni, Cr, Mo, and W surfaces without an applied potential in molten FLiNaK at 700 °C. Finally, we also demonstrate that the interaction between oxide and graphite in molten FLiNaK media produces CO 3 2- .

36 MATERIALS SCIENCE↗
DOE OSTI2021

Characterization of radiation damage in 3D printed SiC

The SiC fuel matrix for advanced gas-cooled high temperature reactors as part of the Transformational Challenge Reactor program serves as the fuel particle container structure, a barrier to fission gas release, and a heat transfer medium. Its performance is particularly important because the fuel matrix must demonstrate good structural stability and thermal behaviors. An additive manufacturing methodology combining a binder jet 3D printing process with chemical vapor infiltration (CVI) for the production of SiC was recently developed. In this study, post irradiation examination by transmission electron microscopy shows that defect accumulation within the printed particles is very similar to other forms of high-purity SiC. However, damage accumulation was not directly observed in the CVI matrix because black spot damage and dislocation loops are difficult to image within the nanoscale highly faulted CVI matrix and because interstitial defects may rapidly annihilate at the stacking faults. Therefore, electron energy loss spectroscopy (EELS) analysis was used to analyze defect swelling in both the printed particles and the CVI matrix. The EELS analysis helped reveal that the radiation-induced swelling in the CVI matrix is similar to that of the printed SiC particles. This work shows that 3D printed SiC has behavior that is comparable to SiC processed by other means and that 3D printing could serve as a suitable processing technique for high-purity SiC for nuclear applications.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Influence of post deposition annealing on the microstructural evolution and tensile behavior of austenitic stainless-steel alloy 709 made by laser powder bed fusion

Structural materials used in the next generation nuclear reactors or other advanced energy systems are often required to withstand higher operating temperatures for a longer service life. Alloy 709 (A709), a Nb-containing and N-stabilized Fe-25Ni-20Cr austenitic stainless steel, has been recommended for high-temperature reactor constructions due to the better performance over the baseline Type 316H stainless steel. Here, in the current manuscript, for the first time, the microstructure evolution and tensile behavior of an A709 made by laser powder bed fusion (LPBF) is discussed. The as deposited and heat treated LPBF alloys are compared with a reference wrought alloy. Owing to the chemical segregation and a higher number of dislocations, the LPBF materials show a significantly higher density of precipitates formed during high temperature treatments when compared to the wrought samples. This is reflected when looking at the tensile properties, both at room and elevated temperatures, where LPBF samples show higher strengths compared to wrought materials.

36 MATERIALS SCIENCE↗
DOE OSTI2014

A Multi-Stage Wear Model for Grid-to-Rod Fretting of Nuclear Fuel Rods

The wear of fuel rod cladding against the supporting structures in the cores of pressurized water nuclear reactors (PWRs) is an important and potentially costly tribological issue. Grid-to-rod fretting (GTRF), as it is known, involves not only time-varying contact conditions, but also elevated temperatures, flowing hot water, aqueous tribo-corrosion, and the embrittling effects of neutron fluences. The multi-stage, closed-form analytical model described in this paper relies on published out-of-reactor wear and corrosion data and a set of simplifying assumptions to portray the conversion of frictional work into wear depth. The cladding material of interest is a zirconium-based alloy called Zircaloy-4, and the grid support is made of a harder and more wear-resistant material. Focus is on the wear of the cladding. The model involves an incubation stage, a surface oxide wear stage, and a base alloy wear stage. The wear coefficient, which is a measure of the efficiency of conversion of frictional work into wear damage, can change to reflect the evolving metallurgical condition of the alloy. Wear coefficients for Zircaloy-4 and for a polyphase zirconia layer were back-calculated for a range of times required to wear to a critical depth. Inputs for the model, like the friction coefficient, are taken from the tribology literature in lieu of in-reactor tribological data. Concepts of classical fretting were used as a basis, but are modified to enable the model to accommodate the complexities of the PWR environment. Factors like grid spring relaxation, pre-oxidation of the cladding, multiple oxide phases, gap formation, impact, and hydrogen embrittlement are part of the problem definition but uncertainties in their relative roles limits the ability to validate the model. Sample calculations of wear depth versus time in the cladding illustrate how GTRF wear might occur in a discontinuous fashion during months-long reactor operating cycles. A means to account for grid/rod gaps and repetitive impact effects on GTRF wear is proposed

fretting↗
DOE OSTI2025

Hydrolysis Reaction Pathways of Thorium Oxide Nanoclusters

Density functional theory benchmarked by correlated molecular orbital theory is used to develop a fundamental and predictive understanding of the interaction of thorium oxide nanoclusters with gas phase water to provide insight into nuclear-waste storage, production of thorium nuclear reactor fuels, and reprocessing of spent fuel. The structures of Th n O 2n (n = 3 – 6) clusters and their interactions with water have been studied at the B3LYP, MP2, and CCSD(T) levels. Hydrolysis is initiated by the formation of Lewis acid-base adducts, with relative H 2 O binding energies (physisorption) ranging from −15 kcal/mol to −22 kcal/mol. The initial H 2 O physisorption energy is ca. −21 kcal/mol regardless of the cluster size and is consistent with the experimentally obtained initial adsorption energy on a thorium dioxide surface. The physisorption enthalpies for additional water molecules can be affected by the presence of terminal groups OH groups generated by proton transfer to a Th-O near the site of adsorption. The hydrolysis products (chemisorption) form either bridging or terminal hydroxides. More exothermic hydrolysis steps were predicted for the formation of terminal hydroxides as compared to the formation of bridging hydroxides. Here, the calculated transition state barriers for transfer of protons from bound water complexes to form the chemisorption products are very low. Overall, water readily reacts with thorium oxide clusters preferring hydroxide products over hydrated complexes. First and second order fits were predicted for the combined physisorption and chemisorption energies for the hydrolysis of thorium oxide clusters. Finally, ionization energies and electron affinities were calculated as were HOMO-LUMO gaps to provide additional insights into the properties of the thorium oxide and hydroxide clusters.

Adsorption↗
DOE OSTI2013

Irradiation-induced composition patterns in binary solid solutions

A theoretical/computational model for the irradiation-driven compositional instabilities in binary solid solutions has been developed. The model is suitable for investigating the behavior of structural alloys and metallic nuclear fuels in a reactor environment as well as the response of alloy thin films to ion beam irradiation. The model is based on a set of reaction-diffusion equations for the dynamics of vacancies, interstitials, and lattice atoms under irradiation. The dynamics of these species includes the stochastic generation of defects by collision cascades as well as the defect reactions and diffusion. The atomic fluxes in this model are derived based on the transitions of lattice defects. The set of reaction-diffusion equations are stiff, hence a stiffly stable method, also known as the Gear method, has been used to numerically approximate the equations. For the Cu-Au alloy in the solid solution regime, the model results demonstrate the formation of compositional patterns under high-temperature particle irradiation, with Fourier space properties (Fourier spectrum, average wavelength, and wavevector) depending on the cascade damage characteristics, average composition, and irradiation temperature.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Analytic error analysis of cross section interpolation methods in nodal diffusion codes - I : Theory

This paper discusses two cross section interpolation methods commonly found in popular nodal codes; the partial derivatives and multiple tables models. The motivation for choosing a model, and thus a case matrix structure, is a trade off between accuracy and computational cost. Due to decades of experience, there are default structures that are sufficient for current light water reactor analysis. However, this is not necessarily the case for advanced reactor designs. Therefore, it is advantageous to understand the sources of error in cross section interpolation models so that the quality of a case matrix may be improved. A mathematical framework for these models is presented in this work that provides a more rigorous connection between the nuclear engineering field's cross section interpolation methods and the broader mathematical field of function approximation. The two cross section models examined in this paper were found to utilize Lagrange interpolation and are a subset of Lagrange tensor products. Classical results of Lagrange polynomial error analysis were then applied to the partial derivative and multiple tables models to derive expressions for the total point-wise error. The analytical results classify the total error into two parts: the model form error and interpolation error. Finally, based on our observations, a better foundation for improving the quality of a case matrix is proposed. (authors)

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2013

Materials Selection for the Lead-Bismuth Corrosion and Erosion Tests in DELTA Loop

This report documents the selection of materials participating in the currently ongoing corrosion/erosion tests in LANL Development of Lead-Alloy Technology and Applications (DELTA) loop, a facility designed to study the long-term corrosive effects of liquid lead-bismuth eutectic (LBE) on structural materials for high temperature applications in advanced reactors, accelerator-driven systems and spallation sources. In this suite of experiments, LBE temperature in the DELTA loop test section is 500°C. Oxygen sensors are used to maintain an LBE Oxygen concentration of 1x10 -6 to 1x10 -8 wt%. Unique to the experimental conditions is the LBE high flow-rate of 3-3.5 m/s in the test section. Results obtained in these corrosion tests represent a substantial extension from existing experimental data currently limited to LBE velocities of maximum ~2 m/s.

36 MATERIALS SCIENCE↗
DOE OSTI2015

Online Monitoring of Concrete Structures in Nuclear Power Plants: Interim Report

The existing fleet of nuclear power plants in the United States have initial operating licenses of 40 years, and many of these plants have applied for and received license extensions. As plant structures, systems, and components age, their useful life—considering both structural integrity and performance—is reduced as a result of deterioration of the materials. Assessment and management of aging concrete structures in nuclear plants require a more systematic approach than simple reliance on existing code-based design margins of safety. Structural health monitoring is required to produce actionable information regarding structural integrity that supports operational and maintenance decisions. The online monitoring of concrete structures project conducted under the Advanced Instrumentation, Information, and Control Technologies Pathway of the Light Water Reactor Sustainability program at Idaho National Laboratory is seeking to develop and demonstrate capabilities for concrete structures health monitoring. Through this research project, several national laboratories and Vanderbilt University propose to develop a framework of research activities for the health monitoring of nuclear power plant concrete structures that includes the integration of four elements—damage modeling, monitoring, data analytics, and uncertainty quantification. This report briefly discusses activities in this project during October-December, 2014. The most significant activity during this period was the organizing of a two-day workshop on research needs in online monitoring of concrete structures, hosted by Vanderbilt University in November 2014. Thirty invitees from academia, industry and government participated in the workshop. The presentations and discussions at the workshop surveyed current activities related to concrete structures deterioration modeling and monitoring, and identified the challenges, knowledge gaps, and opportunities for advancing the state of the art; these discussions are summarized in this report

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2017

FY17 CAES LDRD Annual Report

Metallic alloys are widely used or planned for use as structural and cladding materials in current and future reactors. Under irradiation, grain boundary (GB) cohesion strength decreases due to interaction with defects and impurities, leading to intergranular fracture and embrittlement of alloys. The objective of this project is to develop a technique for quantifying GB cohesion and its impact on fracture behavior in irradiated alloys, by utilizing transmission electron microscopic (TEM) in situ cantilever testing in concert with multi-scale modeling. The TEM in situ cantilever testing is a novel approach for studying the real-time mechanical response of materials. It will be used in this work for studying intergranular fracture behavior in several irradiated iron-based ferritic alloys and providing key information to link atomistic level events with mesoscale/macroscopic mechanical properties. The Multi-Physics Object-Oriented Simulation Environment (MOOSE)-based cohesive zone model (CZM) and extended finite element method (XFEM) for intergranular fracture of irradiated ferritic alloys will be developed in this work by utilizing atomistic results as inputs and experimental results for validation.

36 MATERIALS SCIENCE↗
DOE OSTI2017

Summary report describing CASL accomplishments in support of the GTRF Challenge Problem

Coolant flow-induced relative motions between structural components in the cores of lightwater nuclear reactor cores, a phenomenon called Grid-To-Rod Fretting (GTRF), can result in progressive wear damage. Wear-through of the cladding on fuel rods can introduce radioactive species into the coolant loop. Such an event is termed a “leaker” and may cause premature and expensive reactor shut-down. GTRF results in wear scars of various sizes, shapes, and depths on the sides of the fuel rod cladding. Fretting damage may also occur on the springs and dimples that hold the fuel rods in place, resulting in the formation of gaps. Due to variability in the operating conditions of the reactor (burn-up rates and operating campaigns) and the associated variable cladding surface oxide film growth and removal rates, the wear coefficient is unlikely to remain constant over time. Therefore, constant wear rate models do not accurately account for transients in the operating conditions.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2017

GTRF Cladding Wear Modeling and Experimental Validation

Coolant flow-induced relative motions between certain structural components in the cores of lightwater nuclear reactor cores, a phenomenon called Grid-To-Rod Fretting (GTRF), can result in progressive wear damage. Wear-through of the cladding on fuel rods can introduce radioactive species into the coolant loop. Such an event is termed a “leaker” and may cause premature and expensive reactor shut-down. GTRF results in wear scars of various sizes, shapes, and depths on the sides of the fuel rod cladding. Fretting damage may also occur on the springs and dimples that hold the fuel rods in place, resulting in the formation of gaps. Due to variability in the operating conditions of the reactor (burn-up rates and operating campaigns) and the associated variable cladding surface oxide film growth and removal rates, the wear coefficient is unlikely to remain constant over time. Therefore, constant wear rate models do not accurately account for transients in the operating conditions.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2022

Investigation of Nano-Scale Segregation in Nanostructured Ferritic Alloy 14YWT after Heavy Ion Irradiation

Oxide-dispersion-strengthened (ODS) steels, which contain nano-scale Y-Ti-O particles, are being considered for high-temperature radiation environments of nuclear reactors. It is important to accurately characterize the structure of grain boundaries and understand the behavior of segregation at grain boundaries in ODS steels during irradiation. The effect of heavy ion irradiation at 700 °C on Nanostructured Ferritic Alloy 14YWT was investigated using Atom Probe Tomography. Enrichment of Cr occurs at the grain boundaries as well as at nano oxide particle surfaces in the unirradiated sample. The enrichment of Ti and Y at a grain boundary corresponds with Y-Ti-O nano oxide particles with larger size compared to those in the grain, and the Cr enrichment is particularly accentuated at these larger nano oxide particles. The segregation of W occurs at the grain boundaries that are without nano oxide particles. O is segregated at grain boundaries without oxide particles after irradiation. The segregation behavior of Cr, W, Ti, and Y at the grain boundary in the irradiated samples is similar to that in the unirradiated sample. The nano oxide particles embedded in the grain boundary are a primary reason for the increase in Cr segregation at the grain boundary.

36 MATERIALS SCIENCE↗
DOE OSTI2025

ATOMIC AND MICROSTRUCTURAL ORIGINS OF STORED ENERGY RELEASE IN NEUTRON-IRRADIATED SILICON CARBIDE

Here, we employ a combination of advanced synchrotron-based scattering characterization techniques to understand and unravel the atomic origins of the colossal stored energy release in neutron irradiated silicon carbide. The quantification of the neutron irradiation-induced defects, and their impact on the structureproperty relationship is important for the design and safe operation of advanced fission and fusion reactors. Our experimental results show that the atomic structure in the as irradiated samples is significantly perturbed due to a large fraction of vacancy and interstitial type defects that lead to complex microstructures and additional components in the x-ray diffraction and pair distribution function results. We directly correlate the stored energy release to the recovery of the sub-lattices, with pair distribution function analysis highlighting that the carbon interstitial and vacancy-type defects contribute to stored energy more than those of silicon. We find these results to be striking and believe our discoveries to be timely and noteworthy given the technological importance of silicon carbide to the nuclear fission and fusion communities.

Sprouster, D.J.↗
DOE OSTI2014

Competing effects of electronic and nuclear energy loss on microstructural evolution in ionic-covalent materials

Ever increasing energy needs have raised the demands for advanced fuels and cladding materials that withstand the extreme radiation environments with improved accident tolerance over a long period of time. Ceria (CeO2) is a well known ionic conductor that is isostructural with urania and plutonia-based nuclear fuels. In the context of nuclear fuels, immobilization and transmutation of actinides, CeO2 is a model system for radiation effect studies. Covalent silicon carbide (SiC) is a candidate for use as structural material in fusion, cladding material for fission reactors, and an inert matrix for the transmutation of plutonium and other radioactive actinides. Understanding microstructural change of these ionic-covalent materials to irradiation is important for advanced nuclear energy systems. While displacements from nuclear energy loss may be the primary contribution to damage accumulation in a crystalline matrix and a driving force for the grain boundary evolution in nanostructured materials, local non-equilibrium disorder and excitation through electronic energy loss may, however, produce additional damage or anneal pre-existing defect. At intermediate transit energies where electronic and nuclear energy losses are both significant, synergistic, additive or competitive processes may evolve that affect the dynamic response of materials to irradiation. The response of crystalline and nanostructured CeO2 and SiC to ion irradiation are studied under different nuclear and electronic stopping powers to describe some general material response in this transit energy regime. Although fast radiation-induced grain growth in CeO2 is evident with no phase transformation, different fluence and dose dependence on the growth rate is observed under Si and Au irradiations. While grain shrinkage and amorphization are observed in the nano-engineered 3C SiC with a high-density of stacking faults embedded in nanosize columnar grains, significantly enhanced radiation resistance is attributed to stacking faults that promote efficient point defect annihilation. Moreover, competing effects of electronic and nuclear energy loss on the damage accumulation and annihilation are observed in crystalline 4H-SiC. Systematic experiments and simulation effort are needed to understand the competitive or synergistic effects.

Zhang, Yanwen↗
DOE OSTI2015

A creep-damage model for mesoscale simulations of concrete expansion-degradation phenomena

Long-term performance of aging concrete in nuclear power plants (NPPs) requires a careful examination of the physical phenomena taking place in the material. Concrete under high neutron irradiation is subjected to large irreversible deformations as well as mechanical damage, caused by a swelling of the aggregates. However, these results, generally obtained in accelerated conditions in test reactors, cannot be directly applied to NPP irradiated structures, i.e., the biological shield, operating conditions due to difference in time scale and environmental conditions (temperature, humidity). Mesoscale numerical simulations are performed to separate the underlying mechanisms and their interactions. The cement paste creep-damage model accounts for the effect of the loading rate on the apparent damage properties of the material and uses an event-based approach to capture the competition between creep and damage. The model is applied to the simulation of irradiation experiments from the literature and shows a good agreement with the experimental data.

Concrete↗
DOE OSTI2016

DESIGN CHARACTERISTICS OF THE IDAHO NATIONAL LABORATORY HIGH-TEMPERATURE GAS-COOLED TEST REACTOR

Uncertainty and sensitivity analysis is an indispensable element of any substantial attempt in reactor simulation validation. The quantification of uncertainties in nuclear engineering has grown more important and the IAEA Coordinated Research Program (CRP) on High-Temperature Gas Cooled Reactor (HTGR) initiated in 2012 aims to investigate the various uncertainty quantification methodologies for this type of reactors. The first phase of the CRP is dedicated to the estimation of cell and lattice model uncertainties due to the neutron cross sections co-variances. Phase II is oriented towards the investigation of propagated uncertainties from the lattice to the coupled neutronics/thermal hydraulics core calculations. Nominal results for the prismatic single block (Ex.I-2a) and super cell models (Ex.I-2c) have been obtained using the SCALE 6.1.3 two-dimensional lattice code NEWT coupled to the TRITON sequence for cross section generation. In this work, the TRITON/NEWT-flux-weighted cross sections obtained for Ex.I-2a and various models of Ex.I-2c is utilized to perform a sensitivity analysis of the MHTGR-350 core power densities and eigenvalues. The core solutions are obtained with the INL coupled code PHISICS/RELAP5-3D, utilizing a fixed-temperature feedback for Ex. II-1a.. It is observed that the core power density does not vary significantly in shape, but the magnitude of these variations increases as the moderator-to-fuel ratio increases in the super cell lattice models.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2025

Advanced Manufactured Strain Sensors for Extreme Environments

Experimentation at irradiation test facilities are essential for reducing the innovation time of developmental fuels, fuel cladding, and structural materials employed in next-generation nuclear reactors. However, due to the harsh conditions generated in such reactors and limited instrumentation space, the evaluation of a material’s mechanical properties is often limited to characterization after the materials have been removed from reactor conditions, or post-irradiation examination. These experiments are costly, time-consuming, and fail to capture the critical time-evolving phenomena that occur during the irradiation experiments. Advanced manufactured digital image correlation patterns and strain sensor devices serve as two promising technologies that can be deployed in the confined and challenging orientations of these irradiation experiments while also providing key insight on salient materials phenomena (i.e., mechanical properties). To guide the development of the printed strain sensors prior to their deployment in critical experiments, the adhesion strength between the substrate and printed film interface is measured via tensile testing and a non-contact laser-induced spallation technique. The establishment of these process control steps helped guide the successful fabrication and testing of direct-write strain sensing devices discussed in this work. The fabrication process controls are necessary for enabling the sustained operation of these strain sensing device through experimentation and minimize the potential for premature failure.

36 - MATERIALS SCIENCE↗