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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 OSTI2024

Fitness-for-Service Analysis of Reactor Components under Flexible Load-Following Operating Conditions

Conventional power-generation plants, including nuclear plants, have been traditionally designed to provide a steady baseload energy capacity, optimizing output efficiency while minimizing variable costs. However, the growing adoption of large-scale renewable energy-generation systems, which rely on intermittent sources such as solar and wind, has introduced more variability into the energy supply in interconnected electricity grids. As a result, the next generation of power plants needs to operate in what is known as the load-following mode, requiring flexible adjustments in electricity production to align with the energy demand on the grid. This transition from the steady baseload operation to load-following operating conditions can significantly increase the number of times various plant components are exposed to transient stresses. This increased thermo-mechanical cycling can lead to accelerated material degradation, thereby elevating the risk of premature failure of a component. It becomes imperative to conduct a comprehensive analysis of fatigue, creep-fatigue, and stress corrosion cracking life, to assess the resilience of the various engineering components under these flexible load-following operating conditions. This study aims to develop a comprehensive numerical model of a light-water reactor pressure vessel (RPV) to investigate its degradation under various operating scenarios. This coupled thermo-mechanical finite element analysis evaluated the stress response of the RPV caused by considering fluctuations in thermal and mechanical loads caused by the varying pressure and temperature occurring during the load-following operation. Critical locations on the RPV are subsequently identified based on the stress response. The stress intensity factors for the postulated flaws at those locations are then calculated, followed by an evaluation of the reactor's life in accordance with the ASME Boiler and Pressure Vessel Code Section XI. This comprehensive life assessment covers a number of transients expected during the flexible load-following operation, providing invaluable insights into the RPV's structural integrity. Moreover, the development methodology can be adapted to other reactor components, as well as components of conventional power stations that are affected by varying operating conditions.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2019

Influence of nanochannel structure on helium-vacancy cluster evolution and helium retention

In the fusion reactors, plasma facing materials (PFMs) will be bombarded by large amounts of energetic particles, including helium (He) atoms. These metal-insoluble He atoms are prone to self-trapping or are trapped by vacancies, dislocation cores or grain boundaries, aggregating to form high concentration He bubbles which leads to serious degradation of the PFMs’ properties. Studying the initial stages of He-defect interactions becomes increasingly important because it not only helps us understand the formation mechanism of He bubbles but also provides insight to help design new irradiation-resistant PFMs. As such, in this work we used the positron annihilation Doppler broadening spectroscopy (DBS) and secondary ion mass spectrometry (SIMS) to explore the evolutions of the interactions between vacancy-type defects and He and the retention of He in the nanochannel W film irradiated with 190 keV He + ions to different fluences under different temperatures. It is found that the presence of a nanochannel structure accelerates the release of He from the film even at low irradiation fluences, and the release of He is significantly enhanced at higher fluences, thus inhibiting or delaying the formation of large He-vacancy clusters in the nanochannel W film. Both irradiation fluence and temperature have significant influence on the formation and evolution of He-vacancy clusters, and the evolution of these microstructure also causes hardness changes.

36 MATERIALS SCIENCE↗
DOE OSTI2023

ECAR-6576 Rev 0 MARVEL Secondary Support Structure Analysis

The Microreactor Applications Research Validation and Evaluation (MARVEL) microreactor generates electricity using four Stirling cycle engines. Each Stirling engine, along with its mounting system, is called a Secondary Support Structure (SSS). An individual SSS consists of a Secondary Output Structure (SOS), a Secondary Support Structure Base, an insulation block, and assorted hardware. The SOS consists of the Stirling engine, the Secondary Output Structure Ring, a vibration isolator, and hardware. The purpose of this analysis is to show that the SSS is appropriately designed to meet structural, mechanical, and maintenance requirements for specified operating conditions.

21 - SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLAN↗
DOE OSTI2014

Expanded Materials Degradation Analysis (EMDA) Volume 3: Aging of Reactor Pressure Vessels

In NUREG/CR-6923 ORNL/TM-2013/532, "Expert Panel Report on Proactive Materials Degradation Assessment," referred to as the PMDA report, NRC conducted a comprehensive evaluation of potential aging-related degradation modes for core internal components, as well as primary, secondary, and some tertiary piping systems, considering operation up to 40 years. This document has been a very valuable resource, supporting NRC staff evaluations of licensees' aging management programs and allowing for prioritization of research needs.This report describes an expanded materials degradation assessment (EMDA), which significantly broadens the scope of the PMDA report. The analytical timeframe is expanded to 80 years to encompass a potential second 20-year license-renewal operating-period, beyond the initial 40-year licensing term and a first 20-year license renewal. Further, a broader range of structures, systems, and components (SSCs) was evaluated, including core internals, piping systems, the reactor pressure vessel (RPV), electrical cables, and concrete and civil structures. The EMDA uses the approach of the phenomena identification and ranking table (PIRT), wherein an expert panel is convened to rank potential degradation scenarios according to their judgment of susceptibility and current state of knowledge.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2024

Technical report Letter: RAFM, ODS steels and MMLC for Nuclear energy application

The lifetime, thermodynamic efficiency, safety and economic viability of new generation fission and fusion reactor concepts can largely be tied to the mechanical performance and stability of structural alloys under extreme environments. In this context, engineered nano materials could have broad-reaching impact on the future of advanced nuclear fuel-cycle and reactors. These systems are characterized by a large number density of interfaces which are efficient sinks for point defects and moderately biased; therefore limiting the deleterious effects of irradiation. Broadly, nuclear nano-technology deals with the use of the latest engineered-nanomaterials for improving the nuclear power performances and safety in all areas of nuclear energy production to bring new generations of nuclear power units. New advanced fuel assembly designs also have implications for securities and safeguards. To support the readiness for potential future license applications, an understanding of the technologies that would enable new reactor designs in the areas of component performance and domestic safeguards is necessary. This technical report letter work explores the technical issues and potential regulatory considerations associated with developing and adopting fuel claddings made of advanced nano- materials. Specifically three classes of nanomaterials are considered: (i) reduced activation ferritic/martensitic (RAFM) steels, (ii)oxide dispersed steels (ODS) and (iii) multi-metallic layered composites (MMLC).

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2019

Deflection predictions of involute-shaped fuel plates using a fully-coupled numerical approach

This paper describes the modeling and simulation of fluid structure interactions (FSI) of involute-shaped fuel plates used in nuclear research reactors. We believe this to be the first time that this type of application is described in the literature using a fully-coupled, and monolithic, finite element approach. The simulations are validated against plate deflection data for the conceptual design of the Advanced Neutron Source Reactor (ANSR), which was envisioned to be the world’s most powerful nuclear research reactor for neutron scattering and other applications, but was ultimately never completed. The high performance of the ANSR creates a bounding envelope for involute-shaped research reactors such as that used in the High Flux Isotope Reactor (HFIR) at the Oak Ridge National Laboratory (ORNL) which is undergoing research for the conversion from highly-enriched uranium (HEU) to low-enriched uranium (LEU) fuel. As such, the findings from the present FSI analyses carried out herein for the ANSR plates provide good guidelines and inform designers what should be expected for the next generation of plates in the HFIR. Furthermore it is shown herein that the current approach can accurately capture the leading-edge deflections of the involute-shaped plates and simulations can predict the ‘S-shaped’ deflection of the first mode instilling confidence in the methodology.

42 ENGINEERING↗
DOE OSTI2012

An Assessment of Integrated Health Management (IHM) Frameworks

In order to meet the ever increasing demand for energy, the United States nuclear industry is turning to life extension of existing nuclear power plants (NPPs). Economically ensuring the safe, secure, and reliable operation of aging nuclear power plants presents many challenges. The 2009 Light Water Reactor Sustainability Workshop identified online monitoring of active and structural components as essential to the better understanding and management of the challenges posed by aging nuclear power plants. Additionally, there is increasing adoption of condition-based maintenance (CBM) for active components in NPPs. These techniques provide a foundation upon which a variety of advanced online surveillance, diagnostic, and prognostic techniques can be deployed to continuously monitor and assess the health of NPP systems and components. The next step in the development of advanced online monitoring is to move beyond CBM to estimating the remaining useful life of active components using prognostic tools. Deployment of prognostic health management (PHM) on the scale of a NPP requires the use of an integrated health management (IHM) framework - a software product (or suite of products) used to manage the necessary elements needed for a complete implementation of online monitoring and prognostics. This paper provides a thoughtful look at the desirable functions and features of IHM architectures. A full PHM system involves several modules, including data acquisition, system modeling, fault detection, fault diagnostics, system prognostics, and advisory generation (operations and maintenance planning). The standards applicable to PHM applications are indentified and summarized. A list of evaluation criteria for PHM software products, developed to ensure scalability of the toolset to an environment with the complexity of a NPP, is presented. Fourteen commercially available PHM software products are identified and classified into four groups: research tools, PHM system development tools, deployable architectures, and peripheral tools.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2022

New High-Strength Ni-based Alloys for High Temperature Service in Liquid Fluoride Salt Environments

The ever-increasing demand for higher system thermal efficiency necessitates the operation of power generation cycles and heat conversion systems for chemical processes at progressively higher temperatures. As the system operating temperature increases, fewer and fewer materials are available with the required mechanical properties and environmental compatibility. This dearth of materials is particularly acute in structural applications at temperatures above 700°C in liquid Fluoride Salt Cooled High-Temperature Reactors (FHRs) and Concentrated Solar Power (CSP) systems where liquid fluoride and/or liquid chloride salts are used for their high thermal capacity and low thermal conductivity to store and transport heat. It has been shown that fluorides and chlorides can degrade the properties of the material used for storage and transport due to corrosive effects thus affecting the performance and lifetime characteristics. Thus, materials used for storage and transport for fluoride/chloride-salt must at the minimum have good compatibility with the salt by exhibiting low corrosion rates at the required temperatures. In addition, since many of the components will be subject to stresses in service, they need to have sufficient strength to resist plastic deformation, and the resistance to time dependent creep deformation at these temperatures, and stress levels. Achieving the combination of these properties required for higher temperatures is particularly challenging considering traditionally, the expected lifetime of some of the components used in these systems are from 30 years (CSP) to 80 years (FHRs). Although 316 stainless steel and associated redox corrosion reduction techniques are being considered for use in the first generational systems, use of 316SS is limited to operating temperatures up to ~ 650°C, thereby resulting in lower reactor efficiencies. Hastelloy ® N, developed at ORNL in the 1950s-60s for molten salt service is currently the leading candidate FHR structural alloy but has inadequate creep properties at high temperatures. Using a computationally-guided approach, Oak Ridge National Laboratory had developed new high strength alloys strengthened by γ’ precipitates (about 2X the strength of Hastelloy ® N) in small laboratory-scale heats that show good resistance to corrosion by fluorides and improved creep rupture life at temperatures up to 850°C (U.S. Patent Application No. 13/833,357 entitled “High Strength Alloys for High Temperature Service in Liquid-Salt Cooled Energy Systems”- granted U. S. Patent No. 9,540,714).

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2020

A Mercury Model of the Molly-G Fast Burst Reactor (FBR)

In order to design neutron irradiation experiments at a given nuclear reactor, one requires a representative neutron spectrum for the configuration of the reactor that will exist during the experiment. This usually implies modeling the operation of the reactor using a neutron transport code. Since the modeling of pulsed neutron reactors is quite complex, requiring coupled modeling of neutronics and thermo-structural response, the typical methodology employs analysis of the neutron spectrum which is obtained from a static keff calculation. While this time-independent Eigenfunction is not truly representative of that during a reactor pulse, we postulate that it is a reasonable representation for our purposes. The Nuclear Survivability (NS) Program at LLNL is considering fielding such experiments at the Molly-G (‘Molybdenum Godiva-II’) Fast Burst Reactor (FBR) at the White Sands Missile Range (WSMR). The goal of these experiments is to (a) test / proof / calibrate diagnostics, and (b) test the efficacy of neutron shield configurations, before fielding at other nuclear reactors, such as the Annular Core Research Reactor (ACRR) at SNL/NM. After attempting to secure either drawings or a copy of an existing MCNP model of the Molly-G FBR from various institutions, it was decided to develop a new model for use with the Mercury Monte Carlo transport code. The model described herein will be used to design these experiments.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2021

Advanced Materials Program Summary

Advanced Reactor Technologies (ART) Advanced Materials Program: Provide material solutions to enable design, construction, and operation of licensable advanced reactors Including Gas-cooled Reactors, Fast Reactors, Molten Salt Reactors (solid or liquid fuel) Could be of modular design, and from 350 to 1 Mwe Conduct developmental R&D on structural materials that are best addressed by the national program Integrate program-directed work at national labs & universities and collaboration with international partners to address advanced reactor developer needs Provide qualification data (to NQA-1 or equivalent) on structural materials and develop & validate improved high temperature design methodology Utilize consensus standards organizations when appropriate (e.g., ASME, ASTM, etc.) Target resolution of issues needed for near to mid-term deployment of advanced reactors

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2023

Literature Review of Advanced Reactor Cost Estimates

This report provides a comprehensive review of existing literature on advanced reactor cost estimations in the form of a ‘meta-study’. Over 30 references were evaluated and considered as part of this effort. The information is then distilled into different tiers, each with varying levels of detail and granularity. The recommendations consist of low/medium/high estimates for capital and operating costs that can be adjusted using various correction factors (based on learning, numbers of plants per site, etc.). In addition, reference breakdown in costs based on a code of account structure is provided for the main four types of advanced reactors.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2021

Planning Near-Term Tasks for the Development of Advanced Reactor Mechanistic Source Term Modeling and Simulation Tools

To assist both the advanced reactor industry and U.S. Nuclear Regulatory Commission (NRC) in the pursuit of reactor design and licensing, the U.S. Department of Energy (DOE) Nuclear Energy Advanced Modeling and Simulation (NEAMS) program has established a mechanistic source term (MST) research project under the auspices of the Application Drivers technical area. The MST research project is a collaboration between Argonne National Laboratory (Argonne) and Sandia National Laboratories (SNL) with a high-level objective to coordinate the development of comprehensive advanced reactor MST mod/sim capabilities to support risk-informed design and licensing decisions. As part of this effort, an MST mod/sim development pathway was developed in FY21, which outlines the high-level objectives and near-term tasks necessary to achieve the project objectives. Since publication of the development pathway, Argonne and SNL have been addressing the “near-term tasks” outlined in the report. The current provides a status update of the progress achieved in the fourth quarter of FY21. The report structure follows that of ref and is divided by advanced reactor type: High temperature gas reactor (HTGR), molten salt reactor (MSR) including fluoride salt-cooled high temperature reactor (FHR), and sodium fast reactor (SFR). Each section reviews the near-term tasks associated with the reactor type, current progress, and future plans. The near-term tasks associated with consequence modeling are reviewed in an upcoming work by SNL.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2011

NGNP Project Regulatory Gap Analysis for Modular HTGRs

The Next Generation Nuclear Plant (NGNP) Project Regulatory Gap Analysis (RGA) for High Temperature Gas-Cooled Reactors (HTGR) was conducted to evaluate existing regulatory requirements and guidance against the design characteristics specific to a generic modular HTGR. This final report presents results and identifies regulatory gaps concerning current Nuclear Regulatory Commission (NRC) licensing requirements that apply to the modular HTGR design concept. This report contains appendices that highlight important HTGR licensing issues that were found during the RGA study. The information contained in this report will be used to further efforts in reconciling HTGR-related gaps in the NRC licensing structure, which has to date largely focused on light water reactor technology.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2015

Irradiation response of commercial, high-Tc superconducting tapes: Electromagnetic transport properties

Effects of low dose irradiation on the electrical transport current properties of commercially available high-temperature superconducting, coated-conductor tapes were investigated, in view of potential applications in the irradiative environment of fusion reactors. Three different tapes, each with unique as-grown flux-pinning structures, were irradiated with Au and Ni ions at energies that provide a range of damage effects, with accumulated damage levels near that expected for conductors in a fusion reactor environment. Measurements using transport current determined the pre- and post-irradiation resistivity, critical current density, and pinning force density, yielding critical temperatures, irreversibility lines, and inferred vortex creep rates. Results show that at the irradiation damage levels tested, any detriment to as-grown pre-irradiation properties is modest; indeed in one case already-superior pinning forces are enhanced, leading to higher critical currents.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2021

Molten Salt Reactor Fundamental Safety Function PIRT

The phenomenon identification and ranking table (PIRT) process was employed to evaluate the current capability to assess the ability of liquid-salt–fueled molten salt reactors to achieve their fundamental safety functions (FSFs). The PIRT process provides a structured mechanism to elicit and document expert opinions on the most important phenomena and the corresponding level of knowledge with regard to achieving the FSFs. The PIRT panel included reactor developers, accident progression evaluation tool developers, US Department of Energy (DOE) national laboratory technical staff, university researchers, and US Nuclear Regulatory Commission (NRC) staff. The information-gathering process concentrated on phenomena related to accidents in which the fuel salt—including any in the cover gas—has been released from the first barrier layer. This information-gathering process included identifying all potential accidents that could result in the release of a substantial amount of radionuclides that could breach or bypass the first barrier. The PIRT did not identify any previously unrecognized systemic vulnerabilities. However, the elicitation process identified several areas with low levels of knowledge and significant potential impact on accident progression. These areas either require additional research to improve the state of knowledge or additional design conservatism to accommodate the remaining unknowns.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2022

Embedded acoustic sensing and monitoring techniques for small modular reactors

The goal of this project was to study the applicability of specific innovative instrumentation techniques for assessing parameters needed for safe small modular reactor operation and safeguarding of nuclear material. Small modular reactor core designs are currently being developed to provide energy more effectively and efficiently than in the past because they can be built as modules at fabrication sites and then transported to a power-producing facility. However, these modules and/or the final core will often be sealed and not accessible again until disposal. Instead of instruments that access the core directly, during and after operation, to monitor flux/dose and structural integrity, as current power plants use, new sensors need to be designed that can be built into the reactor initially to determine operating history, structural integrity through operation of the system, and nuclear material accountancy after shutdown and before disposition of the core. Embedded sensors already exist that can provide neutron flux, gamma dose, and temperatures, but techniques to expand upon these for assessing structural health and material inventory in the system over time need to be developed. Structural health assessments include the detection and imaging of cracks in the components that could eventually cause radioactive fission products to be released.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2025

Investigation of Corrosion Behavior of Carbide Phase Strengthened Nickel‐Based Alloy in Molten Fluoride Salt

The corrosion behavior of a high creep strength carbide-phase strengthened Ni-based alloy in molten FLiNaK (LiF-NaF-KF: 46.5-11.5-42 mol%) salt in the temperature range of 700°C–750°C has been investigated as a part of the development of structural alloys for fluoride salt-based molten salt reactors (MSRs). The alloy composition was designed based on Hastelloy-N, but with the goal of improving creep strength. Cr depletion depth, a measure of corrosion, was observed to be single micrometers after several hundred hours of corrosion testing. Sequential corrosion testing involving testing of pre-tested samples in fresh salt coupled with SEM-EDS, scanning transmission electron microscopy (STEM) examinations and thermodynamic and kinetic modeling, suggest that the corrosion rate at the alloy-salt interface is governed by diffusion of elements from the alloy bulk to the surface. The carbide phases in the corrosion-tested sample microstructure were identified to be largely M 6 C-type Mo-rich carbides and MC-type mixed carbides. Atom probe tomography (APT) showed some partitioning of Cr and Ti to the carbide phase and showed the carbide phases to be stable at the salt-facing surface.

Gordon, Ryan [Univ. of Wisconsin, Madison, WI (Uni↗
DOE OSTI2010

A review of irradiation effects on LWR core internal materials - IASCC susceptibility and crack growth rates of austenitic stainless steels.

Austenitic stainless steels (SSs) are used extensively as structural alloys in the internal components of light water reactor (LWR) pressure vessels because of their relatively high strength, ductility, and fracture toughness. However, exposure to neutron irradiation for extended periods changes the microstructure (radiation hardening) and microchemistry (radiation-induced segregation) of these steels, and degrades their fracture properties. Irradiation-assisted stress corrosion cracking (IASCC) is another degradation process that affects LWR internal components exposed to neutron radiation. The existing data on irradiated austenitic SSs were reviewed to evaluate the effects of key parameters such as material composition, irradiation dose, and water chemistry on IASCC susceptibility and crack growth rates of these materials in LWR environments. The significance of microstructural and microchemistry changes in the material on IASCC susceptibility is also discussed. The results are used to determine (a) the threshold fluence for IASCC and (b) the disposition curves for cyclic and IASCC growth rates for irradiated SSs in LWR environments.

36 MATERIALS SCIENCE↗