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All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

MAGNETICALLY SUSPENDED CANNED ROTOR PUMPS FOR THE INTEGRAL MOLTEN SALT REACTOR

This project developed a molten salt pump design for small modular reactors, concentrated solar, and Gen IV nuclear reactors with a magnetically levitated rotor that can operate at temperatures of up to 700 °C. This eliminates the need for rotating seals and roller element bearings which require maintenance and are prone to failure. The pump design is also more compact than existing molten salt pump designs which require long shafts to thermally isolate the electric motor. The aims of the project are to: 1) design and test the molten salt pump, 2) develop and test a high temperature position sensor needed for magnetic bearing control, and 3) develop and test high temperature coil fabrication methods for electric motor and magnetic bearing fabrication. To develop the high temperature coils, conductor materials were analyzed for oxidation, diffusion, cladding, and resistivity. Of the candidate conductor materials that met the requirements, silver was chosen. The long-term impact of radiation on silver resistivity was analyzed by developing a model of a generic molten salt fast reactor to model the conductor irradiation in worst case scenarios. The analysis showed that increased resistivity due to transmutation of silver decreases exponentially with the reactor reflector thickness. Different electrical insulation materials were tested and the final high temperature coils developed were able to withstand conductor to ground voltages up to 1800 V before insulation breakdown. Magnetic bearings require high-precision high-speed measurements of the rotor position to operate. Current commercial position sensors can only operate up to 550 °C so a novel position sensor was developed that can operate up to 800 °C. These sensors were also designed to measure the position of the metallic rotor through a thin metallic corrosion barrier that protects that coils, insulation, and magnetic cores so that the salt containment barrier does not have any penetrations. The high-temperature sensor was tested and had comparable performance to commercially available inductive position sensors. The sensor design and signal processing has led to several invention disclosures. The magnetically levitated molten salt pump design was completed and analyzed. The chloride salt test loop at Oak Ridge National Laboratory was chosen to test the pump and the pump hydraulics and power were designed for the test loop flow and pressure requirements. Classes of motor designs that do not utilize permanent magnetic were considered for the high-temperature motor. After extensive analysis of their performance, a synchronous reluctance motor was chosen for the pump. The design was refined and analyzed to optimize performance. The magnetic bearings were designed to meet the force and frequency requirements necessary to levitate the rotor and reject disturbances from rotor imbalance, motor forces, and hydraulic forces. Compliant mounts for the position sensors were designed that would not damage the ceramic sensor components and maintain sensor alignment over a wide temperature range. A thermal hydraulic analysis of the molten salt coolant flow used to cool the rotor and stator was performed to ensure that the maximum temperature in the rotor and stator will not exceed 725 °C. The corrosion barrier and casing were designed to maintain the salt fluid boundary by using compliant features to absorb large expansion mismatches due to different coefficients of thermal expansion (CTE). Finally, the salt drain and fill systems were designed along with the pump support structure, integration with the test loop, and thermal insulation and heating. Corrosion barrier fabrication experiments were performed to assess using laser cladding to apply a sub-millimeter corrosion barrier to the surface of a Fe-Co-V magnetic core material. The cladding method showed minimal mixing between materials at their interface and withstood temperature cycling without damage to the cladding. The technology commercialization is focused on the high-temperature position sensors and there has been significant interest from the nuclear industry in utilizing these sensors along with some interest from the aerospace industry. The project also led to a research collaboration with a fusion energy industrial partner to study barriers to scaling the pump design from the kW size to the MW size. This research collaboration will also study methods to create high-temperature coils that have conductor to ground breakdown voltages above 5 kV. The successful development of high-temperature electromagnetic coils and high-temperature position sensors greatly increases the temperature limits for electromagnetic devices that don’t rely on permanent magnets. This includes electric motors, magnetic bearings, linear actuators, rotary position and velocity sensing, actuated valves, and generators to name a few. This will fill a current need in molten salt reactors, concentrated solar, and fusion energy for these critical peripheral devices needed for practical reactor designs that do not currently have commercial solutions.

Hines, J Wesley↗
DOE OSTI2014

Surrogate Spent Nuclear Fuel Vibration Integrity Investigation

Transportation packages for spent nuclear fuel (SNF) must meet safety requirements under normal and accident conditions as specified by federal regulations. During transportation, SNF experiences unique conditions and challenges to cladding integrity due to the vibrational and impact loading encountered during road or rail shipment. ORNL has been developing testing capabilities that can be used to improve our understanding of the impacts of vibration loading on SNF integrity, especially for high burn-up SNF in normal transportation operation conditions. This information can be used to meet nuclear industry and U.S. Nuclear Regulatory Commission needs in the area of safety of SNF storage and transportation operations.

bending fatigue↗
DOE OSTI2014

New rig for studying SNF vibration integrity

Transportation packages for spent nuclear fuel (SNF) must meet safety requirements under normal and accident conditions as specified by federal regulations. During transportation, SNF experiences unique conditions and challenges to cladding integrity due to the vibrational loading encountered during road or rail shipment. ORNL has been developing testing capabilities that can be used to improve our understanding of the impact of vibration loading on SNF integrity, especially for high burn-up SNF under normal conditions of transport (NCT). Ultimately, this information can be used to meet nuclear industry and U.S. Nuclear Regulatory Commission needs in the area of safety of SNF transportation operations.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2016

Overview of the experiments performed with Russian claddings at MTA EK

The mechanical and corrosion behavior of the Russian-type zirconium cladding alloy E110, predominantly used in VVERs, has been investigated for many decades. The recent commercialization of a new alloy E110G, produced on a sponge zirconium basis, gave the opportunity to compare the mechanical properties of the old E110 and the new E110G fuel claddings. The mechanical experiments performed with samples from both claddings in MTA EK including axial and tangential (ring) tensile tests at 20, 150 and 300 Celsius degrees. The chosen geometries for the tests were modelled using finite element method. Due to the anisotropy of the cladding tubes the axial yield strength was 6% higher than the tangential. The yield strength of the E110G alloy was 12% higher than for the E110 claddings at ambient temperature, but this difference decreased to 5% at 300 C. degrees. Some samples underwent chemical or thermal treatments and the effects of these were evaluated. These treatments were slight oxidation in steam at 800 C. degrees up to 3 ECR%, hydridation at 600 C. degrees up to 400 ppm, and heat treatment in argon atmosphere at temperatures between 600 and 1000 C. degrees. The results confirm that the heat treatment has more significant effect on the yield strength of the claddings than the chemical treatments. While the yield strength of the oxidized samples was slightly higher, when combined with the data from the heat treatment at 800 C. degrees, the oxidation itself seems to have lowered the yield strength as the thickness of the metal decreased. The hydridation of the cladding samples did not change the yield strength and the samples remained ductile even at room temperature. The thermo-mechanical creep of the two cladding alloys was also investigated. Biaxial and uniaxial creep experiments were performed with 100 mm long cladding tubes. In the biaxial test, samples of both alloys were pressurized with argon to 5, 7.5 and 10 MPa at 500 C. degrees and the test lasted till the depressurization of the tubes. The uniaxial creep was measured at 300 and 500 C. degrees in the axial direction and constant stress was applied using weights. This stress was 14.8 and 27.7 MPa at 300 C. degrees and 3.7 and 6.5 MPa at 500 C. degrees. The elongation and diametrical change of the samples were measured using different methods. (authors)

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2019

ODS Thin-wall Cladding Joining Technique Development

ABSTRACT The oxide dispersion strengthened (ODS) materials are typically fabricated by powder mechanical alloying to form uniform distribution of high concentration nanometer size oxide particles for exceptional high temperature mechanical strength and enhanced radiation tolerance. This report summarizes the recent development on the weld techniques of joining the ODS cladding to the endplug as a part of accident tolerant fuels (ATF) program for both advanced light water reactor (LWR) and advanced fuel cycle (AFC) with fast reactor fuel cladding. It is crucial for the weld of ODS material to maintain the uniform distribution and fine size of oxide particles in the matrix. Pressure Resistance Weld (PRW) is a solid state joining technique without melting therefore a preferred joining technique for ODS materials. Samples joined with PRW were pressure burst tested. Detailed microstructural characterization in this work includes non-destructive 3D x-ray ?m-resolution computer-tomography (?-CT), optical microscopy, SEM/EBSD for grain-orientation-mapping, TEM, STEM/ASTAR for high resolution grain orientation and phase mapping, and APT for high-resolution 3D composition analysis.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2013

Development of advanced strain diagnostic techniques for reactor environments

The following research is operated as a Laboratory Directed Research and Development (LDRD) initiative at Sandia National Laboratories. The long-term goals of the program include sophisticated diagnostics of advanced fuels testing for nuclear reactors for the Department of Energy (DOE) Gen IV program, with the future capability to provide real-time measurement of strain in fuel rod cladding during operation in situ at any research or power reactor in the United States. By quantifying the stress and strain in fuel rods, it is possible to significantly improve fuel rod design, and consequently, to improve the performance and lifetime of the cladding. During the past year of this program, two sets of experiments were performed: small-scale tests to ensure reliability of the gages, and reactor pulse experiments involving the most viable samples in the Annulated Core Research Reactor (ACRR), located onsite at Sandia. Strain measurement techniques that can provide useful data in the extreme environment of a nuclear reactor core are needed to characterize nuclear fuel rods. This report documents the progression of solutions to this issue that were explored for feasibility in FY12 at Sandia National Laboratories, Albuquerque, NM.

Fleming, Darryn D.↗
DOE OSTI2021

FY2021 Progress Report on BISON Metallic Fuel Model Development and V&V Using EBR-II Legacy Data

In this report, the activities and achievements made by Argonne National Laboratory for the Nuclear Energy Advanced Modeling and Simulation (NEAMS) BISON code metallic fuel validation and verification project in FY2021 are summarized. The cladding degradation model based on the FCCI/CCCI wastage calculations has been developed and implemented into BISON. A comprehensive evaluation of the cladding degradation model was performed based on FIPD data of the IFR experiment X447. BISON objects were also developed to enable direct use of time-varying cladding outer surface temperature profile as temperature boundary conditions, which proved to provide more accurate temperature predictions for the metallic fuel pins irradiated in EBR-II. Additionally, a new BISON object was implemented to enable direct comparison between BISON predicted data and FIPD-based post-irradiation examination (PIE) results, which would significantly facilitate BISON metallic fuel verification and validation (V&V) activities. These new BISON-FIPD integration features were used in the establishment of a low-burnup fuel swelling evaluation framework as demonstration. The framework was successfully used to evaluate current fuel swelling models based on the IFR experiment X423.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2017

Comparison of Thermal Diffusivity Degradation of Irradiated Zirlo and SiC-SiC Composite

Zirlo (Zircaloy cladding material from Westinghouse) has been widely used as the fuel cladding material in Light Water Reactors because of its high melting point, low susceptibility to corrosion, good thermal and mechanical shock resistance, and low degradation of mechanical properties under irradiation. But as Zirlo reacts with water at high temperature, which can trigger serious accidents, efforts have been made to explore better candidates to replace Zirlo in the water-cooled reactors. SiC-SiC composite is considered as one of the most viable options due to its comparable mechanical performances and corrosion resistance. However, one of the most important properties, thermal diffusivities of both Zirlo and SiC-SiC composite, and their degradation after irradiation, are not well known yet. Ion-irradiated samples are used to study the thermal property degradation caused by irradiation instead of the neutron-irradiated ones due to the significantly lower radioactivity. The microstructural damage is estimated from the software simulation SRIM/TRIM based on the energy and fluence of the ion, and the target material, and represented by DPA (displacement by atom). Different from neutron-irradiated samples, the damaged layer of ion-irradiated samples is only a few to a few tens of micrometers thick, and the damage is depth dependent. It is impossible to directly measure the bulk property change, and a microscale measurement technique is necessary. Laser-based photothermal reflectance technique is one of the ideal methods to measure local thermal conductivity and diffusivity with high spatial resolution. The main principle of this technique is to heat the solid sample using an intensity-modulated laser, and scan the sample with a constant intensity continuous-wave (CW) laser to detect the thermal wave propagation. On bulk, isotropic material, if the heating laser intensity is modulated as a sine wave, thermal diffusivity of the sample can be derived from the phase lag of the thermal wave, scan distance and modulation frequency in a straight forward manner. By using more specific analytical models, thermal conductivity and diffusivity in complicated cases, such as layered structure materials, composite materials, and/or anisotropic materials, are measurable as well. In this work, thermal diffusivity of the light damage layer of the post-irradiation Zirlo and SiC-SiC composite are measured and compared. The Zirlo sample is irradiated by Ni{sup 9+} ion, and SiC-SiC composite material is irradiated by Si{sup 7+} ion. The peak DPA of both sample is similar as ∼10. For ion-irradiated materials, DPA is known to increase with depth before it reaches the peak, and then sharply drop to zero. In term of light damage layer in this manuscript, we mean by the layer with a DPA smaller than 5% maximum value. In this layer DPA increases slowly and smoothly with depth, and the structure and thus thermal properties are more spatially uniform. For the SiC-SiC composite, the measurements are separately conducted on fibers along radial or axial direction, and on the matrix. Our measurement results show that with similar microstructural damage, thermal diffusivity of matrix SiC reduces more significantly than that of Zirlo. For fiber SiC that has a much lower thermal diffusivity than the matrix SiC before irradiation, the post-irradiation effect on thermal diffusivity is not obvious.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2019

Assessment of SiC-CMC compatibility with components of actinide fuel systems

Silicon carbide (SiC) fiber reinforced SiC ceramic matrix composites (CMC) represent an alternative cladding material for accident tolerant fuel light water reactor (LWR) applications, however, data and technology gaps exist that need to be understood before SiC-CMCs can be considered. One technology gap is the understanding of fuel-clad chemical interactions (FCCI) in SiC-CMC clad LWR systems. A review of SiC interactions with relevant elements to the LWR fuel system is discussed. Insights are drawn from research focusing on the use of SiC for high temperature electronics applications and high temperature structural materials applications as well as insights from tristructural-isotropic (TRISO) coated particle fuel development, where SiC is a critical component of the TRISO design. The interactions discussed in this review are framed relative to the expected conditions for SiC-CMC cladding application. Furthermore, the general observation is that limited risk of FCCI exists under normal operating conditions for SiC-CMC cladding systems in LWR applications.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2015

Characterization and comparative analysis of the tensile properties of five tempered martensitic steels and an oxide dispersion strengthened ferritic alloy irradiated at ≈295 °C to ≈6.5 dpa

Tensile test results at 25 and 300 °C on five 9-12Cr tempered martensitic steels and one 14Cr oxide dispersion strengthened alloy, that were side-by side irradiated to 6.5 dpa at 295 °C in the Advanced Test Reactor (ATR), are reported. The engineering stress–strain curves are analyzed to provide true stress–strain constitutive σ(ε) laws for all of these alloys. In the irradiated condition, the σ(ε) fall into categories of: strain softening, nearly perfectly plastic and strain hardening. Increases in yield stress (Δσ y ) and reductions in uniform strain ductility (e u ) are observed, where as the latter can be understood in terms of the alloy's σ(ε) behavior. Increases in the average σ(ε) in the range of 0–10% strain are smaller than the corresponding Δσ y , and vary more from alloy to alloy. The data are analyzed to establish relations between Δσ y and coupled changes in the ultimate stresses as well as the effects of both test temperature and the unirradiated yield stress (σ yu ). The latter shows that higher σ yu correlates with lower Δσ y . In five out of six cases the effects of irradiation are generally consistent with previous observations on these alloys. However, the particular heat of the 12Cr HT-9 tempered martensitic steel in this study has a much higher e u than observed for earlier heats. The reasons for this improved behavior are not understood and may be microstructural in origin. However, it is noted that the new heat of HT-9, which was procured under modern quality assurance standards, has lower interstitial nitrogen than previous heats. As a result, notably lower interstitial solute contents correlate with improved ductility and homogenous deformation in broadly similar steels.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2019

Elastic moduli reduction in SiC-SiC tubular specimen after high heat flux neutron irradiation measured by resonant ultrasound spectroscopy

The initial results of a post-irradiation examination study conducted on a SiC-SiC tubular specimen irradiated under a high radial heat flux are presented herein. The elastic properties of the specimen were evaluated before and after the irradiation using the resonant ultrasound spectroscopy (RUS) technique. The composite tubular specimen was considered as an orthotropic elastic with nine elastic constants (Young's moduli, shear moduli and Poisson's ratios—three components of each) for representing its full elastic deformation behavior. All the elastic moduli decreased after irradiation; the reduction was as high as 35% in one of the moduli. The significant decrease in the moduli indicates the presence of microcracks. The results from a computational study show significant stress development in the specimen due to irradiation, primarily caused by differential swelling across the thickness of the specimen. The evaluated stresses exceed the proportional limit stress of the material, indicating the likelihood of matrix microcracking, and thus corroborating the results obtained from RUS. X-ray Computed Tomography (XCT) study confirmed the presence of cracks in the irradiated specimen. These cracks occurred at the inner region of the specimen and propagated in axial and hoop directions. Finally, these XCT results are in agreement with the RUS results and stress distribution results from the computational study.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗
DOE OSTI2011

Color Anodizing of Titanium Coated Rolled Carbon Steel Plate

As an important kind of structural materials, the titanium cladded steel plates have the advantages of both metals and have been applied in aviation, spaceflight, chemical and nuclear industries. In this study, the specimens which were prepared under soldering mechanism during rolling were anodized by electrochemical process under a given conditions. The color anodizing takes place by physical phenomenon of color interference. Part of incident light on the titanium oxide is reflected and the other part reflects inside coated titanium layer. Major part of the light which reflects from titanium-oxide interface, reflects again inside of the oxide layer.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Neutron and Thermal Embrittlement of RPV Steels: An Overview

Because the reactor pressure vessel (RPV) represents the first structural line of defense against the release of radiation to the public, the design and fabrication of the RPV for any nuclear reactor facility is performed at very high standards in accordance with consensus codes that are based on mechanical and physical properties of the steels used to construct the vessel. Nuclear RPVs may weigh up to 800 tons with wall thicknesses up to approximately 330 mm and are clad on the inside with stainless-steel weld metal and given a final post-weld heat treatment. The RPV is a unique structural component in that it operates under high pressures and temperatures and is exposed to relatively high neutron radiation. Although typical RPV steels and welds have excellent fracture toughness at room temperature and above when put into service, the degrading effects of high-energy neutron irradiation can cause levels of irradiation-induced embrittlement in radiation-sensitive materials of concern for the structural integrity of the RPV. In recent decades, remarkable progress has been made in developing a mechanistic understanding of irradiation embrittlement. This progress includes developing physically based and statistically calibrated models of Charpy V-notch-indexed transition temperature shifts based on results from RPV surveillance programs complemented by significant results from comprehensive research experiments performed in test reactors. In addition, advances in elastic-plastic fracture mechanics allow for a relatively small number of relatively small specimens to characterize the fracture toughness of RPV steels with statistical confidence. This paper presents a review of the primary mechanical properties, test procedures, examples of applicable codes and standards, and specimen types used to characterize RPV steels and welds, the effects of neutron irradiation on those most relevant mechanical properties, and a brief review of the effects of thermal aging on RPV materials. The paper closes with a summary.

Nanstad, Randy K.↗
DOE OSTI2018

Overview of Aluminum Oxide Prediction Models for High Power Research Reactors

UMo/Al dispersion fuel clad with aluminum alloy cladding is a primary candidate fuel form that is being developed for high power research and test reactors including European high power research reactors (EUHPRR). Oxidation of cladding is considerable due to high power application. One of the objectives of this report is to review the existing oxide prediction models and heat transfer correlations at cladding surface.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2021

Crack Stability in Breached Fuel

This report describes the fracture mechanics formalism to evaluate the stability of cracks in a fuel cladding. Recognized consensus-body linear elastic fracture mechanics (LEFM) was applied to identify the crack instability length, or the length at which unstable mechanical crack extension would occur, as a function of pellet swelling loading (radial strain and fraction conversion from UO 2 to U 3 O 8 ) at the local cracked cladding region for two postulated fracture toughness (K IC ) values of the cladding. The crack opening displacement (COD) and the crack opening area (COA) were also identified. This analysis informs evaluations for crack extension and the potential for pellet debris loss from the fuel rod for cases of pellet oxidation in dry storage canisters where inadvertent residual water may undergo radiolysis causing oxidizing conditions to pellets exposed to the canister environment through breached cladding.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2022

PNNL FY 2022 Sibling Pin Testing Results

This report presents the results of testing two rods after heat treatment at 400C for 8 hours and compares to the results from FY 2021 of similar rods that were tested as baseline. The heat treatment resulted in a decrease in yield stress.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2024

Complete development of LAROMance-type surrogate models for Zircaloy, as well as initial integration and testing in MOOSE, which addresses industry needs for licensing advanced LWR fuels

This milestone report details the progress in the constitutive surrogate modeling framework for Zircaloy’s mechanical behavior under extreme conditions, within the NEAMS program throughout the U.S. fiscal year 2024 (FY24). The presented work expands on the spectral based mechanical solver and the mechanistic material model for Zircaloy, which were introduced in the NEAMS program during FY22 and detailed in the previous fiscal year (FY23). As part of the NEAMS program, the current effort described in this report focused on the development of a novel viscplastic (creep) surrogate for the mechanistic, polycrystal-based model. To this end, the work was subdivided into two interdependent components related to the necessary improvements to the LApx constitutive model and algorithm and, to the development and use of a surrogate model.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗