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DOE OSTI2024

ROADRUNNER MiniFuel Experiment: Irradiation Target Design and Sample Characterization

High-density uranium nitride (UN) is a fuel candidate for several advanced nuclear reactor designs currently under development. Because there are limited UN performance data relative to fuel fabrication impurity and density variation, an irradiation campaign has been developed as part of a collaborative effort among the University of Texas at San Antonio (UTSA), Westinghouse Electric Company, Oak Ridge National Laboratory (ORNL), and Los Alamos National Laboratory (LANL) under the Nuclear Science User Facilities program. This project, entitled ROADRUNNER, or Research On ADvancing the peRformance of UraNium Nitrides in Extreme enviRonments, aimsto support UN fuel qualification for advanced reactors by investigating the impact of density and impurity variations on UN performance as a function of irradiation temperature and burnup. The MiniFuel experiment vehicle developed by ORNL, which leverages the High Flux Isotope Reactor, was selected to perform this accelerated separate-effects irradiation testing. The experiment test matrix consists of six MiniFuel targets containing miniature UN fuel disks, and targets three distinct burnup levels (37.5, 60, and 75 MWd/kg U) and three distinct temperatures (600, 900, and 1200°C). Neutronics and thermal analyses were performed to determine the experimental parameters needed to meet the desired irradiation conditions and to predict the experiment components temperatures. UN pellets were fabricated at LANL with tightly controlled parameters to produce specimens with three distinct densities and three levels of carbon content. The pellets were then thinned down by UTSA to the experiment-required thickness. The pre-characterization of the specimens includes density measurements, carbon and oxygen contents, microstructure analysis, and x-ray computed tomography. The selected specimens will be assembled into the MiniFuel experiment, and the first ROADRUNNER MiniFuel targets are intended for HFIR insertion during the Fall of 2024. After irradiation, the targets will be shipped to ORNL’s hot cell facility for disassembly. The post-irradiation examination on the fuel specimens includes fission gas release measurements, visual inspection, fuel swelling measurements, gamma spectroscopy, and microstructure analysis. The data collected post-irradiation will be used to develop fuel performance models.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2025

Designing a validation experiment for radio frequency condensation

Abstract Theoretical studies have suggested that nonlinear effects can lead to ‘radio frequency (RF) condensation’, where an initially broad current profile can coalesce in islands when they reach sufficient width. In suitable conditions, RF condensation can ‘self-focus’ the driven current to the center of an island, improving stabilization efficiency and reducing control complexity. In unsuitable conditions, the effect can prematurely deplete the RF energy before it reaches the island center, impairing stabilization. It is predicted that the RF condensation effect can significantly impact reactor-scale tokamaks. This paper presents a set of simulations investigating the conditions under which RF condensation might be encountered in present-day tokamaks. For concreteness, the calculations use equilibrium reconstructions for two shots from DIII-D and AUG. The Current Condensation Amid Magnetic Islands (OCCAMI) simulation code has been used for this investigation. The code takes as its input a numerically specified axisymmetric EFIT equilibrium solution, and it perturbatively constructs a 3D field with an island embedded at the appropriate rational surface. In the OCCAMI code, the GENRAY code is used for ray tracing and for calculating the power deposition along a ray trajectory, and GENRAY is coupled self-consistently to a solution of the thermal diffusion equation in the island. The simulation results described in the paper illuminate the conditions required for experimental validation of the theory of RF condensation. The simulations also provide an explanation of why the effect was not noticed in experiments prior to the publication of theoretical papers on the subject.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2024

PIP-II High Beta 650 Prototype Cryomodule Assembly Experience and Related Design Optimization

After shipment to the Daresbury Lab and return to Fermilab, the prototype HB650 cryomodule underwent another phase of 2K RF testing to ascertain any performance issues that may have arisen from the transport of the cryomodule. While measurements taken at room temperature after the conclusion of shipment indicated that there were no negative impacts on cavity alignment, beamline vacuum, or cavity frequency, testing at 2K was required to validate other aspects such as tuner operation, cavity coupling, cryogenic system integrity, and cavity performance. Results of this latest round of limited 2K testing will be presented.

Ozelis, J.↗

DOE OSTI2026

Final Design for Thermal/Epithermal eXperiments (TEX) with Lithium Absorbers to Provide Validation Benchmarks for Y-12 Electrorefining Facility (IER 575, CED-2 Report)

One of the main goals of the Thermal/Epithermal eXperiments (TEX) project is to use existing Nuclear Criticality Safety Program (NCSP) assets to create critical experiment plutonium and uranium test beds for materials important to criticality safety that have insufficient benchmark evaluations. The plutonium test bed experiments were completed in 2018 and are published in the 2020 edition of the International Criticality Safety Benchmark Evaluation Project (ICSBEP) Handbook. The uranium test bed assemblies were completed in 2023 and accepted in the 2024 edition of the ICSBEP Handbook.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗

DOE OSTI2024

Design of a first-of-A-kind instrumented advanced test reactor irradiation Capsule experiment for In situ thermal conductivity measurements of metallic fuel

Metallic fuel undergoes dramatic microstructural changes early in life due to fission gas swelling until ~2–3 at% burnup which affects the conductivity of the material, however the evolution of metallic fuel thermal conductivity during this early phase burnup has never been successfully measured in situ. The Irradiated Material Properties Accelerated Characterization Test (IMPACT) experiment will be the first in a series of experiments to irradiate advanced nuclear metallic fuel specimens with novel embedded thermal conductivity probes in ATR. In the current work the IMPACT experiment final design and supporting analysis is reported in detail. Results are evaluated for various reactor operational conditions to meet the functional requirements of the experiment. Finally, the first iteration of this IMPACT experiment will provide data regarding thermal properties evolution in uranium-zirconium (U10Zr) fuel, but this experiment vehicle is envisioned for future advanced fuels and structural materials irradiations in ATR.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2025

Integral Experiment Request 523 CED-2 Report

This report documents the final design phase of the Critical Experiment Design (CED-2) conducted as part of integral experiment request (IER) 523. The purpose of IER 523 is to determine critical configurations of 35 weight percent (wt%) enriched uranium dioxide beryllium oxide (UO 2 -BeO) material driven by an annular ring of Seven Percent Critical Experiment (7uPCX) fuel rods at Sandia National Laboratories (Sandia). The experiments will provide benchmark data on water moderated, intermediately enriched UO2 systems as well as Be nuclear data. The experiment will also provide partial validation for the beryllium oxide (BeO) thermal neutron scattering law (TSL) in the thermal energy range. Experiment design concepts, neutronic analysis results, and proposed paths for continuing the CED process are presented. This report builds on the feasibility and justification of experimental need report (CED-0) and preliminary experiment design report (CED-1) completed in December 2021 and September 2023, respectively [1, 2].

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗

DOE OSTI2025

A Refined BISON-Griffin Workflow For Designing Targeted TRISO Transient Experiments In The Transient Reactor Test Facility

U.S. industry is expected to deploy tristructural isotropic (TRISO) particle fuel technologies for commercial reactors within the next decade. In our previous work, we defined a preliminary transient design space for TRISO fuels, identified potential gaps in the available data, and began to develop multiphysics modeling tools that could be applied to design targeted Transient Reactor Test Facility (TREAT) experiments to fill these gaps. This work builds on that foundation by (1) updating BISON fuel performance and Griffin reactor physics models to reflect the current TREAT experiment tube and capsule designs,(2) coupling the codes to improve the accuracy and usability of the transient design analyses, and (3) demonstrating their use over an expanded design space that includes fuel burnup. The simulated mechanical responses of the TRISO particles were complex functions of fission product accumulation, fission gas release, and irradiation-induced dimensional change in the pyrolytic carbon layers. Predicted tangential stresses in particle silicon carbide layers were least compressive for preheated tests involving fresh fuels but remained compressive throughout the ranges of temperature, heat rate, and burnup considered in this work. Finally, comparisons between the potential TREAT transients and historical test reactor irradiations showed that the TREAT tests would produce significantly lower average energy deposition rates, yielding less severe transients with greater relevance to near-term commercial applications. Use of these predictive capabilities has the potential to increase the value of each test, improving the overall efficiency and cost effectiveness of transient testing for TRISO and other advanced fuels.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2026

Refinement and demonstration of a coupled BISON-Griffin workflow for designing targeted TRISO transient experiments in TREAT

The U.S. nuclear industry is expected to deploy tristructural isotropic (TRISO) particle fuel technologies for commercial reactors within the next decade. In previous work, we defined a preliminary transient design space for TRISO fuels, identified potential gaps in the available data, and began to develop multiphysics modeling tools that could be applied to design targeted Transient Reactor Test Facility (TREAT) experiments to fill these gaps. Here, this work builds on that foundation by (1) updating BISON fuel performance and Griffin reactor physics models to reflect the current TREAT experiment tube and capsule designs, (2) coupling the codes to improve the accuracy and usability of the transient design analyses, and (3) demonstrating their use over an expanded design space that includes fuel burnup. The simulated mechanical responses of the TRISO particles were complex functions of fission product accumulation, fission gas release, and irradiation-induced dimensional change in the pyrolytic carbon layers. The predicted tangential stresses in the particles' silicon carbide layers were least compressive for preheated tests involving fresh fuels but remained compressive throughout the ranges of temperature, heat rate, and burnup considered in this work. Finally, comparisons between the potential TREAT transients and historical test reactor irradiations showed that the TREAT tests would produce significantly lower average energy deposition rates, yielding less severe transients with greater relevance to near-term commercial applications. The use of these predictive capabilities has the potential to increase the value of each test, improving the overall efficiency and cost-effectiveness of transient testing for TRISO and other advanced fuels.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2026

Enabling integrated AI control on DIII-D: a control system design with state-of-the-art experiments

We present the design and application of a general algorithm for Prediction And Control using MAchiNe learning (PACMAN) in DIII-D. Machine learning (ML)-based predictors and controllers have shown great promise in achieving regimes in which traditional controllers fail, such as tearing mode (TM) free scenarios, ELM-free scenarios and stable advanced tokamak conditions. The architecture presented here was deployed on DIII-D to facilitate the end-to-end implementation of advanced control experiments, from diagnostic processing to final actuation commands. This paper describes the detailed design of the algorithm and explains the motivation behind each design point. We also describe several successful ML control experiments in DIII-D using this algorithm, including a reinforcement learning controller targeting advanced non-inductive plasmas, a wide-pedestal quiescent H-mode ELM predictor, an Alfvén Eigenmode controller, a Model Predictive Control plasma profile controller and a state-machine TM predictor-controller. There is also discussion on guiding principles for real-time ML controller design and implementation.

machine learning↗

DOE OSTI2024

AIACHNE's contribution for Nuclear Energy Agency Working Party on International Nuclear Data Evaluation Co-operation Subgroup 50

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗

DOE OSTI2024

AIACHNE's contribution for Nuclear Energy Agency Working Party on International Nuclear Data Evaluation Co-operation Subgroup 50

The AIACHNE (AI/ML Informed cAlifornium CHi Nuclear data Experiment) project aims at designing an experiment for the 252 Cf Prompt Fission Neutron Spectrum (PFNS) that explores systematic biases in an experimental database retrieved from the EXFOR databases. To that end, machine learning (ML) methods were applied to pint-point measurement features likely related to bia. From that information, we selected a feature that should be explored by the AIACHNE experiment. Measurement features are metadata encapsulating all pertinent information about the physical measurement and analysis techniques. Examples are, for instance, what neutron and fission detectors were used for the physical metadata, and what background reduction techniques were employed for analysis techniques. Such metadata were retrieved both from EXFOR entries as well as the literature of data sets described in detail in Ref. [2]. The prerequisite for applying machine learning techniques is casting the metadata into a format that can be parsed by the algorithm. This step might seem trivial but requires to find a unique language where metadata that carry the same physics meaning across several experiments must have the same identifier. One example is, for instance, the neutron detector. As seen in Figure 1, the machine learning code identified the use of 6 Li detectors as being related to bias in some datasets of the AIACHNE 252 Cf PFNS experimental database. In fact, here are several experiments that used neutron detectors containing 6Li in the database, for instance for the example below. EXFOR format has a unique keywords describing detectors such as “SCIN” or “GLASD”. One may think that these keywords are already sufficient descriptors for ML to uniquely find an issue. However, “SCIN” (used for [3, 4]) and “GLASD” (used for [5]) fail to inform the algorithm what is the active material in the detector. And, the key common issue leading to bias in 252 Cf related to neutron detectors is not whether it is a glass detector or a scintillator. No, the issue is that 6 Li was within both detector types and that even small mistakes in the detector response functions around approximately 200 keV are amplified by the 6 Li(n,α) resonance there leading to bias in data as highlighted in Fig. 1 and Ref. [1]. Hence, the features describing the neutron detector must call out the active material in the detector, rather than the existing EXFOR detector keyword, that the ML algorithm can find physically meaningful features related to bias. The AIACHNE team used a precursor of the WPEC (Working Party on International Nuclear Data Evaluation Co-operation) SG(Subgroup)-50 format to store the metadata for the ML analysis.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗

DOE OSTI2025

Assessment of MiniFuel Subcapsule Design Recommendations on Previous Experiments

MiniFuel describes the class of separate effects nuclear fuels irradiation experiments that have been conducted in the High Flux Isotope Reactor (HFIR) since 2018. These experiments comprise a stack of six fuel-bearing subcapsules contained in a stainless steel target housing that is in contact with HFIR coolant on its exterior. All MiniFuel targets have a near-standardized architecture, and the primary design variables that change between experiments are the radial gap size between the subcapsule and housing and the target fill gas composition. Finite element heat transfer models are used to determine the optimum gas composition and gap sizes, and recent studies were performed to identify model parameters that contribute the most uncertainty to fuel specimen temperature predictions. That work, which is referenced herein, also recommended a set of design modifications to the subcapsule internal architecture and assembly process. These modifications are intended to reduce fuel temperature uncertainty in future experiments. In this report, the subcapsule design modifications were retroactively applied to a previously conducted MiniFuel experiment to determine how these changes affect the established safety and performance envelope of the experimental capability. These effects were determined in two steps. First, the modifications were applied to the subcapsule design without any other changes to determine their isolated effect on the predicted fuel specimen temperatures. This portion of the analysis showed that fuel temperatures were modestly reduced because the implemented changes improved heat transfer efficacy. Next, traditional MiniFuel design activities (i.e., sizing the gas gaps and determining the fill gas composition) were reperformed, and they confirmed that the original desired fuel temperatures could be achieved while remaining within established safety limits. Therefore, this report demonstrates improved performance resulting from the subcapsule modifications, which mitigate uncertainty while meeting the objectives of past experiments. An additional benefit of the design changes is reduced sensitivity of the fuel temperature to the evolving flux spectrum in HFIR, leading to more stable temperatures and enhanced utility of MiniFuel as a separate effects irradiation platform.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2025

Conceptual Designs for Irradiation Creep Testing of SiC in HFIR

Understanding irradiation creep of nuclear fuel cladding is important to properly size the initial fuel-cladding gap and understand when pellet-cladding contact is expected to occur due to a combination of fuel swelling and cladding creep-down. Irradiation creep also plays a role in relaxing stresses that develop in-pile. Silicon carbide fiber–reinforced silicon carbide matrix (SiC/SiC) composites are the leading long-term accident-tolerant fuel cladding concept for light-water reactors (LWRs). Although some limited data are available regarding irradiation creep of the individual constituents (fibers, matrix), data regarding irradiation creep of SiC/SiC composites are currently insufficient. Additional data regarding irradiation creep compliance and the rupture lifetime (combination of creep and slow crack growth) are needed to understand material limitations. This work describes the design and development of two irradiation vehicles that are being pursued for testing SiC/SiC concepts in the High Flux Isotope Reactor (HFIR). The first is a passive experiment, referred to as the PRECISE experiment, that leverages the constant coolant pressure of HFIR to compress a metallic bellows and provide a well-characterized load to drive creep in a SiC/SiC dog bone specimen. The total creep strain would be quantified post-irradiation by measuring dimensional changes of the specimen length as well as local dimensional changes within the gauge region. Non-stressed specimens would also be irradiated under the same conditions to provide an indication of dimensional changes due to radiation-induced swelling in the absence of creep. A second, more complex experiment, referred to as the INSITE experiment, is being designed in parallel that would use pneumatics to pressurize a metal bellows and linear variable differential transformers (LVDTs) to measure the specimen displacement in situ during irradiation. Such an experiment would provide significantly more data regarding the evolution of the creep compliance as a function of dose and applied stress within a single experiment but would require significantly more development time and cost to execute. The primary concern with the INSITE experiment is the accuracy, reliability, and expected lifetime of the LVDTs during irradiation at elevated temperatures. Efforts are being made to adjust the experiment design and operating procedure to limit LVDT temperatures and mitigate or otherwise compensate for uncertainties due to factors such as temperature fluctuations, creep in the surrounding structural materials, and drift of the LVDTs. This work describes the experiment designs, thermal and structural analysis that were performed to ensure that the desired temperature and stress conditions can be achieved, some initial sensitivity analyses to predict the evolution of the radiation-induced specimen displacements, and potential sources of uncertainty in the measurements. Out-of-pile testing is being performed in parallel to confirm that the test trains achieve the expected stress states in the specimens and do not result in prohibitive stress concentrators (e.g., in the grip regions) that might risk pre-mature failure. The PRECISE experiments are proceeding toward fabrication and assembly with HFIR insertion planned during fiscal year 2026. The INSITE experiment is progressing toward out-of-pile demonstrations, which will provide more conclusive evidence regarding the feasibility of executing these tests in HFIR or whether alternative displacement monitoring techniques may need to be considered.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2025

Kinetics of short-range order formation in GeSn alloy: MBE vs CVD

Recently, short-range order (SRO) has attracted significant attention, challenging the conventional view of the atomic positions in alloys being random. Furthermore, the presence of SRO has been predicted to have profound effects on the electronic and topological properties of group-IV alloys, offering a different direction in designing group-IV materials for photoelectronic and quantum devices. However, due to the limited understanding of the formation mechanisms, developing effective methods to manipulate SRO in epitaxy is still challenging. To address this, we propose a mechanism for the GeSn alloy, revealing that surface diffusion plays a key role in SRO formation. Building on this mechanism, we show that the distinct surface conditions in MBE and CVD lead to the formation of SRO with enhanced Sn–Sn pairing in MBE-grown samples, while CVD-grown samples remain random alloys. Furthermore, our findings provide an initial understanding of the kinetic process of SRO formation, providing guidance for the design of experiments to manipulate SRO.

Alloys↗

DOE OSTI2024

A new perspective on density and strength loss profiles at the surface of thermally oxidized nuclear graphite

Oxidation of graphite components could influence their designed life in a high-temperature nuclear reactor. The oxidized regions could potentially lower the allowed stress capacity. The American Society of Mechanical Engineers rules for the design and construction of graphite-moderated reactors recommend that subsurface regions that might become excessively damaged by oxidation during reactor operation be identified and excluded from geometry and stress calculations. Identification of oxidation-affected regions is possible, in principle, through complex modeling exercises of reactor behavior during hypothetical accident scenarios coupled with graphite oxidation models, but this procedure may not have the precision needed for informed decisions. Here, this paper proposes an alternate method, based on interpretation of a series of well-designed oxidation experiments, which could augment the designer's tools. The procedure is illustrated by data on oxidation by air of several graphite grades (NBG-18, PCEA, IG-110, R4-650) that are corroborated with independent literature information, when available. The Wichner model for graphite oxidation used for this analysis provides conservative results that could be quickly implemented in the design process.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Hunga Tonga–Hunga Ha′apai Volcano Impact Model Observation Comparison (HTHH-MOC) project: experiment protocol and model descriptions

The 2022 Hunga volcanic eruption injected a significant amount of water vapor and a moderate amount of sulfur dioxide into the stratosphere, causing observable responses in the climate system. We have developed a model–observation comparison project to investigate the evolution of volcanic water and aerosols and their impacts on atmospheric dynamics, chemistry, and climate, using several state-of-the-art chemistry climate models. The project goals are (1) to evaluate the current chemistry–climate models to quantify their performance in comparison to observations and (2) to understand atmospheric responses in the Earth system after this exceptional event and investigate the potential impacts in the projected future. To achieve these goals, we designed specific experiments for direct comparisons to observations, for example from balloons and the Microwave Limb Sounder satellite instrument. Experiment 1 consists of two sets of free-running ensemble experiments from 2022 to 2031: one with fixed sea-surface temperatures and sea ice and one with coupled ocean. These experiments will help to understand the long-term evolution of water vapor and aerosols; quantify HTHH effects on stratospheric and mesospheric temperatures, dynamics, and transport; understand the impact of dynamic changes on ozone chemistry; quantify the net radiative forcings; and evaluate any surface climate impact. Experiment 2 is a nudged-run experiment from 2022 to 2023 using observed meteorology. To allow participation of more climate models with varying complexities of aerosol simulation, we include two sets of simulations in Experiment 2: Experiment 2a is designed for models with internally generated aerosol, while Experiment 2b is designed for models using prescribed aerosol surface area density. This experiment will help to analyze H 2 O and aerosol evolution, quantify the net radiative forcings, understand the impacts on mid-latitude and polar O 3 chemistry, and allow close comparisons with observations.

Zhu, Yunqian [Univ. of Colorado, Boulder, CO (Unit↗

DOE OSTI2025

Investigation of warm dense matter by combining static and dynamic compression

Shock-compressing material samples that are precompressed with diamond-anvil cells (DACs) enables benchmarking equation of state measurements over a wide range of high-pressure conditions, in particular, warm dense matter relevant to planetary science, astrophysics, and inertial confinement fusion. These targets provide optical access to the shocked sample, so optical velocity interferometry and pyrometry are typical diagnostics. We present a scaling for the coupling of the laser drive to the shock pressure in DACs based on over 150 prior experiments that can be used to design future experiments. For initial static pressures ≤ 5 GPa, using a sapphire window mitigates the effect of photoionization compared to diamond windows and allows the measurement of shock pressures up to 1 TPa with optical diagnostics.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2025

The state of the art for neutron irradiation experiments from the perspective of the High Flux Isotope Reactor (HFIR)

Irradiation experiment campaigns are critical to advancing nuclear energy technologies by providing data on material performance under relevant radiation conditions. Successful irradiation experiments require integrated design efforts that balance technical goals with facility constraints. Here, this paper presents an expert-informed overview of irradiation experiment design at the High Flux Isotope Reactor. It addresses the nuclear materials research and irradiation experiment communities to guide them toward developing technically sound, facility-compatible campaigns. The High Flux Isotope Reactor is a multipurpose reactor supporting isotope production, neutron scattering, and materials testing. Its high, steady-state neutron flux is ideal for irradiation experiments, but successful execution demands coordinated thermal, structural, and reactor physics analyses. The paper outlines the complete development workflow from concept definition and design optimization to safety qualification and post-irradiation examination. Standardized capsule platforms are also discussed in terms of flexibility, specimen capacity, and thermal performance. Common failure modes such as unanticipated geometric variations, can impact temperature-dose profiles and compromise data reliability. Therefore, detailed thermal modeling and accurate as-built characterization are essential for meaningful post-irradiation data interpretation. Key recommendations include early engagement all stakeholders, clearly defined design expectations, and alignment of specimen geometries with post-irradiation examination capabilities. This approach reduces design iterations, enhances data quality, and supports more efficient use of irradiation resources. Strategic and well-planned irradiation testing not only improves individual campaign success but also accelerates the deployment of advanced nuclear technologies. By closing critical data gaps and reducing development risks, the nuclear materials community can more effectively contribute to the future of clean, resilient energy systems.

Experiments↗