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NASA NTRS2006

The Columbia Debris Loan Program; Examples of Microscopic Analysis

Following the tragic loss of the Space Shuttle Columbia NASA formed The Columbia Recovery Office (CRO). The CRO was initially formed at the Johnson Space Center after the conclusion of recovery operations on May 1,2003 and then transferred .to the Kennedy Space Center on October 6,2003 and renamed The Columbia Recovery Office and Preservation. An integral part of the preservation project was the development of a process to loan Columbia debris to qualified researchers and technical educators. The purposes of this program include aiding in the advancement of advanced spacecraft design and flight safety development, the advancement of the study of hypersonic re-entry to enhance ground safety, to train and instruct accident investigators and to establish an enduring legacy for Space Shuttle Columbia and her crew. Along with a summary of the debris loan process examples of microscopic analysis of Columbia debris items will be presented. The first example will be from the reconstruction following the STS- 107 accident and how the Materials and Pro~es~steesa m used microscopic analysis to confirm the accident scenario. Additionally, three examples of microstructural results from the debris loan process from NASA internal, academia and private industry will be presented.

Russell, Rick↗

DOE OSTI2024

Comparison of Results between the Legacy and Refined RELAP5-3D Models of the High Temperature Test Facility in Exercises 1 and 2 of the HTTF Benchmark

Work conducted in FY23 identified that RELAP5-3D was capable of reproducing trends in HTTF data during experiment PG-27 but was incapable of reproducing measured values. The primary cause of this discrepancy between RELAP5-3D results and experimental data was hypothesized to be a distortion in power density that was introduced by the radial nodalization of the model. We further hypothesized that a new model would provide better results when compared to the experiments PG-27 and PG-29. Work this FY developed a new model that is better capable of capturing local heat generation rates and contains a representation of each 1/6 azimuthal sector of the core. We used this model to develop a new set of solutions to Exercises 1 and 2 of Problems 2 and 3 in the benchmark. In this report, we present the first comprehensive comparison of the results between the two models. We see that in Exercise 1A, which is common between problems 2 and 3, the results are similar, though the results from the new model show greater detail than those from the legacy model. In Problem 2 Exercise 1B and Problem 3 Exercise 1B, we see that heat removal is slower in the new model than the legacy model. Problem 3 Exercise 1C shows temperatures that are lower in most places in the new model than the legacy model, but the area with active heat generation has higher block temperatures in the new model than the legacy model. Problem 3 Exercise 1D further shows that long-term heat removal is lower in the new model. Problem 2 Exercise 1C demonstrated that the new model observes higher temperatures in the core regions than the legacy model, justifying the need to preserve the power density in HTTF. The validation of PG-27 and PG-29 also demonstrated the improved temperature agreement in the core regions, particularly with a calibrated model that implements an effective thermal conductivity for the core material. Overall, PG-27 models show reasonable to excellent agreement for steady-state temperatures and minimal to reasonable agreement for transients. PG-29 models showed minimal to insufficient agreement with the data.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2022

Evaluation of the GaAs displacement damage metric using updated nuclear data

The emerging use of the physics-based athermal recombination-corrected displacement per atom (arc-dpa) model for the displacement damage efficiency has motivated a re-evaluation of the historical empirically-derived GaAs damage response function with the purpose of highlighting needs for future analytical and experimental work. The 1-MeV neutron damage equivalence methodology used in the ASTM E-722 standard for GaAs has been re-evaluated using updated nuclear data. This yielded a higher fidelity representation of the GaAs displacement kerma and, through the use of the refined PKA recoil energy-dependent damage efficiency model, an updated 1-MeV(GaAs) displacement damage function. This re-evaluation included use of the Norgett-Robinson-Torrens (NRT) model for an updated threshold treatment, rather than the sharp-threshold Kinchin-Pease model used in the current ASTM standard. The underlying nuclear data evaluations have been updated to use the ENDF/VIII.0 {sup 75}As and TENDL-2019 {sup 71}Ga/{sup 69}Ga evaluations. The displacement kerma and 1-MeV-equivalent damage responses were calculated using a modified NJOY-2016 code which allowed for refinements in some of the damage models. This paper shows that an updated displacement damage function, based upon the latest nuclear data, is consistent with the experimental data used to develop the current ASTM E-722 GaAs standard. Using a double ratio approach to compare the available experimental data with the calculated response, the average legacy double ratio was found to be 0.97 ± 0.05 and the average updated double ratio was found to be 0.94 ± 0.05. (authors)

36 MATERIALS SCIENCE↗

DOE OSTI2024

The Impact of the Halden Reactor Project on the Development of the Bison Fuel Performance Code

The Bison fuel performance code has been under development at Idaho National Laboratory by various programs within the U.S. Department of Energy since 2009. As part of any fuel performance code development, validation is necessary. To this end, several Halden experiments have been used. Early on, the focus was on validating the thermal mechanical behaviour, including pellet cladding mechanical interaction and fission gas release models implemented in Bison. Support for design-basis accident capabilities began in approximately 2014. Also in 2014, the development of models for accident tolerant fuel (ATF) concepts also began. This includes dopedUO2 fuel for which Halden has some experiments with temperature and fission gas release measurements. The Bison team has been fortunate to have two senior developers be secondees to Halden for a year: the late Dr. Giovanni Pastore from May 2015 to April 2016 and the now retired Dr. Richard Williamson in 2018. The paper will provide examples of Bison validation using Halden data for standard UO2 fuel under normal operation and loss-of-coolant accident condition, and ATF concepts. A tribute to the legacy that both the late Giovanni and retired Richard left on the Bison code is provided.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2024

Machine-Learned Force Field Modeling of Metal Organic Frameworks for CO2 Direct Air Capture

To cope with legacy greenhouse gas emissions and to achieve net-zero emissions by 2050, the U.S. Department of Energy (DOE) is funding efforts to develop direct air capture (DAC), a method for removing CO2 directly from air. Metal organic frameworks (MOFs) have been studied as DAC sorbent materials because of their structural and chemical diversity. Thermodynamic calculations using classical force fields are often used to screen MOFs for their performance in separations such as CO2 capture. Machine-learned force fields (MLFFs) can use machine learning to form quantitative relationships between a material’s chemical structure and the forces and energies predicted by more accurate quantum mechanical calculations, such as dispersion-corrected density functional theory (DFT). These descriptions of forces and energies can be used to improve the accuracy of adsorption calculations. In this work, MLFF models were developed for MOFs to achieve DFT-level accuracy for the forces and energies associated with MOF flexibility and CO2 adsorption. These methods were parametrized based on thousands of DFT calculations of CO2 in flexible MOFs and used to predict MOF structural properties as well as CO2 adsorption properties.

Findley, John↗

NASA NTRS2012

Hexavalent Chrome Free Coatings for Electronics Applications: Joint Test Report

Regardless of the corrosivity of the environment, all metals require periodic maintenance activity to guard against the insidious effects of corrosion and thus ensure that alloys meet or exceed design or performance life. The standard practice for protecting metallic substrates is the application of a coating system. Applied coating systems work via a variety of methods (barrier, galvanic, and/or inhibitor) and adhere to the substrate through a combination of chemical and physical bonds. For years hexavalent chromium has been a widely used element within applied coating systems because of its self healing and corrosion resistant properties. Occupational Safety and Health Administration (OSHA) studies have concluded that hexavalent chromium (hex chrome) is carcinogenic and poses significant risk to human health. On May 5, 2011 amendments to the Defense Federal Acquisition Regulation Supplement (DFARS) were issued in the Federal Register. Subpart 223.73 prohibits contracts from requiring hexavalent chromium in deliverables unless certain exceptions apply. These exceptions include authorization from a general or flag officer and members of the Senior Executive Service from a Program Executive Office, and unmodified legacy systems. Otherwise, Subpart 252.223-7008 provides the contract clause prohibiting contractors from using or delivering hexavalent chromium in a concentration greater than 0.1 percent by weight for all new contracts and to be included down to subcontractors for supplies, maintenance and repair services, and construction materials. National Aeronautics and Space Administration (NASA), Department of Defense (DoD), and industry stakeholders continue to search for alternatives to hex chrome in coatings applications that meet their performance requirements in corrosion protection, cost, operability, and health and safety, while typically specifying that performance must be equal to or greater than existing systems.

Kessel, Kurt↗

DOE OSTI2024

Machine-Learned Force Field Modeling of Metal Organic Frameworks for CO2 Direct Air Capture

To cope with legacy greenhouse gas emissions and to achieve net-zero emissions by 2050, the U.S. Department of Energy (DOE) is funding efforts to develop direct air capture (DAC), a method for removing CO2 directly from air. Metal organic frameworks (MOFs) have been well studied as DAC sorbent materials due to their tunable structural and compositional properties. Thermodynamic simulations using force fields are often used to provide predictions of a material’s performance in many separations. However, these force fields often make assumptions about bonds and the physics of the adsorption process. A new class of force fields called machine-learned force fields (MLFFs) use machine learning to form quantitative relationships between a material’s chemical structure and the forces and energies predicted by more accurate quantum mechanical calculations, such as dispersion-corrected density functional theory (DFT). In this work, models were developed to achieve DFT-level accuracy for the forces and energies associated with MOF flexibility and CO2 adsorption using MLFFs. These methods were parametrized based on thousands of DFT calculations of CO2 in flexible MOFs and used to predict MOF structural properties as well as CO2 adsorption in several MOFs.

Findley, John↗

DOE OSTI2021

Concentrating Rare Earth Elements in Coal mine drainage Using Coal Combustion Products through Abandoned Mine Land Reclamation

Rare earth elements (REEs) (including scandium, yttrium and a group of 15 lanthanides) are often considered to be critical components in the productions of renewable energy hardware, electric vehicles, health care and military equipment, and consumer electronic products. The demand of REEs has been projected to be growing at an annual rate of 5-9% in the next 25 years. In 2011, the global demand of total rare earth oxides (REOs) was estimated to be approximately 105,000 tons, which is expected to grow to 210,000 tons by 2025. China overwhelmingly dominates the current worldwide rare earth productions but has strategically restricted its exports, causing significant instability for the global market. In response to the increasing demand for REEs and the supply dominance of China, identifying alternative sources of REEs has become a critical issue for the United States and other countries. Coal, coal ash, and coal mine drainage (CMD) are considered to be the alternative sources of REEs. In the U.S., high REE concentrations have been reported to be closely associated with coal deposits, including the Appalachian Basins. When surface and/or groundwater come in contact with geologic strata containing sulfide minerals exposed by coal mining, the accelerated oxidation of sulfide minerals in the presence of ferric iron and/or oxygen can produce sulfuric acid. The process promotes the weathering of REE-bearing rocks and minerals in the host geologic strata. Compared to average river water and seawater, the concentrations of REEs can be orders of magnitude higher in CMD. In this study, we demonstrated a trap-extract-precipitate (TEP) process that can effectively recover REEs from CMD. The three-stage TEP process uses alkaline industrial by-products to capture REEs from CMD and then applies an extraction/precipitation procedure to produce a feedstock that can be economically processed to produce marketable rare earth oxides. The alkaline industrial by-products tested in this study include the residual from a water softening process (DRWP sludge) and two types of stabilized flue gas desulfurization materials (sFGDs). sFGD material is a mixture of lime (CaO) and two coal combustion by-products, calcium sulfite FGD by-product and fly ash. The objectives of this study are to (1) validate the effectiveness and feasibility; (2) determine mechanisms controlling the rare earth recovery, (3) quantify the associated economic and environmental benefits, and (4) evaluate the full-scale application. To achieve these objectives, tasks to be carried out in this proposed project are organized into three phases. In the first phase, the research team collaborated with Ohio Department of Natural Resources, American Electric Power, The Wilds (a nonprofit wildlife conservation organization), and a private landowner to carry out field investigations aimed to screen and evaluate the seasonal changes of rare earths in the CMD discharges that have high recovery potentials. Next, the recovery of REEs from CMD was tested using a series of lab-scale column and batch tests under, respectively, percolation and completely mixed conditions. Results obtained from these lab-scale studies show that all three tested solids are very effective in retaining REEs. Over 98% of the CMD REEs that contacted the solids were captured before the solids exhausted their neutralization capacities. We also determined an extraction process using a non-acid, organic ligand extraction solution that can effectively remobilize the retained REEs from the spent solids (over 90%). The REE concentrate (>7.5 wt. % of total REEs) is then formed in an aeration process. The TEP process uses environmentally benign industrial by-products and a naturally-occurring organic ligand to mitigate CMD and recover REEs. Techno-economic analysis (TEA) and life-cycle assessment (LCA) was carried out in the third phase. The engineering-economic costs and net energy, net CO2 emissions, and water and other requirements were investigated to understand the economic and environmental implications of this process. This work uses mass and energy balances from laboratory-scale experiments to estimate the economic costs and environmental impacts. The results suggest that passive treatment systems that use DRWP sludge are preferred over those that use sFGD material, because of lower economic costs ($89,300/yr with a unit cost of $86/gT-REE vs. $89,800/yr, or $278/gT-REE) and improved environmental performance across all indicators from two different impact assessment methods. These differences are largely attributable to the larger capacity of DRWP sludge in the passive treatment application. We envision this TEP process can be integrated with abandoned mine land (AML) reclamation to create an approach that can add economic incentives for AML reclamation, remediate CMD discharge, and eliminate public safety hazards and threats to local environment and ecological systems posed by AMLs. It can restore lands and communities that are adversely impacted by legacy mining.

01 COAL, LIGNITE, AND PEAT↗

NASA NTRSDate not supplied

Simulation of etch pit formation through active sites in carbon fiber micro-structures

Erosion of carbon due to oxidation does not occur uniformly but through localized etch pit formation as a result of active surface sites. In this work we demonstrate a newly developed capability to capture pitting of carbon fiber microstructures such as FiberForm, which is commonly used as the base material for NASA’s spacecraft ablative thermal protection systems (TPS). The simulations are performed at the meso-scale in order to capture the pit formation and growth using direct simulation Monte Carlo (DSMC), specifically using the Stochastic PArallel Rarefied-gas Time-accurate Analyzer (SPARTA) code. Legacy and latest models both assume uniform reactivity of carbon surface sites with oxygen even at the meso-scale level. However, in reality the carbon surface has locally different reaction rates due to the presence of defects at the atomic scale. The defective nature of these sites enhances their reactivity with atmospheric gases compared to the non-defective sites (2-3 orders of magnitude) and are termed as “active sites”. Thus, these sites tend to be the first to react and eventually get removed through the formation of gasses such as CO, CO2, and CN. Their removal results in all the neighboring atoms becoming defective, thus leading to chain reaction of localized carbon removal and formation of etch pits. Capturing the formation of pits during the ablation simulation of carbon micro-structures is critical to predicting their structural failure. Recently a detailed surface chemistry framework was developed in SPARTA, capable of incorporating various reaction mechanisms such as adsorption, desorption, Eley-Rideal (ER) and Langmuir-Hinshelwood (LH) mechanisms. We have implemented the capability of a single surface having multiple site sets with different reactivities within this framework. We have used this feature to model the presence of active sites on carbon surfaces, whose reactivity is orders of magnitude higher than that of the passive sites due to the presence of defects. The active site fraction is a property of surface elements within SPARTA and is directly proportional to the local reactivity of each surface element. By introducing an initial distribution of the active site fraction across the carbon surface and propagating it in a manner that mimics the evolution of real reacting carbon surfaces, we can capture the formation and growth of etch pits as a result of surface consumption reactions such as oxidation.

DSMC↗

NASA NTRSDate not supplied

Simulation of Etch Pit Formation in DSMC Through Active Sites in Carbon Fiber Micro-Structures

Erosion of carbon due to oxidation does not occur uniformly but through localized etch pit formation because of active surface sites. In this work we demonstrate a newly developed capability to capture pitting of carbon fiber microstructures such as FiberForm, which is commonly used as the base material for NASA’s spacecraft ablative thermal protection systems (TPS). The simulations are performed at the meso-scale in order to capture the pit formation and growth using direct simulation Monte Carlo (DSMC), specifically using the Stochastic PArallel Rarefied-gas Time-accurate Analyzer (SPARTA) code. Legacy and latest models both assume uniform reactivity of carbon surface sites with oxygen even at the meso-scale level. However, in reality the carbon surface has locally different reaction rates due to the presence of defects at the atomic scale. The defective nature of these sites enhances their reactivity with atmospheric gases compared to the non-defective sites (2-3 orders of magnitude) and are termed as “active sites”. Thus, these sites tend to be the first to react and eventually get removed through the formation of gases such as CO, CO2, and CN. Their removal results in all the neighboring atoms becoming defective, thus leading to chain reaction of localized carbon removal and formation of etch pits. Capturing the formation of pits during the ablation simulation of carbon micro-structures is critical to predicting their structural failure. Recently a detailed surface chemistry framework was developed in SPARTA, capable of incorporating various detailed surface reaction mechanisms. We have implemented the capability of a single surface having multiple site sets with different reactivities within this framework. We have used this feature to model the presence of active sites on carbon surfaces, whose reactivity is orders of magnitude higher than that of the passive sites due to the presence of defects. The active site fraction is a property of surface elements within SPARTA and is directly proportional to the local reactivity of each surface element. By introducing an initial distribution of the active site fraction across the carbon surface and propagating it in a manner that mimics the evolution of real reacting carbon surfaces, we can capture the formation and growth of etch pits as a result of surface consumption reactions such as oxidation.

DSMC↗

NASA NTRSDate not supplied

DSMC Simulation of Etch Pit Formation Through Active Sites in Carbon Fiber Micro-Structures

DSMC↗

DOE OSTI2020

The TRANSCEND University Consortium: An Overview - 20106

The UK government is committed to nuclear energy having an important role in delivering a secure, low-carbon and affordable energy future. Projections indicate that between now and 2035, ∼14 GW of new nuclear generating capacity may be built. Successful delivery of this strategy recognises the need for research and development, skills development and international collaboration as key enablers. One key area is the decommissioning and clean-up of all civil nuclear licensed sites and the implementation of geological disposal of highly active wastes, with a central component being a joined-up approach to nuclear R and D across government, industry and academia which benefits the UK economy and ensures the security of supply. Essential to public acceptance of this strategy remains a demonstrable ability to safely manage and dispose of waste, with acceptance directly linked to having scientifically robust routes for its safe clean-up and disposal. There therefore remains an ongoing need for further research in the areas of decommissioning, immobilisation and management of nuclear waste, and there is significant government and stakeholder support for such research. Given the needs of both new nuclear power generation and legacy wastes, there is a requirement to develop innovative approaches to waste management and decommissioning. Following on from earlier, highly successful projects supported by UK Research and Innovation's Energy Programme, the work of the TRANSCEND (Transformative Science and Engineering for Nuclear Decommissioning) consortium is part of the response to these needs, providing support to a strong and internationally leading group of researchers in this key technology area. The consortium is a collaboration between 11 universities, supported by 8 key industry partners, with a total funding of UK Pounds 9.5 M from the UK Engineering and Physical Research Council, the universities and key project partners. The research being carried out is multidisciplinary and covers both fundamental and applied topics, with 40 research projects clustered in four technical themes: integrated waste management; site decommissioning and remediation; spent fuels; and nuclear materials. Key aims of the consortium are to extend and further develop a relevant academic skill base in the UK associated with the needs of nuclear waste management and decommissioning, to train the next generation of UK researchers, equipping them with skills and experiences relevant to nuclear waste management and decommissioning issues, and to carry out cutting-edge research that has the potential to provide new and innovative pathways to better management of both legacy and future nuclear wastes. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2025

Characterization of Coal Refuse Sites in West Virginia: Stream Loss, Volume Estimation, and Land Cover Analysis for Restoration Feasibility

Coal refuse disposal across Appalachia has resulted in widespread environmental degradation, including stream burial, landscape destabilization, and long-term hydrologic impacts. This study provides a GIS-based spatial characterization of 623 coal refuse sites in West Virginia, evaluating their potential for ecological and economic restoration. Stream loss was quantified through digitization of historic topographic maps, revealing over 194,500 meters of historically present streams lost, with 105,000 meters directly buried beneath refuse piles. Volume estimation using empirical Bayesian kriging and modern LiDAR surfaces indicated approximately 1.96 billion cubic meters of deposited refuse. Land cover analysis based on NAIP-derived classification showed that 48% of the total site area was forested, while 15% remained barren. These results highlight not only the environmental footprint of legacy refuse deposits but also their potential for restoration through stream daylighting and beneficial reuse. Emerging opportunities, including rare earth element recovery and mitigation banking, may offer economic incentives to facilitate reclamation. This work establishes a spatial framework to prioritize refuse sites for restoration, balancing ecological uplift with feasible material management strategies.

58 GEOSCIENCES↗

NASA NTRS2016

Bringing the Future Within Reach: Celebrating 75 Years of the NASA John H. Glenn Research Center

The National Aeronautics and Space Administration (NASA) Glenn Research Center in Cleveland, Ohio, has been making the future for 75 years. The center's work with aircraft engines, high-energy fuels, communications technology, electric propulsion, energy conversion and storage, and materials and structures has been, and continues to be, crucial to both the Agency and the region. Glenn has partnered with industry, universities, and other agencies to continually advance technologies that are propelling the nation's aerospace community into the future. Nonetheless these continued accomplishments would not be possible without the legacy of our first three decades of research, which led to over one hundred R&D 100 Awards, three Robert J. Collier Trophies, and an Emmy. Glenn, which is located in Cleveland, Ohio, is 1 of 10 NASA field centers, and 1 of only 3 that stem from an earlier research organization-the National Advisory Committee for Aeronautics (NACA). Glenn began operation in 1942 as the NACA Aircraft Engine Research Laboratory (AERL). In 1947 the NACA renamed the lab the Flight Propulsion Laboratory to reflect the expansion of the research. In September 1948, following the death of the NACA's Director of Aeronautics, George Lewis, the NACA rededicated the lab as the Lewis Flight Propulsion Laboratory. On 1 October 1958, the lab was incorporated into the new NASA space agency and was renamed the NASA Lewis Research Center. Following John Glenn's return to space on the space shuttle, on 1 March 1999 the center name was changed once again, becoming the NASA John H. Glenn Research Center.

Arrighi, Robert S.↗

DOE OSTI2020

HTGR Simulation Methods & International Collaborations

ART-GCR “Methods” activity is split between Experimental Validation data from the ANL NSTF and OSU HTTF (next three presentations). HTGR core simulation (this presentation). International collaboration within OECD Generation-IV (Gen-IV) and USA/Japan bi-lateral agreements (this presentation) HTGR Simulation Methods No new NE-52 funding for HTGR Methods support in FY20; ~$200K FY19 carry-over funds only. Consists of international code-to-code benchmarks (IAEA CRP on HTGR UAM and OECD/NEA MHTGR-350) and refinement of a few-group Pebble Bed Reactor (PBR) cross section (XS) generation methodology. Funding will be requested in FY21 to produce the final reports for the two benchmarks and continue the development of the PBR XS generation methodology. Additional (non-ART) HTGR-related support work at INL NEAMS: HTR-Application work package at INL Create a benchmark for the pebble shuffling and depletion algorithms being developed for NEAMS Griffin code. iFOA award with X-Energy: Develop independent Monte Carlo model of Xe-100 design. Independent design confirmatory analysis of Xe-100 design using NEAMS tools Griffin and Pronghorn. Support X-Energy design team to use their own legacy design tools (VSOP99 and MGT). Support NEAMS Griffin and Pronghorn development team for the iFOA needs (received $50K additional funding for required development).

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2021

Molecular and Microstructural Bases for Understanding Microplastic Origin, Transport, and Fate

The formation of micro and nanoplastics from parent plastics is one of the most challenging ecological threats since plastic pollution reaches even the most desolate places on earth and is expected to double by 2030. The goal of this project is to understand physico-chemical properties on microplastics formation, transport, and fate by analyzing the microplastics found in environmentally collected samples at SRS, supported by lab-based experiments. An initial assessment found and identified microplastics and micronizing plastics in Fourmile Branch and the Savannah River. Fourmile Branch also carried trace-level radioactive contaminants associated with the Site’s legacy missions, which may incorporate into entrained microplastics.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2021

Post-irradiation examination of legacy high burnup fuel to support safety testing

Safety/transient testing to evaluate performance under off-normal conditions is an essential pillar for both the development of Accident Tolerant Fuels (ATF) and the optimization of fuel operation economics beyond current discharge burnups. Among other factors, the successful interpretation of the transient testing results relies upon the knowledge of the initial conditions of the test, including the characteristics of the fuel system under scrutiny. When testing pre-irradiated material, the assumptions that the fuel and the cladding still have the same properties as in the pre-irradiation stage is obviously wrong and could affect the results of the test. This is particularly true the more burnup accumulates in the fuel rod and irradiation progresses. The knowledge of the initial microstructure of both fuel and cladding allows a clearer interpretation of the subsequent transient testing results, provides validation of the physical phenomena underlying the model predictions and eliminates the uncertainties related to the limited knowledge of the sample status before the test. One example is the phenomenon of fine fragmentation that occurs in Light Water reactor (LWR) fuel. During a Loss of Coolant Accident (LOCA) or Reactivity Initiated Transient (RIA) the fuel can severely fragment. During LOCA, high burnup fuel tend to finely fragment, which has raised safety concerns due to the increased likelihood of dispersal of such small particles once the cladding has burst and due to the increased fission gas release. Therefore, efforts have been devoted to the assessment of a pulverization threshold that could determine the conditions under which fine fragmentation is predominant. However, the lack of information regarding the initial conditions of the fuel, and the connections between those conditions and the pre-transient irradiation history, have hindered the development of a fully mechanistic fragmentation and pulverization criterion. The empirical relationships rely on conservative estimations, due to the lack of information on critical material properties and characteristics. More generally, experimental evidence of the irradiation-induced modifications at microstructural scale are necessary to determine the behavior of the material at the macroscopic scale, with the latter being the one of technological interest. Significant progress has been made in the last two decades in the developments of analytical materials science techniques that can be applied to highly radioactive materials, such as high burnup fuels. The availability of new techniques and the improvement of existing ones has enabled investigations previously not possible that can deepen the understanding of the fuel characteristics and properties at high burnup. The better knowledge of material behavior and irradiation-induced phenomena could help the prediction of its performance. In this context, the scope of the present work is to apply a wide portfolio of advanced characterization techniques to determine properties that are relevant for safety and performance. The results are interpreted in the context of engineering scale post-irradiation examinations and available information on the irradiation conditions.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

NASA NTRSDate not supplied

Parameter, Post-Processing Sensitivities, and Qualification Approach of Laser Powder Bed Fusion Hydrogen Resistant Alloy NASA HR-1

Metal additive manufacturing (AM) processes are being used to enable economical manufacturing of legacy alloys as well as advancing new alloys. Laser powder bed fusion (L-PBF) is a metal AM process that has high maturity and being used to produce a variety of parts for space applications including complex propulsion components. The National Aeronautics and Space Administration (NASA) has identified the need to develop and advance new materials in unique space applications such as high-pressure hydrogen environments. NASA HR-1 is a high strength Fe-Ni based superalloy designed to resist high pressure hydrogen environment embrittlement (HEE), oxidation, and corrosion that has been successfully adapted to laser powder directed energy deposition (LP-DED). Insights gained from the NASA HR-1 development for LP-DED have guided the development process for L-PBF. However, adapting NASA HR-1 to L-PBF posed new challenges due to the distinct differences between the additive manufacturing processes. During parameter development, sensitivities were observed in post-processing that necessitated additional optimization of heat treatments. Additionally, the variations in thickness and how it influenced the microstructural response during heat treatment was characterized. Understanding these sensitivities is important to qualification of the material in a L-PBF machine. This ensures that the microstructures and properties of the material maintain consistency in production. This presentation will cover parameter development along with post-processing challenges and solutions will be discussed in addition to key material properties as it pertains to application performance and qualification per NASA-STD-6030. Improvements made by developing a derivative alloy, NASA HR-2, will be highlighted through preliminary small scale parameter development, material characterization, and initial property testing.

NASA HR-1↗