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UNIRRADIATED

This is the mechanical testing data archive from a neutron irradiation campaign of nuclear structural alloys fabricated by powder metallurgy with hot isostatic pressing (PM-HIP). Data in this archive include uniaxial tensile testing data, fractography of selected tensile bars, and nanoindentation. The irradiation campaign was designed to facilitate a direct comparison of PM-HIP to conventional casting or forging. Five common nuclear structural alloys were included in the campaign: 316L stainless steel, SA508 pressure vessel steel, Grade 91 ferritic steel, and Ni-base alloys 625 and 690. Irradiations were carried out in the Advanced Test Reactor (ATR) at Idaho National Laboratory (INL) to target doses of 1 and 3 displacements per atom (dpa) at target temperatures of 300ºC and 400ºC through the DOE Office of Nuclear Energy, Nuclear Science User Facilities (NSUF) project 15-8242.

Wharry, Janelle↗

Assessing the Success of Shipping High Burn-Up Sister Rods from ORNL to PNNL - 19456

The U.S. Department of Energy's (DoE's) Used Fuel Disposition Campaign (UFDC), in collaboration with the U.S. Nuclear Regulatory Commission and the commercial nuclear industry have initiated a group of projects to obtain data to support the enhancement of the technical bases for the extended storage and transportation of high-burnup (HBU) (>45 GWd/MTU) spent nuclear fuel (SNF). Under this overall effort, a U.S. Nuclear Regulatory Commission-licensed storage cask was loaded with Thirty-Two (32) HBU SNF assemblies. The cask was modified to allow radial and axial temperature profiles to be measured using thermocouple lances inserted through the lid. Twenty-five (25) rods from similar assemblies of similar claddings, in-reactor placement, and burnup histories (herein called 'sister rods') have been shipped from the North Anna Nuclear Power Plant and are currently being nondestructively tested at Oak Ridge National Laboratory (ORNL). To meet UFD's research objectives, testing on ten (10) of these rods is required to be performed at Pacific Northwest National Laboratory (PNNL). Although the twenty-five rods were originally received at ORNL in the 10-160B, the PNNL facility that would need to receive the ten (10) rods did not have an active history with using the 10-160B. This paper first identifies and summarizes various criteria and evaluations used in helping to select which package will be used for the shipment of the ten (10) sister rods to PNNL (i.e., Bases on why the NACLWT was chosen). With the shipment scheduled to be complete, identified potential concerns, issues, lessons learned, and transportation summary documents were studied (post-shipment). The adequacy of the criteria and evaluations used to choose the NAC-LWT were accessed to determine their adequacy. The results show the criteria were adequate. However, it was noted that DOE Order 460.2A, DOE M 460.2-1A, and DOE G 460.2-1 have differences in the terminology and scope, resulting in clarity issues and differences in regulatory interpretation. Since one-of-a kind spent fuel shipments are uncommon, the topic will be significant interest to people who work in radioactive material packaging and transportation. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

Nevada National Security Site Environmental Report Summary 2016

This document is a summary of the full 2016 Nevada National Security Site Environmental Report (NNSSER) prepared by the U.S. Department of Energy, National Nuclear Security Administration Nevada Field Office (NNSA/ NFO). This summary provides an abbreviated and more readable version of the full NNSSER. NNSA/NFO prepares the NNSSER to provide the public an understanding of the environmental monitoring and compliance activities that are conducted on the Nevada National Security Site (NNSS) to protect the public and the environment from radiation hazards and from potential nonradiological impacts. It is a comprehensive report of environmental activities performed at the NNSS and offsite facilities over the previous calendar year. The NNSS is currently the nation’s unique site for ongoing national security–related missions and high-risk operations. The NNSS is located about 65 miles northwest of Las Vegas. The approximately 1,360-square-mile site is one of the largest restricted access areas in the United States. It is surrounded by federal installations with strictly controlled access as well as by lands that are open to public entry. In 2016, National Security Technologies, LLC (NSTec), was the NNSS Management and Operations Contractor accountable for ensuring work was performed in compliance with environmental regulations. NNSS activities in 2016 continued to be diverse, with the primary goal to ensure that the existing U.S. stockpile of nuclear weapons remains safe and reliable. Other activities included weapons of mass destruction first responder training; the controlled release of hazardous material at the Nonproliferation Test and Evaluation Complex (NPTEC); remediation of legacy contamination sites; characterization of waste destined for the Waste Isolation Pilot Plant in Carlsbad, New Mexico, or the Idaho National Laboratory in Idaho Falls, Idaho; disposal of low-level and mixed low-level radioactive waste; and environmental research. Facilities and centers that support the National Security/Defense mission include the U1a Facility, Big Explosives Experimental Facility (BEEF), Device Assembly Facility (DAF), National Criticality Experiments Research Center (NCERC) located in the DAF, Joint Actinide Shock Physics Experimental Research (JASPER) Facility, Dense Plasma Focus (DPF) Facility located in the Los Alamos Technical Facility (LATF), and the Radiological/ Nuclear Countermeasures Test and Evaluation Complex (RNCTEC). Facilities that support the Environmental Management mission include the Area 5 Radioactive Waste Management Complex (RWMC) and the Area 3 Radioactive Waste Management Site (RWMS), which has been in cold standby since 2006.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

Large Plate Experiment of Chloride-induced Stress Corrosion Cracking in Spent Nuclear Fuel Storage Canisters

This report provides a description of the testing (in progress at the Savannah River National Laboratory) to evaluate the corrosion behavior of a large section of welded plate material harvested from the Sandia National Laboratories’ full-size mockup of a spent nuclear fuel (SNF) dry storage canister. The details of the establishment of this plate test, the interim corrosion results (from visual examination), and the general plan for examination of the plate in CY21 to evaluate crack growth behavior (if any) are provided. This work is intended to inform aging management programs for SNF canisters under conditions of extended dry storage. A “large plate” (approximately 51 x 46 cm with thickness 16 mm and weight about 30 kg) and containing a circumferential weldment from the mockup is the test specimen. The knowledge of the salt, temperature, humidity conditions for chloride-induced stress corrosion cracking (CISCC) including the threshold stress intensity factor, K iscc , were used to setup the large plate test in which a set of part-through-wall and through-wall electrical discharge machined (EDM) defects were positioned in the weld residual stress field of the welded plate material from the mockup canister. A marine salt solution was applied to this plate specimen with an air-brush spray, then dried, and then exposed to a sustained 71-73% RH condition at an ambient room temperature of 22 °C. The salt loading and environmental condition is expected to be aggressive to cause CISCC

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

Analysis of Radiological Release From Fueled Irradiation Experiments During Manual Handling (Slides)

Irradiation experiments are manually handled at the Advanced Test Reactor (ATR) by qualified operators using long handled tools. Standard handling evolutions include insertion and removal from the reactor vessel, transfer to/from a storage location or cask in the ATR canal, and handling/reconfigurations at a canal working tray. Such routine handling has the potential to result in mechanical damage to the experiment boundary which is credited to retain fission products. Since damage can occur due to operator error, this is an anticipated occurrence. This work determines the radiological consequences to receptors inside the ATR facility, as well as public receptors. Given the wide variety of fuel types tested at the ATR, a generic approach to the analysis is taken. The radiological inventory is determined to bound a variety of fuel types (e.g., ceramic and molten fuel matrices) and fission powers on the U-235 enrichment spectrum. The source term analysis considers different release fractions to bound different fuel types and burnups. The postulated handling events occur underwater; thus, retention of the released isotopic content is considered within the canal water column. Retention of radionuclides in the water column is determined using a modified approach of United States (US) Nuclear Regulatory Commission (NRC) Regulatory Guide (RG) 1.183. Radiological dose to the facility receptor is determined using a compartment release model. Dose to the public receptor is determined using atmospheric dispersion models using site specific atmospheric conditions with the use of the Radiological Safety Analysis Computer (RSAC) program version 7.2.

21 - SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLAN↗

Axisymmetric and Focusing Analyzers to Enable Efficient Powder and Residual Stress Neutron Diffractometers

Project Summary: Company: Adelphi Technology, Inc., Redwood City, CA 94063-4121 DOE Phase 1 STTR PI: Dr. Jay Theodore Cremer, Jr. Chief Scientist at Adelphi Technology, Inc. DOE Phase 1 STTR with: Dr. Boris Khaykovich of Massachusetts Institute of Technology (MIT) MIT Nuclear Reactor Laboratory DOE Phase 1 STTR Title: Axisymmetric and Focusing Analyzers to Enable Efficient Powder and Residual Stress Neutron Diffractometers Statement of the problem or situation that is being addressed: Although thermal and cold neutron scattering is widely used, and is critical for success in many areas of materials science and engineering, relatively low neutron fluxes severely limit applications of not only laboratory neutrons generators, but also large national neutron facilities. State-of-the-art thermal and cold neutron sources are large expensive national facilities, which serve diverse community of scientific and industrial users. The constant need to improve the instruments performance, stems from the fact that neutron methods are gaining in popularity, and becoming more and more powerful, while new neutron sources are not being constructed, so as to keep pace with the developments and needs of the scientific community. Small research reactors at universities and National Labs, and laboratory-based neutron generators, are necessary not only for education and training, but also when samples cannot be transported to other facilities. However, the standard neutron techniques, which were developed for high-flux facilities, require much higher efficiencies to be used effectively with the low fluxes of small sources. Thus, the efficient use of neutron sources, such as with our proposed analyzer, is important for the progress and broader use of these neutron techniques. General statement of how this problem is being addressed: We strive to achieve the goal of efficient use of available thermal and cold neutrons, by introducing here, novel analyzers for powder diffraction and stress-strain measurements. These analyzers will enable polychromatic cold and thermal neutron diffractometers, which will have much higher throughput than existing instruments. At large national facilities, such as at Oak Ridge National Laboratory, these analyzers would enable very fast instruments for screening of multiple samples, for measuring kinetic processes, or for measuring residual stress tensors. Commercial Applications and Other Benefits: By combining the novel analyzers with the Adelphi thermal neutron generator, we will open a new market, which includes the testing of samples that cannot be transported, such as nuclear fuels, or the testing of parts during production. Given the reasonable cost and size of our proposed analyzer systems, along with the continuing development of more powerful thermal neutron generators, the proposed analyzers will be suitable for weak neutrons sources, which are installed at small to large university, industrial, and government laboratories. Key Words: Neutron powder diffraction, residual stress measurements, thermal neutron generators, TRIGA reactors, low flux thermal and cold neutron sources, neutron diffraction. Summary for Members of Congress: Thermal and cold neutron beams are a powerful materials science probe, which provide unique information about the structure of matter. The proposed innovations expand the reach of neutron-based investigations to new materials and industries by enabling new instrumentation capabilities, thereby greatly enhancing and expanding the role of small, laboratory-based neutron instrumentation, and improving education and training of neutron users.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

A Kuiper Belt Object Orbiter Enabled By 10 kW Kilopower Electric Propulsion

Recently, the New Horizons spacecraft flew by the Kuiper Belt Object Ultima Thule 13 years after launch. While flybys are a necessary 'first look' at the object in question a more comprehensive evaluation of the object will require an orbiter. Due to these object’s low mass a chemical propulsion system is not a viable option for entering their shallow gravity wells. The Dawn mission showed that solar electric propulsion is significantly better at the task of reaching low mass objects, but at Kuiper belt distances solar power is not a viable choice. A small nuclear reactor based on the recent kilopower ground test could provide 1-10 kWe of power for an electric propulsion system. The NASA Compass Team developed a Nuclear Electric Propulsion Kuiper Belt Object Orbiter to explore what a vehicle would look like to orbit these deep space objects.

Kuiper belt Object↗

Preliminary Design Evaluation of a Natural Circulation Molten Salt Irradiation Loop

Many promising Molten Salt Reactor (MSR) concepts under development rely on relatively untested salt compositions. Some level of irradiation data will likely be necessary for the licensing of these concepts. A feasibility study is currently underway at Idaho National Laboratory to establish the possibility of hosting a compact molten salt irradiation loop inside the Advanced Test Reactor (ATR). A case study for a uranium-fueled chloride-based salt will be provided in this paper. Neutronic tools are used to obtain flux levels inside of a specific position inside the ATR. Thermal hydraulic simulations are then conducted to scope the achievable natural circulating velocities and inform design decisions.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOESC Remote Canister Closure System UT Inspection Couplant Solutions

The DOE Standard Canister (DOESC) Remote Canister Closure System is a remotely operated welding and inspection mechanism designed for the packaging of DOE-managed spent nuclear fuel into canisters. The ultrasonic testing (UT) inspection, included in the system, requires the use of water tanks that are opened to act as a couplant between the canister and the sensors. With the couplant, the UT inspection can guarantee accurate results determining imperfections in the weld.

12 - MGMT OF RADIOACTIVE AND NON-RADIOACTIVE WASTE↗

CFD Analysis of RLUOB Zone 1 HEPA Filter Plenum and Testing Manifolds

The purpose of this computational fluid dynamics (CFD) analysis is to ensure that Camfil Farr’s upstream and downstream injection and sampling manifolds can meet or exceed the requirements outlined in the ASME AG-1 1997 a(2000) Code on Nuclear Air and Gas Treatment for the testing of HEPA and adsorbent filters. This paper will present a numerical simulation of airflow in the Radiological Laboratory Utility Office Building (RLUOB) zone 1 HEPA filter plenum and testing manifolds using the commercial CFD software ANSYS FLUENT 2020R1. The CFD analysis focuses on the investigation of the air flow distribution and air-aerosol mixing uniformity. The evaluation was done for all steps of the modeling process: grid generation, physics setup, simulation, and post-processing. The mass flow rate in each section of the zone 1 injection and sampling manifolds is also reported.

42 ENGINEERING↗

SRNL Training Courses for Packaging, Transportation, and Storage of Radioactive Material - 17597

The U.S. Department of Energy (DOE) Packaging Certification Program (PCP), Office of Packaging and Transportation has sponsored a suite of training courses that have been conducted since the early 1990s. Of these training courses, the Savannah River National Laboratory (SRNL) is currently leading the effort for two courses: (1) Management of SARP Preparation, and (2) Nuclear and Other Radioactive Materials Transport Security and Leak Testing. This paper provides an overview of both courses. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

Bubble Mass Transport Measurement in the Large-Scale Test Loops at Oak Ridge National Laboratory

Molten salts are complex fluids that incorporate multi-phase behavior depending on the chemistry and the physical properties of the entrained components. These components include the carrier salt, the actinide fuel, and fission, activation, and corrosion products, the concentrations of which depends on the burnup history of the salt. Radionuclide transport from the salt into the cover gas / off-gas system depends on volatility as predicted by thermochemistry, but data from the Molten Salt Reactor Experiment (MSRE) conducted in the late 1960s suggest that bubble formation and transport are also important. Anomalously high fractions of noble metals were found in the off-gas system and were attributed to transportation with parent salt aerosols and their association with rising noble gas bubbles. The prediction of such phenomena requires coupled neutronic, thermal hydraulic, and chemical equilibrium calculations, the framework of which is being developed within the Nuclear Energy Advanced Modeling and Simulation (NEAMS) program supported by the US Department of Energy (DOE) Office of Nuclear Energy (NE). However, separate effects tests and models of experiments using tools such as SAM and Thermochimica can guide model developers through important processes. Conversely, model development guides the choice of experiments and systems to provide data that are relevant for validation. This report describes several experiments that tracked gas transport in molten salts, ranging from small-scale systems to large-scale loops. Gas transportation in a molten salt, LiCl-KCl, has been studied using the shadowgraph technique. Sensors such as residual gas analysis, Raman spectroscopy, and laser-induced breakdown spectroscopy have been tested for off-gas measurements. These data were used to interpret how the gases move through the upstream salt / cover gas and the interface between them. Differential pressure measurements were able to detect individual gas bubbles as they popped at the liquid–gas interface. Salt aerosols were collected on a cascade impactor. Their formation was also observed directly via the shadowgraph method, and most of these aerosols were launched ballistically into the cover gas. Fine mists could also be observed. Convection currents through the salt were visualized and can be used to calculate the thermophysical properties of the salt itself. The apparatuses described in this report and in a previous work (McFarlane et al. 2023) have been commissioned and are available for use in making further measurements of salt/surrogate fission product behavior. Novel approaches using neutron imaging are planned for the study of fluoride salts, which cannot be contained in quartz, so shadowgraph visualization is not available. Bubble transport in convective flow and in a slow-moving salt column are planned. The mobile laser-induced breakdown spectroscopy (LIBS) system is available for several applications, including iodine capture in a molten hydroxide scrubber, H2 transport though molten salts to complement Raman analysis, and online tracking of salt aerosol generation, transport, and deposition. This report summarizes the findings from FY24 and the plans for FY25. The work completes milestone M2AT-24OR0702013 of the DOE-NE Advanced Reactor Technology, Molten Salt Reactor Campaign, DOE-NE-5.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

Fabrication and testing of a 4-node micro-pocket fission detector array for the Kansas State University TRIGA Mk. II research nuclear reactor

Advancements in nuclear reactor core modeling and computational capability have encouraged further development of in-core neutron sensors. Micro-Pocket Fission Detectors (MPFDs) have been fabricated and tested previously, but successful testing of these prior detectors was limited to single-node operation with specialized designs. Described in this work is a modular, four-node MPFD array fabricated and tested at Kansas State University (KSU). The four sensor nodes were equally spaced to span the length of the fuel-region of the KSU TRIGA Mk. II research nuclear reactor core. The encapsulated array was filled with argon gas, serving as an ionization medium in the small cavities of the MPFDs. The unified design improved device ruggedness and simplified construction over previous designs. A 0.315-in. (8-mm) penetration in the upper grid plate of the KSU TRIGA Mk. II research nuclear reactor was used to deploy the array between fuel elements in the core. The MPFD array was coupled to an electronic support system which has been developed to support pulse-mode operation. Neutron-induced pulses were observed on all four sensor channels. Stable device operation was confirmed by testing under steady-state reactor conditions. Each of the four sensors in the array responded to changes in reactor power between 10 kWth and full power (750 kWth). Reactor power transients were observed in real-time including positive transients with periods of 5, 15, and 30 s. Manual reactor power oscillations were observed in real-time.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

Nuclear Thermal Propulsion (NTP): A Proven Growth Technology for Human NEO/Mars Exploration Missions

The nuclear thermal rocket (NTR) represents the next "evolutionary step" in high performance rocket propulsion. Unlike conventional chemical rockets that produce their energy through combustion, the NTR derives its energy from fission of Uranium-235 atoms contained within fuel elements that comprise the engine s reactor core. Using an "expander" cycle for turbopump drive power, hydrogen propellant is raised to a high pressure and pumped through coolant channels in the fuel elements where it is superheated then expanded out a supersonic nozzle to generate high thrust. By using hydrogen for both the reactor coolant and propellant, the NTR can achieve specific impulse (Isp) values of ~900 seconds (s) or more - twice that of today s best chemical rockets. From 1955 - 1972, twenty rocket reactors were designed, built and ground tested in the Rover and NERVA (Nuclear Engine for Rocket Vehicle Applications) programs. These programs demonstrated: (1) high temperature carbide-based nuclear fuels; (2) a wide range of thrust levels; (3) sustained engine operation; (4) accumulated lifetime at full power; and (5) restart capability - all the requirements needed for a human Mars mission. Ceramic metal "cermet" fuel was pursued as well, as a backup option. The NTR also has significant "evolution and growth" capability. Configured as a "bimodal" system, it can generate its own electrical power to support spacecraft operational needs. Adding an oxygen "afterburner" nozzle introduces a variable thrust and Isp capability and allows bipropellant operation. In NASA s recent Mars Design Reference Architecture (DRA) 5.0 study, the NTR was selected as the preferred propulsion option because of its proven technology, higher performance, lower launch mass, versatile vehicle design, simple assembly, and growth potential. In contrast to other advanced propulsion options, no large technology scale-ups are required for NTP either. In fact, the smallest engine tested during the Rover program - the 25,000 lbf (25 klbf) "Pewee" engine is sufficient when used in a clustered engine arrangement. The "Copernicus" crewed spacecraft design developed in DRA 5.0 has significant capability and a human exploration strategy is outlined here that uses Copernicus and its key components for precursor near Earth object (NEO) and Mars orbital missions prior to a Mars landing mission. The paper also discusses NASA s current activities and future plans for NTP development that include system-level Technology Demonstrations - specifically ground testing a small, scalable NTR by 2020, with a flight test shortly thereafter.

Borowski, Stanley K.↗

Multiaxial Plastic Deformation of Zircaloy-4 Nuclear Fuel Cladding Tubes

Here, this work is motivated by the desire to devise an internal pressure test that can mimic a displacement-controlled loading scenario and demonstrate how to apply the multiaxial stress and strain data from the test to develop an elastic/plastic constitutive model for a thin-walled tubular component. This is achieved by conducting simultaneous measurements of tangential and axial strain during the pressure test and integrating these strain measures into a feedback loop with the pressure controller. It is shown how data from such a test can be used to develop a large mechanical property data set relevant to biaxial loading conditions. The data obtained have high confidence evidenced by their low variability and alignment with other literature studies. Additionally, data from these internal pressure tests combined with full-tube axial tensile tests allow for the derivation of the Hill anisotropic yield function. The developed Hill yield function is validated by comparing the plastic strain ratios from the full-tube tension tests and by comparing the predicted yield stress in the tangential direction with measured values from ring tension tests in a previous study.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Condition assessment of cable insulation materials in advanced reactor environments

While existing cable insulation materials are sufficient for use in the current reactor fleet, environmental conditions inside some advanced reactors, such as small modular reactors, will be substantially harsher. The work herein was conducted to assess the performance and overall survivability of several high-temperature, radiation resistant insulation polymers in a simulated small modular reactor environment. The materials evaluated under this research include polyether ether ketone, polyimide, and silicone rubber. These polymers were subjected to 1000 h of environmental stress exposure under two different conditions: 1) high temperature (i.e., 250 °C) in atmospheric pressure and 2) high temperature in a low-pressure vacuum (i.e., less than 2 psia). During the environmental exposure process, each insulation was periodically tested using several materials characterization techniques including Fourier transform infrared spectroscopy, oxidation induction time, and oxidation induction temperature. The objective of this testing was to assess and monitor changes that occurred in the thermal and chemical properties of the materials during the environmental exposures. The overall survivability of each insulation was assessed based on these property changes. The results of this research revealed that the polyimide and polyether ether ketone insulations had significantly better thermal and chemical stability than the silicone rubber during both the high-temperature atmospheric and vacuum exposures. Both polyimide and polyether ether ketone experienced minimal reductions in their chemical and thermal properties over the course of 1000 h in the simulated environments. Finally, based on this research, polyimide and polyether ether ketone show promise as potential base materials for small modular reactor cable insulation.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗