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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 19 records
All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

Solvent-Free Melt-Processed Cathode Mitigates Li Anode Instability in Polymer-Based Solid-State Batteries

Solvent-free manufacturing of battery components is a promising alternative to traditional slurry processing for reducing the cost and environmental impact. In this work, we used twin-screw melt extrusion to fabricate a polymer-based high voltage composite cathode. The melt-processed cathode is dense (near zero porosity) and thick (65 μm) and has high active material loading (80 wt %). The active particles are distributed uniformly throughout the melt-processed cathode, unlike the traditional slurry-cast cathode, which exhibits inhomogeneous particle distribution. In the melt-processed cathode, polymer and carbon form separate phases, whereas in the slurry-cast cathode they blend into a single phase. Due to these structural differences, the melt-processed cathode shows smooth charge–discharge profiles, while the slurry-cast cathode shows noisy charging and soft-shorting behavior. In conclusion, this work highlights that twin-screw extrusion as a scalable, solvent-free manufacturing method is advantageous in producing uniform cathodes, which mitigates anode instability.

25 ENERGY STORAGE↗
DOE OSTI2026

Bubble explosion induced melt pool instabilities in electron beam melting of aluminum alloy

Electron beam melting (EBM) is an additive manufacturing technology that can process materials and manufacture components otherwise impossible or uneconomical. However, defects, including porosity and surface irregularities, are widely reported in EBM-built components, and their formation mechanisms are not fully understood. Here, using in-situ high-speed synchrotron X-ray imaging, we reveal that bubble explosions in Al6061 during EBM induce melt pool instabilities contributing to defect formation. The melt pool and keyhole evolve through three stages: (1) initial formation of a melt pool, (2) subsurface bubble formation and explosion, and (3) periodic keyhole oscillation. During scanning, periodic bubble explosions can eject molten liquid as spatters and disturb the vapor depression and melt pool, contributing to surface humping, that may trigger lack-of-fusion defects in subsequent layers. The physical insights we report could provide guidance for EBM machine development, process innovation, alloy design and model development.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Ability to Simulate Absorption and Melt Pool Dynamics for Laser Melting of Bare Aluminum Plate: Results and Insights from the 2022 Asynchronous AM-Bench Challenge

The 2022 Asynchronous AM-Bench challenge was designed to test the ability of simulations to accurately predict laser power absorption as well as various melt pool behaviors (width, depth, and solidification) during laser melting of solid metal during stationary and scanned laser illumination. In this challenge, participants were asked to predict a series of experimental outcomes. Experimental data were obtained from a series of experiments performed at the Advanced Photon Source at Argonne National Laboratories in 2019. These experiments combined integrating sphere radiometry with high-speed X-ray imaging, allowing for the simultaneous recording of absolute laser power absorption and two-dimensional, projected images of the melt pool. All challenge problems were based on experiments using bare aluminum solid metal. Participants were provided with pertinent experimental information like laser power, scan speed, laser spot size, and material composition. Additionally, participants were given absorptance and X-ray imaging data from stationary and scanned laser experiments on solid Ti–6Al–4V that could be used for testing their models before attempting challenge problems. In total, this challenge received 56 submissions from eight different research groups for eight individual challenge problems. The data for this challenge, and associated information, are available for download from the NIST Public Data Repository. This paper summarizes the results from the 2022 Asynchronous AM-Bench challenge as well as discusses the lessons learned to help inform future challenges.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Residual stresses in Cu matrix composite surface deposits after laser melt injection

Abstract Tungsten carbide particles reinforced metal matrix composite (MMC) coatings can significantly improve surface wear resistance owing to their increased surface hardness. However, the presence of macro‐ and micro‐residual stresses in MMC coatings can have detrimental effects, such as reducing service life. In this study, neutron diffraction was used to determine the residual stresses in spherical fused tungsten carbide (sFTC) reinforced Cu matrix composite surface deposits after laser melt injection. We also developed a thermo‐mechanical coupled finite element model to predict residual stresses. Our findings reveal that sFTC/Cu composite deposits produced with a preheating temperature of 400°C have low residual stresses, with a maximum tensile residual stress of 98 MPa in the Cu matrix on the top surface. In contrast, the sFTC/bronze (CuAl10Ni5Fe4) composite deposit exhibits very high residual stresses, with a maximum tensile residual stress in the Cu matrix on the top surface reaching 651 MPa. These results provide a better understanding of the magnitudes and distributions of residual stresses in sFTC‐reinforced Cu matrix composite surface deposits manufactured via laser melt injection.

Zhang, Xingxing↗
DOE OSTI2024

Melting and solidification dynamics during laser melting of reaction-based metal matrix composites uncovered by in-situ synchrotron X-ray diffraction

Laser additive manufacturing (AM) of reaction-based metal matrix composites (MMCs) involves highly complex and non-equilibrium material transformation behavior, including melting, dissolution, precipitation, and solidification. Yet, the dynamics and interplay of these phase transformation processes remain poorly understood, posing substantial challenges in identifying the microstructure formation mechanism, and predicting and controlling the microstructure in the printed parts. Here, in this study, we performed the in-situ X-ray diffraction experiment to characterize the phase evolution dynamics of the 316L + 10 vol.%TiC system during laser melting, which provides direct and quantitative insights of the complex phase reaction and evolution dynamics under rapid heating and cooling conditions relevant to additive manufacturing of reaction-based MMCs. Further in-depth thermodynamic and kinetic calculations revealed that most of the phase evolution behavior observed in the in-situ X-ray diffraction experiment cannot be solely explained by widely used equilibrium thermodynamic models, and diffusion-controlled nonequilibrium dissolution and precipitation kinetics must be considered to elucidate the complex phase evolution behavior, including incomplete TiC dissolution, and three-step TiC precipitation. The three distinct types of precipitates generate unique hierarchical TiC micro- and nanostructures, which enhances the yield strength from 513 MPa to 877 MPa by 71 %, tensile strength from 628 MPa to 1054 MPa by 68 %, and Young's modulus from 193 GPa to 221 GPa by 14 %. The findings of our research provide the knowledge foundation for the design of unique microstructures and advanced MMC materials through laser AM.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Equilibrium Fe isotope fractionation between olivine, pyroxene, spinel and MORB glass: Implications for mantle partial melting to generate MORBs

Primitive mid-ocean ridge basalts (MORBs) exhibit Fe isotopic compositions heavier than the upper mantle by +0.074 ± 0.028 ‰ for δ 56 Fe. The processes responsible for this isotopic difference remain unclear. Modeling of Fe isotope fractionation during mantle partial melting requires reliable equilibrium Fe isotope fractionation factors between minerals and melts, for which consistent data are still lacking. Here, in this study, we used Nuclear Resonant Inelastic X-ray Scattering (NRIXS) technique to measure Fe force constants for a MORB glass (ALV 519-4-1) and natural mantle minerals (olivine, orthopyroxene, clinopyroxene, and spinel) to determine the equilibrium Fe isotope fractionation factors between them. The force constants determined in this study, in increasing order, are 167 ± 26 N/m for spinel, 175 ± 17 N/m for olivine, 176 ± 20 N/m for MORB glass, 205 ± 26 N/m for clinopyroxene, and 219 ± 36 N/m for orthopyroxene. We evaluated the previously proposed mechanisms for the heavy Fe isotopic composition of MORBs, including (i) mantle partial melting, (ii) mantle lithological heterogeneity, with pyroxenite in the source, (iii) mantle metasomatism by low-degree melts, and (iv) fractional crystallization of olivine from melts. For (i), we used the pMELTS program to simulate adiabatic decompression melting of mantle peridotites, and calculated Fe isotope fractionation based on Fe 3+ –Fe 2+ equilibrium-controlled fractionation, where Fe 3+ forms stronger bonds and is more incompatible than Fe 2+ . At 10 wt% peridotite melting, corresponding to MORB generation, only +0.03 ‰ Fe isotope fractionation between the melt and the original bulk composition (Δ 56 Fe = δ 56 Fe melt - δ 56 Fe 0 ) was produced, insufficient to account for the observed MORB-upper mantle difference. For (ii), melting of pyroxenites yields smaller Fe isotope fractionation than melting of peridotites, making it unlikely the cause for the MORB-upper mantle isotopic difference. For (iii), both the Fe 3+ /ΣFe ratio and the δ 56 Fe of melts increase with the degree of partial melting, indicating that low-degree melts are not isotopically heavy enough to significantly alter the isotopic composition of lithospheric mantle through metasomatism. For (iv), equilibrium isotope fractionation between olivine and melt is near zero. These results suggest that equilibrium Fe isotope fractionation alone cannot explain the MORB isotopic signature, highlighting the potential role of kinetic isotope fractionation. Using a diffusion model, we calculated kinetic Fe and Mg isotope fractionations associated with (iv) olivine crystallization from a melt, and found that the predicted Fe and Mg isotope fractionations were inconsistent with observations in MORBs. Qualitatively, two processes could have induced kinetic Fe isotope fractionation during MORB generation: (a) Fe-Mg interdiffusion between melt and solid during melt migration and (b) reactive melt-rock interactions during melt focusing. However, a quantitative understanding of their role in modifying the melt isotopic composition remains limited and requires further investigation.

Fe isotopes↗
DOE OSTI2024

Ice-shelf freshwater triggers for the Filchner–Ronne Ice Shelf melt tipping point in a global ocean–sea-ice model

Some ocean modeling studies have identified a potential tipping point from a low to a high basal melt regime beneath the Filchner–Ronne Ice Shelf (FRIS), Antarctica, with significant implications for subsequent Antarctic ice sheet mass loss. To date, investigation of the climate drivers and impacts of this possible event have been limited because ice-shelf cavities and ice-shelf melting are only now starting to be included in global climate models. Using a global ocean–sea-ice configuration of the Energy Exascale Earth System Model (E3SM) that represents both ocean circulations and melting within ice-shelf cavities, we explore freshwater triggers (iceberg melt and ice-shelf basal melt) of a transition to a high-melt regime at FRIS in a low-resolution (30 km in the Southern Ocean) global ocean–sea-ice model. We find that a realistic spatial distribution of iceberg melt fluxes is necessary to prevent the FRIS melt regime change from unrealistically occurring under historical-reanalysis-based atmospheric forcing. Further, improvement of the default parameterization for mesoscale eddy mixing significantly reduces a large regional fresh bias and weak Antarctic Slope Front structure, both of which precondition the model to melt regime change. Using two different stable model con figurations, we explore the sensitivity of FRIS melt regime change to regional ice-sheet freshwater fluxes. Through a series of sensitivity experiments prescribing incrementally increasing melt rates from the smaller, neighboring ice shelves in the eastern Weddell Sea, we demonstrate the potential for an ice-shelf melt “domino effect” should the upstream ice shelves experience increased melt rates. The experiments also reveal that modest ice-shelf melt biases in a model, especially at coarse ocean resolution where narrow continental shelf dynamics are not well resolved, can lead to an unrealistic melt regime change at downstream ice shelves. Thus, we find that remote connections between melt fluxes at different ice shelves are sensitive to baseline model conditions. Our results highlight both the potential and the peril of simulating prognostic Antarctic ice-shelf melt rates in a low-resolution global model.

58 GEOSCIENCES↗
DOE OSTI2024

Ice-shelf freshwater triggers for the Filchner–Ronne Ice Shelf melt tipping point in a global ocean–sea-ice model

Abstract. Some ocean modeling studies have identified a potential tipping point from a low to a high basal melt regime beneath the Filchner–Ronne Ice Shelf (FRIS), Antarctica, with significant implications for subsequent Antarctic ice sheet mass loss. To date, investigation of the climate drivers and impacts of this possible event have been limited because ice-shelf cavities and ice-shelf melting are only now starting to be included in global climate models. Using a global ocean–sea-ice configuration of the Energy Exascale Earth System Model (E3SM) that represents both ocean circulations and melting within ice-shelf cavities, we explore freshwater triggers (iceberg melt and ice-shelf basal melt) of a transition to a high-melt regime at FRIS in a low-resolution (30 km in the Southern Ocean) global ocean–sea-ice model. We find that a realistic spatial distribution of iceberg melt fluxes is necessary to prevent the FRIS melt regime change from unrealistically occurring under historical-reanalysis-based atmospheric forcing. Further, improvement of the default parameterization for mesoscale eddy mixing significantly reduces a large regional fresh bias and weak Antarctic Slope Front structure, both of which precondition the model to melt regime change. Using two different stable model configurations, we explore the sensitivity of FRIS melt regime change to regional ice-sheet freshwater fluxes. Through a series of sensitivity experiments prescribing incrementally increasing melt rates from the smaller, neighboring ice shelves in the eastern Weddell Sea, we demonstrate the potential for an ice-shelf melt “domino effect” should the upstream ice shelves experience increased melt rates. The experiments also reveal that modest ice-shelf melt biases in a model, especially at coarse ocean resolution where narrow continental shelf dynamics are not well resolved, can lead to an unrealistic melt regime change at downstream ice shelves. Thus, we find that remote connections between melt fluxes at different ice shelves are sensitive to baseline model conditions. Our results highlight both the potential and the peril of simulating prognostic Antarctic ice-shelf melt rates in a low-resolution global model.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2023

The effect of composition, temperature and pressure on the oxidation state and coordination environment of copper in silicate melts

Copper is a redox variable element that may occur as Cu 0 , Cu + , and Cu 2+ in the Earth’s crust. The oxidation state will affect its partitioning between coexisting minerals, melts and fluids and hence its behaviour in magmatic processes. Copper bearing silicate glasses were quenched from melts with 23 synthetic compositions (19 CaO-Na 2 O-MgO-Al 2 O 3 -SiO 2 (CNMAS), two “granites” containing K 2 O ± H 2 O, and Fe-bearing “MORB” and “andesite”) equilibrated at oxygen fugacities (fO 2 ), expressed in log units relative to the fayalite-magnetite-quartz (FMQ) buffer, ranging from −0.7 to 14, temperatures from 900 to 1500 °C and pressures from 0 to 2.5 GPa. Cu K-edge X-ray absorption near edge structure (XANES) spectra were recorded from the glasses and a pre-edge feature in the XANES spectra was found to scale with the proportion of Cu + . Cu + /ΣCu (where ΣCu = Cu + + Cu 2+ ) was quantified by fitting the intensity of the pre-edge feature as a function of fO 2 to the thermodynamically expected relationship. Cu + /ΣCu was found to only weakly depend on melt composition, with more basic melts (e.g., basalts rather than granites) preferentially stabilising Cu 2+ . Increasing temperature stabilises Cu + , while increasing pressure had little effect on Cu + /ΣCu in CNMAS melts but preferentially stabilised Cu 2+ in granite melts. Cu + /ΣCu can be predicted in silicate melts by the empirical equation: log(Cu 2+ /Cu + ) = 0.25(ΔFMQ + 8.58 − 25050/T + 940P/T – 0.02P) − 4.73 + 5400/T + 1.99Λ + (280P – 90P2) where T is temperature in K, P is pressure in GPa and is the optical basicity of the composition. The effects of fO 2 , melt composition, temperature and pressure on Cu + /ΣCu indicate that Cu + will be the dominant oxidation state in terrestrial silicate melts (e.g., Cu + /ΣCu = 99% in an andesitic melt at 900 °C, 1 GPa and ΔFMQ = 1). The electron exchange reaction Cu 2+ + Fe 2+ → Cu + + Fe 3+ occurs on cooling and, given the abundance of Fe in natural melts, the oxidation state of Cu in natural glasses is unlikely to correspond to that in the original melt.

Copper↗
DOE OSTI2025

Subglacial discharge effects on basal melting of a rotating, idealized ice shelf

When subglacial meltwater is discharged into the ocean at the grounding line, it acts as a source of buoyancy, enhancing flow speeds along the ice base that result in higher basal melt rates. The effects of subglacial discharge have been well studied in the context of a Greenland-like, vertical calving front, where Earth's rotation can be neglected. Here we study these effects in the context of Antarctic ice shelves, where rotation is important. We use a numerical model to simulate ocean circulation and basal melting beneath an idealized three-dimensional ice shelf and vary the rate and distribution of subglacial discharge. For channelized discharge, we find that in the rotating case, total melt-flux anomaly increases with two-thirds power of the discharge, in contrast to existing non-rotating results for which the melt-flux anomaly increases with one-third power of the discharge. The higher melt-flux anomaly with discharge is attributed to a more extensive area of the ice-shelf base being exposed to direct high melting by the rising plume as it is deflected due to Earth's rotation and its path is prolonged. For distributed discharge, we find that in both the rotating and the non-rotating cases, the melt-flux anomaly increases with two-thirds power of the discharge. Furthermore, in the rotating case, the addition of channelized, subglacial discharge can produce either a higher or a lower ice-shelf basal melt-flux anomaly than the equivalent amount of distributed discharge, depending on its location along the grounding line relative to the directionality of the Coriolis force. This contrasts with previous results from non-rotating, vertical ice-cliff simulations, where distributed discharge was always found to be more efficient than channelized discharge at enhancing the terminus-averaged melt rate. The implication, based on our idealized simulations, is that melt-rate parameterizations attempting to include subglacial discharge effects that are not geometry- and rotation-aware may produce total melt-flux anomalies that are off by a factor of 2 or more.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2024

An Examination of Water-Related Melt Processes in Arctic Snow on Tundra and Sea-Ice

From April through June in 2019 and 2022, we monitored snow melt at three sites near Utqiaġvik, Alaska. Along 200-m lines we measured snow depth, density, stratigraphy, snow-covered area, and spectral albedo. Site 1 (ARM) was sloped tundra drained by water tracks. Site 2 (BEO) was flat polygonal tundra. Site 3 (ICE) was on undeformed landfast sea ice. All three sites were within a 6 km radius. Despite similar pre-melt snow distributions and weather, the melt progression differed markedly between sites. In 2019, by mid-melt, there was 40% less snow-covered area at ARM versus ICE, and 34% less snow-covered area at ARM versus BEO. The 2022 melt started 2 weeks later than in 2019 and was rapid, so smaller differences in snow-covered areas developed. In both years meltout dates varied by up to 25 days between sites, and more than 20 days within sites, with melt rates at locations only meters apart differing by up to a factor of seven. This melt diachroneity led to highly heterogeneous meltout patterns at all three sites. Our measurements and observations indicate that, in addition to reductions in snow reflective properties and wind-driven heat advection, the fate of meltwater plays a key role in producing melt diachroneity. We identify seven snow-water mechanisms that can enhance or inhibit melt rates, all largely controlled by the local topography and the nature of the substrate. These mechanisms are important because the most rapid changes in albedo coincide with the peak of water-snow melt interactions.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2026

Systematic analysis of melt pool dynamics in laser processing of mixed powder feedstocks

Functionally graded materials (FGMs) fabricated via additive manufacturing of blended powders offer the potential to spatially tailor properties for new technologies, such as fusion first-wall systems, turbine blades, and spacecraft. However, processing these materials is difficult due to the multiplicity of processing parameters to optimize, all of which must be changed as substrate material, powder feedstock compositions, and melt pool dynamics evolve. Here, this work systematically evaluates the qualitative and quantitative effects of these variables on the melt pool size, shape, composition, and particle distribution in an exemplar Ti-Ta system, and connects the experimental results to Marangoni flow behavior and phenomena observed in other systems. Increasing laser power linearly increases melt pool size and layer thickness, driving engineering considerations such as part/geometrical tolerances. Decreasing laser velocity changes the melt pool shape from lenticular to convex and reduces chemical homogeneity due to extreme thermal and compositional gradients between the melt pool center and boundaries. Thermophysical property differences between the powder feedstock and substrate material, as well as the directionality of the gradient, affect dilution and melt pool dynamics, which in turn affect the melt pool boundary characteristics, shape, and uniformity. Mixed powder feedstocks of intermediate compositions do not behave according to linear interpolations between single-material endpoints, instead building taller and wider melt pools. As such, it is recommended to quantify process maps for at least one intermediate composition in the FGM or multi-material system of interest to ensure optimized processing parameters, predictable melt pool sizes and shapes, and compositional and spatial precision.

Dissimilar↗
DOE OSTI2023

Wind‐Associated Melt Trends and Contrasts Between the Greenland and Antarctic Ice Sheets

Föhn and katabatic winds (downslope winds) can increase ice sheet surface melt, run-off, and ice-shelf vulnerability to hydrofracture and are poorly constrained on the Greenland and Antarctic ice sheets (GIS and AIS). We use regional climate model simulations of the GIS and AIS to quantify and intercompare trends in downslope winds and associated melt since 1960. Results reveal surface melt associated with downslope wind is significant on both the GIS and AIS representing 27.5 ± 4.5% and 19.7 ± 3.8% of total surface melt respectively. Wind-associated melt has decreased 31.8 ± 5.3% on the AIS while total melt decreased 15.4 ± 2.4% due to decreased föhn-induced melt on the Antarctic Peninsula and increasing stratospheric ozone. Wind-associated melt has increased 10.3 ± 2.5% on the GIS, combining with a more positive North Atlantic Oscillation and warmer surface to increase total melt 34 ± 5.8%.

58 GEOSCIENCES↗
DOE OSTI2025

Basal Melting and Oceanic Observations Beneath Central Fimbulisen, East Antarctica

Abstract Basal melting of ice shelves is fundamental to Antarctic ice sheet mass loss, yet direct observations remain sparse. We present the first year‐round melt record (2017–2021) from a phase‐sensitive radar on Fimbulisen, one of the fastest flowing ice shelves in Dronning Maud Land, East Antarctica. The observed long‐term mean ablation rate at 350 m depth below the central ice shelf was 1.0 ± 0.5 m yr −1 , marked by substantial sub‐weekly variability ranging from 0.4 to 3.5 m yr −1 . 36‐h filtered basal melt rate fluctuations closely align with ocean velocity. On seasonal time scales, melt rates peak during austral spring to autumn (September–March), driven by both elevated ocean velocities and thermal driving near the base. The combined effect of thermal driving and current speed explains the majority of the melt rate variability ( r = 0.84), highlighting the dominant role of shear‐driven turbulence. This relationship enables parameterization of melt rates for the decade‐long ocean record (2010–2021), although deviations appear under low and high forcing conditions. Both observed and parameterized melt rates show similar yearly mean magnitudes compared to satellite‐derived melt rates but with a tenfold lower seasonal amplitude and a 3‐month delay in seasonality. These detailed concurrent ice–ocean observations provide essential validation data for remote sensing and numerical models that aim to quantify and project ice‐shelf response to a change in ocean forcing. In situ measurements and continued monitoring are crucial for accurately assessing and modeling future basal melt rates, and for understanding the complex dynamics driving ice‐shelf stability and sea‐level change.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2025

Size-dependent second-order-like phase transitions in Fe nanocluster melting from low-temperature structural isomerization

Here, in this work, the melting phase transitions of Fe n nanoclusters with 10 ≤ n ≤ 100 atoms are investigated using classical many-body molecular dynamics simulations. For many cluster sizes, surface melting occurs at much lower temperatures than core melting. Surface and core melting points and energetic melting points (temperatures of maximum heat capacity, C v ) are calculated for all cluster sizes. Melting properties are found to be strong functions of cluster structure. Cluster sizes with closed-shell structures always have first-order-like phase transitions. Almost one-third of cluster sizes in the analyzed range exhibit second-order-like phase transitions due to the presence of multiple structural configurations close in energy. 1-shell clusters with one to a few more atoms than a neighboring closed-shell structure have very low surface melting points and very high energetic melting points compared to their closed-shell counterparts. In clusters above 50 atoms with certain core structures, melting of the surface before the core was observed.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2023

P2M Simulation Exercise on Past Fuel Melting Irradiation Experiments

This paper presents the results of the Power To Melt and Maneuverability (P2M) Simulation Exercise on past fuel melting irradiation experiments, organized within the Organisation for Economic Co-operation and Development/Nuclear Energy Agency Framework for IrraDiation ExperimentS (FIDES) framework by the Core Group (CEA, EDF, and SCK·CEN) and open to all FIDES members. The exercise consisted in simulating two past power ramps where fuel melting was detected: (1) the xM3 staircase power transient [ramp terminal level (RTL) 70 kW·m -1 , average burnup 27 GWd·tU -1 ], carried out in 2005 in the R2 reactor at Studsvik (Sweden), where the rodlet maintained its integrity, and (2) the HBC4 fast power transient (RTL 66 kW·m -1 , average burnup 48 GWd·tU -1 ), carried out in 1987 in the BR2 reactor at SCK·CEN (Belgium), where the cladding failed during the experiment. The exercise was joined by 13 organizations from 9 countries using 11 different fuel performance codes. In this paper, the main results of the Simulation Exercise are presented and compared to available postirradiation examinations (PIE) or on-line measurements during the power ramps (fuel and clad diameters, rod elongation, pellet-clad gap, and fission gas release). Since the focus of the Simulation Exercise is on fuel melting assessment, determination of the boundary between melted/nonmelted fuel and the consequent definition of a melting radius from PIE are first discussed. During the HBC4 ramp, fuel melting was predicted by most of the codes despite differences in the melting models. Higher discrepancies were observed for the xM3 rod that can be attributed partly to power uncertainty and partly to the limited capability of the models to describe partial melting of the fuel during this ramp. Finally, possible code developments to improve simulation results are presented.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗