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DOE OSTI2020

Offshore Wind Technology Data Update (2019) [Slides]

The 2019 Offshore Wind Technology Data Update compiles information from peer-reviewed literature, market reports, press releases, industry news reports, manufacturer specification sheets, and offshore wind project announcements to provide a comprehensive snapshot of the state of the global wind industry in 2019. These data, including capacity projections, project characteristics, technology trends, and cost estimates, are categorized, tabulated, and plotted to provide easily recognizable and understandable summaries. A particular focus is given to the United States offshore wind project pipeline, including project announcements, state procurements, deployment timelines, infrastructure investments, grid interconnections, and other related developments. The update is intended to be used as a reference document by researchers, analysts, industry practitioners, and government officials.

17 WIND ENERGY↗

DOE OSTI2022

Pumped Storage Hydropower Augmented with Pressurized Air: The Ground-Level Integrated Diverse Energy Storage (GLIDES) System — GLIDES System Configurations and Use Cases

Energy storage is essential for cost-effective integration of variable renewable energy sources to support a low-carbon grid. It is also a key enabler of a modern grid infrastructure for demand management. However, several main challenges remain for different kind of energy storage technologies in grid scale deployment. Currently, the largest source of utility-scale storage and long-duration storage in the US is pumped storage hydropower (PSH). Prospect of growth in conventional PSH faces challenges that have limited its deployment over the last three decades, including high capital costs and long deployment timelines. Batteries have high energy densities and are the primary technology of choice for small-scale energy storage. Compressed air energy storage (CAES) is another large-scale energy storage technology, but there are few plants deployed worldwide. They suffer from their low round trip efficiency (RTE) due to the use of high-pressure air compressors. To address some of the challenges associated with these various storage technologies, the Ground-Level Integrated Diverse Energy Storage (GLIDES) is a modular PSH technology that was invented in 2015 at Oak Ridge National Laboratory. It utilizes gas compression to store electric energy. GLIDES stores energy by compressing gas using a liquid piston in high-pressure vessels. In doing so the vessels act as the upper reservoir in conventional PSH. Initially, the vessels are filled with gas to a prescribed pressure. To store energy, GLIDES uses a hydraulic piston pump to pump water into the pressurized vessels. As the water volume increases inside the vessels, water acts as a hydraulic piston compressing the gas on top of it. This process can be thought of as pumping water from the lower reservoir to the higher reservoir in PSH, increasing the water head. To dispatch the stored energy, the high-head water in the vessel is discharge through a high head Pelton hydraulic turbine that is connected to an electric generator. Employing high-pressure vessels enables GLIDES to reach water heads ~10-80 times higher than conventional PSH, achieving ~40 times higher energy densities, and overcomes the geographic limitation of conventional PSH. Although its energy density is much lower than that of batteries, GLIDES holds the potential advantages of having long service life, ease of system integration and being less hazardous over batteries. GLIDES prospective scalability could make it suitable for wide range of applications from behind the meter storage in buildings to grid-scale storage. It also makes it suitable for installations in densely populated urban areas where energy storage is most needed and real estate is limited. Over the last 5 years, work has focused on increasing GLIDES’ energy density, decreasing its initial capital cost of the system, and increasing its revenue potential. Several designs were developed and prototyped to verify and demonstrate the improvement in energy density. The latest prototype achieved energy density of 1.21 kWh/m 3 . Our analysis showed that it could achieve up to 1.7 kWh/m 3 with a mixture of air and carbon dioxide as the gas being compressed.

13 HYDRO ENERGY↗

DOE OSTI2020

Acquisition and Implementation of a Comprehensive Environmental Permits Linking Tool at Savannah River Site - 20234

Historically, Savannah River Nuclear Solutions LLC (SRNS) tracked environmental regulatory commitments and the requirements from hundreds of permits at the Savannah River Site (SRS) using several separate methods, making integrated compliance assurance cumbersome and labor-intensive. When SRNS experienced an increase in environmental issues in 2017, SRNS management and U.S. Department of Energy - Savannah River (DOE-SR) management decided a single, proactive approach was needed to capture environmental permit information (including regulations, Consent Orders, DOE Orders, and any other state or federally issued statement of requirements), track the tasks necessary to ensure compliance with these requirements, and thereby mitigate the risk of noncompliance. SRNS developed a list of mandatory objectives that the tool must meet to function as a Comprehensive Environmental Permits Linking Tool (CEPLT). A key requirement was the ability to map Site permits to their governed locations and display the associated requirements at the compliance point (e.g., outfall, stack, waste unit, etc.). Several options included modifying existing onsite resources, building a custom onsite solution, purchasing an off-the-shelf solution, and contracting an offsite developer to build a custom solution. SRNS concluded an off-the-shelf solution with configuration and customization options would provide the flexibility to fit the unique needs of Savannah River Site (SRS) while taking advantage of industry-tested software and providing a reduced deployment timeline. SRNS chose Gensuite{sup R} a, a cloud-based solution that offers numerous a la carte applications in the environmental, health, and safety arenas, as the best candidate. SRNS selected three (3) integrated applications (Compliance Calendar, Permit Manager, and Mapper) to function as the CEPLT. The Compliance Calendar module allows for creation and tracking of regulatory commitment tasks assigned to responsible environmental professionals. Permit Manager organizes permits and other requirement documents, linking the commitments in each to Compliance Calendar tasks and/or implementing procedures. Mapper provides GIS capability for mapping the data from the other two modules to their physical onsite locations. The CEPLT was configured to allow for other SRS Site Tenants to eventually utilize the applications. Additionally, DOE-SR uses the CEPLT to provide an overview of contractor environmental compliance activities and to organize DOE-specific documents and tasks. The CEPLT fulfilled the requirement of meeting current compliance needs as well as providing the ability to grow as new organizations are incorporated and functionality is expanded. SRNS now uses the CEPLT to more effectively manage permit requirements, improve knowledge transfer, and increase the Site's overall protection of the environment, the Site worker, and the public. Possible future uses of the system include integration of mobile applications for timely communication of potential non-compliant conditions and DOE complex-wide deployment allowing for enhanced DOE site and Head Quarters oversight. Implementation of CEPLT will result in cost savings, both in terms of dollars and man-hours. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2024

A mixed integer linear programming approach for the design of chemical process families

Tackling climate change goals requires widespread deployment of process technology variants across many decentralized sites with different geographical, environmental, and operational requirements. Conventional engineering approaches focus on unique designs for each installation (process variant), while missing opportunities for manufacturing standardization. Here, instead we seek to optimize a process platform of common unit designs while simultaneously designing an entire family of process variants that make use of that platform. This reduces engineering effort, deployment timelines, and manufacturing costs. We propose a nonlinear generalized disjunctive programming formulation and convert this to an efficient mixed-integer linear programming (MILP) formulation through discretization of the design space. We formulate our optimization in Pyomo with costing from IDAES, and we demonstrate the computational performance and solution quality on a water treatment desalination system from the PARETO framework and a carbon capture system built in Aspen Plus as part of CCSI2.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2026

Irradiation of UC1+x kernels using the MiniFuel vehicle: Microstructure, phase analysis, and initial post-irradiation examination

Uranium carbide is a candidate fuel form for a wide range of advanced reactors, including larger Generation IV reactors as well as small modular reactors and microreactors. However, its commercial deployment timeline faces challenges via traditional qualification approaches. To address this issue, an accelerated fission rate irradiation test was performed to collect basic fuel performance data to inform fuel performance models and potential future integral tests. Hyperstoichiometric UC (UC1+x) kernels were irradiated in the High Flux Isotope Reactor using the MiniFuel irradiation vehicle. The test matrix spanned two temperature regimes (700 °C and 800 °C) and burnup levels (1.8 % FIMA and 2.8 % FIMA). Between 21 and 63 kernels were tested at each unique temperature and burnup condition. As-fabricated microstructural analysis revealed a multiphase composition with UC, UC2, UC2−y, and U-C-O bearing phases for the irradiated kernels. Following irradiation, fission gas release, swelling, and microstructures were analyzed. Measured fission gas release was below 5 % for all irradiation conditions, reaching a maximum at the highest temperature and burnup condition. A binary swelling response was observed; the lower burnup and temperature conditions resulted in negligible swelling, but the higher burnup and temperature conditions produced significant anisotropic swelling and densification in a subset of kernels. The basic microstructural exams of kernels following irradiation were not capable of showing a correlation between kernels that exhibited excessive swelling and those that did not. Characterization of a subset of samples using the Advanced Photon Source and more detailed microstructural examination of unirradiated kernels revealed that a subset of kernels contained very high UC2 phase fractions. The anomalous swelling response is hypothesized to have been driven by this chemical variation. The results of this irradiation highlight the potential of accelerated fission rate irradiation testing to explore such behaviors and inform the development of fuel specifications.

Adorno Lopes, Denise [ORNL] (ORCID:000900023705987↗

DOE OSTI2025

Mixed-Integer Linear Programming Formulation with Embedded Machine Learning Surrogates for the Design of Chemical Process Families

In previous work, we introduced process family design. The main idea is to design a platform of common elements, and, allowing us to capture additional cost savings, simultaneously design a family of processes, and reducing both engineering and deployment timelines. We formulate this as an optimization problem, specifically a nonlinear generalized disjunctive program (GDP). We have proposed two approaches for reformulating and solving this problem: one based on full-discretization of the design space and one that uses Machine Learning (ML) surrogates to replace the nonlinear process models. Using ML surrogates to predict required system costs and performance indicators allows us to reformulate the nonlinearities in the GDP generate an efficient MILP formulation. In this work, we apply the ML surrogate approach to two case studies. One case study involves designing a family of carbon capture systems to cover a set of different flue gas flow rates and inlet CO 2 concentrations, where we consider the absorber and stripper as common unit module types. The second case study focuses on a water-desalination process, where we design a family of these processes for a variety of salt concentrations and flow rates. In both of these case studies, we demonstrate a scalable optimization approach that enables the design of multiple processes simultaneously, reducing the time-to-market and overall costs by maximizing the cost savings due to both economies of scale and economies of numbers.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2021

TCR Data Management Plan

The Oak Ridge National Laboratory (ORNL) Transformation Challenge Reactor (TCR) program is developing additive manufacturing and artificial intelligence (AI) to deliver enabling technologies for advanced reactors. Through the application of these advanced technologies, the program targets delivering solutions to the high costs and lengthy deployment timelines that threaten the future of nuclear energy—the country’s largest source of carbon-free energy. This document describes the plan for integrating and managing TCR data from multiple sources throughout ORNL and external sources, including novel data sources associated with advanced manufacturing, characterization systems, and the TCR Digital Platform that incorporates various levels of AI and data analytics.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2026

Feasibility and strategic implications of deploying nuclear power reactors in Africa

This report assesses the feasibility and strategic implications of deploying nuclear power reactors, including large-scale plants, advanced small modular reactors (SMRs), and microreactors, in African countries. Case studies focus on South Africa, Egypt, Kenya, Ghana, and Nigeria, examining nuclear energy’s role in Africa’s rapidly evolving energy landscape, marked by fast-growing demand, significant electricity access gaps, increasing renewable penetration, and strong policy commitments to industrialization and energy security. Several U.S. reactor technologies and designs are considered based on their development status and readiness for deployment. The analysis finds that nuclear power can provide reliable, clean baseload and flexible generation, as well as high-temperature process heat for desalination, hydrogen production, and industrial applications. However, suitability is highly country-specific, depending on grid size and stability, transmission capacity, cooling water availability, regulatory readiness, and fuel supply chains. Near-term deployment opportunities are strongest for light-water reactors (such as NuScale, BWRX-300, AP300, and SMR-300) that use low-enriched uranium and build on proven technology. More advanced concepts, including gas-cooled, sodium-cooled, molten-salt cooled reactors, and microreactors, will likely be relevant for African deployment in the 2030s or later, contingent on demonstration projects, high-assay low-enriched uranium (HALEU) fuel availability, and mature international licensing frameworks. Economic analysis shows that SMRs are capital-intensive, with projected overnight costs for 300 MWe units in 2025 ranging from approximately 1.4 to 2.6 billion USD per module. The levelized cost of electricity (LCOE) is highly sensitive to the weighted average cost of capital (WACC). Given typically higher financing costs and utility balance-sheet weaknesses in many African countries, bankable project structures will require sovereign guarantees, robust offtake arrangements, and layered financing from export credit agencies, development finance institutions, and vendor nations. Comparisons with recent large nuclear projects in the United Arab Emirates (UAE) and Egypt underscore the central role of state-backed loans, long tenors, and concessional terms. Country case studies illustrate a spectrum of readiness and opportunity. South Africa operates two 920 MWe pressurized light water reactors (totaling 1,840 MWe) at Koeberg and has the most mature regulatory and industrial base, positioning it as a prime candidate for both large reactors and SMRs to replace coal, support desalination, and anchor industrial hubs. Egypt is constructing four VVER-1200 units at El Dabaa with strong state leadership and could later complement this fleet with SMRs for coastal and industrial applications. Kenya and Ghana are advancing through IAEA Milestones with growing institutional capacity and clear interest in SMRs that match their smaller grids and industrialization plans. Nigeria has the largest demand potential but faces acute constraints in grid reliability, project bankability, and regulatory capacity; targeted deployments of large reactors and SMRs near coastal or industrial sites could have high impact if accompanied by major grid upgrades and institutional reforms. The report identifies cross-cutting challenges such as financing, political continuity, public acceptance, nonproliferation and security, waste and back-end management, regulatory capacity, grid adequacy, and long deployment timelines for first-of-a-kind designs, and ANL/NSE-26/3 ii proposes broad directions for resolution. These include stronger multifaceted financing for nuclear, long-term national energy strategies that transcend electoral cycles, proactive stakeholder engagement, strengthened regional and national regulators, and systematic workforce development through centers of excellence and expanded training. The United States should develop partnerships with African countries and offer end-to-end nuclear package similar to those used effectively by competitors: coordinated project development, state-backed financing, long-term fuel services, and durable in-country support through regional offices and sustained workforce/regulatory training. With timely planning, sustained political commitment, and appropriate financing and institutional support, nuclear energy, both large reactors and advanced SMRs, can become a meaningful, though not dominant, pillar of Africa’s future power mix, enhancing energy security, enabling industrial growth, and supporting climate goals.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2026

Port scanner and Testing Suite

This project addresses the challenge of identifying and managing open network ports across physical and virtual hosts. The current form of verifying ports in use required manually searching individual ports - a process that was both time- consuming and a potential bottleneck for deployment timelines. To resolve this, an automated port scanning tool was developed in Python. The tool supports simultaneous multiple port scans. To ensure functionality and long-term maintainability, a comprehensive testing suite was implemented using Python’s unittest framework. Edge cases, including valid port numbers, reversed ranges, and closed ports, were explicitly tested to ensure robust handling of real-world scenarios. The resulting tool reduces the time required to verify port security across a network, supporting both targeted and host checks and broader Classless Inter-Domain Routing (CIDR) -based network scans. This work demonstrates the value of automation and test-driven development in strengthening network security practices, and provides a foundation for future enhancements.

Rivera, Linda [Fermilab]↗

DOE OSTI2020

Safeguards Technical Objectives for Thorium Molten Salt Reactor Fuel Cycles

China, Denmark, France, India, Indonesia, the United Kingdom, and the United States, among others, are exploring commercial thorium fuel cycles for domestic power production and/or international export. For any thorium fuel cycle facilities built and/or operated in a non-nuclear weapon State with a comprehensive safeguards agreement, those facilities and any associated nuclear material would be subject to international nuclear safeguards by the International Atomic Energy Agency (IAEA). Thorium fuel cycle facilities offered for the application of safeguards under a voluntary offer agreement by a nuclear weapon State would also be subject to safeguards, if selected by the IAEA. Compared to uranium/plutonium fuel cycle facilities, thorium fuel cycle facilities are comparatively diverse from an inspection and accounting perspective, differing greatly in material type, form, and design from uranium/plutonium fuel cycle facilities and also from each other. Of these, the most complex thorium fuel cycles – and therefore likely the most challenging to the implementation of international nuclear safeguards – are those that include thorium molten salt reactors. With thorium fuel cycles approaching near-term commercial deployment timelines, it is imperative that the international nuclear safeguards community begins to think about how to adapt existing international nuclear safeguards concepts and approaches to thorium fuel cycles, as well as mitigate any gaps that may exist. This paper focuses on the development of recommended safeguards technical objectives for efficient and effective application of international nuclear safeguards measures (e.g., containment / surveillance, non-destructive assay, destructive assay, environmental sampling) to thorium molten salt reactors.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2021

Flattening the Radial Temperature Profile across the Transformational Challenge Reactor Core

The Transformational Challenge Reactor (TCR) program is demonstrating an agile development approach to advanced nuclear reactor design, which has traditionally utilized a linear design process. In leveraging artificial intelligence, additive manufacturing, advanced materials, and cutting-edge modeling and simulation, the TCR program aims to minimize the high cost and lengthy deployment timelines now standard in the nuclear industry. Within a relatively short period of time, a robust and mature advanced gas-cooled reactor was iteratively designed under the TCR program, using these cutting-edge technologies. The TCR is a 3 MWt gas-cooled microreactor fueled with uranium nitride (UN) tristructural isotropic (TRISO) fuel particles. Though manufactured via traditional means, these UN TRISO particles are loaded into additively manufactured silicon carbide (SiC) cans [4]. Once loaded with TRISO particles, the SiC cans are densified using a chemical vapor infiltration process. The additively manufactured SiC enables significantly more freedom in the design of the fuel form than could ever be achieved using traditionally manufactured SiC. The helium coolant, pressurized to 5 MPa, enters the core at 300°C and nominally exits it at 500°C. Typically, the most thermally limiting components in any reactor design are the fuel assemblies in the core center. To provide a wide thermal margin in these central fuel assemblies, the flow may be biased toward the center of the core to more effectively cool these fuel assemblies with more power deposition and flatten the core’s radial temperature distribution. An analytical fluid model of the TCR core was developed to explore methods for biasing the flow away from the cooler outer fuel assemblies and towards the hotter inner ones. Higher-fidelity models developed in STAR-CCM+ 2020.3.1, a computational fluid dynamics code, were then utilized to verify the analytical model’s findings.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2020

Environmental Permitting and Compliance Cost Reduction Strategies for the MHK Industry: Lessons Learned from Other Industries

The marine and hydrokinetic (MHK) industry plays a vital role in the U.S. clean energy strategy by providing a renewable, domestic energy source that may offset the need for traditional energy sources. The first MHK deployments in the U.S. have incurred very high permitting costs and long timelines for deploying projects, which increases project risk and discourages investment. A key challenge to advancing an economically competitive U.S. MHK industry is reducing the time and cost required for environmental permitting and compliance with government regulations. Other industries such as offshore oil and gas, offshore wind energy, subsea power and data cables, onshore wind energy, and solar energy facilities have all developed more robust permitting and compliance pathways that provide lessons for the MHK industry in the U.S. and may help inform the global consenting process. Based on in-depth review and research into each of the other industries, we describe the environmental permitting pathways, the main environmental concerns and types of monitoring typically associated with them, and factors that appear to have eased environmental permitting and compliance issues.

other industries↗

NASA NTRS2015

AMO EXPRESS: A Command and Control Experiment for Crew Autonomy Onboard the International Space Station

NASA is investigating a range of future human spaceflight missions, including both Mars-distance and Near Earth Object (NEO) targets. Of significant importance for these missions is the balance between crew autonomy and vehicle automation. As distance from Earth results in increasing communication delays, future crews need both the capability and authority to independently make decisions. However, small crews cannot take on all functions performed by ground today, and so vehicles must be more automated to reduce the crew workload for such missions. NASA's Advanced Exploration Systems Program funded Autonomous Mission Operations (AMO) project conducted an autonomous command and control experiment on-board the International Space Station that demonstrated single action intelligent procedures for crew command and control. The target problem was to enable crew initialization of a facility class rack with power and thermal interfaces, and involving core and payload command and telemetry processing, without support from ground controllers. This autonomous operations capability is enabling in scenarios such as initialization of a medical facility to respond to a crew medical emergency, and representative of other spacecraft autonomy challenges. The experiment was conducted using the Expedite the Processing of Experiments for Space Station (EXPRESS) rack 7, which was located in the Port 2 location within the U.S Laboratory onboard the International Space Station (ISS). Activation and deactivation of this facility is time consuming and operationally intensive, requiring coordination of three flight control positions, 47 nominal steps, 57 commands, 276 telemetry checks, and coordination of multiple ISS systems (both core and payload). Utilization of Draper Laboratory's Timeliner software, deployed on-board the ISS within the Command and Control (C&C) computers and the Payload computers, allowed development of the automated procedures specific to ISS without having to certify and employ novel software for procedure development and execution. The procedures contained the ground procedure logic and actions as possible to include fault detection and recovery capabilities. The autonomous operations concept includes a reduction of the amount of data a crew operator is required to verify during activation or de-activation, as well as integration of procedure execution status and relevant data in a single integrated display. During execution, the auto-procedures (via Timerliner) provide a step-by-step messaging paradigm and a high-level status upon termination. This messaging and high-level status is the only data generated for operator display. To enhance situational awareness of the operator, the Web-based Procedure Display (WebPD) provides a novel approach to the issues of procedure display and execution tracking. WebPD is a web based application that serves as the user interface for electronic procedure execution. It incorporates several aspects of the HTML5 standard. Procedures are written in a dialect of XML called Procedure Representation Language (PRL). WebPD tracks execution status in the procedure or procedures being displayed. WebPD aggregates and simplifies the auto-sequence execution status information, and formatted to be easily followed and understood by an operator who is not dedicated to actively monitoring the task. WebPD also provides an integrated data and control interface to pause or halt the execution in order to provide a check point of operation and to examine progress before starting the next sequence of activities. For this demonstration, the procedure was initiated and monitored from the ground. As the Timeliner sequences executed, their high-level execution status was written to PLMDM memory. This memory is read and downlinked via Ku-Band at a 1 Hz rate. The data containing the high-level execution status is de-commutated on the ground, and rebroadcast for WebPD consumption. A future demonstration will be performed onboard, with ISS astronauts initiating the operations instead of ground controllers. The AMO EXPRESS experiment demonstrated activation and de-activation of EXPRESS rack 7, providing the capability of future single button activations and deactivations of facility class racks. The experiment achieved numerous technical and operations 'firsts' for the ISS

Stetson, Howard K.↗

NASA NTRS2015

AMO EXPRESS: A Command and Control Experiment for Crew Autonomy Onboard the International Space Station

Stetson, Howard K.↗

DOE OSTI2023

Pathways to Overcome Geothermal Deployment Barriers

Geothermal resources represent a vast domestic energy supply that can provide a fexible and reliable source of electricity as well as contribute to clean energy goals. In the United States, geothermal exploration and development are subject to numerous permits, authorizations, and other regulatory requirements at the federal, state, and local level. These are necessary to address potential environmental and resource impacts at geothermal project sites, but may act as barriers to geothermal deployment, slowing timelines and raising costs. The 2022 NREL report, Non-Technical Barriers to Geothermal Development in California and Nevada, presents fndings of a study on non-technical barriers that may infuence geothermal project development.

geothermal↗

DOE OSTI2022

A Framework to Assess Advanced Reactor Spent Fuel Management Facility Deployment

Previous planning and prioritization for LWR SNF management investigated the risks and uncertainties of deploying facilities such as consolidated interim storage [1, 2, 3, 4]. As part of that work, activities and milestones were collected into success precedence diagrams that charted a path to achieving facility deployment [1]. In that framework, activities are any research, development, design, or decision required to achieve an intermediate goal; milestones are activity endpoints and mark the completion of deliverables. Milestones can be thought of as achievements required to reach the final goal of facility deployment; activities are the means by which milestones are accomplished. In planning, activities and milestones are compiled into comprehensive flow charts that visualize the steps necessary for deployment. This framework has been used to quantify risks, timelines, and costs of deploying SNF management facilities.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2025

Development and Evaluation of Embrittlement Resistant Alloys for Advanced LWR Cladding

The primary challenge preventing the deployment of reactor designs that leverage wrought FeCrAl as an advanced light-water reactor (LWR) cladding is irradiation hardening and embrittlement. Wrought FeCrAl alloys experience a loss of post-irradiation ductility and fracture toughness under low-temperature neutron irradiation (< 350°C) resulting from the combined effects of dislocation loop formation and the irradiation-enhanced precipitation of Cr-rich alpha-prime precipitates throughout the microstructure. Over the past decade, significant improvements in our understanding regarding the effect of Cr and Al content have been enabled through neutron irradiations, but even optimized wrought alloys such as C26M remain vulnerable to brittle failure during storage, transportation, and handling following irradiation. This report summarizes multiple irradiation campaigns initiated over the past 7 years and provides recent insights into the effect of (1) minor alloying composition, (2) alloy processing strategy, (3) crystal structure, and (4) the use of advanced oxide dispersion strengthened (ODS) alloys. The first irradiation campaign irradiated body-centered cubic FeCrAl alloy C26M with and without elements such as Mo and Y. It also included face-centered cubic alumina-forming austenitic (AFA) alloys that have a steeper neutronic penalty but that have far superior high-temperature strength than wrought FeCrAl. Finally, this campaign compared conventional wrought C26M with the same material produced using modern powder metallurgical hotisostatic pressing (PM-HIP). The second irradiation campaign, initiated in 2018, irradiated wrought and FeCrAl-ODS materials up to 50 dpa to assess their irradiation resistance to high-doses. The results of this work indicate that wrought C26M suffers significant degradation following neutron irradiation at LWR-relevant temperatures regardless of Mo and Y content. The PM-HIP variant appears to be more resilient to irradiation-induced ductility loss in comparison with wrought variants but still loses almost all ductility by 8 dpa. Notably, the AFAs retained at least 5% total elongation after irradiation at the same dose and temperature condition, although additional deterioration may be expected at higher fluence levels. FeCrAl-ODS materials show the greatest promise as a transformative longer-term accident-tolerant fuel (LT-ATF) cladding material. The extruded 106ZY10C alloy retained 10% total elongation after 16 dpa irradiation and retained 8% total elongation after 50 dpa. Additional challenges with FeCrAl-ODS alloys also remain, including optimization of end cap joining methodologies, enhancement of fracture toughness, scaling production to prove economic viability, and optimizing post-pilger heat treatments to maximize ductility and irradiation resistance. This series of irradiations demonstrates the efficacy of the LWR testbed available within the United States for the rapid irradiation and down-selection of LT-ATF candidates. As the country rapidly accelerates its timeline for the deployment of advanced reactor concepts, the effective utilization of the High Flux Isotope Reactor for separate-effects style irradiations should continue to be prioritized to answer the final questions pertaining to LT-ATF candidates necessary for the deployment of advanced boiling water reactors and small modular reactors.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2021

Artificial Intelligence for Multiphysics Nuclear Design Optimization with Additive Manufacturing

The geometric flexibility of additively manufactured metals and ceramics generates a very large and open design space that requires advanced modeling and simulation tools for physics simulations and the rigorous definition of design problems. This effort deploys artificial intelligence (AI) and machine learning (ML) algorithms to understand the design space, evaluate potential designs, and more efficiently generate optimized results. The Transformational Challenge Reactor (TCR) program is leveraging advances in several scientific areas—including materials, manufacturing, sensors and control systems, data analytics, and high-fidelity modeling and simulation—to accelerate the design, manufacturing, qualification, and deployment of advanced nuclear energy systems. Through a manufacturing-informed design approach, the TCR program seeks to integrate digital data for rapid nuclear innovation; accelerate the adoption of advances in manufacturing, materials, and computational sciences for nuclear applications; and dramatically reduce deployment costs and timelines for new nuclear reactor technologies. This report documents efforts under the TCR program to leverage advanced modeling and simulation techniques driven by AI/ML algorithms on high-performance computing (HPC) systems to yield more optimized TCR core designs. A multiphysics ML surrogate model was developed to run on the HPC architectures. The surrogate model is trained on high-fidelity simulation data of coupled neutronics and thermofluidics and is used to quickly evaluate thousands of candidate core designs in parallel, which drives the evolution of the cooling channel shapes to minimize temperature peaking and material stress. Outcomes from these activities provide design information and feedback into the core design efforts.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗