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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 OSTI2019

First Annual Report on Pulsed Thermal Tomography Nondestructive Evaluation of Additively Manufactured Reactor Materials and Components: Pulsed Thermal Tomography Nondestructive Examination of Additively Manufactured Reactor Materials and Components

Additive manufacturing (AM, or 3D printing) for commercial nuclear energy applications is an emerging method for cost-efficient manufacturing aimed at replacing aging nuclear reactor parts and reducing costs for new construction. Because of the geometry of metallic structures of interest for nuclear applications, which consist of planar primitives with no symmetry of revolution, limited options are available for nondestructive evaluation (NDE), either during or post manufacturing. Known material flaws in AM include low-density regions consisting of non-sintered powder, which have to be detected to ensure the safety of long-term performance nuclear reactor components. As a solution to NDE of AM, we are developing pulsed thermal tomography (PTT) models and depth inversion algorithms for 3D imaging. PTT has many advantages because the method is non-contact and allows for in-service, NDE of AM nuclear reactor parts. By analyzing transients of surface temperature response due to internal thermal resistances, one can obtain 3D reconstructions of material effusivity using a unique inversion algorithm developed at Argonne. This report provides results of preliminary performance evaluation of PTT capability in detection of flaws in metallic structures, as well imaging complex geometry AM structures. Performance of PTT was investigated through modeling and experiments, Computer models of PTT were developed using COMSOL Heat Transfer module. Defects were modeled as cylindrical flat bottom holes (FBH), which is a common model of calibrated material flaws in thermal tomography experiments. Materials considered in this study include stainless steel 316 (SS316), stainless steel 304 (SS304), and Inconel 718. Theoretical analyses were conducted to validate inversion of simulated PTT data with COMSOL for a plate. Subsequently, 3D reconstructions were performed on COMSOL simulations for FBH, revealing a decrease in spatial resolution over depth due to thermal diffusion. The results of this study show that the performance of the inversion algorithm for detecting smaller defects depends strongly on the depth of the defect as well as the incident heat flux. The size of detectable defect was estimated by fitting a Gaussian function to surface temperature profile. The criteria for detectability was taken as 20mK noise equivalent temperature difference (NETD), which is currently the sensitivity limit of high-performance infrared cameras. It was determined through computer simulations that the smallest detectable FBH in SS316 has a 50µm diameter and is located 0.5mm below the plate surface. Preliminary experimental studies were performed to evaluate PTT performance in detecting calibrated flaws using metallic specimens with AM defects simulated as drilled-in FBH’s. High strength Stainless Steel 316 and Inconel 718 alloys were considered, as well as lower grade Stainless Steel 304, Nickel 200, and Hastelloy C276. Specimens investigated in this report consisted of approximately 1/4in-thick plates made out of these alloys using conventional manufacturing methods. The diameters of FBH’s varied from 1mm to 8mm, and their depths below the plate flat surface varied between 1mm and 6mm. The size of the smallest FBH was limited to 1mm because conventional mechanical drills were used for creating the holes. PTT imaging results have shown that 1mm-diameter FBH located 1mm and 2mm below the surface were detectable. Larger size FBH were detectable at greater depth. For example, 6mm-diameter FBH could be detected at 8mm depth. Image contrast varied slightly between the specimens, with the best reconstructions obtained in SS316 and C276 plates. Finally, PTT capability in imaging several AM structures fabricated from Inconel 718 (IN718) powder feedstock was investigated. The AM structures have complex geometry, but do not have calibrated internal defects. The objective is to determine PTT settings, such as the total integration time, for imaging of representative AM structures. A new FLIR X8500sc IR camera with higher spatial resolution (1280x1024 at 181Hz frame rate) was integrated into the PTT laboratory setup. Software tools were developed to ensure compatibility of new camera files with legacy effusivity reconstruction codes. The new camera was used to obtain 3-D reconstructions of AM IN718 nozzle plate and a particle filter plate. It was shown that PTT can scan through 2/3in-thick Inconel 718 plates in approximately 15s. Several modes of 3-D data visualization were explored, including using ImageJ and MATLAB software packages. The results demonstrate the capability of PTT in 3-D imaging of complex geometry AM structures. Intermediate results demonstrated in this report will be developed further to investigate detection of flaws in AM specimens.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2024

Thermal Gradient and Neutron Irradiation Experiment Design for Fusion Reactor Materials in the Advanced Test Reactor

This work outlines a hypothetical coupled thermal gradient and neutron irradiation experiment in the Advanced Test Reactor (ATR) at the Idaho National Laboratory. Although the ATR is a thermal spectrum test reactor and doesn’t inherently produce a flux spectrum dominated by the high-energy neutrons typical in a fusion reactor, it’s multitude of experiment positions and dynamic flux environment make it a suitable platform for investigating fusion related issues.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Perspectives on Tailoring Neutron Energy Spectra in Material Test Reactors

Material test reactors (MTRs) are used to irradiate nuclear fuels and materials to develop data for how they endure neutron bombardment in or near reactor cores. Most historic MTRs, and all that remain operational in the US today, are water-cooled types and produce a thermalized neutron flux. New irradiation facilities are needed which can produce neutron energy spectra relevant to fast and fusion reactor environments. Construction of these facilities will take several years of steadfast funding to complete, which poses a formidable schedule challenge for current fast and fusion reactor developers. Irradiation designs which modify the neutron energy spectra delivered to test specimens in thermal spectrum MTRs, an approach referred to as “spectral tailoring”, can be used to approximate several relevant phenomena in the materials needed to enable fast and fusion reactor technologies. This approach is imperfect, but still valuable in the present situation. Here, the two highest flux MTRs operational in the United States, the Advanced Test Reactor (ATR) and High Flux Isotope Reactor (HFIR), have rich histories, ongoing developments, and new potentials for spectral tailoring that will be reviewed and discussed in this paper.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Retractable Sensors for In-Core Service in Material Test Reactors

Material Test Reactors (MTRs) such as the Advanced Test Reactor (ATR) at the Idaho National Laboratory (INL) are used to irradiate nuclear fuels and materials to evaluate their performance after high levels of exposure to a reactor in-core environment. The most critical tests are equipped with instrumentation leads, which allow real-time data collection. However, because of the very harsh environment inside high-power MTR experiments, there are very few sensors that can survive and maintain their calibrated readings for the time periods required to obtain the high neutron doses needed for new fuels and materials qualification. As a result, sometimes sponsoring programs are forced to accept low reliability of sensors, collecting useful data for only part of the experiment duration. The work described herein is based on the observation that MTRs normally run at constant power and the corresponding conditions within reactor experiments typically evolve relatively slowly. Therefore, even one or two measurements per day would provide a complete and representative data set. With this in mind, INL has embarked on a program to develop a mechanism capable of pushing a very small-diameter sensor (typically a thermocouple or optical fiber) into the location to be measured, leave the sensor for roughly 60 seconds to allow it to reach equilibrium and transmit the signal, then pull it up and away from the high neutron flux and high-temperature region. Small-diameter capillary tubes, up to 8 m long, are used to guide the sensors to the appropriate locations. These capillary tubes serve as essentially very deep, thin-walled thermowells. The distance a thermocouple or optical fiber would need to traverse is on the order of 40 - 80 cm. By adopting this infrequent cycling strategy, the thermocouple or optical fiber would spend only a few hours in the high-neutron flux/high-temperature environment over the duration of even the longest irradiation experiment. To date, INL has developed two styles of drive mechanisms. The first is based on counter-rotating wheels which drive the sensors in a manner similar to a small MIG welder. This has the advantage of being able to accommodate a very long insertion length. The second is based on a ball screw drive and has the advantages of positive attachment and being able to move more than one sensor at a time. Both drive mechanisms have been fabricated and tested in a laboratory setting. Both systems can handle hard mineral insulated cable (such as thermocouples) or optical fibers encased in small diameter tube. The sizes tested to date are 1 - 1.6 mm diameter. Work in this area is ongoing with an eye toward demonstration in the Massachusetts Institute of Technology's MITR reactor, followed by deployment in an ATR irradiation experiment.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2023

Retractable Sensors for In-Core Service in Material Test Reactors

Material Test Reactors (MTRs) such as the Advanced Test Reactor (ATR) at the Idaho National Laboratory (INL) are used to irradiate nuclear fuels and materials to evaluate their performance after high levels of exposure to a reactor in-core environment. The most critical tests are equipped with instrumentation leads, which allow real-time data collection. However, because of the very harsh environment inside high-power MTR experiments, there are very few sensors that can survive and maintain their calibrated readings for the time periods required to obtain the high neutron doses needed for new fuels and materials qualification. As a result, sometimes sponsoring programs are forced to accept low reliability of sensors, collecting useful data for only part of the experiment duration. The work described herein is based on the observation that MTRs normally run at constant power and the corresponding conditions within reactor experiments typically evolve relatively slowly. Therefore, even one or two measurements per day would provide a complete and representative data set. With this in mind, INL has embarked on a program to develop a mechanism capable of pushing a very small-diameter sensor (typically a thermocouple or optical fiber) into the location to be measured, leave the sensor for roughly 60 seconds to allow it to reach equilibrium and transmit the signal, then pull it up and away from the high neutron flux and high-temperature region. Small-diameter capillary tubes, up to 8 m long, are used to guide the sensors to the appropriate locations. These capillary tubes serve as essentially very deep, thin-walled thermowells. The distance a thermocouple or optical fiber would need to traverse is on the order of 40 – 80 cm. By adopting this infrequent cycling strategy, the thermocouple or optical fiber would spend only a few hours in the high-neutron flux/high-temperature environment over the duration of even the longest irradiation experiment. To date, INL has developed two styles of drive mechanisms. The first is based on counter-rotating wheels which drive the sensors in a manner similar to a small MIG welder. This has the advantage of being able to accommodate a very long insertion length. The second is based on a ball screw drive and has the advantages of positive attachment and being able to move more than one sensor at a time. Both drive mechanisms have been fabricated and tested in a laboratory setting. Both systems can handle hard mineral insulated cable (such as thermocouples) or optical fibers encased in small diameter tube. The sizes tested to date are 1 – 1.6 mm diameter. Work in this area is ongoing with an eye toward demonstration in the Massachusetts Institute of Technology’s MITR reactor, followed by deployment in an ATR irradiation experiment.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2020

Imaging of Calibrated Defects in Additively Manufactured Materials: Pulsed Thermal Tomography Nondestructive Examination of Additively Manufactured Reactor Materials and Components

Additive manufacturing (AM, or 3D printing) for commercial nuclear energy applications is an emerging method for cost-efficient manufacturing aimed at replacing aging nuclear reactor parts and reducing costs for new construction. Known material flaws in AM include low-density regions consisting of non-sintered powder, which have to be detected to ensure the safety of long-term performance nuclear reactor components. Currently, limited options are available for nondestructive evaluation (NDE), either during or post manufacturing. As a solution to NDE of AM, we are developing pulsed thermal imaging which is non-contact, one-sided, and scalable to arbitrary size and shape of the AM parts. Pulsed thermography (PT) system utilizes a high intensity flash lamp to rapidly heat surface of sample, and a high sensitivity fast-frame megapixel infrared (IR) camera to capture data of surface temperature variations. The acquired data cube consists of a stack of surface temperature images taken at different times. Information about material internal defects is extracted by analyzing the data cube. This report provides results of preliminary performance evaluation of pulsed thermal imaging capability in detection of imprinted flaws in AM metallic structures. The flaws were introduced into AM parts as imprinted hemispherical low density regions, consisting of trapped un-sintered metallic powder. Specimens for developed for this study consisted of AM stainless steel 316 and Inconel 718 plates. The diameters of imprinted defects varied from 1mm to 8mm, and their depths below the plate flat surface varied between 1mm and 6mm. Pulsed thermal tomography (PTT) processes the measured data cube to obtain 3D reconstructions of material effusivity using a unique inversion algorithm developed at Argonne. PTT has been previously used in imaging of similar size flat bottom hole (FBH) simulated defects in stainless steel 316 and Inconel 718 specimens. In the study involving AM specimens, PTT imaging results have shown that 1mm-diameter defects located 1mm and 2mm below the surface of specimens were detectable. Larger size defects were detectable at greater depth. We also explored an alternative approach to detection of material flaws in PT data cube, which is using neural learning-based approach to blind source separation. Detection of small material defects requires finding features in the data cube which have signal contrast levels approaching sensitivity limit of IR camera. In this study, an optimized Neural Learning based Blind Source Separation (NLBSS) algorithm, including Principal Component Analysis (PCA), and Independent Component Analysis (ICA) is demonstrated to automatically extract principal temporal and spatial features of thermography frames to enhance flaw detection. By using the NLBSS algorithm, material internal defects can be automatically detected. Furthermore, this processing approach compensates for experimental thermal imaging artifacts, such as noise and uneven heating. By merging artificial intelligence with phtotothermics, the NDE system detects internal calibrated defects of various sizes and depths in AM nuclear-grade metallic alloys.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Material Control and Accounting for Liquid-Fueled Molten Salt Reactors: Material Control and Holdup Considerations

The US Nuclear Regulatory Commission (NRC) will likely require license applicants for liquid-fueled molten salt reactors (MSRs) with circulating fuel to submit a nuclear material control and accounting (MC&A) plan or detailed MC&A program description for the facility. In liquid-fueled MSRs with special nuclear material (SNM) in bulk (i.e., not in discrete items) form and rapidly changing quantities due to fuel transmutation and depletion, using traditional nuclear material accounting methods with material balance evaluations is challenging. In reactors with changing inventories, these expected quantities of SNM must be calculated based on operational parameters. Reducing uncertainties on these expected quantities is challenging in the case of MSRs without decades of operational experience to verify and validate predictive computational codes. Moreover, many areas in MSRs are inaccessible because of high-temperature and high-radiation environments, making measurements challenging.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2026

Specimen sizing and remaining life sample calculations for high temperature reactor material surveillance

Advanced high-temperature nuclear reactors rely on structural components that will operate for decades under combined mechanical, thermal, and environmental loading. Materials surveillance programs are a promising strategy for managing the resulting uncertainty in long-term structural integrity by monitoring degradation in service using passively actuated mechanical test articles. Previous reports have developed a simplified, spreadsheetimplementable framework for sizing these test articles and for inferring accumulated creep damage and remaining life from ex-situ test data. This report advances that work toward practical deployment by providing a sample-problem book: a collection of worked, end-toend examples in which the ASME Section III, Division 5 design analysis of a representative high-temperature reactor component is carried through to a sized surveillance article, verified with detailed finite-element analysis, and concluded with a remaining-life assessment based on an assumed ex-situ creep-rate measurement on the retrieved specimen. The report also summarizes ongoing ANL engagement with ASTM Committee E10 on Nuclear Technology and Applications toward drafting a standard covering surveillance procedures for advanced reactors.

Barua, Bipul (ORCID:0000000247184113)↗
DOE OSTI2024

Fast Reactor Materials R&D Update

Presentation detailing Major focus: Deployment of A709 for fast reactor structural applications in the area of Design, Fabrication, Supply Chain, and Adx Rx Operation. Also discuss additional work to support A709 development, High level timeline for Irradiation design data, and processing parameters.

36 MATERIALS SCIENCE↗
DOE OSTI2019

PTT System Performance Evaluation in 3-D Imaging of Calibrated Defects: Pulsed Thermal Tomography Nondestructive Examination of Additively Manufactured Reactor Materials and Components

Research activity in this project is aimed at developing pulsed thermal tomography (PTT) architecture and algorithms for in-service non-destructive examination (NDE) of additively manufactured (AM) reactor components and materials. Recent advances in AM technology could allow cost-efficient fabrication of parts for operating reactors. However, because of stringent safety requirements, long-term performance of AM reactor components needs to be investigated before AM is widely accepted. Because of the complex shapes and significant surface roughness of components due to layer-by-layer welding process in AM, conventional methods might not be useful for in-service NDE of AM components. PTT is ideally suited for in-service NDE of AM metallic components because the method is non-contact, and offers high resolution #-D imaging of material flaws. The objective of this report is to provide initial evaluate of PTT performance sin detecting calibrated flaws in reactor structural materials. Preliminary COMSOL models were developed to conduct super computing simulations of PTT. In the experimental studies, high strength Stainless Steel 316 and Inconel 718 alloys were considered, as well as lower grade Stainless Steel 304, Nickel 200, and Hastelloy C276. Specimens investigated in this report consisted of approximately 1/4in-thick plates made out of these alloys using conventional manufacturing methods. The calibrated defects were created in the form of flat bottom holes (FBH) drilled in metallic plates. The diameters of FBH's varied from 1mm to 8mm, and their depths below the plate flat surface varied between 1mm and 6mm. The size of the smallest FBH was limited to 1mm because conventional mechanic drills were used for creating the holes. PTT imaging results have shown that 1mm-diameter FBH located 1mm and 2mm below the surface were detectable. Larger size FBH were detectable at greater depth. For example, 6mm-diameter FBH could be detected at 8mm depth. Image contrast varied slightly between the specimens, with the best reconstructions obtained in SS316 and C276 plates. In addition, a 2/3in-thick Inconel 718 nozzle plate produced with additive manufacturing method was imaged with PTT. It was shown that PTT can scan through the plate in approximately 20s. Several modes of 3-D data visualization were explored, including using ImageJ and MATLAB software packages.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2025

Guidance Regarding Probable Approaches and Instrumentation to Liquid Fuel Molten Salt Reactor Material Control and Accounting (MC&A) Rev. 1

With the rapid development of advanced reactors and numerous companies requesting pre-application engagements with the Nuclear Regulatory Commission (NRC), there is need for the NRC to best prepare themselves for new challenges presented by advanced technologies. One specific reactor type of interest is the molten salt reactor (MSR) that uses liquid salt as the fuel for the reactor. Liquid salt fuel reactors have specific challenges with regards to performing material control and accounting (MC&A). The challenges result from the fuel form being a continuous fissile material form rather than discrete units like is found with fuel assemblies in traditional light water reactors (LWRs). The goal of this document is to provide the NRC with guidance on the different approaches and technologies that may be proposed by reactor designers to address these problems to prepare staff for regulatory reviews.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2026

Development of a Framework and Methodology for an Advanced Reactor Materials Environmental Effects Design Guide

Advanced non-light-water reactor components may operate at elevated temperature while experiencing cyclic loading, significant neutron irradiation, and exposure to reactor coolant. ASME Boiler and Pressure Vessel Code, Section III, Division 5, provides design rules for elevated-temperature service but does not include specific procedures to account for environmental effects on material properties. This report develops an initial framework and methodology for an Environmental Effects Design Guide (EEDG) focused on neutron irradiation; coolant-environment effects are reserved for future work. The proposed approach treats irradiation as a property-based overlay on the existing Division 5 design process, with two routes: a sparse-data route applying two reduction factors — FCR on creep-rupture strength and FF on fatigue life — for the creep-fatigue evaluations that typically control the design of advanced high-temperature reactor components, and a fuller framework developing the property-to-rule chain across the four Division 5 checks (primary load, strain limits and ratcheting, creep-fatigue, and buckling), together with swelling and weldments as scope items. Both routes are scoped by an in-pile qualification that restricts the use of post-irradiation-examination-derived properties in regimes where an in-pile mechanism could control the design outcome. Illustrative outputs derived on a compiled annealed Type 316 database — FCR ≈ 0.78–0.86 and FF ≈ 0.4 — demonstrate the calculation method within that specific dataset. The framework is an initial, testable design-rule concept; it identifies a practical path for preliminary design evaluations under sparse data and the material data and testing needed to develop the framework further.

Barua, Bipul (ORCID:0000000247184113)↗
DOE OSTI2023

Fast Reactor Materials R&D Update

Focus on materials and design methods to support advanced reactors deployment Design, construction, licensing and operations

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2025

High Temperature Gas Cooled Reactor Materials

Overview of high temperature materials testing within the ART Gas Cooled Reactor Program. Covers 800H weldment creep testing and Alloys 617 and 709 creep and creep-fatigue crack growth rate testing.

36 - MATERIALS SCIENCE↗
DOE OSTI2024

Promoting regulatory acceptance of combined ion and neutron irradiation testing of nuclear reactor materials: Modeling and software considerations

As the needs for the nuclear energy industry continue to evolve in the 21st century, timely adoption of new technological solutions acceptable to regulatory agencies is critical. Quantitative prediction of radiation damage in materials and its impact on mechanical properties is a key component of licensing and regulatory decisions regarding nuclear power plants. Accelerated testing methodologies such as combined ion and neutron irradiation data sets are crucial for the development and deployment of new materials and new manufacturing methods (e.g., additive manufacturing). However, regulatory acceptance of accelerated testing methodologies is necessary for their adoption. Further, the present work discusses the fundamental basis for comparing ion- and neutron-induced material microstructures, the theory behind interpreting radiation damage across length and time scales and radiation types, and the codes, standards, and quality assurance concerns surrounding different modeling methods and software. In particular, recommendations are given as to the path forward that will enable national laboratories, academia, and industry to develop the modeling and software basis for regulatory acceptance of the combined use of ion and neutron irradiation for material performance evaluation.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗