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DOE OSTI2016

Nuclear Energy Enabling Technologies (NEET) Reactor Materials: News for the Reactor Materials Crosscut, May 2016

In this newsletter for Nuclear Energy Enabling Technologies (NEET) Reactor Materials, pages 1-3 cover highlights from the DOE-NE (Nuclear Energy) programs, pages 4-6 cover determining the stress-strain response of ion-irradiated metallic materials via spherical nanoindentation, and pages 7-8 cover theoretical approaches to understanding long-term materials behavior in light water reactors.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
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 OSTI2017

Irradiation effects in Generation IV nuclear reactor materials

Generation IV reactor structural materials will be exposed to high doses and temperatures during reactor operation that may lead to irradiation-induced degradation. This degradation will differ from that seen in light water reactors and therefore understanding mechanisms controlling material performance during irradiation is critical for evaluating viability of Generation IV nuclear reactor concepts. This chapter discusses irradiation effects and microstructural changes that affect mechanical properties and dimensional stability of Generation IV reactor materials.

36 MATERIALS SCIENCE↗
DOE OSTI2016

Final Report on Developing Microstructure-Property Correlation in Reactor Materials using in situ High-Energy X-rays

This report provides a summary of research activities on understanding microstructure – property correlation in reactor materials using in situ high-energy X-rays. The report is a Level 2 deliverable in FY16 (M2CA-13-IL-AN_-0403-0111), under the Work Package CA-13-IL-AN_- 0403-01, “Microstructure-Property Correlation in Reactor Materials using in situ High Energy Xrays”, as part of the DOE-NE NEET Program. The objective of this project is to demonstrate the application of in situ high energy X-ray measurements of nuclear reactor materials under thermal-mechanical loading, to understand their microstructure-property relationships. The gained knowledge is expected to enable accurate predictions of mechanical performance of these materials subjected to extreme environments, and to further facilitate development of advanced reactor materials. The report provides detailed description of the in situ X-ray Radiated Materials (iRadMat) apparatus designed to interface with a servo-hydraulic load frame at beamline 1-ID at the Advanced Photon Source. This new capability allows in situ studies of radioactive specimens subject to thermal-mechanical loading using a suite of high-energy X-ray scattering and imaging techniques. We conducted several case studies using the iRadMat to obtain a better understanding of deformation and fracture mechanisms of irradiated materials. In situ X-ray measurements on neutron-irradiated pure metal and model alloy and several representative reactor materials, e.g. pure Fe, Fe-9Cr model alloy, 316 SS, HT-UPS, and duplex cast austenitic stainless steels (CASS) CF-8 were performed under tensile loading at temperatures of 20-400°C in vacuum. A combination of wide-angle X-ray scattering (WAXS), small-angle X-ray scattering (SAXS), and imaging techniques were utilized to interrogate microstructure at different length scales in real time while the specimen was subject to thermal-mechanical loading. In addition, in situ X-ray studies were complemented and benchmarked by ex situ characterization using advanced electron microscopy, atom probe tomography (APT) and micro/nano-indentation. The report presented in situ tensile test results on neutron-irradiated pure Fe, Fe-9Cr model alloy, 316 SS and CASS CF-8. These in situ experiments demonstrate the broad applications of the new capability in understanding several outstanding issues related to irradiated materials.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2017

Predictive characterization of aging and degradation of reactor materials in extreme environments. Final report, December 20, 2013 - September 20, 2017

Understanding of reactor material behavior in extreme environments is vital not only to the development of new materials for the next generation nuclear reactors, but also to the extension of the operating lifetimes of the current fleet of nuclear reactors. To this end, this project conducted a suite of unique experimental techniques, augmented by a mesoscale computational framework, to understand and predict the long-term effects of irradiation, temperature, and stress on material microstructures and their macroscopic behavior. The experimental techniques and computational tools were demonstrated on two distinctive types of reactor materials, namely, Zr alloys and high-Cr martensitic steels. These materials are chosen as the test beds because they are the archetypes of high-performance reactor materials (cladding, wrappers, ducts, pressure vessel, piping, etc.). To fill the knowledge gaps, and to meet the technology needs, a suite of innovative in situ transmission electron microscopy (TEM) characterization techniques (heating, heavy ion irradiation, He implantation, quantitative small-scale mechanical testing, and various combinations thereof) were developed and used to elucidate and map the fundamental mechanisms of microstructure evolution in both Zr and Cr alloys for a wide range environmental boundary conditions in the thermal-mechanical-irradiation input space. Knowledge gained from the experimental observations of the active mechanisms and the role of local microstructural defects on the response of the material has been incorporated into a mathematically rigorous and comprehensive three-dimensional mesoscale framework capable of accounting for the compositional variation, microstructural evolution and localized deformation (radiation damage) to predict aging and degradation of key reactor materials operating in extreme environments. Predictions from this mesoscale framework were compared with the in situ TEM observations to validate the model.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2016

Advanced 3D Characterization and Reconstruction of Reactor Materials FY16 Final Report

A coordinated effort to link advanced materials characterization methods and computational modeling approaches is critical to future success for understanding and predicting the behavior of reactor materials that operate at extreme conditions. The difficulty and expense of working with nuclear materials have inhibited the use of modern characterization techniques on this class of materials. Likewise, mesoscale simulation efforts have been impeded due to insufficient experimental data necessary for initialization and validation of the computer models. The objective of this research is to develop methods to integrate advanced materials characterization techniques developed for reactor materials with state-of-the-art mesoscale modeling and simulation tools. Research to develop broad-ion beam sample preparation, high-resolution electron backscatter diffraction, and digital microstructure reconstruction techniques; and methods for integration of these techniques into mesoscale modeling tools are detailed. Results for both irradiated and un-irradiated reactor materials are presented for FY14 - FY16 and final remarks are provided.

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 OSTI2016

Thermal Desorption of Tritium from Fluoride Salt-Cooled Reactor Materials

The fluoride-salt-cooled high-temperature reactor (FHR) is a high-temperature fission reactor concept involving a liquid fluoride salt coolant, coated particle fuel, and enhanced passive safety mechanisms. Utilizing a low-pressure coolant and high temperature fuel allows for smaller reactor buildings and use of gas Brayton power cycles for higher efficiency in electricity production. One of the fluoride salts being considered for the FHR coolant is 2LiF - BeF{sub 2} (flibe). Tritium is generated frequently in flibe from thermal neutron transmutation of Li-6 and Be-9. Tritium retention in irradiated structural materials presents a challenge to the design of the FHR; high neutron fluence can induce significant material damage and alteration of microstructures to trap tritium in the structure, particularly in carbon-based materials (such as steels). Investigation of tritium transport in flibe salt and structural materials is also critical to evaluating mass balance of tritium in a system for quantifying leakage of tritium to the environment. It is important to understand the uptake of tritium in these proposed core materials since the transport of tritium within an FHR is of critical concern for operational safety due to corrosion, and to prevent tritium release into the environment. The presence of TF corrodes stainless steel by oxidizing chromium. Tritium gas (T{sub 2}) easily diffuses through reactor materials and can be released into the environment through the primary piping and heat exchangers. There is great interest in identifying materials that are compatible with the FHR environment that can be used to getter tritium from the salt, or to inhibit the diffusion of tritium to prevent its release into the environment. As part of the FHR Integrated Research Project (IRP), capsules containing proposed core materials immersed in flibe salt were irradiated at 700 deg. C for 1000 hours (FS-1) and 300 hours (FS-2) in the MIT Research Reactor (MITR). During irradiation, tritium is produced in the salt, and then interacts with the other materials in the capsule. Measurements of the effluent gas during the FHR IRP irradiation experiments indicated that less than 1% of the tritium generated in the salt escaped in the gas phase. It is assumed that most of the tritium was captured, either via diffusion or surface adsorption, on the materials inside the capsule. Tritium frequently adsorbs to sample surfaces in the form of HTO, which requires relatively low temperatures to release (on the order of 100 deg. C). In certain cases, tritium can be bound in the bulk of materials from diffusion or neutron transmutation of lithium and beryllium in the structural materials. Accurate measurement of very small concentrations of hydrogen is difficult; by taking advantage of the radioactive decay of tritium (which emits low-energy beta radiation), several methods become available to detect and quantitatively measure the tritium. The most sensitive method is liquid scintillation counting (LSC), which requires the tritium to be suspended in optically-transparent liquid media that is compatible with scintillating solution, such as water. This measurement technique requires the tritium to be extracted from the material, which can be achieved through leaching into water, thermal desorption, or complete destruction of the sample by acid digestion or pyrolysis. A less destructive method is preferred in order to preserve the specimens, reduce the generation of radioactive mixed wastes, and minimize the carryover of other activation products. For total thermal desorption of tritium from the materials, the tritiated materials must be heated to temperatures in excess of 300 deg. C. Heating the specimens above the irradiation temperature will re-mobilize the tritium and allow it to be captured from the gas stream directly into LSC media. (authors)

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
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 OSTI2014

Nanocrystalline SiC and Ti 3 SiC 2 Alloys for Reactor Materials: Diffusion of Fission Product Surrogates

MAX phases, such as titanium silicon carbide (Ti 3 SiC 2 ), have a unique combination of both metallic and ceramic properties, which make them attractive for potential nuclear applications. Ti 3 SiC 2 has been suggested in the literature as a possible fuel cladding material. Prior to the application, it is necessary to investigate diffusivities of fission products in the ternary compound at elevated temperatures. This study attempts to obtain relevant data and make an initial assessment for Ti 3 SiC 2 . Ion implantation was used to introduce fission product surrogates (Ag and Cs) and a noble metal (Au) in Ti 3 SiC 2 , SiC, and a dual-phase nanocomposite of Ti 3 SiC 2 /SiC synthesized at PNNL. Thermal annealing and in-situ Rutherford backscattering spectrometry (RBS) were employed to study the diffusivity of the various implanted species in the materials. In-situ RBS study of Ti 3 SiC 2 implanted with Au ions at various temperatures was also performed. The experimental results indicate that the implanted Ag in SiC is immobile up to the highest temperature (1273 K) applied in this study; in contrast, significant out-diffusion of both Ag and Au in MAX phase Ti 3 SiC 2 occurs during ion implantation at 873 K. Cs in Ti 3 SiC 2 is found to diffuse during post-irradiation annealing at 973 K, and noticeable Cs release from the sample is observed. This study may suggest caution in using Ti 3 SiC 2 as a fuel cladding material for advanced nuclear reactors operating at very high temperatures. Further studies of the related materials are recommended.

36 MATERIALS SCIENCE↗
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 OSTI2014

Nanocrystalline SiC and Ti 3 SiC 2 Alloys for Reactor Materials: Annual Report

A new dual-phase nanocomposite of Ti 3 SiC 2 /SiC is being synthesized using preceramic polymers, ceramic powders, and carbon nanotubes (CNTs) designed to be suitable for advanced nuclear reactors and perhaps as fuel cladding. The material is being designed to have superior fracture toughness compared to SiC, adequate thermal conductivity, and higher density than SiC/SiC composites. This annual report summarizes the progress towards this goal and reports progress in understanding certain aspects of the material behavior but some shortcomings in achieving full density or in achieving adequate incorporation of CNTs. The measured thermal conductivity is adequate and falls into an expected range based on SiC and Ti 3 SiC 2 . Part of this study makes an initial assessment for Ti 3 SiC 2 as a barrier to fission product transport. Ion implantation was used to introduce fission product surrogates (Ag and Cs) and a noble metal (Au) in Ti 3 SiC 2 , SiC, and a synthesized at PNNL. The experimental results indicate that the implanted Ag in SiC is immobile up to the highest temperature (1273 K) applied in this study; in contrast, significant out-diffusion of both Ag and Au in MAX phase Ti₃SiC₂ occurs during ion implantation at 873 K. Cs in Ti₃SiC₂ is found to diffuse during post-irradiation annealing at 973 K, and noticeable Cs release from the sample is observed. This study may suggest caution in using Ti 3 SiC 2 as a fuel cladding material for advanced nuclear reactors operating at very high temperatures. Progress is reported in thermal conductivity modeling of SiC-based materials that is relevant to this research, as is progress in modeling the effects of CNTs on fracture strength of SiC-based materials.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗