Busby, Jeremy | Engineering Papers

DOE OSTI2024

How irradiation promotes intergranular stress corrosion crack initiation

Irradiation assisted stress corrosion cracking (IASCC) is a form of intergranular stress corrosion cracking that occurs in irradiated austenitic alloys. It requires an irradiated microstructure along with high temperature water and stress. The process is ubiquitous in that it occurs in a wide range of austenitic alloys and water chemistries, but only when the alloy is irradiated. Despite evidence of this degradation mode that dates back to the 1960s, the mechanism by which it occurs has remained elusive. Here, using high resolution electron backscattering detection to analyze local stress-strain states, high resolution transmission electron microscopy to identify grain boundary phases at crack tips, and decoupling the roles of stress and grain boundary oxidation, we are able to unfold the complexities of the phenomenon to reveal the mechanism by which IASCC occurs. The significance of the findings impacts the mechanical integrity of core components of both current and advanced nuclear reactor designs worldwide.

36 MATERIALS SCIENCE↗

DOE OSTI2021

Varied enhancements in mechanical properties and sodium compatibility of Grade 92 by thermomechanical treatments

As a candidate material for advanced nuclear reactors, a ferritic-martensitic (FM) steel Grade 92 in the standard normalized and tempered (NT) condition was subjected to two types of thermomechanical treatments (TMTs) with one having a lower level of deformation (T5A) and the other having a higher level of deformation (T5B). The testing results of the three conditions indicated that the TMTs significantly improved yield strength, creep resistance, fracture toughness, and sodium corrosion resistance compared with the NT condition. T5A excelled at creep resistance while T5B at sodium corrosion resistance. Microstructural characterization of the three conditions supports the varied enhancements in the properties. This study suggests that an appropriate TMT can be developed and applied to FM steels to better meet specific application requirements.

36 MATERIALS SCIENCE↗

DOE OSTI2021

A microscopic and crystallographic study of proton irradiated alloy 718

Solution annealing and age hardening are important processes for achieving good engineering and chemical properties of alloy 718. The composition of alloy 718 also plays an important role as it can affect both mechanical (γ”- and γ’-phase formation) and irradiation behaviors. Therefore, in this study five different sets of alloy 718 samples with two different chemical compositions were fabricated using different processing conditions and irradiated up to 4 dpa. Based on the effects of irradiation on the microstructural data of γ”- and γ’-phases, irradiation-induced dislocation statistics, and crystallographic data, it can be inferred that the samples processed at high solution annealing temperature (1093°C) behave better under irradiation compared to the samples processed at low solution annealing temperatures (945 and 1065°C).

36 MATERIALS SCIENCE↗

DOE OSTI2019

Technical Gap Assessment for Materials and Component Integrity Issues for Molten Salt Reactors

Material selection and qualification is an important consideration for the deployment of molten salt reactors (MSRs). This report summarizes the most important materials issues that must be considered for licensing MSRs. Because of the variety of MSR designs under consideration, this report considers materials for both fluoride and chloride applications, with both fast and thermal neutron spectra.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2018

Technologies to Reactors: Enabling Accelerated Deployment of Nuclear Energy Systems Workshop Report

Nuclear energy provides almost 20% of the electric power in the United States, producing power with high availability while accounting for 63% of our carbon-free energy production. While we have the capacity to expand this clean power source within the United States, we have not built any advanced reactor plant designs in our rapidly evolving electricity generation market, where cost is a major driver. With construction cost and plant safety being major elements of cost for new nuclear, advanced reactor technologies could provide lower cost, safer, carbon-free, grid-resilient energy sources for the US electricity grid. When the current fleet of nuclear reactors was originally designed, many of today’s science and technology (S&T) advances were not available. Today these advances show great promise for transforming our national approach to nuclear reactor design. Other industries are capitalizing on rapid innovations in materials, manufacturing, sensors and control systems, and high-fidelity modeling and simulation (M&S), along with data analytics to provide lower costs in manufacturing and extended ranges of operations. In the nuclear industry, these innovations can translate into similar benefits as well as rapid design and qualification of advanced nuclear fuels. Effectively implementing these types of innovations could position American expert leadership to compete more fully in the international nuclear energy market. In July of 2018, the US Department of Energy (DOE) Office of Nuclear Energy sponsored a workshop to address these possibilities: “Technologies to Reactors: Enabling Accelerated Deployment of Nuclear Energy Systems.” Workshop participants explored how modern and emerging S&T can be used to transform the approach to nuclear reactor design, licensing, and operation to accelerate deployment of advanced nuclear energy systems. More than 80 experts from federal agencies, academia, and industry participated in the workshop to develop consensus on priority technology directions (PTDs) and recommend technology and deployment initiatives to explore and demonstrate key benefits for the nuclear community.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2017

Plastic Deformation Processes Accompanying Stress Corrosion Crack Propagation in Irradiated Austenitic Steels

During stress corrosion crack propagation, stress values in the crack tip vicinity often exceed material yield stress limit. Plastic deformation processes may accompany and influence cracking. Here, stress corrosion crack propagation and deformation mechanisms were investigated using EBSD analysis. The investigated material was 304L Ti-enriched austenitic stainless steel irradiated to 10.4 dpa at 320°C in the BOR-60 fast reactor. Crack growth tests were conducted in a simulated Normal Water Chemistry (NWC) environment in the temperature range 288–320 °C using compact tension specimens. By analyzing crack trajectory and grain structure in the crack vicinity, it was established that grain orientation with respect to the acting stress direction was not a key factor controlling crack propagation. No crystallographic orientation susceptible to cracking was identified. Also, EBSD analysis revealed strong inhomogeneity in plastic strain distribution along the crack path. Most crack-adjacent grains remained virtually strain-free whereas few grains experienced strong plastic strain. These areas were presumed to be “plastic bridges” or “ductile ligaments.”

Gussev, Maxim N↗

DOE OSTI2017

Basic Research Needs for Future Nuclear Energy: Report of the Basic Energy Sciences Workshop for Future Nuclear Energy, August 9-11, 2017

Nuclear power today accounts for approximately 20% of the electrical supply for the US. It provides reliable energy that helps to stabilize the national grid. In contrast to current nuclear power facilities, future concepts operate at higher temperatures, are operationally more efficient, more fully utilize the energy stored within the fuel, and reduce the amount of waste produced. Recent advances in chemistry and materials sciences provide an unprecedented opportunity to develop the critical systems—the fuel, coolant, and structural materials—needed for deployment of advanced nuclear reactor designs. To address the challenge of stringent demands on material systems as their properties and performance continuously evolve over the operational lifetime, the frameworks to uncover the underlying processes that cause reduced performance have been developed over the last decade. There is now the prospect of designing materials that report upon their own damage, are self-healing, and leverage what would be considered deleterious chemical processes to increase their performance within advanced reactor designs. Success will provide an energy source needed to secure a stable and safe energy supply for the nation. To identify the key research directions required to discover the chemical processes and material degradation mechanisms that result in loss of performance of the fuel, coolant, and structural materials, nearly 150 theoreticians, computational experts, and experimentalists from industry, national laboratories, academia, and federal agencies participated in a workshop held in August 2017. Based on the discussions held at the workshop, five Priority Research Directions (PRDs) were identified. These PRDs defined the key scientific challenges that must be met as well as the opportunities that can be exploited to achieve a multi-scale spatial and temporal understanding of fundamental processes that govern the properties and performance of the different material systems required for advanced reactors.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2017

Characterization of alloy 718 subjected to different thermomechanical treatments

Chemical phase and microstructural investigations of alloy 718 solution-annealed and age-hardened were performed in this study. We focused on the effects of solution annealing temperature, aging temperature and holding time, and the amount of intermediate cold work on the alloy. We also studied the formation of secondary phases such as γ’-phase, γ”-phase, and δ-phase, grain sizes, and any deformations of the microstructure with respect to the processed conditions. Statistics such as size and number densities of these precipitates with respect to the processing conditions were evaluated and a discussion on optimum conditions in obtaining finer and higher density of γ’- and γ”-phase precipitates is also presented.

36 MATERIALS SCIENCE↗

DOE OSTI2014

Light Water Reactor Sustainability Program Integrated Program Plan

Nuclear power has safely, reliably, and economically contributed almost 20% of electrical generation in the United States over the past two decades. It remains the single largest contributor (more than 70%) of non-greenhouse-gas-emitting electric power generation in the United States. Domestic demand for electrical energy is expected to experience a 31% growth from 2009 to 2035. At the same time, most of the currently operating nuclear power plants will begin reaching the end of their initial 20-year extension to their original 40-year operating license for a total of 60 years of operation. Figure E-1 shows projected nuclear energy contribution to the domestic generating capacity. If current operating nuclear power plants do not operate beyond 60 years, the total fraction of generated electrical energy from nuclear power will begin to decline—even with the expected addition of new nuclear generating capacity. The oldest commercial plants in the United States reached their 40th anniversary in 2009. The U.S. Department of Energy Office of Nuclear Energy’s Research and Development Roadmap (Nuclear Energy Roadmap) organizes its activities around four objectives that ensure nuclear energy remains a compelling and viable energy option for the United States. The four objectives are as follows: (1) develop technologies and other solutions that can improve the reliability, sustain the safety, and extend the life of the current reactors; (2) develop improvements in the affordability of new reactors to enable nuclear energy to help meet the Administration’s energy security and climate change goals; (3) develop sustainable nuclear fuel cycles; and (4) understand and minimize the risks of nuclear proliferation and terrorism. The Light Water Reactor Sustainability (LWRS) Program is the primary programmatic activity that addresses Objective 1. This document summarizes the LWRS Program’s plans.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2013

Light Water Reactor Sustainability Program Integrated Program Plan

Nuclear power has safely, reliably, and economically contributed almost 20% of electrical generation in the United States over the past two decades. It remains the single largest contributor (more than 70%) of non-greenhouse-gas-emitting electric power generation in the United States. Domestic demand for electrical energy is expected to experience a 31% growth from 2009 to 2035. At the same time, most of the currently operating nuclear power plants will begin reaching the end of their initial 20-year extension to their original 40-year operating license for a total of 60 years of operation. Figure E-1 shows projected nuclear energy contribution to the domestic generating capacity. If current operating nuclear power plants do not operate beyond 60 years, the total fraction of generated electrical energy from nuclear power will begin to decline—even with the expected addition of new nuclear generating capacity. The oldest commercial plants in the United States reached their 40th anniversary in 2009. The U.S. Department of Energy Office of Nuclear Energy’s Research and Development Roadmap (Nuclear Energy Roadmap) organizes its activities around four objectives that ensure nuclear energy remains a compelling and viable energy option for the United States. The four objectives are as follows: (1) develop technologies and other solutions that can improve the reliability, sustain the safety, and extend the life of the current reactors; (2) develop improvements in the affordability of new reactors to enable nuclear energy to help meet the Administration’s energy security and climate change goals; (3) develop sustainable nuclear fuel cycles; and (4) understand and minimize the risks of nuclear proliferation and terrorism. The Light Water Reactor Sustainability (LWRS) Program is the primary programmatic activity that addresses Objective 1. This document summarizes the LWRS Program’s plans.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2012

Light Water Reactor Sustainability Program Integrated Program Plan

Nuclear power has safely, reliably, and economically contributed almost 20% of electrical generation in the United States over the past two decades. It remains the single largest contributor (more than 70%) of non-greenhouse-gas-emitting electric power generation in the United States. Domestic demand for electrical energy is expected to experience a 31% growth from 2009 to 2035. At the same time, most of the currently operating nuclear power plants will begin reaching the end of their initial 20-year extension to their original 40-year operating license for a total of 60 years of operation. Figure E-1 shows projected nuclear energy contribution to the domestic generating capacity. If current operating nuclear power plants do not operate beyond 60 years, the total fraction of generated electrical energy from nuclear power will begin to decline - even with the expected addition of new nuclear generating capacity. The oldest commercial plants in the United States reached their 40th anniversary in 2009. The U.S. Department of Energy Office of Nuclear Energy's Research and Development Roadmap (Nuclear Energy Roadmap) organizes its activities around four objectives that ensure nuclear energy remains a compelling and viable energy option for the United States. The four objectives are as follows: (1) develop technologies and other solutions that can improve the reliability, sustain the safety, and extend the life of the current reactors; (2) develop improvements in the affordability of new reactors to enable nuclear energy to help meet the Administration's energy security and climate change goals; (3) develop sustainable nuclear fuel cycles; and (4) understand and minimize the risks of nuclear proliferation and terrorism. The Light Water Reactor Sustainability (LWRS) Program is the primary programmatic activity that addresses Objective 1. This document summarizes the LWRS Program's plans.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

NASA NTRS2008

Structural Materials and Fuels for Space Power Plants

A fission reactor combined with Stirling convertor power generation is one promising candidate in on-going Fission Surface Power (FSP) studies for future lunar and Martian bases. There are many challenges for designing and qualifying space-rated nuclear power plants. In order to have an affordable and sustainable program, NASA and DOE designers want to build upon the extensive foundation in nuclear fuels and structural materials. This talk will outline the current Fission Surface Power program and outline baseline design options for a lunar power plant with an emphasis on materials challenges. NASA first organized an Affordable Fission Surface Power System Study Team to establish a reference design that could be scrutinized for technical and fiscal feasibility. Previous papers and presentations have discussed this study process in detail. Considerations for the reference design included that no significant nuclear technology, fuels, or material development were required for near term use. The desire was to build upon terrestrial-derived reactor technology including conventional fuels and materials. Here we will present an overview of the reference design, Figure 1, and examine the materials choices. The system definition included analysis and recommendations for power level and life, plant configuration, shielding approach, reactor type, and power conversion type. It is important to note that this is just one concept undergoing refinement. The design team, however, understands that materials selection and improvement must be an integral part of the system development.

Bowman, Cheryl↗