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Gerczak, Tyler J.

Publications and source records attributed to Gerczak, Tyler J..

The effect of powder feedstock and heat treatment on the thermal and mechanical properties of binder jet printed ZrC

In this study, zirconium carbide (ZrC) disks were fabricated using binder jet printing to study the effect of powder feedstock, print parameters, and heat treatment on flowability and final materials properties. A median volumetric particle size smaller than 10 μm was shown to cause the powder to stop flowing during printing. Disks were printed using ZrC with suitable flowability and then heat-treated at temperatures between 1800°C and 2200°C for 1 or 5h. The density, part shrinkage, thermal diffusivity, and fracture strength all increased with increasing temperature and time. The heat-treated disks were then heated to 2200°C for 5h and the properties converged for disks of the same particle size, indicating the hottest temperature and longest time of exposure dictates the final properties. Lastly, it was shown that larger particles produce lower density materials with worse thermal diffusivity, most likely because of poor connectivity between particles after heat treatment.

36 MATERIALS SCIENCE↗

Quality Control Methods for Measurement of UCO Kernel Composition and SiC Microstructure

Quality control (QC) is critically important to tristructural-isotropic (TRISO) particle fuels owing to the complexity of and reliance on the fuel form to contain fission products during irradiation. Characterization methods for particle fuel QC have decades of history and have continued to develop as new insights into fuel performance inform revised fuel specifications and as advances in underlying technologies expand the possibilities of what may be characterized. Two relatively new methods for characterization of TRISO fuels have been published in open literature: optical microscopy image analysis for mixed uranium carbide/uranium oxide (UCO) kernel composition analysis and automated grain boundary detection in backscattered electron (BSE) images of the silicon carbide (SiC) layer in TRISO particles for grain size characterization. Suggestions and guidelines for the application of these methods to TRISO fuel qualification are provided in this report.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Structure–property relations in graphitic pebbles for nuclear applications

This work presents an analytical approach for holistically characterizing graphitic matrix pebbles for nuclear applications whereby the macrostructure, microstructure, and thermophysical properties of pebbles are determined. A systematic sectioning method was applied to several pebbles to describe the regional properties of the samples. Intact matrix-only spheres and sections of spheres fabricated by Kairos Power were characterized via optical imaging, x-ray computed tomography, x-ray diffraction, and ellipsometry to determine 2D and 3D macrostructure and anisotropy. The thermophysical properties of these materials were determined via measurements of density, specific heat, thermal expansion, and thermal diffusivity. The results of this study indicate that the pebble fabrication methods and their resultant effect on microstructure have a nontrivial effect on thermophysical properties, confirming the importance of robust characterization of these components. A discussion of the characterization approach and its applicability to nuclear fuel development activities is also included.

42 ENGINEERING↗

UCO TRISO Minifuel FY23 NSUF-Kairos Power Post-Irradiation Examination Status Report

Irradiation of miniature tristructural isotropic (TRISO)–coated particle fuel compacts at high-power particle was performed in the Oak Ridge National Laboratory’s (ORNL’s) High Flux Isotope Reactor (HFIR) using the MiniFuel irradiation capability. Each compact comprised 20 TRISO particles with a low-enriched uranium carbide uranium oxide (UCO), natural UCO, or low-enriched UO 2 kernel within a graphitic matrix. After irradiation, the MiniFuel targets and subcapsules were disassembled to recover the irradiated fuel specimens and pursue post-irradiation examination (PIE) to inform Kairos Power on the fuel specimen performance. This report describes the PIE results collected to date, including dilatometry on the passive thermometry to confirm the irradiation temperature, fission gas release measurements, and gamma counting. This work was funded by the Nuclear Science User Facilities program.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Comparison of unirradiated and irradiated AGR-2 TRISO fuel particle oxidation response

The silicon carbide (SiC) coating in a tristructural isotropic (TRISO) particle acts as a barrier to fission product release during reactor operation and accident scenarios. Oxidation and subsequent failure of the SiC layer during a rare air ingress event is a proposed mechanism for fission product release in a high-temperature gas-cooled reactor (HTGR). Although previous oxidation studies have analyzed unirradiated TRISO particle response, this study compared the oxidation behavior of irradiated and unirradiated TRISO particles from the second Advanced Gas Reactor Fuel Development and Qualification Program irradiation experiment (AGR-2). Particles with exposed SiC were subjected to six varying oxidizing tests in the Furnace for Irradiated TRISO Testing (FITT), examined for failure fraction with the Irradiated Microsphere Gamma Analyzer (IMGA) and characterized with focused ion beam and scanning/transmission electron microscopy techniques to analyze the oxide layer. Uncorrelated unirradiated particle failures throughout the series of exposures suggests that external factors inherent to the experiment increased particle failure sensitivity. However, irradiated particle observations indicated an increased failure response at 400 h 1400 °C in both 2% and 21% O 2 atmospheres above failure associated with external factors. Oxide thickness measurements after 400 h at 1400 °C revealed a greater oxidation rate than predicted by parabolic growth, which was attributed to the increased complexity of the oxide structure at longer exposure times. Altering the atmosphere from 21% to 2% O 2 reduced the average oxide thickness by approximately 12%–14% in both irradiated and unirradiated particles at 400 h 1400 °C. Altogether, the minor variations observed between irradiated and unirradiated particles in this study led to the conclusion that unirradiated TRISO particles can be used to approximate irradiated TRISO oxidation kinetics.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Microstructural analysis of tristructural isotropic particles in high-temperature steam mixed gas atmospheres

High-temperature gas-cooled reactors (HTGRs) use tristructural isotropic (TRISO) particles embedded in a graphitic matrix material to form the integral fuel element. Potential off-normal reactor conditions for HTGRs include steam ingress with temperatures above 1,000 °C. Fuel element exposure to steam can cause the graphitic matrix material to evolve, forming an atmosphere composed of oxidants and oxidation products and potentially exposing the TRISO particles to these conditions. Investigating the oxidation response of TRISO particles exposed to a mixed gas atmosphere will provide insight into the stability under off-normal conditions. In this study, surrogate TRISO particles were exposed to high temperatures (T = 1,200 °C) in flowing steam (3% < pH 2 O < 21%) and CO (pCO < 1%) to determine the oxidation behavior of the SiC layer when exposed to various mixed gas atmospheres. Scanning electron microscopy, x-ray diffraction, and focused ion beam milling was used to determine the impact of CO and steam on the oxidation behavior of the SiC layer. Therefore, the data presented demonstrates how the SiC layer showed strong oxidation resistance due to limited SiO 2 growth and maintained its structural integrity under these off-normal conditions.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Investigation of Coincidence Counting for Improving Minimal Detectable Activity of 110m Ag in Single Particle Gamma Analysis

Post-irradiation examination (PIE) of fuel particles from the fourth Advanced Gas Reactor Fuel Development and Qualification (AGR) Program irradiation (AGR-5/6/7) is being performed at Oak Ridge National Laboratory (ORNL). Tristructural isotropic (TRISO)-coated particles and associated compacts for the AGR-5/6/7 experiment fabricated by BWX Technologies Nuclear Operations Group were formed into a graphite matrix compact and irradiated at the Advanced Test Reactor at Idaho National Laboratory. At ORNL, particles are deconsolidated from the graphite matrix compact and individually scanned for emitted gamma rays with the Irradiated Microsphere Gamma Analyzer (IMGA). The IMGA system comprises a single high purity germanium (HPGe) detector, an automated particle handling vacuum system, and an ORTEC DSPEC-50 digital spectrometer for gamma ray analysis. IMGA quantifies gamma ray-emitting fission product inventories of individual TRISO particles, and these inventories can be compared with the measured average inventories per particle and radionuclide inventories predicted by AGR-5/6/7 physics calculations to determine if a particle experienced radionuclide release. Details on IMGA data collection methods can be found in the literature. The TRISO particle’s SiC layer provides structural support, as well as a barrier for fission product release during irradiation or subsequent safety testing. A weakened or compromised SiC layer can be identified by the release of radionuclides, such as 137 Cs, which is detected by IMGA. However, select radionuclides, such as 90 Sr, 110 mAg, and 154 Eu have been shown to migrate through an intact SiC layer. Measurement of the radionuclide 110 mAg is significant as its release has been shown to be particularly sensitive to in-reactor conditions (e.g., temperature) with broad variable particle to-particle release behaviors observed within a single compact. As such, 110 mAg activity is often used for particle selection for comprehensive PIE as bounding 110 mAg retention particles are hypothesized to represent limits in particle behaviors within a compact. As TRISO particle fuel PIE activities continue over time, IMGA measurements of the 110 mAg inventory are eventually hindered because of its relatively short half-life (~250 days). As the fuel ages from its end of irradiation (EOI) date, the measurement uncertainty and minimum detectable activity (MDA) of 110m Ag increase because the detector background continuum begins to dominate. For particles from the second AGR irradiation experiment (AGR-2), the 110m Ag MDA was above 20% of the calculated average particle inventory after approximately five half-lives, and 110m Ag activity was no longer measurable with IMGA after approximately seven half-lives. Therefore, coincidence counting approaches have been explored to determine feasibility of leveraging new approaches to overcome limitations associated with increasing MDA over time.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Simulation of a TRISO MiniFuel irradiation experiment with data-informed uncertainty quantification

An irradiation experiment using tristructural isotropic (TRISO) fuel particles and the miniature fuel (MiniFuel) irradiation vehicle was performed in Oak Ridge National Laboratory’s High Flux Isotope Reactor (HFIR) to support development of the Kairos Power fluoride salt–cooled, high-temperature reactor (KP-FHR). Here, this paper describes modeling predictions of temperatures and fuel burnup for the as-built experiment. An uncertainty quantification (UQ) analysis was performed to determine the effect of TRISO particle volume and position on the temperature predictions at various fuel heat generation rates (HGRs). This UQ study utilized fuel kernel position and volume measurements previously collected using X-ray computed tomography (XCT) techniques and Monte Carlo sampling methods to generate fuel compact cases that were then analyzed using a finite element thermal model. The UQ analysis indicated that uncertainty in calculated temperatures caused by varying TRISO particle arrangement is relatively small, even at high fuel HGR. Final predictions of particle temperatures throughout the irradiation are shown to be relevant to KP-FHR normal and off-normal operating conditions and to previous TRISO irradiation experiments. The combination of XCT with UQ analyses will inform post-irradiation examination (PIE) of the irradiated fuel compacts, and these analyses can be used to develop fuel performance models for coated particle fuel forms. Both PIE of separate-effects irradiation data and enhanced fuel performance modeling support accelerated qualification of TRISO fuels for a broad range of advanced reactor applications. The novel approach demonstrated here of measuring TRISO particle configurations with XCT methods and generating representative fuel compacts for finite element modeling and UQ analysis could be leveraged by the broader particle fuel community in the development of other TRISO fuel experiments in which these variables may have a significant impact on key outcomes.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗