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At least 1,801 records · Page 100

Severe Accident Test Station (SATS) Activity Report

Enhancing safety margins in light water reactor (LWR) severe accidents is currently the focus of a number of international R&D programs. The current UO 2 /Zr-based alloy fuel system is particularly susceptible since the Zr-based cladding experiences rapid oxidation kinetics in steam at elevated temperatures. Therefore, alternative cladding materials that offer slower oxidation kinetics and a smaller enthalpy of oxidation can significantly reduce the rate of heat and hydrogen generation in the core during a coolant-limited severe accident. In the U.S. program, the high temperature steam oxidation performance of accident tolerant fuel (ATF) cladding solutions has been evaluated in the Severe Accident Test Station (SATS) at Oak Ridge National Laboratory (ORNL) since 2012. This report summarizes the capabilities of the SATS and provides an overview of the oxidation kinetics of several candidate cladding materials. A suggested baseline for evaluating ATF candidates is a two order of magnitude reduction in the steam oxidation resistance above 1000°C compared to Zr-based alloys. The ATF candidates are categorized based on the protective external oxide or scale that forms during exposure to steam at high temperature: chromia, alumina, and silica. Comparisons are made to literature and SATS data for Zr-based alloys and other less-protective materials.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Radiological Toolbox User’s Guide

The Radiological Toolbox software developed by Oak Ridge National Laboratory (ORNL) for U. S. Nuclear Regulatory Commission (NRC) is designed to provide electronic access to the vast and varied data that underlies the field of radiation protection. These data represent physical, chemical, anatomical, physiological, and mathematical parameters detailed in various handbooks which a health physicist might consult while in his office. The initial motivation for the software was to serve the needs of the health physicist away from his office and without access to his handbooks; e.g., NRC inspectors. The earlier releases of the software were widely used and accepted around the world by not only practicing health physicist but also those within educational programs. This release updates the software to accommodate changes in Windows operating systems and, in some aspects, radiation protection. This release has been tested on Windows 7 and 8 and on 32- and 64-bit machines. The nuclear decay data has been updated and thermal neutron capture cross sections and cancer risk coefficients have been included. This document and the software’s user’s guide provide further details and documentation of the information captured within the Radiological Toolbox.

59 BASIC BIOLOGICAL SCIENCES↗

Understanding the Role of Hot Isostatic Pressing Parameters on the Microstructural Evolution of Ti-6Al-4V and Inconel 718 Fabricated by Electron Beam Melting

In this project, Avure and ORNL evaluated the influence of hot isostatic pressing (HIP) and thermal cycling as standalone post processing techniques on the microstructure of electron beam powder bed deposited Ti-6Al-4V and Inconel 718 alloys. Electron beam powder bed deposition is an effective technology for fabricating complex net shape components that cannot be manufactured with conventional processes. However, material deposited by this technology results in columnar grain growth which is detrimental for many applications. For Ti-6Al-4V, it has been found that thermal cycling alone is not sufficient to breakdown the columnar microstructure that is typical of electron beam powder bed technology. HIP, on the other hand, has the potential to be an effective technique to break down the columnar microstructure of Ti-6Al-4V into a more equiaxed and refined β grain structure, and provide a more homogeneous microstructure compared to the thermally cycled samples. Overall, the project showed that hot isostatic pressing reduced/eliminated porosity in both Ti-6Al-4V and Inconel 718 However, based on the unique thermal cycle and the application of pressure in the HIP vessel, Ti-6Al-4V e-beam deposited microstructures were modified from columnar grain growth to equiaxed microstructures; a significant outcome to this collaboration. Inconel 718, on the other hand, shows no change in the macrostructure as a result of the current HIP cycle based on the thermal history, and would require further investigation. Though the results of HIP cycle were very good at changing the microstructure, further development in optimizing the post heat treatments and HIP cycles is required to improve mechanical properties.

36 MATERIALS SCIENCE↗

Alternative Refrigerant Evaluation for High-Ambient Temperature Environments: R-22 and R-410A Alternatives for Mini-Split Air Conditioners

The Oak Ridge National Laboratory (ORNL) High-Ambient Temperature Testing Program for Low-GWP Refrigerants aims to develop an understanding of the performance of low-Global Warming Potential (low-GWP) alternatives to Hydrochlorofluorocarbon (HCFC) and Hydrofluorocarbon (HFC) refrigerants in mini-split air conditioners under high ambient temperature conditions. This interim working paper describes the parties involved, the alternative refrigerants selection process, the test procedures, and the preliminary results.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

Flexible Friction Stir Joining Technology

Reported herein is the final report on a U.S. Department of Energy (DOE) Advanced Manufacturing Office (AMO) project with industry cost-share that was jointly carried out by Oak Ridge National Laboratory (ORNL), ExxonMobil Upstream Research Company (ExxonMobil), and MegaStir Technologies (MegaStir). The project was aimed to advance the state of the art of friction stir welding (FSW) technology, a highly energy-efficient solid-state joining process, for field deployable, on-site fabrications of large, complex and thick-sectioned structures of high-performance and high-temperature materials. The technology innovations developed herein attempted to address two fundamental shortcomings of FSW: 1) the inability for on-site welding and 2) the inability to weld thick section steels, both of which have impeded widespread use of FSW in manufacturing. Through this work, major advance has been made toward transforming FSW technology from a “specialty” process to a mainstream materials joining technology to realize its pervasive energy, environmental, and economic benefits across industry.

36 MATERIALS SCIENCE↗

ADVANTG—An Automated Variance Reduction Parameter Generator (Rev. 1)

The primary objective of ADVANTG is to reduce both the user effort and the computational time required to obtain accurate and precise tally estimates across a broad range of challenging transport applications. ADVANTG has been applied to simulations of real-world radiation shielding, detection, and neutron activation problems. Examples of shielding applications include material damage and dose rate analyses of the Oak Ridge National Laboratory (ORNL) Spallation Neutron Source and High Flux Isotope Reactor (Risner and Blakeman 2013) and the ITER Tokamak (Ibrahim et al. 2011). ADVANTG has been applied to a suite of radiation detection, safeguards, and special nuclear material movement detection test problems (Shaver et al. 2011). ADVANTG has also been used in the prediction of activation rates within light water reactor facilities (Pantelias and Mosher 2013). In these projects, ADVANTG was demonstrated to significantly increase the tally figure of merit (FOM) relative to an analog MCNP simulation. The ADVANTG-generated parameters were also shown to be more effective than manually generated geometry splitting parameters.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

Mechanical Fatigue Testing of High Burnup Fuel for Transportation Applications

This report describes testing designed to determine the ability of high burnup (HBU) (>45 GWd/MTU) spent fuel to maintain its integrity under normal conditions of transportation. An innovative system, Cyclic Integrated Reversible-bending Fatigue Tester (CIRFT), has been developed at Oak Ridge National Laboratory (ORNL) to test and evaluate the mechanical behavior of spent nuclear fuel (SNF) under conditions relevant to storage and transportation. The CIRFT system is composed of a U-frame equipped with load cells for imposing the pure bending loads on the SNF rod test specimen and measuring the in-situ curvature of the fuel rod during bending using a set up with three linear variable differential transformers (LVDTs).

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Severe Accident Scoping Simulations of Accident Tolerant Fuel Concepts for BWRs

Accident-tolerant fuels (ATFs) are fuels and/or cladding that, in comparison with the standard uranium dioxide Zircaloy system, can tolerate loss of active cooling in the core for a considerably longer time period while maintaining or improving the fuel performance during normal operations. It is important to note that the currently used uranium dioxide Zircaloy fuel system tolerates design basis accidents (and anticipated operational occurrences and normal operation) as prescribed by the US Nuclear Regulatory Commission. Previously, preliminary simulations of the plant response have been performed under a range of accident scenarios using various ATF cladding concepts and fully ceramic microencapsulated fuel. Design basis loss of coolant accidents (LOCAs) and station blackout (SBO) severe accidents were analyzed at Oak Ridge National Laboratory (ORNL) for boiling water reactors (BWRs). Researchers have investigated the effects of thermal conductivity on design basis accidents, investigated silicon carbide (SiC) cladding, as well as the effects of ATF concepts on the late stage accident progression. These preliminary analyses were performed to provide initial insight into the possible improvements that ATF concepts could provide and to identify issues with respect to modeling ATF concepts. More recently, preliminary analyses for a range of ATF concepts have been evaluated internationally for LOCA and severe accident scenarios for the Chinese CPR1000 and the South Korean OPR-1000 pressurized water reactors (PWRs). In addition to these scoping studies, a common methodology and set of performance metrics were developed to compare and support prioritizing ATF concepts. A proposed ATF concept is based on iron-chromium-aluminum alloys (FeCrAl). With respect to enhancing accident tolerance, FeCrAl alloys have substantially slower oxidation kinetics compared to the zirconium alloys typically employed. During a severe accident, FeCrAl would tend to generate heat and hydrogen from oxidation at a slower rate compared to the zirconium-based alloys in use today. The previous study, [2], of the FeCrAl ATF concept during station blackout (SBO) severe accident scenarios in BWRs was based on simulating short term SBO (STSBO), long term SBO (LTSBO), and modified SBO scenarios occurring in a BWR-4 reactor with MARK-I containment. The analysis indicated that FeCrAl had the potential to delay the onset of fuel failure by a few hours depending on the scenario, and it could delay lower head failure by several hours. The analysis demonstrated reduced in-vessel hydrogen production. However, the work was preliminary and was based on limited knowledge of material properties for FeCrAl. Limitations of the MELCOR code were identified for direct use in modeling ATF concepts. This effort used an older version of MELCOR (1.8.5). Since these analyses, the BWR model has been updated for use in MELCOR 1.8.6, and more representative material properties for FeCrAl have been modeled. Sections 2 4 present updated analyses for the FeCrAl ATF concept response during severe accidents in a BWR. The purpose of the study is to estimate the potential gains afforded by the FeCrAl ATF concept during BWR SBO scenarios.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Development and Quality Assessments of Commercial Heat Production of ATF FeCrAl Tubes

Development and quality assessment of the 2 nd generation ATF FeCrAl tube production with commercial manufacturers were conducted. The manufacturing partners include Sophisticated Alloys, Inc. (SAI), Butler, PA for FeCrAl alloy casting via vacuum induction melting, Oak Ridge National Laboratory (ORNL) for extrusion process to prepare the master bars/tubes to be tube-drawn, and Rhenium Alloys, Inc. (RAI), North Ridgeville, OH, for tube-drawing process. The masters bars have also been provided to Los Alamos National Laboratory (LANL) who works with Century Tubes, Inc., (CTI), San Diego, CA, as parallel tube production effort under the current program.

36 MATERIALS SCIENCE↗

Report of the Final Configuration of the Johnson Noise Thermometry System

This document is a report on the final box and software configuration of the Johnson Noise Thermometry System being developed at ORNL. Much of this has been reported previously so that this report will be a systems-level summary of those reports, In addition we will describe some of the issues encountered during development.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

Evaluation of Additive Manufacturing for Composite Part Molds

The ORNL Manufacturing Demonstration Facility (MDF) collaborated with Tru-Design to test the quality and durability of molds used for making fiber reinforced composites using additive manufacturing. The partners developed surface treatment techniques including epoxy coatings and machining to improve the quality of the surface finish. Test samples made using the printed and surface finished molds demonstrated life spans suitable for one-of-a-kind and low-volume applications, meeting the project objective.

36 MATERIALS SCIENCE↗

High Efficiency Room Air Conditioner

This project was undertaken as a CRADA project between UT-Battelle and Geberal Electric Company and was funded by Department of Energy to design and develop of a high efficiency room air conditioner. A number of novel elements were investigated to improve the energy efficiency of a state-of-the-art WAC with base capacity of 10,000 BTU/h. One of the major modifications was made by downgrading its capacity from 10,000 BTU/hr to 8,000 BTU/hr by replacing the original compressor with a lower capacity (8,000 BTU/hr) but high efficiency compressor having an EER of 9.7 as compared with 9.3 of the original compressor. However, all heat exchangers from the original unit were retained to provide higher EER. The other subsequent major modifications included- (i) the AC fan motor was replaced by a brushless high efficiency ECM motor along with its fan housing, (ii) the capillary tube was replaced with a needle valve to better control the refrigerant flow and refrigerant set points, and (iii) the unit was tested with a drop-in environmentally friendly binary mixture of R32 (90% molar concentration)/R125 (10% molar concentration). The WAC was tested in the environmental chambers at ORNL as per the design rating conditions of AHAM/ASHRAE (Outdoor- 95F and 40%RH, Indoor- 80F, 51.5%RH). All these modifications resulted in enhancing the EER of the WAC by up to 25%.

EER↗

Multi-material Preforming of Structural Composites

Fiber-reinforced composites offer significant weight reduction potential, with glass fiber composites already widely adopted. Carbon fiber composites deliver the greatest performance benefits, but their high cost has inhibited widespread adoption. This project demonstrates that hybrid carbon-glass solutions can realize most of the benefits of carbon fiber composites at much lower cost. ORNL and Owens Corning Reinforcements along with program participants at the ORISE collaborated to demonstrate methods for produce hybrid composites along with techniques to predict performance and economic tradeoffs. These predictions were then verified in testing coupons and more complex demonstration articles.

36 MATERIALS SCIENCE↗

Steam Oxidation of FeCrAl and SiC in the Severe Accident Test Station (SATS)

Numerous research projects are directed towards developing accident tolerant fuel (ATF) concepts that will enhance safety margins in light water reactors (LWR) during severe accident scenarios. In the U.S. program, the high temperature steam oxidation performance of ATF solutions has been evaluated in the Severe Accident Test Station (SATS) at Oak Ridge National Laboratory (ORNL) since 2012 and this facility continues to support those efforts in the ATF community. Compared to the current UO 2 /Zr-based alloy fuel system, alternative cladding materials can offer slower oxidation kinetics and a smaller enthalpy of oxidation that can significantly reduce the rate of heat and hydrogen generation in the core during a coolant-limited severe accident. Thus, steam oxidation behavior is a key aspect of the evaluation of ATF concepts. This report summarizes recent work to measure steam oxidation kinetics of FeCrAl and SiC specimens in the SATS.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Oak Ridge Reservation Annual Site Environmental Report for 2014

The US Department of Energy’s (DOE’s) Oak Ridge Reservation (ORR) is located in Roane and Anderson counties in East Tennessee, about 40 km (25 miles) from Knoxville. ORR is one of DOE’s most unique and complex sites. It encompasses three major facilities and thousands of employees that perform every mission in the DOE portfolio—energy research, environmental restoration, national security, nuclear fuel supply, reindustrialization, science education, basic and applied research in areas important to US security, and technology transfer. ORR was established in the early 1940s as part of the Manhattan Project for the purposes of enriching uranium and pioneering methods for producing and separating plutonium. Today, scientists at the Oak Ridge National Laboratory (ORNL), DOE’s largest multipurpose national laboratory, conduct world-leading research in advanced materials, alternative fuels, climate change, and supercomputing. The Y-12 National Security Complex (Y-12 or Y-12 Complex) is vital to maintaining the safety, security, and effectiveness of the US nuclear weapons stockpile and reducing the global threat posed by nuclear proliferation and terrorism. The East Tennessee Technology Park (ETTP), a former uranium enrichment complex, is being transitioned to a clean, revitalized industrial park.

54 ENVIRONMENTAL SCIENCES↗

Advanced Variable Speed Air-Source Integrated Heat Pump (AS-IHP) Development (Final Report)

Between August 2011 and September 2015, Oak Ridge National Laboratory (ORNL) and Nordyne, LLC (now Nortek Global HVAC LLC, NGHVAC) engaged in a Cooperative Research and Development Agreement (CRADA) to develop an air-source integrated heat pump (AS-IHP) system for the US residential market. Two generations of laboratory prototype systems were designed, fabricated, and lab-tested during 2011-2013. Performance maps for the system were developed using the latest research version of the DOE/ORNL Heat Pump Design Model, or HPDM, (Rice 1991; Rice and Jackson 2005; Shen et al 2012) as calibrated against the lab test data. These maps were the input to the TRNSYS (SOLAR Energy Laboratory, et al, 2010) system to predict annual performance relative to a baseline suite of equipment meeting minimum efficiency standards in effect in 2006 (combination of 13 SEER air-source heat pump (ASHP) and resistance water heater with Energy Factor (EF) of 0.9). Predicted total annual energy savings, while providing space conditioning and water heating for a tight, well insulated 2600 ft2 (242 m2) house at 5 U.S. locations, ranged from 46 to 61%, averaging 52%, relative to the baseline system (lowest savings at the cold-climate Chicago location). Predicted energy use for water heating was reduced 62 to 76% relative to resistance WH. Based on these lab prototype test and analyses results a field test prototype was designed and fabricated by NGHVAC. The unit was installed in a 2400 ft2 (223 m2) research house in Knoxville, TN and field tested from May 2014 to April 2015. Based on the demonstrated field performance of the AS-IHP prototype and estimated performance of a baseline system operating under the same loads and weather conditions, it was estimated that the prototype would achieve ~40% energy savings relative to the minimum efficiency suite. The estimated WH savings were >60% and SC mode savings were >50%. But estimated SH savings were only about 20%. It is believed that had the test house been better insulated (more like the house used for the savings predictions noted above) and the IHP system nominal capacity been a bit lower that the energy savings estimate would have been closer to 45% or more (similar to the analytical prediction for the cold climate location of Chicago).

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

Total Dissolved Gas Prediction and Optimization in RIVERWARE

Management and operation of dams within the Columbia River Basin (CRB) provides the region with irrigation, hydropower production, flood control, navigation, and fish passage. These various system-wide demands can require unique dam operations that may result in both voluntary and involuntary spill, thereby increasing tailrace levels of total dissolved gas (TDG) which can be fatal to fish. Appropriately managing TDG levels within the context of the systematic demands requires a predictive framework robust enough to capture the operationally related effects on TDG levels. Development of the TDG predictive methodology herein attempts to capture the different modes of hydro operation, thereby making it a viable tool to be used in conjunction with a real-time scheduling model such as RiverWare. The end result of the effort will allow hydro operators to minimize system-wide TDG while meeting hydropower operational targets and constraints. The physical parameters such as spill and hydropower flow proportions, accompanied by the characteristics of the dam such as plant head levels and tailrace depths, are used to develop the empirically-based prediction model. In the broader study, two different models are developed a simplified and comprehensive model. The latter model incorporates more specific bubble physics parameters for the prediction of tailrace TDG levels. The former model is presented herein and utilizes an empirically based approach to predict downstream TDG levels based on local saturation depth, spillway and powerhouse flow proportions, and entrainment effects. Representative data collected from each of the hydro projects is used to calibrate and validate model performance and the accuracy of predicted TDG uptake. ORNL, in conjunction with IIHR - Hydroscience & Engineering, The University of Iowa, carried out model adjustments to adequately capture TDG levels with respect to each plant while maintaining a generalized model configuration. Validation results indicate excellent model performance with coefficient of determination values exceeding 92% for all sites. This approach enables model extension to an increasingly wider array of hydropower plants, i.e., with the proper data input, TDG uptake can be calculated independent of actual physical component design. The TDG model is used as a module in the systematic optimization framework of RiverWare, a river and reservoir modeling tool used by federal agencies, public utility districts, and other dam owners and operators to forecast, schedule, and manage hydropower assets. The integration and testing of the TDG module within RiverWare, led by University of Colorado's Center for Advanced Decision Support for Water and Environmental Systems (CADSWES), will allow users to generate optimum system schedules based on the minimization of TDG. Optimization analysis and added value will be quantified as system wide reductions in TDG achieved while meeting existing hydropower constraints. Future work includes the development of a method to predict downstream reservoir forebay TDG levels as a function of upstream reservoir tailrace TDG values based on river hydrodynamics, hydro operations, and reservoir characteristics. Once implemented, a holistic model that predicts both TDG uptake and transport will give hydropower operators valuable insight into how system-wide environmental effects can be mitigated while simultaneously balancing stakeholder interests.

13 HYDRO ENERGY↗

Mining Archived HYSPEC User Data to Analyze the Prompt Pulse at the SNS

The Hybrid-Spectrometer (HYSPEC) is one of 17 instruments currently operated at the Spallation Neutron Source (SNS) at Oak Ridge National Laboratories (ORNL). The secondary spectrometer of this instrument is located inside an out-building off the north side of the SNS instrument hall. HYSPEC has experienced a larger background feature than similar inelastic instruments since its commissioning in 2011. This background feature is caused by a phenomenon known as the “prompt pulse” which is an essential part of neutron production in a pulsed spallation source but comes with unfortunate side effects.

background↗

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