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At least 199 records · Page 11
All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Crack Propagation Modeling of a High-Speed Outer Rotor Motor

This study aims to investigate the propagation of initial cracks in electric motors and their rate of spread through the rotor structure under various operating conditions. Traction motors are subjected to high centrifugal load owing to their speed and rapid acceleration and deceleration. In the manufacturing process, some initial imperfections or cracks in the rotor components are likely to occur. Under the influence of loading, these cracks will grow, and factors such as loading frequency, material strength, and location of material voids will affect this threshold speed. In the current study, a fracture mechanics–based approach has been used to investigate the crack growth rate for a 100 kW outer rotor motor with a rated speed of 6,000 rpm and a peak speed of 20,000 rpm for an integrated drive application.

Barua, Himel↗
DOE OSTI2021

A review of machine learning in building load prediction

The surge of machine learning in recent years has been empowering engineer modeling in various fields. The decreasing hardware cost, increasing data accessibility, and advances of building automation system (BAS) allow the collection and storage of a significant amount of building operation data. The two facts provide great opportunities of applying machine learning to building energy systems modeling and analysis. There are a great number of research papers on this topic but there lacks a comprehensive and general review to summarize the current development, limitations, gaps and future trend. In this review paper series, machine learning techniques in building energy system modeling and analysis are reviewed under the organization and logic of the machine learning definition by Tom M. Mitchell: a computer program is said to learn from experience E with respect to some class of tasks T and performance measure P if its performance at tasks in T, as measured by P, improves with experience E. This paper is the first part of the review paper series, which focuses on building load prediction. First, the applications of building load prediction model (task T) are reviewed. Then, the modeling algorithms improving machine learning performance and accuracy (performance P) are reviewed. At the same time, the literature on the data perspective for modeling (experience E), including data engineering from sensors level to data level, pre-processing, feature extraction and selection, is reviewed. Finally, what is well-studied and what is lacking but with great potential are concluded; the gaps between present and future utilization of machine learning techniques are identified; the future trend and development are also predicted. The target readers of this paper are not only researchers from the building side who can get exposed to cutting edge machine learning tools, but also those from machine learning side who can understand the potential and challenge to apply machine learning in buildings.

Liang, Zhang↗
DOE OSTI2024

Using Additive Manufacturing to Repair Gas Turbine Hot Section Components

Ni-based superalloys are used in the hot sections of gas turbine engines due to their excellent high temperature performance. During service the material degrades due to exposure at high temperature and mechanical loads. Hence, utility provides often inspect, service, and repair components in gas turbine engines to ensure safe operation. A major challenge, however, is that the most heat-resistant alloys are generally considered ‘non-weldable’ rendering them difficult to repair via welding operations. In these cases components are often scrapped and then replaced by parts which must be re-manufactured. This burdens utilities with additional cost and supply chain issues can result in long term outages or reduced operating limtis. In this work EPRI and ORNL investigated a proposed repair strategy for gas turbine hot section components. Hot section superalloy GTD-111 was selected as a candidate repair material system and AM material ABD-900 the repair material. Sandwich structures were fabricated via electron beam melting additive manufacturing (EBM-AM) producing tensile bars with gage sections consisting of dissimilar ABD-900 / GTD-111 / ABD-900 material. Metallography revealed that the interface exhibited no deleterious phases or processing defeats. Creep rupture experiments on heat treated material demonstrates that the emulated repair coupons exhibit creep resistance between GTD-111 and ABD-900. This study demonstrates that the proposed EBM-AM repair strategy presents a viable opportunity towards enabling AM repair of gas turbine engine components.

99 GENERAL AND MISCELLANEOUS↗
DOE OSTI2024

Using Additive Manufacturing to Repair Gas Turbine Hot Section Components

Ni-based superalloys are used in the hot sections of gas turbine engines due to their excellent high temperature performance. During service the material degrades due to exposure at high temperature and mechanical loads. Hence, utility provides often inspect, service, and repair components in gas turbine engines to ensure safe operation. A major challenge, however, is that the most heat-resistant alloys are generally considered ‘non-weldable’ rendering them difficult to repair via welding operations. In these cases components are often scrapped and then replaced by parts which must be re-manufactured. This burdens utilities with additional cost and supply chain issues can result in long term outages or reduced operating limits. In this work EPRI and ORNL investigated a proposed repair strategy for gas turbine hot section components. Hot section superalloy GTD-111 was selected as a candidate repair material system and AM material ABD-900 the repair material. Sandwich structures were fabricated via electron beam melting additive manufacturing (EBM-AM) producing tensile bars with gage sections consisting of dissimilar ABD-900 / GTD-111 / ABD-900 material. Metallography revealed that the interface exhibited no deleterious phases or processing defeats. Creep rupture experiments on heat treated material demonstrates that the emulated repair coupons exhibit creep resistance between GTD-111 and ABD-900. This study demonstrates that the proposed EBM-AM repair strategy presents a viable opportunity towards enabling AM repair of gas turbine engine components.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Investigating sol–gel matrix loading capacity toward producing surrogate nuclear explosive debris with realistic composition

Post detonation nuclear forensic materials which resemble the size, color, elemental composition, and radionuclide content of real nuclear debris would be valuable for developing and validating new nuclear forensic techniques. As nuclear fallout types vary significantly, the ability to tailor each of these parameters accurately is desired to produce materials capable of testing analytical methods under a wide array of forensic scenarios. Sol–gel synthesis techniques can provide tunability of size, shape and composition for producing a wide variety of solid nuclear forensics benchmarking materials. Further, the sol–gel process consists of forming a metal oxide material, often silica, through polymerization of a metal-alkoxy precursor. In this work, we characterize the ability to load sol–gel particles with secondary elemental components such as iron, aluminum, and calcium toward producing benchmarking materials approximating the elemental composition of historic nuclear debris from the Nevada National Security Site. We also demonstrate quantitative radionuclide encapsulation toward producing benchmarking materials with controllable radionuclide content. Finally, we employ these techniques to produce nuclear debris benchmarking materials with controllable elemental matrix composition and radionuclide content and compare these samples with the composition of a historic fallout sample previously reported from the Nevada National Security Site.

36 MATERIALS SCIENCE↗
DOE OSTI2023

FINITE ELEMENT MODEL MESH REFINEMENT EFFECTS ON QUALIFICATION OF NUCLEAR GRADE GRAPHITE COMPONENTS

The American Society of Mechanical Engineers (ASME) provides the full and simplified design-by-analysis probabilistic assessments for determining acceptance of nuclear grade graphite core components. The assessments can be characterized by three parts: (1) a component stress distribution, often determined by a finite element (FE) model; (2) a Weibull probability density function (pdf) that characterizes the experimental tensile strength distribution; and (3) the post-processor, which combines the FE model and the Weibull strength distribution in accordance with the full and simplified assessments to determine component acceptance. It is known that the level of mesh refinement in FE models can affect the modeled component’s calculated stress distribution. Depending on the component geometry, the stress distribution may converge with sufficient refinement. It was previously unknown whether the acceptance decision resulting from the full and simplified assessments might change even with sufficient mesh refinement. This study explores that question using experimental strength results for a dog-bone geometry for two graphite grades, IG-110 and PCEA. The simplified assessment has two criteria that must be met, the first limits the combined membrane stress by the allowable stress and the second limits the peak equivalent stress by the allowable stress scaled by the ratio of flexural to tensile strength. In the application of the simplified assessment, convergence of the peak equivalent stress required extreme mesh refinement, however, the acceptance decision was not affected. It is hypothesized that more complex geometries with stress concentrations may present mesh refinement effects on the simplified assessment acceptance decision. Mesh refinement did affect the acceptance decision in the full assessment for the applied pressure loadings in this study. This work suggests component stress distribution convergence is not a sufficient criteria for POF convergence in the full assessment and that mesh refinement should continue until the POF has converged, especially where the resulting POF is bordering the SRC acceptable POF limit.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2020

Nuclear Criticality Safety Assessment of Criticality Control Containers without Moderation Control at the Waste Isolation Pilot Plant

The Waste Isolation Pilot Plant (WIPP) provides for safe, permanent disposal of government-owned transuranic (TRU) and TRU mixed wastes. Receipt and disposal of waste at the WIPP site began in March 1999. The Sandia report, Consideration of Nuclear Criticality When Disposing of Transuranic Waste at the Waste Isolation Pilot Plant, addressed potential nuclear criticality safety issues based on the projected inventory characteristics known at the time [1]. As designs for inventory, waste forms, and disposal packages have changed, new analyses have been performed, and updates have been made to address any potential effects to the WIPP safety basis. New analyses performed include Saylor 2017 [2] and Brickner 2019 [3], which address certain waste containers with specified loadings under post-closure conditions. Both examined several hypothetical scenarios and included analyses to bound (from a criticality potential standpoint) credible configurations that could occur at WIPP during the repository regulatory post-closure disposal time period for feature, event, and process (FEP) considerations—10,000 years. During this post-closure period at WIPP, the screening of FEPs is governed by the risk-based standards and implementing regulations of the US Environmental Protection Agency (EPA) (i.e., 40 CFR 191 and 40 CFR 194, respectively) [4,5]. An FEP screening can be based on either a low-consequence or low-probability rationale. A low-probability rationale includes either (a) a qualitative rationale that the FEP is not credible or (b) a quantitative demonstration that the probability is less than 10-4 in 104 years. In this evaluation, a qualitative lowprobability rationale of not credible is used by demonstrating that bounding configurations of the waste are not critical. The demonstration of subcriticality is through quantitative calculations, but a probability of criticality is not evaluated. Rather, the rationale for this evaluation is that bounding configurations with an effective neutron multiplication factor (keff) well below the upper subcriticality limit (USL) make criticality incredible. Reference [2] documented a nuclear criticality assessment of the WIPP repository for disposal of dilute surplus plutonium materials using the Dilute and Dispose Approach and packaging in criticality control overpacks (CCOs). The CCO is the waste disposal container recently designed to allow for up to 380 fissile gram equivalent (FGE) 239 Pu per drum, which is a higher fissile loading than typical waste containers. The CCO consists of a criticality control container (CCC) positioned by upper and lower plywood spacers within a standard 55 gal drum. The CCC is used to establish a geometry control for fissile materials during transportation and WIPP emplacement operations. The current WIPP waste acceptance criteria for CCO payloads limit beryllium to less than or equal to 1% by weight of the waste contents and require the waste form to be non-machine compacted. Reference [2] considered two scenario progressions—room closure from salt creep, hereafter referred to as the reconfigured dry scenario, and flooding with brine, hereafter referred to as the reconfigured wet scenario. The subsequent drying out of the reconfigured wet scenarios was also considered. For all scenarios, subcriticality was maintained when 50 g of B 4 C (acting as a neutron absorber) per CCC was intermixed within the plutonium disposition waste form. The analysis used a waste form description that limits the amount of moderation that could be present within the waste form (i.e., it limits the amount of water and polyethylene that could be present based on planned processing conditions). This analysis to evaluate increased limits on the amount of moderation that could be present was performed as a companion to Reference [2] to address concerns associated with verifying moisture and/or plastic contents of waste materials following packaging of dilute surplus plutonium in the CCO. To that end, this analysis used the models and methods from Reference [2] to evaluate a more generic base waste form consisting of water and polyethylene that is more similar (and nearly identical) to the generic waste forms utilized in other models/analyses supporting the TRU Package Transporter Model II (TRUPACTII) safety analysis [6] (all are without moderation controls). The waste form in this analysis uses a base mixture of 75% water and 25% polyethylene, the total amount of which is varied to determine the optimum moderation to fissile material (H/Pu) ratio. The fissile loading is maintained at up to 380 FGE 239 Pu (modeled as PuO 2 ) per CCO with an additional 545 g of beryllium (to bound the 1% by weight contents restriction) and 50 g of B 4 C intermixed per CCO. The beryllium content (1% by weight) is based on the total allowed waste weight (this does not include packaging and container weights). Figures ES-1 and ES-2 display summary results, showing that with this model including 50 g of B 4 C per CCO, the system keff remains under 0.85 for all moderator amounts and provides a significant margin against post-closure criticality under postulated bounding conditions for compaction. Figure ES-1 compares an infinite model with a room model at the initial emplacement spacing and under full radial compaction. Full radial compaction places each CCC in direct contact and does not credit any anticipated spacing associated with current post-closure geomechanical modeling of the repository [7]. The effects of variations in the H/Pu ratio were evaluated by varying the amount of the water/polyethylene component of the waste model, with fissile loading maintained at 380 239 Pu FGE. Similarly, Figure ES-2 illustrates how various amounts of B 4 C per CCO influence k eff at different radial compactions, all at the H/Pu ratio of 200 (in the room array model). Therefore, while the results from Saylor 2017 [2] modeled more realistic process limits associated with packaging of dilute surplus plutonium, this analysis demonstrates that limits on moderation (plastic and water content) are not necessary to ensure subcriticality in the WIPP repository, provided the requisite B 4 C absorber is present.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2023

Prototype HB650 Cryomodule Heat Loads Simulations

During the design stages of the PIP-II cryomodules, many analytical calculations and FEA have been performed on simpler geometry in order to estimate the heat loads and also to optimize the design. To better analyze the cryomodule cold tests, simulations have been performed with MATLAB to determine the temperature of the main components during cool down and to determine the heat loads of the cryomodule. These simulations have been applied to the High Beta 650 MHz prototype cryomodule design and compared to the cold tests performed on it.

43 PARTICLE ACCELERATORS↗
DOE OSTI2023

Sensitivity analysis of the effect of wind and wake characteristics on wind turbine loads in a small wind farm

Abstract. Wind turbines are designed using a set of simulations to determine the fatigue and ultimate loads, which are typically focused solely on unwaked wind turbine operation. These structural loads can be significantly influenced by the wind inflow conditions. Turbines experience altered inflow conditions when placed in the wake of upstream turbines, which can additionally influence the fatigue and ultimate loads. It is important to understand the impact of uncertainty on the resulting loads of both unwaked and waked turbines. The goal of this work is to assess which wind-inflow-related and wake-related parameters have the greatest influence on fatigue and ultimate loads during normal operation for turbines in a three-turbine wind farm. Twenty-eight wind inflow and wake parameters are screened using an elementary effects sensitivity analysis approach to identify the parameters that lead to the largest variation in the fatigue and ultimate loads of each turbine. This study uses the National Renewable Energy Laboratory (NREL) 5 MW baseline wind turbine, simulated with OpenFAST and synthetically generated inflow based on the International Electrotechnical Commission (IEC) Kaimal turbulence spectrum with the IEC exponential coherence model using the NREL tool TurbSim. The focus is on sensitivity to individual parameters, though interactions between parameters are considered, and how sensitivity differs between waked and unwaked turbines. The results of this work show that for both waked and unwaked turbines, ambient turbulence in the primary wind direction and shear are the most sensitive parameters for turbine fatigue and ultimate loads. Secondary parameters of importance for all turbines are identified as yaw misalignment, streamwise integral length, and the exponent and streamwise components of the IEC coherence model. The tertiary parameters of importance differ between waked and unwaked turbines. Tertiary effects account for up to 9.0 % of the significant events for waked turbine ultimate loads and include veer, non-streamwise components of the IEC coherence model, Reynolds stresses, wind direction, air density, and several wake calibration parameters. For fatigue loads, tertiary effects account for up to 5.4 % of the significant events and include vertical turbulence standard deviation, lateral and vertical wind integral lengths, non-streamwise components of the IEC coherence model, Reynolds stresses, wind direction, and all wake calibration parameters. This information shows the increased importance of non-streamwise wind components and wake parameters in the fatigue and ultimate load sensitivity of downstream turbines.

17 WIND ENERGY↗
DOE OSTI2020

Structural integrity of additively manufactured stainless steel with cold sprayed barrier coating under combined cyclic loading

Integration of metal additive manufacturing (AM) and cold spray (CS) technologies provide an unprecedented opportunity to manufacture coated material systems with complex geometrical features. The application of these material systems in functionally critical components requires adequate structural integrity, particularly in the presence of cyclic loading. This article researches the multiaxial fatigue (axial-torsional cyclic loading) behavior of a coated material system consisting of 15Cr-5Ni precipitation-hardening stainless steel (15-5 PH SS) substrate additively manufactured by direct metal laser sintering with a layer of chromium carbide nickel (CrC-Ni) barrier coating deposited by CS. The influence of AM and CS-induced residual stresses on fatigue performance of test specimens was thoroughly studied. Additionally, the effect of surface roughness and processes induced defects were considered to explain the crack growth mechanism. Stresses assessed by synchrotron X-ray diffraction indicated a substantial accumulation of residual stresses, particularly in the outer surface of the as-fabricated 155 PH SS specimens. The state of residual stress was changed notably following the deposition of CrC-Ni coating in the axial, hoop, and radial directions of the fatigue test specimen. Also, CS deposition of CrC-Ni coating caused significant improvement in the surface quality of the additively manufactured components. Fatigue test results indicated, CS deposition of CrC-Ni substantially enhances the fatigue life of the AM-produced 15-5 PH SS substrate in all loading conditions, particularly in the high cycle fatigue regime. The improvement in the fatigue life of the specimens with coating was associated with a reduction in equivalent residual stress at the substrate surface and improvement in the specimens' surface condition (i.e., reduced surface roughness). The fractographic analysis of the specimen indicated the cracks tend to initiate in the surface of both as-fabricated and cold-sprayed specimens. However, the mechanism of crack growth changed notably following the deposition of CrC-Ni coating. The cracks tended to propagate in the planes parallel or with a small deviation from the build layers of the AM-produced specimens. On the other hand, deposition of CrC-Ni coating increased the deviation of crack growth plane from the build layers of the substrate.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Dynamic stiffness modification by internal features in additive manufacturing

Dynamic stiffness, or the product of the modal stiffness and damping ratio, is an important consideration for the design of additively manufactured parts that will experience dynamic loading. Here, this paper describes a demonstration component which was designed and manufactured in two configurations using a metal wire arc additive process. The first configuration was an open channel structure, while the second contained a dynamic absorber in the internal cavity. Frequency response measurements of the two components showed a significant magnitude reduction for the modified component at the original open channel structure's natural frequency and an overall increase in dynamic stiffness. Polymer damping material was then added to further increase the dynamic stiffness.

Additive manufacturing↗
DOE OSTI2026

UV–Vis–NIR Reflectance Spectroscopy and Chemometrics for Monitoring Pu Directly on an Ion Exchange Column

Here, we present a fiber-optic UV–vis–NIR reflectance spectroscopy method for direct, noninvasive monitoring of Pu(IV) in a glass ion exchange column during dynamic loading and elution in a glovebox. A movable probe enables spatially resolved spectral acquisition along the column axis, capturing distinct features associated with Pu(IV) nitrate complexes during loading and free ions during elution. Principal component analysis was applied to extract the dominant spectral variance and resolve relative concentration profiles without requiring precise knowledge of optical penetration depth or species identity. This in situ approach reveals spatial gradients and speciation dynamics in real time, which provides actionable insight into Pu(IV) ion migration, resin saturation, and breakthrough behavior under evolving flow conditions. The method offers a practical, fiber-compatible strategy to monitor glass column–based separations for Pu and other lanthanides or actinides and to characterize metal–resin interactions in flow-through systems.

actinide↗
DOE OSTI2022

Nonane and Hexanol Adsorption in the Lamellar Phase of a Nonionic Surfactant: Molecular Simulations and Comparison to Ideal Adsorbed Solution Theory

Adsorption of n-nonane/1-hexanol (C9/C6OH) mixtures into the lamellar phase formed by a 50/50 w/w triethylene glycol mono-n-decyl ether (C10E3)/water system was studied using configurational-bias Monte Carlo simulations in the osmotic Gibbs ensemble. The interactions were described by the Shinoda–Devane–Klein coarse-grained force field. Prior simulations probing single-component adsorption indicated that C9 molecules preferentially load near the center of the bilayer increasing the bilayer thickness, whereas C6OH molecules are more likely to be found near the interface of the polar and non-polar moieties swelling the bilayer in the lateral dimension. Here, we extend this work to binary C9/C6OH adsorption to probe whether the difference in the spatial preferences may lead to a synergistic effect and enhanced loadings for the mixture. Comparing loading trends and the thermodynamics of binary adsorption to unary adsorption reveals that C9–C9 interactions lead to the largest enhancement, whereas C9–C6OH and C6OH–C6OH interactions are less favorable for this bilayer system. As a result, ideal adsorbed solution theory yields satisfactory predictions of the binary loading.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2025

ASSESSING THE EFFECTIVENESS OF ULTRASONIC IMPACT TREATMENT ON RESIDUAL STRESS PROFILES IN DISSIMILAR WELDED JOINTS

Residual stresses (RS) induced during welding processes are a critical concern in materials engineering, as they can significantly impair the mechanical performance of components by reducing fatigue strength and tensile load capacity. This challenge is especially pronounced in dissimilar metal welds (DMWs), where variations in thermal expansion properties between the joined alloys exacerbate the formation of tensile RS. Conventional post-weld heat treatments, though effective for homogeneous materials, often require substantial energy, specialized equipment, and extensive processing time, making them less practical for DMW applications. Thus, there is a clear need for innovative, energy-efficient techniques to mitigate these detrimental stresses. This study investigates ultrasonic impact treatment (UIT) as a possible alternative for mitigating tensile RS in both similar and dissimilar metal welds. To evaluate UIT’s effectiveness, neutron diffraction (ND) was employed as a nondestructive technique to quantify RS in three orthogonal directions—longitudinal, transverse, and normal. The results showed that UIT significantly reduced peak tensile RS, particularly in the longitudinal direction, by up to 180 MPa in similar welds and up to 150 MPa in dissimilar welds. Given the limited literature on UIT application in DMWs, this work contributes valuable data on stress redistribution mechanisms and highlights UIT’s potential as a practical stress-relief method. The findings lay the groundwork for further investigations aimed at optimizing process parameters and understanding long-term performance in welded joints.

EisaZadeh, Hamid [Western Carolina University, Cul↗
DOE OSTI2023

Effects of finite sampling on fatigue damage estimation of wind turbine components: A statistical study

The variability of the wind turbine loads complicates fatigue assessment in the design phase, as performing simulations covering the entire lifetime is computationally expensive. The current work provides important information for assessing the uncertainty in fatigue damage estimation due to finite data. Here we study the sample size effect on mean, variance, and skewness of damage in each wind bin, identify the important wind bins, and study the uncertainty propagation from each wind bin to the lifetime damage using 3600 aeroelastic simulations and bootstrapping. To achieve less than 1% error in the damage estimation across all load channels in the current case study, at least 100 turbulence seeds are needed. Damage in different wind bins follows a lognormal distribution when using the conventional approach of six seeds. The provided insights and information allow the designer to achieve a specific level of accuracy for a given computational cost using strategic bin sampling.

17 WIND ENERGY↗
DOE OSTI2021

Report on Properties and Microstructure of 3D Printed Inc-718

The report presents the microstructure and mechanical properties of 3D printed Inconel 718 to assess its potential use as a structural material for the Transformation Challenge Reactor (TCR). The structural components near the outlet of the core will experience significant neutron fluxes and outlet coolant temperatures from the hot standby temperature of 300°C to nearly 550°C at the center of the part. These components must support the core in appropriate loading conditions and require structural analysis at relevant temperatures. Strong spatial and chemical heterogeneity was found in as-built (ASB) Inconel 718. Three heat treatments were designed and conducted to simplify the microstructure and determine how each precipitating phase contributed to the overall strength. Baseline mechanical properties were measured from uniaxial tensile tests on subsize SS-J2 specimens at room temperature and at elevated temperatures of 300, 450, and 600°C. Microstructure electron microscopy was performed on ASB Inconel 718 and heat treated to correlate the observed mechanical properties with nanoscale features. Homogenization of the microstructure led to a highly ductile Inconel with lower strength compared with wrought Inconel 718. The tensile properties of additively manufactured 718 using a standard ASTMrecommended heat treatment were consistent with literature and with the ASTM for the properties of this alloy. A higher fraction of the δ phase led to shorter uniform elongation without altering other engineering properties.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2022

Report on Evolution of Inconel 718 Following HFIR Irradiation

The report presents the microstructure and mechanical properties of 3D printed Inconel 718 after irradiation in the High Flux Isotope Reactor (HFIR) at Oak Ridge National Laboratory (ORNL) to assess its potential use as a structural material. The structural components near the outlets of several proposed reactor cores will experience significant neutron fluxes and outlet coolant temperatures ranging from the hot standby temperature of 300 °C to nearly 550 °C at the center of the part. These components must support the core in appropriate loading conditions and require structural analysis at relevant temperatures. In FY21, three heat treatments were designed and conducted to simplify the microstructure and to determine how each precipitating phase contributed to the overall strength. In FY21, baseline mechanical properties were measured from uniaxial tensile tests on subsize SS-J2 specimens at room temperature and at elevated temperatures of 300, 450, and 600 °C to serve a comparison to the irradiated properties. Four capsules containing 3D printed Inconel 718 were inserted into HFIR in FY21 for a matrix of two temperatures and two doses. The lower of the two doses was available for characterization in FY22. Multiple heat treatments of Inconel 718 irradiated to nominal conditions of 2 displacements per atom (dpa) at either 300 or 600 °C were strained with uniaxial tensile tests at the Irradiated Material Examination and Testing (IMET) Facility to discern the mechanical properties. Transmission electron microscopy was performed to correlate the observed mechanical properties with nanoscale features. The initially homogenous AM718-HM increased in strength at both irradiation temperatures based on a high density of nanometer-scale radiation-induced cavities at lower temperature and nucleation and growth of γ" precipitates at higher temperatures. The precipitate-hardened AM718-HT2 showed very small differences in strength before and after irradiation: the contribution to strength from γ" precipitates was replaced with dislocation loops. Because the radioactivity of the nickel superalloys from neutron activation limited the scope of the analysis, a feasibility study examined the possibility of an ultra-miniature specimen geometry, colloquially SS-Tiny (SS-T), for mechanical property determination using the nonirradiated Inconel 718. This study found an overestimation of ductility from the SS-T geometry with yield strength and ultimate tensile strength slightly above the SS-J2 geometry: this could be contributed to a reduction in specimen thickness.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Planning for Material Control and Accountancy at Liquid Fueled Molten Salt Reactors

The purpose of this report is to provide molten salt reactor (MSR) developers and future US Nuclear Regulatory Commission (NRC) license applicants with recommendations for developing an effective and practical material control and accounting (MC&A) plan, focused primarily on MSR designs that use circulating liquid fuel. Because of the breadth of MSR designs, there is no single, generic, detailed MC&A plan that will work for every design. The wide variation of fresh fuel salts, the method and frequency of loading fresh fuel, the reactor system design components (e.g., tanks, filtration systems, chemical processing streams), and waste streams will determine the specific measurement locations and instrumentation that can best meet MC&A objectives throughout an MSR facility. Additionally, MSR designs are rapidly evolving, and new design features and deployment scenarios that will affect MC&A are being explored and pursued. This report defines a generic MC&A approach that was developed for terrestrial (as opposed to maritime) deployments to meet the intent of NRC domestic safeguards and MC&A. MSR license applicants should consider nuclear safeguards (both domestic and international) and security throughout the design, as early as the preconceptual design phase. MC&A of special nuclear material (SNM) is an aspect of the NRC’s domestic safeguards program, alongside physical protection. Because liquid-fueled MSRs are reactors with SNM in nondiscrete (or item) form, it is likely that the NRC may require liquid-fueled MSR license applicants to submit a formal MC&A plan as a part of their license application. Currently, the NRC licensing protocol presents a challenge because the NRC MC&A regulations have not been updated to accommodate advanced reactors, including types of MSRs. Because no liquid-fueled MSR has been licensed for operation at the time of this report, no template or precedence for a successfully licensed MSR MC&A plan exists. However, the MSR license applicant can take advantage of the NRC’s published commitments to performance-based regulations. The authors recommend that the license applicant, or MSR designers, develop an MC&A plan throughout the design lifecycle and plan to submit a detailed MC&A program description, or MC&A plan, to the NRC as a part of a license application. No MC&A plan template or guidance exists that is specific to liquid-fueled MSRs. The authors recommend that license applicants discuss the topic of MC&A during preapplication engagement. Because of the uniqueness of MC&A for liquid fueled MSRs, the authors recommend that liquid fueled MSR developers engage with the NRC on the topic of MC&A in the early phases of its design development and follow up any time there are significant modifications in design plans that would affect MC&A. For example, topics like modifications in fuel handling processes, changes in uranium enrichment, or additional chemical processing streams added to the design could be discussed with the NRC specifically on the topic of MC&A.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗