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All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

Prospects for additive manufacturing of nuclear fuel forms

Additive manufacturing (AM) is viewed as a critical enabling technology for achieving superior performance and improved economics across many sectors. Although the past decade has seen increased application of AM methods to nuclear reactor cladding and structural materials, exploration of AM as applied to the uranium-bearing nuclear fuel forms has been limited. The two major families of nuclear fuel forms (monolithic, particle/dispersion) are utilized with their own set of core objectives in mind, and their differences require distinct fabrication infrastructures. These reference fabrication methods impose many limitations on nuclear fuels. Further, both currently operating reactors and future concepts have the potential for improved performance if these accepted limitations are relaxed or removed entirely. The primary limitations of reference fabrication processes for the common nuclear fuel forms are outlined in this paper. This groundwork is then used to identify avenues of fuel performance specific to each of these fuel architectures that could be exploited if the restrictions of conventional fuel fabrication are removed. Moreover, multiple targets for AM studies are laid out for each of the major nuclear fuel variants. Finally, key strategic components to guide research activities in AM of nuclear fuels are outlined, with an emphasis on use of modeling and simulation to motivate research aims and embrace of an accelerated testing methodology to screen and quality new fuel forms.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2025

Device for steam cladding oxidation testing at TREAT

To compare the chemical degradation of conventional zirconium alloy (Zry) cladding to advance silicon carbide (SiC) cladding in a post loss of coolant accident (LOCA) environment, new nuclear testing capabilities are necessary. The Transient Reactor Test (TREAT) Facility at Idaho National Laboratory (INL) has matured its transient fuel testing capabilities since its 2017 restart. The most recent experiment architecture is the Transient Water Irradiation System in TREAT (TWIST), which is designed to support qualification of accident tolerant fuels in light water reactors. INL has designed and analyzed a natural circulation steam flow modification for TWIST to produce prototypic conditions of cladding oxidation. The in-situ device will be electrically heated to drive natural circulation. Moreover, the SiC cladding requires heating above 1700 °C to observe failure, thus internal prototypic nuclear heating with radiation effects will be used. Thermal hydraulic analysis with RELAP5-3D (Reactor Excursion and Leak Analysis Program) estimated steam fluxes greater than 50 mg cm −2 s −1 can be achieved. These fluxes are adequate to test Zry cladding according to draft regulatory guides and to test SiC cladding according to past experiments.

Oxidation↗
DOE OSTI2024

Sensitivity Analysis of Irradiated Fueled Experiments using the MOOSE Framework [Slides]

Modeling and simulation (M&S) methods are able to predict uncertainties in experimental parameters (e.g., power and fission density) during irradiation. A shortfall exists in predicting how sensitive some of the parameters will behave during the experimental process. Sensitivity and Uncertainty Quantification (SUQ) is critical in support of qualification and licensing reactor fuels. The application of a method to quantify the uncertainty in these experiments is critical to the prediction of their performance. In this work, we propose the use of a polynomial chaos expansion (PCE) method to quantify the sensitive parameters in these simulations and, in an extension, their experimental surrogates. We propose to perform M&S using PCE uncertainty quantification on a previously irradiated fueled experiment in order to provide a validation case for Griffin and expand its use as a verification and validation (V&V) tool for experiments with a neutronics component. Griffin is an advanced, deterministic neutronics analysis code built using the MOOSE (multiphysics object-oriented simulation environment) framework which can provide state-of-the-art neutronic analysis on M&S of experiments. We will use the stochastic tools module (STM) in MOOSE to provide PCE uncertainty quantification on the proposed experimental setup. Idaho National Laboratory (INL) does not yet have an in-house developed code with V&V approval for experiments performed on-site; this work would provide a necessary addition of support for experiments performed at INL. The Nuclear Regulatory Commission (NRC) has explicitly requested uncertainties in calculated values such as fuel power and burnup, and the development of this capability would benefit the relationship between INL and the NRC.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2021

A Verification and Validation Approach for COMSOL Multiphysics to Support High Flux Isotope Reactor (HFIR)

Over the last several decades, many reactors have successfully been converted from high enriched uranium (HEU) to low enriched uranium (LEU) fuels in United States in support of its global non-proliferation objectives. Of the reactors slated for conversion, five high-performance research reactors (HPRRs) remain. The high-flux isotope reactor (HFIR) at Oak Ridge National Laboratory (ORNL) is one of the five. Conversion of HFIR requires the qualification of a new fuel. To aid in the conversion process as well as improve safety margins, COMSOL Multiphysics was chosen to support and eventually supplement the steady-state heat-transfer code (SSHTC). In order to use COMSOL as a supplementary tool, i.e. one used for safety basis calculations, the code needs to undergo a verification and validation process. Verification and validation are important processes for the use of any software; however, physics-based solvers have a unique challenge, in that the validation is much more rigorous and its domain is only applicable to the general scope of the problem. This document details the verification and validation of COMOSL for analysis of HFIR. This report is intended for two different users: (1) current and future users of COMSOL for HFIR and (2) for individuals interested in assessing the scope of the validation of COMSOL for HFIR. This report is divided into six sections. The first of which details the process of verification and validation. Section one provides an overview of key concepts from ASME V&V 10, 20, and 40 and how these concepts are used to provide a validation of any multiphysics software. Section two covers the approach needed in order to validate multiphysics software for a given HFIR analysis. Parts three through five split up the key concepts highlighted in section two. The final section provides concluding remarks which demonstrate the scope and limitations of the validation study and how these may be expanded and improved.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2025

Developing Open-Source Tools for Increasing the Efficiency of Synthetic Aviation Turbine Fuel Certification Process

FuelLib is an open-source Python-based fuel library, developed by NREL, that leverages the group contribution method (GCM) of [1] to systematically estimate the thermodynamic and transport properties of hydrocarbon fuels. FuelLib predicts these properties based on the molecular structure of individual compounds or compound families, using weight percentages of a fuel's composition, typically measured using techniques such as gas chromatography (GC). FuelLib enables property estimation over a wide range of temperatures and pressures of multi-component fuels in the absence of detailed molecular composition data, making it particularly valuable for complex fuel mixtures where detailed experimental characterization of fuel composition is unavailable. These capabilities contribute directly to synthetic aviation turbine fuels (SATF) development, supporting the short-term American Society for Testing and Materials (ASTM) qualification of drop-in fuels while potentially expanding ASTM boundaries to certify a broader range of fuels.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2026

Methods development towards automated, physics-informed, quantitative quality control of TRISO-SiC

Tristructural-isotropic (TRISO) fuel particles have been developed as a high-performance fuel for use in high-temperature gas-cooled reactor (HTGR) systems due to their high efficiency and stability under both normal and off-normal conditions. Broader deployment of this technology in advanced nuclear applications may benefit from quantitative quality assurance and quality control (QA/QC) methods that directly link TRISO properties to downstream performance. A key TRISO property is the SiC layer microstructure, which influences fission product retention during irradiation. However, existing QA/QC for the TRISO-SiC microstructure comprises only a qualitative visual inspection; therefore, there is a clear opportunity for the development of quantitative methods for TRISO QA/QC. Here, to this end, previous work has demonstrated an image processing approach to grain boundary (GB) identification and subsequent extraction of microstructural metrics; however, extensive twinning within the SiC layer complicates such analyses because twin GBs significantly influence microstructural metrics but are not expected to contribute to fission product transport. This study presents the initial development, training, and testing of an ML-based image segmentation algorithm designed to identify and remove twin GBs from standard backscattered electron micrographs, providing an industrially applicable, quantitative, and physically meaningful QA/QC approach for the TRISO-SiC microstructure. Although pixel-wise performance metrics for the twin predictions are low, the change in grain area and the number of GB pixels after twin removal predicted by the ML workflow are within 1% of the true values calculated using crystallographic data. This suggests that the model is well capable of predicting overall twin boundary structures and grain morphology, and continued advancement of this approach could enable automated, scalable, and physics-informed QA/QC for TRISO-SiC microstructures, supporting the reliable qualification of coated particle fuels for next-generation reactor systems.

Computer vision↗
DOE OSTI2022

Computational determination of a primary diffusion mode in γ U-10Mo under irradiation

Low enriched uranium (< 20 % 235 U)-molybdenum (U-Mo) monolithic fuel is the primary candidate for high performance research and test reactors, and is in the process of being qualified to replace highly enriched uranium (≥ 20 % 23 5U) fuel. As part of the qualification process, it is critical to understand and predict the behavior of fission gas bubbles under irradiation, which affects fuel swelling and fuel failure. Mechanistic fuel models are being developed that can both reproduce the existing experimental data for fuel swelling, and be further applied to irradiation conditions beyond the experimental scope. Diffusion of species under irradiation conditions is an important parameter in the mechanistic fuel models; however, no temperature-relevant experimental diffusion data exists. In the present work, radiation-enhanced diffusion coefficients of U, Mo, and Xe in λU-10wt.%Mo were calculated in the temperature range between 300 K and 1400 K via rate-theory models and molecular dynamics simulations with an embedded-atom method interatomic potential for the U-Mo-Xe system. Accordingly, total diffusion coefficients under relevant irradiation conditions are determined using previously obtained intrinsic thermal diffusion and radiation-driven diffusion coefficients, as well as the newly calculated radiation-enhanced diffusion coefficients presented herein. Radiation-enhanced diffusion of U and Mo was dominant in the intermediate temperature range, whereas radiation-enhanced diffusion of Xe did not significantly contribute to total diffusion of Xe at the relevant fission rate densities. Radiation-enhanced diffusion of Xe became faster than both intrinsic thermal diffusion and radiation-driven diffusion at a fission rate density of 5 x 10 22 fissions/m 3 /s, which is higher than the typical fission rate density range in research reactors. The temperature regime that radiation-enhanced diffusion of each element dominated was dependent on the fission rate density. Finally, the total diffusion coefficients of U, Mo, and Xe, updated in this work, will be utilized as parameters in the mechanistic fuel models to help predict the behavior of fission gas bubbles under irradiation more accurately.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2022

Micro-tensile testing of the bond line in hot isostatic pressed aluminum

Considerable effort is being devoted to development and regulatory qualification of low enriched fuels for research and test reactors by many agencies worldwide. One promising fuel configuration being examined for United States higher power research and test reactors (USHPRRs) are plate-type fuels composed of a metallic uranium-molybdenum foil clad in an aluminum alloy. The two pieces of aluminum alloy cladding are bonded using a hot isostatic pressing method. The mechanical properties of the resulting bond line in the aluminum alloy cladding will vary by the HIP'ing parameters, requiring a need to characterize the bond line. Small scale mechanical testing can provide a path for evaluating the mechanical properties and deformation behavior of the bond line both prior to and following irradiation. Here, in this research, room temperature micro-tensile specimens of non-irradiated and irradiated samples containing an Al alloy (AA 6061) bond line were tested to evaluate its strength and deformation behavior. Observations indicated that the strain rate did not affect the deformation behavior or strength and most of the micro-tensile specimens failed in a ductile mode in grains around the bond line. There was no indication that the microstructural features from the bond line affected the mechanical properties of the micro-tensile specimens. An initial examination was performed on irradiated material but further systematic studies of the effects of irradiation can be performed in the future.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2024

Qualification and Quantification of Porosity at the Top of the Fuel Pins in Metallic Fuels Using Image Processing

Approximately 130,000 metal fuel pins were irradiated in the Experimental Breeder Reactor II (EBR-II) during its 30 years of operation to develop and characterize existing and prospective fuels. For many of the metal fuel irradiation experiments, neutron radiography imaging was performed to characterize fuel behavior, such as fuel axial expansion. While several fuel expansion results obtained from neutron radiography imaging have been published, the analysis of neutron radiography for the purpose of describing statistical properties of porous matter formed on top of the fuel pins, also referred to as fluff in previous publications, is significantly less represented in the literature with just a single paper so far. This study aims to validate and augment results reported in previous publications using automated image processing. The paper describes the statistical properties of the porous matter in terms of nine parameters derived from radiography images and correlates those parameters with such fuel properties as composition, expansion, temperature, and burnup. The reported results are based on 1097 fuel pins of eight different fuel compositions. For three major fuel types, U-10Zr, U-8Pu-10Zr, and U-19Pu-10Zr, a clear negative correlation is found between the Pu content and five parameters describing the amount of porous matter generated. The parameters describing granularity properties, however, showed either negative correlation or nonlinear dependency from fuel composition. The parameters describing the amount showed a positive correlation with fuel axial expansion, while granularity parameters showed a negative correlation with axial expansion. The dependency on cladding temperature was found to be weak. A positive correlation is demonstrated for volume parameters and fuel burnup. In general, reported results confirm and validate findings published in previous studies using a much larger number of pins and automated processing techniques, which easily lend themselves to reproducibility, thus avoiding subjective bias.

36 MATERIALS SCIENCE↗
DOE OSTI2026

EDS Analysis of FCCI in AFC-FAST Fuel Pins

The Advanced Fuel Campaign’s Fission Accelerated Steady-state Testing (FAST) program uses metallic fuel pins with small diameters to reach a desired burnup more quickly. This enables accelerated testing of advanced fuel designs and decreases the time between idea conception and commercial usage. Post-irradiation examination is critical in this process, especially with respect to the fuel-cladding chemical interactions (FCCI). In this work, energy dispersive X-ray spectroscopy (EDS) is used to track how elements from the fuel and fission products have diffused through the cladding. Elemental redistribution along the fuel-cladding interface is mapped and FCCI region thicknesses are measured. The correlations between geometry, temperature, burnup, and FCCI thickness are presented.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2022

Subscale maturation of advanced reactor technologies (SMART): A path forward for nuclear thermal propulsion fuel and reactor development

Nuclear Thermal Propulsion (NTP) systems are actively being developed for future crewed missions to Mars. NTP systems excel in missions where both high thrust and high specific impulse are required, but modern NTP systems currently do not have a Technology Readiness Level (TRL) high enough for use in crewed space exploration. TRLs are used to demonstrate the level of rigor with which a component/system has been tested/demonstrated for its intended use. While space systems technology in general must be qualified as a unit, nuclear technology must be first demonstrated to meet qualification level requirements both at the fuel (component) level and the reactor (subsystem) level. Here, in this paper, historic NTP development programs are surveyed to identify a testing and development strategy that can be effectively implemented to allow for NTP reactor development. Based on this strategy, required facilities to enable such activities are identified. Current domestic experimental capabilities to support NTP qualification are limited to separate effects testing of individual components. Separate effects testing is found extensively in historic NTP development efforts but is not sufficient for full fuel and reactor qualification. Combined effects testing allows for an accurate assessment of fuel performance but is not achievable for NTP conditions in existing facilities. Assessment of historic development programs suggests that an intermediate, subscale test facility is necessary to advance NTP TRLs. A solution to meet this need is proposed, namely the Subscale Maturation of Advanced Reactor Technologies (SMART) facility. SMART will mitigate risk to NTP development by enabling performance and reactor physics demonstrations of NTP subsystems. A SMART facility could be built by modifying existing nuclear test facilities, which may potentially enable schedule and cost savings. To pursue reactor qualification beyond the subscale, a new ground test facility will be necessary. This ground test facility should be developed concurrently with SMART to allow for the facility to be operational in time for expedited NTP engine demonstration.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗
DOE OSTI2026

Quality Assurance of Legacy Post-Irradiation Examination Data for Metallic Fuels

The U.S. DOE-NE’s Advanced Reactor Technologies (ART) Fast Reactor Program (FRP) and the NE-4 Advanced Fuels Campaign (AFC) have jointly undertaken the qualification of the legacy post-irradiation examination (PIE) data held in the Fuels Irradiation & Physics Database (FIPD), covering metallic fuel experiments conducted in the Experimental Breeder Reactor II (EBR-II) and the Fast Flux Test Facility (FFTF). In FY26 this effort reached a milestone: six major types of PIE data—contact profilometry, isotopic gamma scan, fission gas chemistry, fission gas release, laser profilometry, and neutron radiography—have been qualified for all available experiments in FIPD, and the U.S. nuclear industry can now draw on them with confidence in licensing activities for metallic fuel-based advanced fast reactors. This report documents the qualification process and the resulting status of the PIE data.

Mo, Kun↗
DOE OSTI2026

Results of the AGR-5/6/7 UCO TRISO fuel irradiation test in the Advanced Test Reactor

AGR-5/6/7 was the last in a series of irradiation experiments sponsored by the U.S. Department of Energy in support of the development and qualification of TRISO coated particle fuel for use in a high-temperature gas-cooled reactor. This experiment was conducted to verify the performance of the reference-design TRISO-coated low-enriched UCO fuel for modular high-temperature gas-cooled reactor normal operating conditions and to explore fuel performance at temperatures substantially beyond those typical of normal operation. A total of 194 UCO fuel compacts in five capsules were irradiated in the Advanced Test Reactor for 360.9 effective full-power days, achieving final burnup ranging from 5.66% to 15.26% fissions per initial heavy metal atom and fast neutron fluence ranging from 1.62 × 10 25 to 5.55 × 10 25 n/m 2 (E > 0.18 MeV). Calculated time-averaged fuel temperatures ranged from 467 °C to 1432 °C, with a peak fuel temperature of 1536 °C. During the first five irradiation cycles (∼180 effective full-power days), 85m Kr fission gas release-rate-to-birth-rate ratios were 10 −7 –10 −6 , indicating no particle failures. Near the end of the sixth cycle, a substantial number of in-pile particle failures occurred in Capsule 1. The fission gas release from this capsule impacted the readings from the other four capsules and led to unreliable fission gas release measurements for all capsules during the last four cycles. A preliminary post-irradiation examination of Capsule 1 fuel and internal components revealed the in-pile particle failures resulted from operational issues with the capsule, not subpar performance of the fuel particles.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2024

Neutronics analysis of Full Size Plate–1 Experiment using MC21

Qualification and testing of Low Enriched Uranium fuel is desired so that it can be used in research reactors instead of High Enriched Uranium. The Full Size Plate - 1 (FSP-1) experiment involves irradiating a low enriched metallic fuel in the Advanced Test Reactor to assist in this general qualification. Prior to irradiation, an in-depth neutronics analysis is needed to ensure the safety requirements of the Advanced Test Reactor are met. To accomplish this, the MC21 software was used to analyze the FSP-1 experiment, which will allow a test run to be performed with this new fuel in the Advanced Test Reactor Critical facility. By verifying and validating the results of the MC21 software with comparisons to other codes and the preliminary irradiation in the Advanced Test Reactor Critical facility, the FSP-1 experiment will be ready to irradiate using the Advanced Test Reactor. This work is concerned with the neutronics analysis of the FSP-1 experiment using the MC21 software.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2023

Data-driven methods for diffusivity prediction in nuclear fuels

The growth rate of structural defects in nuclear fuels under irradiation is intrinsically related to the diffusion rates of the defects in the fuel lattice. The generation and growth of atomistic structural defects can significantly alter the performance characteristics of the fuel. This alteration of functionality must be accurately captured to qualify a nuclear fuel for use in reactors. Predicting the diffusion coefficients of defects and how they impact macroscale properties such as swelling, gas release, and creep is therefore of significant importance in both the design of new nuclear fuels and the assessment of current fuel types. In this article, we apply data-driven methods focusing on machine learning (ML) to determine various diffusion properties of two nuclear fuels—uranium oxide and uranium nitride. We show that using ML can increase, often significantly, the accuracy of predicting diffusivity in nuclear fuels in comparison to current analytical models. We also illustrate how ML can be used to quickly develop fuel models with parameter dependencies that are more complex and robust than what is currently available in the literature. In conclusion, these results suggest there is potential for ML to accelerate the design, qualification, and implementation of nuclear fuels.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2024

Summary of Leach-Burn-Leach Round-Robin Test Results

Tristructural isotropic (TRISO) coated particle fuel is of interest to multiple member states associated with the Generation IV International Forum (GIF). Qualification and acceptance testing of TRISO fuel includes the determination of particle defect fractions and impurities in the as-fabricated TRISO fuel particle and/or composited fuel form, which are typically determined using burn-leach (BL) or leach-burn-leach (LBL) analysis methods. A round-robin test focusing on LBL analysis was undertaken by the GIF Very High Temperature Reactor System Fuel and Fuel Cycle Project Management Board. Participating in this LBL round-robin test were research staff from the Institute of Nuclear and New Energy Technology (INET) in the People’s Republic of China, the Korean Atomic Energy Research Institute (KAERI) in the Republic of Korea, and Oak Ridge National Laboratory (ORNL) in the United States of America. The motivation of this LBL benchmarking exercise was to explore consistency in results generated by LBL and to elucidate the potential influence of variations in the procedures used by the participating members on the accurate determination of the measured fuel properties.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2023

BISON validation to in situ cladding burst test and high-burnup LOCA experiments

The process for developing and qualifying nuclear fuels for commercial nuclear application requires fundamental material development, characterization, and design; out-of-pile testing on unirradiated materials; integral fuel rod irradiations, testing, and postirradiation examinations; and transient analyses. The historical approach depends on the generation of large empirical datasets and series of integral fuel rod irradiations, and this approach ultimately takes ~20 years—or sometimes longer—to acquire data through extensive sequential testing. Thus, the qualification and eventual deployment of new fuel systems constitute a long process. However, recent technological advancements have provided researchers the opportunity to perform out-of-cell, in situ measurements to assess material performance for the duration of the experiment. One such example of this capability is the use of digital image coordination and thermal imaging to assess Zircaloy cladding performance under a simulated loss-of-coolant accident (LOCA) transient condition. In situ measurements generally provide high-fidelity strain, strain rates, and temperature surface maps. This is critical for the US nuclear industry, which is actively developing a technical basis to support extending the peak rod average burnup from 62 to ~75 GWd/tU and the deployment of accident-tolerant fuel. However, the US Nuclear Regulatory Commission (NRC) outlined in its research information letter several technical issues that the industry must address before extending burnup. One topic of specific interest is understanding the cladding balloon and rupture geometry during the LOCA heat-up phase. By leveraging these advanced in situ capabilities, this work used in situ data generated from a simulated LOCA to better understand high-temperature creep and its effect on Zircaloy balloon and rupture performance. Here, this work used the BISON fuel performance code to assess the high-temperature creep model predictions with in situ data.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗