Results for “Metallic fuels” — Page 15

DOE OSTI2020

Oak Ridge Response to Versatile Test Reactor Environmental Impact Statement Data Request

The Versatile Test Reactor (VTR) is a fast-spectrum test reactor being developed in the United States under the direction of the US Department of Energy Office of Nuclear Energy (DOE-NE). The VTR mission is to enable accelerated testing of advanced reactor fuels and materials required for advanced reactor technologies. The conceptual design of the 300 MWth sodium-cooled metallic-fueled pool-type fast reactor has been led by the US National Laboratories in collaboration with General Electric–Hitachi and Bechtel National, Inc. In support of the VTR project, DOE issued a Notice of Intent (NOI) in the Federal Register on August 5, 2019, announcing the intent to prepare an Environmental Impact Statement (EIS) in accordance with the National Environmental Policy Act (NEPA) and its implementing regulations. The EIS will evaluate alternatives for a versatile reactor–based fast-neutron source facility and associated facilities for the preparation, irradiation, and post-irradiation examination (PIE) of test/experimental fuels and materials. Specifically, the NOI identified two siting alternatives for the VTR reactor facility: Idaho National Laboratory (INL) or Oak Ridge National Laboratory (ORNL). In addition, the NOI also specified two siting alternatives for VTR fuel fabrication: INL and the Savannah River Site (SRS). This report provides information in response to data requests made to ORNL to fill in site-specific knowledge gaps to develop a high-quality EIS. The responses provided are not required to provide full details in every aspect; instead, they adequately bound possible environmental impacts or provide sufficient information to adequately assess likely environmental impacts. This work is being performed under a subcontract from INL to ORNL using DOE-NE funds and is directed by DOE-NE and DOE-ID. Leidos has been contracted by DOE-NE to write the VTR EIS, so most data requests have come from Leidos but were often routed through INL or DOE-ID. DOE-ID is overseeing the NEPA and EIS processes for the VTR project. Leidos will use the information provided in this report to inform the VTR EIS and will also cite this document to establish a clear, publicly available source of the information. Section 2 of this report briefly describes the proposed ORNL VTR Alternative and illustrates the location of the proposed site for the ORNL VTR Alternative. Sections 3 through 7 provide direct responses to data requests received by ORNL. These sections use a tabular format in which data requests are divided into separate items to be addressed; the items are numbered, the data requests are restated with more topical information included, and then the responses are provided. Initial data requests and follow-on requests for additional information (RAIs) are combined under the original data request fields. Finally, Section 8 presents summarized conclusions and describes future work.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2025

User Manual for the Thermal Hydraulic Code SE2RCT

SE2-ANL is a modified version of SUPERENERGY-2 which interfaces the power distribution in the ANL maintained physics codes for the user. SE2RCT is a special version of SE2-ANL developed for specific use on models of the Experimental Breeder Reactor-II (EBR-II). SE2RCT fulfills a specific role in the calculated results as part of the Fuels Irradiation and Physics Database (FIPD) and is built to connect with the Physics and Analysis DataBase (PADB) for metallic fuel research and development in advanced sodium-cooled fast reactors (SFRs) created for EBR-II. SE2RCT is primarily a thermal analysis code that interfaces with the RCT based pin power details instead of the built-in pin power dehomogenization strategy in SE2-ANL. Beyond the thermal hydraulic calculation, the SE2RCT code provides detailed axial distributions of the RCT calculated results. SE2RCT also calculates the the axial distribution of pin wise DPA for the cladding materials which is part of the FIPD calculated results. This report serves as the user manual for SE2RCT and thus eliminates the QA gap of missing documentation on the SE2RCT software. All of the features and limitations of SE2RCT are documented in this report. The input and output specifications of SE2RCT are discussed in detail, and some unique features of SE2RCT, e.g. accurate pin power and temperature results for problems with non-uniform composition within an assembly, are also demonstrated and tested.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

NASA NTRS1989

Moon base reactor system

The objective of our reactor design is to supply a lunar-based research facility with 20 MW(e). The fundamental layout of this lunar-based system includes the reactor, power conversion devices, and a radiator. The additional aim of this reactor is a longevity of 12 to 15 years. The reactor is a liquid metal fast breeder that has a breeding ratio very close to 1.0. The geometry of the core is cylindrical. The metallic fuel rods are of beryllium oxide enriched with varying degrees of uranium, with a beryllium core reflector. The liquid metal coolant chosen was natural lithium. After the liquid metal coolant leaves the reactor, it goes directly into the power conversion devices. The power conversion devices are Stirling engines. The heated coolant acts as a hot reservoir to the device. It then enters the radiator to be cooled and reenters the Stirling engine acting as a cold reservoir. The engines' operating fluid is helium, a highly conductive gas. These Stirling engines are hermetically sealed. Although natural lithium produces a lower breeding ratio, it does have a larger temperature range than sodium. It is also corrosive to steel. This is why the container material must be carefully chosen. One option is to use an expensive alloy of cerbium and zirconium. The radiator must be made of a highly conductive material whose melting point temperature is not exceeded in the reactor and whose structural strength can withstand meteor showers.

Chavez, H.↗

DOE OSTI2023

Development of Instrumented Advanced Test Reactor Irradiation Capsule Experiment for In-situ Thermal Conductivity Measurements of High-Density Fuels

Idaho National Laboratory (INL) is developing a first-of-a-kind leadout instrumented capsule experiment design to enable in-situ measurement capabilities in the Advanced Test Reactor (ATR) core. The Ceramic Advanced Thermal Evolution Research (CRATER) experiment supports the aLEU program objective to accelerate fuel performance irradiation testing for identifying alternative high-assay, low enriched uranium (HALEU) fuel systems. CRATER is a fueled, instrumented capsule experiment to measure in-situ temperature and thermal conductivity of ceramic fuels. Two ceramic fuel types will be used, uranium mono-nitride (UN) and uranium mono-carbide (UC), with a third metallic fuel used for comparison (UMo). The three fuel specimens will use a stainless-steel cladding. Programmatic objectives include linear heat generation rates (LHGR) of 210 ± 25 Watts per cm. and an inner clad temperature of 300-450 °C. The evolution of fuel thermal conductivity during irradiation has never been successfully measured in-situ for these systems and this experiment is designed to use advances in measurement sciences to characterize how thermal transport properties evolve while in reactor. Neutronic simulations of the experiment and its surrounding reactor environment were conducted using the Monte Carlo N-Particle Transport code (MCNP) and result in optimized fuel enrichment to meet target linear heat generation rates (LHGRs) influencing fuel temperatures, and fuel burnup requirements. Fabrication research and development (R&D) efforts are underway to produce annular right cylinder UC and UN pellets using carbothermic reduction and nitridation (or hydride-dehydride-nitride) synthesis methods, followed double-action die cold isostatic pressing.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2020

On the Pressure Generated by Thermite Reactions Using Stress-Altered Aluminum Particles

Here we examine pressure build-up and decay in thermites upon impact ignition and interprets reactivity based on the holistic pressure history. The thermite is a mixture of aluminum (Al) combined with bismuth trioxide (Bi 2 O 3 ) powder. Four different Al particles sizes were examined that ranged from 100 nm to 18.5 μm mean diameter and for each size, two different Al powder treatments were examined: stress-altered compared to untreated, as-received Al powder. Stress-altered Al powders have been shown to be more reactive, such that the stress-altered Al powder thermites offer a metric for analyzing thermite reactivity in terms of pressure development compared to untreated Al powder. In a binary thermite system, multiple phase changes and interface chemistry influence the transient pressure response during reaction. Results reveal three key pressure metrics that need consideration specifically for thermite combustion: (1) delay time to peak pressure, (2) peak pressure, and (3) decay after peak pressure. Our experiments show that a lower peak pressure corresponds with higher thermite reactivity because aluminum consumption of oxygen generated by decomposing solid oxidizer reduces the peak pressure. Faster rates of reaction consume oxygen at higher rates such that pressure development becomes more limited than less reactive thermites and the result is a lower peak pressure. This conclusion is opposite of traditional studies using metal fuels with a gaseous environment that typically show higher peak pressures correspond with greater reactivity.

42 ENGINEERING↗

NASA NTRS2012

Near Earth Asteroid Human Mission Possibilities Using Nuclear Thermal Rocket (NTR) Propulsion

The NTR is a proven technology that generates high thrust and has a specific impulse (Isp (is) approximately 900 s) twice that of today's best chemical rockets. During the Rover and NERVA (Nuclear Engine for Rocket Vehicle Applications) programs, twenty rocket reactors were designed, built and ground tested. These tests demonstrated: (1) a wide range of thrust; (2) high temperature carbide-based nuclear fuel; (3) sustained engine operation; (4) accumulated lifetime; and (5) restart capability - all the requirements needed for a human mission to Mars. Ceramic metal fuel was also evaluated as a backup option. In NASA's recent Mars Design reference Architecture (DRA) 5.0 study, the NTR was selected as the preferred propulsion option because of its proven technology, higher performance, lower launch mass, versatile vehicle design, simple assembly, and growth potential. In contrast to other advanced propulsion options, NTP requires no large technology scale-ups. In fact, the smallest engine tested during the Rover program - the 25 klbf 'Pewee' engine is sufficient for a human Mars mission when used in a clustered engine configuration. The 'Copernicus crewed NTR Mars transfer vehicle design developed for DRA 5.0 has significant capability that can enable reusable '1-year' round trip human missions to candidate near Earth asteroids (NEAs) like 1991 JW in 2027, or 2000 SG344 and Apophis in 2028. A robotic precursor mission to 2000 SG344 in late 2023 could provide an attractive Flight Technology Demonstration of a small NTR engine that is scalable to the 25 klbf-class engine used for human missions 5 years later. In addition to the detailed scientific data gathered from on-site inspection, human NEA missions would also provide a valuable 'check out' function for key elements of the NTR transfer vehicle (its propulsion module, TransHab and life support systems, etc.) in a 'deep space' environment prior to undertaking the longer duration Mars orbital and landing missions that would follow. The initial mass in low Earth orbit required for a mission to Apophis is approximately 323 t consisting of the NTR propulsion module ((is) approximately 138 t), the integrated saddle truss and LH2 drop tank assembly ((is) approximately 123 t), and the 6-crew payload element ((is) approximately 62 t). The later includes a multi-mission Space Excursion Vehicle (MMSEV) used for close-up examination and sample gathering. The total burn time and required restarts on the three 25 klbf 'Pewee-class' engines operating at Isp (is) approximately 906 s, are approximately 76.2 minutes and 4, respectively, well below the 2 hours and 27 restarts demonstrated on the NERVA eXperimental Engine, the NRX-XE. The paper examines the benefits, requirements and characteristics of using NTP for the above NEA missions. The impacts on vehicle design of HLV payload volume and lift capability, crew size, and reusability are also quantified.

Borowski, Stanley↗

DOE OSTI2021

Streamlining the Coupling of BISON and Dakota Through the NEAMS Workbench

Metallic nuclear fuels for use in advanced reactors are an active area of research and development. Robust, accurate metallic fuel performance models are necessary for the design, analysis, and licensing of such reactors. However, metallic fuel performance models require additional development; they are not as mature as uranium dioxide fuel performance models. To support further metallic fuel development, Oak Ridge National Laboratory and the University of Florida have streamlined the coupling of the BISON fuel performance code with Design Analysis Kit for Optimization and Terascale Applications (Dakota) statistical analysis tool through the Nuclear Energy Advanced Modeling and Simulation (NEAMS) Workbench. This work included performing three different sensitivity analyses on metallic nuclear fuel models in BISON. The analyses examined were a general model of the IFR-1 experiment, the X430 experiment T654 pin, and the X430 experiment T651 pin. The results suggest that BISON and Dakota can be integrated through NEAMS Workbench to perform sensitivity and uncertainty analyses and visualize the results.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2020

Microstructure, Thermal, and Mechanical Properties Relationships in U and UZr Alloys (Final Report)

Uranium-zirconium (U-Zr) alloys are candidate fuel systems for transmutation based reactors that can be used to burn long-lived minor actinides and fission products in fast spectrum reactors. Metallic fuels have also been gaining more recent attention for applications as accident tolerant fuels, as well as for use in small modular reactors. This research focused on a “science-based” approach to capture the connections between U and U-Zr alloys’ three-dimensional (3-D) microstructure, thermal properties, and mechanical properties through closely coordinated experiments and modeling efforts from the unirradiated to the irradiated fuels. Advanced characterization and modeling techniques were used to understand irradiation-induced microstructural evolution and its direct impact on the thermal and mechanical properties of U and U-Zr fuel. Closely coordinated experiments and modeling were performed to provide crucial data that does not currently exist. Overall, this research spanned multiple length and time scales within the models and experiments. The scope of the research encompassed the understanding of the irradiation effects in U and various U-Zr alloys with particular attention paid to three task areas: (1) microstructural evolution, (2) in-situ/ex-situ thermal and mechanical properties, and (3) multiscale modeling connections to microstructure, thermal, and mechanical properties. This research resulted in (1) the 3-D characterization of neutron irradiated U-Zr fuel in multiple phase regions to better understand fission gas swelling and constituent redistribution, (2) development of a microstructural model linking thermal and mechanical properties via in situ Raman and nanoindentation, (3) and mesoscale phase field modeling was coupled with the AEH method in the MOOSE framework was used to calculate the effective thermal conductivities of U-Zr fuels consisting of α-U and δ-UZr 2 heterogeneous microstructures.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

NASA NTRSDate not supplied

Composite Technologies for Science Missions

ASTROLAB, Lunar Geophysical Network, Mars Icebreaker and Mars PLACER Net missions propose use of various types of vehicles – such as rovers, landers and flying probes - to accomplish their scientific objectives. Although designs for such vehicles are myriad, many structural components can be made using composite manufacturing technologies. Composite materials are also myriad, by nature, but carbon fiber reinforced polymers (CFRP) in particular are sought after for their high specific strength and specific stiffness. CFRP components could be especially beneficial in vehicle designs for Moon or Mars missions due to their nearly negligible coefficient of thermal expansion (CTE). CTE is a critical design characteristics in environments where significant thermal swings are prevalent, such as those of atmosphere-less Moon and Mars.MSFC/EM42 houses several relevant composites technologies. Strong and rigid struts can be filament-wound. Shells and platforms can be laid-up using automated fiber placement (for repeatability) or by hand (for small features). Monolithic structures can even be designed to reduce part count and therefore reduce the risk of joint failures. Composites are also tailorable, allowing the incorporation of different material types or formats through the thickness of a part. This includes materials which shield from radiation or electrostatic discharge. Finally, the rigidity of composite parts minimizes overall vibration and compliance within a design.Additionally, missions such as Triton Ocean World Surveyor anticipate use of traditional, metallic fuel tanks. Composite overwrapped pressure vessels (COPVs) are suitable for use in this application as well. The Triton mission even cites a concern for heat retention, for which CFRP also offers improved characteristics over traditional metallic tanks.

Lightweight↗

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↗

NASA NTRS2015

Revised Point of Departure Design Options for Nuclear Thermal Propulsion

In an effort to further refine potential point of departure nuclear thermal rocket engine designs, four proposed engine designs representing two thrust classes and utilizing two different fuel matrix types are designed and analyzed from both a neutronics and thermodynamic cycle perspective. Two of these nuclear rocket engine designs employ a tungsten and uranium dioxide cermet (ceramic-metal) fuel with a prismatic geometry based on the ANL-200 and the GE-710, while the other two designs utilize uranium-zirconium-carbide in a graphite composite fuel and a prismatic fuel element geometry developed during the Rover/NERVA Programs. Two engines are analyzed for each fuel type, a small criticality limited design and a 111 kN (25 klbf) thrust class engine design, which has been the focus of numerous manned mission studies, including NASA's Design Reference Architecture 5.0. slightly higher T/W ratios, but they required substantially more 235U.

Nuclear Thermal Rockets↗

DOE OSTI2020

Self-assembly of solid nanoclusters in molybdenum under gas ion implantation

The self-assembly of defects in materials could create unique physical and chemical properties. In nuclear fuels, the formation of self-assembled fission products mitigates fission-gas-release and swelling. In this work, we report the formation of a solid nanocluster superlattice in molybdenum, an important constituent in metallic fuels, under krypton gas ion implantation. X-ray absorption near edge structure measurements coupled with density functional theory calculations show that the pressure of krypton nanoclusters in molybdenum is ~2 GPa and molecular dynamic simulations reveal that the krypton atoms are solid in the nanoclusters with a krypton-to-vacancy ratio of ~0.28 at 300 K.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗

DOE OSTI2022

Versatile Test Reactor Conceptual Core Design

The VTR is a 300-MW(thermal) sodium-cooled fast reactor (SFR) designed for the specific purpose of delivering unique testing capabilities to enable the advancement of all reactor technologies. With its flux level, irradiation volume, and operational flexibility, the VTR will enable accelerated testing of materials, fuels, and various components needing irradiation testing. Proven SFR technologies and design approaches have been leveraged in designing the VTR core, ensuring the highest possible readiness level. This resulted in the VTR using ternary metallic fuel and delivering fast flux levels in excess of 4 x 10 15 n/cm 2 ∙ s over large useful volumes, corresponding to about 60 dpa/year in steel. As part of the design efforts, the VTR core performance has been determined for a representative configuration, ensuring that the reactivity control systems offer sufficient shutdown margins, that the core can be safely cooled in all situations, and that reactivity feedback coefficients are conducive to a favorable safety behavior. Furthermore, the incorporation of features such as fuel assembly storage in the shield region supports the flexible and reliable operation of the VTR. Additional design work has been ongoing as well. This includes thorough shielding performance evaluations to ensure safe operation of the VTR, verification and validation of the design tools used to achieve compliance with Nuclear Quality Assurance (NQA-1) requirements, early assessment of the impact of irradiation experiments on the core performance envelope and associated margins, and in-depth uncertainty quantification efforts to quantify the anticipated range of performance characteristics. An experimental program supporting the VTR core design has been set up, with the current focus being on thermal-hydraulic experiments. The purpose of this experimental program is to obtain confirmatory measurements to serve directly as part of the core design basis or as part of the validation cases supporting the simulation tools used.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2021

Development of a U-19Pu-10Zr fuel performance benchmark case based on the IFR-1 experiment

Metallic nuclear fuels are subject to research and development for use in advanced reactors. Robust, accurate metallic fuel performance models are important for the design, safety analysis, and licensing of these reactors. However, metallic fuel performance models require additional development; they are not as mature as UO 2 fuel performance models. A benchmark case based on the IFR-1 experiment was developed to better gauge the accuracy of existing models, identify models for high-priority development, and potentially quantify any future improvements made by further model development.This work collected publicly available information on the IFR-1 experiment and used it to develop the benchmark case. Fuel behavior during the IFR-1 irradiation was simulated by using the fuel performance code BISON, and the predicted results were compared with postirradiation examination data from the IFR-1 experiment. Furthermore, a sensitivity study and tuning studies were performed as a preliminary investigation into the causes of inaccurate temperature and dimensional change predictions.The benchmark predicted reasonably accurate values for the burnup and fission gas release. There was error in the predicted temperatures, which could be explained by uncertainty in the input parameters and legacy temperatures. BISON over-predicted dimensional changes in the fuel and cladding. The sensitivity study showed that the dimensional changes were most sensitive to the fuel swelling anisotropy and the cladding void swelling model. Future benchmark and model development should focus on cladding swelling behaviors to improve dimensional change predictions.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2022

Development of green-colour-emitting pyrotechnics as a core for 3D temperature imaging sensors inside coal boilers

Efficiency in the control operation of the boilers for coal and coal with biomass can be further improved if the flue gas temperature distribution can be better characterized. This is very difficult in these harsh environmental systems, where spatially resolved measurements are nearly impossible with solid-state sensors. Here, in this work, we evaluate the development of pyrotechnic compounds that would serve as the basis for a novel optical mapping of the temperature inside coal boilers. For this purpose, various green-colour-emitting pyrotechnics using BaCl 2 · 2H 2 O and Ba(NO 3 ) 2 as the green light source were prepared, as this colour offers a distinct signal from the combustion-based background in the boiler. These pyrotechnics were characterized using thermogravimetric analysis (TGA) and X-ray diffraction (XRD) and tested using a flat-flame burner. Furthermore, the composition was varied to evaluate the effect of different metal fuels such as Sn, Co, and Mg, as well as various binders such as ethylcellulose, shellac, parlon, and PVC on green light emission. The emission intensity and the apparent ignition temperature were strongly dependent on the metal type, with Mg showing higher intensities. On the other hand, the effect of the binder showed that the ignition behaviour, emission intensity, and spectral purity were influenced by the nature and exothermicity of the binder. The addition of other potential green light-producing materials, such as boric acid, increased the intensity of emission by 17% for a BaCl 2 · 2H 2 O-based composition. This study identified prospective compositions with intense and bright green-colour emissions that have high spectral purities.

42 ENGINEERING↗

DOE OSTI2019

Summary Report for Out-of-Pile Transient Testing Database Development

The DOE Advanced Reactor Technology program has supported knowledge preservation efforts to recover and preserve fuel data from the US sodium cooled fast reactor (SFR) program. Efforts have focused on establishing databases of experimental data generated during the Integral Fast Reactor program (at EBR-II, FFTF, and TREAT) as well as during related out-of-pile examinations of the fuel irradiated at EBR-II. The information in these databases is essential to support further development and licensing activities for advanced fast reactor designs. OPTD is a database of out-of-pile furnace transient tests on metallic fuel. It includes records of 62 tests on irradiated fuel pins conducted in furnace apparatuses constructed in the Alpha-Gamma Hot Cell Facility at ANL. This report describes efforts during FY19 to improve visibility and access, expand the content of, and improve the user experience with the FIPD and OPTD databases.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2021

Advanced Fuels Campaign Execution Plan

The Advanced Fuels Campaign (AFC) Execution Plan outlines the strategy, mission, scope, near-term and long-term goals, structure, and organization associated with nuclear fuels and materials research, development, and demonstration activities within the Department of Energy’s (DOE) Nuclear Fuel Cycle and Supply Chain (NFCSC) program. NFCSC has been given responsibility to identify and mature advanced fuel technologies for the DOE using a science-based approach, focused on developing a fundamental understanding of nuclear fuels and materials to drive development of integrated nuclear fuel and materials technology. This science-based approach combines theory, experiments, and multiscale modeling and simulation to achieve a predictive understanding of relevant behaviors ranging from fuel fabrication processes (and their resulting fuel microstructures) through fuel/cladding performance under irradiation (in contrast to more empirical, observation-based approaches frequently used in fuel performance modeling and fuel qualification). The traditional scope of AFC includes the evaluation and development of multiple fuel forms to support two fuel cycle options: once-through and full recycle. The word “fuel” is used generically to include conventional fuels, transmutation targets, and any associated cladding or duct materials. The once-through fuel cycle addresses advanced light water reactor fuels with enhanced performance, extended burnup, and reduced waste generation. In fiscal year (FY) 2012, AFC’s scope expanded to include research, development, and demonstration (RD&D) for light water reactor (LWR) fuels with enhanced accident tolerance. Fuel fabrication activities include the development of innovative methods to enhance process efficiencies, reduce waste, and improve control over as-fabricated fuel microstructural properties to achieve desired in-reactor performance. Using modern modeling and simulation approaches, the objective is to predict fresh fuel properties given the feedstock characteristics and fabrication process parameters. The performance-related activities include small-scale, in-reactor, and out-of-reactor phenomenological testing (distinct from, but synergistic with, integral prototypic testing) and extensive, quantitative characterization (focusing on characterization of fuel and cladding materials at the scale of microstructure) both before and after testing. Larger-scale, prototypic experiments are conducted in concert with phenomenological testing to drive a Fuel Development and Qualification program, incorporating a fundamental understanding of fuel behavior performance characteristics. Then, using the tools developed under the productive science-based approach, fuels will be optimized to meet specific performance requirements, thereby minimizing the need to repeatedly perform large-scale, integral experiments over a wide parametric range as a means of experimental exploration. Two significant initiatives are underway within AFC. First, a gap analysis completed in early FY 2019 identified critical irradiation testing needs that are lacking within the national light water reactor (LWR) fuels testbed since the shutdown of the Halden Reactor in 2018. The identified gaps are for instrumented, prototypic testing of LWR fuels, especially under boiling water reactor conditions, ramp conditions, and conditions leading to fuel failure; these needs exist for supporting current LWR fuels and their possible extension to higher burnups, but are especially urgent relative to near-term development and qualification of accident-tolerant fuels. Recommendations that resulted from the Halden Gap Analysis focused on enhancements at Advanced Test Reactor (ATR) and Transient Reactor Test Facility (TREAT) to fill gaps in testing capabilities relative to these needs. Second, a concerted effort to develop and demonstrate a systematic approach to accelerating the development, testing, and qualification of new fuel systems has been initiated. This is highlighted by a test strategy that combines the considerable advances in multiscale, mechanistic fuel modeling of recent years with a MiniFuel separate effects test program in the High Flux Isotope Reactor (HFIR) and a Fission Accelerated Steady-state Testing (FAST) semi-integral accelerated test program in ATR. This approach is being tested/demonstrated using the metallic fuel system, but if successful it is expected to be extensible to multiple fuel types and diverse applications. This document includes an overview of the NFCSC program, a definition of science-based development of nuclear fuels, near-term goals for Advanced LWR fuels (ALFs), and longer-term goals for Advanced Reactor Fuels (ARFs) RD&D. This includes the activities that will be conducted to achieve success toward the grand challenge, as well as the goals and milestones to be achieved over the next few decades of research and development. Long-term goals are based on the DOE Office of Nuclear Energ

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2024

Advanced Fuels Campaign Execution Plan

The Advanced Fuels Campaign (AFC) Execution Plan outlines the strategy, mission, scope, near-term and long-term goals, structure, and organization associated with nuclear fuels and materials research, development, and demonstration activities within the Department of Energy’s (DOE) Nuclear Fuel Cycle and Supply Chain (NFCSC) program. NFCSC has been given responsibility to identify and mature advanced fuel technologies for the DOE using a science-based approach, focused on developing a fundamental understanding of nuclear fuels and materials to drive development of integrated nuclear fuel and materials technology. This science-based approach combines theory, experiments, and multiscale modeling and simulation to achieve a predictive understanding of relevant behaviors ranging from fuel fabrication processes (and their resulting fuel microstructures) through fuel/cladding performance under irradiation (in contrast to more empirical, observation-based approaches frequently used in fuel performance modeling and fuel qualification). The traditional scope of AFC includes the evaluation and development of multiple fuel forms to support two fuel cycle options: once-through and full recycle. The word “fuel” is used generically to include conventional fuels, transmutation targets, and any associated cladding or duct materials. The once-through fuel cycle addresses advanced light water reactor fuels with enhanced performance, extended burnup, and reduced waste generation. In fiscal year (FY) 2012, AFC’s scope expanded to include research, development, and demonstration (RD&D) for light water reactor (LWR) fuels with enhanced accident tolerance. Fuel fabrication activities include the development of innovative methods to enhance process efficiencies, reduce waste, and improve control over as-fabricated fuel microstructural properties to achieve desired in-reactor performance. Using modern modeling and simulation approaches, the objective is to predict fresh fuel properties given the feedstock characteristics and fabrication process parameters. The performance-related activities include small-scale, in-reactor, and out-of-reactor phenomenological testing (distinct from, but synergistic with, integral prototypic testing) and extensive, quantitative characterization (focusing on characterization of fuel and cladding materials at the scale of microstructure) both before and after testing. Larger-scale, prototypic experiments are conducted in concert with phenomenological testing to drive a Fuel Development and Qualification program, incorporating a fundamental understanding of fuel behavior performance characteristics. Then, using the tools developed under the productive science-based approach, fuels will be optimized to meet specific performance requirements, thereby minimizing the need to repeatedly perform large-scale, integral experiments over a wide parametric range as a means of experimental exploration. Two significant initiatives are underway within AFC. First, a gap analysis completed in early FY 2019 identified critical irradiation testing needs that are lacking within the national light water reactor (LWR) fuels testbed since the shutdown of the Halden Reactor in 2018. The identified gaps are for instrumented, prototypic testing of LWR fuels, especially under boiling water reactor conditions, ramp conditions, and conditions leading to fuel failure; these needs exist for supporting current LWR fuels and their possible extension to higher burnups, but are especially urgent relative to near-term development and qualification of accident-tolerant fuels. Recommendations that resulted from the Halden Gap Analysis focused on enhancements at Advanced Test Reactor (ATR) and Transient Reactor Test Facility (TREAT) to fill gaps in testing capabilities relative to these needs. Second, a concerted effort to develop and demonstrate a systematic approach to accelerating the development, testing, and qualification of new fuel systems has been initiated. This is highlighted by a test strategy that combines the considerable advances in multiscale, mechanistic fuel modeling of recent years with a MiniFuel separate effects test program in the High Flux Isotope Reactor (HFIR) and a Fission Accelerated Steady-state Testing (FAST) semi-integral accelerated test program in ATR. This approach is being tested/demonstrated using the metallic fuel system, but if successful it is expected to be extensible to multiple fuel types and diverse applications. This document includes an overview of the NFCSC program, a definition of science-based development of nuclear fuels, near-term goals for Advanced LWR fuels (ALFs), and longer-term goals for Advanced Reactor Fuels (ARFs) RD&D. This includes the activities that will be conducted to achieve success toward the grand challenge, as well as the goals and milestones to be achieved over the next few decades of research and development. Long-term goals are based on the DOE Office of Nuclear Energ

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗