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The goal of the Advanced Materials and Manufacturing Technologies (AMMT) program is to accelerate the deployment of new materials and manufacturing technologies into advanced nuclear-related systems. Although 316H stainless steel fabricated by laser powder bed fusion (LPBF) has already been identified as an alloy that could have a significant effect on various reactor technologies, many other materials and manufacturing techniques are being evaluated. Nickel-based alloys typically offer higher-temperature capabilities compared with advanced stainless steels, and previous reports looked at three Ni-based alloy categories: low-Co alloys with a potential use close to the reactor core; high-temperature, high-strength alloys; and molten salt–compatible alloys. Due to the increasing interest in the low Co 625 alloy for nuclear applications, the alloy was compared at the Oak Ridge National Laboratory (ORNL) with 617, 230, two high-temperature, high-strength solution-strengthened alloys. Hot cracking could not be suppressed for alloy 230, and it was shown that these cracks, which were elongated along the build direction (BD), had a drastic effect on the ductility of alloy 230 at room temperature when specimens were machined perpendicular to the BD. Cracking was not as significant for alloy 617, but still led to significant variation in ductility at room temperature along the build direction. On the contrary, LPBF printing of crack-free alloy 625 was achieved using similar printing parameters, and the alloy looks like a very promising candidate for various reactor technologies.
Kilowatt Reactor Using Stirling TechnologY (KRUSTY) was a prototype for the U.S. National Aeronautics and Space Administration’s Kilopower Program. KRUSTY has a highly enriched uranium–molybdenum alloy (with 7.65 wt% molybdenum) annular core reflected by beryllium oxide with an outer stainless steel shield. Five configurations from the experimental campaign were chosen to be evaluated as benchmark cases. Uncertainties were evaluated in five categories: (1) criticality measurement, (2) mass and density, (3) dimensions, (4) material compositions, and (5) positioning. The largest contribution to the overall uncertainty in each case was from the radial alignment of the movable platen. A simplified model was created to increase computational efficiency, and an average bias of –16 pcm was calculated due to the simplifications. Sample calculations were completed for each case using MCNP6.2, COG, and MC21, all with ENDF/B-VIII.0 nuclear data. For MCNP6.2, the average difference (absolute value) between the calculated and experimental $k_{eff}$ for the five configurations was 14 pcm for both the detailed and the simplified models. The $k_{eff}$ results from all three codes are within 1σ of the benchmark values. KRUSTY’s value as a benchmark is due to its sensitivity to beryllium and molybdenum. For beryllium, KRUSTY adds an 18th benchmark with a total cross-section sensitivity greater than 0.05%/%/(unit lethargy). For molybdenum, KRUSTY adds a 9th benchmark with a total cross-section sensitivity greater than 0.004%/%/(unit lethargy).
Whiteshell Laboratories, located in Manitoba, Canada, provided research facilities for the Canadian nuclear industry since the early 1960's. The facility was centered on an organically cooled, heavy water moderated nuclear reactor in the world, Whiteshell Reactor 1 (WR-1). WR-1 was safely shut down in 1985, de-fueled and drained, and has been in a safe Storage with Surveillance (Deferred Decommissioning) state until present day. In support of an Environmental Assessment for proposed In Situ Decommissioning of WR-1, detailed characterization information regarding the reactor core components (calandria, calandria tubes, pressure tubes) was necessary to verify inventory estimates and neutron activation models produced circa 1992. The Fuel Channels of WR-1 (pressure tubes) were expected to be the most activated components of the reactor core, and to account for about 60% of the reactor core inventory. The interior surface of the fuel channel is also the most readily accessible surface within the reactor core. As such the decision was made to collect a sample of one of each of 3 Fuel Channel material types (Stainless Steel, Zr-2.5Nb, Ozhenite) for comparison to modelled estimates of neutron activation of various core materials. The expected dose rates from the samples were between 5 and 100 mSv (500-10,000 mrem) on contact based on a 200 mg sample. Sampling the Fuel Channels required verification the Fuel Channel was drained of organic coolant, removal of residual organic coolant from the Fuel Channel wall, removal of material from the interior surface of the Fuel Channel at the centerline of flux (∼25' below the operator position), and extraction of that material from the core. Several options for existing tooling and technologies, including hydraulic scrapers, and horizontal drill technologies, were looked at for their applicability to WR-1. While suitable approaches to higher radiation field sample collection, they were overly complex, costly and time consuming for the configuration at WR-1. In an effort to reduce costs, and to simplify the sampling process, a specialized and simple tool was developed to mechanically scrape a small sample of the interior wall of the Fuel Channels, collect the sample into a vial, and remove the sample from the core for analysis. The tool was designed, constructed, tested and implemented in the field entirely by Canadian Nuclear Laboratories Staff. The tool required no powered components, or electronic guidance or measurements; and was designed and constructed for a fraction of the cost of other commercially available technologies for sample collection within reactor cores. The samples were successfully collected without any injuries, contamination events or equipment failures. The tool remains operational in the event additional sampling is required. This paper provides additional details of the design, construction, testing and use of the tool and the successes and lessons learned during the various stages of design and implementation. (authors)
The irradiation-induced void swelling of HT9 stainless steel has been observed many times, but there are little data available to quantify the amount of swelling expected as a function of neutron exposure and temperature. This is further complicated by potential heat-to-heat chemical variations or heat treatment conditions during fabrication. Herein, this paper summarizes the results of most of the relevant previously completed studies, then focuses on the swelling behavior of HT9 mixed-oxide fuel cladding and wrapper wire irradiated to high neutron exposures. Note that the hexagonal duct used for the ACO-3 experiment (in the Fast Flux Test Facility, or FFTF) was also made from HT9 and has been studied previously by other researchers. The cladding enables a wider range of operating temperatures. Immersion density and transmission electron microscopy were used to identify a peak in the amount of swelling located axially, just below core centerline, for both the cladding and the wire. The peak roughly coincided with a peak seen in the cladding diameter profile. The wrapper wire showed enhanced swelling compared to the cladding, likely due to over-tempering during wire fabrication heat treatment. The grains showed decreased martensitic structure were larger in size. These data do not provide for the means to fully characterize the swelling of HT9, but do provide further insight into the factors controlling it. The onset of breakaway swelling was not indicated in this data.
The kinetics of uptake and desorption impact the performance of graphite as a vector for tritium in high-temperature fission reactors and in the blanket of fusion reactors. Graphite components in these reactors are exposed to temperatures > 500 °C and H 2 partial pressures of few Pa and desorption temperatures are limited to < 1600 °C; limited data is available at these conditions. Here we review the mechanisms for uptake in, transport and desorption of hydrogen from graphite at high temperature, compiling data on uptake rates, diffusion coefficients and activation energies and providing a discussion of the impact of irradiation, pre-oxidation and isotope. At FHR conditions, trapping impacts uptake rates, leading to a reduction in apparent diffusivity by 35 to 80% compared to higher partial-pressure uptake. Timelines for desorption are not clearly defined; extrapolating from available data, at 1150 °C desorbing 80% of tritium uptaken at FHR conditions may take from 100 to 10,000 h.
The NGNP, which is an advanced HTGR concept with emphasis on both electricity and hydrogen production, involves helium as the coolant and a closed-cycle gas turbine for power generation with a core outlet/gas turbine inlet temperature of 750-1000°C. Alloy 617 is a prime candidate for VHTR structural components such as reactor internals, piping, and heat exchangers in view of its resistance to oxidation and elevated temperature strength. However, lack of adequate data on the performance of the alloy in welded condition prompted to initiate a creep test program at Argonne National Laboratory. In addition, Testing has been initiated to evaluate the creep rupture properties of the pressure vessel steel A508/533 in air and in helium environments. The program, which began in December 2009, was certified for quality assurance NQA-1 requirements during January and February 2010. Specimens were designed and fabricated during March and the tests were initiated in April 2010. During the past year, several creep tests were conducted in air on Alloy 617 base metal and weldment specimens at temperatures of 750, 850, and 950°C. Idaho National Laboratory, using gas tungsten arc welding method with Alloy 617 weld wire, fabricated the weldment specimens. Eight tests were conducted on Alloy 617 base metal specimens and nine were on Alloy 617 weldments. The creep rupture times for the base alloy and weldment tests were up to ~3900 and ~4500 h, respectively. The results showed that the creep rupture lives of weld specimens are much longer than those for the base alloy, when tested under identical test conditions. The test results also showed that the creep strain at fracture is in the range of 7-18% for weldment samples and were much lower than those for the base alloy, under similar test conditions. In general, the weldment specimens showed more of a flat or constant creep rate region than the base metal specimens. The base alloy and the weldment exhibited tertiary creep after 50-60% of the rupture life, irrespective of test temperature in the range of 750-950°C. The results showed that the stress dependence of the creep rate followed a power law for both base alloy and weldments. The data also showed that the stress exponent for creep is the same and one can infer that the same mechanism is operative in both base metal and weldments in the temperature range of the current study. SEM fractography analysis indicated that both base metal and weldment showed combined fracture modes consisting of dimple rupture and intergranular cracking. Intergranular cracking was more evident in the weldment specimens, which is consistent with the observation of lower creep ductility in the weldment than in the base metal.
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The use of optical instrumentation in advanced nuclear fission systems, such as molten salt reactors, liquid metal-cooled reactors, and high-temperature gas-cooled reactors, has the potential to enhance reactor safety and economic performance through in situ and online measurement of reactor conditions. Selection of suitable optical components, such as optical windows and fibers, is essential for operation of optical instrumentation in intense radioactive and thermal environments inherent to nuclear reactor systems. We present the development and performance of a self-contained and mobile post-irradiation examination system for rapid characterization of the optical properties of materials. The instrument combines linear absorption and nanosecond Z-scan modules in a compact, relocatable design. The system mobility allows for the evaluation of optical samples at the site of irradiation, minimizing the delay between extraction from the irradiation site and optical characterization. This provides nearly real-time information on the material performance under simultaneous irradiation and thermal annealing, simulating the relevant conditions for the use of those components in nuclear power systems.
Getters are among the key functional components in the Tritium Producing Burnable Absorber Rods (TPBARs) of Light Water Reactors, and are used to capture the released tritium gas. They are cylindrical tubes comprised of the alloy zircaloy-4 which is coated with nickel plating both internally and externally. Their exposure to tritium as well as the irradiation environments in the light water reactors changes their structure, chemical composition and chemistry. Understanding the radial tritium distribution is key to gaining insight into the evolution of new chemistry upon irradiation in order to predict getter performance. Consequently, efforts are underway to devise a method that can allow selective probing into the getter core radially to probe the chemistry akin to carefully and selectively peeling of the layers of an onion. We have recently devised an electrochemical dissolution technique for controlled radial dissolution of zirconium based liners; this work describes the first proof-of-concept demonstration of the applicability of this technique on the controlled radial dissolution of nickel plated getters. The technique is complemented with periodic analysis of the electrolyte solution to measure the rates of release of the various elemental components and therefore glean information on their radial distribution across the getter; further complementary microscopy on the exposed surfaces allows us insight into the chemistry at the getter core.
A vital component of the U.S. reactor licensing process is an integrated safety analysis in which a source term representing the release of radionuclides during normal operation and accident sequences is analyzed. Historically, source term analyses have utilized bounding, deterministic assumptions regarding radionuclide release. However, advancements in technical capabilities and the knowledge state have enabled the development of more realistic and best-estimate retention and release models such that a mechanistic source term assessment can be expected to be a required component of future licensing of advanced reactors. Recently, as part of a Regulatory Technology Development Plan effort for sodium cooled fast reactors (SFRs), Argonne National Laboratory has investigated the current state of knowledge of potential source terms in an SFR via an extensive review of previous domestic experiments, accidents, and operation. As part of this work, the significant sources and transport processes of radionuclides in an SFR have been identified and characterized. This effort examines all stages of release and source term evolution, beginning with release from the fuel pin and ending with retention in containment. Radionuclide sources considered in this effort include releases originating both in-vessel (e.g. in-core fuel, primary sodium, cover gas cleanup system, etc.) and ex-vessel (e.g. spent fuel storage, handling, and movement). Releases resulting from a primary sodium fire are also considered as a potential source. For each release group, dominant transport phenomena are identified and qualitatively discussed. The key product of this effort was the development of concise, inclusive diagrams that illustrate the release and retention mechanisms at a high level, where unique schematics have been developed for in-vessel, ex-vessel and sodium fire releases. This review effort has also found that despite the substantial range of phenomena affecting radionuclide release, the current state of knowledge is extensive, and in most areas may be sufficient. Several knowledge gaps were identified, such as uncertainty in release from molten fuel and availability of thermodynamic data for lanthanides and actinides in liquid sodium. However, the overall findings suggest that high retention rates can be expected within the fuel and primary sodium for all radionuclides other than noble gases.
This report summarizes the activities and status of the ASME design code development effort for Composite Core Components for High Temperature Reactors during Fiscal Year 2018. The subsection drafts develop for ASME BPVC Division 5 Section III, namely Subsection HA Subpart B and Subsection HH Subpart B, are near publication. It is likely that Subsection HH Subpart B will be accepted during the next ASME review meeting. Subsection HA Subpart B may have to continue through more review iterations before final acceptance. Two new standards for fiber-reinforced advanced ceramic composites have been published and a report on the technology gap for Molten Salt Reactor applications of SiC/SiC composites was completed.
Extending service of Light Water Reactors (LWRs) to beyond 60 years will demand a high integrity of materials and components in reactors. The accurate evaluation and prediction of materials performance under anticipated operation conditions are of particular importance for ensuring the safe operation of nuclear power plants over their extended lifetime. The duplex structure stainless steels including cast austenitic stainless steels (CASS) and welds of austenitic stainless steels are widely used in LWRs. The CASS alloys are mainly used in LWRs primary pressure boundary and for some limited core structural components. The type 308/309 welds are used for welding the reactor components made of 304 and 316 stainless steels and as a cladding layer on the inner surface of reactor pressure vessel. The core support columns made of CF8 CASS in a B and W design PWR are expected to be exposed to a fluence of between 1x10{sup 21} and 1x10{sup 22} n/cm{sup 2}, E>1.0 MeV, and the austenitic stainless steel welds can potentially receive a fluence up to 5x10{sup 22} n/cm{sup 2}, E>1.0 MeV. In addition to the thermal aging effect, the radiation induced fracture toughness in those duplex structure stainless steel components located in the high neutron fluence regions in LWRs hasn't be fully evaluated. Previous studies showed that the spinodal decomposition in the delta ferrite phase in CASS or type 308/309 welds is the primary embrittlement mechanism, and the G-phase precipitates were also identified but with less impact on the reduction of fracture toughness. It is generally agreed that the irradiation induced fracture toughness decrease in CASS and weld steels saturates after 10 dpa (∼1x10{sup 22} n/cm{sup 2}, E>1.0 MeV). Nevertheless, there are not enough high dose data points to confirm the lower bound in measured fracture toughness as the reported doses are limited to 15 dpa. The work in this paper is to present a more comprehensive study on the microstructural evolution in the ferrite phase in a CF3 CASS, and the results provide a scientific basis for extrapolating the change of fracture toughness to a high dose range.
. Irradiation assisted stress corrosion cracking (IASCC) is a known issue in current reactors. In a 60 year lifetime, reactor core internals may experience fluence levels up to 15 dpa for boiling water reactors (BWR) and 100+ dpa for pressurized water reactors (PWR). To support a safe operation of our fleet of reactors and maintain their economic viability it is important to be able to predict any evolution of material behaviors as reactors age and therefore fluence accumulated by reactor core component increases. For PWR reactors, the difficulty to predict high fluence behavior comes from the fact that there is not a consensus of the mechanism of IASCC and that little data is available. It is however possible to use the current state of knowledge on the evolution of irradiated microstructure and on the processes that influences IASCC to emit hypotheses. This report identifies several potential changes in microstructure and proposes to identify their potential impact of IASCC. The susceptibility of a component to high fluence IASCC is considered to not only depends on the intrinsic IASCC susceptibility of the component due to radiation effects on the material but to also be related to the evolution of the loading history of the material and interaction with the environment as total fluence increases. Single variation type experiments are proposed to be performed with materials that are representative of PWR condition and with materials irradiated in other conditions. To address the lack of IASCC propagation and initiation data generated with material irradiated in PWR condition, it is proposed to investigate the effect of spectrum and flux rate on the evolution of microstructure. A long term irradiation, aimed to generate a well-controlled irradiation history on a set on selected materials is also proposed for consideration. For BWR, the study of available data permitted to identify an area of concern for long term performance of component. The efficiency of hydrogen water chemistry mitigation technology may decrease as fluence increases for high-stress intensity factors. This report describes a program plan to determine the efficiency of hydrogen water chemistry as a function of the stress intensity factor applied and fluence. The use of existing, available, materials and the generation of additional materials via irradiation in a research reactor are considered.
This work demonstrates a controlled potential electrochemistry with correlative microscopy for insight into the radial H-distribution into TPBAR components of light water reactors.
The Advanced Reactor Technologies Graphite research and development program is conducting an extensive graphite irradiation program to provide data to assist in licensing of a high temperature reactor (HTR) design. In past applications, graphite has been used effectively as a structural and moderator material in both research and commercial high temperature gas cooled reactor designs.[ , ] Nuclear graphite H 451, used previously in the United States for nuclear reactor graphite components, is no longer available. New nuclear graphite grades have been developed and are considered suitable candidates for new HTR designs. To support the design and licensing of HTR core components within a commercial reactor, a complete properties database must be developed for these current grades of graphite. Quantitative data on in service material performance is required for the physical, mechanical, and thermal properties of each graphite grade with a specific emphasis on data accounting for the life limiting effects of irradiation creep. Further details on the research and development activities and associated rationale required to qualify nuclear grade graphite for use within the HTR are documented in the graphite technology research and development plan.[ ] Based on experience with previous graphite core components, the phenomenon of irradiation induced creep within the graphite has been shown to be a critical parameter in determining the total useful lifetime of graphite components. Irradiation induced creep occurs under the simultaneous application of high temperatures, neutron irradiation, and applied stresses within the graphite components. A second, much more significant, internal stress is experienced within the graphite components due to irradiation induced dimensional changes. These induced stresses result from neutron irradiation causing physical changes in the graphite structure, first shrinking it and then expanding it, with increasing neutron dose. This disparity in material volume change can induce significant internal stresses within graphite components. Irradiation induced creep relaxes these large internal stresses, thus reducing the risk of crack formation and component failure. Obviously, higher irradiation creep levels tend to relieve more internal stress, thus allowing the components longer useful lifetimes within the core. Determining the irradiation creep rates of nuclear graphite grades is critical for determining the useful lifetime of graphite components and is a major component of the Advanced Graphite Creep (AGC) experiment.
As part of the Accelerated Basin De-inventory (ABD) program, H Canyon plans to dissolve non-aluminum spent nuclear fuel (NASNF) in the 6.3D electrolytic dissolver. NASNF Campaign 1 plans to electrolytically dissolve 68 bundles of fuel assemblies from the Carolinas-Virginia Tube Reactor (CVTR), Heavy Water Components Test Reactor (HWCTR), and Experimental Boiling Water Reactor (EBWR). The fuel assemblies are intact Zircaloy or stainless steel (SS) clad UO 2 rods, tubes, and plates. The H Canyon electrolytic dissolver previously dissolved a variety of UO 2 core fuel types in SS, Zircaloy, Nichrome, or Incoloy cladding from 1969 to 1980. The objective of this study was to identify flowsheet conditions through literature review and laboratory experimentation to safely dissolve NASNF Campaign 1 bundles in the H Canyon electrolytic dissolver. Bench-scale electrolytic dissolution tests were performed to demonstrate a flowsheet for NASNF Campaign 1 bundles. The outer bundles are composed of SS or Al alloy, Al 6061-T6, and contain intact Zircaloy or SS clad UO 2 fuel assemblies. The key objectives of these tests were to determine bounding dissolver chemistries and the sparge requirement to ensure H 2 concentration remain less than 60 vol % of the lower flammability limit (LFL) during dissolution. The impact of HNO 3 concentration and the addition of fluoride on the dissolution efficiency of Zircaloy, 304L SS, Al 6061-T6, and Inconel 625 were examined. While SS, Al, and Inconel 625 readily dissolve utilizing electrolytic dissolution, Zircaloy disintegrated anodically; the surface of Zircaloy oxidized and the oxide layer spalled off and settled at the bottom of the dissolver as an insoluble material. The black flakes were identified as ZrO 2 and 85% of the Zr processed was converted to black ZrO 2 flakes when Zr was anodically disintegrated in 9.5 M HNO 3 .