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DOE OSTI2025

NDMAS

Overview of Current ART-GCR Data: Fuel Fabrication, Irradiation Monitoring (Fuel & Graphite – near real-time for HDG-1), Post-Irradiation Examination (Fuel & Graphite), Graphite Characterization (Baseline and Irradiated), High Temperature Metals Mechanical Tests, Design, Methods, and Validation Data, Japan Atomic Energy Agency’s High Temperature Test Reactor (HTTR), Argonne National Laboratory’s Natural convection Shutdown heat removal Test Facility (NSTF), Oregon State University’s High Temperature Test Facility (HTTF), Generation IV International VHTR Materials Handbook, Additional related data, and Advanced Test Reactor operations (near real-time).

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2021

Physics Studies for the LBNF Graphite Target Design

We present the simulated physics performance of the Long-Baseline Neutrino Facility (LBNF) graphite target that is being designed by the RAL High Power Targets Group for the Deep Underground Neutrino Experiment (DUNE). We first compare three conceptual cylindrical target design options as a function of target length (up to 2.2 m): downstream supported, two individual targets and an upstream-supported cantilever. Choosing the cantilever design as the baseline, we show the effect of widening the upstream inner conductor of the first focusing horn to provide extra space for supporting the target. We also give estimates of the expected performance of the 1.5 m prototype and 1.8 m production cantilevered targets. Furthermore, we show the effects of the main engineering updates made to the other two focusing horns since the DUNE TDR.

43 PARTICLE ACCELERATORS↗

DOE OSTI2025

Energy, greenhouse gas, and water life cycle analysis of synthetic graphite anode production in the United States

This study presents a comprehensive life cycle analysis of potential synthetic graphite battery anode material (BAM) production in the U.S. based on industrial-scale data. The analysis focuses on three impacts: greenhouse gas (GHG) emissions, total energy use, and water consumption. We also conducted sensitivity analyses to evaluate the effect of variation in process parameters and energy sources used for synthetic graphite BAM production on its life cycle GHG emissions. A detailed supply chain analysis of graphite BAM in the U.S. was also undertaken, along with a study of its associated GHG emissions. The results show GHG emissions of 29.7 kg CO 2 -eq. per kg BAM, total energy use of 580 MJ kg −1 BAM, and water consumption of 121 L kg −1 BAM for the baseline condition. The graphitization step is a major process hotspot, contributing to over 74% of all impacts. This is attributed to the energy and material input requirements for this step, particularly through the use of crucibles. Across the entire synthetic graphite production process, electricity is the primary contributor, followed by crucibles used in graphite block production, and then calcined petroleum coke. Sensitivity analyses indicate that improvement in micronization yield, reuse of crucibles, and use of low-carbon nuclear energy can significantly reduce GHG emissions of potential domestic graphite production (by ∼70%). Supply chain analysis identified major graphite BAM sources in the U.S. and showed that the U.S. has a competitive advantage in domestic production of synthetic graphite BAM in terms of reduced life cycle GHG emissions compared to present-day imported sources (by ∼20%).

Battery anode↗

DOE OSTI2025

Non-destructive structural characterization of graphite components using mechanical resonance and deep learning

As compared to conventional nuclear reactors, microreactors have the potential to significantly reduce construction timelines and capital costs, decreasing the barriers for advanced nuclear reactor technologies. However, the lower power output of these microreactors (typically < 20 MWe) creates challenging economics if operation and maintenance costs cannot be sufficiently reduced. The compact size of these designs presents an opportunity for comprehensive in-situ structural health monitoring to provide real-time feedback in order to reduce operational costs associated with maintenance and downtime. Many microreactor concepts use graphite for both in-core neutron moderation and as a structural material, which has typically required some form of periodic and laborious inspection. This report provides a description and assessment of recent work with graphite to couple acoustic-based experimental measurements and characterization with machine learning models to mature structural health monitoring capabilities and generate benefits for the nuclear microreactor industry. With resilient embedded sensors in development in other programs funded by the US Department of Energy’s Office of Nuclear Energy and elsewhere, the work described herein builds upon previously funded efforts to mature non-destructive testing technology that relates measured vibrational signatures to structural changes, using a combination of new experimental measurements and machine learning processing. Building on past successful demonstrations of predictive workflows to identify structural changes in a hexagonal stainless steel test article with excellent acoustic propagation, we first performed baseline characterization on graphite samples with canonical geometries to ensure compatibility and confidence in the applied techniques for a material with distinctly different mechanical properties. In contrast to efforts in previous years, we worked exclusively with unidirectional vibration data that is more comparable to those expected from the existing embedded sensor technologies which are suitable for deployment in a reactor setting. Established acoustic and modern machine-learning-based characterization approaches were applied to the resulting datasets from these simple geometries. Both approaches were found to be highly capable of detecting even small geometric irregularities amongst nominally identical samples. As such, we then moved to testing these approaches for detection of artificial local stress perturbations introduced into a more complex geometry: a hexagonal block with drilled holes. A main outcome of this work is that a generalizable ML workflow can be used to detect and predict the characteristics of small artificial anomalies in a graphite component with a relevant geometry. While this work was performed using surficial vibration data, we expect the approach to be flexible and viable for other monitoring scenarios, such as those with different arrangements or types of sensor arrays. As compared to previously funded efforts, an existing ML workflow based on neural networks was enhanced through the addition of recently developed Fourier neural operators. As applied to previously collected and new vibration datasets, prediction accuracies of anomaly characterizations were greatly improved with minimal added computational cost. As trained on small durations of vibration data (tens of seconds) collected over a realistic number of locations, the model was able to reliably determine the presence of a subtle stress anomaly and begin to provide location estimates. Such an approach is likely to be viable for more relevant reactor damage scenarios for graphite components, such as progressive crack growth or creep.

36 MATERIALS SCIENCE↗

NASA NTRS1980

Hybridized polymer matrix composites

The extent to which graphite fibers are released from resin matrix composites that are exposed to fire and impact conditions was determined. Laboratory simulations of those conditions that could exist in the event of an aircraft crash and burn situation were evaluated. The effectiveness of various hybridizing concepts in preventing this release of graphite fibers were also evaluated. The baseline (i.e., unhybridized) laminates examined were prepared from commercially available graphite/epoxy, graphite/polyimide, and graphite/phenolic materials. Hybridizing concepts investigated included resin fillers, laminate coatings, resin blending, and mechanical interlocking of the graphite reinforcement. The baseline and hybridized laminates' mechanical properties, before and after isothermal and humidity aging, were also compared. It was found that a small amount of graphite fiber was released from the graphite/epoxy laminates during the burn and impact conditions used in this program. However, the extent to which the fibers were released is not considered a severe enough problem to preclude the use of graphite reinforced composites in civil aircraft structure. It also was found that several hybrid concepts eliminated this fiber release. Isothermal and humidity aging did not appear to alter the fiber release tendencies.

House, E. E.↗

DOE OSTI2023

Microstructural characterization of nuclear graphite: from the microscale to the nanoscale

Multiple reactor designs use graphite as a moderator of the nuclear reactions and as structural support. During the lifetime of the reactor, multiple aging factors such as neutron irradiation, oxidation, and temperature along with others induce changes in the microstructure and crystal lattice of graphite components. The pore morphology and crystal structure of some phases in graphite can be used to trace the evolution of irradiation defects and mechanical properties of graphite. We present a combination of results from several microscopy techniques to investigate the differences between nuclear graphite grades and the effects of neutron irradiation and oxidation at multiple length scales. This multiscale approach is needed to understand the microstructural variations caused by the raw materials and manufacturing processes as well as how the different phases of graphite are affected by the reactor environment. The results provide insight into the oxidation- and radiation-induced changes of graphite and create a robust baseline of microstructure information that can be used for the selection of materials for the next generation of nuclear power stations. Moreover, the experiments conducted in this work provide an overview of the advantages and limitations of the most common techniques used to characterize nuclear graphite and how these techniques might be applied to study other carbon-based materials used in the nuclear industry.

Arregui Mena, Jose'↗

NASA NTRS1975

Development of lightweight reinforced plastic laminates for spacecraft interior applications

Lightweight, Kevlar - reinforced laminating systems that are non-burning, generate little smoke in the space shuttle environment, and are physically equivalent to the fiberglass/polyimide system used in the Apollo program for non-structural cabin panels, racks, etc. Resin systems representing five generic classes were screened as matrices for Kevlar 49 reinforced laminates. Of the systems evaluated, the polyimides were the most promising with the phenolics a close second. Skybond 703 was selected as the most promising resin candidate. With the exception of compression strength, all program goals of physical and mechanical properties were exceeded. Several prototype space shuttle mobility and translation handrail segments were manufactured using Kevlar/epoxy and Kevlar-graphite/epoxy. This application shows significant weight savings over the baseline aluminum configuration used previous. The hybrid Kevlar-graphite/epoxy is more suitable from a processing standpoint.

Hertz, J.↗

DOE OSTI2021

Progress Report on Graphite-Salt Interaction Studies (FY21)

This report summarizes the activities performed in FY21 to investigate the interactions between nuclear graphite and molten salts, such as FLiNaK. First, building on last year’s achievements, the team improved the procedure for measurements on pressurized salt intrusion in nuclear graphite and performed new experiments at variable pressures with specimens of different sizes and shapes. Additionally, the team actively provided suggestions and comments for ASTM D8091, Standard Guide for Impregnation of Graphite with Molten Salts , which came up for periodic revision in 2021. Second, the team expanded its capabilities to further characterize salt-impregnated graphite by procuring and installing a laser-induced breakdown spectroscopy (LIBS) instrument capable of producing a 3D chemical composition of a surface and subsurface region of specimens. A methodology for accurately analyzing information was developed, and a manuscript was submitted for publication. The LIBS instrument sample cell is sealed in controlled inert atmosphere, which is an advantage for using humidity-sensitive samples and Be-contaminated samples. This aligns with the team’s effort to expand the capabilities of handling FLiBe and Becontaining materials in two newly installed glovebox units. Third, the team performed preliminary tribology tests for pebble graphite wear in contact with stainless steel in dry state and in molten salt at high temperature. These tests are needed to establish the baseline for the wear of pebble graphite by friction against metallic walls. The friction and wear of pebbles in the fluoride salt-cooled hightemperature reactor are expected to generate dust, which is a concern for other components’ properties and safe reactor operation.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2023

Parametric Study of Lithium-Ion Batteries using BatPaC (Final Report)

The Battery Performance and Cost Model (BatPaC) is a tool developed by Argonne National Laboratory to design lithium-ion battery (LIB) packs for automotive applications. The material demand and design specifications are used to estimate the cost of manufacturing the battery pack in a large volume production plant (5-50 GWh/year). With the option to select from various electrode chemistries and materials with their associated properties and prices, the resultant battery pack mass, volume, and cost can vary considerably. This report is the result of a parametric sensitivity study that helps identify the key parameters and prices that affect the battery metrics – the specific energy (Wh/kg) and the pack cost ($/kWh). The study was conducted with LiNi 0.6 Mn 0.2 Co 0.2 O 2 (NMC622) and graphite (G) electrodes as the baseline materials used in a battery pack for a 300-mile range battery electric vehicle (BEV300) and a 50-mile range plug-in hybrid electric vehicle (PHEV50).

25 ENERGY STORAGE↗

NASA NTRS2004

PS300 Tribomaterials Evaluated at 6500C by Bushing Test Rig

A new facility has been developed to test the tribological behavior (friction and wear) of PS300 solid lubricant bushings at high temperatures. PS300 is a commercially available solid lubricant invented at the NASA Glenn Research Center. It can be prepared as a plasma spray coating or as a free-standing powder metallurgy component, designated PM300. PS300 and PM300 composites are designed to lubricate sliding components at temperatures above the capability of today's best oils, greases, and solid lubricants. One of the primary applications being pursued for PM300 is the development of bushings for use in high-temperature machinery. Examples include inlet guide vane bushings for gas turbines and conveyors, and bearings for industrial furnaces and ovens. Encouraging preliminary field trials indicate that PS300 and PM300 lubricant materials have been commercialized successfully in several industrial applications. However, the lack of laboratory performance data has hindered further commercialization especially for new applications that differ significantly from the established experience base. The purpose of the newly developed bushing test rig will be to determine the performance characteristics of PM300, and other materials, under conditions closely matching intended applications. The data will be used to determine engineering friction and wear rates and to estimate the life expectancy of bushings for new applications. In the new rig, the bushing is loaded against a rotating shaft inside a furnace enclosure (see the preceding photograph). Loads can vary from 5 to 200 N, speeds from 1 to 400 rpm, and temperatures from 25 to 800 C. Furnace temperature, bushing temperature, shaft speed, and torque are monitored during the test, and wear of both the bushing and the shaft is measured after testing is completed. Initially, PM300 bushings will be evaluated and compared with lower temperature, traditional bushing materials like graphite and porous bronze. The baseline PM304 composition is 60 wt% NiCr (a binder), 20 wt% Cr2O3 (a hardener), 10 wt% BaF2/CaF2 (a high-temperature lubricant), and 10 wt% Ag (a low-temperature lubricant). Future research efforts will include determining the effects of load, sliding speed, and temperature on tribological performance and, possibly, tailoring composition for specific applications. We expect that the availability of measured performance data will enhance the market penetration of PM300 technology.

Striebing, Donald R.↗

NASA NTRS1984

Evaluation of long-duration exposure to the natural space environment on graphite-polyimide and graphite-epoxy mechanical properties (A0175)

The primary objective of this experiment is to accumulate the needed operational data associated with the exposure of graphite-polyimide and graphite-epoxy material to the environments of space. The experiment will be mounted in two 3-in.-deep peripheral trays. Graphite-polyimide specimens will occupy 1 1/3 trays and the graphite-epoxy specimens will occupy two-thirds of a tray. The experiment approach requires two matched sets of specimens with traceable records that are maintained for materials processing and specimen quality. After fabrication, one set of each test specimen will be sectioned and structurally tested to serve as a data baseline. After the flight, the other set of specimens will undergo extensive measurements of mechanical properties for comparison with the original data baseline. Structural testing of the graphite-polyimide specimens will provide strength and elastic data in tension, compression, and shear. Transverse tension microcracking and crack propagation will be evaluated by photomicroscopy. Structural testing of the graphite-epoxy specimens will include verification of laminate, core, adhesive, and fatigue properties as applied to the design and analysis of the payload bay door. Microcracking and crack propagation will also be analyzed by photomicroscopy.

Powell, J. H.↗

DOE OSTI2025

Update on R&D progress by DOE

High temperature materials and graphite and composite program review to include: Baseline for unirradiated material properties, ASTM test development, design and construction rules (ASME-based), new fuel matrix mechanical studies, Irradiation damage studies, vender irradiation capsules, graphite supply chain worries, and ceramic composite activities.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

NASA NTRS1987

Baseline tensile tests of composite materials for LDEF (Long Duration Exposure Facility) exposure

Tensile specimens of five graphite fiber reinforced composite materials were tested at room temperature to provide baseline data for similar specimens exposed to the space environment in low-Earth orbit on the NASA Long Duration Exposure Facility. All specimens were 4-ply (+ or - 45 deg)s layups; at least five replicate specimens were tested for each parameter evaluated. Three epoxy-matrix materials and two polysulfone-matrix materials, several fiber volume fractions, and two sizes of specimen were evaluated. Stress-strain and Poisson's ratio-stress curves, ultimate stress, strain at failure, secant modulus at 0.004 strain, inplane shear stress-strain curves, and unidirectional shear modulus at .004 shear strain are presented.

Witte, William G.↗

NASA NTRS1990

Flammabilities Of Graphite-Reinforced Composites

Report describes tests and comparisons of flammabilities, thermal properties, and selected mechanical properties of composite materials made of epoxy and other matrices reinforced by graphite fibers. Composites also compared with baseline epoxy/fiberglass composite. Considers such properties as limiting oxygen index, smoke evolution, products of thermal degradation, total heat release, heat-release rate, loss of mass, spread of flames, resistance to ignition, and thermal stability.

Kourtides, Demetrius A.↗

DOE OSTI2020

Status Report on ASME Code Development for Nonmetallic Core Components in 2020

The purpose of this report is to provide a status update on the progress and ongoing activities of the current ASME Boiler Pressure Vessel (BPV) Code Section III, Division 5, on nonmetallic core components and assemblies which includes the design rules for graphite and ceramic composite materials. Section III is concerned with the design and construction of nuclear reactor components and Division 5 focuses on high temperature reactors (HTR). The ASME Section III Committee’s function for nuclear items other than pressure-retaining components, is to establish rules of safety related to structural integrity. The term “construction” refers to the all-inclusive effort comprising of materials, design, fabrication, examination, inspection, testing, certification, and pressure relief. The Department of Energy (DOE) supports industry codes and standards development through focused research providing the technical basis for new or modified codes and standards and the participation of subject matter experts in codes and standards committees. The activities for the nonmetallic core components and assemblies committees are the pursuit of two working groups that meet quarterly during ASME BPV Code Week meetings. The two working groups are General Requirements for Graphite and Ceramic Composite Core Components and Assemblies (GR GCCCCA) and Nonmetallic Design and Materials (NDM). The rules on general requirements for nonmetallic core components are discussed in the articles of Subsection HA subpart B. Ceramic composites were recently incorporated within the rules, and the GR GCCCCA working group is now in the process of aligning the requirements with the subsections and articles of ASME BPV Code Section III NCA, the general requirements for Division 1 and 2 of the code. The NDM working group is concerned with the design rules for graphite and composite materials for core components and assemblies discussed in Subsection HH (Class SN Nonmetallic Core Components) subpart A and subpart B which reference graphite and composite materials respectively. The bulk of the progress and work is done within this working group. A significant undertaking, with discussion that started in 2015, is to gain endorsement of ASME Section III, Division 5, by the U.S. Nuclear Regulatory Commission (NRC). In June 2018, ASME formally recommended endorsement to the NRC. The NRC has since initiated the endorsement review process, which is to be concluded early in 2021. ASME task groups on metallic structures and components, as well as non-metallic core support structures, have been formed to define potential pathways and schedules for NRC endorsement of Division 5. NRC determined to perform a review on the 2017 edition of Section III Division 5 as a baseline. As a result, the use of graphite as nonmetallic core components formed part of the review, but it excluded composite materials (which were first introduced in the 2019 edition). This report documents progress in FY 2020 directed toward ASME’s efforts to develop design codes for graphite and composites. Progress includes a major code review by NRC, the first code enquiry, and its solution, an overhaul of the treatment of Weibull Statistics, and the addition of Nonmandatory Appendices to the composites code relating to carbon-carbon composite materials.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2024

Physics analysis and design of heavy water reflected thermal test reactor

Here, this work investigates the option of modifying the Advanced Test Reactor by replacing the current beryllium reflector with heavy water. Such a change may provide some potential benefits for not only increasing the thermal irradiation capabilities but also resolving other problems such as reflector integrity issues due to fast fluence damage, which is always a limiting factor in the lifetime of the current beryllium reflector. This paper presents the analysis and estimation of the ATR core physics parameters by replacing the current beryllium reflector with heavy water (D 2 O). The paper first describes the details of two selected conceptual designs, which are partially reflected with either beryllium or graphite, and how they are derived from the baseline beryllium reflector concept. Then, reactor physics performance parameters for the two new concepts are assessed by comparing with those of the baseline concept. The performance parameters considered in this paper include in-pile tube neutron and gamma fluxes and heating rates, maximum loop voiding reactivity, core power behavior with different power splits, predicted cycle length with a given fuel loading, and thermal hydraulic analysis with a higher lobe power split. It is important to note that this study focuses on the reactor physics aspects and does not delve into the engineering challenges associated with such a design modification.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

NASA NTRS1976

Structural design of space telescope

Problematic areas are discussed relative to the design of the NASA Large Space Telescope with a view toward showing how these areas are currently being treated so that the primary goals of the program can be met. The discussion covers basic mission, design parameters, metering structural material, and measurements of thermal expansion coefficient and scale testing. Since the test program has not been completed, there are so far no data available to show comparison between the baseline metering structure design and test. However, graphite-epoxy appears very favorable for structural uses, where precise alignment is necessary and a high degree of thermal stability is desired. It is anticipated that there will be a convergence on a straightforward method of arranging the basic structure for the ease of manufacturing and cost savings.

Arnts, G. W., Jr.↗

DOE OSTI2025

Ceramic Composite Inert Matrix Fuel Forms in High-Temperature Gas-Cooled Microreactors

Here, this work optimizes micro-prismatic high-temperature gas reactor (HTGR) designs to reduce the energy-normalized mass of spent nuclear fuel (SNF) and high-level waste (HLW) produced. The optimization was performed for the current graphite moderator and an inert matrix fuel (IMF) concept employing different composite moderators in a prismatic design architecture. The fuel matrix is magnesium oxide (MgO) with entrained tristructural-isotropic (TRISO) fuel. The moderator materials, including beryllium oxide (MgO-BeO) and beryllium (MgO-Be) at 40 vol % loading and yttrium hydride (MgO-YH x=1.9 ) and zirconium hydride (MgO-ZrH x=1.9 ) at 15 vol % loading, were entrained within the MgO host matrix. A generic graphite micro-prismatic HTGR is used as the baseline point design where the external dimensions are held constant. The composite moderator designs use 19.9% enriched uranium nitride TRISO fuel and hexagonal assemblies. For each IMF concept, an optimization study was performed to maximize the discharge burnup of the fuel by varying the TRISO packing fraction and the lattice pitch of the assemblies. The mass of SNF and HLW, other waste metrics, fuel cost, environmental impact metrics, and the activity of the SNF and HLW at 100 years and 100 000 years were calculated for the optimized IMF and graphite reference designs. The IMF results were subsequently compared to those of the graphite reference and the values for a light water reactor (LWR) and a small modular LWR. For the SNF and HLW, all the IMF concepts and the graphite reference produced less waste compared to the traditional LWR designs. However, the IMF concepts outperformed the graphite reference regarding the mass of SNF and HLW. For the other waste metrics, the IMF concepts showed reductions in fuel cost with improved environmental metrics relative to the graphite reference. Overall, the IMF concepts significantly reduced the SNF and HLW produced per unit of energy generated compared to traditional LWR designs.

TRISO↗