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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 379 records · Page 21
All sourcesNASA NTRSDOE OSTI
DOE OSTI2026

BIL High Speed Fuel Cell Stack Manufacturing

General Motors LLC (GM) was awarded a project to develop and implement technologies for manufacturing 20,000 units of Fuel Cell Stacks per year on two shifts per day basis. GM leveraged prior in-house expertise in designing the Fuel Cells, deploying the manufacturing process steps in the laboratory environment as well as the deployment in the industrial environment on a smaller scale. The project focus was to design, build, and deploy a manufacturing line consisting of an anode and cathode electrode processing, unitized electrode assembly, fuel cell stacking, compression, testing, and final assembly of the fuel cell stack. The project was terminated in the first budget period.

08 HYDROGEN↗
DOE OSTI2026

Material Control & Accounting Statistical Test Modeling Supporting the Low Enriched Fuel Fabrication Facility Using F3M and MAPIT

This report covers the application of the TRi-structural ISOtropic (TRISO) fuel fabrication facility material control & accounting (MC&A) modeling capability developed by Sandia National Laboratories (SNL) under the U.S. Department of Energy (DOE) Materials Protection, Accounting, and Control Technologies (MPACT) program to support the development of MC&A approaches for the Low Enriched Fuel Fabrication Facility (LEFFF) at Los Alamos National Laboratory (LANL).

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2023

Assembly and Initial Testing of the Gamma-Ray Emission Tomography Assessment Prototype for Irradiated Fuel

The following report documents the final development, assembly, and initial testing of the gamma-ray emission tomography assessment system (GRETA-1) for post-irradiation examination of irradiated fuel. It includes descriptions of the system components, including the high-purity germanium gamma-ray detector, the surrounding shield and collimator, the sample scanning hardware, and the control and collection software package. A series of MCNP6 simulations were performed that modeled a fuel rod scan to test image reconstruction algorithms with a complex and understood source distribution. A bench-top scan of isotopic check sources was also performed and analyzed using standard image reconstruction algorithms. The system is currently awaiting deployment at Idaho National Laboratory’s Hot Fuel Examination Facility.

46 - INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AN↗
DOE OSTI2021

Advancing Platooning with ADAS Control Integration and Assessment Test Results

The application of cooperative adaptive cruise control (CACC) to heavy-duty trucks known as truck platooning has shown fuel economy improvements over test track ideal driving conditions. However, there are limited test data available to assess the performance of CACC under real-world driving conditions. As part of the Cummins-led U.S. Department of Energy Funding Opportunity Announcement award project, truck platooning with CACC has been tested under real-world driving conditions and the results are presented in this paper. First, real-world driving conditions are characterized with the National Renewable Energy Laboratory’s Fleet DNA database to define the test factors. The key test factors impacting long-haul truck fuel economy were identified as terrain and highway traffic with and without advanced driver-assistance systems (ADAS). Track and on-highway testing guided by SAE J1321 procedures were conducted to assess truck platooning operation under the characterized real-world driving conditions. On-highway testing is done on a route in Indiana representing operation of long-haul Class 8 trucks in the United States. The road includes low-, medium-, and high-grade segments. The highway test results of a two-truck platooning configuration indicate considerable fuel-saving reduction comparing to the test track data collected under ideal driving conditions. The test data indicate that platooning could lead to increases in fuel consumption during traffic or high-grade portions of the route, causing reduction of the overall fuel saving on the road comparing to test track results. However, integration of ADAS features on the lead truck during on-road tests leads to significant improvement of fuel saving for both trucks in CACC operation.

ADAS↗
DOE OSTI2020

Effects of increasing the initial nitric acid concentration from a maximum of 7.5 to 8.5 M during the dissolution of aluminum spent nuclear fuel

H-Canyon is blending solutions from the dissolution of High Flux Isotope Reactor (HFIR) and Material Test Reactor (MTR) fuels with Target Residue Material (TRM) to prepare feed solution for the 1st Cycle of solvent extraction. The initial acid concentration for HFIR fuel dissolution is limited to 7.5 M by the flowsheet; however, an increase in the initial concentration is desirable to more easily achieve the target acidity for solvent extraction using the current blending strategy. To provide flexibility in batching the highly enriched uranium (HEU) solutions, the Savannah River National Laboratory (SRNL) was requested to evaluate the potential for increasing the maximum HNO3 concentration for HFIR fuel dissolution from 7.5 to 8.5 M. In response to this request, a literature review was performed to evaluate the impact of a higher starting HNO3 concentration on the dissolution of aluminum spent nuclear fuels (ASNF) including both HFIR and MTR fuels.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2022

Irradiation of MiniFuel Targets Bearing TRISO Fuel Compacts (Status Report)

Irradiation testing of MiniFuel compacts bearing tristructural isotropic (TRISO) fuel particles was performed at Oak Ridge National Laboratory (ORNL) to support the development of Kairos Power’s (KP’s) fluoride salt–cooled high-temperature reactor concept. The fuel compacts were fabricated with TRISO fuel particles of different types—including low-enriched uranium oxide, uranium carbide (LEUCO), natural uranium oxide, uranium carbide (NUCO), and low-enriched uranium dioxide (LEUO 2 )—and inserted into MiniFuel irradiation targets. Five targets were assembled and inserted in the High Flux Isotope Reactor (HFIR) for four cycles. The data collected post-irradiation will provide experimental input to validate TRISO fuel performance models for high particle power operations. This report summarizes the completion of the HFIR irradiation, the as-irradiated numerical analysis, and the post-irradiation work performed to date. This work was performed under the Nuclear Science User Facility program.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2022

Optimal management of electric hotel loads in mild hybrid heavy duty truck

Here, the problem of engine idling for heavy-duty trucks has been under study for decades with Auxiliary Power Units (APUs) and Truck Stop Electrification (TSE) as the most compelling solutions. With the electrification of trucks approaching feasibility in terms of cost-effective technology, hybridization offers another “degree of freedom” to tackle the problem. Here, this work aims at exploiting a battery pack of a 48 V mild-hybrid heavy-duty truck to store sufficient onboard energy for powering the auxiliary loads during the hoteling. This problem is not trivial, as the battery packs typically cannot recover the entire energy required through regeneration alone; hence an optimal energy management strategy needs to be employed to charge the battery through the engine during drive operation. This strategy optimizes powertrain performances among the four modes: (i) Engine of Coasting (EOC), (ii) Regeneration by braking, (iii) Regeneration by engine, and (iv) engine idling. This paper presents the development of a Dynamic Programming (DP) framework that employs a multi-objective cost function to minimize the fuel consumption and maximize the regeneration using the above-mentioned four modes. A typical heavy-duty truck drive cycle is used to represent the drive phase, with mandatory hoteling stops as per regulations. A comprehensive powertrain model is developed using validated components’ model. The DP employs two state variables: battery State-of-Charge (SOC) and engine mode, and three control inputs: (i) the engine ON–OFF state, (ii) clutch engagement state, and (iii) power request at the Electric Machine (EM) for calculating optimal SOC trajectory. The framework also tackles rapid engine ON–OFF scenarios to avoid the challenges associated with DP and the compromises in fuel cost with those approaches. Finally, the effectiveness of the proposed framework is tested for potential fuel savings on two different battery packs by performing the full cycle simulations. The results show 6.47% of fuel consumption reduction as compared to traditional APU-based heavy-duty truck.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2020

Spring 2020 Dissertation Update [Slides]

An update is provided on the dissertation underway and what has been learned thus far. Work thus far: Developed analytic models for each region in the spent fuel cask – Used to identify and explain physical processes which create features in detailed casks; Developed simplified computational models to identify details not seen in analytic models; SC were calculated in the fuel region; The difference in SC’s between the analytic model and the simplified computational model were identified. Outstanding issues: Analysis of analytic models in stainless steel and carbon steel – These materials are thin and have few features (just the slope); Discrepancies between absorption SC’s in fuel; Create a test problem to show the effects of the high energy resonances in the fuel region. Future Work: Sensitivity analysis needs to be continued through the cask – The detailed model will be added to the remaining materials; Sensitivity analysis paper; and, Addressing outstanding issues.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2022

SAS4A/SASSYS-1 Validation with the FFTF LOFWOS Tests #10-12

The FFTF liquid sodium cooled test reactor was built to assist the development and testing of advanced fuels and material for fast reactors. The goals of the FFTF Passive Safety Testing program included confirming the safety margins of FFTF as a liquid metal reactor, providing data for computer code validation, and demonstrating the inherent and passive safety benefits of its specific design features. The program included thirteen unprotected loss of flow without scram tests. The results of modeling and simulation of LOFWOS Tests #10, #11, and #12 are presented in this report to support validation of Argonne’s SAS4A/SASSYS-1 fast reactor safety analysis code. These three tests did not use the primary loop pony motors and thus transitioned to natural circulation flow rates from varying initial power levels. This validation activity leverages modeling and simulation efforts that originated under an International Atomic Energy Agency Coordinated Research Project (CRP) for benchmark analysis of the FFTF LOFWOS Test #13. The SAS4A/SASSYS-1 model originally developed for the CRP has been extended to include LOFWOS Tests #10-12 and modernized to utilize new code features and modeling practices. Predicted results from SAS4A/SASSYS-1 were compared to measured test data and differences were investigated. Overall, it was concluded that, for LOFWOS Tests #10-12, there was good agreement between the flow, power, and temperature predictions and the measured data.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2025

SAS4A/SASSYS-1 Validation with FFTF Tests

The FFTF liquid sodium cooled test reactor was built to assist the development and testing of advanced fuels and material for fast reactors. The goals of the FFTF Passive Safety Testing program included confirming the safety margins of FFTF as a liquid metal reactor, providing data for computer code validation, and demonstrating the inherent and passive safety benefits of its specific design features. The program included thirteen unprotected loss of flow without scram tests. In preparation for the Passive Safety Testing program, a series of individual reactivity feedback tests were performed which were designed to simulate and validate specific features and reactivity feedbacks of the FFTF core.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2022

FAST irradiations and initial post irradiation examinations – Part I

The Advanced Fuels Campaign Fission Accelerated Steady-state Test (FAST) at Idaho National Laboratory (INL) completed its first irradiation cycle within the Advanced Test Reactor (ATR). The test focused on the irradiation of alloy fuel forms for use in sodium fast reactors. Tests included the use of fuel additives (Sn, Sb, and Pd) for reducing the gettering of lanthanide fission products, zirconium liners to mitigate fuel-cladding chemical interaction, and annular fuel geometry for sodium-free fuel designs. The first cycle of FAST testing was completed and a series of rodlets were removed for the initial post irradiation examination (PIE) of FAST rodlets. The rodlet irradiation conditions was evaluated using Monte Carlo N-Particle (MCNP) for as-run power history and COMSOL for temperature analysis. These rodlets include a set of low burnups (~2.5 % heavy metal [%FIMA]) control rodlets and a helium bonded annular rodlet (4.7 %FIMA). Initial non-destructive PIE has been completed and includes, visual inspection, neutron radiography and gamma scanning of the FAST rodlets. Radiography confirmed the integrity of the experiments as well as showing the complete filling of the annulus in the annular fuel at a modest burnup (4.7 %FIMA) and potential slumping of the cooler rodlets at lower burnup. Precision gamma scanning indicated mostly usual fission product behavior with the exception of the ceasium in the He-bonded annular fuel. Future destructive PIE will be necessary in order to fully understand the effects of accelerated irradiation on U-Zr metallic fuel behavior.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2022

Estimation of China Fusion Engineering Test Reactor performance and burning fraction in different pellet fueling scenarios by a multi-species radial transport model

Tritium self-sufficiency in future deuterium–tritium fusion reactors is a crucial challenge. As an engineering test reactor, the China Fusion Engineering Test Reactor requires a burning fraction of 3% for the goal to test the accessibility to the future fusion plant. To self-consistently simulate burning plasmas with profile changes in pellet injection scenarios and to estimate the corresponding burning fraction, a one-dimensional multi-species radial transport model is developed in the BOUT++ framework. Here several pellet-fueling scenarios are then tested in the model. The results show that the increased fueling depth improves the burning fraction by particle confinement improvement and fusion power increase. Nevertheless, by increasing the depth, the pellet cooling-down may significantly lower the temperature in the core region. Taking the density perturbation into consideration, the reasonable parameters of the fueling scenario in these simulations are estimated as pellet radius ${r}_{{\rm{p}}}=3\,{\rm{mm}},$ injection rate $=\,4\,\mathrm{Hz},$ and pellet injection velocity $=\,1000\mbox{-}2000\,{\rm{m}}\,{{\rm{s}}}^{-1}$ without drift or $450\,{\rm{m}}\,{{\rm{s}}}^{-1}$ with high-field-side drift.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2023

Local Power Impact Experiment Design for a New Fuel Type for use in the Advanced Test Reactor

The Advanced Test Reactor (ATR), and complimentary zero-power ATR Critical (ATRC) reactor, located at Idaho National Labs (INL), are undergoing conversion from Highly Enriched Uranium (HEU) to Low Enriched Uranium (LEU). Both have a variety of testing locations that can receive large variations in flux due to its unique serpentine design, consisting of five lobes (see Figure 1). Initial criticality and power distribution throughout the core are controlled by core-external outer shim control cylinders (OSCCs). Distinct test loops allow for testing at specific temperatures, pressures, and irradiation conditions. The ATR is one of the key nuclear engineering research and testing facilities within the DOE National Laboratory Complex, and the ATRC supports its operation [1]. Currently, the Office of Material Management and Minimization (M3) within the National Nuclear Security Administration of the DOE is working to convert the remaining research reactors, including the ATR, from 93% HEU fuel to 19.75% LEU fuel (LEU) to support non-proliferation [2]. Extensive materials testing at INL and internationally has demonstrated that a high-density uranium molybdenum (U 10Mo) alloy can meet the performance requirements of the remaining high powered research reactors. However, there are many technical challenges to address before the conversion to LEU can be successful, including the accurate characterization of the reactor core physics with LEU fuel. Reactor physics safety evaluations currently use Monte Carlo for the 21st Century (MC21), a continuous-energy Monte Carlo radiation transport code [3]. Existing MC21 models of the ATR and ATRC cores have a validation basis for use in neutronics analyses with HEU fuel. The models are used to support safety analyses that include comparisons to the safety requirements for the reactors. However, the use of the LOWE element in the ATR and ATRC is not currently covered by the current model validation basis. To deploy the new fuel type, extensive computational reactor physics support is necessary to support the use of LOWE in the ATR and ATRC. Therefore, LOWE requires a rigorous validation basis, aligned with that of HEU fuel, that takes advantage of the existing software tools and processes currently used for the ATR and ATRC. The experiment to validate of the MC21 models for determining power, the Power Impact Validation Experiment, will consist of two flux runs in the ATRC, one with fully HEU loading and one with a single LOWE element. Both flux runs will be instrumented with 20 sets of azimuthal fission wires and 3 sets of axial fission wires, as shown in Figure 4. Standard flux run methodology will be used [4]. Power Impact Validation Experiment data will be compared against MC21 calculated data, both for absolute fission rate accuracy and to determine the relative change in fission rates between the two runs. The results of the Power Impact Validation Experiment and subsequent evaluations will provide the validation basis for MC21 for use with LOWE elements. Key features of the Power Impact Validation Experiment include: (1) Two flux runs to allow for LOWE perturbed measurements to be compared to already validated measurements taken from a full core of HEU fuel, (2) Optimization of instrumentation to balance analytical needs with practical considerations (e.g., limited time window to count beta particles from fission products), and (3) Standard ATRC core loading, including both driver positions and flux traps, to minimize cost while remaining representative of typical ATR core loading.

42 ENGINEERING↗
DOE OSTI2024

Thermal Conductivity Measurements on Irradiated TRISO Fuel at IMCL

INL is leading the development and testing of accident tolerant fuels: fuels that resist melting down and that contain radioactive byproducts, preventing their release into their environment. One such fuel, called TRi-structural ISOtropic particle fuel (TRISO) See Fig 1. Understanding how heat propagates through a fuel is essential to fuel development and qualification. When irradiated in a reactor the properties that affect heat transport change. Our objective is to quantify the change in thermal properties of TRISO after irradiation.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2020

Evaluation of the Dissolution Behavior of L-Bundle End Caps and HFIR Fuel Carriers

The H-Canyon facility is currently using the 6.1D dissolver for the dissolution of Material Test Reactor (MTR) fuel and the 6.4D dissolver for the dissolution of High Flux Isotope Reactor (HFIR) fuel using mercury-catalyzed HNO₃ dissolution flowsheets. The processing strategy for both dissolvers involves the dissolution of multiple charges of fuel per batch. After the designated heating cycle, the dissolvers are opened, and the charging wells are probed to determine if the MTR or HFIR fuel has dissolved. If undissolved fuel fragments are beyond a certain height, the dissolver must be closed and heated for an additional amount of time to dissolve the remaining material. In recent MTR fuel dissolutions, “high probes” (i.e., excessive undissolved material) were frequently observed, which resulted in extended dissolution times. The suspected cause of the high probes was the incomplete dissolution of the L-Bundle End Cap, rather than the fuel or fuel bundles. The End Cap is hypothesized to be binding in the insert well and not dropping into the acid as the L-Bundle and fuel dissolve. Once the End Cap is dislodged by the probe and drops into the acid, the dissolution rate of the End Cap appears to be significantly reduced compared to the dissolution rate of the fuel and other parts of the L-Bundle. A similar issue has also been observed with the lifting bail on the HFIR fuel carriers. During HFIR fuel dissolutions, the lifting bail on the outer carrier has resulted in high probes due to incomplete dissolution. In one case, a partially dissolved bail was caught in one of the insert well holes which prevented the probe from going to the bottom of the well.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2025

Fracture toughness measurement of ceramics with fuel pellet geometry

The crack initiation of nuclear fuel pellets, driven by extreme temperature gradients, is a critical factor impacting reactor performance. Although this fact is widely acknowledged, there is limited fracture toughness data for specimens with representative geometry and fabricated using relevant processing methods. Here, to address this, a new chevron-notched short-rod specimen configuration with diameter and length both equal to 10 mm, representative of a conventional fuel pellet and tested in tension, was developed in an attempt to validly measure Mode I fracture toughness, K Ic . Test calibration was carried out by testing polycrystalline ZrO 2 , SiC, and Si 3 N 4 ceramics fabricated with conventional fuel pellet geometry and known fracture toughnesses. The results suggest that the method described in this paper produces valid K Ic measurements using conventional ceramic fuel pellets.

Ceramics↗