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DOE OSTI2022

Sister Rod Destructive Examinations (FY2021)

As a part of DOE NE High Burnup Spent Fuel Data Project, Oak Ridge National Laboratory (ORNL) is performing destructive examinations (DEs) of high burnup (HBU) (>45 GWd/MTU) spent nuclear fuel (SNF) rods from the North Anna Nuclear Power Station operated by Dominion Energy. The SNF rods, called sister rods or sibling rods, are all HBU and include four different kinds of fuel rod cladding: standard Zircaloy-4 (Zirc-4), low-tin (LT) Zirc-4, ZIRLO, and M5. This report documents the status of the ORNL Phase 1 DEs of 7 sister rods and outlines the DE tasks performed and the data collected to date, as guided by the sister rod test plans.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2022

Sister Rod Destructive Examinations (FY2021) Appendix F: Cyclic Integrated Reversible-Bending Fatigue Tests

As a part of DOE NE High Burnup Spent Fuel Data Project, Oak Ridge National Laboratory (ORNL) is performing destructive examinations (DEs) of high burnup (HBU) (>45 GWd/MTU) spent nuclear fuel (SNF) rods from the North Anna Nuclear Power Station operated by Dominion Energy. The SNF rods, called sister rods or sibling rods, are all HBU and include four different kinds of fuel rod cladding: standard Zircaloy-4 (Zirc-4), low-tin (LT) Zirc-4, ZIRLO, and M5. This appendix documents the status of the ORNL Phase 1 DE activities related to tests of the sister rods using the Cyclic Integrated Reversible-Bending Fatigue Tester (CIRFT) in Phase 1 of the sister rod test program.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2022

Sister Rod Destructive Examinations (FY2020) Appendix I: SNF Aerosols Released During Rod Fracture

As a part of the DOE NE High Burnup Spent Fuel Data Project, Oak Ridge National Laboratory (ORNL) is performing destructive examinations (DEs) of high burnup (HBU) (>45 GWd/MTU) spent nuclear fuel (SNF) rods from the North Anna Nuclear Power Station operated by Dominion Energy. The SNF rods, called sister rods or sibling rods, are all HBU and include four different kinds of fuel rod cladding: standard Zircaloy-4 (Zirc-4), low-tin Zirc-4, ZIRLO, and M5. This report documents the status of the ORNL Phase 1 DE activities related to the collection of SNF aerosol particles released during fuel rod fracture in four-point bending in Phase 1 of the sister rod test program.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2022

Sister Rod Destructive Examinations (FY2021) Appendix C: Rod Internal Pressure, Void Volume, and Gas Transmission Tests

As a part of the DOE NE High Burnup Spent Fuel Data Project, Oak Ridge National Laboratory (ORNL) is performing destructive examinations (DEs) of high burnup (HBU) (>45 GWD/MTU) spent nuclear fuel (SNF) rods from the North Anna Nuclear Power Station operated by Dominion Energy. The SNF rods, called the sister rods or sibling rods, are all HBU and include four different kinds of fuel rod cladding: standard Zircaloy-4 (Zirc-4), low-tin (LT) Zirc-4, ZIRLO, and M5. This Appendix C documents the status of the ORNL Phase 1 DE activities [C-2, C-3] related to rod internal pressure and void volume measurement techniques, fission gas stack flow measurements applied to selected sister rods, and fission gas release calculations in Phase 1 of the sister rod test program.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2020

Physical and Thermomechanical Properties of Yttrium Hydride from Large Scale Bulk Metal Hydriding Furnace

Given the superior thermal stability and highly attainable hydrogen density, yttrium hydride is an excellent high-temperature moderator material in advanced thermal neutron spectrum reactors that require small core volumes. Yttrium hydride has been selected as the moderator material for the Transformational Challenge Reactor, which was launched at Oak Ridge National Laboratory (ORNL) in 2019. However, fabrication of large-scale crack-free yttrium hydride is challenging and very limited efforts have been committed to the characterization of bulk yttrium hydride in response to the need to establish a complete database of the thermomechanical properties of YHx. In this report, the challenges associated with fabricating large-scale crack-free yttrium hydride are discussed herein. In response to those challenges, a hydriding system was designed and constructed at ORNL and was used to successfully fabricate crack-free yttrium hydride in complex geometries at large scales. This was accomplished by precisely controlling the hydrogen’s partial pressure and the retort temperature, which was informed by the well-established thermodynamic properties of the binary H-Y system. Hydrogen content in as-fabricated hydride was determined by the weight change method and vacuum hot extraction technique, complemented by the X-ray diffraction (XRD). In addition, significant efforts are being dedicated to establishing a complete database of the thermomechanical properties of as-fabricated yttrium hydride. In FY2020, we investigated the thermophysical properties of yttrium hydrides as a function of temperature (room temperature to 700°C) and hydrogen concentration (H/Y ratio ranges from 1.52 to 1.93). The results indicate that at the temperatures below 300 °C, the hydrogen content did not have a significant influence on the thermal expansion, while the specific heat capacity, the thermal diffusivity, and the calculated thermal conductivity were slightly higher for the higher H/Y ratio. Between 300°C and 700 °C, a reversible second-order endothermic transition in all measured thermal properties was observed. It was also found that the onset temperatures of the observed transition varied, with the composition having inverse dependence on the hydrogen content. An attempt was made to explain the behavior of the thermophysical properties at higher temperatures by considering the order– disorder transition as a result of hydrogen redistribution. In addition, nanoindentation was employed to determine the elastic modulus and hardness and to capture the crystal orientation dependence of these parameters. Vickers hardness was also reported. The final section of the report introduces ongoing neutron irradiation campaign of yttrium hydride.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2022

Sustainable Low-Carbon Building Materials Workshop Report

The virtual Sustainable Low-Carbon Building Materials Workshop, organized and held by the US Department of Energy’s (DOE’s) Oak Ridge National Laboratory (ORNL) on January 25, 2022, focused on identifying the technical barriers to the research, development, and deployment (RD&D) of low-carbon building materials, and on determining what can be done to overcome these technical barriers in the short-, mid-, and long-term future. The meeting brought together key players in the construction chain from industry, academia, and ORNL to promote collaborations that could help meet the goals of accelerating the development and deployment of low-carbon building materials in the United States, and of developing a net-zero (or even negative) carbon neighborhood in the Southeast United States by 2030.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Assessment of the High Flux Isotope Reactor Cybersecurity Initiative

Recent cyber-attacks on industrial control systems, and inadvertent exposure of nuclear plant systems to cyber-exploits underscore the need for plant operators to adopt and deploy cyber-security defense solutions made for industrial control systems. Of increasing concern is the fact that international cyber hackers are beginning to target critical infrastructure, and because these more modern controls systems depend on advanced use of digital systems, they are more vulnerable than ever before to cyber-attacks. Traditional cyber defense strategies and products that have been available for decades are tailored for use on IT or corporate networks but can cause interruptions and catastrophic damage when deployed on industrial control system networks. The Department of Energy (DOE) Office of Nuclear Energy established the Gateway for Accelerated Innovation in Nuclear (GAIN) program to provide private companies pursuing innovative nuclear energy technologies with access to the technical support necessary to move toward commercialization. One of these GAIN small business vouchers was awarded to Dragos, Inc. to enable collaboration with Oak Ridge National Laboratory (ORNL) to evaluate the Dragos Platform on a production nuclear reactor test bed, hence laying the path for future commercial adoption. The vision was to provide a guide for industrial operators on implementing an industrial monitoring solution and to show how these solutions can be deployed without causing safety and reliability issues. This report documents the results of the collaboration between ORNL and Dragos, Inc.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2020

Technology Enabling Zero-EPZ Micro Modular Reactors: Fabrication of Zirconium Hydride with Controlled Hydrogen Loading

This report completes Milestone M2.2.2 - ZrH pellet fabricated with controlled hydride loading: ZrH1.5±0.1 single phase pellets fabricated with controlled and thermally stable hydride loading. Hydrogen content to be quantified and single-phase confirmed by X-ray diffraction. In this milestone, we report the successful fabrication of delta-phase zirconium hydride pellets using the ORNL bulk metal hydriding system. The successful deployment of zirconium hydride moderator in advanced reactors requires development of a consistent and affordable production pathway along with implementation of a hydrogen retention solution throughout the reactor life. Fabrication of delta-phase zirconium hydride is challenging since the absorption of a large amount of hydrogen into alpha-zirconium induces significant volume expansion and the present hydrogen concentration gradient results in cracking. A fully programmable hydriding system with continuous hydrogen partial pressure and flow control to facilitate processing of massive metal hydride has been developed at ORNL. In this report, the working principle of the hydriding system will be introduced. Characterization of the produced zirconium hydride includes X-ray powder diffraction to identify the present phases and X-ray Computed Tomography to visualize the internal microstructure (including cracks). The results indicate that single delta-phase zirconium hydride pellets with various sizes have been successfully produced.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Experimental Determination of Constitutive Response of Alloy 800H in Support of Viscoplastic Constitutive Model Development for ASME Section III, Division 5, Class A Applications

In FY 2022, a development effort was initiated at the US Department of Energy’s Argonne National Laboratory (Argonne) and Oak Ridge National Laboratory (ORNL) to develop the Alloy 800H viscoplastic constitutive model so that inelastic analysis methods can support high-temperature gas-cooled reactor (HTGR) designs. The viscoplastic constitutive equations will be developed at Argonne. The ORNL effort focuses on generating test data from various high-temperature experiments with specially designed loading histories to probe Alloy 800H’s constitutive response.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Small Hydropower Interconnections: Small Hydropower in the United States

Small hydropower projects, which we define as generators below 20 MW in capacity have been the predominant source of hydropower growth over the past decade and create the most cost-effective and environmentally permissible avenues for new hydropower installation in the United States (DOE 2016; Johnson et al. 2018). Small hydropower developers across the United States have found that interconnecting these projects with the grid can be challenging due to unexpected costs and schedule overruns. Understanding the interconnection challenges and improving the process may allow more small hydropower projects to be successful. Noting these challenges, the U.S. Department of Energy Water Power Technologies Office enlisted Pacific Northwest National Laboratory (PNNL) and Oak Ridge National Laboratory (ORNL) to investigate the small hydropower interconnection landscape across the United States. To begin to analyze the existing interconnection processes and challenges facing small hydropower, the state of small hydropower development in the U.S. must first be described to understand the characteristics of the industry. The first in a series, this paper presents the state of small hydropower projects in the U.S. to describe their type, location, and size based on data extracted from the HydroSource database (ORNL 2020). The following papers in the series will detail the variety of state interconnection processes to connect power generators with the grid (“Small Hydropower Interconnections: State Interconnection Processes”), analyze these interconnection processes (“Small Hydropower Interconnections: Analysis of Interconnection Processes”), and present best practices in interconnection processes (“Small Hydropower Interconnections: Best Practices”) that will help overcome barriers to future small hydropower development.

13 HYDRO ENERGY↗
DOE OSTI2022

Small Hydropower Interconnections: Best Practices

Small hydropower projects have been the predominant source of capacity growth of U.S. hydropower for more than a decade, and they present the most cost-effective and environmentally permissible avenues for hydropower growth (DOE 2016; Johnson et al. 2018). However, interconnection to electricity distribution and transmission grids is a persistent barrier due to cost surprises and schedule overruns. As a culmination to research into the status and requirements of small hydropower interconnection across the United States, this paper presents the best practices for setting interconnection standards that can improve the process for small hydropower developers. As part of the analysis, the interconnection costs are compared between small hydropower, solar, and wind. The analysis of the small hydropower interconnection landscape across the United States was carried out by Pacific Northwest National Laboratory (PNNL) and Oak Ridge National Laboratory (ORNL) with support from the U.S. Department of Energy Water Power Technologies Office. The research team was guided by a Technical Advisory Group (TAG) and gleaned data from publicly available sources, such as the HydroSource database (ORNL 2020) and interconnection queues hosted by utilities, balancing authorities, independent system operators (ISOs), and regional transmission organizations (RTOs). The results of this work are shared in a series of papers detailing the state of small hydropower in the United States (“Small Hydropower Interconnections: Small Hydropower in the United States”), the variety of state interconnection processes to connect power generators with the grid (“Small Hydropower Interconnections: State Interconnection Processes”), and an analysis of the interconnection processes (“Small Hydropower Interconnections: Analysis of Interconnection Processes”). In this, the final paper in the series, best practices for interconnection processes (“Small Hydropower Interconnections: Best Practices”) are identified from the solar energy and distributed wind energy industries that are transferrable to small hydropower development. This information will help overcome barriers to future small hydropower development.

13 HYDRO ENERGY↗
DOE OSTI2022

Large-Scale Additive Manufacturing of Silicon Carbide with Process Monitoring

This report summarizes new capabilities in additive manufacturing (AM) of large-scale silicon carbide (SiC) components under the Advanced Materials and Manufacturing Technologies (AMMT) program. SiC is a promising material that is being considered for many advanced reactor designs due to its high temperature strength, radiation tolerance, minimal neutron absorption, and oxidation resistance [1-8]. One of the primary limitations to using SiC as an in-core structural material is the inability to fabricate large SiC components with complex geometries. While under the former Transformational Challenge Reactor (TCR) program, ceramic AM systems at the Oak Ridge National Laboratory (ORNL) were limited in the quantity and overall size achievable for producing ceramic AM components. To address this, ORNL has improved its infrastructure for binder jet and chemical vapor infiltration (CVI) processes with cutting-edge equipment coming online in a newly renovated laboratory space capable of producing larger components and higher throughput without compromise on part size. This report details the laboratory renovation progress, focusing specifically on the DesktopMetal (formerly ExOne) X25Pro binder jet, a large scale CVI furnace, and the added functionality of a software tool called Peregrine for quality assurance and control purposes.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Subcriticality Measurements for a Changing Concentration Uranyl Nitrate Solution Tank by Californium Source-Driven Noise Analysis

Subcritical californium source-driven noise analysis (CSDNA) measurements were performed at the Oak Ridge Critical Experiments Facility in 1983 using a stainless-steel tank with an inside diameter of 76.2 cm and a height of 91.4 cm but only filled with a uranyl (93.16 wt.% 235 U) nitrate solution to a height of 76.2 cm for all measurements. The free acid content of the uranyl nitrate solution was less than 0.01 N to minimize hazards in handling. The total available highly enriched uranium for these measurements was 5,296 g. The concentration of the solution was varied from the highest density of 14.71 grams of uranium per liter (g U/L) initially in 16 steps, lowering the concentration to 0.3492 g U/L, and finally using a tank filled with only water. The tank had a Plexiglas lid to minimize evaporation. The Cf source was contained in a re-entrant Lexan tube which could be in the solution parallel to the axis of the cylindrical tank. The detectors were 3 He proportional counters in the solution in shrink-fit tubing to isolate the counters from the fissile solution and adjacent to the outside of the tank. In some cases, the detectors were scintillators adjacent to the outside of the tank. In other cases, the source was external to the tank. Some data presented in this report are from notes and are not in the logbook. The prompt neutron decay constant was obtained from fitting the date from the CSDNA measurements. The purpose of this report is to document the experimental information for the measurements performed so that later, researchers could perform the required uncertainty and calculational analyses and documentation to use these data for an International Nuclear Criticality Safety Benchmark Program (ICSBEP) or a Nuclear Energy Agency benchmark. The prompt neutron decay measurements could be the basis of as International Reactor Physic Benchmark Program. The data from these measurements are available from the Records Management Services Department of Oak Ridge National Laboratory, and the logbook is also available from the ICSBEP at Idaho National Laboratory. Preparation of the present report is part of a larger cooperative effort between Idaho National Laboratory (INL) and Oak Ridge National Laboratory (ORNL) to document more than 15 undocumented critical and subcritical experiments enumerated in ORNL/TM-2019/18 and performed by ORNL at ORCEF and other USDOE critical experiments facilities using more than 500 operational days of critical facility time.

98 NUCLEAR DISARMAMENT, SAFEGUARDS, AND PHYSICAL P↗
DOE OSTI2022

CRADA Number NFE-19-07845 with American Nanotechnologies, Inc. (CRADA Final Report)

Cooperative Research and Development Agreement (CRADA) NFE-19-07845 between Oak Ridge National Laboratory (ORNL) and American Nanotechnologies, Inc. (ANI) focused on studying the use of dielectrophoresis as a mechanism to purify nanoparticles, particularly semiconducting carbon nanotubes (CNTs). The successful development of low-cost purification processes is a significant bottleneck in the adoption of semiconducting CNTs in commercial semiconducting devices. ANI is a startup company developing scalable systems for performing nanoparticle dielectrophoresis, which has previously been used only in microfluidic devices. The work done under this CRADA is exploring the use of ANI’s patent resonant dielectrophoresis (rDEP) technology and its ability to purify semiconducting CNTs at large scale. While continued work is on-going, r-DEP has proven to be a viable way to control nanoparticles in bulk dispersions. Optimization of the process is now underway to reach minimum viable product and begin material sales. Additionally, ANI and ORNL continue to collaborate on leveraging this technology to reach down the value chain and create new commercial devices.

77 NANOSCIENCE AND NANOTECHNOLOGY↗
DOE OSTI2022

Doppler-Free Saturation Spectroscopy (DFSS) for Magnetic and Electric Field Measurements in an FRC plasma

The Cooperative Research and Development Agreement (CRADA) between Oak Ridge National Laboratory (ORNL) and TAE Technologies (TAE) focused on a feasibility study of Doppler-free saturation spectroscopy (DFSS) as a diagnostic strategy to measure the internal magnetic and electric fields of TAE’s C-2W field-reversed configuration (FRC) fusion device. Non-perturbative measurements of magnetic and electric fields in the core of FRCs can provide critical information needed to constrain equilibrium models and for the continued advancement of the fusion research program at TAE. DFSS is a well-established, laser-based absorption spectroscopy technique used to suppress inhomogeneous (Doppler) broadening linewidths and reveal Zeeman/Stark split hyperfine structures of target emission lines. The collaboration involved the use of ORNL’s suite of experimentally validated quantum mechanical modelling codes to simulate theoretical atomic spectra for a variety of machine parameters and laser beam configurations. TAE’s expertise was heavily used to provide measurements/models of the required machine parameters needed as inputs to the simulations. Results of an all-encompassing error analysis demonstrate the favourable capabilities of the diagnostic and provided invaluable insights as to how DFSS can be best used to accurately measure internal B/E-fields in C-2W.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2022

ExaSGD: 2022 Kernel Thrust Activities

The Kernel Thrust milestone ADSE22-407 covers the development of device-capable optimization algorithms and solvers technologies required by the ExaSGD project’s software stack in order to solve security-constrained alternating current optimal power flow (SC-ACOPF) problems on emerging exascale architectures. To this extent, in FY22 the main objective of the Kernel Thrust was (i) provide sparse optimization solver that runs efficiently on hardware accelerator devices (i.e., NVIDIA and AMD GPUs) to perform intra-node computations, (ii) strengthen the reliability and increase the performance of the mixed-dense sparse (MDS) solver of HiOp for deployment on the FY22 target architectures, Summit and Crusher, and (iii) increase performance by improving the mathematical algorithm and refining the parallel MPI-based implementation of the coarse-grain parallel solver HiOp-PriDec for capabilities deployment on the FY22 target architectures, Summit and Crusher. This document presents the developments and contributions done by the Kernels Thrust Team in FY22 toward completion of the above-mentioned objectives. These contributions progressed along four main development (sub)thrusts: (1) Design and implementation of a sparse optimization solver for use on hardware accelerators; (2) Improvement of the mathematical algorithm and of the parallel implementation of HiOp-PriDec to ensure readiness and efficient coarse-grain parallelism for FY23 target exascale machine; and (3) Support Software and Application Development Thrusts of the exaSGD project in their deployment of the project’s software stack on AMD- and NVIDIA-based architectures. The development of the sparse optimization solver (thrust 1 above) was new in FY22 and resulted in a new sparse solver in HiOp (available as of version 0.6). The second development thrust was a continuation of the efforts from FY21 and improved the mathematical algorithm and the communication strategy of the HiOp-PriDec solver. The last developement thrust is a large collaborative effort. Namely, the project’s teams from multiple labs (LLNL, PNNL, ORNL, and NREL) performed large-scale demonstration of the ExaSGD software stack, namely the optimization solvers of HiOp interfaced with the modeling front-end ExaGO and the stochastic sampler PowerScenarios. These demonstration efforts solved large-scale instances of the SC-ACOPF challenge problem of medium network sizes (10, 000-bus system) and large number of contingencies on Summit (NVIDIA accelerators) and Crusher (AMD accelerators) systems at ORNL.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2021

LANL Critical Benchmark Comparison Study and Subsequent Revision for Cases Involving LEU and MIX

As part of an international collaboration within the DOE Nuclear Criticality Safety Program (NCSP), LANL is involved in a comparison study to quantify differences in k-effective results from neutron transport simulations of critical benchmark experiments. The DOE NCSP Mission and Vision details the activity in which the French Institut de Radioprotection et de Sûreté Nucléaire (IRSN) leads the study with LANL, ORNL, and LLNL to compare results of various neutron transport codes and nuclear data libraries for ICSBEP benchmarks held in common by the entities. The task statement from the DOE NCSP Five-Year Execution Plan is given as: "The proposal is for IRSN to lead a new intercomparison based on the MORET code with the latest JEFF-3.3 data and ENDF/B-VIII.0 data, when available, using their existing comprehensive selection of 2,714 benchmarks and collate their results together with those from LLNL (COG), LANL (MCNP) and ORNL (SCALE). Due to the large number of benchmarks involved, this effort is envisioned to take three years with an additional year for IRSN to complete a summary report. The benchmark development will be performed independently to minimize modeling errors through discovery and resolution of discrepant results. A summary report will be generated (led by IRSN) to document the results of this study." This report documents results obtained for revisions made to cases involving Intermediate Enriched Uranium (IEU) and a mixture of Pu and Uranium (MIX), with a focus on the changes made to LANL benchmarks modeled with MCNP6 using ENDF/B-VII.1 nuclear data that appeared to have discrepant results when compared with results of other codes. Feedback was used to pinpoint review of particular benchmark input files and to revise them when necessary. This report documents the results of review and revision of specific benchmarks highlighted as possibly discrepant in the comparison study. In addition, there is an effort tied to this work involving collaboration between LANL XCP and NCS Divisions in the development of a shared review/revision procedure and use of a new benchmark repository.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗
DOE OSTI2022

Evaluation of AddUp Precision L-PBF Technology for Tooling and Other Industrial Applications

ORNL (Contractor) and AddUp Inc. (Participant) collaborated to enable the adoption of laser powder bed fusion for tooling applications, critical for reshoring the manufacturing sector in the U.S. Most of the work on laser powder bed fusion has focused on high value materials such as Ti-6Al-4V and Inconel 718 for niche applications in aerospace, biomedical and energy sectors. In this collaboration, ORNL and AddUp worked laser powder bed fusion of maraging steels for tooling applications while leveraging the unique ability of the AddUp laser powder bed fusion system to deposit fine powders. We demonstrated that the AddUp technology is capable of depositing complex artifacts and features such as overhangs within desired tolerances. We also showed that direct aging of the deposited parts result in simultaneously higher strength and elongation compared to the conventional two step heat treatments, which could result in significant energy savings. Finally, we developed thermos-kinetic models to enable design of heat treatments for optimal material properties compared to the energy intensive empirical methods currently used. The report summarizes the detailed findings of this collaboration.

36 MATERIALS SCIENCE↗