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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 505 records · Page 28
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DOE OSTI2025

Evaporator Temperature Transient Testing of a High-Performance Sodium Filled Heat Pipe

Heat pipes are two-phase heat transfer devices that enable passive removal of heat from the reactor core to the power conversion system in heat pipe-cooled microreactor designs. Experimental investigations of heat pipe transients are needed for technology demonstration, verification and validation of numerical codes, and the establishment of regulatory requirements. The Single Primary Heat Extraction and Removal Emulator (SPHERE) facility at Idaho National Laboratory (INL) serves as a platform for evaluating the dynamic response of high-temperature heat pipes under a variety of operating conditions. The present work details the experimental investigation of a high-performance, defined as over 2 kW sodium heat pipe subjected to rapid input power fluctuations induced by sudden changes in the evaporator temperature setpoint. In addition, the heat pipe was subjected to an asymmetrical heat load where a subset of heaters operated at 30% and 70% below their nominal power. These experimental conditions were chosen to simulate thermal and operational stresses expected to be encountered in microreactors to provide data on heat pipe behavior during such important transient events. Key data and performance metrics, including time series of temperatures and strains, axial temperature profiles, thermal response times, and heat transfer capabilities, the thermal output over thermal input, were reported and discussed. The results highlight the resilience of heat pipes, revealing their potential to maintain thermal stability and efficiency under varying power loads. Lastly, the paper concludes with a discussion on the significance of the results and their implications for future research.

22 - GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2024

Safety Considerations for Advanced Material Irradiation at the Advanced Test Reactor

The Advanced Test Reactor (ATR) is a light water reactor with aluminum-clad driver fuel. A primary mission of the ATR is to support the next generation of nuclear reactors. This support necessarily requires irradiation of advanced materials such as sodium, fuel salts, and metal eutectics. Irradiation of advanced materials in the ATR environment presents a challenge when completing accident analyses and demonstrating compliance to the Safety Analysis Report (SAR). Many advanced materials have the possibility to react with the ATR protective barriers such as the cladding or primary coolant system (PCS) boundary during postulated accident scenarios. Further, molten fuel experiments fall outside of the standard regulatory framework for dose consequence analyses. ATR is currently developing new safety analysis methods to support irradiation of advanced materials. The primary considerations for this development are 1) experiment containment design requirements, 2) primary coolant system response to an experiment containment failure, and 3) dose analyses for molten fuels.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2024

Safety Considerations for Advanced Material Irradiation at the ATR

The Advanced Test Reactor (ATR) is a light water reactor with aluminum-clad driver fuel. A primary mission of the ATR is to support the next generation of nuclear reactors. This support necessarily requires irradiation of advanced materials such as sodium, fuel salts, and metal eutectics. Irradiation of advanced materials in the ATR environment presents a challenge when completing accident analyses and demonstrating compliance to the Safety Analysis Report (SAR). Many advanced materials have the possibility to react with the ATR protective barriers such as the cladding or primary coolant system (PCS) boundary during postulated accident scenarios. Further, molten fuel experiments fall outside of the standard regulatory framework for dose consequence analyses. ATR is currently developing new safety analysis methods to support irradiation of advanced materials. The primary considerations for this development are 1) experiment containment design requirements, 2) primary coolant system response to an experiment containment failure, and 3) dose analyses for molten fuels.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2024

Design and optimization of flexible decoupled high-temperature gas-cooled reactor plants with thermal energy storage

Advanced nuclear power plants are well-positioned for future zero-carbon grids, however, the need for flexible power generation will be required over the traditional emphasis on baseload generation for meeting historical demands. To achieve such flexibility, this work examines viable configurations for coupling nuclear energy production with thermal energy storage. Previous designs on nuclear-thermal energy storage configurations for advanced reactor designs, which utilized reactor steam as the heat source for charging the thermal energy storage, are restricted by the heat diversion ratio and efficiency losses, thus their impacts can be limited. In this context, this study proposes configurations for fully decoupling the nuclear reactor from the power cycle and positioning the storage as an intermediate loop, thereby achieving an unconstrained heat diversion ratio and improved efficiency. Compared with a standard high-temperature gas-cooled reactor’s power cycle, steady-state thermodynamic modeling and dispatch optimizations quantify the benefits of a steam reheat cycle within the fully decoupled thermal energy system to separate the plant cycle from the high-pressure primary side. These benefits are further detailed, compatible with required high-temperature and high-pressure conditions, through (1) open-source dynamic transient models that examine the impact of off-design operation on the systems, (2) the investigation of components design and costing and finally (3) sizing and dispatch optimization. The fully-decoupled design achieves a cycle efficiency of 43.1%, an enhancement over the vendor’s standard efficiency of 42.2% (Xe-100 design). Here, the proposed design offers strengthened physical barriers from the nuclear island as well as superior operational flexibility and power boosting. Dispatch optimization and market analysis reveal that thermal energy storage size is highly dependent on the peak patterns of electricity prices and the minimum generation level constraint imposed on the balance of plant. Evaluation of off-design operation demonstrates that the full decoupling design with the suggested fail-safe control mechanisms ensures a minimal impact on reactor parameters, even during rapid power ramping.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2024

Development of Data Reporting Standards for High-Temperature Gas-cooled Reactor (HTGR) Nuclear Energy University Program (NEUP) Thermal-Fluid Experiments

Since 2009, the U.S. Department of Energy (DOE) Office of Nuclear Energy's Nuclear Energy University Program (NEUP) has been at the forefront of nuclear research, specifically concentrating on advancing high-temperature gas-cooled reactor (HTGR) technologies. By Fiscal Year 2023, NEUP has authorized 35 projects dedicated to HTGR research, each contributing significantly to the enhancement of our understanding of this technology. The outcomes of these diverse projects have been disseminated through final NEUP reports, peer-reviewed journal articles, and presentations at academic conferences, forming a comprehensive tapestry of knowledge. Despite the substantial value of these findings, their dissemination has been fragmented, posing challenges for accessibility to researchers and policymakers and leading to underutilization of DOE investments. Recognizing this critical gap and its potential consequences for the future of nuclear research, the Advanced Reactor Technologies (ART) Gas-Cooled Reactor (GCR) program conducted an extensive survey of completed and ongoing HTGR NEUP projects. This survey enabled the compilation of crucial data, resulting in the development of a specialized public-access database tailored for computational fluid dynamics and system code validation, specifically designed for HTGR applications. However, the data collection process revealed a significant challenge in central data organization due to individual researchers from different institutes employing varying logics and preferences for recording and documenting experimental data. Consequently, an urgent need has been identified to establish a standardized reporting format for HTGR experimental projects. Addressing this issue is essential for enhancing collaboration, maximizing the impact of DOE investments, and ensuring the seamless advancement of HTGR technologies in nuclear research.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2026

Influence of fabrication on microstructure and heat affected zone width in weldments of nuclear reactor pressure vessel steel

Advanced manufacturing routes such as electron beam welding and powder metallurgy with hot isostatic pressing are increasingly used across energy and aerospace industries, where the reliable prediction of weld behavior and heat affected zone (HAZ) evolution is critical. This study examines how fabrication routes and post-weld heat treatments influence phase distribution, crystallite size, microstrain, and dislocation density in nuclear reactor pressure vessel steels using synchrotron X-ray diffraction (SXRD). Retained austenite occurs only in samples that did not undergo austenitization, whereas an austenitizing heat treatment fully eliminates retained austenite and produces a more uniform microstructure across the weldment in terms of phase fraction, dislocation density, and microstrain. The Rosenthal solution underestimates the HAZ width for powder metallurgy samples. A newly proposed modified Rosenthal solution, reducing density by accounting for porosity, matches the SXRD-measured HAZ width with a 0.65% error. Structure–property correlations reveal that dislocation density correlates strongly with nanohardness in homogenous microstructures, while in heterogenous weldments nanohardness is further influenced by the presence of dissimilar phase boundaries. These findings provide new insight into the thermal and microstructural response of powder metallurgy fabricated steels and offer a framework for optimizing welding procedures and heat treatments in advanced manufacturing applications.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗
DOE OSTI2022

Coolant Channel Design for Additively Manufactured Reactor Cores

Additive manufacturing (AM) methods are currently being explored for applications in nuclear reactors to make advanced reactors more efficient, safe, and reliable. The Transformational Challenge Reactor (TCR) program has explored AM for nuclear by designing a high-temperature gas reactor (HTGR) using an AM silicon carbide fuel form with uranium nitride–tristructural isotropic fuel. In this study, we detail the design process for the TCR fuel form’s coolant channels using computational fluid dynamics models with conjugate heat transfer. Additionally, this work discusses how these models were interfaced with other design teams, project milestones, and the agile design method used to mature the reactor design. The methodology deployed was able to create a channel design with lower maximum fuel temperatures and thermal stresses in the fuel form over traditional channel designs that can be manufactured subtractively. These results were achieved with only small manufacturing penalties. Results are discussed and presented on lessons learned for designing AM components for nuclear reactors. Finally, areas of opportunity are discussed for advanced design tools to further automate design activities and optimize reactors with fewer built-in assumptions.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2021

Implementation of a Drift-Flux Model in SAM for Modeling of Passively Transported GAS in Molten Salt Reactors

The Nuclear Energy Advanced Modeling and Simulation (NEAMS) program is further developing the Multiphysics Object Oriented Simulation Environment (MOOSE) system thermal hydraulics (T/H) code, System Analysis Module (SAM), to include modeling of molten salt reactor (MSR) designs. MSR designs in which the fuel is dissolved in the salt coolant poses unique modeling and simulation (M&S) challenges because fission products—some of which will be noncondensable gasses—travel with the coolant, thus allowing for deposition and interaction throughout the entire system flow loop. This behavior must be modeled to successfully understand MSR system behavior during normal and off-normal operation events. In past work, SAM has been extended to include a passive species transport capability for modeling of MSR fission products that travel with the salt coolant. This work extends the model to include a drift-flux model to capture the tendency of the gas phase to move at a different velocity than the bulk liquid. Additional constitutive models have also been added for calculation of gas volume fraction, bubble radius, and interfacial area, which will be important for calculation of species phase migration in future coupling activities. Testing has been performed to ensure that the new model agrees with expected values for several simple models, but additional future work will be required to test the model for more complex geometries that will be needed for full-scale MSR simulations.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2023

Scoping Study for Fast Flux Testing in the Advanced Test Reactor

The value of fast spectrum reactors remains prominent in the nuclear technology portfolio. The performance of these reactors can be maximized with advancements in nuclear fuel technologies, but development of these technologies is currently held back by lack of fast spectrum test reactors available to the United States. Spectral modification of experiment positions in the thermal spectrum Advanced Test Reactor (ATR) has long been used to support fast reactor fuel development, but these methods have not been progressed to their full potential. This study investigated the use of concentric rings of aluminum-clad fuel plates in ATR flux traps and thermal neutron absorbing filters to increase fast neutron flux on test specimens. This concept was termed the Boosted Energy Advanced Spectrum Test (BEAST). This approach will enable irradiation of advanced fuel designs in prototypic-length fuel pins and representative flux environment to support post irradiation exams, enable transient testing, and produce the type of data that will permit lead test assembly irradiations in true Sodium Fast Reactors (SFRs) when they become available. Neutronic predictions were performed to investigate BEAST design options and thermal hydraulic models were produced to ensure feasibility of BEAST. Two versions were considered based on the geometric limitations of ATR’s small and large flux traps. The small version was found to be preferable due to slightly higher fast flux and fast-to-thermal neutron ratio. Perhaps more influentially, the small flux trap option was also preferred to avoid conflict with ongoing very high temperature reactor fuel irradiation programs in ATR’s large northeast flux trap. The small flux trap option provided less than half the test volume of the large version, but still had adequate volume for seven SFR pins in cross section which could be stacked two-high in ATR’s 1.2m long core to accommodate up to 14 EBR-II size pins. The preference for the small flux trap configuration should be revisited if additional collaborative test programs emerge with the need to irradiate a significant volume of additional specimens. Calculations were performed regarding a lithium deuteride ring to convert thermal neutrons into 14 MeV fusion neutrons. At the time this report was written these calculations were partially complete and it remains to be seen whether the concept would be worth including in BEAST. Given the preference for the small flux trap option, which does not afford enough room for the 14 MeV ring, it was concluded to defer future work on the lithium deuteride ring. This decision could be revisited if fusion material research programs emerge for collaborative testing in BEAST. A cadmium-lined specimen holder design was found to be adequate in filtering thermal neutrons and preferred over other neutron absorbers based on past experience with cadmium baskets. It was acknowledged that cadmium-bearing hardware would become depleted and need to be replaced occasionally, which appeared feasible from a mechanical design perspective. Neutronic studies investigated different enrichment levels in the booster fuel using uranium-molybdenum alloy dispersion fuel which has performed well in past ATR irradiations. Both options were able to drive fuel pins to SFR-like fission heating rates. The high enriched booster fuel option outperformed the low enriched option by ~20% on key metrics including fast flux and fast-to-thermal ratio, but the low enriched option was favored in order to broaden options for potential fuel suppliers. The preferred BEAST design options including cadmium filter with low enriched booster fuel in the small flux trap configuration was predicted to achieve 6.2E14 n/cm2sec fast flux (>0.1 MeV) with a fast-to-thermal ratio of 44.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2020

Demonstration of Embedded Sensors in Ceramic Structures

The Transformational Challenge Reactor (TCR) program seeks to demonstrate an advanced 3D printed nuclear reactor core. A binder jet additive manufacturing process is used to fabricate the complex SiC ceramic components of the TCR core. After printing, the components are densified via chemical vapor infiltration (CVI). This process allows complex cavities to be created in which sensors can be placed at strategic locations. Inserting the sensors during the CVI process allows the sensors to be embedded within the component as it is infiltrated. The primary challenge for embedding the sensors is identifying the sensors and sensor sheath materials that can survive the temperatures (>1,000°C) and chemical exposure to H 2 and HCl during CVI. The embedded sensors that are being investigated for use during TCR operation include thermocouples, self-powered neutron detectors, and spatially distributed fiber-optic temperature sensors. This report describes the CVI materials compatibility tests and initial trials for embedding functional sensors. Mo is identified as the most suitable sensor sheath material based on its availability in small diameter tubing, relatively low neutron absorption cross section, and compatibility with H 2 , HCl, and the surrounding SiC matrix at the process temperatures. Amorphous SiO2 fiber-optic samples with Au and Cu metal coatings were successfully embedded in SiC along with bare fibers, although the metal coatings showed some evidence of localized melting during CVI. Initial experiments attempting to embed functional sensors showed that the sensors can be embedded in 3D printed SiC parts, but there are still challenges that must be overcome to ensure that the sensors and sensor sheaths do not fail during CVI. In particular, Nb-sheathed Mo-Nb thermocouples failed at temperatures far lower than expected despite thermodynamic calculations and materials compatibility tests that show the Nb sheath to be compatible with the CVI environment. One potential explanation for the large expansion of the Nb sheath could be related to hydride formation in the lower temperature region of the sheath. Future work will focus on Mo-sheathed thermocouples instead of Nb. The fiberoptic sensors tested during the instrumented experiment broke due to the lack of mechanical protection after their polymer-based coatings were vaporized. Future instrumented experiments will use metal-coated optical fibers for strain sensing to provide additional mechanical protection. However, custom coatings with higher melting points than commercially available Au and Cu might be required. Regardless, fiber-optic sensors are still candidates for spatially distributed temperature measurements since they can be inserted into an embedded metal sheath after CVI.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2025

Innovative Nuclear Materials Outboard-A Project Specimen Preparation Guide

The Innovative Nuclear Materials (INM) Program was recently established by the U.S. Department of Energy (DOE) to develop advanced material technologies for use in nuclear reactors. The INM program is presently focused on researching in-core non-fueled materials for application in fast spectrum nuclear reactors. The widespread deployment of fast reactors continues to be a prominent aspiration for advanced nuclear technology developers. However, companies working to license these reactors have no choice but to rely on historic material technologies since further optimization and advancement of these materials is impeded by the lack of fast neutron irradiation test facilities. INM-OA is a non-fueled drop-in experiment which will irradiate material specimens of interest to fast reactor applications. This experiment will be irradiated at Idaho National Laboratory (INL) in the Advanced Test Reactor (ATR) outboard-A (OA) position during normal and high temperature steady state (HTSS) cycles. It will include material specimens supplied by members of the INM program and will utilize a cadmium-lined basket to filter out incident thermal neutrons, thus simulating a faster neutron energy spectrum. Material specimens will undergo post-irradiation examination including microscopy and mechanical testing. In addition to absorption reactions, fast neutrons cause microstructural damage in materials by atom displacement, which can cause exacerbated changes in physical properties and behavior. Thus, the data obtained from the INM-OA experiment will be crucial for understanding the engineering-scale behavior of reactor materials. This document is intended for the Principal Investigators providing samples for this project. Topics included are a general description of the experiment, the irradiation experiment/capsule design, sample geometries, number of samples to be provided, documentation to be provided, a brief list potentially useful characterization methods that can be leveraged at INL, and other miscellaneous requirements specific to this project. This document is intended for informational use only.

innovative nuclear materials↗
DOE OSTI2025

Thermal Hydraulics Validation Activities in the ART-GCR Campaign

The Advanced Reactor Technologies - Gas Cooled Reactor Campaign (ART-GCR) is part of the United States Department of Energy - Office of Nuclear Energy's Advanced Reactor Technologies program aimed at developing a High Temperature Gas-cooled Reactor (HTGR) which will offer enhancements in safety and efficiency. The Design, Methods, and Validation arm of the ART-GCR program provides experience and advanced tools for HTGR design and analysis. The Methods and Validation arm is developing data to validate predictions of decay heat removal through an extensive experimental campaign the Natural Convection Shutdown Heat Removal Test Facility at Argonne National Laboratory. In-core thermal hydraulics validation is being facilitated through the OECD/NEA's Thermal Hydraulic Code Validation Benchmark for High Temperature Gas-Cooled Reactors using HTTF Data. That benchmark contains code-to-code and code-to-data comparisons for 3 sets of HTGR thermal hydraulics phenomena. This ongoing benchmark activity has 16 participants from 9 countries developing leading insights into HTGR thermal hydraulics code validation. The ART-GCR campaign is also working on the development of state-of-the-art MOOSE-based models of the High Temperature Engineering Test Reactor (HTTR). Through the OECD/NEA's HTTR Loss of Forced Cooling (LOFC) program, the ART-GCR campaign is developing a multiphysics transient code validation benchmark based on 3 HTTR experiments that will provide an opportunity for international collaboration on multiphysics code validation.

22 - GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2021

Planning Near-Term Tasks for the Development of Advanced Reactor Mechanistic Source Term Modeling and Simulation Tools

To assist both the advanced reactor industry and U.S. Nuclear Regulatory Commission (NRC) in the pursuit of reactor design and licensing, the U.S. Department of Energy (DOE) Nuclear Energy Advanced Modeling and Simulation (NEAMS) program has established a mechanistic source term (MST) research project under the auspices of the Application Drivers technical area. The MST research project is a collaboration between Argonne National Laboratory (Argonne) and Sandia National Laboratories (SNL) with a high-level objective to coordinate the development of comprehensive advanced reactor MST mod/sim capabilities to support risk-informed design and licensing decisions. As part of this effort, an MST mod/sim development pathway was developed in FY21, which outlines the high-level objectives and near-term tasks necessary to achieve the project objectives. Since publication of the development pathway, Argonne and SNL have been addressing the “near-term tasks” outlined in the report. The current provides a status update of the progress achieved in the fourth quarter of FY21. The report structure follows that of ref and is divided by advanced reactor type: High temperature gas reactor (HTGR), molten salt reactor (MSR) including fluoride salt-cooled high temperature reactor (FHR), and sodium fast reactor (SFR). Each section reviews the near-term tasks associated with the reactor type, current progress, and future plans. The near-term tasks associated with consequence modeling are reviewed in an upcoming work by SNL.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2020

Initial Evaluation of Fuel-Reactor Concepts for Advanced LEU Fuel Development

The National Nuclear Security Administration (NNSA) Office of Defense Nuclear Nonproliferation R&D has commenced a project to evaluate and develop low-enriched uranium (LEU) fuel systems, materials, and fabrication technologies that could be used for compact, advanced LEU (aLEU) fuel, power-producing, high-burnup reactor applications. Potential applications are intended to be off-grid power sources for ship-borne systems and transportable systems to fixed locations, e.g., to a remote base or to a seawater desalination service location. Reactors with these qualities and fuel enrichments between 5 and 20% are atypical. The aLEU Fuel for Nonproliferation Applications Project addresses this technology gap.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2022

Exploring Advanced Computational Tools and Techniques with Artificial Intelligence and Machine Learning in Operating Nuclear Plants

This report presents the project Idaho National Laboratory conducted for Nuclear Regulatory Commission to explore the advanced computational tools and techniques, such as artificial intelligence (AI) and machine learning (ML), for operating nuclear plants. The report reviews the nuclear data sources, with the focus on the operating experience data, that could be applied by advanced computational tools and techniques. Plant-specific and generic (national and international) data from different sources are described. The report describes the relationships between statistics and AI/ML and then introduces the most widely used AI/ML algorithms in both supervised and unsupervised learning. The report reviews the recent applications of advanced computational tools and techniques in various fields of nuclear industry, such as reactor system design and analysis, plant operation and maintenance, and nuclear safety and risk analysis. Finally, the report presents the insights from the project on the potential applicability of AI/ML techniques in improving advanced computational capabilities, how the advanced tools and techniques could contribute to the understanding of safety and risk, and what information would be needed to provide meaningful insights to decision makers. The report also documents an NRC survey on the current state of commercial nuclear power operations relative to the use of AI and ML tools as well as the role of AI/ML tools in nuclear power operations was published by the NRC as in FRN NRC-2021-0048 in April 2021. A summary of the survey including the survey questions, survey participants, survey responses, and the conclusions and insights derived from the survey is provided in the report. Finally, the report investigates potential applications of using AI/ML in operating NPPs and advanced reactors (both advanced LWRs and advanced NLWRs) to improve nuclear plant safety and efficiency. Three main application fields are defined and discussed: (1) plant safety and security assessments; (2) plant degradation modeling, fault and accident diagnosis and prognosis; and (3) plant operation and maintenance efficiency improvement.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2023

Build-to-Replace: A New Paradigm for Reducing Advanced Reactor O&M Costs

Nuclear energy is a carbon free source of reliable, resilient, and dispatchable energy that has the potential to feature prominently in a future energy mix. To this end, many new reactor designs are being developed to help reduce cost and improve safety. Operating and maintenance (O&M) costs can make up a significant portion of lifecycle costs. Traditional approaches for nuclear plant design O&M is to perform significant inspections and testing of plant equipment to extend the life of equipment as long as possible. This is contrasted with approaches used in other industries where equipment is replaced when it is no longer functional in lieu of spending time and resources on maintenance. This research investigated the “build-to-replace” approach for new nuclear power plants. A methodology was developed to evaluate the effectiveness of the “build-to-replace” approach. Several scenarios were developed and analyzed using the approach. Modest reductions in O&M costs were obtained in some cases.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗