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DOE OSTI2019

PTT System Performance Evaluation in 3-D Imaging of Calibrated Defects: Pulsed Thermal Tomography Nondestructive Examination of Additively Manufactured Reactor Materials and Components

Research activity in this project is aimed at developing pulsed thermal tomography (PTT) architecture and algorithms for in-service non-destructive examination (NDE) of additively manufactured (AM) reactor components and materials. Recent advances in AM technology could allow cost-efficient fabrication of parts for operating reactors. However, because of stringent safety requirements, long-term performance of AM reactor components needs to be investigated before AM is widely accepted. Because of the complex shapes and significant surface roughness of components due to layer-by-layer welding process in AM, conventional methods might not be useful for in-service NDE of AM components. PTT is ideally suited for in-service NDE of AM metallic components because the method is non-contact, and offers high resolution #-D imaging of material flaws. The objective of this report is to provide initial evaluate of PTT performance sin detecting calibrated flaws in reactor structural materials. Preliminary COMSOL models were developed to conduct super computing simulations of PTT. In the experimental studies, high strength Stainless Steel 316 and Inconel 718 alloys were considered, as well as lower grade Stainless Steel 304, Nickel 200, and Hastelloy C276. Specimens investigated in this report consisted of approximately 1/4in-thick plates made out of these alloys using conventional manufacturing methods. The calibrated defects were created in the form of flat bottom holes (FBH) drilled in metallic plates. The diameters of FBH's varied from 1mm to 8mm, and their depths below the plate flat surface varied between 1mm and 6mm. The size of the smallest FBH was limited to 1mm because conventional mechanic drills were used for creating the holes. PTT imaging results have shown that 1mm-diameter FBH located 1mm and 2mm below the surface were detectable. Larger size FBH were detectable at greater depth. For example, 6mm-diameter FBH could be detected at 8mm depth. Image contrast varied slightly between the specimens, with the best reconstructions obtained in SS316 and C276 plates. In addition, a 2/3in-thick Inconel 718 nozzle plate produced with additive manufacturing method was imaged with PTT. It was shown that PTT can scan through the plate in approximately 20s. Several modes of 3-D data visualization were explored, including using ImageJ and MATLAB software packages.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2019

Safety Testing and Destructive Examination of AGR-2 UCO Compact 6-4-3

Post-irradiation examination (PIE) and elevated-temperature safety testing are being performed on tristructural-isotropic (TRISO) coated-particle fuel compacts from the Advanced Gas Reactor (AGR) Fuel Development and Qualification Program’s second irradiation experiment (AGR-2). Details on this irradiation experiment have been previously reported. The AGR-2 PIE effort builds upon the understanding acquired throughout the AGR-1 PIE campaign (Demkowicz et al. 2015) and is establishing a database for the different AGR-2 fuel designs. The AGR-2 irradiation experiment included TRISO fuel particles coated at BWX Technologies (BWXT) with an engineering-scale coater, which had a coating chamber 150 mm in diameter. Two coating batches were tested in the AGR-2 irradiation experiment. Batch G73H-10-93085B had uranium dioxide (UO2) kernels with an average diameter of 508 µm. Batch G83J-14-93073A had UCO kernels with an average diameter of 427 µm; in this kernel design, some of the uranium oxide is converted to uranium carbide during fabrication to provide a getter for oxygen liberated during fission and to limit CO production. Fabrication and property data for the AGR-2 coating batches have been compiled and compared to AGR-1. The AGR-2 TRISO coatings were most like the AGR-1 Variant 3 TRISO deposited in the Oak Ridge National Laboratory (ORNL) laboratory-scale coater, which had a coating chamber 50 mm in diameter (Hunn and Lowden 2006). In both cases, the hydrogen and methyltrichlorosilane coating gas mixture that was used to deposit the SiC was diluted with argon to produce a finer grained, more equiaxed SiC microstructure. In addition to the fact that AGR-1 fuel had smaller UCO kernels that were 350 µm in diameter, other notable differences in the TRISO particle properties included (1) the pyrocarbon anisotropy, which was slightly higher in the particles coated in the engineering-scale coater, and (2) the exposed kernel defect fraction, which was higher for AGR-2 fuel due to the detected presence of particles with impact damage that was introduced during TRISO particle handling.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2019

Safety Testing and Destructive Examination of SGR-2 UCO Compact 2-1-2

Post-irradiation examination (PIE) and elevated-temperature safety testing are being performed on tristructural-isotropic (TRISO) coated-particle fuel compacts from the Advanced Gas Reactor (AGR) Fuel Development and Qualification Program’s second irradiation experiment (AGR-2). Details on this irradiation experiment have been previously reported. The AGR-2 PIE effort builds upon the understanding acquired throughout the AGR-1 PIE campaign and is establishing a database for the different AGR-2 fuel designs. The AGR-2 irradiation experiment included TRISO fuel particles coated at BWX Technologies (BWXT) with an engineering-scale coater, which had a coating chamber 150 mm in diameter. Two coating batches were tested in the AGR-2 irradiation experiment. Batch G73H-10-93085B had uranium dioxide (UO2) kernels with an average diameter of 508 µm. Batch G83J-14-93073A had UCO kernels with an average diameter of 427 µm; in this kernel design, some of the uranium oxide is converted to uranium carbide during fabrication to provide a getter for oxygen liberated during fission and to limit CO production. Fabrication and property data for the AGR-2 coating batches have been compiled and compared to AGR-1. The AGR-2 TRISO coatings were most like the AGR-1 Variant 3 TRISO deposited in the Oak Ridge National Laboratory (ORNL) laboratory-scale coater, which had a coating chamber 50 mm in diameter (Hunn and Lowden 2006). In both cases, the hydrogen and methyltrichlorosilane coating gas mixture that was used to deposit the SiC was diluted with argon to produce a finer grained, more equiaxed SiC microstructure. In addition to the fact that AGR-1 fuel had smaller UCO kernels that were 350 µm in diameter, other notable differences in the TRISO particle properties included (1) the pyrocarbon anisotropy, which was slightly higher in the particles coated in the engineering-scale coater, and (2) the exposed kernel defect fraction, which was higher for AGR-2 fuel due to the detected presence of particles with impact damage that was introduced during TRISO particle handling.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2019

Assessment of CReST-VCT Deployment in Real-Time Environments: Communication System Examination

Incorporation of decentralized generation or distributed energy resources (DERs) such as solar and wind, is transforming the electricity grid. These resources have the potential to provide greater overall value when they are grid connected and coordinated between transmission and distribution systems. The Coordinated Real-Time Sub-Transmission Volt-VAr Control Tool (CReST-VCT) has been proposed to provide co-optimization between transmission and distribution systems maximizing DER utilization while maintaining overall grid stability. In this paper, we examine the communication systems that are necessary to support the integration of the CReST-VCT optimization mechanism in a real-time operational environment. The required communication interfaces will be identified based on the operation model of CReST-VCT. The characteristics of the communication systems at these interfaces will be described to establish the context within which CReST-VCT will operate. The related protocols and cybersecurity domain will be reviewed. Potential issues and concerns will then be identified to guide subsequent integration efforts.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2020

Safety Testing and Destructive Examination of AGR-2 UO 2 Compact 3-1-1

Post-irradiation examination and elevated-temperature safety testing are being performed on compacts from the Advanced Gas Reactor (AGR) Fuel Development and Qualification Program’s second irradiation experiment (AGR-2). The compacts in the AGR-2 irradiation experiment held either tristructural isotropic (TRISO)-coated particles containing uranium oxide fuel kernels (UO 2 ) or TRISO-coated particles containing fuel kernels with both uranium carbide and uranium oxide phases (UCO). In UO 2 TRISO particles, oxygen released by uranium fission can react with the surrounding carbon in the buffer layer to form carbon monoxide (CO). Excess CO can lead to various irradiation performance issues under certain operating conditions, such as pressure-induced fracture, kernel migration, and silicon carbide (SiC) corrosion. In UCO TRISO particles, CO formation is reduced because the chemical potential for oxidation of uranium carbide is lower than for oxidation of carbon.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2019

Evaluation of Nondestructive Examination Responses from Chloride-Induced Stress Corrosion Cracks: Fabrication of Base Metal Test Specimens

This report documents efforts to create actual chloride-induced stress corrosion cracks (CISCCs) in stainless-steel specimens for evaluating application of nondestructive examination (NDE) technologies for detection and sizing of CISCC in stainless-steel canisters in dry storage systems (DSSs) for spent nuclear fuel. In the United States, several DSSs for commercial spent nuclear fuel are approaching the end of their initial licensed or certified term. Many of these systems were originally licensed or certified for 20 years, after which the licensing or certification may be renewed for periods up to 40 years, according to Title 10 of the Code of Federal Regulations (10 CFR), Part 72, “Licensing Requirements for the Independent Storage of Spent Nuclear Fuel, High-Level Radioactive Waste, and Reactor-Related Greater than Class C Waste.” Guidance for review of renewal applications is provided in NUREG-1927, Standard Review Plan for Renewal of Spent Fuel Dry Cask Storage System Licenses and Certificates of Compliance. A review of aging effects that could affect important-to-safety structures, systems, and components is required in renewal applications and applicants are required to address aging effects using either a time-limited aging analysis or an aging management program. The U.S. Nuclear Regulatory Commission (NRC) issued NUREG-2214, Managing Aging Processes In Storage (MAPS) Report, which provides guidance on the evaluation of known aging degradation mechanisms to determine if they could affect the ability of dry storage system components to fulfill their safety functions in the 20- to 60-year period of extended operation.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2020

First Examination of Irradiated Fuel with Pulsed Neutrons at LANSCE (Preliminary Results)

We present preliminary results on the characterization of an irradiated U-lOZr-lPd fuel sample that was prepared from the irradiated AFC-3A-R5A sample. U-lOZr metallic fuels are researched as host materials for potential transmutation fuels and the addition of palladium strives to bind lanthanides, thus preventing fuel-cladding chemical interactions (FCCI). These interactions limit the lifetime of metallic fuels and are caused by migration of lanthanide fission products to the periphery of the fuel slug, where they start to interact with the D9 or HT9 steel cladding, ultimately leading to failure of the mechanical integrity of the cladding. Neutrons offer bulk characterization of irradiated materials for which X-ray tomography methods are not suitable due to the immense gamma background emitted from the samples. In particular pulsed neutrons provide information from the ability to resolve the neutron energy using their time-of-flight and thus the potential to utilize neutron absorption resonance to characterize the spatial distribution of isotopes. This, in turn, may allow to characterize the distribution of fission and neutron capture products non-destructively and may ultimately be applied to the bulk of an irradiation capsule prior to destructive post-irradiation examination to identify regions of interest. To allow the characterization of entire irradiation capsules, a cask is under development in the advanced post-irradiation work package at LANL and progress on this development was reported elsewhere. In parallel, an irradiated U-lOZr-lPd sample cut from the AFC-3AR5A irradiation was shipped to LANL and will be fully characterized with an NSUF funded rapid turnaround experiment (RTE) in the 2020 LANSCE run cycle. The sample emits at a dose rate of ~3R/hr on contact and is therefore manageable with remote handling, without requiring a cask. The disk-shaped material is larger than samples prepared for analysis using electron or X-ray methods and is therefore an intermediate step towards characterization of bulk samples at LANSCE. However, since it covers the full diameter of the irradiated fuel slug, some insight on redistribution of elements, spatially resolved information on microstructure, e.g. phase composition and texture, will be possible using the pulsed neutron-based methods developed for fuel characterization at LANSCE. This report describes the development of procedures to handle the sample at LANSCE as well as preliminary data and results from tests conducted in December 2019 on the energy-resolved neutron imaging (ERNI) beam line at flight path 5 and the high pressure-preferred orientation diffractometer (HIPPO) at LANSCE. This effort is a collaboration between LANL, INL, and ORNL. To compare our capabilities with prior work, we present an overview of previously reported bulk characterization of irradiated or spent fuels. The overview addresses neutron diffraction and neutron absorption resonance spectroscopy, both of which have only few reported applications on irradiated or spent nuclear fuel, as well as neutron radiography. This literature review was already described in a previous report but is repeated here to put our current efforts in context of previous work.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2020

Microwave Cast Material Examination

Microwave-cast material dating from the latest prototype development period and subsequent TRL 7 advancement testing was sent to LANL for additional characterization. The initial characterization described here is considered a supplement to and verification of that performed by Y-12 during the Technology Readiness Assessment process. The carbon chemistry results from Y-12 and LANL regarding early prototype microwave cast test object (CTO) and cylinder castings match within expectations. Only one fully intact as-cast CTO was available for examination in which carbon chemistry does not appear to vary spatially, at least at relatively low carbon levels (hypoeutectic). The large as-cast grain size leads to relatively poor grain size statistics and similar difficulties were encountered during the TRA. Small, isolated gas pores were observed in four of the five metallographic samples in prototype CTO casting PT-01. Finally, the next phase of characterization work, which focuses on corrosion behavior, has started and is described briefly.

36 MATERIALS SCIENCE↗

DOE OSTI2020

Examining the Ice-Nucleating Particles from the Southern Great Plains Field Campaign Report

The recent U.S. Department of Energy (DOE) Atmospheric Radiation Measurement (ARM) user facility field campaign, named Examining the Ice-Nucleating Particles from Southern Great Plains (ExINP-SGP), targeted experimentally characterizing abundance and other properties of ambient ice-nucleating particles (INPs) at the SGP site in Oklahoma (36° 36' 18" N, 97° 29' 6" W) during the period of October 1 to November 14, 2019. This campaign was funded through the DOE Office of Science Early Career Research Program (DE-SC0018979) as one of three major campaigns to be conducted at three ARM observatories, including the Eastern North Atlantic (ENA) station in 2020–2021 and North Slope of Alaska (NSA) site in 2021–2023, besides SGP. Different INP episodes were assessed to develop an SGP-relevant ice nucleation parameterization that would help understand convective and mixed-phase cloud systems typically observed in this region.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2021

Post Examination of Candidate NpO 2 Targets for 238 Pu Production

Four targets composed of sintered NpO 2 pellets enclosed in Zircaloy cladding were irradiated in the High Flux Isotope Reactor for 2 to 4 cycles to determine if an oxide pellet and Zircaloy cladding would be usable candidates for 238 Pu production. The pellets were sintered to a high fraction of theoretical density (TD) and melt wires were placed in small holes that had been drilled in the center of selected pellets to determine if the pellet centers exceeded desirable operating temperatures. After irradiation, the targets were punctured to determine the internal target pressure and the fission gas release. None of the targets had excessive pressure, and fission gas release was in the range of 4 to 38%. The targets were then cut into segments for radiochemical analysis, and metallography (MET) mounts were created to examine the pellet microstructure and to search for the melt wires to determine if they had melted. Three of the four targets resulted in successful MET mounts; the two-cycle pellets were too friable to be handled. No signs of pellet melting were noted, and unfortunately, none of the melt wires could be recovered. The results indicate that this pellet/clad design offers a practical option for 238 Pu production.

36 MATERIALS SCIENCE↗

DOE OSTI2021

Cesium Batch Contact Equilibrium Testing of Crystalline Silicotitanate (CST) Sieve Cuts in SRS Average Simulant and Examination of CST Samples Aged in Caustic and Simulant in Support of Tank Closure Cesium Removal 1A (TCCR-1A)

Batch contact testing to determine cesium equilibrium loading on Crystalline Silicotitanate ion exchange media in Savannah River Site Average Waste Simulant at 25 °C indicated that smaller diameter particles isolated by sieving pretreated CST media may load slightly higher (<10%) amounts of cesium, though the differences are within analytical uncertainty. In addition, ion exchange media sub-samples stored in 2-4 M NaOH and caustic simulant solutions for ~2.5 years were examined by optical microscopy and the 3 M NaOH sample was also analyzed to determine whether changes in the particle size distribution occurred during storage. No visual indications of particle attrition or agglomeration were observed for any sample. Particle size analysis indicated that a slight decrease occurred in the average particle diameter following contact with 3 M NaOH (541 µm average diameter versus 566 µm for the pretreated CST prior to contact). A small increase (from 0 to <0.5 wt. %) in the number of particles ranging from 271 and 322 µm was also observed for the CST sample contacted with 3 M NaOH relative to a sample of the original pretreated material. However, this small change could be due to sub-sampling differences or analytical uncertainty. It does not appear that small particles are formed to a significant degree during CST caustic contact or that small particles which do form (presumably from attrition of larger particles during pretreatment) load significantly more cesium than the bulk material. Minimal other negative consequences were observed associated with CST extended caustic or simulant contact, except for the tendency for more concentrated salt solutions to form some salt crystals which deposit on the media over time.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2021

Oxidation Testing and Examination of AGR-2 Particles

Post-irradiation examination (PIE) oxidation testing is being performed at Oak Ridge National Laboratory (ORNL) on fuel particles from the second Advanced Gas Reactor (AGR) irradiation experiment (AGR-2). Tristructural isotropic (TRISO)-coated particles containing mixed uranium carbide and uranium oxide (UCO) fuel kernels were taken from AGR-2 Compact 5-4-2 and heated in the Furnace for Irradiated TRISO Testing (FITT) under varying oxidizing conditions. Details on Compact 5-4-2 PIE can be found in a previous report (Hunn et al. 2018).

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2021

An Examination of the Hydropower Licensing and Federal Authorization Process

Site-permitting and regulation are necessary to ensure hydropower projects (both original and relicensed) comply with statutory requirements and address multiple stakeholder priorities that consider a range of factors, including water quality, species protection, cultural resource impacts, and recreation. However, the time involved in acquiring a license for an individual hydropower project can be highly variable by project, leading to increased project costs, financial risks, and uncertainties. In part, this variability is the result of a regulatory structure that has evolved over time to include multiple approvals and compliance requirements administered by the Federal Energy Regulatory Commission (FERC), U.S. Army Corp of Engineers (USACE), federal land management agencies, federal and state resource agencies, and Indian Tribes. Ultimately, the time, benefits, costs, and risks to developers associated with hydropower regulatory processes and/or the preparation (e.g., studies) required for regulatory agency review are not well documented or synthesized in the public domain, which may increase uncertainty and variability within the process. This report addresses these needs by presenting results of a comprehensive examination of hydropower licensing including quantitative and qualitative analyses of timelines, causal factors, and their combined effect on risk and costs to developers.

13 HYDRO ENERGY↗

DOE OSTI2022

Examining the Ice-Nucleating Particles from the Eastern North Atlantic (ExINP-ENA) (Field Campaign Report)

The Examining the Ice-Nucleating Particles from the Eastern North Atlantic (ExINP-ENA) field campaign was conducted at the U.S. Department of Energy (DOE) Atmospheric Radiation Measurement (ARM) user facility’s Eastern North Atlantic (ENA) observatory on Graciosa Island, Azores (39.0916° N, 28.0257° W). The ExINP-ENA campaign began on October 1, 2020, and collected data until March 28, 2021, for a total of 179 days of data generated, with a 45-day intensive operational period (IOP) from October 10 to November 24. This campaign was funded by the DOE Office of Science Early Career Research Program through grant DE-SC001879. This grant contains funding for three field campaigns. The previous field campaign at the Southern Great Plains (SGP) site in Oklahoma, ExINP-SGP, was completed in 2020 (36.6073° N, 97.4876° W), and the upcoming field campaign at the North Slope of Alaska (NSA), ExINP-NSA, will take place from October 2021 at the National Oceanic and Atmospheric Administration (NOAA) Barrow Atmospheric Baseline Observatory (71.3230° N, 156.6114° W).

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2021

Demonstration of Dimensional and Microstructural Postirradiation Examination Capabilities on MiniFuel Disk Specimens

This work demonstrates two new MiniFuel postirradiation examination (PIE) capabilities, laser profilometry and serial sectioning, for future use on alpha-U specimens for the upcoming Mini-99 irradiation campaign. Representative U–Mo disk specimens—3 mm in diameter and approximately 0.75 mm in thickness—were subjected to dimensional measurements using standard calipers, as well as a new Keyence CL-3000 series laser profilometry system designed to measure the surface of both sides of the disk simultaneously. The laser profilometry system captured thickness gradients across the specimens as large as 0.2 mm. Additionally, because of the limitations inherent to the use of calipers, caliper measurements consistently overestimated the initial volume of MiniFuel disk specimens compared to the laser profilometry method by up to 5%. However, the results show that optimal data collection and analysis procedures are crucial to avoiding significant artifacts during data collection that can lead to large errors (approximately 10%). Serial sectioning using a combination of ion milling and electron imaging was also demonstrated for the analysis of micron-sized control volumes. Nanometer- to micron-scale porosity was resolved on a representative U–Mo specimen before irradiation, even when the surface of the specimen appeared free of porosity. Future efforts to relate microstructural features (porosity, fission product distributions, and so on) to macroscale effects (dimensional changes, thermal conductivity degradation) require accurate characterization methods such as those demonstrated in this work. These advanced PIE capabilities will be applied to optimized alpha-U specimens for the upcoming Mini-99 neutron irradiation campaign.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2022

Sister Rod Destructive Examinations (FY2021) Appendix E Mechanical Testing

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

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 J: Leaching of High Burnup Used Nuclear Fuel in De-ionized Water

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. The leaching experiment was a part of a larger study by Yadukrishnan Sasikumar in defending his doctoral thesis at The Open University, School of Engineering and Innovation [13]. It utilized post-CIRFT Sister Rod test specimens that were slated for disposal. The leaching experiment aims to understand the trends in the radiolytic dissolution of High Burnup Spent Nuclear Fuel (SNF) when exposed to water (e.g., in-reactor or in-pool cladding failures). Specimens from a baseline M5-clad rod and a heat-treated M5 rod were cut from the fractured CIRFT specimens and placed in 100 mL de-ionized water for a period of 128 days. Both radial and axial sections were cut to provide different surface areas of fuel in contact with the leachate. During the four-month exposure period, aliquot samples of the leachate were analyzed gamma spectroscopy and inductively coupled plasma mass spectrometry (ICP-MS). The analysis quantified the amount of fuel leached into the solutions and provided individual isotopic release fractions (of 30+ isotopes) which were compared as a function of time and surface area of fuel exposed.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗