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All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

Considerations for Hydride Moderator Readiness in Microreactors

The emergence of microreactor technology has helped to drive supporting nuclear materials qualification and acceptance processes. One essential component in these small reactors is a solid moderator, which typically consists of metal hydride and cladding. While the behavior and performance of metal-hydride moderators go back to early advanced reactor development for nuclear-powered aviation and space propulsion, there remains a knowledge gap in the understanding of hydrogen transport–related phenomena and irradiation performance for hydride moderators. This impacts the acceptance/qualification of hydride moderators for microreactors. The goal of this technical note is to lay out a potential path forward for advanced moderator qualification and acceptance for designers and developers of microreactors. The proposed approach has benefited from a model microreactor core with the design parameters of a hydride moderator. Based on the model core and design parameters, a simple chart was developed for the major challenges of hydride moderators where potential incidents, causes, effects, and resolutions are described. The relation between the offered resolutions and the maturity of the metal-hydride moderator technology was emphasized using technological readiness. Technological readiness levels (TRLs) were clustered to three sets: physical phenomena related, reactor irradiations, and system demonstration. Some essential needs to fill the knowledge gaps are discussed for physical phenomena–related TRLs. For reactor irradiations, the importance of identifying goals and priorities is stressed to reach certain TRLs. For system demonstration, it is noted that metal-hydride moderator qualification must comply with the overall microreactor design.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Basic Energy Sciences Roundtable: Foundational Science to Accelerate Nuclear Energy Innovation

Energy security, availability, and reliability are among the greatest challenges facing the nation and the planet. An abundant potential source of energy resides in the fundamental atomic building blocks of the universe in the form of nuclear fission and fusion reactions. In fact, energy from nuclear fission currently provides the majority of the world’s zero-carbon electricity, and future fusion energy systems offer great promise; carbon-free nuclear energy technologies can be key to the world’s decarbonized energy future. Although contemporary fission systems use well-established technologies to supply safe and efficient baseload power, they could be more fuel efficient and less costly. Moving beyond massive light-water fission reactors to a variety of advanced nuclear systems—which will vary in size and operate in extremes of temperature, corrosivity, and other parameters—will place stringent conditions on materials and chemical systems. New demands will be placed on the coolants and solvents, the materials, and the monitoring tools used in these reactors. Fusion-based nuclear energy will require superior materials to withstand extremely high temperatures, plasma exposure, radiation damage, and implanted gases. The advantages associated with these new fission and fusion technologies will be realized only through continued advancements in the fundamental science underpinning our knowledge of the physics and chemistry of nuclear systems gained via improved experimental and computational methods. In July 2022, the U.S. Department of Energy’s Office of Basic Energy Sciences—in coordination with the Offices of Nuclear Energy, Fusion Energy Sciences, and Advanced Scientific Computing Research—held a virtual roundtable titled “Foundational Science to Accelerate Nuclear Energy Innovation” to discuss the scientific and technical barriers for advanced nuclear energy systems. Five priority research opportunities were identified to address these scientific and technical challenges and to accelerate progress toward the realization of next-generation fusion and fission energy systems. The foundational science gaps inhibiting the advancement of nuclear energy technologies are identified and tackled in five priority research opportunities. These opportunities pave the way to accelerate the development and ultimately the adoption of new nuclear energy systems. They include the fundamental aspects of ion-electron interactions; novel properties of next-generation coolants and solvents; interfacial dynamics, not only in solids, but in other aspects of nuclear reactors; novel operando and in situ monitoring and sensing; and artificial intelligence to accelerate condensed phases discovery. Building on the foundation established by previous Basic Energy Sciences workshops, these opportunities encompass recent advances in fundamental knowledge and focus on the experimental and computational methods needed to resolve major technical challenges for nuclear energy technologies. Through developing fundamental scientific insight as well as pushing the frontiers of modeling complex systems and probing the operation of materials and chemical systems in extreme environments, research motivated by the priorities identified here will further develop the promise, potential, and utilization of nuclear energy for a clean energy future.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2023

INL Report: Multiphysics Modeling and Simulation of Deimos, an Advanced Reactor Experiment

When designing a novel reactor, nuclear experiments are essential to validate the predictive capability of modeling/simulation tools and to justify the investment of a full-scale prototype. Being able to accurately predict temperature reactivity coefficients is of high importance to reactor designers as it impacts the safety and performance of the system. Deimos is a proposed graphite-moderated, beryllium-reflected, high assay low-enriched uranium (HALEU) tri-structural isotropic (TRISO) fueled experiment for NCERC. Deimos is a valuable experiment for validating the predictive performance of modeling and simulation tools since it comprises a relatively thermal energy spectrum with 84% thermal neutrons causing fission, 15% epithermal neutrons causing fission, and 1% fast neutrons causing fission. Additionally, by electrically heating the experiment, reactivity can be validated at various temperatures. Deimos will serve as a testbed for future advanced reactor concepts.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2021

Post-irradiation examination of optical components for advanced fission reactor instrumentation

The use of optical instrumentation in advanced nuclear fission systems, such as molten salt reactors, liquid metal-cooled reactors, and high-temperature gas-cooled reactors, has the potential to enhance reactor safety and economic performance through in situ and online measurement of reactor conditions. Selection of suitable optical components, such as optical windows and fibers, is essential for operation of optical instrumentation in intense radioactive and thermal environments inherent to nuclear reactor systems. We present the development and performance of a self-contained and mobile post-irradiation examination system for rapid characterization of the optical properties of materials. The instrument combines linear absorption and nanosecond Z-scan modules in a compact, relocatable design. The system mobility allows for the evaluation of optical samples at the site of irradiation, minimizing the delay between extraction from the irradiation site and optical characterization. This provides nearly real-time information on the material performance under simultaneous irradiation and thermal annealing, simulating the relevant conditions for the use of those components in nuclear power systems.

Morgan, Bryan William (ORCID:0000000224668764)↗
DOE OSTI2024

ADVANCED CONSTRUCTION TECHNOLOGY INITIATIVE (ACTI)

Advanced reactor technologies have attracted considerable financial support, catalyzing innovation in the nuclear energy landscape. These next generation reactors are designed with enhanced passive safety systems and the potential for cost reductions. As these advanced reactors approach technological maturity, their commercial success also requires focused examination and essential support. Economic assessments in the nuclear energy sector often emphasize construction costs and the risk of scheduling delays as primary contributors to deployment expenditures. Traditionally, vital elements of nuclear energy deployment including civil/structural engineering, design sophistication and automation have been either undervalued or postponed in the development cycles. Additionally, the nuclear industry’s collective experience in nuclear project execution has diminished over the past several decades due to the infrequency of new plant constructions. Hence, The National Reactor Innovation Center’s (NRIC) Advanced Construction Technology Initiative (ACTI) program aims to reduce cost overruns and schedule slippages that have plagued the construction of nuclear power plant projects. With this initiative, NRIC is facilitating the development of advanced nuclear plant construction technologies and approaches through partnerships that would provide game-changing benefits to the construction of advanced nuclear power plants.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2026

Development of Digital Twin-Informed Predictive Maintenance for Critical Components in Advanced Reactors

Small modular reactors (SMRs) and microreactors, along with other advanced reactor (AR) technologies, are key to the future of nuclear energy. For these systems to achieve low operating costs, high reliability, and flexibility across applications, their operation and maintenance must be optimized. Digital twin (DT) technology is one of the technologies that enables real-time (or faster than real-time) monitoring and prognosis of critical components which are vital for operational efficiency, low costs, and enhanced safety of ARs, accelerating their deployment. DT technology provides dynamic virtual representation of physical assets by integrating real-time data, physics-based models, and advanced analytics, which is critical to optimizing the performance of the entire energy system throughout the life cycle. DTs empower engineers and operators to virtually explore different scenarios, configurations, and control strategies, allowing for the identification of optimal solutions that maximize reactor efficiency, safety, and economics.

22 - GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2022

Integration of Wireless Sensor Networks and Battery-free RFID for Advanced Reactors

To address an important need for Nuclear Power Plants (NPPs) to significantly reduce the amount of the required cables for sensor data communications, this Phase I SBIR effort successfully developed and demonstrated a novel low-cost proof-of-concept prototype of a secure wireless sensor network backbone communications system. This system combines commercially available low power, low cost XBEE wireless communications network and passive (battery-free) Radio Frequency Identification (RFID) systems to report individual sensor data and their location through the containment wall for rapid response to anomalies in nuclear facilities. This WIreless Sensing and Locating (WISLO) system network architecture allows non-intrusive wireless collection of sensor data with the sensor’s accurate location information from inside of the instrumentation or containment area with minimal need for power sources. The multi-node sensor data in the containment area is wirelessly transmitted to outside through the metal reinforced concrete walls without the need for any batteries. The WISLO system could be readily used in current reactor fleet and future advanced reactors, as well as in small modular reactors (SMR). The WISLO system is the first dual frequency battery-free trough the wall communications backbone system developed specifically for use in nuclear power plants. It not only can modernize the sensor monitoring practices in the existing reactor fleet, but also offers a secure, low-cost solution to advanced reactors and SMRs by removing cables and issues related to them such as cable integrity, reporting delays, and installation and maintenance costs. The intent is to improve process safety, reliability, efficiency, and cost effectiveness to the monitoring and maintenance process in current and future plants. As we address the next productization and manufacturing capabilities in the next phase, this system will serve the needs of many commercial and government applications in remote monitoring of sensor data that demand battery-free transmission of sensor data such as Internet-of-Things (IOT).

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2025

Mechanistic nuclear fuel performance modeling of uranium nitride

Uranium mononitride (UN) is a nuclear fuel candidate for advanced reactor designs and an alternative being considered for light water reactors due to its higher thermal conductivity and uranium density than UO 2 . As with any nuclear fuel, swelling and fission gas release are important factors for safety, while also being some of the hardest phenomena to predict with a high degree of confidence. Getting a grasp on the gas swelling behavior and release is crucial to lower the barrier for UN utilization. An accelerated swelling rate at high temperatures observed experimentally, sometimes referred to as “breakaway swelling,” further complicates the prediction of fuel performance of UN. A mechanistic model has been developed using a multiscale approach to describe the intragranular and intergranular fission gas behavior. Lower-length-scale calculations have been employed to inform models of the gas and self-diffusion behavior, resolution rate, and bubble shape. Leveraging previous work on high burnup UO 2 , two populations of intragranular bubbles are considered; small bulk bubbles and larger bubbles located along dislocations. The dislocation bubbles were found to be crucial to the overall swelling behavior, and the breakaway swelling transition was associated with the transition in the gas atom diffusion mechanism from an irradiation-induced athermal diffusion regime at lower temperatures to an intrinsic thermal equilibrium regime at higher temperatures, accelerating the growth of the dislocation bubbles. Similarly, the threshold for fission gas release was associated with the grain boundary vacancy diffusivity surpassing the gas atom diffusivity at sufficiently high temperatures, allowing the over-pressurized grain boundary bubble to grow in size and interconnect. Using thermo-mechanical models with the fission gas model, two integral fuel pin assessment cases were simulated. Finally, this work demonstrates the ability of a multiscale approach to accelerate the understanding of advanced fuel forms when experimental data is limited.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2025

Prioritizing Nuclear Materials for SAM-3 Neutron Irradiation Campaign: Structural and Cladding Materials Candidates

This report outlines a framework for selecting structural and cladding materials for the Nuclear Science User Facilities (NSUF) SAM-3 neutron irradiation campaign to support the advancement of nuclear energy technologies. The document begins with an introduction that provides background context, highlights the motivations for launching a new irradiation campaign, and defines the overall objectives. The core of the report describes the design considerations for the irradiation campaign, including capsule configurations, irradiation temperature ranges, and target dose levels (defined by displacements per atom, or dpa). The material recommendation was guided by the Specimen Identification and Prioritization (SIP) Working Group, a multidisciplinary team of experts representing national laboratories, academia, industry, federal government and agency. This group played a central role in identifying candidate materials, evaluating technical justifications, and ensuring alignment with boarder programmatic goals. A detailed set of criteria for material prioritization is then presented, taking into account reactor relevance, performance gaps, advanced manufacturing methods, and emerging material classes. Based on the input of SIP working group, specific materials were selected and justified for inclusion in the irradiation campaign by the NSUF leadership and its U.S. Department of Energy (DOE)-Office of Nuclear Energy (NE) management. The final section provides recommended capsule designs, summarizing critical parameters such as material type, fabrication method, sample geometry, irradiation conditions, and specimen quantities. This report serves as a foundation for executing a focused and high-impact neutron irradiation campaign aimed at addressing key materials challenges for both existing and advanced nuclear reactors.

36 - MATERIALS SCIENCE↗
DOE OSTI2024

Nuclear Requalification of the ATR Core

The Advanced Test Reactor (ATR) creates a unique, high neutron flux materials testing environment that subsequently causes neutron embrittlement damage to its beryllium reflector. The reflector is eventually required to be replaced during a reactor Outage. Concurrently, a piece-for-piece core replacement is conducted to maintain reactor functionality called a core internals changeout (CIC). Once changeout is complete, ATR Reactor Engineering utilizes previous CIC data, notably 1977-1994 CIC data, to conduct predictive criticality analysis on the new, unirradiated core. However, CIC data has been inconsistently reported over the years making it difficult, and in some cases impossible, to utilize. These inconsistencies arise in various forms of not using correct units, inconsistent diagram usage, and not portraying the same kind of data similarly across the reports. To work around this inconsistency issue, Reactor Engineering is implementing the use of several new neutronic modeling codes that utilize modern computation speeds and methods to model the new core in different criticality environments. Further validation is then conducted by nuclear testing and bringing the reactor critical and conducting various irradiation tests. Upon completion and certification that the reactor passed all testing requirements, ATR can once again re-start normal operations.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2022

Modularity-at-scale for advanced reactors presentation

Modularity options have been limited for traditional nuclear energy deployment due to the conventional light water reactor (LWR) safety requirements, such as high pressure retaining heavy and robust containment structures. However, a relatively new regulatory approach called ‘Functional Containment’ has potential to allow less expensive and more flexible designs for non-LWRs. Functional containment provides flexibility in design and deployment based on risk-informed and performance-based criteria, so that reactors are not over-designed. Non-nuclear industry has successfully used modular design approaches in automotive, aerospace, chemical processing, building construction, and ship building. These industries have shown that modular construction reduces construction time by around 30% - 50% compared to the conventional stick-built approach. The nuclear industry can use similar approaches to reduce construction time and costs, balanced with safety requirements, using the functional containment approach. This paper discussing the background of modularity in nuclear energy, examples of less learned, modularity approaches in non-nuclear industries and the potential of cost and schedule savings through the emerging regulatory design flexibilities potentially enabling combination of modular deployment at different scales.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2025

Status Report on the Development of Cladding Inner-wall and Outer-wall Coatings

Advanced cladding is critical for nuclear reactors with enhanced performance in radiation tolerance, neutron transparency and reactor safety. Using advanced cladding will ensure the adequate thermal conductivity and mechanical stability of the cladding base material, corrosion resistance and high-temperature coolant compatibility of the cladding surface, and chemical stability in the cladding inner wall against fuel cladding chemical interaction (FCCI). An innovative cladding with a three-layer structure (i.e., a modified outer surface, a robust clad base material, and a modified inner wall) promises to meet all these requirements. In this status report, the initial efforts on the development of cladding inner-wall and outer-wall coatings are summarized. The activities covered in this report are (1) High-resolution TEM studies of TiN/HT-9 interface atomic structure and chemistry after ion irradiation, (2) High-resolution TEM studies of TiN/14YWT ODS interface atomic structure after thermal cycling, (3) Inner-wall TiN coating for an experimental 14YWT ODS cladding, and (4) Corrosion test of TiN coated Ziracloy-4 bar samples.

36 - MATERIALS SCIENCE↗
DOE OSTI2025

Final report on assessment of molten salt corrosion testing of unirradiated and ion irradiated advanced manufactured high entropy alloys

Generation IV reactors and future fusion reactor designs have led to more demanding materials performance requirements due to their increased operating temperatures, corrosive coolants, and increased radiation doses compared to the current light-water reactor fleet. Among the innovative nuclear technologies under development, molten salt reactors stand out for their potential to offer superior fuel utilization, intrinsic safety characteristics, and economic viability. Of the proposed Generation IV designs, the gas fast reactor operates at 450 to 850°C and the molten salt reactor operates at 565 to 850°C, with the molten salt reactor design needing molten salt corrosion resistant materials [1, 2]. These increased temperatures and more extreme corrosion environments necessitate higher material performance, such as creep strength, radiation-tolerant microstructures, corrosion resistance, and high-temperature tensile properties. Hastelloy-N, a nickel-based alloy with additions of molybdenum and chromium, has been successfully employed to contain molten fluoride salt at temperatures up to 705°C. However, Hastelloy-N becomes embrittled upon neutron irradiation, primarily due to the accumulation of helium produced by (n,a) transmutation reactions. Furthermore, the corrosive nature of molten fluoride and chloride salts presents a formidable challenge, as these salts can react with and dissolve alloying elements such as Cr, Mo, and Fe, leading to selective leaching, loss of protective oxide layers, and accelerated degradation. High entropy alloys (HEAs) and refractory high entropy alloys (RHEAs) have emerged as a prominent area of interest, due to their ability to achieve tailored chemical compositions for specific applications. Unlike conventional alloys, HEAs are characterized by having multiple principal elements in equimolar or near equimolar ratios, leading to an unconventional alloying strategy [3]. This alloying strategy is believed to promote unique properties, such as single-phase stabilization of chemically compatible elements, lattice distortion effects due to atomic radius differences, and proposed sluggish diffusion effects. For extreme-environment applications, RHEAs have garnered much research interest because of the possibility of creating relatively ductile materials that can operate in extremely high-temperature environments, beyond the operating temperatures where other Ni-based superalloys begin to lose strength [4-6]. Idaho National Laboratory (INL) initiated a joint international effort with the Czech Republic to explore the feasibility of manufacturing HEAs for high-temperature nuclear applications using advanced manufacturing. This effort was funded at INL by the United States Department of Energy's Office of Nuclear Energy under the Advanced Reactor Technologies and Advanced Materials and Manufacturing Technologies (AMMT) Program. The HEAs were specifically designed for the corrosive and irradiation environments experienced in gas-cooled fast reactors, molten salt reactors, and fusion power. These alloys have been manufactured by multiple processes to determine the impact of manufacturing processes on the performance of the alloys in corrosive and irradiation environments. Preliminary molten salt corrosion testing showed that equimolar MoNbTiV and MoNbTi alloys exhibit exceptional performance, with arc-melted variants demonstrating only minimal degradation after 1000 hours of exposure to molten chloride salt at 700°C. Conversely, Nb2TiVZr2 showed significant molten salt corrosion susceptibility and microstructural instability during high-temperature molten salt exposures, and was, therefore deemed unfit for molten salt reactor applications. The MoNbTiV, MoNbTi, and Nb2TiVZr2 alloys were further evaluated through ion irradiation experiments conducted at the Michigan Ion Beam Laboratory at the University of Michigan. The microstructural stability and the evolution of irradiation-induced defects were characterized to assess the irradiation resistance of each of these alloys.

36 - MATERIALS SCIENCE↗