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DOE OSTI2015

Test Plan for the Boiling Water Reactor Dry Cask Simulator

The thermal performance of commercial nuclear spent fuel dry storage casks are evaluated through detailed numerical analysis . These modeling efforts are completed by the vendor to demonstrate performance and regulatory compliance. The calculations are then independently verified by the Nuclear Regulatory Commission (NRC). Carefully measured data sets generated from testing of full sized casks or smaller cask analogs are widely recognized as vital for validating these models. Recent advances in dry storage cask designs have significantly increased the maximum thermal load allowed in a cask in part by increasing the efficiency of internal conduction pathways and by increasing the internal convection through greater canister helium pressure. These same vertical, canistered cask systems rely on ventilation between the canister and the overpack to convect heat away from the canister to the environment for both above and below-ground configurations. While several testing programs have been previously conducted, these earlier validation attempts did not capture the effects of elevated helium pressures or accurately portray the external convection of above-ground and below-ground canistered dry cask systems. The purpose of the investigation described in this report is to produce a data set that can be used to test the validity of the assumptions associated with the calculations presently used to determine steady-state cladding temperatures in modern vertical, canistered dry cask systems. The BWR cask simulator (BCS) has been designed in detail for both the above-ground and below-ground venting configurations. The pressure vessel representing the canister has been designed, fabricated, and pressure tested for a maximum allowable pressure (MAWP) rating of 24 bar at 400 deg C. An existing electrically heated but otherwise prototypic BWR Incoloy-clad test assembly is being deployed inside of a representative storage basket and cylindrical pressure vessel that represents the canister. The symmetric single assembly geometry with well-controlled boundary conditions simplifies interpretation of results. Various configurations of outer concentric ducting will be used to mimic conditions for above and below-ground storage configurations of vertical, dry cask systems with canisters. Radial and axial temperature profiles will be measured for a wide range of decay power and helium cask pressures. Of particular interest is the evaluation of the effect of increased helium pressure on allowable heat load and the effect of simulated wind on a simplified below ground vent configuration. While incorporating the best available information, this test plan is subject to changes due to improved understanding from modeling or from as-built deviations to designs. As-built conditions and actual procedures will be documented in the final test report.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2015

Crystal Plasticity Model of Reactor Pressure Vessel Embrittlement in GRIZZLY

The integrity of reactor pressure vessels (RPVs) is of utmost importance to ensure safe operation of nuclear reactors under extended lifetime. Microstructure-scale models at various length and time scales, coupled concurrently or through homogenization methods, can play a crucial role in understanding and quantifying irradiation-induced defect production, growth and their influence on mechanical behavior of RPV steels. A multi-scale approach, involving atomistic, meso- and engineering-scale models, is currently being pursued within the GRIZZLY project to understand and quantify irradiation-induced embrittlement of RPV steels. Within this framework, a dislocation-density based crystal plasticity model has been developed in GRIZZLY that captures the effect of irradiation-induced defects on the flow stress behavior and is presented in this report. The present formulation accounts for the interaction between self-interstitial loops and matrix dislocations. The model predictions have been validated with experiments and dislocation dynamics simulation.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2016

Advanced Energy Harvesting Control Schemes for Marine Renewable Energy Devices

The Advanced Energy Harvesting Control Schemes for Marine Renewable Energy Devices (Project) investigated, analyzed and modeled advanced turbine control schemes with the objective of increasing the energy harvested by hydrokinetic turbines in turbulent flow. Ocean Renewable Power Company (ORPC) implemented and validated a feedforward controller to increase power capture; and applied and tested the controls on ORPC’s RivGen® Power Systems in Igiugig, Alaska. Assessments of performance improvements were made for the RivGen® in the Igiugig environment and for ORPC’s TidGen® Power System in a reference tidal environment. Annualized Energy Production (AEP) and Levelized Cost of Energy (LCOE) improvements associated with implementation of the recommended control methodology were made for the TidGen® Power System in the DOE reference tidal environment. System Performance Advancement (SPA) goals were selected for the project. SPA targets were to improve Power to Weight Ratio (PWR) and system Availability, with the intention of reducing Levelized Cost of Electricity (LCOE). This project focused primarily reducing in PWR. Reductions in PWR of 25.5% were achieved. Reductions of 20.3% in LCOE were achieved. This project evaluated four types of controllers which were tested in simulation, emulation, a laboratory flume, and the field. The adaptive Kω2 controller performs similarly to the non-adaptive version of the same controller and may be useful in tidal channels where the mean velocity is continually evolving. Trends in simulation were largely verified through experiments, which also provided the opportunity to test assumptions about turbine responsiveness and control resilience to varying scales of turbulence. Laboratory experiments provided an essential stepping stone between simulation and implementation on a field-scale turbine. Experiments also demonstrated that using “energy loss” as a metric to differentiate between well-designed controllers operating at an optimal tip-speed ratio set-point is difficult, which anticipated the outcome from field experiments. The clear message is that the feedforward Kω2 controller out-performs the feedback controllers in almost all aspects and modes of evaluation. The controllers proved a substantial improvement over the baseline performance of the TidGen® turbine, in terms of energy capture. The effects of noise-contaminated angular velocity signals were investigated and validated by simulation as an explanation for the performance limitations observed for TidGen® turbine operations in Eastport, Maine. Measurements of loads performed as part of the laboratory testing indicate that there are limited differences in average axial thrust force between control architectures. This suggests that none of the control strategies are likely to substantially affect loads on the turbine support structure. Velocity measurements during the ORPC RivGen® turbine deployment at Igiugig, Alaska, in 2014 were used to assess the variability of the river flow. Results suggest that the river flow is approximately steady, in the mean sense, at any particular location in the river, with random turbulent fluctuations that are around 10% of the mean flow. The mean flow in the center channel of the river is 2.5 m/s, with reductions near the riverbanks and in the shallows. Spectral analysis and lagged correlation results indicate that temporal fluctuations at a given point are dominated by large scale fluctuations, such that measurements at the turbine location are just as useful for inflow control implementation as upstream measurements. At this site, and likely at many other river sites, flow is generally steady at a given location, but flow varies dramatically between locations, particularly laterally across the river. The primary result is that a lateral change in position of a few meters results in changes to flow speed that far exceed the turbulence fluctuations at any given location. The turbulence is dominated by long time scales. Following final system tests, the RivGen® device was submerged and each evaluated controller was tested across a range of gain/set point values and filter configurations for a minimum of 5 minutes, with longer runs attempted for well-performing cases. In addition to testing controllers during the 2015 deployment season, LGL Alaska Research Associates Inc. (LGL) performed a fish monitoring study in compliance with Alaska Department of Fish and Game fisheries habitat permit for the project. During the season, LGL reviewed 10% of 179 one-hour blocks of footage (6 minutes on the hour) and documented a total of over 1200 fish in the vicinity of the RivGen® device, including over 800 salmon smolt and over 350 adult salmon. No evidence of adverse effects including passage delay by upstream migrating salmon was noted. This is an important result for future deployments and has a direct impact on commercial system designs.

16 TIDAL AND WAVE POWER↗

DOE OSTI2016

Results for the Aboveground Configuration of the Boiling Water Reactor Dry Cask Simulator

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2017

A thermal conductivity model for U-Si compounds

U 3 Si 2 is a candidate for accident tolerant nuclear fuel being developed as an alternative to UO 2 in commercial light water reactors (LWRs). One of its main benefits compared to UO 2 is higher thermal conductivity that increases with temperature. This increase is contrary to UO 2 , for which the thermal conductivity decreases with temperature. The reason for the difference is the electronic origin of thermal conductivity in U 3 Si 2 , as compared to the phonon mechanism responsible for thermal transport in UO 2 . The phonon thermal conductivity in UO 2 is unusually low for a fluorite oxide due to the strong interaction with the spins in the paramagnetic phase. The thermal conductivity of U 3 Si 2 as well as other U-Si compounds has been measured experimentally [1-4]. However, for fuel performance simulations it is also critical to model the degradation of the thermal conductivity due to damage and microstructure evolution caused by the reactor environment (irradiation and high temperature). For UO 2 this reduction is substantial and it has been the topic of extensive NEAMS research resulting in several publications [5, 6]. There are no data or models for the evolution of the U 3 Si 2 thermal conductivity under irradiation. We know that the intrinsic thermal conductivities of UO 2 (semi-conductor) and U 3 Si 2 (metal) are very different, and we do not necessarily expect the dependence on damage to be the same either, which could present another advantage for the silicide fuel. In this report we summarize the first step in developing a model for the thermal conductivity of U-Si compounds with the goal of capturing the effect of damage in U 3 Si 2 . Next year, we will focus on lattice damage. We will also attempt to assess the impact of fission gas bubbles.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2016

Development of Macroscale Models of UO 2 Fuel Sintering and Densification using Multiscale Modeling and Simulation

Light water reactor fuel pellets are fabricated using sintering to final densities of 95% or greater. During reactor operation, the porosity remaining in the fuel after fabrication decreases further due to irradiation-assisted densification. While empirical models have been developed to describe this densification process, a mechanistic model is needed as part of the ongoing work by the NEAMS program to develop a more predictive fuel performance code. In this work we will develop a phase field model of sintering of UO 2 in the MARMOT code, and validate it by comparing to published sintering data. We will then add the capability to capture irradiation effects into the model, and use it to develop a mechanistic model of densification that will go into the BISON code and add another essential piece to the microstructure-based materials models. The final step will be to add the effects of applied fields, to model field-assisted sintering of UO 2 . The results of the phase field model will be validated by comparing to data from field-assisted sintering. Tasks over three years: 1. Develop a sintering model for UO 2 in MARMOT 2. Expand model to account for irradiation effects 3. Develop a mechanistic macroscale model of densification for BISON

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2017

High temperature high velocity direct power extraction using an open-cycle oxy-combustion system

The implementation of oxy-fuel technology in fossil-fuel power plants may contribute to increased system efficiencies and a reduction of pollutant emissions. One technology that has potential to utilize the temperature of undiluted oxy-combustion flames is open-cycle magnetohydrodynamic (MHD) power generators. These systems can be configured as a topping cycle and provide high enthalpy, electrically conductive flows for direct conversion of electricity. This report presents the design and modeling strategies of a MHD combustor operating at temperatures exceeding 3000 K. Throughout the study, computational fluid dynamics (CFD) models were extensively used as a design and optimization tool. A lab-scale 60 kWth model was designed, manufactured and tested as part of this project. A fully-coupled numerical method was developed in ANSYS FLUENT to characterize the heat transfer in the system. This study revealed that nozzle heat transfer may be predicted through a 40% reduction of the semi-empirical Bartz correlation. Experimental results showed good agreement with the numerical evaluation, with the combustor exhibiting a favorable performance when tested during extended time periods. A transient numerical method was employed to analyze fuel injector geometries for the 60-kW combustor. The ANSYS FLUENT study revealed that counter-swirl inlets achieve a uniform pressure and velocity ratio when the ports of the injector length to diameter ratio (L/D) is 4. An angle of 115 degrees was found to increase distribution efficiency. The findings show that this oxy-combustion concept is capable of providing a high-enthalpy environment for seeding, in order to render the flow to be conductive. Based on previous findings, temperatures in the range of 2800-3000 K may enable magnetohydrodynamic power extraction. The heat loss fraction in this oxy-combustion system, based on CFD and analytical calculations, at optimal operating conditions, was estimated to be less than 10 percent. Furthermore, the heat transfer design removed approximately 7 MW/m2. The results observed in the lab-scale system were employed to develop a 1-MW scaled prototype. Scaling methods were based on critical design criteria found in similar systems, aimed at replicating combustion flow fields and reducing possible instabilities. A numerical simulation of the combustor wall was developed for a combined thermal steady model and static structural model. This combined model was developed predict combined stress parameters within the wall during testing conditions. Both models were developed within ANSYS FEA software package. The relative accuracy presented as well major performance parameters are discussed to assess the design's validity and ensure safety. The scaled prototype was manufactured through selective laser melting (SLM)-based additive manufacturing to reduce lead times and increase geometrical complexity. Additional CFD models were developed to optimize coolant manifold system parameters and perform a parametric study on channel geometry. An investigation on coolant manifold geometry demonstrated improvements in channel flow distribution when enlarging manifold lengths and increasing the number of tubes feeding into the flow. A three-dimensional model based on a single channel was developed to capture the effect of variable properties and thermal stratification. All cases in the simulation exhibited higher wall temperatures and lower convective coefficients than those determined through 1-D analytical equations. This implies that pressure and velocity safety factors must be implemented during system operation. Overall, the findings made in this investigation are thought to be of value to researchers and industrial practitioners when designing oxy-fuel direct power extraction systems operating at temperatures exceeding 3000 K. In addition to this, the implementation of the developed technology at pilot and commercial scales could result in a significant improvement in the efficiencies of heritage and next-generation power cycles.

03 NATURAL GAS↗

DOE OSTI2017

Thermal-Hydraulic Results for the Boiling Water Reactor Dry Cask Simulator.

The thermal performance of commercial nuclear spent fuel dry storage casks is evaluated through detailed numerical analysis. These modeling efforts are completed by the vendor to demonstrate performance and regulatory compliance. The calculations are then independently verified by the Nuclear Regulatory Commission (NRC). Carefully measured data sets generated from testing of full sized casks or smaller cask analogs are widely recognized as vital for validating these models. Recent advances in dry storage cask designs have significantly increased the maximum thermal load allowed in a cask in part by increasing the efficiency of internal conduction pathways and by increasing the internal convection through greater canister helium pressure. These same canistered cask systems rely on ventilation between the canister and the overpack to convect heat away from the canister to the environment for both aboveground and belowground configurations. While several testing programs have been previously conducted, these earlier validation attempts did not capture the effects of elevated helium pressures or accurately portray the external convection of aboveground and belowground canistered dry cask systems. The purpose of this investigation was to produce validation-quality data that can be used to test the validity of the modeling presently used to determine cladding temperatures in modern vertical dry casks. These cladding temperatures are critical to evaluate cladding integrity throughout the storage cycle. To produce these data sets under well-controlled boundary conditions, the dry cask simulator (DCS) was built to study the thermal-hydraulic response of fuel under a variety of heat loads, internal vessel pressures, and external configurations. An existing electrically heated but otherwise prototypic BWR Incoloy-clad test assembly was deployed inside of a representative storage basket and cylindrical pressure vessel that represents a vertical canister system. The symmetric single assembly geometry with well-controlled boundary conditions simplified interpretation of results. Two different arrangements of ducting were used to mimic conditions for aboveground and belowground storage configurations for vertical, dry cask systems with canisters. Transverse and axial temperature profiles were measured throughout the test assembly. The induced air mass flow rate was measured for both the aboveground and belowground configurations. In addition, the impact of cross-wind conditions on the belowground configuration was quantified. Over 40 unique data sets were collected and analyzed for these efforts. Fourteen data sets for the aboveground configuration were recorded for powers and internal pressures ranging from 0.5 to 5.0 kW and 0.3 to 800 kPa absolute, respectively. Similarly, fourteen data sets were logged for the belowground configuration starting at ambient conditions and concluding with thermal-hydraulic steady state. Over thirteen tests were conducted using a custom-built wind machine. The results documented in this report highlight a small, but representative, subset of the available data from this test series. This addition to the dry cask experimental database signifies a substantial addition of first-of-a-kind, high-fidelity transient and steady-state thermal-hydraulic data sets suitable for CFD model validation.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2017

Modeling 3D PCMI using the Extended Finite Element Method with higher order elements

This report documents the recent development to enable XFEM to work with higher order elements. It also demonstrates the application of higher order (quadratic) elements to both 2D and 3D models of PCMI problems, where discrete fractures in the fuel are represented using XFEM. The modeling results demonstrate the ability of the higher order XFEM to accurately capture the effects of a crack on the response in the vicinity of the intersecting surfaces of cracked fuel and cladding, as well as represent smooth responses in the regions away from the crack.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2016

Results for the Aboveground Configuration of the Boiling Water Reactor Dry Cask Simulator

The thermal performance of commercial nuclear spent fuel dry storage casks are evaluated through detailed numerical analysis. These modeling efforts are completed by the vendor to demonstrate performance and regulatory compliance. The calculations are then independently verified by the Nuclear Regulatory Commission (NRC). Carefully measured data sets generated from testing of full sized casks or smaller cask analogs are widely recognized as vital for validating these models. Recent advances in dry storage cask designs have significantly increased the maximum thermal load allowed in a cask in part by increasing the efficiency of internal conduction pathways and also by increasing the internal convection through greater canister helium pressure. These same canistered cask systems rely on ventilation between the canister and the overpack to convect heat away from the canister to the environment for both above and belowground configurations. While several testing programs have been previously conducted, these earlier validation attempts did not capture the effects of elevated helium pressures or accurately portray the external convection of aboveground and belowground canistered dry cask systems. The purpose of the current investigation was to produce data sets that can be used to test the validity of the assumptions associated with the calculations used to determine steady-state cladding temperatures in modern dry casks that utilize elevated helium pressure in the sealed canister in an aboveground configuration. An existing electrically heated but otherwise prototypic BWR Incoloy-clad test assembly was deployed inside of a representative storage basket and cylindrical pressure vessel that represents a vertical canister system. The symmetric single assembly geometry with well-controlled boundary conditions simplifies interpretation of results. The arrangement of ducting was used to mimic conditions for an aboveground storage configuration in a vertical, dry cask systems with canisters. Transverse and axial temperature profiles were measured for a wide range of decay power and helium cask pressures. Of particular interest was the evaluation of the effect of increased helium pressure on peak cladding temperatures (PCTs) for identical thermal loads. All steady state peak temperatures and induced flow rates increased with increasing assembly power. Peak cladding temperatures decreased with increasing internal helium pressure for a given assembly power, indicating increased internal convection. In addition, the location of the PCT moved from near the top of the assembly to ~1/3 the height of the assembly for the highest (8 bar absolute) to the lowest (0 bar absolute) pressure studied, respectively. This shift in PCT location is consistent with the varying contribution of convective heat transfer proportional with of internal helium pressure.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2016

Point Spread Function Estimation and Uncertainty Quantification

An important component of analyzing images quantitatively is modeling image blur due to effects from the system for image capture. When the effect of image blur is assumed to be translation invariant and isotropic, it can be generally modeled as convolution with a radially symmetric kernel, called the point spread function (PSF). Standard techniques for estimating the PSF involve imaging a bright point source, but this is not always feasible (e.g. high energy radiography). This work provides a novel non-parametric approach to estimating the PSF from a calibration image of a vertical edge. Moreover, the approach is within a hierarchical Bayesian framework that in addition to providing a method for estimation, also gives a quantification of uncertainty in the estimate by Markov Chain Monte Carlo methods.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2019

Tonopah Test Range Air Monitoring: CY2018 Meteorological, Radiological, and Wind Transported Particulate Observations

In 1963, the U.S. Department of Energy (DOE) (formerly the Atomic Energy Commission [AEC]), implemented Operation Roller Coaster on the Tonopah Test Range (TTR) and an adjacent area of the Nevada Test and Training Range (NTTR) (formerly the Nellis Air Force Range). This operation resulted in radionuclide-contaminated soils at the Double Tracks site and Clean Slate I, II, and III sites. This report documents observations made during ongoing monitoring of radiological, meteorological, and dust conditions at stations installed adjacent to the Clean Slate sites and at the TTR Sandia National Laboratories (SNL) Range Operations Center (ROC). The primary objective of the monitoring effort is to support the DOE Environmental Management Nevada Program (EM NV) in the safe remediation of the environmental legacy of nuclear device development and testing by determining if wind blowing across the Clean Slate sites is transporting particles of radionuclide-contaminated soil beyond the physical and administrative boundaries of the sites, and to provide information for designing long-term monitoring of the sites. The monitoring program in 2018 included five stations. Station 400, located within TTR Area 3 and near the ROC, monitors conditions near the local workforce center. Stations 401 and 403 are located on the northern and southeastern perimeter fence lines, respectively, of the Clean Slate III site. Stations 404 and 405 are along the northern and eastern boundary fence, respectively, at Clean Slate II. The stations are generally downwind of the contaminated areas during either northwesterly or southerly winds, which are the predominant wind directions. The stations—which are similar in design to the Community Environmental Monitoring Program (CEMP) stations operating at locations surrounding the Nevada National Security Site and TTR—include meteorological instruments and continuous-flow, low-volume air samplers. Three pressurized ionization chambers for measuring gamma energy are in use at Stations 400, 401, and 403. Saltation sensors and saltation traps are deployed at the stations adjacent to the Clean Slate sites. Detailed meteorological data are recorded on data loggers, with periodic uploads via a satellite system to the Western Regional Climate Center (WRCC) at Desert Research Institute (DRI), to monitor instrument and site conditions. Air filter samples are collected every two weeks and the deposits in the saltation traps are collected when a sufficient sample mass for analysis has accumulated (generally a six- to eight-month interval). Monitoring at TTR in calendar year (CY) 2018 provided surveillance of both ambient conditions, and ground disturbance associated with remediation activities at Clean Slate II and III. The first half of CY2018 data from Stations 404 and 405 at Clean Slate II were collected during remediation activities at that site, and data collected during the final third of the year at Stations 401 and 403 at Clean Slate III coincided with remediation work at the site. Ambient conditions prevailed at Station 400 throughout the year. Dust transport by suspension and saltation is strongly dependent on wind speed. Concentrations of PM 10 (particulate matter of aerodynamic diameter ≤10 micrometers [μm], a size fraction of small particles that are suspended in the air and can be easily inhaled) remain low until winds exceed approximately 32 kilometers per hour (km/hr) (20 miles per hour [mph]). Saltation particle counts also increase above the same general threshold wind speed. Wind speeds in excess of 32 km/hr (20 mph) occur less than three percent of the time at the sites. Ground disturbing remediation activities were carried out at Clean Slate II from October 31, 2017, until July 26, 2018. Station 404 is located closest to the remediation area and is downwind of the area when winds are from the south. By late November, analysis of dust from the air sampler at Station 404 registered increases in plutonium-239+240 ( 239+240 Pu) concentrations. Peak plutonium concentrations, accompanied by elevated gross alpha concentrations and the detection of americium-241 ( 241 Am) by gamma spectroscopy, occurred between March and May 2018. During spring and early summer of 2018, elevated radionuclide concentrations were also measured in dust collected from the air sampler at Station 405, which is more than twice the distance from the remediation activity as Station 404. A minor but sustained increase in gross alpha concentration of suspended dust collected at Stations 400, 401, and 403 was also observed starting in May 2018 and continuing into August. Stations 401 and 403 are approximately 4.8 to 6.4 km (three to four miles) from Clean Slate II and Station 400 is approximately 13 km (eight miles) from that site. The radionuclide content of material that saltated into the passive Big Spring Number Eight (BSNE) traps during the Clean Slate II remediation period increased in both the traps facing toward and away from the fenced contamination area at Station 404, with the largest increases in concentration (almost five times the previous 239+240 Pu concentration) observed in the traps facing the fenced area. The radionuclide concentration in material in the trap facing away from the fence more than doubled from that measured in 2017. A similar increase was observed for the saltation trap facing away from the fenced area at Station 405, although no increase was observed for material captured in the trap facing the fenced area. Particles ranging in size from 50 to 500 µm generally move by saltation processes and are not expected to significantly contribute to dose for someone breathing in the standard respiratory zone for adult humans (1.5 to 1.7 m [4.9 to 5.6 ft] above ground level) because they are too large to be entrained in the air as suspended dust. Remediation activities at Clean Slate III began on September 5, 2018, and continued until a brief hiatus started on December 20, 2018. Although Station 401 is much closer to the remediation area than Station 403, the first increase in gross alpha and 239+240 Pu concentrations was noted in dust from filters collected at Station 403 in early November 2018. The highest radionuclide concentrations of 2018 at the Clean Slate III stations were recorded in air samples taken from Stations 401 and 403 in late December 2018 and these concentrations were comparable between the two station locations. Gamma rate data measured by the PICs was slightly higher than the annual average at Stations 401 and 403 after remediation activities began, but no single measurement was outside of the range observed in 2018 prior to remediation activities. No increase in radionuclide concentration was observed for the Clean Slate III remediation time period on air filters collected from the other stations. Radiological monitoring at Station 400—which is located at the ROC, and therefore the closest regularly staffed work location to the Clean Slate sites—recorded a higher mean gross alpha activity from dust collected on air sampler filters than in previous years. The individual biweekly air filters yielded measurements of gross alpha that were at or below the mean plus one standard deviation measured in CY2017, except for the period from April 25, 2018, through September 12, 2018. Nonetheless, gamma spectroscopy of all air filters from Station 400 identified only naturally occurring radionuclides, with no detection of americium-241 ( 241 Am) (which is used as an indicator of plutonium-241[ 241 Pu]). Alpha spectroscopy of selected air filters collected at Station 400 did not detect plutonium-238 ( 238 Pu) or 239+240 Pu above the analytical detection limit. Gross beta and gamma exposure rate data were comparable to data from regional CEMP stations. No saltation traps are deployed at Station 400. Considering the ambient monitoring periods during CY2018, the monitoring stations adjacent to the Clean Slate sites recorded above-background 238 Pu and 239+240 Pu concentrations (SNL, 1998; Turner et al., 2003) in samples collected by passive saltation traps and on selected air filters. These observations were consistent with previous years and indicated that radionuclide movement occurred under ambient conditions by processes of both saltation and suspension. The presence of radionuclides in all saltation traps, both upwind and downwind of the fenced contamination areas, was consistent with previous radiological survey results (EG&G, 1979) that show lower concentration radiologically contaminated material dispersed outside the fenced area. Although 239+240 Pu concentrations in the air filter samples were sometimes orders of magnitude higher than background, the concentrations were below risk-based action levels defined for an industrial area worker scenario (U.S. DOE, 2014). The interception of airborne dust with above-background radionuclide concentrations demonstrates that dispersal processes are continuing. Strong winds are the driver for both suspension and saltation of dust and soil. The recorded wind speed and PM10 during remediation activities at Clean Slate II and III identified discrete wind events lasting approximately five to eight hours each, which accounted for the greatest PM 10 concentrations at the monitoring stations. These events captured the effect of winds from the northwest and from the south. The observed differences in dust loading and radionuclide concentrations for the monitoring stations when they were either upwind or downwind of the contamination area identify the remediation area as a source of plutonium contaminated dust. The increase in concentration of radionuclides in airborne dust during the remediation activities, compared with measurements under previous ambient conditions (mean 239+240 Pu concentrations during remediation activities are approximately nine to 40 times higher compared to pre-remediation concentrations, depending on monitoring station), highlights the impact of land disturbance on wind-borne contaminant transport from the Clean Slate test areas. The meteorological and particulate matter monitoring indicated that conditions for wind-borne contaminant movement exist at the Clean Slate sites, and that transport of radionuclide-contaminated soil by both suspension and saltation occurred under ambient conditions and accelerated when the sites were disturbed. The 239+240 Pu alpha spectroscopy results indicated that airborne concentrations during remediation activities ranged from 2 × 10-16 to 380 × 10-16 µCi/ml. These results can be compared to the derived air concentration limit for 239 Pu of 6 × 10-11 µCi/ml for occupational workers contained in Code of Federal Regulations 10 CFR 835, Occupational Radiation Protection. Even though the air sampling results document an increase in concentration during remediation activities, the observed concentrations are less than 0.06 percent of the occupational limit. The Corrective Action Unit (CAU) closure strategy uses a risk-based approach, whereby acceptable contaminant concentrations are determined as a function of anticipated human exposure.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2019

Initial Development of an Improved Creep-Fatigue Design Method that Avoids the Separate Evaluation of Creep and Fatigue Damage and Eliminates the Requirement for Stress Classification

This report describes a method for capturing the effect of strain range, temperature, hold time, and elastic follow up on the cyclic life of a material undergoing uniaxial load. Developing design correlations of this type requires methods for extrapolating experimental data as a function of hold time and follow up factor. Various extrapolation methods are developed and discussed here and recommendations are developed for the final approaches to be adopted for design use. The report also describes comparisons between the new creep-fatigue design method, described here, and current creep-fatigue design methods in the ASME Boiler and Pressure Vessel Code and associated nuclear Code Cases. These comparisons demonstrate several advantages of the new method: it is easier to execute and is less over conservative than many current approaches. This report, along with a companion on extending these results to multiaxial load and on combining load cycles, represents the accumulation of several years of work on the development of this new approach to creep-fatigue design, combining an elastic perfectly plastic analysis method with simplified model tests measuring the effect of elastic follow up on creep-fatigue cyclic life. The conclusions to this report describe a path forward to developing the required design data for high temperature advanced reactor structural materials and guiding the adoption of the new method in the ASME Boiler and Pressure Vessel Code and related standards.

36 MATERIALS SCIENCE↗

DOE OSTI2020

Calculation of Friction Factors in Heat Pipes Using CFD in Support of the Sockeye Code

A heat pipe is two-phase heat transfer device which relies on surface tension and capillary pressure to provide a very efficient heat transfer mechanism. Currently, there is interest in designing micro nuclear power reactors using high temperature heat pipes to provide totally passive cooling. To support this, Sockeye is being developed as a heat pipe simulation capability. To support the development of Sockeye, individual phenomena must be tested. This work focuses on applying a CFD model to evaluate friction factors for use in Sockeye. A CFD model has been developed in Nek5000 which simulates each component fluid, i.e. sodium liquid and vapor, independently and captures the effects of the wick on friction factor. The model tests the effect of the wick permeability and the thickness of the wick occupied by each fluid component. The thickness of the wick occupied by each component can be directly related to the local vapor volume fraction from the Sockeye heat pipe model. Results from the CFD model indicate that friction factor in the liquid flow decreases with increasing wick permeability, while the friction factor in the vapor flow increases with increasing wick permeability. In the liquid, this is likely a direct result of the increased cross sectional area available for the flow. For the vapor, this is explained as the wick acting like a rough wall, while the increased area has only a negligible impact. Results for the tests of the thickness of the wick occupied by each fluid showed a thresholding behavior for both liquid and vapor. When the thickness of the wick occupied by each fluid was increased, it increased the effect of the wick, but only up to a certain point. Once a certain thickness was reached, the friction factors remained constant. When the fluid occupied only a very small fraction of the wick, friction factors returned to nominal values.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2021

Simulating Boundary Region Plasma Instabilities

The boundary regions of low-temperature plasmas are known to be susceptible to kinetic instabilities, which can affect the energies and fluxes of particles directed at the material boundary. For example, both the ion acoustic instability as well as an instability near the electron plasma frequency have been observed. Particle-in-cell (PIC) simulation is a tool that, alongside experiments, can capture the effects these instabilities have on the particle distribution functions. Ultimately, simulations can determine under what conditions these effects are significant by comparing to theoretical predictions and explore conditions unamenable to experiments.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2022

A New 1-step Arrhenius Decomposition Model for PBX 9501: Calibration with Isochoric-Adiabatic High-Activation-Energy Asymptotics and Uncertainty Quantification

Here we present a new 1-step Arrhenius thermal decomposition model of PBX 9501. As opposed to previous studies, we use high-energy asymptotic theory, and previously published equations of state to parameterize the model to experimental critical-time data. The model parameters were fit to experimental data using a bootstrapping procedure to capture the effects of experimental uncertainty. Subsequent implementation of the model in a chemicalkinetics ODE solver shows good agreement of times to ignition vs initial temperature in isochoric thermal explosion calculations with the results of the high-energy asymptotic theory. We also compare the resultant ZND structures to those of one of our previously calibrated burn models.

45 MILITARY TECHNOLOGY, WEAPONRY, AND NATIONAL DEF↗

DOE OSTI2023

Development of HPC based phase field simulations tool for modification of alloy morphology to enhance material properties during additive manufacturing (AM) process

Currently, additive manufacturing (AM) technology is extensively used to manufacture aerospace components because of the unique advantages of the technique in producing custom designs, complex geometries in a near-net fashion that significantly reduces the manufacturing cost, and improved energy efficiency. However, the thermodynamic properties of existing aerospace alloys and the thermal conditions that prevail in most of the powder-bed based additive manufacturing processes lead to undesirable columnar / columnar-dendritic microstructures that promote solidification cracking during the process, and the development of anisotropy in the mechanical properties of the as-built components. Time consuming, energy-intensive post AM treatments are required to recover the mechanical properties of the wrought components for which the existing alloy compositions were designed for. However, novel alloy compositions, that exploit the AM thermal conditions to produce fine, equiaxed grain structures in the as-built condition, with mechanical properties equal to or exceeding those of the wrought work-horse alloy, Ti-6Al-4V has recently been demonstrated in Ti-Cu alloys. Significant energy savings up to 66% can be obtained for a typical aerospace component through digitally designing the AM process, process parameters, and alloy composition. The current project focused on developing a fundamental understanding of the evolution of the columnar to equiaxed transition (CET) occurring during solidification under AM thermal conditions in Ti-Cu and Ti-Cu-X alloys using high-fidelity phase field (PF) simulations using the leadership class computing facilities that exist in the national laboratories. The simulations were able to capture the effect of alloy and process conditions on CET, and clearly showed the beneficial effect of a ternary solute addition to Ti-Cu binary alloys on CET. The simulations indicated that bulk nucleation in the liquid ahead of the solidifying epitaxial front was promoted by a large, transient, thermal undercooling promoted by the mismatch between the growth rate of the dendrite tips in the epitaxial front and the imposed solidification rate. AM experiments performed at Raytheon Technologies Research Center using the same thermal conditions used in the PF simulations indicated the formation of equiaxed grains, although the grain size was bigger than the ones reported in the literature. On the other hand, the equiaxed grain size predicted by PF simulations were smaller than the grain size of Ti-Cu alloys reported in the literature. The industry will follow up the existing work in a future program that would involve further optimization of the process for the Ti-Cu-X alloys to demonstrate the application of the process and the alloy to a specific aerospace component.

36 MATERIALS SCIENCE↗

DOE OSTI2022

Additive Manufacturing Flaw Assessment Methodology

An evolution fatigue data and flaw tolerance of components produced using the Powder Bed Fusion (PBF) Additive Manufacturing (AM) process is documented in this report. Initial differences in fatigue data for AM components compared to smooth bar fatigue data indicated a need for a more detailed analysis of AM data available in technical literature. The investigation was initiated to support the development of a fatigue analysis methodology for AM components to support the of codification of AM technology for pressure equipment. The project was initiated to collect and analyze stainless steel 304L and 316L AM fatigue test data and corresponding process and quality information to develop S-N and E-N based fatigue data representation. Additional AM fatigue test data including Inconel Ti-6-4 and aluminum alloys were also considered for comparison purposes Metallic AM parts tend to contain various forms of defects distributed throughout the part. If an AM part is subjected to fatigue loading in service, a fatigue analysis needs to be performed during the design process to ensure an acceptable service life for the part. Post-process machining and polishing do not to improve fatigue resistance in any significant degree. The low cycle fatigue regime is of particular interest to this project in support of flaw acceptance criteria currently under development by ASME’s BPTCS/BNCS. Internal defects become exposed as external surface defects during machining for the machining of the AM part to final dimensions. This implies that as long as inherent AM defects are within a controlled limit in terms of both size and distribution characteristics, the corresponding fatigue test data in terms of either S-N (stress life) or E-N (strain life) can be investigated and characterized to establish fatigue properties of AM parts for design and fatigue evaluation purposes. The resulting S-N or E-N curves and their scatter bands can be used to derive fatigue design allowable stress values by capturing the effects of distributed discontinuities within an acceptable limit.

36 MATERIALS SCIENCE↗