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682 records · Page 38
All sourcesNASA NTRSDOE OSTI
DOE OSTI2020

Test Report for the Qualification Testing of the ORNL-SFC-W-1 Special Form Capsule

Three prototypes the ORNL-SFC-W-1 special form capsules (SFCs) of the same design were evaluated to determine if the requirements of Title 49, Code of Federal Regulations (CFR), Part 173.469, Tests for Special Form Class 7 (Radioactive) Materials, were met. The results of the special form tests are documented in this test report. This report describes the special form testing activities performed on the three ORNL-SFC-W-1 capsules. The test units were designated as TU-1, TU-2 and TU-3. TU-1 was subjected to leak testing, impact testing and percussion testing. TU-1 was leak tested using the leak rate test specified in 49 CFR 173.469(a)(4)(i). The impact test was conducted according to the requirements in 49 CFR 173.469 (b)(1). The percussion test that was carried out on TU-1 was conducted in accordance with 49 CFR 173.469 (b)(2). Both TU-2 and TU-3 were subjected to a leak rate test as specified in 173.469(a)(4)(i) and a heat test as specified in 49 CFR 173.469(b)(4). Each test unit was leak tested before and after these respective tests. The leak rate tests performed were helium back-pressure tests and bubble tests as specified in American National Standards Institute (ANSI) N14.5-2014.The measured leak rates were converted to standard condition leak rates as specified in American Society for Testing and Measurement (ASTM) E 493. The determined standardized leak rates obtained from the test and the calculations for all the test units met the requirements for special form certification. The testing was performed under the direction of the Oak Ridge National Laboratory (ORNL) Package Testing Program (PTP).

42 ENGINEERING↗
DOE OSTI2022

Summary of Geometric Parameters and Their Effects on Performance of U-10Mo Fuel Plates

A monolithic plate-type fuel system has been under development to convert high-performance test reactors from highly enriched uranium to low-enrichment uranium fuels and is now moving into the qualification phase, a predecessor to the timely conversion of the target reactors. To qualify this fuel system, the plates must meet safety standards and perform well in a reactor. The plates must maintain mechanical integrity, exhibit geometric stability, and have stable and predictable in-reactor behavior. The requirement to maintain mechanical integrity under normal operating conditions is primarily demonstrated by successful testing. However, each high-performance reactor employs a distinct design, resulting in distinct plate geometries, with unique features, attributes, irregularities, and tolerances. Due to the abundance of such distinct geometric varieties, a single “generic” plate geometry capturing all extremes is not achievable. It is also impractical to test each of these proposed designs in a reactor. This limitation necessitates cautious evaluations since the thermomechanical response of a plate with a certain geometry may not be representative for a plate with a significantly different geometry. To address concerns related to in-reactor plate performance, large set of sensitivity studies were performed. These parametric studies aimed to better understand irradiation performance, while evaluating the sensitivity of results to various modeling inputs, including geometric, operational, and material parameters. This work studied selected geometric parameters based on provided fuel specifications and performed a series of parametric simulations. The resulting temperature, displacement, and stress strains were comparatively evaluated to determine the effects of various geometric parameters. This draft provides a “high-level summary” of our parametric sensitivity studies and summarizes the key findings.

42 ENGINEERING↗
DOE OSTI2021

An investigation into the effects of cyclic strain rate on the high cycle and very high cycle fatigue behaviors of wrought and additively manufactured Inconel 718

Additive Manufacturing (AM) has increasingly been used to fabricate parts in aerospace applications, which may require service lives beyond ten-million cycles due to the imposed high loading frequencies. Understanding the very high cycle fatigue (VHCF) behavior of these additive manufactured (AM) parts is an important step towards their design and qualification processes. This study focuses on the high cycle fatigue (HCF) and VHCF behaviors of both wrought and laser beam-powder bed fusion (LB-PBF) fabricated Inconel 718 in machined/polished surface condition, emphasizing on the influence of test frequency (i.e., cyclic strain rate). Uniaxial, fully-reversed force- and stress-controlled fatigue tests were conducted utilizing a servo-hydraulic and an ultrasonic test system operating at 5 Hz and 20 kHz, respectively, on wrought as well as LB-PBF vertically and diagonally built specimens. Fatigue cracks in the majority of the specimens were found to initiate from intra-granular slip bands near or at the surface, which gives rise to strong anisotropy in fatigue resistance in LB-PBF specimens due to the presence of columnar grains along the build directions. Longer fatigue lives were obtained at 20 kHz, which was ascribed to possibly lower-than-intended stresses applied in the ultrasonic tests. The corrected stress-life fatigue data at 20 kHz were found to converge to the one obtained from conventional testing at 5 Hz, implying no effect of cyclic strain rate on the fatigue behavior of Inconel 718 regardless of the fabrication process. The findings of this work confirm the use of ultrasonic fatigue testing to expedite generation of AM materials data to keep up with the current demand; however, the applied stress may need to be corrected.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Moisture ingress in commercial steel drums: Water content determination, diffusion modelling and predicted permeation rates

Commercial steel drums underpin the global economy, playing a pivotal role in the storage and transportation of critical materials. Transported and stored materials, such as food, chemical and nuclear waste, can be sensitive to ambient conditions, particularly moisture that can enhance negative effects such as corrosion and material degradation. Although international standards and regulations are in place for the qualification of steel drums, there are no current testing requirements, established limits or boundaries for the permeation of moisture into the drums during transportation or storage. This work aims to provide insights into the moisture ingress over time into properly sealed steel drums and provides estimated moisture ingress rates over time through extrapolation. Water vapour transmission rate (WVTR) measurements through the gasket material at 10–40°C were 0.11–2.1 g/m 2 /day resulting in a permeation activation energy of 30.2 kJ/mol. Water sorption measurements and Karl Fischer titration (KFT) on ethylene propylene diene monomer (EPDM) gasket material revealed a decrease in equilibrium moisture saturation with increasing temperature. KFT measurements also revealed the presence of moisture within the adhesive and drum wall after exposure to ambient conditions. KFT and Fourier transform infrared spectroscopy (FTIR) show that moisture will desorb from the EPDM and drum wall after exposure to desiccating conditions, although a minimal amount of moisture will remain present. When sealed to the manufacturer's recommendations, the steel drums are effective in minimizing moisture ingress. In conclusion, in sealed empty drums, moisture ingress rates for 19-L drums were 0.4–1.5 mg/day at 25°C 15% relative humidity (RH) and increased to 7.1–8.8 mg/day at 40°C 90% RH, and moisture ingress rates for 210-L drums were 2.5 and 3.5 mg/day at field deployment conditions of 15.5°C 51.5% RH and 23°C 40% RH, respectively.

42 ENGINEERING↗
DOE OSTI2025

Laser Powder Bed Fusion Additive Manufacture Nb1Zr Development

Next generation fission and fusion nuclear reactors require materials that can withstand operating temperatures greater than 500 °C, neutron irradiation doses of up to 200 displacements per atom (dpa), and potentially corrosive coolants such as the alkali liquid metals sodium, lithium, and NaK (Na33K eutectic alloy). Refractory alloys, such as Nb1Zr (Nb-1wt%Zr) and Molybdenum alloy TZM (Mo-0.5wt%Ti-0.08wt%Zr) have been traditionally considered viable candidates for advanced fission and fusion reactor concepts. However, it is relatively difficult to generate complex geometries of interest from these alloys using traditional manufacturing methods. In addition, there needs to be a concentrated effort to address refractory metal challenges at elevated temperature operation. In order to generate complex geometries of interest, modern manufacturing techniques are considered to increase the technological readiness level (TRL), cost-effectiveness, and schedule savings. This work focused on the continued development of laser powder bed fusion (L-PBF) additive manufacturing (AM) to improve both design flexibility, evaluate microstructure and properties, and ultimately accelerate the TRL and qualification of these processes and alloys for components to potentially be put into service. Niobium alloy Nb1Zr was identified through a down-selection process outlined in previous reports as a candidate to develop in L-PBF AM. Historically, Nb1Zr had been explored for high temperature fast spectrum fission reactors for both terrestrial and space applications. Molybdenum alloy TZM has also been considered for these reactor concepts due to exceptional high-temperature strength, creep resistance, and stability under irradiation. L-PBF AM of TZM has previously been investigated at LANL under the Microreactor program, NASA, ORNL, and in academia. However, due to the crack prone nature of TZM, L-PBF AM of TZM resulted in significant microcracking and additional development is required to pursue viable maturation. Other AM methods have been found to be more successful in printing TZM, and those alternatives approaches are discussed in this effort. The efforts detailed in this report focused on continued development of Nb1Zr through L-PBF and development of TZM via L-PBF and electron powder bed fusion (E-PBF). The objective of this work was to further the development of these AM techniques for the chosen refractory alloys, elucidating and addressing associated challenges through characterization of several demonstration builds. At LANL, Nb1Zr builds were completed using an EOS M290 and M400 machines, and a refractory alloy-dedicated L-PBF system, the Xact Metal XM200G, was installed. The XM200G primary purpose was to do the Nb1Zr parameter development process; however, due to difficulties associated with the machine installation and qualification process, it was decided to pivot development to the larger M400 and M290 machines. Although the supply of Nb1Zr powder was limited, it was sufficient to generate sub-scale metallographic specimens for the purpose of parameter development. This was first accomplished on the EOS M400 then the M290 due to machine schedule availability. Further development of TZM has been initiated at the University of Texas El Paso (UTEP) under contract with LANL to use both a heated build envelope L-PBF machine and E-PBF machine that have been found in the literature to mitigate microcracking. UTEP was provided with TZM powder and build plates to support parallel TZM parameter development across both machines. As part of the contract, UTEP will also be conducting microstructural characterization once optimized process parameters have been identified. The optimized process parameters for each machine will be used to generate a series of metallographic, mechanical, and surface finish specimens for subsequent characterization and testing. In the next section, we provide a detailed discussion of the methodology used for investigating the feasibility of leveraging these alloys for use in advanced reactor applications.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Combining synchrotron X-ray diffraction, mechanistic modeling and machine learning for in situ subsurface temperature quantification during laser melting

Laser melting, such as that encountered during additive manufacturing, produces extreme gradients of temperature in both space and time, which in turn influence microstructural development in the material. Qualification and model validation of the process itself and the resulting material necessitate the ability to characterize these temperature fields. However, well established means to directly probe the material temperature below the surface of an alloy while it is being processed are limited. To address this gap in characterization capabilities, a novel means is presented to extract subsurface temperature-distribution metrics, with uncertainty, from in situ synchrotron X-ray diffraction measurements to provide quantitative temperature evolution data during laser melting. Temperature-distribution metrics are determined using Gaussian process regression supervised machine-learning surrogate models trained with a combination of mechanistic modeling (heat transfer and fluid flow) and X-ray diffraction simulation. The trained surrogate model uncertainties are found to range from 5 to 15% depending on the metric and current temperature. The surrogate models are then applied to experimental data to extract temperature metrics from an Inconel 625 nickel superalloy wall specimen during laser melting. The maximum temperatures of the solid phase in the diffraction volume through melting and cooling are found to reach the solidus temperature as expected, with the mean and minimum temperatures found to be several hundred degrees less. The extracted temperature metrics near melting are determined to be more accurate because of the lower relative levels of mechanical elastic strains. However, uncertainties for temperature metrics during cooling are increased due to the effects of thermomechanical stress.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Cost- and Risk-Based Seismic Design Optimization of Nuclear Power Plant Safety Systems

Seismic analysis, design, and qualification of systems, structures, and components (SSCs) is a significant contributor to the capital cost of a nuclear power plant. To reduce capital costs of advanced nuclear power plants and make commercial nuclear energy more competitive, innovations are needed in their structural design and construction, and not just in the reactor core and associated systems. Seismic isolation has been identified as an important cost-cutting technology that enables standardization of equipment across various sites. This paper develops and demonstrates a cost- and risk-based seismic design optimization of a representative safety system in a nuclear power plant with the dual goals of minimizing overnight capital cost and meeting safety goals. The design optimization can also include component seismic isolation, in which case, the optimized design includes a set of equipment that needs to be seismically isolated to minimize capital cost. The open-source codes MASTODON and Dakota are used for seismic probabilistic risk assessment and design optimization, respectively. A generic nuclear facility with a safety system comprising SSCs that are common to nuclear power plants is considered for the demonstration of the design optimization and is assumed to be located at the Idaho National Laboratory site. Generic costs and seismic design cost functions are assumed for the SSCs of the safety system. The sum of the costs of the SSCs is minimized in the optimization process, while the risk of failure of the safety system is provided as a constraint. Furthermore, results show that the optimization process reduces capital costs significantly while automatically prioritizing the safety of SSCs that contribute most to the risk of the safety system.

42 ENGINEERING↗
NASA NTRS2010

Launch Pad Flame Trench Refractory Materials

The launch complexes at NASA's John F. Kennedy Space Center (KSC) are critical support facilities for the successful launch of space-based vehicles. These facilities include a flame trench that bisects the pad at ground level. This trench includes a flame deflector system that consists of an inverted, V-shaped steel structure covered with a high temperature concrete material five inches thick that extends across the center of the flame trench. One side of the "V11 receives and deflects the flames from the orbiter main engines; the opposite side deflects the flames from the solid rocket boosters. There are also two movable deflectors at the top of the trench to provide additional protection to shuttle hardware from the solid rocket booster flames. These facilities are over 40 years old and are experiencing constant deterioration from launch heat/blast effects and environmental exposure. The refractory material currently used in launch pad flame deflectors has become susceptible to failure, resulting in large sections of the material breaking away from the steel base structure and creating high-speed projectiles during launch. These projectiles jeopardize the safety of the launch complex, crew, and vehicle. Post launch inspections have revealed that the number and frequency of repairs, as well as the area and size of the damage, is increasing with the number of launches. The Space Shuttle Program has accepted the extensive ground processing costs for post launch repair of damaged areas and investigations of future launch related failures for the remainder of the program. There currently are no long term solutions available for Constellation Program ground operations to address the poor performance and subsequent failures of the refractory materials. Over the last three years, significant liberation of refractory material in the flame trench and fire bricks along the adjacent trench walls following Space Shuttle launches have resulted in extensive investigations of failure mechanisms, load response, ejected material impact evaluation, and repair design analysis (environmental and structural assessment, induced environment from solid rocket booster plume, loads summary, and repair integrity), assessment of risk posture for flame trench debris, and justification of flight readiness rationale. Although the configuration of the launch pad, water and exhaust direction, and location of the Mobile Launcher Platform between the flame trench and the flight hardware should protect the Space Vehicle from debris exposure, loss of material could cause damage to a major element of the ground facility (resulting in temporary usage loss); and damage to other facility elements is possible. These are all significant risks that will impact ground operations for Constellation and development of new refractory material systems is necessary to reduce the likelihood of the foreign object debris hazard during launch. KSC is developing an alternate refractory material for the launch pad flame trench protection system, including flame deflector and flame trench walls, that will withstand launch conditions without the need for repair after every launch, as is currently the case. This paper will present a summary of the results from industry surveys, trade studies, life cycle cost analysis, and preliminary testing that have been performed to support and validate the development, testing, and qualification of new refractory materials.

Calle, Luz M.↗
NASA NTRS2015

Multiscale and Multiphysics Modeling of Additive Manufacturing of Advanced Materials

The objective of this proposed project is to research and develop a prediction tool for advanced additive manufacturing (AAM) processes for advanced materials and develop experimental methods to provide fundamental properties and establish validation data. Aircraft structures and engines demand materials that are stronger, useable at much higher temperatures, provide less acoustic transmission, and enable more aeroelastic tailoring than those currently used. Significant improvements in properties can only be achieved by processing the materials under nonequilibrium conditions, such as AAM processes. AAM processes encompass a class of processes that use a focused heat source to create a melt pool on a substrate. Examples include Electron Beam Freeform Fabrication and Direct Metal Deposition. These types of additive processes enable fabrication of parts directly from CAD drawings. To achieve the desired material properties and geometries of the final structure, assessing the impact of process parameters and predicting optimized conditions with numerical modeling as an effective prediction tool is necessary. The targets for the processing are multiple and at different spatial scales, and the physical phenomena associated occur in multiphysics and multiscale. In this project, the research work has been developed to model AAM processes in a multiscale and multiphysics approach. A macroscale model was developed to investigate the residual stresses and distortion in AAM processes. A sequentially coupled, thermomechanical, finite element model was developed and validated experimentally. The results showed the temperature distribution, residual stress, and deformation within the formed deposits and substrates. A mesoscale model was developed to include heat transfer, phase change with mushy zone, incompressible free surface flow, solute redistribution, and surface tension. Because of excessive computing time needed, a parallel computing approach was also tested. In addition, after investigating various methods, a Smoothed Particle Hydrodynamics Model (SPH Model) was developed to model wire feeding process. Its computational efficiency and simple architecture makes it more robust and flexible than other models. More research on material properties may be needed to realistically model the AAM processes. A microscale model was developed to investigate heterogeneous nucleation, dendritic grain growth, epitaxial growth of columnar grains, columnar-to-equiaxed transition, grain transport in melt, and other properties. The orientations of the columnar grains were almost perpendicular to the laser motion's direction. Compared to the similar studies in the literature, the multiple grain morphology modeling result is in the same order of magnitude as optical morphologies in the experiment. Experimental work was conducted to validate different models. An infrared camera was incorporated as a process monitoring and validating tool to identify the solidus and mushy zones during deposition. The images were successfully processed to identify these regions. This research project has investigated multiscale and multiphysics of the complex AAM processes thus leading to advanced understanding of these processes. The project has also developed several modeling tools and experimental validation tools that will be very critical in the future of AAM process qualification and certification.

Liou, Frank↗
NASA NTRSDate not supplied

Overview of the Dragonfly Entry Aerosciences Measurements (DrEAM) Suite

NASA Ames and Langley arepartnering with DLR to propose acomprehensive instrumentation suite known as the Dragonfly Entry Aerosciences Meas-urements (DrEAM). DrEAM being the first competed mission to fly EDL instrumentation as part of NASA’s Engineering Science Investigation (ESI).DrEAM will provide key aerothermodynamicdata and performance analysisfor Dragonfly’s forebody and backshell therma lprotection system (TPS),and also includes a DLR-provided Data Acquisition System(DAS).Titan’s atmosphere predominantly consists of nitro-gen (~98% by mole) with small amounts of methane(~2% by mole)and other trace gases. CN is a strong ra-diator and is found in nonequilibriumconcentrationsfor Titan entry. The accurate modeling of nonequilibrium CN radiation has proven to be a difficult task. Prompted by the Huygensmission, many experimental campaigns and analyses were performed to better understand the aerothermal environments experience by the probe dur-ing Titan entry[1].However, the Huygens probe carried no heatshieldinstrumentation. Therefore,the DrEAM instrumentation suite will significantly advance the state-of-the-art not only by documenting theenviron-ment and performance of Dragonfly’sentry system but also by making keymeasurements in Titan’s atmos-phere for thefirst time, thus providing new benchmark dataapplicable to entry science more generally. Current Measurement Goals: Aerothermal envi-ronments and TPS responsewill be measured using sen-sors similarto the Mars Entry, Descent, and Landing In-strumentation2 (MEDLI2) Integrated Sensor Plug(MISP) and the COMbined Aerothermaland Radiome-ter Sensor (COMARS)suite[2], with the latter supplied by DLR.For MEDLI2, MISP usedembedded thermo-couples (TCs) todirectly measure in-depth temperature of theTPS at several locations,which can also be used to infer surface environmentsvia inverse analysis. For DrEAM, the MISPstyle plugswill be known as Drag-onfly Sensors for Aero-Thermal Reconstruction (Drag-STR)plugs. On Schiaparelli, the COMARSsuite in-cludedthree total surface-mounted heatflux sensors, three pressure sensors, and one radiometer. For DrEAM, the COMARS package will be known as COmbined Sensor System for Titan Atmosphere (COSSTA). Atmospheric density measurements and capsuleaerodynamic data will be obtained throughthe onboard Inertial Measurement Unit (IMU),supple-mented by pressure transducers similar tothose used by the MEDLI Mars Entry AtmosphericData System (MEADS).The DrEAM pressure sensors will be known as Dragonfly Atmospheric Flight Transducers(DrAFT) Both DragSTR and DrAFThave flight heritagefrom MISP and MEADS on the MSLand Mars 2020mis-sions, and the COMARS suite successfullyflew on the ESA Schiaparelli EDMlander. A preliminary layout of the sensors is shown in Fig. 1. Because Dragonflyuses the same aeroshell provider (i.e., LockheedMartin) and materials for the TPS,with what are expected to be sim-ilar thicknesses as MSL and Mars 2020on both the heat shield and backshell, theDrEAMinstrumentation will look to utilize the same techniques and processes as de-veloped byMEDLI and MEDLI2for vehicle integra-tion. This commonality alsoenables DrEAMto lever-age the extensiveground test qualifications performed forMEDLI and MEDLI2 and claim substantial heritagefor this system.

A Brandis↗
DOE OSTI2023

In-Situ Monitoring Assisted Large-Scale Additive Manufacturing of Mild Steel and 316L Alloys for Nuclear Application

The Advanced Materials and Manufacturing Technologies (AMMT) Program is aimed at developing cross-cutting technologies in support of a broad range of nuclear reactor parts, and to maintain U.S. leadership in materials and manufacturing technologies for nuclear energy applications. The overarching vision of the AMMT program is to accelerate the development, qualification, demonstration and deployment of advanced materials and manufacturing technologies to enable reliable and economical nuclear energy. One of its three goals is to target big challenges and game-changing technologies, to realize the mission and vision of AMMT program. Based on this context, this multi-year work package focuses on understanding the current state of large-scale additive manufacturing (AM) technology for the deposition of 316L stainless steel materials for final components and mild steel for use in nuclear manufacturing processes. The targeted AM modality is directed energy deposition (DED), capable of fabricating components on the size scale of meters including valves, pumps, impellers. etc. that are challenging or difficult to source, especially when developing new systems or replacing obsolete components. Accordingly, the current writeup aims at providing a baseline literature survey on structure-property relationships in mild steel and 316L alloys. Also, information on preliminary trials to date involving these two alloys show tremendous potential of printing parts having complex geometry and thin- walled structures, such as nuclear valve and Hot isostatic Press (HIP) can, using wire based (Wire Arc Additive Manufacturing and Hybrid Additive Manufacturing) as well as blown powder DED machines. All of this is aimed towards (i) demonstrating the ability to fabricate large components for pressure boundary applications relevant to the nuclear community and nuclear manufacturing technology, and (ii) understanding the effect of different manufacturing technology on AM can production and post HIPed material for nuclear applications. Another target of this writeup is to compile various in-situ monitoring tools that have been incorporated for different DED AM modalities, in order to understand process variability during the entire fabrication process. This can be correlated with processing-structure-property response surfaces and would add confidence around process quality verification and ultimately component certification for nuclear applications.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2023

Evaluation of LPBF Steels for Nuclear Applications

This report provides an update on the prioritization of existing reactor materials for advanced manufacturing. This report is a Milestone 3 deliverable in FY2023, under work package CT-23AN130401 to support research and qualification activities supported by the Advanced Materials and Manufacturing Technologies (AMMT) program here at Argonne National Laboratory (ANL). The focus of FY23 for ANL included the determination of a decision criteria matrix for the prioritization of existing materials, the literature review of a select few Fe-based alloys, and working with vendors to obtain customized powders. The work package also includes fabricating test samples in a Renishaw AM400 Laser Powder Bed Fusion (LPBF) system and optimizing the process parameters. The major outcomes of this work package are: With collaborations from PNNL, ORNL, and INL, we were able to establish a decision criteria matrix containing a total of 6 categories and 31 different criteria. These will be used to downselect alloys for further evaluation; As part of that, 6 different Fe-based alloys were selected, 3 austenitic stainless steels (A709, D9, AFA) and 3 ferritic/martensitic steels (HT9, Grade 91, Grade 92). Customized powders were obtained from vendors in small quantities to fabricate initial prints to check printability of these specific alloys; A total of 72 single track experiments were performed on two alloy systems, 1 austenitic stainless steel (A709) and 1 ferritic/martensitic steel (Grade 91) in order to optimize the process parameters for the full 3d prints. The optimization led to the selection of 20 different processing conditions, 10 for each class of alloys; D9 and AFA alloys showed extensive cracking and porosity in the samples. This was due to less-than-ideal conditions present in the chamber during the deposition. A709 printed using the same process parameters showed almost fully dense samples with no noticeable porosity or any other defects. SEM and EBSD analysis revealed single phase FCC microstructure with cellular structure within the grains; HT9, Grade 91, Grade 92 alloys also showed no noticeable signs of cracking and ImageJ analysis showed porosity <0.5% in all conditions. While Grade 91 and Grade 92 showed single phase BCC microstructures, the presence of martensite laths was noted in HT9 alloy; Future work will include further characterization of these alloys to better understand the microstructural evolution during the 3d printing process.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
NASA NTRSDate not supplied

How Can We Efficiently Build A Spacecraft That Has Longevity? Experiences From the GSFC Perspective to Inform Lunar Exploration and Science Orbiter’s Architecture

Recent successes in NASA planetary science missions has shown that long-lived missions can yield significant science return. These missions, despite their longevity, were not planned to operate beyond their deign life. For example, the Lunar Reconnaissance Orbiter has a design life of 2-3 years, and yet we are entering its 14th year on orbit. Spacecraft longevity in practice has been related to: 1) mission class; 2) did we test it long enough and resolve all the anomalies to be beyond the early failure curve; 3) consumables budgets, and 4) how components are de-signed and tested. Mission class has been perceived as one of the primary ways to drive longevity. But higher mission class is a significant cost and mission driver. Parts selection only from the limited military standard parts and extensive parts qualification adds to development time and cost. Largely redundant (often erroneously interpreted as fully redundant) adds to launch mass and increases testing complexity (which may reduce the amount of testing in the nominal con-figuration). Lower Risk Posture (reflected in a higher mission class) drives significant additional processes and quality assurance analyses. Higher mission class also drives significantly greater sparing and life testing costs. This discussion focuses on whether this is indeed the best way to achieve longevity efficiently or whether there are more efficient ways to achieve longevity. Empirical evidence shows that lower mission classes that implement effective risk reduction and selective redundancy generally results in long life at a lower Spacecraft bus cost. By evaluating redundancy careful-ly, spacecraft cost can be lowered which can enable a more capable payload. Risk of the mission is highly dependent on the complexity of the mission and is only loosely dependent on Class of Mission. High complexity missions can have many single point failures and require the development of new technology, while lower class mission can have lower risk by baselining or incorporating: (selective) redundancy, fault-tolerant design, design for minimum risk, ability to reset, and/or design for graceful degradation. The team met with Goddard Space Flight Center Space Systems Mission Operations leaders to discuss which avionics have proven in flight to be the most reliable and which have had lifetime issues. The paper proposes a list of components to focus on for redundancy for a long-lived lunar mission. Reliability numbers are presented for both single string and dual string missions. The history of life-time performance versus planned mission life according to mission class is presented. A mission with well thought out selective redundancy and effective on the ground test program, can be expected to last well beyond its mission lifetime and provided enhanced return for the community. This approach minimizes project expenditures that do not retire significant risk and allows the project to focus risk mitigation efforts on those risks that will have a significant likelihood of threatening mission success. This is aided by keeping the amount of technology maturation and mission complexity low, while focusing effort on ensuring all component stress-ing parameters well within the bounds of their capabilities.

Lessons Learned↗
DOE OSTI2020

Drop Analysis of the Advanced Test Reactor Fresh Fuel Shipping Container with Heavier Low-Enriched Uranium Fuel Contents

The Advanced Test Reactor Fresh Fuel Shipping Container (ATR FFSC) is a rectangular stainless steel container used for shipping radioactive material. The container is described in the ATR FFSC Safety Analysis Report (SAR). Per the ATR FFSC SAR, the ATR FFSC is designated a Type AF-96 packaging per the definition of 10 CFR §71.4, and was originally designed to transport high enriched uranium (HEU) reactor fuel elements for the Advanced Test Reactor (ATR), the Advanced Test Reactor Critical (ATRC) facility, the Massachusetts Institute of Technology Reactor (MITR), and the University of Missouri Research Reactor (MURR). The Department of Energy, National Nuclear Security Administration’s (NNSA), Office of Material Management and Minimization (M3) is working with the Idaho National Laboratory (INL) to develop and qualify new low enriched uranium (LEU) fuels and technologies for use in the ATR, ATRC, MITR, and MURR reactors. The LEU fuel elements will weigh significantly more than the current HEU designs and, combined with their associated Fuel Handling Enclosures for packaging, some configurations will exceed the 50 lbf used in the ATR FFSC qualifying drop tests. There are LEU versions of MITR, MURR, and ATR fuel elements. However, for this evaluation, drop analysis of the ATR FFSC with only the heavier ATR Low Enrichment (LOWE) fuel element is considered in this evaluation because the LOWE fuel element is the heaviest of the considered LEU fuel elements. The ATR HEU fuel element and the ATR LOWE fuel element are identical in every design aspect except for the fuel meat inside the 19 fuel plates. The LEU fuel meats are made using a U-10Mo high-density foil rather than uranium dispersed in aluminum in the HEU fuel elements. The high density of the uranium in the LEU fuel meat increases the LOWE fuel element weight to just under 44 lbf (versus the 22.1 lbf weight of the tested ATR HEU fuel element). ATR fuel elements are placed in a thin-gauge aluminum weldment called a "Fuel Handling Enclosure" during packaging. The Fuel Handling Enclosure is used to cover and protect the element during loading and unloading operations. The ATR Fuel Handling Enclosure weighs about 15 lbf per the drawings in the ATR FFSC SAR and the weight is accounted for in this evaluation. Transporting the heavier LEU fuel elements require evaluation of two issues. The first is the effect of the increased mass of the LEU fuel elements on the survivability of the ATR FFSC package following the requisite drop qualifications. The second is the effect of the increased mass of the fuel plates on the fuel element during the same drops. The ATR FFSC containing an ATR HEU fuel element in an ATR Fuel Handling Enclosure was physically dropped multiple times to qualify the container as a Type AF-96 package. The ATR FFSC SAR describes the drop tests performed with an actual ATR HEU fuel element weighing 22.1 lbf contained in a 14.3 lbf Fuel Handling Enclosure for a total payload of 36.4 lbf. Those drop tests showed that the ATR FFSC maintained containment of the ATR HEU fuel element and the fuel element was not significantly damaged. (Containment herein is not defined as a leak tight but is retention of the radioactive contents.) The purpose of the evaluation is to analytically show that, for a similar set of tests, the ATR FFSC maintains containment of the heavier ATR LOWE fuel element and to assess the damage to the fuel element during the drops. The approach was to create finite element analysis (FEA) models that produce the same results as the physical drops. Those models were then used as the benchmarks for the follow-on analyses using the heavier contents. FEA models of the drops of ATR FFSC using up to a 115 lbf fuel element were run and evaluated. Likewise, drops of a LOWE fuel element weighing 44 lbf in the ATR FFSC were run and evaluated. It is important to note that this report was done at the quality level necessary to be included in a nuclear facility safety basis. However, it is not the intent of this report to conclude the suitability of the ATR FFSC for transporting the heavier payloads. This report only describes the results of the FEA as related to the required drop scenarios. Incorporation of the FEA into the safety basis will be evaluated by the ATR FFSC design authority. The physical drop tests of the HEU fuel element and FEA drop analysis for the LOWE fuel element showed noteworthy damage to the fuel plates. An aluminum protective block was conceived to mitigate the damage. The concept requires the blocks to be placed in the fuel element between the end boxes and fuel plates. Additional FEA drop analyses were performed using the protective block. The addition of the blocks is primarily intended to mitigate the damage to the LOWE fuel element fuel plates. However, FEA drop analyses of the ATR HEU fuel element with the blocks were also performed and included for information.

42 ENGINEERING↗
DOE OSTI2020

NMDQi Thermal-hydraulic Optimization, Analysis, and Scoping Tool (TOAST)

The Thermal-hydraulic Optimization, Analysis, and Scoping Tool (TOAST) is developed to support the thermal-hydraulic aspects for the design of optimal irradiation vehicles for the Nuclear Materials Discovery and Qualification initiative (NMDQi). TOAST is currently a MATLAB-based tool that utilizes a simplified steady-state analytical model where a radial thermal resistance circuit is utilized to account for conduction through up to 2 capsules, a gas gap, a thermal bond, a sample cladding, and a sample, as well as the convection from a water coolant outside the capsules. The geometry is discretized axially along the user-defined height of a basket with a user-defined number of points/nodes, essentially turning TOAST into a semi-2D heat transfer analysis utility for cylindrical irradiation vehicles with practically any configuration, solving for temperatures radially at multiple axial locations. TOAST utilizes a Graphical User Interface (GUI) in-which a user can define the geometrical layout, the materials utilized for each component, the coolant characteristics, and the required solution. The user can define the geometry by inputting the diameters, thicknesses, and heights for each component, whereas the materials are defined via the user-provided constant or variable thermal conductivities. The user can select the coolant's inlet temperature, pressure, and the pressure drop across the height of the problem (which is used to calculate the velocity of the flow). Finally, the user can choose to solve for a sample heat generation rate limit by inputting temperature limits for the sample and capsules or can choose to purely solve for the axial temperature distributions of each component by inputting a pre-selected heat generation rate. Either way, TOAST provides the user with axial temperature distributions of all the components including the coolant, and the heat generation rate limit as well as the maximum outlet coolant temperature. The user can also choose to do one of 6 sensitivity analyses in TOAST. The sensitivity analyses yield plots of the sensitivity of the heat generation rate limit, the maximum coolant temperature, and the pressure limit for the annular components due to perturbations in 1-2 unknown variables based on the selected sensitivity analysis. Benchmarks between computations in TOAST and equivalent 2D axis symmetric ABAQUS models are presented, showing that TOAST results are within less than 3% of ABAQUS results in most cases, and a maximum of 8% difference in some cases. The benchmarks also revealed that this uncertainty is tied to the selection of an appropriate Nusselt number correlation and appropriate thermal conductivities, which the user can do from the GUI. Regardless, TOAST is demonstrated as a computationally efficient, highly accessible, and accurate utility for optimization and scoping s of studies different irradiation vehicles.

42 ENGINEERING↗
DOE OSTI2025

Advancing Additive Manufacturing Through Artificial Intelligence–Powered, High-Throughput, Nondestructive Characterization and Process Optimization

This Cooperative Research and Development Agreement (CRADA) between Oak Ridge National Laboratory (ORNL) and ZEISS Industrial Metrology has demonstrated the transformative potential of artificial intelligence (AI)-enabled x-ray computed tomography (XCT) to accelerate the qualification and certification of additively manufactured (AM) parts. At the core of this effort is Simurgh, an AI-powered XCT reconstruction framework jointly advanced by ORNL and ZEISS that integrates computer-aided design (CAD) models, physics-based simulations, and deep learning to overcome the long-standing challenges of metal artifact correction, long scan durations, and limited flaw detectability in dense and geometrically complex components. Simurgh enables high-throughput, high-quality 3D reconstruction from sparse and fast scans, which reduces XCT acquisition times by more than an order of magnitude and simultaneously improves defect detection limits by up to fourfold compared with industry-standard approaches. This capability reduces scan costs by more than 50%, lowers labor overhead, and makes XCT characterization economically viable for routine industrial use. By enabling reliable flaw detection in minutes rather than hours, Simurgh facilitates real-time feedback loops for process parameter optimization, which was highlighted in a recent npj Computational Materials (a Nature journal) issue. In the published study, more than 100 alloy coupons were characterized within a single day. This work represents a tenfold acceleration in the development of novel AM alloys and processes compared with conventional workflows. The ZEISS collaboration has also demonstrated the scalability of Simurgh to diverse application domains, including aerospace, nuclear, automotive, and biomedical components; in these applications, ensuring structural integrity is paramount. By drastically reducing barriers to XCT adoption, this partnership has laid the foundation for digital twins and data-driven certification pipelines and directly addressed bottlenecks in qualifying new materials and designs. Together, ORNL and ZEISS have shown that Simurgh advances the state of the art in nondestructive evaluation and aligns with the broader mission of enabling Industry 4.0 manufacturing ecosystems, in which intelligent, cost-effective, rapid quality assurance is integral to accelerating innovation and ensuring safety in critical applications.

36 MATERIALS SCIENCE↗