Engineering Papers⌕ Search

SEARCH · Engineering Papers

Results for “fuel performance modeling”

Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 73 records · Page 4
All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

The advanced characterization, post-irradiation examination, and materials informatics for the development of ultra high-burnup annular U-10Zr metallic fuel

U-Zr metallic fuel is a promising fuel candidate for Gen Ⅳ fast spectrum reactors. Previous experimental irradiation campaigns showed that the sodium thermal bonded U-10Zr fuel design can achieve a burnup of 10% fissions per initial heavy metal atom (FIMA). Advanced metallic fuel designs are pushing the burnup limit to 20% or even 30% FIMA. To achieve the higher burnup and eliminate the pyrophoric sodium, a prototypical annular fuel has been designed, fabricated, clad with HT-9 in the Materials and Fuels Complex, and irradiated in the Advanced Test Reactors of Idaho National Laboratory (INL) to a peak burnup of 3.3% FIMA. During irradiation, the mechanical contact between fuel and cladding acts as a thermal bond. The irradiation lasted for 132 days in the reactor. Recently, the archived fresh and irradiated fuel samples were characterized using advanced characterization capabilities in the Irradiated Materials Characterization Laboratory (IMCL) of INL. This article summarizes the results of advanced characterization and computer vision-based materials informatics to reveal the irradiation effects on U-Zr metallic fuel. Future work will focus on further implementation of advanced characterization and statistical data mining to improve the fidelity of fuel performance modeling and support U-Zr metallic fuel qualification for fast spectrum reactors.

Yao, Tiankai↗
DOE OSTI2023

Building a DFT+U machine learning interatomic potential for uranium dioxide

Despite uranium dioxide (UO 2 ) being a widely used nuclear fuel, fuel performance models rely extensively on empirical correlations of material behavior, leveraging the historical operating experience of UO 2 . Mechanistic models that consider an atomistic understanding of the processes governing fuel performance (such as fission gas release and creep) will enable a better description of fuel behavior under non-prototypical conditions such as in new reactor concepts or for modified UO 2 fuel compositions. To this end, molecular dynamics simulation is a powerful tool for rapidly predicting physical properties of proposed fuel candidates. However, the reliability of these simulations depends largely on the accuracy of the atomic forces. Traditionally, these forces are computed using either a classical force field (FF) or density functional theory (DFT). While DFT is relatively accurate, the computational cost is burdensome, especially for f-electron elements, such as actinides. By contrast, classical FFs are computationally efficient but are less accurate. For these reasons, we report a new accurate machine learning interatomic potential (MLIP) for UO 2 that provides high-fidelity reproduction of DFT forces at a similar low cost to classical FFs. We employ an active learning approach that autonomously augments the DFT training data set to iteratively refine the MLIP. To further improve the quality of our predictions, we utilize transfer learning to retrain our MLIP to higher-accuracy DFT+U data. We validate our MLIPs by comparing predicted physical properties (e.g., thermal expansion and elastic properties) with those from existing classical FFs and DFT/DFT+U calculations, as well as with experimental data when available.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2022

DOE Advanced Gas Reactor Fuel Development and Qualification Program Overview

AGR-3/4 post-irradiation examination and data analysis AGR-5/6/7 PIE and safety testing Supplemental fuel microanalysis and method development Fuel oxidation testing Air/moisture Ingress Experiment (AMIX) system development (deployed in FY23) Single particle testing in FITT Data management and analysis Fuel performance modeling

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2026

BISON analyses of TRISO fuel performance, its dependence on time-at-temperature, and possible implications for fuel design and qualification

The Advanced Gas Reactor Fuel Development and Qualification (AGR) program has established a substantial technical foundation to support private entry into the U.S. high-temperature gas-cooled reactor market. However, emerging tristructural isotropic (TRISO)-fueled reactor applications include small modular reactors and microreactors with longer fuel residence times, which may expose fuels to higher time-at-temperature (TAT) values than were explored by the AGR program. Increased TAT could affect diffusive and thermomechanical behaviors such as Pd penetration, fission gas release, creep, and fission product transport. In this work, we applied multiscale best-estimate BISON fuel performance modeling to assess these effects within a representative design space based on the AGR-5/6/7 experiment and analyzed trends in predicted particle and compact fuel performance metrics with possible implications for near-term fuel design and qualification. BISON unambiguously predicted that TRISO fuel performance is sensitive to TAT. Increasing TAT was not predicted to increase the magnitude of failure-inducing tangential stresses in particle coating layers. Predictions obtained using a mechanistic model for Pd penetration indicated that penetration depth does not depend strongly on TAT. While these observations suggest that AGR testing provides a conservative upper bound for the steady-state operation of TRISO particles at lower powers and higher residence times, BISON also predicted that the release of poorly retained Ag would increase with TAT. Because these analyses applied models to extrapolate beyond the available experimental data, the authors recommend performing targeted experiments to confirm these predictions. Nevertheless, these predictions may provide reactor developers with enough confidence to make near-term design decisions associated with the potential fuel performance trade-offs of increasing TAT.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2021

Radiation driven diffusion in γU-Mo

A monolithic fuel design based on a U-Mo alloy has been selected as the fuel type for conversion of the United States High-Performance Research Reactors (HPRRs). A critical phenomenon of interest with U-Mo monolithic fuel is the large amount of swelling that takes place during operation, particularly at high fission densities. The accurate prediction of fuel evolution under irradiation requires implementation of correct thermodynamic and kinetic properties into mesoscale and continuum level fuel performance modeling codes. One such property where there exists incomplete data is the diffusion of relevant species under irradiation. Fuel performance swelling predictions rely on an accurate representation of diffusion in order to determine the rate of fission gas swelling and the local microstructural evolution. In this work, we present molecular dynamics simulations of the radiation driven diffusion of U, Mo and Xe in U-Mo nuclear fuels. Diffusion coefficients for each species are determined over a range of temperatures and compositions. In this work, updated diffusion coefficients are presented that are applicable under irradiation that incorporate both intrinsic and radiation driven diffusion.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2023

DOE Advanced Gas Reactor Fuel Development and Qualification Program Overview

Slides discussing the DOE Advanced Gas Reactor Fuel Development and Qualification Program Overview to include focus on LEU UCO TRISO fuel in cylindrical compacts, with data for fuel qualification in support of reactor licensing and a path to establish a domestic commercial TRISO fuel fabrication capability. Timelines from 2004 through 2029. Major program highlights include: Developed fuel performance models based on past observed behavior, Study to understand differences between US and German (“good”) fuel, Developed and improved fuel fabrication and characterization methods, Fabricated lab-scale fuel (AGR-1) with very high quality; excellent in-pile and post-irradiation high-temperature fuel performance, Scale-up coating fabrication (AGR-2) with excellent in-pile performance, AGR-3/4 fuel fabrication and irradiation experiment to assess FP transport behavior, Scale-up matrix fabrication (AGR-5/6/7); & fuel performance evaluation in progress.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2025

SiC cladding R&D execution plan

To advance the development of accident-tolerant fuel cladding for light-water reactors, the Advanced Fuels Campaign actively addresses the R&D gap between the specialized technological progress in SiC-based composite materials, led by industrial partners, and the fundamental scientific understanding of material behavior under reactor operating conditions. The laboratory activities are systematically organized based on the Development Strategy document, which outlines critical barriers to the use of SiC composites in nuclear energy applications for the coming decade and beyond. To complement the strategy, this execution plan specifies a detailed year-by-year work package and establishes key milestones for assessing progress in technological advancement. This plan has been formulated in collaboration with principal investigators at national laboratories, stakeholders, and industry partners with the goal of closing technology gaps and readying SiC-based cladding technologies for full-scale commercial testing. The research conducted at the national laboratories is categorized into three primary subjects: (1) addressing challenges associated with the performance of SiC cladding under normal operating environments, (2) identifying the failure limits of SiC cladding under accident conditions, and (3) modeling fuel performance for SiC cladding systems. Comprehensive laboratory activities integrate the development of advanced modeling tools for SiC-based cladding systems with experimental validation via integrated testing of multiphysics phenomena. This document lays out the laboratory plan to support the development of SiC-based technologies, which have the potential for significant operational and safety benefits for the U.S. nuclear industry. This plan aligns with industry developer needs, relevant Nuclear Energy University Programs, and Nuclear Energy Advanced Modeling and Simulation Programs to ensure SiC cladding technologies are matured as efficiently as possible and will be maintained and updated to accommodate the dynamically evolving progress of development, capability needs, and resource availability.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2025

Assessing High Burnup U-19Pu-10Zr Fuel Performance against Historical and Modeled Behavior

Advancing the deployment of sodium-cooled fast reactors (SFRs) requires thorough testing of metallic fuel pins under accident conditions to establish safe operational limits of high burnup fuel. To conduct transient testing, a comprehensive understanding of steady-state fuel behavior obtained through both experimental characterization and accurate predictive capabilities is needed. This study comparatively assesses the steady-state irradiation performance of two high burnup U-19Pu-10Zr fuel pins, DP-36 and DP-40, irradiated under prototypic fast reactor conditions in preparation for planned safety testing at the Transient Reactor Test Facility. Since DP-40 was designated for use in the test and DP-36 serves as its sibling pin, non-destructive, engineering-scale post-irradiation examinations (PIE) were conducted on both pins while destructive examinations were performed exclusively on DP-36. The results were then assessed against historical performance data from similar fuel pins irradiated in the Experimental Breeder Reactor-II. Additionally, the steady-state irradiation of each pin was modeled using the BISON fuel performance code to assess the accuracy of current modeling capabilities in predicting the baseline irradiation behavior. Non-destructive examinations included neutron radiography to measure fuel column elongation, gamma scanning to verify pin integrity and fission product migration, and profilometry to assess dimensional changes. Benchmarking against existing PIE data revealed consistent patterns in axial fuel column growth and cladding diametral strain, though both pins exhibited longer low-density “fluff” structures, which can have implications for core reactivity and source term calculations. Destructive examinations on DP-36 included fission gas release analysis and sectioning for optical microscopy, which showed more complex constituent redistribution patterns than the traditionally accepted 3-ring model. The axial evolution of fractional areas and porosities of each of the redistributed zones were quantified and presented. Modeling comparisons showed agreement in fractional fission gas release but consistently overestimated axial and radial swelling and disagreed with measured axial porosity patterns. These conservative overpredictions suggested that the pins would appear closer to failure or operational limits at the start of transient tests, potentially leading to higher strain accumulation during the transient. While conservative estimates provide safety margins, they can negatively impact fuel economics. A review of the swelling models identified areas for improvement in the gaseous swelling, solid swelling, and fuel hot-pressing models when applied to ternary fuel. The results of this study highlight the critical importance of conducting pre-test characterization on both test and sibling pins to accurately capture steady-state fuel behavior, providing a precise baseline for post-test evaluations and essential inputs for transient modeling of the planned experiments. The analysis also revealed significant data gaps that require further investigation to enhance the understanding and prediction of fuel swelling and pore dynamics. Collecting comprehensive data across different irradiation conditions, burnup levels, and fuel compositions are essential for refining existing models and developing mechanistic models for both binary and ternary metallic fuels, ultimately improving the integration of modeling and experimental approaches in accident testing.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2025

Pre-Transient Characterization of MLOF-1 Test Pin

This study focuses on the pre-transient characterization of U-10Zr test and sibling fuel pins for the THOR-M-LOF test series. Using neutron radiography, element contact profilometry (ECP), precise gamma scan (PGS), and gas assay, sampling, and recharge (GASR) analysis, it was confirmed that the fuel pins were intact and suitable for testing. Key fuel behaviors quantified include axial elongation, diametral strain, fluff structure geometry, axial isotope distribution, and fission gas release. Any deviations from historically expected behaviors were investigated and attributed to factors other than the irradiation behavior of the fuel pin. These pre-transient measurements establish a baseline for future post-transient analysis, which will be used to inform fuel performance models and safety criteria for sodium-cooled fast reactors (SFRs). The results will enhance understanding of transient fuel behavior and expand limited data on LOF scenarios.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2021

Temperature Effect over Gas Bubble Evolution in Uranium-10 wt.% Molybdenum alloy Irradiated by Swift Xe Ions

Results from post-irradiation examination (PIE) of U-10Mo binary metallic fuel irradiated by 84 MeV Xe ions at two different temperatures (450°C & 275°C) have been evaluated and reported. The main goal of this study was to understand gas bubble formation (due to accumulation of Xe gas) and corresponding size evolution dependent upon net Xe deposition at two different temperatures, for the U-10Mo fuel samples. From the post ion irradiation examination analysis, it can be concluded that at 450°C the Xe gas bubbles seems to coarsen more easily compared to 275°C. The results of ion irradiation testing can provide initial data that may be beneficial for fuel system down-selections, and for the development and validation of fuel performance models.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2023

TRISO fuel performance analysis: Uncertainty quantification toward optimization

Tri-structural isotropic (TRISO) fuel particles are a fuel form being considered for potential use in next-generation nuclear reactors (i.e., high-temperature gas-cooled reactors). Though the TRISO fuel manufacturing process has continually advanced in recent years, particle comparisons still reveal statistical variations and uncertainties in terms of geometric configurations and material properties. Given that the physical processes ongoing in TRISO fuel particles during reactor operation are highly correlated with each other, a small degree of uncertainty in one model may lead to significant uncertainty in another. This makes appropriate uncertainty quantification of TRISO fuel particles essential. However, one may wonder about the extent to which the current version of TRISO particles has been optimized, and whether any room remains for further improvements. This paper quantifies TRISO fuel performance model uncertainties that stem from geometric and material data. For this analysis, the BISON code was used, and the Advanced Gas Reactor (AGR)-2 experiment served as a reference case. A total of 10 5 calculations was performed for the uncertainty and optimization analysis, altering the geometric and material data within their uncertainty range. Lastly, the optimization potential of TRISO particles is evaluated from a fuel performance perspective.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2026

A Multiphysics Evaluation of Annular Uranium-Zirconium Metallic Fuels [Poster]

This study examines the performance of U-10Zr annular metallic fuel rodlets which were experimentally evaluated as part of the Advanced Fuels Campaign (AFC). The AFC mission is to develop novel fuel technologies and facilitate the implementation of those technologies by industry partners. A key objective is to improve steady-state and transient performance over current fuel types. The experiments of interest in this study included annular metallic U-Zr fuel rodlets within HT-9 cladding which were placed in SS-316 capsules and inserted in the Advanced Test Reactor (ATR). Certain mechanical and thermal conditions cannot be directly evaluated through experiments and fuel performance modeling is used to shed light on this evolution over time. In this study, BISON Multiphysics simulations are leveraged to investigate the state of the fuel system throughout and after the experimental conditions.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2021

Uranium carbide properties for advanced fuel modeling – A review

Uranium carbides are receiving renewed interest as a preferred nuclear fuel composition for advanced reactors due to their numerous favorable properties. Like many other refractory and transition metal carbides these compounds exist in both hypo- and hyper-stoichiometric compositions which results in significant variations in physical, thermal, and mechanical properties. This manuscript surveys both historic and recent literature to compile important properties data mainly as a function of temperature and carbon content to support fuel performance modeling. Expressions and fits for such properties are also suggested when allowed by complete data sets. Finally, the manuscript also attempts to highlight gaps and discrepancies in the reported data to assist the nuclear fuels community identify key areas that may require further attention in terms of future research and development.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2025

Status of Multiple Channel Fuel Performance Capabilities Within the SAS4A/SASSYS-1 Safety Analysis Software

SAS4A/SASSYS-1 (SAS) is a fast-running simulation tool used to perform deterministic analysis of anticipated events as well as design basis and beyond design basis accidents for advanced liquid-metal-cooled nuclear reactors. It is a critical element of safety analysis capabilities for the U.S. Department of Energy and is utilized within industry to perform the transient safety analyses required to support the licensing of Liquid Metal-cooled Fast Reactors (LMFRs). Although SAS is exceptionally fast for most transient scenarios, fuel performance calculations, along with the associated pre-transient characterization of the fuel pin, may be required for transient scenarios where fuel pin failure is hypothesized. Both the pre-transient characterization and the transient fuel performance calculation are necessary to properly quantify margins to potential fuel failure and assess the time spent potentially exceeding such margins during events. While safety analysis calculations with fuel performance models provide a more detailed characterization of the reactor during a transient, the pre-transient characterization can be time-consuming and computationally expensive. Often, large numbers of fuel pins have been exposed to similar pre-transient irradiation conditions. Similarly, the same pre-transient fuel characterization may be applicable to numerous transient conditions. This provides an opportunity to optimize the SAS computational framework such that pre-transient fuel characterization can be shared across multiple channels (fuel pins) and across multiple simulations, thus dramatically reducing overall computational costs. This report summarizes progress toward enhancing the SAS computational framework to support shared, multiple channel fuel performance characterizations intended to significantly reduce computational costs. Preliminary testing has shown that the computational time saved by using the pre-transient sharing capability is approximately equal to the time it takes to perform the pre-transient characterization.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2021

Density functional theory calculations of the thermodynamic and kinetic properties of point defects in β -U

Density functional theory (DFT) calculations of the thermodynamic and kinetic properties of point defects in the β phase of uranium are reported. Defect energies and entropies were calculated using 2 x 2 x 2 supercells and the Generalized Gradient Approximation (GGA) of Perdew-Burke-Ernzerhof (PBE) for the exchange-correlation potential. Due to computational cost, calculations of the vibrational properties governing entropies were performed by only displacing atoms within (roughly) the 3rd or 4th nearest neighbor shell of the defect, which implicitly assumes that atoms beyond this distance are unaffected by the defect. Migration barriers were estimated by nudged elastic band (NEB) calculations. The low symmetry of the β-U phase (the unit cell is tetragonal and contains 30 atoms) results in many point defect configurations and even more migration pathways. A connectivity map, starting from the most stable point defects, was developed in order to identify the rate-limiting step controlling the net diffusion rate in each crystallographic direction. The uranium self-diffusivity tensor was calculated by combining the defect formation energies, entropies, migration barriers and attempt frequencies. The fastest diffusion rate was determined to be a vacancy mechanism in the z crystallographic direction. The predicted uranium self-diffusivity for this mechanism agrees well with available experimental data. Finally, the diffusion mechanisms and rates identified in this study will inform fuel performance models of swelling and gas evolution.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2021

Modifications to MiniFuel Vehicle Needed to Enable Higher Temperature UO 2 Irradiation Capabilities (Summarizing Issue Report)

The Advanced Fuels Campaign (AFC) within the US Department of Energy Office of Nuclear Energy (DOE-NE) supported the conception and initial demonstration of the miniature fuel (MiniFuel) irradiation capability in the High Flux Isotope Reactor (HFIR) at Oak Ridge National Laboratory. These MiniFuel experiments are a key component of a larger effort to accelerate the qualification of novel fuel concepts and to reduce uncertainty in fuel performance models. MiniFuel experiments to date have been conducted in HFIR’s outer vertical experimental facility (VXF) positions. However, there is motivation to achieve irradiation temperatures and fuel burnup accumulation rates greater than what is achievable in the VXF positions to explore high-temperature phenomena and further accelerate fuel qualification. Therefore, MiniFuel irradiation experiments are being considered in HFIR’s removable beryllium region, which is closer to the fueled core than the VXF region. This report summarizes the design modifications to the MiniFuel irradiation vehicle needed to enable high-temperature (i.e., >1,000°C) irradiation tests with rapid burnup accumulation.

10 SYNTHETIC FUELS↗
DOE OSTI2024

Recent High Burnup LOCA Testing at Oak Ridge National Laboratory

To improve fuel cycle economics, increasing the fuel burnup limit in light-water reactors requires a solid technical foundation. Observations from experiments at Halden and Studsvik highlighted severe fuel fragmentation during loss-of-coolant-accident (LOCA) conditions, indicating a need for further technical considerations. These experiments suggest that the fragmentation threshold for high-burnup fuel might be influenced by pre-transient power levels. Consequently, additional LOCA test data are essential to complement existing findings and to deepen our understanding. Oak Ridge National Laboratory’s Severe Accident Test Station has been instrumental in advancing knowledge about high-burnup fuel fragmentation, relocation, and dispersal. This milestone report details two high-burnup LOCA tests designed to evaluate the effects of terminal temperature and grid spacers (or cladding restraints) on fuel fragmentation and relocation susceptibility. In addition, BISON fuel performance modeling and out-of-cell benchmark testing were conducted to better interpret the in-cell test results. These tests were developed in collaboration with fuel vendors to ensure that the results provide valuable data for topical reports and support the Nuclear Regulatory Commission’s review.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2023

Accelerated fission rate irradiation design, pre-irradiation characterization, and adaptation of conventional PIE methods for U-10Mo and U-17Mo

Metallic U alloys have high U density and thermal conductivity and thus have been explored since the beginning of nuclear power research. Alloys of U with modest amounts of Mo, such as U-10 wt % Mo (U-10Mo), are of particular interest because the γ-U crystal structure in this alloying addition shows prolonged stability in reactor service. Historically, radiation data on U-10Mo fuels were collected in Na fast reactors or lower temperature research reactor conditions, but little is known about irradiation behavior, particularly swelling and creep, at irradiation temperatures between 250 and 500°C. This work discusses the methodology and pre-irradiation characterization results from a U-Mo irradiation campaign performed in the High Flux Isotope Reactor at Oak Ridge National Laboratory. U-10Mo and U-17Mo samples irradiations are being completed at temperatures ranging from 250 to 500°C to three targeted fission densities between 2 × 10 20 and 1.5 × 10 21 fissions per cubic centimeter. Swelling measurement of the specimen sizes studied here required development and assessment of new methods for volume determination before and after irradiation. Laser profilometry and X-ray computation tomography (XCT) were used to provide preirradiation characterization of samples to determine the error and applicability of each to determine swelling following irradiation. These outcomes are contextualized through use of BISON simulations performed to assess the predicted expansion of U-Mo fuels subjected to the irradiation conditions of this work. Use of existing BISON fuel performance models predicted a maximum of 7% swelling under the irradiation conditions of this study. Pre-irradiation characterization revealed the as-cast U-Mo fuel samples were uniformly large-grained fully cubic U crystals with small U-C/N bearing precipitates and pores distributed throughout. Samples were found to contain a bulk porosity between .4 and 3% because of the casting process. Local porosity in areas far from large, interconnected pores was found by Slice-and-View to be under .2%. Nanometer-sized precipitates rich in C and N were identified in all samples, likely because of impurities during the fabrication process. Dendritic bands were also observed throughout the samples. These bands were characterized by variable Mo content that deviated from the overall Mo content by 2–3 wt %. No other microstructural features were correlated to these bands. Mechanical properties were found to be slightly strengthened compared to literature reports of bulk U-Mo fuels due to the nano-scale precipitates throughout the sample.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗