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All sourcesNASA NTRSDOE OSTI
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↗
DOE OSTI2024

Laser Powder Bed Fusion of Steels for Nuclear Applications

This report provides an update on laser powder bed fusion of steels for nuclear applications. This report is a Milestone 3 deliverable in FY2024, under work package CT-24AN130401 to support research and qualification activities supported by the Advanced Materials and Manufacturing Technologies (AMMT) program here at Argonne National Laboratory (ANL). Continuing from FY23, the focus of FY24 for ANL includes further optimization of process parameters for three alloys: A709, G91, G92. The work package also includes fabricating test samples to conduct a thorough microstructural analysis and perform preliminary mechanical testing. For the same, we have used CALPHAD-based thermodynamic kinetic modeling to optimize the experimental activities.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Additive Manufacturing of Fe-based Alloys for Nuclear Reactor Environments

This report is a Milestone 2 deliverable in FY2025, under work package MT-25AN090211 to support research and qualification activities supported by the Advanced Materials and Manufacturing Technologies (AMMT) program. It provides an update on the work done on the laser based additive manufacturing of steels for nuclear applications, conducted collaboratively by Argonne National Laboratory and Pacific Northwestern National Laboratory. Building upon FY23 and FY24 efforts, the focus of FY25 includes continued optimization of process parameters for the alloys: A709 & G92. The work package also includes fabricating test samples to conduct a thorough microstructural analysis and perform preliminary mechanical testing. The major accomplishments of this work package are summarized below, applicable to both Laser Powder Bed Fusion (LPBF) processes conducted at Argonne National Laboratory and Laser Powder Directed Energy Deposition (LP-DED) processes conducted at Pacific Northwest National Laboratory.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2022

Initial Observations from AGR 5/6/7 Capsule 1

The fourth and final irradiation experiment in the Advanced Reactor Technologies (ART) Advanced Gas Reactor (AGR) fuel development and qualification program is designated as AGR-5/6/7. Data collected from the fabrication, irradiation, and post-irradiation examination (PIE) of this tristructural isotropic (TRISO) fuel are intended to serve as the primary data set for the qualification of this fuel for use in high-temperature gas-cooled reactors (INL 2021, Collin 2018b). However, data collected from the three preceding irradiations (i.e., AGR-1, AGR-2, and AGR-3/4) may also be used to supplement data collected from AGR-5/6/7. All components of the AGR-5/6/7 fuel (i.e., UCO kernels, TRISO coatings, and fuel compacts) were produced on an engineering scale at BWXT (Lynchburg, Virginia USA) according to the fuel specification (Marshall 2017). This fuel was irradiated in the northeast flux trap (NEFT) at the Advanced Test Reactor (ATR) at Idaho national Laboratory (INL) from February 16, 2018 to July 22, 2020 (Pham et al. 2021). Measurements in the fission product monitoring system (FPMS) indicated unexpected and significant numbers of failures of TRISO particles in Capsule 1 near the end of the sixth irradiation cycle (ATR Cycle 166A). In the fourth cycle (ATR Cycle 164B) and beyond, the sweep gas flow became very low (presumably from degradation of the capsule gas outlet line via an unidentified mechanism), and the program deliberately isolated Capsule 1 from gas flow periodically. In later cycles, attempts to reestablish any kind of flow in Capsule 1 were unsuccessful. With little or no flow through Capsule 1, FPMS measurements and enumerations of failed particles in Capsule 1 were difficult or impossible as was the ability to control the helium/neon gas mixture used for temperature control. Gas flows and fission gas activity in the effluent gas from the other AGR-5/6/7 capsules were also impacted by the Capsule 1 gas flow issues and the large increase in fission gas released from the Capsule 1.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2023

Machine Learning Enabled Sensor Fusion for In-Situ Defect Detection in Laser Powder Bed Fusion

Laser Powder Bed Fusion (L-PBF) Additive Manufacturing (AM) is among the metal 3D printing technologies most broadly adopted by the manufacturing industry. The current industry qualification paradigm for critical-application L-PBF parts relies heavily on expensive non-destructive inspection techniques such as X-Ray Computed Tomography (XCT), which significantly limits the use-cases of L-PBF. In situ monitoring of the process promises a less expensive alternative to ex situ testing, but existing sensor technologies and data analysis techniques struggle to detect sub-surface flaws (e.g., porosity and cracking) on production-scale L-PBF printers. RTX Technologies Research Center (RTRC) has licensed ORNL’s Peregrine software package – a printer- and camera-agnostic data analytics tool designed specifically for detecting process anomalies using in situ data collected during powder bed printing. The goal of this project was to feed temporally rich, multi-modal sensor data, including visible light, integrated near infrared (NIR), and spatially mapped co-axial melt pool thermal emission data into Peregrine to enable detection of subsurface flaws. XCT data was used as ground truth training data to allow Peregrine’s deep learning algorithms to recognize anomalies in these complex data streams in both test artifacts and industrially relevant geometries. Completion of this program has seen the successful implementation of multi-modal, multi-layer sensor data footprints for training of machine learning models in Peregrine. Flaws detected in XCT data have been successfully detected directly from this in situ data footprint, and initial analyses of the in situ probability-of-detection has been conducted, showing performance levels commensurate with traditional non-destructive evaluation (NDE) methods. The in situ monitoring methodology was then applied to an industrially relevant component that was using post-build NDE, highlighting the utility of the proposed method for hard-to-inspect AM components. As a direct result of this program, two journal manuscripts [1], [2] have been published in Additive Manufacturing, with additional manuscripts planned following program completion.

36 MATERIALS SCIENCE↗
DOE OSTI2023

TRISO Fuel Development and Qualification in the US

Presentation of TRISO Fuel Development and Qualification in the US. Including Status of HTGR and TRISO Technology Circa 2000, Advanced Gas Reactor focus on licensing and domestic TRISO fuel fabrication capabilities. Irradiation experiments discussed include AGR-1, AGR-2, AGR-5/6/7, and AGR-3/4. Results, of tests and Kernel and coating behaviors during irradiation, Fission product release from UCO Fuel Compacts, study of failed particles, safety and accident performance summaries, and Parfume modeling and capabilities.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2023

Scalable in situ non-destructive evaluation of additively manufactured components using process monitoring, sensor fusion, and machine learning

Laser Powder Bed Fusion (L-PBF) Additive Manufacturing (AM) is among the metal 3D printing technologies most broadly adopted by the manufacturing industry. However, the current industry qualification paradigm for critical-application L-PBF parts relies heavily on expensive non-destructive inspection techniques, which significantly limits the use-cases of L-PBF. In situ monitoring of the process promises a less expensive alternative to ex situ testing, but existing sensor technologies and data analysis techniques struggle to detect sub-surface flaws (e.g., porosity and cracking) on production-scale L-PBF printers. In this work, an in situ NDE (INDE) system was engineered to detect subsurface flaws detected in X-Ray Computed Tomography (XCT) directly from process monitoring data. A multilayer, multimodal data input allowed the INDE system to detect numerous subsurface flaws in the size range of 200–1000µm using a novel human-in-the-loop annotation procedure. Furthermore, a framework was established for generating probability-of-detection (POD) and probability-of-false-alarm (PFA) curves compliant with NDE standards by systematically comparing instances of detected subsurface flaws to post-build XCT data. Here, we also introduce for the first time in the AM in situ sensing literature the a 90/95 – the flaw size corresponding to a 90% detection rate on the lower 95% confidence interval of the POD curve. The INDE system successfully demonstrated POD capabilities commensurate with traditional NDE methods. Traditional ML performance metrics were also shown to be inadequate for assessing the ability of the INDE system’s flaw detection performance. It is the hope of the authors that future studies will adopt the POD and PFA approach outlined here to provide better insight into the utility of process monitoring for AM.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Current and Future Technological Issues Challenges for Nuclear Graphite Components

Historical and current data requirements for component qualification, as-manufactured graphite material properties, Irradiated & degraded material issues, code rules – Construction & Operation, status of current ASME code rules, progress in design rules, degradation, construction vs. operation, what should we be planning, and new technical areas getting started.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2022

Sensor fusion of pyrometry and acoustic measurements for localized keyhole pore identification in laser powder bed fusion

We report in-situ process monitoring as an aid to part qualification for laser powder-bed fusion (L-PBF) technology is a topic of increasing interest to the additive manufacturing community. In this work, airborne acoustic and inline pyrometry measurements were recorded simultaneously with the laser position. X-ray radiography imaging was used to spatio-temporally register keyhole pore locations to the pyrometry and acoustic signals, enabling binary labeling of data partitions based on pore formation. These labeled partitions were subsequently featurized using a highly comparative time-series analysis toolbox. Acoustic data was found to be much more effective than the pyrometry data for keyhole pore identification. However, when the information contained in both sensing modalities was combined in a sensor fusion strategy, the error rates of the top performing models were significantly reduced.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Advanced Manufactured Strain Sensors for Extreme Environments

Experimentation at irradiation test facilities are essential for reducing the innovation time of developmental fuels, fuel cladding, and structural materials employed in next-generation nuclear reactors. However, due to the harsh conditions generated in such reactors and limited instrumentation space, the evaluation of a material’s mechanical properties is often limited to characterization after the materials have been removed from reactor conditions, or post-irradiation examination. These experiments are costly, time-consuming, and fail to capture the critical time-evolving phenomena that occur during the irradiation experiments. Advanced manufactured digital image correlation patterns and strain sensor devices serve as two promising technologies that can be deployed in the confined and challenging orientations of these irradiation experiments while also providing key insight on salient materials phenomena (i.e., mechanical properties). To guide the development of the printed strain sensors prior to their deployment in critical experiments, the adhesion strength between the substrate and printed film interface is measured via tensile testing and a non-contact laser-induced spallation technique. The establishment of these process control steps helped guide the successful fabrication and testing of direct-write strain sensing devices discussed in this work. The fabrication process controls are necessary for enabling the sustained operation of these strain sensing device through experimentation and minimize the potential for premature failure.

36 - MATERIALS SCIENCE↗
DOE OSTI2024

Ensemble Manufacturing Techniques for Steam Turbine Components Across Length Scales

Faster design to manufacturing requirements were sought for steam turbine components to meet the changing demands of today’s power grid of improved efficiency through operating temperature increases and enhanced operational flexibility from baseload to cyclic operations. Advances in multiple advanced manufacturing (AM) process enabled redesign of turbine components for extreme environments with the potential to reduce cost. AM is of particular interest to improve component functionality, higher temperature capability, and superior durability in large scale steam turbine applications. AM methods have an immense potential to open-up the design space by working directly with the 3D model to produce near-net shapes, enable fast design-manufacturing iterations, thereby significantly reducing product cost and lead-time up to 25 % from current baseline. However, these benefits cannot be fully realized due to the potential for unknown AM processing defects and their resultant effect upon component performance in service. Siemens is partnering with Oak Ridge National Laboratory (ORNL), Electric Power Research Institute (EPRI), and Connecticut Center for Advanced Technology (CCAT) to advance the knowledge of complex process-material interactions for desired microstructures and properties that are closely interlinked to component geometries across different length scales. The proposed program utilized an ensemble of multidisciplinary technologies to accelerate the development of materials, high-throughput experiments for their qualification, and design flexibility/topology optimization for repair/redesign of components to address critical failure mechanisms for improved performance and increased reliability of existing power plant components. The proposed activities, if successfully demonstrated for identified components, will enable paradigm shift in customized manufacturing and accelerated qualification/certification towards increased steam turbine component durability, increased turbine efficiency, and reduced CO 2 emissions in load-following environments compared to today’s technology. Technology maturation is built into the project as successful research will include customized process-component down-selection enabling AM methodologies to be incorporated directly into the existing supply chain. The specific activities of the proposed effort are: 1. Topology optimization of down-selected steam turbine parts that are amenable to additive and hybrid manufacturing for cost/performance improvement. 2. Process-structure-property relationships for five AM processes for steam turbine materials of interest to compare with conventional materials. 3. Perform part/assembly build process using advanced additive/hybrid machine tools followed by quality inspection of the built components for insight into qualification for production scale-up. Steam turbine rig testing of printed components under targeted, well monitored and characterized environmental conditions of for performance comparison of baseline and redesigned components.

36 MATERIALS SCIENCE↗
DOE OSTI2023

High Inlet Temperature Combustor for Direct-Fired Supercritical Oxy-Combustion

It is envisioned that supercritical CO 2 (sCO 2 ) electric power plant efficiencies can exceed 52% with 99% carbon capture using direct-fired oxy-combustion. Such efficiencies would be competitive with Natural Gas Combined Cycles (NGCC) and operate with nearly zero carbon emissions. To achieve high plant efficiencies, turbine inlet conditions must approach 1,200 °C at 250 bar. Such conditions, while desirable from a systems perspective, exceed the current state of the art in turbine design and materials qualification. The team of Southwest Research Institute ® (SwRI ® ), Georgia Institute of Technology (Georgia Tech), Spectral Energies, LLC (Spectral), GE Global Research (GE-GRC), and the University of Central Florida (UCF) sought to demonstrate an intermediate step toward these high efficiency plants with the development of a 1 MWth, subscale direct-fired oxy-fuel combustor. The efforts focused largely on the development of an auto-ignition based combustion system capable of providing the targeted 1200 °C and the pilot-scale plant to operate the combustor. While the project was stopped short of the commissioning and demonstration work, the advances made in this effort will reduce risks associated with chemical kinetics, thermal management, water separation, flue gas cleanup, materials selection, and corrosion in future demonstration efforts for the direct-fired oxy-fuel combustion cycles. The following report documents the design, analysis, and installation efforts completed during the project periods of performance.

03 NATURAL GAS↗
DOE OSTI2024

Advanced Manufacturing Techniques and Compositions of High Entropy Alloys for Nuclear Applications

In line with the objectives of the Department of Energy, Office of Nuclear Energy, Advanced Materials and Manufacturing Technologies (AMMT) program, this work focuses on new materials development and qualification research and development for next-generation, high-temperature nuclear reactors. High entropy alloys (HEAs) have the potential to serve in these extreme environments of next-generation nuclear reactors because of their unique phase transformation pathways and nanoscale and mesoscale microstructures. The current work focuses on understanding such nuclear-energy-relevant HEAs through a detailed literature survey, selected experimental work, and developing a decision matrix with criteria for the identification of HEAs that may have the most impact and value for further examination.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Feasibility Study of Advanced Manufacturing Techniques and Compositions of High Entropy Alloys

In line with the objectives of Department of Energy’s Office of Nuclear Energy Advanced Materials and Manufacturing technologies program (AMMT), this work focuses on new materials development and qualification research and development for next-generation, high-temperature nuclear reactors. While the currently qualified nuclear materials have demonstrated significant irradiation resistance at high temperatures, the community is still interested in materials that can sustain the harsh environments found in nuclear reactors for temperatures up to 1,000°C for nearly 100,000 hours. High entropy alloys (HEAs) have the potential to serve in these extreme environments of next generation nuclear reactors due to their unique phase transformation pathways and nanoscale and mesoscale microstructures. The current work focuses on understanding such nuclear energy relevant HEAs through a detailed literature survey and developing a decision matrix with criteria for identification of HEAs with may have most impact and value for further examination.

36 MATERIALS SCIENCE↗
DOE OSTI2023

A review of neutronics and thermal hydraulics–based screening methods applied to accelerated nuclear fuel qualification

This paper reviews the state-of-the-art engineering approach for using thermal hydraulic (TH) and neutronics modeling and simulation (M&S) tools to perform rapid screening studies of novel nuclear fuel concepts within the context of accelerated fuel qualification. Global research efforts have introduced nuclear fuel and material concepts that mark a significant departure from traditional reactor materials. The number of new technologies being considered for development for light water reactors and advanced reactor types has created the need for an accelerated fuel qualification procedure. A key component of this procedure is the rapid identification of the most promising fuel concepts using computational screening studies. Advanced TH and neutronic M&S tools should be leveraged to efficiently determine whether the reactor performance and safety characteristics of a given concept warrant additional studies or whether the concept requires modification or elimination. This paper reviews best practices for performing these TH and neutronics screening studies at various stages during a fuel concept's progression through the qualification procedure. The motivation behind standardizing this approach is to minimize time and resources spent on qualification activities for fuel concepts that could be quickly refined or eliminated from consideration based on their reactor physics and TH characteristics. Adoption of this screening procedure—which focuses primarily on nuclear fuels but may be applicable to other reactor materials—will also help accelerate new material qualification by generating boundary conditions crucial to fuel performance evaluations and highlighting needed areas of separate effects experimentation. This article reviews the motivation behind the introduction of novel nuclear fuel concepts, provides incentive for utilizing TH- and neutronics-based screening studies, describes the screening approach and methodology, and includes discussion on how to interpret screening results to provide recommendations for the continued development of a given concept.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2023

AGR-5/6/7 Irradiation Disassembly and Metrology First Look

The Advanced Gas Reactor (AGR) Fuel Development and Qualification Program was established to perform research and development on tristructural isotropic (TRISO)-coated particle fuel to support deployment of high-temperature gas-cooled reactors (HTGRs), which are graphite-moderated nuclear reactors cooled with helium. This work continues as part of the Advanced Reactor Technologies (ART) TRISO Fuel Program. The overarching program goal is to provide a baseline fuel qualification data set to support licensing, deployment, and operation of HTGRs in the United States. To achieve these goals, the program includes fuel fabrication, irradiations of TRISO fuels and high-temperature materials (e.g., graphite), safety testing and post-irradiation examination (PIE), fuel performance modeling, and fission product transport and source term determination. The ART AGR program has conducted four distinct fuel irradiation experiments in the Advanced Test Reactor (ATR) at Idaho National Laboratory (INL). The first of these irradiation tests, designated AGR-1, began in ATR in December of 2006 and ended in November 2009. This experiment was primarily to act as a shakedown test of the multi-capsule test train design and to provide early data on fuel performance that would be used in fuel fabrication process development. AGR-1 fuel kernels were produced on an engineering scale, but the TRISO coatings and cylindrical fuel compacts were fabricated on a laboratory scale. The AGR-1 PIE was completed and the final report was published in 2015. The second irradiation test, AGR-2, started in ATR in June 2010 and ended in October 2013. The AGR-2 irradiation test was designed to provide fuel performance data for coated particles fabricated on an engineering-scale pilot line using a coater with an internal chamber diameter of 150 mm (6 in.). The final PIE report was published in 2021. AGR-3/4, a single irradiation that combined what were originally conceived as the third and fourth tests, was to support the refinement of fission product transport models and to assess the effects of sweep gas impurities on fuel performance and fission product transport. PIE of the AGR-3/4 experiment is still in progress as of this writing. The subject of this report is AGR-5/6/7, the final qualification test of AGR TRISO fuel made entirely at the engineering scale.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2024

Updated ASME design correlations and qualification plan for powder bed fusion 316H stainless steel

This report provides an update on the Advanced Materials and Manufacturing Technologies (AMMT) program effort to qualify Laser-Powder Bed Fusion (L-PBF) 316H stainless steel for use with the ASME Boiler & Pressure Vessel Code Section III, Division 5 rules. The report summarizes progress in testing and characterizing L-PBF material at elevated temperatures by providing preliminary design data for L-PBF 316H and by comparing the elevated temperature performance of the L-PBF material to wrought and conventional fusion welded 316H. The report then updates the initial AMMT qualification plan for L-PBF 316H, originally developed in 2023, to update the accelerated qualification strategy adopted in that plan to account for the new high temperature test data. The report also explores a few methods for further accelerating the qualification process using machine learning techniques to supplement the more conventional, empirical analysis methods typically used by ASME to correlate and extrapolate time-dependent material test data.

36 MATERIALS SCIENCE↗