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Test Report for DPP-1 Regulatory Compliance Testing. Volume 1 - Main Report

Consolidated Nuclear Security, LLC (CNS), the management and operating contractor for the Y-12 National Security Complex (Y-12) for the National Nuclear Security Administration (NNSA), is currently responsible for the regulatory testing of a new Type B fissile material shipping package called the Defense Programs Package (DPP)-1. The DPP-1 is a drum packaging with an inner liner and a removable lid. Both the drum body and the lid are filled with an impact-limiting, thermal-insulating material that protects the inner containment vessel (CV) during normal conditions of transport (NCT) and hypothetical accident conditions (HAC) as defined by 10 US code of Federal Regulations (CFR) 71. In fiscal year 2021, the Oak Ridge National Laboratory (ORNL) Package Testing Program (PTP), located at the National Transportation Research Center (NTRC), conducted Type B performance tests as prescribed in Title 10 Code of Federal Regulations Part 71 (10 CFR 71) on seven DPP-1 prototype units. This test report documents test unit (TU) preparation, pretest condition, conditioning of each TU, NCT and HAC testing, and posttest measurements and observations made of the damage resulting from these tests.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Laser-based conversion electron Mössbauer spectroscopy of 229 ThO 2

The exceptionally low-energy 229 Th nuclear isomeric state is expected to provide several new and powerful applications, including the construction of a robust and portable solid-state nuclear clock, perhaps contributing to a redefinition of the second, exploration of nuclear superradiance and tests of fundamental physics. Further, analogous to the capabilities of traditional Mössbauer spectroscopy, the sensitivity of the nucleus to its environment can be used to realize laser Mössbauer spectroscopy and, with it, new types of strain and temperature sensors and a new probe of the solid-state environment, all with excellent sensitivity. However, current models for examining the nuclear transition in a solid require the use of a high-bandgap, vacuum ultraviolet (VUV) transmissive host, severely limiting the applicability of these techniques. Here we report the first, to the authors’ knowledge, demonstration of laser-induced conversion electron Mössbauer spectroscopy (CEMS) of the 229 Th isomer in a thin ThO 2 sample whose bandgap (approximately 6 eV) is considerably smaller than the nuclear isomeric state energy (8.4 eV). Unlike fluorescence spectroscopy of the 229 Th isomeric transition, this technique is compatible with materials whose bandgap is less than the nuclear transition energy, opening a wider class of systems to study and the potential of a conversion-electron-based nuclear clock.

36 MATERIALS SCIENCE↗

TREAT Slide Decks for Alabama A&M

Slides to introduce TREAT and two senior design projects to a professor and senior engineering students at Alabama A&M. Slide Deck 1 is an overview of the TREAT Reactor and its mission. Use for Space Nuclear Thermal Propulsion Testing is mentioned, but no details of space reactor fuel are included. Review for unlimited release is requested. Slide deck 2 presents technical background for neutron radiography, with contrast to x-radiography, and then presents the application of TREAT for Flash Radiography. Slide Deck 3 describes the background behind the second senior design project, which is to design powered actuators for TREAT core clamps. Slide Deck 3 includes photos of different sides of the TREAT reactor and sketches of internal components associated with the core clamping system. These were presented via Teams on October 5, but we want to provide the slidedeck files to the university for student reference.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

Experimental Methods for the Performance Test of Environment-Assisted Cracking (EAC) in Nuclear Industry and Examples through NSUF

Environmentally assisted cracking (EAC) is a critical failure mode in nuclear reactor environments, where materials are exposed to high temperatures, radiation, and corrosive media. Specific EAC studies in nuclear environments include stress corrosion cracking in primary water chemistry, irradiation-assisted stress corrosion cracking (IASCC) under neutron exposure, and hydrogen induced cracking (HIC) in reactor pressure vessels. The experimental methodologies of EAC include slow strain rate testing (SSRT), constant load, and cyclic loading techniques, conducted in autoclaves designed to simulate the reactor’s operational environments. This paper highlights several experimental case studies, especially on IASCC, conducted within the Nuclear Science User Facilities (NSUF).

36 - MATERIALS SCIENCE↗

Nuclear Systems Kilopower Overview

The Nuclear Systems Kilopower Project was initiated by NASAs Space Technology Mission Directorate Game Changing Development Program in fiscal year 2015 to demonstrate subsystem-level technology readiness of small space fission power in a relevant environment (Technology Readiness Level 5) for space science and human exploration power needs. The Nuclear Systems Kilopower Project consists of two elements. The primary element is the Kilopower Prototype Test, also called the Kilopower Reactor Using Stirling Technology(KRUSTY) Test. This element consists of the development and testing of a fission ground technology demonstrator of a 1 kWe fission power system. A 1 kWe system matches requirements for some robotic precursor exploration systems and future potential deep space science missions, and also allows a nuclear ground technology demonstration in existing nuclear test facilities at low cost. The second element, the Mars Kilopower Scalability Study, consists of the analysis and design of a scaled-up version of the 1 kWe reference concept to 10 kWe for Mars surface power projected requirements, and validation of the applicability of the KRUSTY experiment to key technology challenges for a 10 kWe system. If successful, these two elements will lead to initiation of planning for a technology demonstration of a 10 kWe fission power capability for Mars surface outpost power.

Space Nuclear Power↗

Preliminary neutronic analysis of a cavity test reactor

A reference configuration was calculated for a cavity test reactor to be used for testing the gascore nuclear rocket concept. A thermal flux of 4.1 x 10 to the 14th power neutrons per square centimeter per second in the cavity was provided by a driver fuel loading of 6.4 kg of enriched uranium in MTR fuel elements. The reactor was moderated and cooled by heavy water and reflected with 25.4 cm of beryllium. Power generation of 41.3 MW in the driver fuel is rejected to a heat sink. Design effort was directed toward minimization of driver power while maintaining 2.7 MW in the cavity during a test run. Ancillary data on material reactivity worths, reactivity coefficients, flux spectra, and power distributions are reported.

Whitmarsh, C. L., Jr.↗

Internal curing of cement pastes by means of superabsorbent polymers visualized by neutron tomography

Highlights: • The kinetics of water release from SAPs were studied by neutron tomography. • The time window for internal curing was linked to the water release from SAPs. • The water release links to the SAP effectiveness to mitigate autogenous shrinkage. • One SAP type was effective while another prematurely released its stored water. Superabsorbent polymers (SAPs) are used to counteract self-desiccation in order to mitigate autogenous shrinkage, a problem in cementitious systems with a low water-to-cement ratio. The release kinetics during internal curing are of importance as not all SAP types are able to efficiently mitigate autogenous shrinkage. In this study, neutron tomography is used to study and visualize the water release kinetics over time. Per-voxel analysis of the time-attenuation curve was performed using piecewise-constant functions. Two different SAP types were studied, one being able to mitigate autogenous shrinkage and one quickly releasing its stored water after final setting. The tomography results correspond to autogenous shrinkage measurements and nuclear magnetic resonance tests. The visualization provides information on the time of water release by the SAPs after setting and the time window of internal curing. This opens additional insights towards the application of SAPs in the construction sector and provides information on the mechanism of internal curing.

36 MATERIALS SCIENCE↗

Insights Developed Into the Damage Mechanism of Teflon FEP Thermal Control Material on the Hubble Space Telescope

Metalized Teflon FEP (DuPont; fluorinated ethylene propylene) thermal control material on the Hubble Space Telescope (HST) has been found to degrade in the space environment. Teflon FEP thermal control blankets retrieved during the first servicing mission were found to be embrittled on solar-facing surfaces and to contain microscopic cracks (the FEP surface is exposed to the space environment). During the second servicing mission, astronauts noticed that the FEP outer layer of the multilayer insulation blanketing covering the telescope was cracked in many locations. Large cracks were observed on the light shield, forward shell, and equipment bays. A tightly curled piece of cracked FEP from the light shield was retrieved during the second mission. This piece was severely embrittled, as witnessed by ground testing. A Failure Review Board was organized by NASA Goddard Space Flight Center to determine the mechanism causing the multilayer insulation degradation. This board included members of the Electro-Physics Branch of the NASA Glenn Research Center at Lewis Field. Density measurements of the retrieved materials obtained under the review board's investigations indicated that FEP from the first servicing mission was essentially unchanged from pristine FEP but that the second servicing mission FEP had increased in density in comparison to pristine FEP (ref. 1). The results were consistent with crystallinity measurements taken using x-ray diffraction and with results from solid-state nuclear magnetic resonance tests (see the table and ref. 1). Because the second servicing mission FEP was embrittled and its density and crystallinity had increased in comparison to pristine FEP, board researchers expected that the first servicing mission FEP, which was also embrittled, would also have increased in crystallinity and density, but it did not. Because the retrieved second servicing mission material curled while in space, it experienced a higher temperature extreme during thermal cycling (estimated at 200 C) than the first servicing mission material (estimated at 50 C). Therefore, Glenn initiated and conducted an investigation of the effects of heating pristine FEP and FEP that had been exposed on the Hubble Space Telescope. Samples of pristine and first and second servicing mission FEP were heated to 200 C and evaluated for changes in density and morphology. We hoped that the results would help explain why FEP degrades in the Hubble Space Telescope space environment.

deGroh, Kim K.↗

External fuel thermionic reactor system.

Thermionic reactors are prime candidates for nuclear electric propulsion. The national thermionic reactor effort is concentrated on the flashlight concept with the external-fuel concept as the backup. The external-fuel concept is very adaptable to a completely modular power subsystem which is attractive for highly reliable long-life applications. The 20- to 25-cm long, externally-fueled converters have been designed, fabricated, and successfully tested with many thermal cycles by electrical heating. However, difficulties have been encountered during encapsulation for nuclear heated tests and none have been started to date. These nuclear tests are required to demonstrate the concept feasibility.

Mondt, J. F.↗

Accelerating nuclear fuel development and qualification: Modeling and simulation integrated with separate-effects testing

In this work, an approach to transform and accelerate nuclear fuel development and qualification is outlined. The approach exploits advanced modeling and simulation at the outset to inform constituent and system selection and to enable integral fuel performance analyses. Analyses using these tools identify and prioritize the most important fuel performance parameters and phenomena for subsequent targeted characterization with separate-effects tests. Separate-effects testing spans out-of-pile and in-pile tests and is meant to iterate with and inform engineering-scale integral fuel performance analyses throughout the development process. Exercising this cycle in an agile fashion will increase confidence in the integral fuel performance predictions while reducing uncertainties. This process sets the stage for executing a much more limited set of well-defined integral irradiation tests designed to validate engineering-scale fuel performance codes and to confirm the performance and safety of the fuel system under prototypic conditions. This approach will reduce the time for development and qualification of a new fuel system, and it will also reduce associated costs.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

OPTI-TWIST Test Report, FY2025

OPTI-TWIST is the out-of-pile testing prototype and instrumentation TWIST with analogous components without nuclear material. Fabrication, construction, and testing in FY2025 is described in this test report.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Self-welding of Inconel 617 under high-pressure-high-temperature conditions for nuclear reactors

In response to continuously declining availability of fossil fuels, nuclear power has become an important alternative source of power generation. Growing application of nuclear power has relieved the shortage of electricity. However, it is also accompanied with new drawbacks, such as radioactive waste, and potential catastrophic consequences in case of major accidents. For nuclear power plants, severe accidents mostly originate from the reactor, making the reliability of the reactor of paramount importance to the overall safety of a nuclear power plant. Massive heat generation through nuclear fission/fusion and heat exchange render the whole reactor operating at extremely high temperatures (i.e., 900–1000 °C), which, in conjunction with large load from subsystems/ components made of special heavy alloys, renders the reactor under the risk of self-welding, a phenomenon that could lead to strong bonding between components and paralyze the operability of the nuclear reactor. This paper investigates the self-welding behavior of Inconel 617, a primary candidate nickel alloy for key components of the next generation gas cooled nuclear plant, inside a controlled atmospheric furnace with preset static load, simulating the high-pressure high-temperature conditions inside nuclear reactors. Therefore, test results show that Inconel 617 experiences self-welding through common oxide zone at the interface, and it has remarkable bonding strength, requiring 4114 N (57.15 MPa) and 4338 N (60.25 MPa) to break apart a mated sample pair, under an apparent contact pressure of 0.341 MPa after 50-h aging, in helium and air atmospheres, respectively. The higher oxygen presence in air results in slightly stronger oxide bond at the interface, compared to helium, and the bond strength increases with dwell time.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗

Evaluation of the MARVEL Reactor Inhalation Dose Consequences

A dose consequence analysis was performed to support the preliminary Microreactor Applications Research Validation and Evaluation Project (MARVEL) design effort. The purpose of the MARVEL project is to develop a nuclear microreactor applications test bed at Idaho National Laboratory (INL) to perform research and development on various operational features of microreactors to ultimately improve integration of microreactors to end-user applications. The MARVEL concept is a 100 kilowatt (kW) thermal (kWth) and approximately 20-kW electric (kWe) generating microreactor. The MARVEL system will be located in the INL TREAT facility in the north high-bay equipment pit. The analysis considers the bounding release fractions of the MARVEL reactor concept and documents the dose consequences to the public and collocated worker.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

ECAR-5127 Rev 1 Evaluation of the MARVEL Reactor Inhalation Dose Consequences

The following dose consequence analysis is performed to support the preliminary Microreactor Applications Research Validation and Evaluation Project (MARVEL) design effort. The purpose of the MARVEL project is to develop a nuclear microreactor applications test bed at Idaho National Laboratory (INL) to perform research and development on various operational features of microreactors to ultimately improve integration of microreactors to end-user applications. The MARVEL concept is a 100 kilowatt (kW) thermal (kWth) and approximately 20-kW electric (kWe) generating microreactor. The MARVEL system will be located in the INL TREAT facility in the north high-bay equipment pit. This ECAR considers the bounding release fractions of the MARVEL reactor concept and documents the dose consequences to the public and collocated worker.

21 - SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLAN↗

Evaluation of the NSUF Reactor Activation and Damage (RAD) Calculator damage component

The Nuclear Science User Facilities (NSUF) provide researchers access to nuclear research facilities and expertise all over the United States and at the Belgian Center for Nuclear Research (SCK/CEN). One special capability of the NSUF is providing access to nuclear research and test reactors often used for conducting material testing experiments. These services are provided at no cost to the researcher through a competitive, peer-reviewed process. With so many proposals being submitted simultaneously, an NSUF information management resource called the Combined Materials Experiment Toolkit (CoMET) was implemented to speed up the review process and give users access to the information and tools necessary for designing meaningful experiments and writing the best proposals possible. One of CoMET’s tools is the Reactor Activation and Damage (RAD) Calculator. For those with little or no background in it, neutron irradiation in research and test reactors can be a challenging subject to include in a proposal. That is why the RAD Calculator was created to assist users with providing estimates of irradiation and post-irradiation conditions, enabling them to select the best neutron irradiation and post-irradiation examination facilities for reaching their experiment goals. The RAD Calculator is a general scoping tool that estimates radiation damage in terms of DPA, in addition to the resulting radioactivity of the material post-irradiation. This report evaluates the neutron damage component of the RAD Calculator. The evaluation of the activation component of the calculator is covered in report INL/EXT-20-58080.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

Local Power Impact Experiment Design for a New Fuel Type for use in the Advanced Test Reactor

The Advanced Test Reactor (ATR), and complimentary zero-power ATR Critical (ATRC) reactor, located at Idaho National Labs (INL), are undergoing conversion from Highly Enriched Uranium (HEU) to Low Enriched Uranium (LEU). Both have a variety of testing locations that can receive large variations in flux due to its unique serpentine design, consisting of five lobes (see Figure 1). Initial criticality and power distribution throughout the core are controlled by core-external outer shim control cylinders (OSCCs). Distinct test loops allow for testing at specific temperatures, pressures, and irradiation conditions. The ATR is one of the key nuclear engineering research and testing facilities within the DOE National Laboratory Complex, and the ATRC supports its operation [1]. Currently, the Office of Material Management and Minimization (M3) within the National Nuclear Security Administration of the DOE is working to convert the remaining research reactors, including the ATR, from 93% HEU fuel to 19.75% LEU fuel (LEU) to support non-proliferation [2]. Extensive materials testing at INL and internationally has demonstrated that a high-density uranium molybdenum (U 10Mo) alloy can meet the performance requirements of the remaining high powered research reactors. However, there are many technical challenges to address before the conversion to LEU can be successful, including the accurate characterization of the reactor core physics with LEU fuel. Reactor physics safety evaluations currently use Monte Carlo for the 21st Century (MC21), a continuous-energy Monte Carlo radiation transport code [3]. Existing MC21 models of the ATR and ATRC cores have a validation basis for use in neutronics analyses with HEU fuel. The models are used to support safety analyses that include comparisons to the safety requirements for the reactors. However, the use of the LOWE element in the ATR and ATRC is not currently covered by the current model validation basis. To deploy the new fuel type, extensive computational reactor physics support is necessary to support the use of LOWE in the ATR and ATRC. Therefore, LOWE requires a rigorous validation basis, aligned with that of HEU fuel, that takes advantage of the existing software tools and processes currently used for the ATR and ATRC. The experiment to validate of the MC21 models for determining power, the Power Impact Validation Experiment, will consist of two flux runs in the ATRC, one with fully HEU loading and one with a single LOWE element. Both flux runs will be instrumented with 20 sets of azimuthal fission wires and 3 sets of axial fission wires, as shown in Figure 4. Standard flux run methodology will be used [4]. Power Impact Validation Experiment data will be compared against MC21 calculated data, both for absolute fission rate accuracy and to determine the relative change in fission rates between the two runs. The results of the Power Impact Validation Experiment and subsequent evaluations will provide the validation basis for MC21 for use with LOWE elements. Key features of the Power Impact Validation Experiment include: (1) Two flux runs to allow for LOWE perturbed measurements to be compared to already validated measurements taken from a full core of HEU fuel, (2) Optimization of instrumentation to balance analytical needs with practical considerations (e.g., limited time window to count beta particles from fission products), and (3) Standard ATRC core loading, including both driver positions and flux traps, to minimize cost while remaining representative of typical ATR core loading.

42 ENGINEERING↗

Friction and wear of nuclear graphite exposed to molten FLiNaK salt environment

This report formally documents the completion of the Advanced Reactor Technologies Level 3 Milestone (M3TG-25OR0501104), “Initiate graphite wear studies of graphite samples exposed to molten salt environment,” due August 1, 2025. The report summarizes the ongoing activities aimed at characterizing the friction and wear behavior of graphite in molten LiF–NaF–KF (FLiNaK) salt environment. The wear and friction behavior of self-mated ET-10 nuclear graphite were tested at varying temperatures (550°C and 650°C), contact loads (40 and 80 N) and sliding speeds (1 and 10 mm/s) in a controlled argon environment. The results were compared to the wear and friction behavior of the same graphite material in a dry argon environment. This report presents initial studies on the friction and wear behavior of graphite in sliding contact mode, with future work focused on investigating the graphite matrix materials, as well as rolling and impact contact modes. The outcomes of this report could provide insights into assessing the integrity of the graphitic components of pebble-bed fluoride salt–cooled high-temperature reactors (PB-FHRs) to enhance their safe operation.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

Specimen Size Artifacts Associated with a Glovebox Deployable Laser Flash Diffusivity Measurement System

To accelerate nuclear fuel qualification and deployment efforts, Oak Ridge National Laboratory has led the world in developing vehicles for accelerating burnup accumulation in nuclear fuel by testing miniature samples in the High Flux Isotope Reactor. However, a challenge remains to establish parity between post irradiation characterization methods for miniature fuel specimens in comparison to conventional fuel elements. This work aims to identify artifacts associated with the thermal analysis of miniature disk specimens in comparison to samples of standardized dimensions through a combination of experimental and computational tools. Using a newly procured Netzsch 427 laser flash diffusivity system, preliminary data on mild steel specimens were collected, and finite element techniques were used to model heat transfer using 1D conditions to assess issues associated with pulse width and data collection frequency effects. These preliminary investigations found that significant variability in measured thermal diffusivity exist within datasets. These variations are not necessarily attributed to limitations with respect to data collection rate; nor are they associated with limitations on pulse width. Instead, these artifacts may be a result of limitations in detector intensity. Future work aims to design a focusing lens to better measure the smaller surface area of miniature specimens analyzed using the laser flash analysis system.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗