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All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

Codes and standards for ceramic composite core materials for High Temperature Reactor applications

Fiber-reinforced ceramic matrix composites are attractive for high-temperature nuclear applications due to excellent thermal and mechanical properties as well as reasonable-to-outstanding radiation resistance. Over the past 20 years, the use of ceramic matrix composite applications expanded to many commercial non-nuclear industries as fabrication and application of the technologies mature. The ASME Boiler Pressure Vessel Code, under Section III Division 5, provides the design and construction rules for High Temperature Reactor components. It published the first rules for ceramic matrix composites to be used for reactor core components. The rules lay out the quality requirements together with the design and materials criteria for the use and application of silicon carbide- and carbon-based matrix material technologies. As with the established graphite rules, the ceramic composite material rules are structured in Subsection HH (from Section III), that addresses the criteria for class SN nonmetallic core components. The code rules rely heavily on the development and publication of standards for composite specification, classification, and testing of mechanical, thermal, and other properties. These test methods are developed in ASTM Committee C28 on Advanced Ceramics, with a current focus on ceramic composite tubes. This article describes the detail of the composites code, the design methodology and similarities to the graphite code, the guidance for the development of specifications for ceramic composites (for nuclear applications) including recent standard developments, and it mentions the next steps to support licensing aspects by validating the code with benchmarking data.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2016

Thermoelectric-Driven Sustainable Sensing and Actuation Systems for Fault-Tolerant Nuclear Incidents

The Fukushima Daiichi nuclear incident in March 2011 represented an unprecedented stress test on the safety and backup systems of a nuclear power plant. The lack of reliable information from key components due to station blackout was a serious setback, leaving sensing, actuation, and reporting systems unable to communicate, and safety was compromised. Although there were several independent backup power sources for required safety function on site, ultimately the batteries were drained and the systems stopped working. If, however, key system components were instrumented with self-powered sensing and actuation packages that could report indefinitely on the status of the system, then critical system information could be obtained while providing core actuation and control during off-normal status for as long as needed. This research project focused on the development of such a self-powered sensing and actuation system. The electrical power is derived from intrinsic heat in the reactor components, which is both reliable and plentiful. The key concept was based around using thermoelectric generators that can be integrated directly onto key nuclear components, including pipes, pump housings, heat exchangers, reactor vessels, and shielding structures, as well as secondary-side components. Thermoelectric generators are solid-state devices capable of converting heat directly into electricity. They are commercially available technology. They are compact, have no moving parts, are silent, and have excellent reliability. The key components to the sensor package include a thermoelectric generator (TEG), microcontroller, signal processing, and a wireless radio package, environmental hardening to survive radiation, flooding, vibration, mechanical shock (explosions), corrosion, and excessive temperature. The energy harvested from the intrinsic heat of reactor components can be then made available to power sensors, provide bi-directional communication, recharge batteries for other safety systems, etc. Such an approach is intrinsically fault tolerant: in the event that system temperatures increase, the amount of available energy will increase, which will make more power available for applications. The system can also be used during normal conditions to provide enhanced monitoring of key system components.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2019

Calculation of Neutron Damage to Sodium Coolant Inlet Plenum

The coolant inlet plenum is a life limiting component of a Sodium-cooled Fast Reactor (SFR). The inlet plenum is a fixed reactor component which receives sodium from the cold side of the sodium pool redan and directs it into the inlet nozzles of the fuel assemblies. Neutron leakage from the reactor core causes irradiation damage to the steel components of the inlet plenum leading to a reduction in strength. The life of the reactor is essentially tied to the acceptable strength degradation of the inlet plenum. Therefore, typical SFR designs employ a neutron reflector/shield as an integral feature of the fuel assembly. The role of the axial reflector/shield is to: 1) direct fast neutrons back to the core, and 2) attenuate the neutron flux to minimize neutron interaction with the inlet plenum. The longer the reflector and the greater the share of steel within the reflector design, the greater the attenuation. The axial reflector is heated by gamma rays from the core, and must have sufficient coolant penetrations to ensure adequate cool-ability. Also, the sodium coolant must pass through the reflector before reaching the fuel rods above it. The present work investigates varying reflector geometries in support of the Versatile Test Reactor (VTR), a SFR research reactor planned to restart fast reactor irradiation capabilities in the U.S. DOE laboratory complex. This work will demonstrate that the neutron damage to the inlet plenum is relatively insensitive to the number and arrangements of coolant channel penetrations through the reflector.

61 RADIATION PROTECTION AND DOSIMETRY↗
DOE OSTI2023

An integrated coupling model for solving multiscale fluid-fluid coupling problems in SAM code

In this study, an integrated coupling method has been developed for solving multiscale fluid-fluid coupling problems in plant-scale safety analysis models in SAM (System Analysis Module) code. In this method, a higher-fidelity multi-dimensional (3D) flow module is used for reactor components of complex flow features (e.g., reactor core) and a lumped parameter one-dimensional (1D) flow module for plant-scale flow loops (e.g., primary loop pipe network), respectively. In this method, the 3D fluid equation/domain and 1D fluid equation/domain are tightly coupled at the residual level and solved simultaneously using the Newton’s method to overcome the convergence issues typically seen in existing approaches like separate domain approach, where the 3D fluid equation and 1D fluid equation are solved separately. Extensive and successful code verifications and demonstrations have been performed for this newly developed method. This new modeling approach significantly simplify the work flow in developing high-fidelity plant-scale safety analysis model, e.g. for pool-type reactors and pebble-bed reactors.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2019

Particle Flow Solarthermal Redox Process to Split Water

The aim of this project is to develop novel solarthermal water splitting (STWS) materials and a STWS reactor capable of producing hydrogen gas in an economic (<2/gge H 2 ) and efficient manner (>26% solar to hydrogen efficiency) at commercial scales (>50,000 kg of H 2 /day). To meet these targets, new materials must be developed with high intrinsic STWS efficiencies and then fabricated into a robust, long-lived “reactor ready” form. Additionally, scalable novel reactors are necessary to efficiently deliver the solar heat to the reacting materials while minimizing parasitic efficiency losses such as unnecessary heating and cooling, electrical work and heat losses from the reactor (such as radiation, or conduction). In this project we will: 1) develop new materials capable of meeting the targets outlined above; 2) develop particle formulation capable of producing attrition resistant, long lived, “reactor ready” particles; 3) evaluate and refine the individual reactor components of our Particle Flow Solarthermal Reactor design; 4) develop an overall system model to be used for reactor design improvement and economic analysis; and 5) produce at least three liters of H 2 on-sun in an eight hour day using our developed materials and reactor design principles. Overall, we will move our STWS process from Technology Readiness Level (TRL) 2 to TRL3.

08 HYDROGEN↗
NASA NTRS1959

NASA Reactor Facility Hazards Summary

The Lewis Research Center of the National Aeronautics and Space Administration proposes to build a nuclear research reactor which will be located in the Plum Brook Ordnance Works near Sandusky, Ohio. The purpose of this report is to inform the Advisory Committee on Reactor Safeguards of the U. S. Atomic Energy Commission in regard to the design Lq of the reactor facility, the characteristics of the site, and the hazards of operation at this location. The purpose of this research reactor is to make pumped loop studies of aircraft reactor fuel elements and other reactor components, radiation effects studies on aircraft reactor materials and equipment, shielding studies, and nuclear and solid state physics experiments. The reactor is light water cooled and moderated of the MTR-type with a primary beryllium reflector and a secondary water reflector. The core initially will be a 3 by 9 array of MTR-type fuel elements and is designed for operation up to a power of 60 megawatts. The reactor facility is described in general terms. This is followed by a discussion of the nuclear characteristics and performance of the reactor. Then details of the reactor control system are discussed. A summary of the site characteristics is then presented followed by a discussion of the larger type of experiments which may eventually be operated in this facility. The considerations for normal operation are concluded with a proposed method of handling fuel elements and radioactive wastes. The potential hazards involved with failures or malfunctions of this facility are considered in some detail. These are examined first from the standpoint of preventing them or minimizing their effects and second from the standpoint of what effect they might have on the reactor facility staff and the surrounding population. The most essential feature of the design for location at the proposed site is containment of the maximum credible accident.

Source record↗
DOE OSTI2015

System-Level Heat Transfer Analysis, Thermal- Mechanical Cyclic Stress Analysis, and Environmental Fatigue Modeling of a Two-Loop Pressurized Water Reactor. A Preliminary Study

This report provides an update on an assessment of environmentally assisted fatigue for light water reactor components under extended service conditions. This report is a deliverable in April 2015 under the work package for environmentally assisted fatigue under DOE's Light Water Reactor Sustainability program. In this report, updates are discussed related to a system level preliminary finite element model of a two-loop pressurized water reactor (PWR). Based on this model, system-level heat transfer analysis and subsequent thermal-mechanical stress analysis were performed for typical design-basis thermal-mechanical fatigue cycles. The in-air fatigue lives of components, such as the hot and cold legs, were estimated on the basis of stress analysis results, ASME in-air fatigue life estimation criteria, and fatigue design curves. Furthermore, environmental correction factors and associated PWR environment fatigue lives for the hot and cold legs were estimated by using estimated stress and strain histories and the approach described in NUREG-6909. The discussed models and results are very preliminary. Further advancement of the discussed model is required for more accurate life prediction of reactor components. This report only presents the work related to finite element modelling activities. However, in between multiple tensile and fatigue tests were conducted. The related experimental results will be presented in the year-end report.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2016

Effect of irradiation on terminal solid solubility of hydrogen in Zr-2.5Nb - 2016-0044

Knowledge of the temperature dependence of hydrogen solubility is used to define the conditions necessary for brittle hydrides to be present in reactor components during service. The terminal solid solubility (TSS) of hydrogen is affected by several factors, including irradiation, cold work, and decomposition of the β phase in Zr-2.5Nb. TSS temperatures for specimens irradiated in Osiris, Halden, and CANDU{sup R} reactors are reported. TSS was measured on Zr-2.5Nb specimens using differential scanning calorimetry (DSC) to complete four heatup/cool-down cycles (heat to a peak temperature and cool to room temperature at a rate of 10 deg. C/min) followed by a 1-h anneal at 500 deg. C, and then four more heat-up/cool-down cycles. As with Zircaloy, irradiation slightly decreases the TSS temperatures, but subsequent annealing increases them. These changes are attributed to an initial effect of irradiation damage and reconstitution of the β phase and reversal of these effects by annealing, as indicated by X-ray diffraction data showing reduced dislocation density and higher β-phase volume fraction after the specimens were annealed. (authors)

36 MATERIALS SCIENCE↗
DOE OSTI2015

Heat Transfer Salts for Nuclear Reactor Systems - Chemistry Control, Corrosion Mitigation, and Modeling

The concept of a molten salt reactor has existed for nearly sixty years. Previously all work was done during a large collaborative effort at Oak Ridge National Laboratory, culminating in a research reactor which operated for 15,000 hours without major error. This technical success has garnished interest in modern, high temperature, reactor schemes. Research using molten fluoride salts for nuclear applications requires a steady supply of high grade molten salts. There is no bulk supplier of research grade fluoride salts in the world, so a facility which could provide all the salt needed for testing at the University of Wisconsin had to be produced. Two salt purification devices were made for this purpose, a large scale purifier, and a small scale purifier, each designed to clean the salts from impurities and reduce their corrosion potential. As of now, the small scale has performed with flibe salt, hydrogen, and hydrogen fluoride, yielding clean salt. This salt is currently being used in corrosion testing facilities at the Massachusetts Institute of Technology and the University of Wisconsin. Working with the beryllium based salts requires extensive safety measures and health monitoring to prevent the development of acute or chronic beryllium disease, two pulmonary diseases created by an allergic reaction to beryllium in the lungs. Extensive health monitoring, engineering controls, and environment monitoring had to be set up with the University of Wisconsin department of Environment, Health and Safety. The hydrogen fluoride required for purification was also an extreme health hazard requiring thoughtful planning and execution. These dangers have made research a slow and tedious process. Simple processes, such as chemical handling and clean-up, can take large amounts of ingenuity and time. Other work has complemented the experimental research at Wisconsin to advance high temperature reactor goals. Modeling work has been performed in house to re-evaluate thermophysical properties of flibe and flinak. Pacific Northwest National Laboratories has focused on evaluating the fluorinating gas nitrogen trifluoride as a potential salt purification agent. Work there was performed on removing hydroxides and oxides from flinak salt under controlled conditions. Lastly, the University of California Berkeley has spent considerable time designing and simulating reactor components with fluoride salts at high temperatures. Despite the hurdles presented by the innate chemical hazards, considerable progress has been made. The stage has been set to perform new research on salt chemical control which could advance the fluoride salt cooled reactor concept towards commercialization. What were previously thought of as chemical undesirable, but nuclear certified, alloys have been shown to be theoretically compatible with fluoride salts at high temperatures. This preliminary report has been prepared to communicate the construction of the basic infrastructure required for flibe, as well as suggest original research to performed at the University of Wisconsin. Simultaneously, the contents of this report can serve as a detailed, but introductory guide to allow anyone to learn the fundamentals of chemistry, engineering, and safety required to work with flibe salt.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2019

PTT System Design and Data Analysis for Improved Performance: Pulsed Thermal Tomography Nondestructive Examination of Additively Manufactured Reactor Materials and Components

Additive manufacturing (AM, or 3D printing) for commercial nuclear energy applications is an emerging method for cost-efficient manufacturing aimed at replacing aging nuclear reactor parts and reducing costs for new construction. Because of the geometry of metallic structures of interest for nuclear applications, which consist of planar primitives with no symmetry of revolution, limited options are available for non-destructive evaluation (NDE) either during or post manufacturing. Known material flaws in AM include low density regions consisting of non-sintered powder, which have to be detected to ensure the safety of long-term performance nuclear reactor components. As a solution to NDE of AM, we are developing pulsed thermal tomography (PTT) models and depth inversion algorithms for 3D imaging. PTT has many advantages because the method is non-contact and allows for in-service, NDE of AM nuclear reactor parts. By analyzing transients of surface temperature response due to internal thermal resistances, one can obtain 3D reconstructions of material effusively using a unique inversion algorithm developed at Argonne. This study investigates the limits of PTT capability in detection of defects in metallic plates using COMSOL numerical modeling of heat transfer. Defects are modeled as cylindrical flat bottom holes (FBH), which is a common model of calibrated material flaws in thermal tomography experiments. Materials considered in this study include stainless steel 316 (SS316), stainless steel 304 (SS304), and Inconel 718. Theoretical analyses were conducted to validate inversion of simulated PTT data with COMSOL for a plate. Subsequently, 3D reconstructions were performed on COMSOL simulations for FBH, revealing a decrease in spatial resolution over depth due to thermal diffusion. The results of this study show that the performance of the inversion algorithm for detecting smaller defects depends strongly on the depth of the defect as well as the incident heat flux. The size of detectable defect was estimated by fitting a Gaussian function to surface temperature profile. The criteria for detectability was taken as 20mK noise equivalent temperature difference (NETD), which is currently the sensitivity limit of high-performance infrared cameras. It was determined through computer simulations that the smallest detectable FBH in SS316 has a 50µm diameter and is located 0.5mm below the plate surface.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2020

FY2019 Performance Assessment Annual Review for the E-Area Low-Level Waste Facility

The Savannah River Site (SRS) E-Area Low-Level Waste Facility (ELLWF) consists of six types of disposal units described in the Performance Assessment (PA) (WSRC, 2008): Low Activity Waste Vault (LAWV), Intermediate Level Vault (ILV), Trenches [Slit Trenches (STs), Engineered Trenches (ETs), and Component-in-Grout (CIG) Trenches], and Naval Reactor Component Disposal Areas (NRCDAs). The ELLWF is a part of the Solid Waste Management Facility (SWMF). SWMF is managed and operated by the SRS Management and Operations prime contractor, Savannah River Nuclear Solutions (SRNS). Within SRNS, the Solid Waste Management (SWM) organization is responsible for operating the SWMF, and the Savannah River National Laboratory (SRNL) is the technical agency responsible for preparing and maintaining the PA. SWMF operations have been performed at SRS since 1952. The mission of the SWMF is to provide storage, processing, disposal, and shipment of radioactive, hazardous, and mixed waste. The SWMF is committed to treat, store, and dispose of these waste products in a manner that protects the environment and the health and safety of the facility worker, the co-located worker, and the offsite general public. Wastes handled in the SWMF include low level waste, transuranic waste, hazardous waste, Toxic Substances Control Act waste, and mixed waste (containing both hazardous and radioactive constituents).

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2020

FY2019 Performance Assessment Annual Review for the E-Area Low-Level Waste Facility

The Savannah River Site (SRS) E-Area Low-Level Waste Facility (ELLWF) consists of six types of disposal units described in the Performance Assessment (PA) (WSRC, 2008): Low Activity Waste Vault (LAWV), Intermediate Level Vault (ILV), Trenches [Slit Trenches (STs), Engineered Trenches (ETs), and Component-in-Grout (CIG) Trenches], and Naval Reactor Component Disposal Areas (NRCDAs). The ELLWF is a part of the Solid Waste Management Facility (SWMF). SWMF is managed and operated by the SRS Management and Operations prime contractor, Savannah River Nuclear Solutions (SRNS). Within SRNS, the Solid Waste Management (SWM) organization is responsible for operating the SWMF, and the Savannah River National Laboratory (SRNL) is the technical agency responsible for preparing and maintaining the PA. SWMF operations have been performed at SRS since 1952. The mission of the SWMF is to provide storage, processing, disposal, and shipment of radioactive, hazardous, and mixed waste. The SWMF is committed to treat, store, and dispose of these waste products in a manner that protects the environment and the health and safety of the facility worker, the co-located worker, and the offsite general public. Wastes handled in the SWMF include low level waste, transuranic waste, hazardous waste, Toxic Substances Control Act waste, and mixed waste (containing both hazardous and radioactive constituents).

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2021

FY2020 performance assessment annual review for the E-area low-level waste facility

The Savannah River Site (SRS) E-Area Low-Level Waste Facility (ELLWF) consists of six types of disposal units described in the Performance Assessment (PA) (WSRC, 2008): Low Activity Waste Vault (LAWV), Intermediate Level Vault (ILV), Trenches [Slit Trenches (STs), Engineered Trenches (ETs), and Component-in-Grout (CIG) Trenches], and Naval Reactor Component Disposal Areas (NRCDAs). The ELLWF is a part of the Solid Waste Management Facility (SWMF). SWMF is managed and operated by the SRS Management and Operations prime contractor, Savannah River Nuclear Solutions (SRNS). Within SRNS, the Solid Waste Management (SWM) organization is responsible for operating the SWMF, and the Savannah River National Laboratory (SRNL) is the technical agency responsible for preparing and maintaining the PA. SWMF operations have been performed at SRS since 1952. The mission of the SWMF is to provide storage, processing, disposal, and shipment of radioactive, hazardous, and mixed waste. The SWMF is committed to treat, store, and dispose of these waste products in a manner that protects the environment and the health and safety of the facility worker, the co-located worker, and the offsite general public. Wastes handled in the SWMF include low level waste, transuranic waste, hazardous waste, Toxic Substances Control Act waste, and mixed waste (containing both hazardous and radioactive constituents). The FY2020 PA Annual Review for the ELLWF affirms that the disposal facility continued to operate within the bounds of the current PA and Composite Analysis (CA) baseline and the subsequent SA’s and satisfied all the requirements, conditions, and limitations identified in the 2008 DAS (DOE 2008a), RWMB SRNL_STI-2020-00588 Revision 0 vi (McGill, 2020), and ELLWF Low-Level Waste Acceptance Criteria (SRS-1S, 2014). This annual review affirms that the supporting studies performed in FY2020 do not alter the conclusions of the ELLWF PA (WSRC, 2008) and that there is a reasonable expectation that the ELLWF will meet the performance objectives delineated in DOE Manual 435.1-1 (DOE 2011)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2016

RELAP-7 Pressurizer Component Development Updates

RELAP-7 is a nuclear systems safety analysis code being developed at the Idaho National Laboratory (INL). RELAP-7 development began in 2011 to support the Risk Informed Safety Margins Characterization (RISMC) Pathway of the Light Water Reactor Sustainability (LWRS) program. The overall design goal of RELAP-7 is to take advantage of the previous thirty years of advancements in computer architecture, software design, numerical methods, and physical models in order to provide capabilities needed for the RISMC methodology and to support nuclear power safety analysis. The code is being developed based on Idaho National Laboratory’s modern scientific software development framework – MOOSE (the Multi-Physics Object-Oriented Simulation Environment). The initial development goal of the RELAP-7 approach focused primarily on the development of an implicit algorithm capable of strong (nonlinear) coupling of the dependent hydrodynamic variables contained in the 1-D/2-D flow models with the various 0-D system reactor components that compose various boiling water reactor (BWR) and pressurized water reactor nuclear power plants (NPPs). As part of the efforts to expand the capability for PWR simulation, an equilibrium single-region pressurizer model has been implemented in RELAP-7. The pressurizer component can simulate pressure and water level change through insurge, spray, and heating processes. Two simple tests – one for insurge process and another for outsurge process – have been reported to demonstrate and verify the functions of the pressurizer model. The typical single-phase PWR system model presented in the first RELAP-7 milestone report has been updated, as part of system level test for the new pressurizer model. The updated PWR system model with the pressurizer component can be used for more realistic transient simulations. The addition of the equilibrium single-region pressurizer model represents the first step of developing a suite of pressurizer models with different levels of fidelities. Non-equilibrium two-region two-zone model and non-equilibrium five-region three zone model will be implemented in the near future. Cross comparison and validation will be pursued when higher fidelity pressurizer models are completed.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2014

RELAP-7 Beta Release: Summary of Capabilities

RELAP-7 is a nuclear systems safety analysis code being developed at the Idaho National Laboratory (INL). Building upon the decades of software development at the INL, we began the development of RELAP-7 in 2011 to support the Risk Informed Safety Margins Characterization (RISMC) Pathway. As part of this development, the first lines of RELAP-7 code were committed to the software revision control repository on November 7th, 2011. The overall design goal of RELAP-7 is to take advantage of the previous thirty years of advancements in computer architecture, software design, numerical methods, and physical models in order to provide capabilities needed for the RISMC methodology and to support nuclear power safety analysis. RELAP-7 is built using the INL’s modern scientific software development framework, MOOSE (Multi-physics Object Oriented Simulation Environment). MOOSE provides improved numerical calculations (including higher-order integration in both space and time, yielding converged second-order accuracy). The RELAP-7 code structure is based on multiple physical component models such as pipes, junctions, pumps, etc. Each component can have options for different fluid models such as single- and two-phase flow. This component-based and physics-based software architecture allows RELAP-7 to adopt different physical models for different applications. A relatively new two-phase hydrodynamic model, termed the ''7-Equation model'' for two phasic pressures, velocities, energies, and volumetric fraction, is incorporated into RELAP-7 for liquid-gas (water-steam) flows. This new model allows second-order integration because it is well-posed, which will reduce the numerical error associated with traditional systems analysis codes. In this paper, we provide a RELAP-7 capability list describing analysis features, range of applicability, and reactor components that will be available for the December 15th, 2014 beta release of the software.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2015

Decommissioning of a facility in a historical reactor at SRS: achieving both historical significance preservation and effective in-situ decommissioning - 15275

The Savannah River Site (SRS) is an 802 square-kilometer United States Department of Energy (US DOE) nuclear facility located along the Savannah River near Aiken, South Carolina, where Management and Operations are performed by Savannah River Nuclear Solutions, LLC (SRNS). In 2004, US DOE recognized SRS as a structure within the Cold War Historic District of national, state and local significance because it is composed of the first generation of facilities constructed and operated from 1950 through 1989 to produce plutonium and tritium for our nation's defense. US DOE agreed to manage the SRS 105-C Reactor Facility as a potentially historic property due to its significance in supporting the U.S. Cold War Mission and for potential for future interpretation. The Disassembly Basin (DB) in C Reactor was evaluated for action under CERCLA. Data indicated there were over 830 curies of radioactivity associated with the basin sediments and approximately 9.1 million (M) liters (L) of contaminated water, not including a large quantity of activated reactor equipment, scrap metal, and debris on the basin floor. The release of DB water could potentially migrate to the aquifer and contaminate groundwater. The need for an action was identified to reduce risks to personnel in the facility and to eliminate the possible release of contaminants into the environment. In-situ decommissioning was selected as the remedy. The remedial action proceeded in stages: -Above-grade modifications to the interior of DB building -Relocation of irradiated scrap and reactor components to the deepest segments of the DB - Construction of a metal building to house evaporators - Forced evaporation of the DB's radiologically contaminated water - Grouting with special hybrid grouts - Removal of the evaporators and temporary building. Since the building itself was not demolished and will remain unchanged in appearance with the exception of filling the DB with grout, this ISD removal action/methodology did not adversely impact the historical significance of the 105-C Reactor Building, in accordance with the National Historic Preservation Act, nor did it adversely affect the ability to determine the full extent and details of preservation at some later date. Both special hybrid grout materials met all requirements. Overall average 7-day compressive strength for the dry area mix was 1.54 MPa (223 psi) and for the underwater mix 2.94 MPa (427 psi).Overall 28-day compressive strength for the dry area mix was 2.88 MPa (417 psi) and for the underwater mix 4.99 MPa (724 psi). A limited amount of testing was also performed at 91 days, where the overall compressive strength for the dry area mix was found to be 9.40 MPa (1363 psi) and for the underwater mix 13.98 MPa (2028 psi). All compressive strength values far exceeded the 0.34 MPa (50 psi) minimum requirements. The special, flowable-fill grouts designed and used for P- and R-Reactor ISD and used again for this 105-C ISD removal action resulted in considerable labor, cost, and schedule savings versus conventional materials. As an added bonus/benefit, the CO{sub 2} footprint of the SRS C-Reactor DB ISD was minimized by using a small amount of cement and byproduct material to produce the structural fill materials. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2020

Imaging of Calibrated Defects in Additively Manufactured Materials: Pulsed Thermal Tomography Nondestructive Examination of Additively Manufactured Reactor Materials and Components

Additive manufacturing (AM, or 3D printing) for commercial nuclear energy applications is an emerging method for cost-efficient manufacturing aimed at replacing aging nuclear reactor parts and reducing costs for new construction. Known material flaws in AM include low-density regions consisting of non-sintered powder, which have to be detected to ensure the safety of long-term performance nuclear reactor components. Currently, limited options are available for nondestructive evaluation (NDE), either during or post manufacturing. As a solution to NDE of AM, we are developing pulsed thermal imaging which is non-contact, one-sided, and scalable to arbitrary size and shape of the AM parts. Pulsed thermography (PT) system utilizes a high intensity flash lamp to rapidly heat surface of sample, and a high sensitivity fast-frame megapixel infrared (IR) camera to capture data of surface temperature variations. The acquired data cube consists of a stack of surface temperature images taken at different times. Information about material internal defects is extracted by analyzing the data cube. This report provides results of preliminary performance evaluation of pulsed thermal imaging capability in detection of imprinted flaws in AM metallic structures. The flaws were introduced into AM parts as imprinted hemispherical low density regions, consisting of trapped un-sintered metallic powder. Specimens for developed for this study consisted of AM stainless steel 316 and Inconel 718 plates. The diameters of imprinted defects varied from 1mm to 8mm, and their depths below the plate flat surface varied between 1mm and 6mm. Pulsed thermal tomography (PTT) processes the measured data cube to obtain 3D reconstructions of material effusivity using a unique inversion algorithm developed at Argonne. PTT has been previously used in imaging of similar size flat bottom hole (FBH) simulated defects in stainless steel 316 and Inconel 718 specimens. In the study involving AM specimens, PTT imaging results have shown that 1mm-diameter defects located 1mm and 2mm below the surface of specimens were detectable. Larger size defects were detectable at greater depth. We also explored an alternative approach to detection of material flaws in PT data cube, which is using neural learning-based approach to blind source separation. Detection of small material defects requires finding features in the data cube which have signal contrast levels approaching sensitivity limit of IR camera. In this study, an optimized Neural Learning based Blind Source Separation (NLBSS) algorithm, including Principal Component Analysis (PCA), and Independent Component Analysis (ICA) is demonstrated to automatically extract principal temporal and spatial features of thermography frames to enhance flaw detection. By using the NLBSS algorithm, material internal defects can be automatically detected. Furthermore, this processing approach compensates for experimental thermal imaging artifacts, such as noise and uneven heating. By merging artificial intelligence with phtotothermics, the NDE system detects internal calibrated defects of various sizes and depths in AM nuclear-grade metallic alloys.

36 MATERIALS SCIENCE↗