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DOE OSTI2012

Fast 704 MHz Ferroelectric Tuner for Superconducting Cavities

The Omega-P SBIR project described in this Report has as its goal the development, test, and evaluation of a fast electrically-controlled L-band tuner for BNL Energy Recovery Linac (ERL) in the Electron Ion Collider (EIC) upgrade of the Relativistic Heavy Ion Collider (RHIC) at Brookhaven National Laboratory (BNL). The tuner, that employs an electrically-controlled ferroelectric component, is to allow fast compensation to cavity resonance changes. In ERLs, there are several factors which significantly affect the amount of power required from the wall-plug to provide the RF-power level necessary for the operation. When beam loading is small, the power requirements are determined by (i) ohmic losses in cavity walls, (ii) fluctuations in amplitude and/or phase for beam currents, and (iii) microphonics. These factors typically require a substantial change in the coupling between the cavity and the feeding line, which results in an intentional broadening of the cavity bandwidth, which in turn demands a significant amount of additional RF power. If beam loading is not small, there is a variety of beam-drive phase instabilities to be managed, and microphonics will still remain an issue, so there remain requirements for additional power. Moreover ERL performance is sensitive to changes in beam arrival time, since any such change is equivalent to phase instability with its vigorous demands for additional power. In this Report, we describe the new modular coaxial tuner, with specifications suitable for the 704 MHz ERL application. The device would allow changing the RF-coupling during the cavity filling process in order to effect significant RF power savings, and also will provide rapid compensation for beam imbalance and allow for fast stabilization against phase fluctuations caused by microphonics, beam-driven instabilities, etc. The tuner is predicted to allow a reduction of about ten times in the required power from the RF source, as compared to a compensation system with narrower bandwidth. It is planned to build a 704 MHz version of the tuner, to check its underlying principles, and to make high-power tests at power densities aimed towards controlling 50 kW of average power. Steps towards this goal will be limited by, among other factors, losses in the actual ferroelectric elements in the ferroelectric assemblies. As the ferroelectric material loss tangent is reduced through efforts by the supplier Euclid TechLabs LLC, the concomitant power loss in its ferroelectric assemblies will drop, and the average power-handling capability of the Omega-P tuner will rise. It can thus be anticipated that the Phase II development project of the 704 MHz tuner will be iterative, but the pace and ultimate power-handling level of the tuner is difficult to predict at this early stage in Euclid's development program. Fortunately, since Omega-P's conceptual tuner is a simple module (nominally rated for 5 kW), so that the number of modules required in each tuner can be chosen, depending upon the cavity power level needed, plus the power for tuner losses.

43 PARTICLE ACCELERATORS↗

DOE OSTI2025

Structure of Iridium Oxides and Their Oxygen Evolution Electrocatalysis in Acidic Media

Proton exchange membrane water electrolyzers (PEMWEs) have emerged as one of the most promising technologies for the large-scale production of clean hydrogen. Gigawatt scale deployment of PEMWEs requires substantial reduction in the loading of iridium (Ir), which is one of the most expensive and rarest elements. Substantial reduction in Ir loading calls for the development of innovative Ir-based anodes, which requires a clear understanding of how iridium oxides accelerate the sluggish oxygen evolution reaction (OER) in acidic media. Herein, we studied the structure and OER electrocatalysis of three representative iridium oxides ─ hydrous, amorphous, and rutile ─ by employing a combination of physicochemical and electrochemical characterization. Additionally, we found that the hydrous iridium oxide had a different local structure of IrO 6 octahedra and a superior OER intrinsic activity compared with the other two, and that the OER activities of all three types decreased with decreasing pH of acidic solution. We proposed that the OER process of these iridium oxides is limited by water nucleophilic attack on the OER intermediate oxygenated adsorbates. Based on this mechanism, we attributed the superior OER activity of hydrous iridium oxides to their longer Ir–O bonds and the pH-dependent OER activity of iridium oxides to the pH-dependent oxidation of Ir.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2025

ELECTRIFICATION OF A HEAVY-DUTY OFF-ROAD MATERIAL HANDLER: ENERGY SAVINGS AND EMISSION REDUCTIONS

Federal regulations are driving the adoption of electrification technologies to reduce carbon dioxide equivalent (CO2e) emissions, a metric that quantifies the global warming potential of various greenhouse gases in terms of carbon dioxide (CO2). Although no specific CO2 regulations exist for heavy-duty off-road machines, future reductions are likely, given stricter emissions standards for on-road vehicles. The heavy-duty off-road sector offers significant fuel-saving potential, as its focus has traditionally been on reliability and performance rather than fuel efficiency. This dissertation examines fuel and CO2e savings opportunities on a heavy-duty off-road material handler, the Pettibone Cary-Lift 204i, from stock configuration to simple modifications to a complete teardown and reconfiguration of the machine with a plug-in series hybrid architecture using electrified hydraulics. The study begins by modeling the baseline machine’s fuel and energy consumption, calibrating with experimental data from custom operating cycles. An energy analysis identifies key areas for fuel savings. Two simple powertrain modifications result in a combined 16.2% fuel savings. Next, a Pugh-style analysis narrows a list of electrified architectures, leading to high-fidelity models that evaluate total lifetime CO2e and costs. Higher electrification levels reduce CO2e emissions but increase costs, and electricity grid emissions significantly impact CO2e for plug-in architectures. A plug-in series hybrid is chosen for the project. In its base control form, 49% fuel and 29% CO2e savings are expected from the plug-in series hybrid compared to the baseline machine. Further savings are pursued through regenerative braking (6.3%) and load-following hydraulic control (17.8%), totaling 24.1% fuel savings, and leading to a total of 61% fuel and 41% CO2e savings compared to the baseline. Battery chemistries and charging strategies are also analyzed for cost and CO2e impacts, finding LFP batteries as superior due to longevity, and overnight level 2 charging usually at a lower cost but resulting in higher emissions than opportunity DC fast-charging (DCFC). DCFC emissions are highly dependent on grid emissions, and DCFC cost is highly dependent on grid demand charges. Finally, artificial intelligence is applied to operating cycle recognition. Neural network accuracy ranges from 81% to 99%, with applications to worksite efficiency and safety improvements.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2019

Technology solutions to mitigate electricity cost for electric vehicle DC fast charging

Widespread adoption of alternative fuel vehicles is being hindered by high vehicle costs and refueling or range limitations. For plug-in electric vehicles, direct-current fast charging (DCFC) is proposed as a solution to support long-distance travel and relieve range anxiety. However, DCFC has also been shown to be potentially more expensive compared to residential or workplace charging. In particular, electricity demand charges can significantly impact electricity cost for fast charging applications. Here we explore technological solutions that can help reduce the electricity cost for electric vehicle fast charging. In particular, we consider thousands of electricity rates available in the United States and real-world vehicle charging load scenarios to assess opportunities to reduce the cost of DCFC by deploying solar photovoltaics (PV) panels and energy storage (battery), and implementing a co-location configuration where a DCFC station is connected to an existing meter within a commercial building. Results show that while the median electricity cost across more than 7000 commercial retail rates remains less than $0.20/kWh for all charging load scenarios considered, cost varies greatly, and some locations do experience significantly higher electricity cost. Co-location is almost always economically viable to mitigate fixed cost and demand charges, but the relative benefit of co-locating diminishes as station size and utilization increase. Energy storage alone can help mitigate demand charges and is more effective at reducing costs for 'peaky' or low-utilization loads. On the other hand, PV systems primarily help mitigate energy charges, and are more effective for loads that are more correlated with solar production, even in areas with lower solar resource. PV and energy storage can deploy synergistically to provide cost reductions for DCFC, leveraging their ability to mitigate demand and energy charges.

25 ENERGY STORAGE↗

DOE OSTI2020

Electric Vehicle Adoption in Illinois

Over 1.3 million plug-in electric vehicles (PEVs) have been sold in the United States since 2010 when the first Chevy Volt and Nissan Leaf vehicles came on the market. Currently, electric vehicles account for about 2% of monthly light-duty vehicle (LDV) sales. More than 40 different electric vehicle models are actively being marketed, and most of these are LDVs. Over the last few years, automakers have brought more models, with varying mileage ranges, to the market, including medium-duty and heavy-duty trucks and buses. Government agencies at the federal, regional, and state levels, as well as utilities across the United States, have provided financial and non-financial incentives to promote electric vehicle adoption and charging infrastructure deployment. Argonne National Laboratory, sponsored by the U.S. Department of Energy, has developed tools and collected data to quantify the energy, economic, and environmental benefits of electric vehicles. This project has three objectives. First, we summarize the policies and other actions of the federal government, various states/regions, and utilities to promote PEV adoption, and evaluate their relative effectiveness based on a review of the literature. Second, we identify possible PEV adoption paths or scenarios that would result in PEVs making up 15% of all on-road vehicles in Illinois, and we quantify the resulting impacts on petroleum consumption and electricity demand. We also summarize the possible reduction in greenhouse gas (GHG) and criteria pollutant emissions due to PEV adoption. The PEV scenarios include private and public adoption of electric cars, light trucks (e.g., sports utility vehicles [SUVs], vans, pickups), medium-duty vehicles (MDVs), and heavy-duty vehicles (HDVs). Third, we estimate hourly charging loads of light-duty PEVs in 2030 associated with these scenarios, incorporating assumptions about vehicle electric range, efficiency, and travel behavior.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2016

Overview of the Salt at Wall Thermal Exchanges (SWATH) Experiment

Molten Salt Reactors have attracted increased attention in recent years because of the design and safety possibilities offered by the use of a liquid fuel. The European project SAMOFAR1 (2015-2019) is currently coordinating the research efforts on the Molten Fast Salt Reactor (MSFR) concept in Europe. The MSFR is a fast-spectrum breeder reactor with a large negative power coefficient that can be operated in a Thorium fuel cycle. The fast spectrum allows the reduction of the reprocessing requirements and a better reactor breeding ratio. Other advantages of the MSFR design are the possibility for actinide burning and extending fuel resources, on-line fuel loading and reprocessing and the use of novel passive safety systems such as the fuel salt draining system. The reference MSFR concept is a 3000 MW(th) reactor with three different circuits: the fuel circuit, the intermediate circuit and the power conversion system. The main components of the fuel circuit are the fuel salt which serves as fuel and coolant, the core cavity, the inlet and outlet pipes, the gas injection system (not shown in the figure), the salt-bubble separators, the fuel heat exchangers and the pumps. A lithium fluoride salt has been selected as the fuel matrix. The initial composition (non-irradiated) of the MSFR fuel salt is a mixture of a lithium fluoride, thorium fluoride salts and actinides fluoride (LiF-ThF{sub 4}-{sup 233}UF{sub 4} or LiF-ThF{sub 4}- {sup enr}UF{sub 4}-(Pu-MA)F{sub 3}), with the proportion of LiF fixed at about Development of accurate numerical models for the MSFR can only be accomplished by the use of a multiphysics approach which allows taking into account the coupling between relevant neutronics, thermal hydraulics and thermomechanics phenomena. As it is discussed in the next section, such a reactor model requires further progress on the knowledge of molten salt thermal hydraulics, in particular regarding the accuracy of the fuel salt Computational Fluid Dynamics (CFD) models. The Salt at Wall: Thermal Exchanges (SWATH) experiment is being designed to contribute to this particular point. SWATH is one of the experimental activities of the European H2020 SAMOFAR project and includes both experimental and numerical developments. The main objectives of SWATH are to: (i) Improve molten salt numerical models used for design and safety studies and (ii) Demonstrate the working principles of the cold plug device. The cold plug device is a key safety component of the salt draining system of the MSFR. The cold plug is intended to passively melt during accidental conditions thus allowing the flow of the nuclear fuel from the core cavity to the fuel salt draining tanks by gravity forces. The fuel salt draining tanks are designed to ensure that adequate margins are obtained regarding the fuel cooling capabilities and the reactivity control. The next sections provide an overview of the current challenges in molten salt thermal hydraulics modeling and the SWATH experiment design. (authors)

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

NASA NTRSDate not supplied

An Overview of Experiments and Modeling of Polysiloxane-Coated Thermal Protection Systems for Missions to Mars, Titan, and Beyond.

Phenolic Impregnated Carbon Ablator (PICA) gained heritage during the historic Stardust mission, where it successfully returned samples from a comet’s tail and has since been instrumental in delivering payloads to the surface of Mars [1-3]. Most recently, PICA enabled the safe return of samples collected from asteroid Bennu as part of the OSIRIS-REx mission. This rich legacy underscores PICA’s critical role in allowing NASA’s most ambitious exploration missions. However, the friable nature of its phenolic phase presents challenges during handling and pre-launch activities. To mitigate this issue, PICA is coated with a polysiloxane resin system, which serves to suppress particulate dispersion and thereby safeguard spacecraft components. A comprehensive understanding of the polysiloxane resin’s behavior is imperative, as it profoundly shapes the material response of PICA during atmospheric entry by influencing its thermal and oxidative stability. This influence extends to thermocouple plugs embedded within thermal protection systems. These plugs have demonstrated their significance in missions such as Mars Science Laboratory (MSL) and Mars 2020, where the MEDLI and MEDLI2 instrumentation suites delivered in-valuable insights into the performance of thermal protection systems during entry into the Martian atmosphere [4]. Looking ahead, missions such as Dragonfly, set to descend into Titan’s dense atmosphere, aim to leverage advanced sensor technologies to further refine our understanding of thermal protection response [5]. Moreover, thermocouple plugs play an essential role in validating cutting-edge material response models, such as those pioneered under NASA’s Entry Systems Modeling Project (ESM), designed, in-part, to predict the operational integrity of thermal protection systems under the extreme stresses of atmospheric entry. To achieve these modeling goals, ground-based experiments are crucial to provide the foundational data necessary for developing and refining these predictive tools. To this end, an extensive test campaign was conducted at the Hypersonic Materials Environmental Test System (HyMETS) to investigate the high-temperature behavior of the polysiloxane resin in an air environment [6]. These experiments revealed critical phenomena, including the formation of a silicon oxycarbide layer that enhances oxidation resistance, moderates surface temperatures, and alters in-depth thermal response. Building on these findings, subsequent tests were designed to simulate atmospheric entry conditions in reactive gases, such as CO2 and N2, to mimic the environments of Mars and Titan, respectively, as well as non-reactive gases representing the atmospheres of the Ice Giants (Neptune and Uranus). A heating rate dependent decomposition mechanism has been identified for the polysiloxane resin under oxidizing conditions (Fig. 1). In the initial stage, the resin and the underlying thermal protection system undergo pyrolysis, rapidly generating a thin amorphous silicon oxycarbide interwoven with carbonaceous char and residual fibers from PICA. During the second stage, the nascent oxide layer establishes a robust, oxidation-resistant thermal barrier coating, which significantly impedes heat transfer to the underlying carbonaceous char, resulting in a stagnation of the surface temperature. A key factor contributing to this thermal resistance is the low recombination efficiency of atomic oxygen (γ), which further diminishes the heat load on the material’s interior layers [7]. Moreover, as the surface temperature stagnates, the silicon oxycarbide phase separates into distinct regions of silica and free graphite. Ultimately, when the heat flux reaches a critical threshold, a third stage is triggered, leading to the breakdown of the coating through carbothermal reduction, exposing the underlying char layer. This exposure leads to a dramatic surface temperature spike, driven by highly exothermic reactions between atomic oxygen and the char layer, further accelerating material degradation. A detailed mass and heat transfer model of PICA coated with polysiloxane resin was implemented in the Porous material Analysis Toolbox based on OpenFOAM, PATO [8]. The initial stage was considered negligible in this model because the resin decomposition occurs rapidly within a thin surface layer. Instead, the coating was directly considered as an oxygen-resistant thermal barrier coating. For the second stage, the thin amorphous silicon oxycarbide was treated as a pure silica surface to simplify the thermochemical behavior. The model ac-counts for surface equilibrium processes using representative elements of the coating-environment system. For the third stage, specific boundary conditions were developed to estimate the onset and progression of the coating removal. Two-dimensional material response simulations were conducted to compare uncoated and coated PICA using boundary conditions calibrated with HyMETS data. Fig. 2 illustrates that the simulations closely align with experimental data, successfully reproducing measured temperature profiles. This work will include the latest advancements in the coating model, including the calibration of recombination of atomic oxygen at the surface during the second phase. These simulated results will be further validated against additional CO2 data points from HyMETS, reinforcing the models’ predictive capabilities. These mechanisms and their effects on thermal protection systems, including thermochemical behavior and thermocouple probe performance in extreme environments, provide crucial insights for optimizing spacecraft designs that safeguard scientific payload and ensure mission success in future planetary exploration endeavors.

Active Oxidation↗

DOE OSTI2016

Idling Reduction for Long-Haul Trucks: An Economic Comparison of On-Board and Wayside Technologies

Reducing the idling of long-haul heavy-duty trucks has long been recognized as a particularly low-hanging fruit of fuel efficiency and emissions reduction. The displacement of about 10 hours of diesel idling every day, for most days of the year, for as many as a million long-haul trucks has very clear benefits. This report considers the costs and return on investment (ROI) for idling reduction (IR) equipment for both truck owners and electrified parking space (EPS) equipment owners. For the truck owners, the key variables examined are idling hours to be displaced (generally 1,000 to 2,000 hours per year) and the price of fuel ($0 to $5/gal). The ideal IR option would provide complete services in varied climates in any location and offer the best ROI on trucks that log many idling hours. For trucks that have fewer idling hours, options with a fixed cost per hour (i.e., EPS) might be most attractive if they were available to all, or even most, truck drivers. EPS, however, is particularly cost effective for trucks on prescribed routes with a need for regular, extended stops at terminals. (EPS is also called truck stop electrification, or TSE.) The analysis shows that all IR options save money when fuel costs more than $2/gal. For trucks requiring bunk heat, a simple heater (plug-in or diesel) is almost always the most costeffective way to provide heat, even if the truck is equipped with an auxiliary power unit (APU) or is parked at a single-system EPS location. For trucks requiring bunk air-conditioning, the use of single-system EPS is most cost effective for those logging fewer idling hours. Even for trucks with higher idling hours, the cost of EPS may be about the same as that for on-board air-conditioning. Clearly, trucks’ locations and seasonal factors—and the availability of EPS— are significant in the choice of “best fit” IR equipment for truck owners. This report also considers costs and payback for owners of EPS infrastructure. An industry that 5 years ago had at least five players has been narrowed to two companies—one in single-system EPS (IdleAir) and the other in dual-system EPS (Shorepower Technologies). Use of EPS by truck drivers has not met initial expectations for a variety of reasons. One area where EPS has particular promise, however, is in the cost-effective provision of reliable air-conditioning. This analysis is focused strictly on cost and fuel savings; it does not consider the important benefits of reduced emissions (i.e., greenhouse gases and criteria pollutants). It is important to note that all IR options provide some emissions benefits. Even where an IR option may not have a rapid ROI, the emissions-reduction benefit may be considerable. Finally, as the U.S. Environmental Protection Agency (EPA) and the U.S. Department of Transportation’s National Highway Traffic Safety Administration (NHTSA) set stricter standards to reduce greenhouse gas emissions and improve the fuel efficiency of medium- and heavy-duty vehicles, the emissions benefits of IR strategies will become increasingly important.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

NASA NTRSDate not supplied

Quantifying Leak Rates and Vacuum Impact on Granular Soil Column Pneumatic Seal

Introduction: All In-Situ Resource Utilization (ISRU) regolith reactor systems that aim to extract gases or vapors must maintain a seal along the flow path of the regolith from the inlet hopper to where extracted gases or vapors are generated. Using a column of regolith at the inlet has been proposed as an alternative to systems using series of mechanical valves to reduce mass and complexity. Preliminary investigations into the use of regolith itself as a barrier to escaping fluids have been conducted, which this research seeks to expand upon. Different vertical regolith simulant plug diameters and heights were tested under vacuum with dry nitrogen to observe leak rates and approximate steady state pressure gradient equilibria. The effect of absolute ambient pressure was also studied by repeating tests at incremental pressures ranging from 10e-5 Torr up to 1 atm to corroborate ambient bench tests from previous work. The impact of regolith dynamics was addressed to emulate continuous-feed regolith reaction processes by measuring leak rates through continuously draining simulant columns. OB-1 lunar highlands regolith simulant was used. Experimental Setup: Regolith simulant columns were constructed using a motorized butterfly valve separating upper acrylic tubes of various diameters from a larger, lower aluminum pipe plenum (See Figure 1). The butterfly valve was cracked open such that gas could freely pass through whereas regolith would bridge and stay suspended as a cohesive plug above in the acrylic portion. These assemblies were loaded into a vacuum chamber, and a compressed dry nitrogen line was routed into the lower plenum. Pressure transducers measured the absolute pressure of the lower plenum, which was compared to absolute chamber pressure to monitor the pressure gradient across the regolith simulant. A precision mass flow controller enabled fine control of plenum pressure. The plenum pressure was quasi-statically increased to set points informed by previous work [1] before shutting off the gas supply to allow the now pressurized gas volume to dissipate through the simulant into the chamber in what was referred to as a ‘leak test.’ In a separate set of tests, the pressure was allowed to quasi-statically build until visual disturbances in the soil were observed via remote camera feeds. Initial leak rate tests were repeated on the disturbed soil to observe changes in leak rates between initial as-poured and post-bubbling soil conditions. This test schedule was applied to simulant columns of three different diameters (approximately 2, 4, and 6 inches) as well as two different heights (around 8 and 16 inches) and was repeated at least three times for each configuration. Plenums were also pressurized while the butterfly valves were opened slightly further to facilitate slow, controlled, constant flowrate draining of the simulant to observe the impact that continuous-feed systems might have on leak rate through the regolith column. Finally, the regolith columns were reset and refilled and static leak rate tests were repeated approximately every decade in ambient pressure from 10e-5 Torr up to ambient conditions to observe the impact of transitioning out of the molecular flow regime on regolith column seal performance. Analysis: Trends with respect to each factor examined were constructed and reported alongside commentary on the most likely responsible physical phenomena. Confidence intervals were applied to the predictive findings of the data by quantifying instrumentation error and accounting for probabilistic impacts of curve fitting the generic exponential function onto pressure decay data. The leak rate is assumed directly proportional to the exponential term coefficient, while the steady-state static pressure gradient is assumed to be the asymptotic limit of each curve fit. Finally, a generic model developed by Ogino et al. [2] and later tuned for ambient testing was re-tuned using vacuum data to estimate leak rates on the lunar surface. Results: Pressure decay rates decreased up to 27-fold under vacuum when compared to ambient pressure, as shown in Figure 2. Simulant column diameter was found to exponentially correlate to both regolith column leak rate and steady-state equilibrium pressure delta. Height was found to be linearly related to leak rate –doubling the regolith column height consistently yielded around a 40% reduction in leak rate. Dynamic regolith draining was found to slightly increase leak rate, although to a lower degree than expected. Conclusion: Because of the transition into molecular gas flow through regolith, vacuum testing is required to properly estimate performance. Regolith columns should be designed as narrow as possible to avoid bridging and minimize leak rate, and as tall as is feasible to both further reduce leak rate and to help prevent bubbling, which has been shown to degrade the quality of the regolith seal. Disrupted soil was found to exhibit higher leak rates than pristine, as-poured soil, indicating the need to consider the impact of recovery from depressurization events. Regolith columns appear equally feasible for both dosed and continuous-feed reactors.

ISRU↗

DOE OSTI2025

Identifying Challenges in Safeguards for Metallic Fuel Fabrication Facilities

As new advanced reactors gain popularity, there is an increasing interest in metallic fuel fabrication for fast reactors. While metallic fuels themselves are not a new idea, as many of the first reactors employed metallic fuels, new designs, compositions, and fabrication methods are appearing throughout the nuclear community. As the interest grows and facilities are constructed, both domestic and international safeguards will need to be heavily involved to support safeguards-by-design (SBD) measures from the start. This work compiles a review of historical and modern fuel types and fabrication methods, fabrication processes, safeguards gaps, and potential safeguards solutions. Metallic nuclear fuel types have been around for many decades and were included in some of the first reactors including the Experimental Breeder Reactor (EBR)-I and -II, the Fermi 1 reactor, the Integral Fast Reactor (IFR), and the Dounreay Fast Reactor (DFR). These reactors used various compositions including pure uranium (U) metal, U-zirconium (Zr) alloys, plutonium (Pu)-aluminum (Al) alloys, U-fissium (Fs) alloys, U-Pu-Zr alloys, and U-molybdenum (Mo) alloys [1, 2, 3, 4, 5]. These small alloying additions are included to improve the material properties of the pure U metal. The alpha-phase U (stable below 661C) suffers elongation in one direction causing grain boundary cracking and increasing creep rate due to irradiation growth, thermal cycling, and preferential crystal orientation. It is ideal to utilize the gamma-phase U (typically stable above 769C) by adding small amounts of alloying elements such as Zr or Mo to stabilize this phase down to room temperature [3]. Additionally, some research has been focused on U with transuranic (TRU) elements present, typically coming from the used fuel recycling process. Including these elements in fast reactor fuel can aid in the reduction of nuclear waste by burning minor long-lived actinides. However, the additions of TRU elements can cause concerns to arise when trying to fabrication or safeguard metallic fuels. A typical metallic fuel element is shown in Figure 1. Sodium is added into the cladding to create a thermal bond between the fuel slug and cladding wall. The fuel slug is then inserted and the end plug is welded on to the top of the fuel element. A gas plenum is left to create a headspace for gaseous fission products to escape rather than continue to build in the fuel itself [1, 5]. Other fuel element geometries exist as well, such as the Lightbridge twisted cruciform geometry shown in Figure 2 [6]. This design allows for better cooling performance and provides room for fuel rod swelling without impacting the fuel rod diameter. There are many different fabrication methods for metallic fuels, which is one of the many benefits of these fuel types. Many of these fabrication methods are relatively easy and cost-efficient. The most popular fabrication method is injection casting, sometimes called vacuum induction melting (VIM), shown in Figure 3 [4, 8, 9, 7, 10]. This method was largely used for EBR-II fuel fabrication. The injection casting system is contained inside of a vessel consisting of a Y2O3-coated graphite crucible surrounded by an induction coil with ZrO2-coated quartz molds suspended above the crucible. The fuel feedstock is placed inside of the graphite crucible and melted using the induction furnace. The induction furnace utilizes a dual frequency with the high frequency melting the feedstock and the low frequency causing stirring of the melted feedstock to form a homogeneous mixture. The mixture is heated to approximately 1600C in an argon environment. The vessel is evacuated and then the quartz molds are lowered into the graphite crucible containing the molten metal and the vessel is repressurized to inject the metal fuel upwards into the molds. The molds are removed and then shattered to release the fuel slugs. This fabrication method was used to fabricate 39,000 metallic fuel pins for EBR-II. While injection casting has been the most common metallic fuel fabrication method throughout the decades, many other methods have been explored including low-pressure gravity casting, microwave casting, continuous casting, centrifugal casting, coextrusion, and many others [11, 12, 8, 13, 14, 15]. Some of these methods aim to mitigate challenges that arise with americium (Am) volatilization during the casting process for TRU-containing fuel feedstocks, an issue with injection casting. Coextrusion is one of the methods explored at the Idaho National Laboratory (INL) and has been utilized for the initial fabrication tests of Lightbridge's unique fuels, as well as other metallic fuels with cladding coextruded. In this process, large billets are formed and machined and then inserted into a molten salt bath for approximately 30 minutes. The billets are then loaded into the extrusion press and extruded. This process can be seen in Figure 4 [15].

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗