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

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At least 937 records · Page 52
All sourcesNASA NTRSDOE OSTI
DOE OSTI2019

Low-Cost, Efficient and Durable High Temperature Wireless Sensors by Direct Write Additive Manufacturing for Application in Fossil Energy Systems

In-situ monitoring of physical parameters in fossil energy (FE) systems is challenging because of their high operating temperatures and oxidizing environments. This research aims utilize Aerosol Jet (AJ) nanoparticle printing, an advanced additive manufacturing method, to fabricate high temperature sensors for FE applications. Sensor films were fabricated by the AJ printing method with an excellent control over film microstructure and properties, in addition to creating less waste. Printing of six different materials, namely, silver (Ag), nickel (Ni), nickel-chromium (NiCr) alloy, copper (Cu), copper-nickel (CuNi), and carbon nanotubes (CNTs) was carried out for their evaluation of as sensor films. The films were then characterized using impedance spectroscopy, scanning electron microscopy (SEM), transmission electron microscopy (TEM), x-ray diffraction (XRD), and x-ray photoelectron spectroscopy (XPS). Film microstructure was correlated with the sensor electrical and mechanical behavior at different temperatures (24-500 °C) and frequencies (0.02 - 300 kHz). This knowledge was then used to fabricate, test, and characterize strain and temperature sensors for high temperature applications. The strain sensors were shown to have a very low thermal strain up to 500 °C and a 57% higher gauge factor compared to the commercially available counterparts. This enhance performance was attributed to the inherent porosity in the sensor films that allowed the films to exhibit a metamaterial-like behavior when deformed. The AJ printed temperature sensors were shown to have the highest Seebeck coefficient amongst all the film-based temperature sensors. In addition, fundamental aspects of crystal structure and phase transformations in Ba(Fe0.7Ta0.3)O3-δ (BFTO), a high temperature sensor material, was investigated along with 3D printed antennas that can transmit sensor signals at high temperatures. Two PhD students, one from first generation college-going underrepresented minority community (URM), two postdoctoral fellows, and several masters and undergraduate students were supported by this award. This work opens up the possibility of realizing low-cost high-performance sensor devices using advanced manufacturing techniques for high temperature FE applications.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2020

Risk-Informed Safety Analysis for Accident Tolerant Fuels

Accident Tolerant Fuels (ATF) are being tested by different nuclear vendors and research organization and their introduction in light water reactors fleet is planned for the second half of the 2020`s. In the framework of the US-DOE Light-Water Reactor Sustainability program, Risk-Informed Safety Analysis pathway (LWRS-RISA), research activities are being conducted at the Idaho National Laboratory (INL) for developing tools and methods that can help the industry in quantifying the ATF introduction benefits. In this paper we describe the developed risk-informed methodology, the codes improvements and we present some results for selected accidental conditions. The developed methodology combines INL state-of-the-art deterministic Best Estimate tools like RELAP5-3D code, and Probabilistic Risk Analysis tools like RAVEN and SAPHIRE codes. The analyses are performed on a three-loops pressurized water reactor (PWR) simulating accidental conditions like Station Blackout and LB-LOCA and considering near-term ATF (FeCrAl and Chromium-coated clads). Finally, we show, through our methodologies, how the delta-Core Damage Frequency can be assessed.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2020

Plane-Strain Tension Testing of ATF FeCrAl Cladding (Progress Report)

Performance of advanced accident-tolerant fuel (ATF) claddings must be assessed under all relevant scenarios, including normal and off-normal operating conditions, as well as during a reactivity-initiated accident (RIA). During RIA, the fuel pellet may expand and cause significant loads on cladding, a condition known as pellet cladding mechanical interaction (PCMI), which may even lead to cladding failure. This report describes the fiscal year (FY) 2020 research activities and results from the development of separate-effects testing for ATF cladding candidate iron-chromium-aluminum (FeCrAl) tube specimens under loading conditions expected during RIA/PCMI events. To assess material performance under PCMI, a high strain rate burst test, often termed the modified burst test (MBT), is commonly employed. However, execution of such a test in a hot cell requires significant research. To overcome the complexities of performing MBTs in a hot-cell environment on irradiated samples, a plane-strain tension (PST) test was proposed by several authors as an alternative approach for PCMI testing. A new fixture was developed so that PST specimens could be tested using a more accommodating design for hot-cell manipulators. This report presents the PST fixture design, evaluates the possibility of modifying the specimen geometry, and discusses experimental results with unirradiated Al 6061 and FeCrAl tubes at various lengths. Furthermore, this report discusses the relevance and compatibility of the PST results to RIA scenarios and compares the PST and MBT results.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2020

The Opus radiative opacity code, a new implementation of the super-transition array method

This report describes the development of our new radiative opacity code Opus, submitted as part of a 2020 Level 2 milestone requirement. This code aims to incorporate the capabilities in existing but separate opacity codes previously developed at LLNL (Opal, Topaz, and Tycho). The first phase in the development, which was to implement the super-transition (STA) method of Bar-Shalom and co-workers is now completed. In this work, we describe the underlying physics, implementation, usage, and regression testing as well as providing numerical examples for the opacity tables of boron, chromium, iron, and nickel. The latter are benchmarked against the LLNL legacy STA code Tycho, with an average absolute relative difference of ~1.5 and 0.5% for Planck and Rosseland opacity means, respectively. The cases where differences are larger are well understood in terms of numerical instabilities near discontinuities of the average degree of ionization inherent to the assumed opacity/equation-of-state model.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2020

Report Summarizing Boiling Transition (Dryout) Testing of FeCrAl Cladding

Nuclear fuel and cladding in a light water reactor must maintain integrity under all normal operational and anticipated operational occurrences. In a Boiling Water Reactor (BWR) some Anticipated Operational Occurrences (AOOs) and Anticipated Transients Without SCRAM (ATWS) events have been known to result in cladding damage due to dryout with conventional Zircaloy-2 claddings. This work presents an assessment of commercially-fabricated, accident tolerant iron-chromium-aluminum (FeCrAl) alloy C26M cladding in such events with regard to the ballooning failure mode for unirradiated cladding In the severe accident test station (SATS), an experiment has been developed to gauge accident tolerance of fuel cladding materials under simulated cyclic dryout conditions. Thermal cycling from 300°C to 650°C was implemented on C26M and Zircaloy-2 tubes. The C26M tube did not fail after 54 cycles. The Zircaloy- 2 tube run under the same parameters as the C26M tube failed during the fourth cycle, consistent with expectations from the literature. Due to thermal gradients present in the furnace, both tubes experienced a maximum temperature at ~780°C. Due to differences in tube geometry, the hoop stress of the C26M tube was significantly higher than that of the Zircaloy-2 tube, 76 MPa at the maximum peak temperature compared to 55 MPa at burst, respectively. The cyclic dryout experiments show an increased performance of C26M over Zircaloy-2 under simulated conditions, an indication of C26M possessing superior high temperature oxidation resistance, mechanical properties and potentially resistance to fatigue.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2020

The transient properties of 2D magnets: from mechanical exfoliation to ultrafast optical spectroscopy of CrX 3 materials

The discovery of two-dimensional (2D) systems hosting intrinsic long-range magnetic order represents a seminal achievement, adding to the already diverse array of physics supported by layered van der Waals (vdW) materials. This finding has spurred great interest among the research community, with efforts aimed at uncovering their fundamental properties and light- matter interactions. A prototypical example of a 2D magnetic material is Crl 3 , where the strong relationship between crystalline structure and magnetic order, along with strong light- matter interactions, provide a promising platform to explore the nature of couplings between magnetism and the other degrees of freedom at the 2D limit. In this report, we highlight our efforts involving the use of time-resolved magneto-optical Kerr effect (TR-MOKE) spectroscopy to probe the magnetization and vibrational dynamics of Crl 3 . These measurements reveal evidence of strong exchange-mediated coupling between lattice vibrations and spin oscillations. Additionally, we discuss our related efforts to explore other material from the Chromium trihalide family through mechanical exfoliation to support subsequent optical spectroscopy investigations.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Fiscal Year 2020 Filtration of Hanford Tank Waste 241-AP-105

Bench-scale filtration testing of 15 liters of 241-AP-105 supernatant was conducted using a Mott inline filter Model 6610 (media grade 5) backpulsed dead-end filter (BDEF) in the hot cells of the Radiochemical Processing Laboratory at Pacific Northwest National Laboratory. The as-received samples were diluted with raw water from the Hanford Site to assess the propensity for solids to form upon dilution and to assess the impact those solids have on filtration performance. The feed was split into two batches. The first batch was settled and decanted as planned in Tank Side Cesium Removal operations. The BDEF was used to filter this AP-105 feed at a targeted flux of 0.065 gpm/ft 2 and exhibited no measurable pressure increase during filtration. The second batch was fed to the BDEF with solids resuspended. This was also operated at the targeted flux of 0.065 gpm/ft 2 . In this case, the target pressure differential of 2 psid (resistance of 6.24 × 10 10 m -1 ) was reached in slightly more than 12 h. A backpulse restored the filter flux; however, the time to the next backpulse was slightly shorter. These tests indicate that after the addition of raw water, settle and decant effectively removed solids from the feed. It is not possible to assess the time required for these solids to settle based on the result from these tests. However, if sufficient time is allowed for the solids to settle, no measurable filter fouling was observed in current testing. In contrast, if insufficient time is allowed for solids to settle, filter fouling will occur relatively quickly and will likely require backpulses more frequently than every 12 hours (1.91 m 3 /m 2 volume filtered). Solids concentrated from backpulse solutions displayed large variability in composition with Al-silicates and mixed chromium-aluminum oxide phases. Amounts of Mg, Fe, and Ca were also found in the presence of Na and O. These solids could be grouped in three categories: (1) soluble Na-salts that formed large block-like particles but were made up of fibrous materials, (2) amorphous Al-phases, and (3) colloidal iron oxides with an average particle diameter of 4.2 µm.

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

Spatiotemporal Analyses of Groundwater and Shoreline Cr(VI) Concentrations in the 100 Areas at Hanford

Cleanup efforts have been ongoing since the late 1990s to remediate contaminated waste sites and groundwater in the 100 Areas at the U.S. Department of Energy (DOE) Hanford Site. One of the primary contaminants of concern is hexavalent chromium (Cr(VI)), which was used as a corrosion inhibitor in cooling water for nuclear reactors that formerly operated along the shoreline of the Columbia River. Cleanup efforts have included 1) removal, treatment (as needed), and disposal of contaminated sediments; 2) in situ redox manipulation as a permeable reactive barrier; 3) pump-and-treat; 4) soil flushing; and 5) monitored natural attenuation. DOE’s annual groundwater monitoring reports document the significant reductions in Cr(VI) plume areas that have occurred over the past 10 years or more as a result of these cleanup efforts. The Record of Decision for the 100-HR-3 operable unit specified a cleanup level (CUL) for Cr(VI) in groundwater of 48 µg/L to protect human receptors, and a surface water CUL of 10 µg/L to protect aquatic organisms in the Columbia River. The Record of Decision did not specify point-of-compliance locations for the surface water CUL. Data for 2019 from the six groundwater operable units (OUs) in the 100 Areas indicate that the 48 μg/L groundwater CUL has been achieved in 100% of the wells in the 100-BC and 100-NR OUs, and in 89- 97% of the wells in the other OUs (100-KR, 100-HR-D, 100-HR-H, 100-FR). Data for 2019 indicate that 100% of the aquifer tubes monitored for Cr(VI) in the 100 Areas have concentrations below the 48 μg/L groundwater CUL. However, the 10 μg/L standard has not yet been consistently achieved for both inland groundwater monitoring wells and shoreline aquifer tubes. This report describes a series of data analyses performed to identify consistent relationships, if any, between inland well and shoreline Cr(VI) concentrations within the 100 Areas. To this end, select monitoring data for Cr(VI) measured in groundwater and aquifer tubes at the 100 Areas were analyzed for a 10-year period—2010 to 2019. Relationships between inland groundwater plumes and surface-water points of discharge in and along the Columbia River were examined through several analyses that included inland well and aquifer tube concentrations as a function of distance from the shoreline, evaluation of cumulative probability plots, trend analysis, correlation analysis, cluster analysis, and identification of plume trajectories for each of the 100 Areas. The analyses did not identify consistent relationships between inland groundwater Cr(VI) concentrations and shoreline concentrations within the 100 Areas due to several confounding factors influencing groundwater flow directions and Cr(VI) concentrations. The proximity of groundwater Cr(VI) plumes to the river, and the highly dynamic nature of the river, influence the transport behavior of the plumes and create challenges for quantifying attenuation of Cr(VI) between the inland monitoring wells and shoreline concentrations. Other factors contributing to temporal and spatial Cr(VI) concentrations, as supported by some of the data analyses, include the presence of vadose zone sources, variable sorption behavior, and complexities associated with Cr(VI) mass transfer between the upper and lower aquifers and their interactions with the river. Hence, monitoring to assess compliance with target CULs will need to be determined for each area individually since several factors influence Cr(VI) concentrations in the 100 Areas.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2020

IER-519 CED-2: Final Design for Thermal/Epithermal eXperiments (TEX) with Absorbers to Provide Validation Benchmarks for Hanford Tank Farms

The Hanford tank farms contain 56 million gallons of waste across 177 tanks. The primary criticality safety concern for the waste is the plutonium inventory in waste solids – approximately 670 kg in total. Criticality safety analysis credits the absorption and dilution properties of the large quantities of other elements (aluminum, chromium, iron, manganese, nickel, silicon, sodium, and zirconium) present in the waste. Of these, iron and manganese are by far the most significant neutron absorbers, particularly for the waste compositions of highest criticality safety concern. The criticality safety analyses at the Hanford Waste Treatment and Vitrification Plant (WTP) and the Savannah River tank farms also credit iron and manganese as the primary neutron absorbers to demonstrate subcriticality.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2021

Sensing and arresting metal corrosion in molten chloride salts at 800 degrees Celsius

Originally this was planned as a 5 task, 3 year project, starting in May 2019. Task 1 Detecting oxidants and metal corrosion in molten chloride salt at 800°C. Task 2 Effectiveness of Zr getter using head gas sensors of inlet and outlet gases. Task 3 Cathodic protection of metal in molten salt at reducing potential. Task 4 Find reduction potential of metals in molten chloride salts & quantum modeling. Task 5 Develop corrosion test sections integrated into molten salt flow loop. After Q4, the project was scaled back and the reorganized SOPO was reduced to 3 tasks to be completed at the end of Q7 on 01/05/2021. The 3 SOPO tasks are: Task 1 Sense oxidants and the metal corrosion in molten Na-K-Mg-Cl salt at 800°C. Task 3 Cathodically protect H230 alloy in molten Na-K-Mg-Cl salt at 800C by making H230 alloy the cathode of a power supply with a chromium-rich-metal as the anode. Task 4 Find the reduction potential of Cr metal in molten Na-K-Mg-Cl salt at 800°C. The total timeline was reduced from 12 to 7 quarters with the end date being, January 5, 2021. This amounted to task 1,3 and 4 being done in Q5,6 and 7 of an extended year 1, ending on January 5, 2021. Task 1, 3 and 4 were completed. For task1) the increase of oxidants in molten salt is detected by two things: i) a positive shift of the electrode potential for a Haynes 230 alloy (H230) metal coupon versus a silver/silver-chloride reference electrode (SSE) and ii) an increase in the corrosion rate of a H230 electrode at 800C. For task 3) applying a cathodic potential (negative overpotential) to a H230 electrode versus SSE arrested the corrosion of the cathodically protected H230 compared to an unprotected “spectator H230 electrode” in the same molten chloride salt. Lastly, for task 4) the reduction potential of chrome and chrome rich, and nickel metal electrodes were measured. The most valuable outcome of this work is that a power supply can arrest metal corrosion for metal in molten chloride salt when the power supply applies a cathodic potential to bare metal, like H230, in molten chloride salts, like ternary Mg-K-Na-chloride salt. H230 is a high strength metal for containing molten chloride salt and ternary Mg-K-Na-chloride salt is used as heat transfer fluids in concentrating solar power plants. When to use cathodic protection for protecting metal in molten chloride salts? Two scenarios are envisioned: 1) for protecting high-valued components, like solar collectors and heat exchangers and 2) for protecting the bare surface in holidays (point defects) of corrosion inhibitors that are to intended to cover the entire surface of metal.

14 SOLAR ENERGY↗
DOE OSTI2021

Vadose and Saturated Zone Flow and Transport Calculations for the Active Trenches of the Low-Level Burial Grounds, Hanford Site, Washington

The purpose of the fate and transport modeling described in this environmental calculation file (ECF) is to evaluate the impacts to groundwater associated with waste disposal operations at Mixed Waste Low-Level Burial Ground (LLBG) Trenches 31 and 34 to satisfy requirements in DOE O 435.1, Radioactive Waste Management. The model integrates the flow and transport in the vadose zone beneath the active trenches with the saturated zone downgradient of the trenches to predict the radionuclide concentration at the point of assessment (POA). DOE M 435.1-1, Radioactive Waste Management Manual, defines the POA as the point of highest projected dose or concentration beyond a 100 m (328 ft) buffer zone surrounding the disposed waste. The modeling is conducted in accordance with the DOE G 435.1, Implementation Guide for Use with DOE M 435.1-1, performance assessment (PA) guidelines. The modeling involves evaluation of the groundwater concentrations and radionuclide arrival times during the 1,000-year compliance and 10,000-year sensitivity-uncertainty periods per DOE O 435.1 and DOE M 435.1. This analysis does not consider radionuclide release during facility operations, only the post-closure impacts of the radionuclides to the environment. The evaluation of potential radiological dose to groundwater receptors caused by releases from a closed facility containing radioactive waste typically includes the following: (1) Release of radionuclides from that facility (2) Transport of those radionuclides through the environment, and (3) Exposure to humans to environmental concentration levels of those radionuclides The fate and transport three-dimensional (3D) model analysis involves the post-closure impacts to the environment of the technetium-99, iodone-129, and uranium (all isotopes in the waste). The residual inventory estimates include several radionuclides, but technetium-99 is typically responsible for almost all of the beta-gamma dose equivalent associated with groundwater (water resources) protection per 40 CFR 141, “National Primary Drinking Water Regulations” (e.g., see the results in WCH-520, Performance Assessment of Environmental Restoration Disposal Facility, Hanford Site, Washington; hereinafter referred to as the ERDF PA), and iodone-129 can also be a significant dose contributor for some waste (e.g., RPP-RPT-59958, Performance Assessment for the Integrated Disposal Facility, Hanford Site, Washington; hereinafter referred to as the IDF PA). Uranium does not typically factor significantly into the impacts to groundwater, even during the 10,000-year sensitivity-uncertainty period, but always remains of interest as a contaminant. This ECF does not address vadose and saturated zone modeling for Trench 94 of the 200 East Area LLBG. Current information confirms the validity of the low corrosion rate of the naval reactor plant carbon steel (HY-80), and the even lower corrosion rate of the nickel-iron-chromium alloy reactor vessel (Inconel Alloy 600) presented in DOE/EIS-0259, Final Environmental Impact Statement on the Disposal of Decommissioned, Defueled Cruiser, Ohio Class, and Los Angeles Class Naval Reactor Plants. Based on these low corrosion rates, the time to breach the reactor vessel to allow release of radionuclides from the activated metal of the reactor vessel internal structure is at least 10,000 years. This time to breach precludes the need to evaluate the vadose and saturated zone transport of contaminants released from the reactor compartment disposal packages in the 200 East Area LLBGs PA (CP-63826, Waste Release Model Package Report for the Active Trenches of the Low-Level Burial Grounds, Hanford Site, Washington).

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

Alpha Spectrometry Results for Groundwater Samples Collected in Northern Iraq and a Summary of the Environmental Setting of the Adaya Burial Site

The Radiation Protection Center (RPC) of the Iraqi Ministry of Environment continues to evaluate the potential health impacts associated with the Adaya Burial Site, which is located 33 kilometers (20.5 miles) southwest of Mosul. This report documents the radiological analyses of 16 groundwater samples collected from wells located in the vicinity of the Adaya Burial Site and at other sites in northern Iraq. The Adaya Burial Site is a high-risk dump site because a large volume of radioactive material and contaminated soil is located on an unsecure hillside above the village of Tall ar Ragrag. The uranium activities for the 16 water samples in northern Iraq are considered to be naturally occurring and do not indicate artificial (man-made) contamination. With one exception, the alpha spectrometry results for the 16 wells that were sampled in 2019 indicate that the water quality concerning the three uranium isotopes (Uranium-233/234, Uranium-235/236, and Uranium-238) was acceptable for potable purposes (drinking and cooking). However, Well 7 in Mosul had a Uranium-233/234 activity concentration that slightly exceeded the World Health Organization guidance level. Eight of the 16 wells are located in the villages of Tall ar Ragrag and Adaya and had naturally occurring uranium concentrations. Wells in the villages of Tall ar Ragrag and Adaya are located near the Adaya Burial Site and should be sampled on an annual schedule. The list of groundwater analytes should include metals, total uranium, isotopic uranium, gross alpha/beta, gamma spectroscopy, organic compounds, and standard water quality parameters. Our current understanding of the hydrogeologic setting in the vicinity of the Adaya Burial Site is solely based on villager's domestic wells, topographic maps, and satellite imagery. To better understand the hydrogeologic setting, a Groundwater Monitoring Program needs to be developed and should include the installation of twelve groundwater monitoring wells in the vicinity of Tall ar Ragrag and the Adaya Burial Site. Characterization of the limestone aquifer and overlying alluvium is needed. RPC should continue to support health assessments for the villagers in Tall ar Ragrag and Adaya. Collecting samples for surface water (storm water), airborne dust, vegetation, and washway sediment should be conducted on a routine basis. Human access to the Adaya Burial Site needs to be strictly limited. Livestock access on or near the burial site needs to be eliminated. The surface-water exposure pathway is likely a greater threat than the groundwater exposure pathway. Installation of a surface-water diversion or collection system is recommended in order to reduce the potential for humans and livestock to come in contact with contaminated water and sediment. To reduce exposure to villagers, groundwater treatment should be considered if elevated uranium or other contaminants are detected in drinking water. Installing water-treatment systems would likely be quicker to accomplish than remediation and excavation of the Adaya Burial Site. The known potential for human exposure to uranium and metals (such as arsenic, chromium, selenium, and strontium) at the Adaya Burial Site is serious. Additional characterization , mitigation, and remediation efforts should be given a high priority.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2022

Impacts of LEU+ and ATF on Fresh Fuel Storage Criticality Safety

The use of increased fuel enrichment, which is still in the realm of low-enriched uranium (LEU) fuel, has been of interest to commercial light water reactor operators as part of the next iteration in fuel cycle technological advances and research and development. Using increased enrichment fuel, or high-assay LEU (HALEU), in power plants has clear benefits for being able to load cores with additional power-producing fuel. Although HALEU enrichments can range up to 20%, the more guarded approach of investigating enrichments above current fuels within 10% enrichment is referred to as LEU plus (LEU+) to reflect the less drastic change in operating conditions and requirements and similarity to current fuel cycles. Of additional interest and increasing maturity is the incorporation of accident-tolerant fuel (ATF) concepts, which are also applicable to the current fleet. This class of technologies involves changes such as cladding (e.g., chromium coating or FeCrAl) and fuel composition (e.g., chromia dopant) alterations to demonstrate improved fuel performance under accident scenarios. The ability to properly store fuel before and after residence time in the reactor is crucial to plant operation. Typically, this is done in either a new fuel vault (NFV) or spent fuel pool (SFP). Storing, loading, and unloading dozens of fuel assemblies within the same general area provides opportunities for obvious criticality concerns. These concerns are addressed with regulations to the subcriticality margin that the NFV and SFP must maintain in certain conditions. Adopting LEU+ fuel results in inherent reactivity increases, which are extremely relevant for safe fuel storage. Therefore, a clear understanding of the effects of LEU+ fuel and ATF on criticality safety margins to regulatory limits is required, as well as an understanding of the degree of absorber crediting under normal and accident conditions.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2022

Supramolecular Control of Redox-Mediated Interactions for Ion-Selective Electroseparations

This report summarizes efforts from the Su Group at the University of Illinois at Urbana-Champaign in researching and developing materials and processes for the recovery of rare earth elements and other metal elements that are critical to the United States economy and national security, under DOE Award No. DE-SC0021409. This report highlights efforts in the recovery of: • Transition metal elements (including arsenic, chromium, molybdenum, rhenium, vanadium): Redox-active metallopolymers are able to capture these elements in their oxyanion form. Direct control of target ion capture/release through electrochemical-mediated switching of metallocene binding sites reduces chemical input and lowers generation of waste in element recovery processes. We study the effects of metallopolymer structure on targeted ion binding through a combination of experimental screening of ion selectivity from multi-component mixtures, computational efforts which elucidate the charge-transfer origins of metallocene binding and provide insight on how binding site structure influences selectivity, and state-of-the-art neutron reflectivity of metallocene polymer films to understand the interplay of polymer-ion (charge-transfer), polymer-solvent (polymer hydrophilicity/hydrophobicity), and ion-solvent (ion hydration) interactions with spatial resolution of polymer films. • Rare earth elements (including yttrium, neodymium, europium, gadolinium, dysprosium, cerium): Here we employ redox-copolymers for recovery of rare earth elements by electrochemically regenerated ion-exchange. Rare earth elements require an alternative route to capture/release than directly with metallopolymers since rare earth elements typically exist in cationic form in water. To address this, copolymerization of traditional ion-exchange moieties with metallocene moieties allowed for capture of rare earth elements with the ion-exchange moieties and electrochemical-mediated release of rare earth elements through oxidation of metallocene moieties.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Corrosivity Screening of Pyrolysis Bio-Oils by Short-Term Alloy Exposures. Laboratory Analytical Procedure (LAP), Issue Date: May 12, 2022

Bio-oils contain organic acids and oxygenated compounds that can lead to corrosion issues during bio-oil processing and storage. This Laboratory Analytical Procedure (LAP) allows for rapid screening of a bio-oil's corrosivity without the need for complex equipment and long-term exposures. A robust and repeatable method for assessing the corrosivity of bio-oils is necessary in order to remove materials degradation as an obstacle to research, upgrading, use and storage of bio-oils. This LAP involves the incubation of a representative alloy, 410 stainless steel (410 SS), specimen in bio-oil over a period of 48 hours at 50 degrees C in a sealed container. The corrosive species in the bio-oil react with and deplete alloy elements such as iron (Fe) and/or chromium (Cr) from the specimen into the bio-oil solution. The depletion of Fe and Cr from the specimen results in a significant mass loss that can be recorded. The mass loss is directly correlated to the corrosivity of a bio-oil. Examples of bio-oils in scope include the ones produced by fast pyrolysis and catalytic fast pyrolysis, as well as liquids produced from hydrothermal liquefaction.

09 BIOMASS FUELS↗
DOE OSTI2022

Optimization of WAAM Process to Produce AUSC Components with Increased Service Life

Additive manufacturing has the potential to revolutionize industrial hardware and unlock efficiency gains through the fabrication of geometries and architectures not possible by conventional processing. Wire Arc Additive manufacturing (WAAM) process is a class of directed energy deposition process enabling higher build rate and allowing custom wire feedstock allowing spatial variation of microstructure. The larger spot size and lower speed creates a larger melt pool, reducing residual stress and often time creating directional/columnar microstructure for Ni-superalloy. The use of flexible platform provides freedom in deposition strategy, which can accommodate complex substrates, including feature addition onto existing structures, non-flat layers, and repair methods. However, the certification of the final component needs to match the strength requirement. Hence, the quality of the component produced is stringently monitored to avoid buildup of residual stress, cracks, porosity and to reduce detrimental segregated phases commonly observed during alloy solidification. Simulation plays a huge role in predicting the melt pool dimension and can be used to optimize the process parameter. Similar development is also required to perform physics-based modeling of microstructural development in WAAM that can predict the microstructural features during solidification and can be used to optimize the process more effectively. To move toward this goal, Raytheon Technologies Research Center together with Siemens worked to create a set of computational tools to control the process parameters, enable on-line measurements and acquisition with feedback to the optimized process parameters, and eventually track material evolution through each step of the additive process. Computational fluid dynamics is used for accurate prediction and calibration of the thermal field during WAAM process. and phase field models for microstructure evolution as a function of processing parameters to establish a connection between additive parameters and the final microstructure. Here we report cellular automata (CA) model development to predict the dendritic microstructure evolution with surface and bulk nuclei for single track and multiple layers. The CA model was developed to account for secondary element addition and predict segregation, local melting, and latent heat release as well as prediction of Euler angles from orientation information and validated against experiments. This framework was utilized to tailor spatially-varying composition in a part by appropriately controlling the microstructure evolution during the additive process. Functionally graded Haynes 282 alloy with high Cr content at the surface was tested for oxidation and mechanical properties. An advanced physics-based reaction-diffusion model predicting the simultaneous creation of chromium oxide and alumina is developed and validated to extend life expectancy of the WAAM manufactured high temperature part. A machine-learning data-driven framework establishing the process-structure relationship from a dataset of real microstructure images and corresponding process history data has been developed and implemented in the NX Siemens design system. The digital twin configuration along with the tool path generation enabled prediction of WAAM component buildup time and the techno-economic analysis provided a favorable option for all 4 cases with 15-40% cost reduction.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2022

Fiscal Year 2022. Filtration of Hanford Tank 241-AP-101 Supernatant at 16 °C

Bench-scale filtration testing of ~9 liters of supernatant from Hanford waste tank 241-AP-101, chilled to 16 °C, was conducted using a backpulse dead-end filter (BDEF) filtration system equipped with a feed vessel and a Mott inline filter Model 6610 (Media Grade 5) in the hot cells of the Radiochemical Processing Laboratory at Pacific Northwest National Laboratory. This was done to assess the performance of the anticipated third feed to the Tank Side Cesium Removal (TSCR) system. The as-received samples were diluted to the target sodium concentration and transferred to 1.5-liter polyethylene bottles and held at 16 °C for approximately 1 week prior to filtration. The feed was filtered through the BDEF system at a targeted flux of 0.065 gpm/ft 2 to match the prototypic operation of the TSCR system. During filtration, the differential pressure required to effect filtration at 0.065 gpm/ft 2 increased little over the filtration campaign and never reached 2 psid (the TSCR action limit). This indicates that the TSCR filter should perform well when processing AP-101 supernatant. After completing filtration of the AP-101 feed, the filter was cleaned. Solids concentrated from the backpulse solutions displayed sodium nitrate-type phases, aluminum and silicon phases reported as cancrinite or nitrate-cancrinite, a mixed chromium-aluminum oxide, iron oxides, and Ca-bearing phases (calcite). Scanning electron microscopy analyses showed that the average particle size was 0.5 micron.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2022

Physical and Flow Properties of Glass Forming Chemicals (V2O5, SnO, SnO2, Cr2O3, FeCr2O4, and ZrSiO4) and Mixtures

For a sustainable nuclear waste vitrification process at the Hanford Tank Waste Treatment and Immobilization Plant (WTP), proper selection and consistent supply of glass-forming chemicals (GFCs) are crucial. Establishing rigorous acceptance criteria for the characterization of GFCs will be required to operate the vitrification facility and to mitigate any processing issues or failures. Low-activity wastes (LAW) are blended with GFCs to form slurry melter feeds and vitrified in a melter. To enhance properties of waste glasses, new chemicals are being introduced to the current GFC mixture (Vienna et al. 2016; Muller et al. 2017, 2019). In this study, three new GFCs were evaluated for enhanced LAW glass formulations: chromium oxide (Cr 2 O 3 ), vanadium oxide (V 2 O 5 ), and stannic oxide (SnO 2 ). These three oxide components are included in enhanced waste glass (EWG) formulations and GFCs with the appropriate physical and flow properties are needed. As a starting point, single metal oxide GFCs: Cr 2 O 3 , V 2 O 5 , and SnO 2 were sourced and tested. To characterize these new individual GFCs and mixtures of GFCs, the industrial bulk characterization consultant, Jenike and Johanson, was employed to measure physical and flow properties of individual GFCs and their mixtures. Pacific Northwest National Laboratory (PNNL) also measured several selected physical properties for data evaluation as a quality assurance step. In addition, PNNL measured physical and rheological properties of slurry melter feeds containing those GFCs. Subsequent data analyses and verification were conducted. The purpose of this report is to assess the applicability of these GFCs for LAW vitrification based on their properties. This report will help understand measured data and evaluate new GFCs for use. Moreover, this report may give useful insights to help troubleshoot any GFC and melter feed transport and mixing issues that arise during processing, leading to a successful cleanup mission at WTP.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗