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At least 955 records · Page 53
All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

Laser Powder Bed Fusion Additive Manufacture Nb1Zr Development

Next generation fission and fusion nuclear reactors require materials that can withstand operating temperatures greater than 500 °C, neutron irradiation doses of up to 200 displacements per atom (dpa), and potentially corrosive coolants such as the alkali liquid metals sodium, lithium, and NaK (Na33K eutectic alloy). Refractory alloys, such as Nb1Zr (Nb-1wt%Zr) and Molybdenum alloy TZM (Mo-0.5wt%Ti-0.08wt%Zr) have been traditionally considered viable candidates for advanced fission and fusion reactor concepts. However, it is relatively difficult to generate complex geometries of interest from these alloys using traditional manufacturing methods. In addition, there needs to be a concentrated effort to address refractory metal challenges at elevated temperature operation. In order to generate complex geometries of interest, modern manufacturing techniques are considered to increase the technological readiness level (TRL), cost-effectiveness, and schedule savings. This work focused on the continued development of laser powder bed fusion (L-PBF) additive manufacturing (AM) to improve both design flexibility, evaluate microstructure and properties, and ultimately accelerate the TRL and qualification of these processes and alloys for components to potentially be put into service. Niobium alloy Nb1Zr was identified through a down-selection process outlined in previous reports as a candidate to develop in L-PBF AM. Historically, Nb1Zr had been explored for high temperature fast spectrum fission reactors for both terrestrial and space applications. Molybdenum alloy TZM has also been considered for these reactor concepts due to exceptional high-temperature strength, creep resistance, and stability under irradiation. L-PBF AM of TZM has previously been investigated at LANL under the Microreactor program, NASA, ORNL, and in academia. However, due to the crack prone nature of TZM, L-PBF AM of TZM resulted in significant microcracking and additional development is required to pursue viable maturation. Other AM methods have been found to be more successful in printing TZM, and those alternatives approaches are discussed in this effort. The efforts detailed in this report focused on continued development of Nb1Zr through L-PBF and development of TZM via L-PBF and electron powder bed fusion (E-PBF). The objective of this work was to further the development of these AM techniques for the chosen refractory alloys, elucidating and addressing associated challenges through characterization of several demonstration builds. At LANL, Nb1Zr builds were completed using an EOS M290 and M400 machines, and a refractory alloy-dedicated L-PBF system, the Xact Metal XM200G, was installed. The XM200G primary purpose was to do the Nb1Zr parameter development process; however, due to difficulties associated with the machine installation and qualification process, it was decided to pivot development to the larger M400 and M290 machines. Although the supply of Nb1Zr powder was limited, it was sufficient to generate sub-scale metallographic specimens for the purpose of parameter development. This was first accomplished on the EOS M400 then the M290 due to machine schedule availability. Further development of TZM has been initiated at the University of Texas El Paso (UTEP) under contract with LANL to use both a heated build envelope L-PBF machine and E-PBF machine that have been found in the literature to mitigate microcracking. UTEP was provided with TZM powder and build plates to support parallel TZM parameter development across both machines. As part of the contract, UTEP will also be conducting microstructural characterization once optimized process parameters have been identified. The optimized process parameters for each machine will be used to generate a series of metallographic, mechanical, and surface finish specimens for subsequent characterization and testing. In the next section, we provide a detailed discussion of the methodology used for investigating the feasibility of leveraging these alloys for use in advanced reactor applications.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Disassembly and Initial Post-Irradiation Examination of the Mini99 Experiment

The Miniature Fuel Molybdenum-99 (Mini99) experiment is a first-of-a-kind experiment in the High Flux Isotope Reactor. Mini99 is the first MiniFuel irradiation experiment to use liquid metal inside the MiniFuel subcapsule for additional temperature control. In this work, the initial post-irradiation examination is reported. As-built simulations were conducted and compared with designs, and physical post-irradiation examinations were conducted to determine actual test temperatures via SiC thermometry samples, to evaluate the extent of fission gas release from the samples, and to remove the fuel from the subcapsules. As-built simulations compared well with experiment designs and were in reasonable agreement with the measured temperatures inferred from the passive SiC thermometers. Additionally, fission gas release values were relatively small (on the order of 3%); one sample reached approximately 8%. Although some of this behavior is attributable to recoil, most of the gas release was likely caused by the physics of the fuel behavior during the test. Finally, disassembly showed that at least four of the fuel samples degraded into small components and granules at some point during the test, with the state of the other two samples unproven. Additional work is planned for further examination of these samples via various microscopy techniques.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2025

BOILER Experiment Material Characterization and HFIR Irradiation Status

Pre-oxidized alumina-forming austenitic (AFA) steels have been previously identified as candidate alloys for structural components in lead-cooled fast reactors (LFRs). They offer compatibility with liquid Pb, high-temperature strength, formability, and cost advantages. However, variations in Ni content can affect the formation and stability of the Al 2 O 3 layer, influencing compatibility with liquid Pb. The effect of fast neutron irradiation on Al 2 O 3 stability in liquid Pb also requires evaluation. Therefore, understanding how Ni concentrations impacts pre-oxidized AFAs under combined extremes of irradiation and liquid metal corrosion is essential before safe deployment. The Behavior Of In-situ Lead Environments & Radiation (BOILER) experiment was developed under the Nuclear Science User Facilities (NSUF) program to integrate alloy development, irradiation experiment design, and irradiated materials characterization. In this effort, two pre-oxidized AFA steels with 20 wt% and 25 wt% Ni, hereinafter referred to as GA05-20Ni and GA05-25Ni, were produced. An irradiation experiment was then planned for the High Flux Isotope Reactor (HFIR), designed for passive heating of irradiation rabbit capsules from gamma heating in the HFIR flux trap (1 × 10 15 n/cm 2 ·s, >0.1 MeV). This heating melts Pb and exposes the pre-oxidized AFA steel specimens to nominal temperatures of 400 and 650°C. Detailed neutronics and thermal analyses were performed, though based on nominal design rather than as-built, as-irradiated conditions. This report documents further characterization of the pre-oxidized AFAs in the unirradiated condition. It also includes as-built thermal analysis using measured component dimensions, updated fill gas concentrations, and actual HFIR irradiation positions. Finally, the report summarizes capsule fabrication, current irradiation status, projected completion, estimated damage accumulation, and initial plans for post-irradiation examination plans.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2025

Oklo Sponsored Testing using PELICAN: System, Subchannel, and High-Fidelity Software Validation (Final CRADA Report)

Argonne National Laboratory (the Contractor), located in Lemont IL, and Oklo, Inc., (the Participant), headquartered in Santa Clara, CA, propose to enter into a Cooperative Research and Development Agreement (CRADA) to perform a gap analysis of thermal hydraulic data, perform prototypical fuel assembly pressure drop and cavitation model validation, generate the experimental data as well as the corresponding uncertainties for this matrix and, finally, develop the validation models with the Argonne system level code SAS4A/SASSYS-1, the Argonne subchannel analysis code DASSH, the Argonne high fidelity code Nek5000, and/or the Idaho National Laboratory code Pronghorn Subchannel. The work outlined below will significantly improve the experimental and validation database currently available for liquid metal fast reactors, thus making it a viable part of a comprehensive reactor design and licensing suite to be used by the participant.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2026

Design of a high power 8 MeV electron beam injector for the LERF

We present the beamline design for a high power 8 MeV electron injector to be installed at the Low Energy Recirculator Facility (LERF). The injector is designed to provide beam power of up to 80 kW for testing positron source target candidates. We discuss the results of beam dynamics simulations conducted using the General Particle Tracer (GPT) software, where electromagnetic beamline elements were optimized using multi-objective genetic algorithm tools. Additionally, we present preliminary studies on secondary particle generation from both rotating solid and free surface liquid metal jet targets described elsewhere in this workshop.

Lizarraga-Rubio, Victor [Thomas Jefferson National↗
DOE OSTI2026

Design of a high power 8 MeV electron beam injector for the LERF

Here, we present the beamline design for a high power 8 MeV electron injector to be installed at the Low Energy Recirculator Facility (LERF). The injector is designed to provide beam power of up to 80 kW for testing positron source target candidates. We discuss the results of beam dynamics simulations conducted using the General Particle Tracer (GPT) software, where electromagnetic beamline elements were optimized using multi-objective genetic algorithm tools. Additionally, we present preliminary studies on secondary particle generation from both rotating solid and free surface liquid metal jet targets described elsewhere in this workshop.

Lizarraga-Rubio, Victor Manuel [Thomas Jefferson N↗
DOE OSTI2025

Polarized positrons at Ce\(^+\)BAF

A baseline concept for a continuous wave (CW) polarized positron injector was developed for the Continuous Electron Beam Accelerator Facility (CEBAF) at Jefferson Lab [1]. This concept is based on positron beam generation by a high current polarized electron beam (1 mA, 120 MeV, >85% polarization) irradiating a 4 mm thick rotating water-cooled tungsten target or liquid metal target. The update on the development of the Ce+BAF injector concept including the polarized electron source, the development of high power targets, simulations of positron capture, the design of the transport line from the positron injector to the CEBAF North Linac and the planned experiment to measure the upper limits of transverse and longitudinal emittances accepted by the 12 GeV CEBAF optics are presented. [1] J. Grames et al., "Positron beams at Ce+BAF", in Proc. 14th Int. Particle Accelerator Conf. (IPAC’23), Venice, Italy, MOPL152, pp. 896–899 (2023). doi:10.18429/JACoW-IPAC2023-MOPL152

Ushakov, Andriy↗
DOE OSTI2024

Microstructure and Mechanical Properties of Ni-based Alloys Fabricated by Laser Powder Bed Fusion

The Advanced Materials and Manufacturing Technologies (AMMT) program is aiming at the accelerated incorporation of new materials and manufacturing technologies into nuclear-related systems. Complex Ni-based components fabricated by laser powder bed fusion (LPBF) could enable operating temperatures at T > 700°C in aggressive environments such as molten salts or liquid metals. However, available mechanical properties data relevant to material qualification remains limited, in particular for Ni-based alloys routinely fabricated by LPBF such as IN718 (Ni- 19Cr-18Fe-5Nb-3Mo) and Haynes 282 (Ni-20Cr-10Co-8.5Mo-2.1Ti-1.5Al). Creep testing was conducted on LPBF 718 at 600°C and 650°C and on LPBF 282 at 750°C. finding that the creep strength of the two alloys was close to that of wrought counterparts. with lower ductility at rupture. Heat treatments were tailored to the LPBF-specific microstructure to achieve grain recrystallization and form strengthening γ' precipitates for LPBF 282 and γ' and γ" precipitates for LPBF 718. In-situ data generated during printing and ex-situ X-ray computed tomography (XCT) scans were used to correlate the creep properties of LPBF 282 to the material flaw distribution. In- situ data revealed that spatter particles are the potential causes for flaws formation in LPBF 282. with significant variation between rods based on their location on the build plate. XCT scans revealed the formation of a larger number of creep flaws after testing in the specimens with a higher initial flaw density. which led to a lower ductility for the specimen.

Dryepondt, Sebastien↗
DOE OSTI2022

Monitoring of Temperature Measurements for Different Flow Regimes in Water and Galinstan with Long Short-Term Memory Networks and Transfer Learning of Sensors

Temperature sensing is one of the most common measurements of a nuclear reactor monitoring system. The coolant fluid flow in a reactor core depends on the reactor power state. We investigated the monitoring and estimation of the thermocouple time series using machine learning for a range of flow regimes. Measurement data were obtained, in two separate experiments, in a flow loop filled with water and with liquid metal Galinstan. We developed long short-term memory (LSTM) recurrent neural networks (RNNs) for sensor predictions by training on the sensor’s own prior history, and transfer learning LSTM (TL-LSTM) by training on a correlated sensor’s prior history. Sensor cross-correlations were identified by calculating the Pearson correlation coefficient of the time series. The accuracy of LSTM and TL-LSTM predictions of temperature was studied as a function of Reynolds number (Re). The root-mean-square error (RMSE) for the test segment of time series of each sensor was shown to linearly increase with Re for both water and Galinstan fluids. Using linear correlations, we estimated the range of values of Re for which RMSE is smaller than the thermocouple measurement uncertainty. For both water and Galinstan fluids, we showed that both LSTM and TL-LSTM provide reliable estimations of temperature for typical flow regimes in a nuclear reactor. The LSTM runtime was shown to be substantially smaller than the data acquisition rate, which allows for performing estimation and validation of sensor measurements in real time.

Pantopoulou, Stella↗
DOE OSTI2020

Direct Write of 3D Nanoscale Mesh Objects with Platinum Precursor via Focused Helium Ion Beam Induced Deposition

The next generation optical, electronic, biological, and sensing devices as well as platforms will inevitably extend their architecture into the 3rd dimension to enhance functionality. In focused ion beam induced deposition (FIBID), a helium gas field ion source can be used with an organometallic precursor gas to fabricate nanoscale structures in 3D with high-precision and smaller critical dimensions than focused electron beam induced deposition (FEBID), traditional liquid metal source FIBID, or other additive manufacturing technology. In this work, we report the effect of beam current, dwell time, and pixel pitch on the resultant segment and angle growth for nanoscale 3D mesh objects. We note subtle beam heating effects, which impact the segment angle and the feature size. Additionally, we investigate the competition of material deposition and sputtering during the 3D FIBID process, with helium ion microscopy experiments and Monte Carlo simulations. Our results show complex 3D mesh structures measuring ~300 nm in the largest dimension, with individual features as small as 16 nm at full width half maximum (FWHM). These assemblies can be completed in minutes, with the underlying fabrication technology compatible with existing lithographic techniques, suggesting a higher-throughput pathway to integrating FIBID with established nanofabrication techniques.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Hierarchical Tactile Sensation Integration from Prosthetic Fingertips Enables Multi-Texture Surface Recognition

Multifunctional flexible tactile sensors could be useful to improve the control of prosthetic hands. To that end, highly stretchable liquid metal tactile sensors (LMS) were designed, manufactured via photolithography, and incorporated into the fingertips of a prosthetic hand. Three novel contributions were made with the LMS. First, individual fingertips were used to distinguish between different speeds of sliding contact with different surfaces. Second, differences in surface textures were reliably detected during sliding contact. Third, the capacity for hierarchical tactile sensor integration was demonstrated by using four LMS signals simultaneously to distinguish between ten complex multi-textured surfaces. Four different machine learning algorithms were compared for their successful classification capabilities: K-nearest neighbor (KNN), support vector machine (SVM), random forest (RF), and neural network (NN). The time-frequency features of the LMSs were extracted to train and test the machine learning algorithms. The NN generally performed the best at the speed and texture detection with a single finger and had a 99.2 ± 0.8% accuracy to distinguish between ten different multi-textured surfaces using four LMSs from four fingers simultaneously. The capability for hierarchical multi-finger tactile sensation integration could be useful to provide a higher level of intelligence for artificial hands.

Abd, Moaed A. (ORCID:0000000284954244)↗
DOE OSTI2021

Overview of the fusion nuclear science facility, a credible break-in step on the path to fusion energy

The Fusion Nuclear Science Facility (FNSF) is examined here as part of a two step program from ITER to commercial power plants. This first step is considered mandatory to establish the materials and component database in the real fusion in-service environment before proceeding to larger electricity producing facilities. The FNSF can be shown to make tremendous advances beyond ITER, toward a power plant, particularly in plasma duration and fusion nuclear environment. A moderate FNSF is studied in detail, which does not generate net electricity, but does reach the power plant blanket operating temperatures. The full poloidal Dual Coolant Lead Lithium (DCLL) blanket is chosen, with alternates being the Helium Cooled Lead Lithium (HCLL) and Helium Cooled Ceramic Breeder/Pebble Bed (HCCB/PB). Several power plant relevant choices are made in order to follow the philosophy of targeted technologies. Any fusion core component must be qualified by fusion relevant neutron testing and highly integrated non-nuclear testing before it can be installed on the FNSF in order to avoid the high probability of constant failures in a plasma-vacuum system. A range of missions for the FNSF, or any fusion nuclear facility on the path toward fusion power plants, are established and characterized by several metrics. A conservative physics strategy is pursued to accommodate the transition to ultra-long plasma pulses, and parameters are chosen to represent the power plant regime to the extent possible. An operating space is identified, and from this, one point is chosen for further detailed analysis, with R = 4.8 m, a = 1.2 m, IP = 7.9 MA, BT = 7.5 T, βN Gr = 0.9, fBS = 0.52, q95 = 6.0, H98 ∼1.0, and Q = 4.0. The operating space is shown to be robust to parameter variations. A program is established for the FNSF to show how the missions for the facility are met, with a He/H, a DD and 5 DT phases. The facility requires ∼25 years to complete its DT operation, including 7.8 years of neutron production, and the remaining spent on inspections and maintenance. The DD phase is critical to establish the ultra-long plasma pulse lengths. The blanket testing strategy is examined, and shows that many sectors have penetrations for heating and current drive (H/CD), diagnostics, or Test Blanket Modules (TBMs). The hot cell is a critical facility element in order for the FNSF to perform its function of developing the in-service material and component database. The pre-FNSF R&D is laid out in terms of priority topics, with the FNSF phases driving the time-lines for R&D completion. A series of detailed technical assessments of the FNSF operating point are reported in this issue, showing the credibility of such a step, and more detailed emphasis on R&D items to pursue. These include nuclear analysis, thermo-mechanics and thermal-hydraulics, liquid metal thermal hydraulics, transient thermo-mechanics, tritium analysis, maintenance assessment, magnet specification and analysis, materials assessments, core and scrape-off layer (SOL)/divertor plasma examinations.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
NASA NTRS1965

Heats of mixing in praseodymium-neodymium solid solutions.

The heats of solution in liquid tin of pure praseodymium, pure neodymium and nine praseodymium-neodymium binary alloys have been measured using liquid metal solution calorimetry. A plot of the measured heat effect for the alloys as a function of composition is linear, with the terminal points being the measured values for the pure components. This linear dependency indicates that the heat of mixing in the binary praseodymium-neodymium system is zero within experimental error, and therefore the binary alloys obey one of the criteria for an ideal solution.

Calorimetry↗
NASA NTRS1966

Inductive system detects level of conducting fluids

Inductive system monitors the liquid level of a conductive fluid that is at a high temperature in a fully closed opaque container. The system is useful in any high temperature liquid-metal system. It shows fast response and is relatively insensitive to temperature fluctuations.

Roeske, P. W.↗
NASA NTRS1966

Rubber and alumina gaskets retain vacuum seal in high temperature EMF cell

Silicone rubber gasket and an alumina gasket retain a vacuum inside a high temperature EMF cell in which higher and lower density liquid metal electrodes are separated by an intermediate density fused salt electrolyte. This innovation is in use on a sodium bismuth regenerable EMF cell in which the fused salts and metals are at about 500 deg to 600 deg C.

Hesson, J. C.↗