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DOE OSTI2023

Retractable Sensors for In-Core Service in Material Test Reactors

Material Test Reactors (MTRs) such as the Advanced Test Reactor (ATR) at the Idaho National Laboratory (INL) are used to irradiate nuclear fuels and materials to evaluate their performance after high levels of exposure to a reactor in-core environment. The most critical tests are equipped with instrumentation leads, which allow real-time data collection. However, because of the very harsh environment inside high-power MTR experiments, there are very few sensors that can survive and maintain their calibrated readings for the time periods required to obtain the high neutron doses needed for new fuels and materials qualification. As a result, sometimes sponsoring programs are forced to accept low reliability of sensors, collecting useful data for only part of the experiment duration. The work described herein is based on the observation that MTRs normally run at constant power and the corresponding conditions within reactor experiments typically evolve relatively slowly. Therefore, even one or two measurements per day would provide a complete and representative data set. With this in mind, INL has embarked on a program to develop a mechanism capable of pushing a very small-diameter sensor (typically a thermocouple or optical fiber) into the location to be measured, leave the sensor for roughly 60 seconds to allow it to reach equilibrium and transmit the signal, then pull it up and away from the high neutron flux and high-temperature region. Small-diameter capillary tubes, up to 8 m long, are used to guide the sensors to the appropriate locations. These capillary tubes serve as essentially very deep, thin-walled thermowells. The distance a thermocouple or optical fiber would need to traverse is on the order of 40 – 80 cm. By adopting this infrequent cycling strategy, the thermocouple or optical fiber would spend only a few hours in the high-neutron flux/high-temperature environment over the duration of even the longest irradiation experiment. To date, INL has developed two styles of drive mechanisms. The first is based on counter-rotating wheels which drive the sensors in a manner similar to a small MIG welder. This has the advantage of being able to accommodate a very long insertion length. The second is based on a ball screw drive and has the advantages of positive attachment and being able to move more than one sensor at a time. Both drive mechanisms have been fabricated and tested in a laboratory setting. Both systems can handle hard mineral insulated cable (such as thermocouples) or optical fibers encased in small diameter tube. The sizes tested to date are 1 – 1.6 mm diameter. Work in this area is ongoing with an eye toward demonstration in the Massachusetts Institute of Technology’s MITR reactor, followed by deployment in an ATR irradiation experiment.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

DOE OSTI2021

Characterization of Embedded Sensors in Stainless Steel Test Articles and Design/Planning for MAGNET Testing

The nuclear industry is pursuing microreactors that can be factory assembled and deployed to remote regions for reliable power generation. One class of microreactors uses a monolithic metal core block coupled to heat pipes for heat rejection, which results in significant thermal stresses in the monolithic structures. This work describes the initial characterization and test plan for evaluating stainless steel test articles fabricated with embedded sensors for measuring heat pipe performance limits, as well as spatially distributed temperatures and strains during electrically heated thermal testing. The electrically heated testing will be performed in the non-nuclear Microreactor Agile Non-Nuclear Testbed and Single Primary Heat Extraction and Removal Emulator facilities located at Idaho National Laboratory. The goals of these tests are to (1) accurately monitor temperature and strain distributions that result from differential thermal expansion in the test articles and (2) quantify heat rejection limits of heat pipes as a function of operating temperature and working fluid during steady-state and transient operations. More generally, the ability to monitor component and system health during microreactor operation is attractive for providing a high sensor density to inform a limited number of microreactor operators to ultimately reduce operation and maintenance costs and move toward semi-autonomous operation. This report discusses the characterization of embedded thermocouples and fiber optic sensors in relevant test articles, including cylindrical pipes and hexagonal monolithic test articles for heat pipe-based reactors. The sensors were embedded by placing them in machined channels and then building up additional material by using ultrasonic additive manufacturing (UAM). UAM is a solid-state welding process that uses downward pressure and a lateral scrubbing motion to bond thin metal foils to a base material layer by layer. The ultrasonic welding process relies on the plastic deformation of the metal—as opposed to typical melting and solidification—to break oxide scales and bond the metal layers. The characterization of these embedded sensors included evaluating fiber optic signal attenuation, observing residual strain in the fibers, investigating microstructural and mechanical aspects, and demonstrating the sensors under various thermal loads and acoustic vibrations. Post-embedding characterization showed a fine grain structure (<1 μm) near the interfaces of the bonded foils as a result of severe deformation from the welding process. A large increase in hardness was observed at the foil interfaces and the fiber/matrix interface compared with the bulk matrix. Even when compared with the SS304 interfaces, the higher hardness observed around the embedded fiber suggests a higher degree of deformation due to the soft metal coating around the silica fiber core. The distributed fiber-optic temperature sensors and embedded thermocouples reliably measured temperature distributions during steady-state and transient thermal testing. The embedded fiber-optic sensors reliably measured strain during both transient and steady-state testing and properly identified resonant frequencies during acoustic testing.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2023

Retractable Sensors for In-Core Use in Material Test Reactors - conf paper

Material Test Reactors (MTRs) such as the Advanced Test Reactor (ATR) at the Idaho National Laboratory (INL) are used to irradiate nuclear fuels and materials to evaluate their performance after high levels of exposure to a reactor in-core environment. The most critical tests are equipped with instrumentation leads, which allow real-time data collection. However, because of the very harsh environment inside high-power MTR experiments, there are very few sensors that can survive and maintain their calibrated readings for the time periods required to obtain the high neutron doses needed for new fuels and materials qualification. As a result, sometimes sponsoring programs are forced to accept low reliability of sensors, collecting useful data for only part of the experiment duration. The work described herein is based on the observation that MTRs normally run at constant power and the corresponding conditions within reactor experiments typically evolve relatively slowly. Therefore, even one or two measurements per day would provide a complete and representative data set. With this in mind, INL has embarked on a program to develop a mechanism capable of pushing a very small-diameter sensor (typically a thermocouple or optical fiber) into the location to be measured, leave the sensor for roughly 60 seconds to allow it to reach equilibrium and transmit the signal, then pull it up and away from the high neutron flux and high-temperature region. Small-diameter capillary tubes, up to 8 m long, are used to guide the sensors to the appropriate locations. These capillary tubes serve as essentially very deep, thin-walled thermowells. The distance a thermocouple or optical fiber would need to traverse is on the order of 40 - 80 cm. By adopting this infrequent cycling strategy, the thermocouple or optical fiber would spend only a few hours in the high-neutron flux/high-temperature environment over the duration of even the longest irradiation experiment. To date, INL has developed two styles of drive mechanisms. The first is based on friction drive wheels which drive the sensors in a manner similar to a small MIG welder. This has the advantage of being able to accommodate a very long insertion length. The second is based on a ball screw drive and has the advantages of positive attachment and being able to move more than one sensor at a time. Both drive mechanisms have been fabricated and tested in a laboratory setting. Both systems can handle hard mineral insulated cable (such as thermocouples) or optical fibers encased in small diameter tube. The sizes tested to date are 1 - 1.6 mm diameter. Work in this area is ongoing with an eye toward demonstration in the Massachusetts Institute of Technology's MITR reactor, followed by deployment in an ATR irradiation experiment.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

DOE OSTI2023

Retractable Sensors for In-Core Service in Material Test Reactors

Material Test Reactors (MTRs) such as the Advanced Test Reactor (ATR) at the Idaho National Laboratory (INL) are used to irradiate nuclear fuels and materials to evaluate their performance after high levels of exposure to a reactor in-core environment. The most critical tests are equipped with instrumentation leads, which allow real-time data collection. However, because of the very harsh environment inside high-power MTR experiments, there are very few sensors that can survive and maintain their calibrated readings for the time periods required to obtain the high neutron doses needed for new fuels and materials qualification. As a result, sometimes sponsoring programs are forced to accept low reliability of sensors, collecting useful data for only part of the experiment duration. The work described herein is based on the observation that MTRs normally run at constant power and the corresponding conditions within reactor experiments typically evolve relatively slowly. Therefore, even one or two measurements per day would provide a complete and representative data set. With this in mind, INL has embarked on a program to develop a mechanism capable of pushing a very small-diameter sensor (typically a thermocouple or optical fiber) into the location to be measured, leave the sensor for roughly 60 seconds to allow it to reach equilibrium and transmit the signal, then pull it up and away from the high neutron flux and high-temperature region. Small-diameter capillary tubes, up to 8 m long, are used to guide the sensors to the appropriate locations. These capillary tubes serve as essentially very deep, thin-walled thermowells. The distance a thermocouple or optical fiber would need to traverse is on the order of 40 - 80 cm. By adopting this infrequent cycling strategy, the thermocouple or optical fiber would spend only a few hours in the high-neutron flux/high-temperature environment over the duration of even the longest irradiation experiment. To date, INL has developed two styles of drive mechanisms. The first is based on counter-rotating wheels which drive the sensors in a manner similar to a small MIG welder. This has the advantage of being able to accommodate a very long insertion length. The second is based on a ball screw drive and has the advantages of positive attachment and being able to move more than one sensor at a time. Both drive mechanisms have been fabricated and tested in a laboratory setting. Both systems can handle hard mineral insulated cable (such as thermocouples) or optical fibers encased in small diameter tube. The sizes tested to date are 1 - 1.6 mm diameter. Work in this area is ongoing with an eye toward demonstration in the Massachusetts Institute of Technology's MITR reactor, followed by deployment in an ATR irradiation experiment.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

NASA NTRS1997

Optical Sensors Based on Single Arm Thin Film Waveguide Interferometer

All the goals of the research effort for the first year were met by the accomplishments. Additional efforts were done to speed up the process of development and construction of the experimental gas chamber which will be completed by the end of 1997. This chamber incorporates vacuum sealed multimode optical fiber lines which connect the sensor to the remote light source and signal processing equipment. This optical fiber line is a prototype of actual optical communication links connecting real sensors to a control unit within an aircraft or spacecraft. An important problem which we are planning to focus on during the second year is coupling of optical fiber line to the sensor. Currently this problem is solved using focusing optics and prism couplers. More reliable solutions are planned to be investigated.

Sarkisov, Sergey S.↗

NASA NTRS1992

Erbium-doped fiber amplifier elements for structural analysis sensors

The use of erbium-doped fiber amplifiers (EDFA's) in optical fiber sensor systems for structural analysis is described. EDFA's were developed for primary applications as periodic regenerator amplifiers in long-distance fiber-based communication systems. Their in-line amplification performance also makes them attractive for optical fiber sensor systems which require long effective lengths or the synthesis of special length-dependent signal processing functions. Sensor geometries incorporating EDFA's in recirculating and multiple loop sensors are discussed. Noise and polarization birefringence are also considered, and the experimental development of system components is discussed.

Hanna-Hawver, P.↗

NASA NTRS1981

Method and apparatus for holographic processing

A method and apparatus for holographically processing optical signals in a fiber-optic sensor system. In the present invention, holographic processors are utilized in various combinations with light sources, fiber-optic transmission means, sensors and detectors to provide low cost, compact, sensitive and accurate sensor systems. By means of the holographic processors of the present invention, the aforementioned sensor systems are used to monitor such physical parameters as temperature, pressure, flow-rate, and the like, and to provide output signal indications thereof that are compatible with digital receiving stations and immune to electro-magnetic interference, hazardous atmosphere, and the inimical effects of inadvertent intensity variation due to equipment vibration and the like. In one typical embodiment, a pair of holographic processors are employed in a color multiplex-demultiplex sensor system in which a first holographic processor is employed to color multiplex a sensor signal and a second holographic processor is employed to decode the color-multiplexed signal into a binary pattern that is then transmitted onto a set of photodetectors. In each of the embodiments of the invention disclosed, a unique geometrical orientation of a hologram is utilized to minimize spurious signal interference that would otherwise hamper or totally preclude the holographic processing.

Quick, William H.↗

NASA NTRS2015

Optical Energy Transfer and Conversion System

An optical power transfer system comprising a fiber spooler, a fiber optic rotary joint mechanically connected to the fiber spooler, and an electrical power extraction subsystem connected to the fiber optic rotary joint with an optical waveguide. Optical energy is generated at and transferred from a base station through fiber wrapped around the spooler, through the rotary joint, and ultimately to the power extraction system at a remote mobility platform for conversion to another form of energy.

Stone, William C.↗

NASA NTRS1993

Fiber-Coupled Acousto-Optical-Filter Spectrometer

Fiber-coupled acousto-optical-filter spectrometer steps rapidly through commanded sequence of wavelengths. Sample cell located remotely from monochromator and associated electronic circuitry, connected to them with optical fibers. Optical-fiber coupling makes possible to monitor samples in remote, hazardous, or confined locations. Advantages include compactness, speed, and no moving parts. Potential applications include control of chemical processes, medical diagnoses, spectral imaging, and sampling of atmospheres.

Levin, Kenneth H.↗

NASA NTRS1993

Application of new electro-optic technology to Space Station Freedom data management system

A low risk design methodology to permit the local bus structures to support increased data carrying capacities and to speed messages and data flow between nodes or stations on the Space Station Freedom Data Management System in anticipation of growing requirements was evaluated and recommended. The recommended design employs a collateral fiber optic technique that follows a NATO avionic standard that is developed, tested, and available. Application of this process will permit a potential 25 fold increase in data transfer performance on the local wire bus network with a fiber optic network, maintaining the functionality of the low-speed bus and supporting all of the redundant transmission and fault detection capabilities designed into the existing system. The application of wavelength division multiplexing (WDM) technology to both the local data bus and global data bus segments of the Data Management System to support anticipated additional highspeed data transmission requirements was also examined. Techniques were examined to provide a dual wavelength implementation of the fiber optic collateral networks. This dual wavelength implementation would permit each local bus to support two simultaneous high-speed transfers on the same fiber optic bus structure and operate within the limits of the existing protocol standard. A second WDM study examined the use of spectral sliced technology to provide a fourfold increase in the Fiber Distributed Data Interface (FDDI) global bus networks without requiring modifications to the existing installed cable plant. Computer simulations presented indicated that this data rate improvement can be achieved with commercially available optical components.

Husbands, C. R.↗

NASA NTRS1986

Guided transmission for 10 micron tunable lasers

Performance characteristics are reported for two types of IR tunable laser guided transmission, one of which incorporates a CO2 laser, metallic piping or fiber-optics, and a detector system, while the other employs a tunable diode laser, fiber-optics, and a detector system. While existing technology furnishes low loss, rugged, near-single mode piping, fiber-optics exhibits appreciably higher loss, and its multimode fibers are fragile and chemically unstable. Studies have accordingly concentrated on such relevant fiber parameters as loss, toxicity, hygroscopicity, refractive index, flexibility, and thermal behavior at low temperature.

Yu, C.↗

NASA NTRS1991

Apparatus for precision focussing and positioning of a beam waist on a target

The invention relates to optical focussing apparatus and, more particularly, to optical apparatus for focussing a highly collimated Gaussian beam which provides independent and fine control over the focus waist diameter, the focus position both along the beam axis and transverse to the beam, and the focus angle. A beam focussing and positioning apparatus provides focussing and positioning for the waist of a waisted beam at a desired location on a target such as an optical fiber. The apparatus includes a first lens, having a focal plane f sub 1, disposed in the path of an incoming beam and a second lens, having a focal plane f sub 2 and being spaced downstream from the first lens by a distance at least equal to f sub 1 + 10 f sub 2, which cooperates with the first lens to focus the waist of the beam on the target. A rotatable optical device, disposed upstream of the first lens, adjusts the angular orientation of the beam waist. The transverse position of the first lens relative to the axis of the beam is varied to control the transverse position of the beam waist relative to the target (a fiber optic as shown) while the relative axial positions of the lenses are varied to control the diameter of the beam waist and to control the axial position of the beam waist. Mechanical controllers C sub 1, C sub 2, C sub 3, C sub 4, and C sub 5 control the elements of the optical system. How seven adjustments can be made to correctly couple a laser beam into an optical fiber is illustrated. Prior art systems employing optical techniques to couple a laser beam into an optical fiber or other target simply do not provide the seven necessary adjustments. The closest known prior art, a Newport coupler, provides only two of the seven required adjustments.

Lynch, Dana H.↗

NASA NTRS1983

Data systems - Optical bus will connect distributed system

The fiber optics buses currently under consideration for the NASA space station program will have data rates of at least 20 Mb/sec. The network interconnection scheme that will eventually be used is, however, uncertain. A NASA-Langley effort on graph networks includes adaptive, fault-tolerant and self-correcting operations. A breadboard program at NASA-Johnson includes evaluations of standard devices, called 'bus interface units', in an adaptive and fault-correcting chordal or concentric ring type of network. Fiber optics would allow an evolution to wavelength modulation techniques in such systems.

Swingle, W. L.↗

DOE OSTI2020

Demonstration of Embedded Sensors in Ceramic Structures

The Transformational Challenge Reactor (TCR) program seeks to demonstrate an advanced 3D printed nuclear reactor core. A binder jet additive manufacturing process is used to fabricate the complex SiC ceramic components of the TCR core. After printing, the components are densified via chemical vapor infiltration (CVI). This process allows complex cavities to be created in which sensors can be placed at strategic locations. Inserting the sensors during the CVI process allows the sensors to be embedded within the component as it is infiltrated. The primary challenge for embedding the sensors is identifying the sensors and sensor sheath materials that can survive the temperatures (>1,000°C) and chemical exposure to H 2 and HCl during CVI. The embedded sensors that are being investigated for use during TCR operation include thermocouples, self-powered neutron detectors, and spatially distributed fiber-optic temperature sensors. This report describes the CVI materials compatibility tests and initial trials for embedding functional sensors. Mo is identified as the most suitable sensor sheath material based on its availability in small diameter tubing, relatively low neutron absorption cross section, and compatibility with H 2 , HCl, and the surrounding SiC matrix at the process temperatures. Amorphous SiO2 fiber-optic samples with Au and Cu metal coatings were successfully embedded in SiC along with bare fibers, although the metal coatings showed some evidence of localized melting during CVI. Initial experiments attempting to embed functional sensors showed that the sensors can be embedded in 3D printed SiC parts, but there are still challenges that must be overcome to ensure that the sensors and sensor sheaths do not fail during CVI. In particular, Nb-sheathed Mo-Nb thermocouples failed at temperatures far lower than expected despite thermodynamic calculations and materials compatibility tests that show the Nb sheath to be compatible with the CVI environment. One potential explanation for the large expansion of the Nb sheath could be related to hydride formation in the lower temperature region of the sheath. Future work will focus on Mo-sheathed thermocouples instead of Nb. The fiberoptic sensors tested during the instrumented experiment broke due to the lack of mechanical protection after their polymer-based coatings were vaporized. Future instrumented experiments will use metal-coated optical fibers for strain sensing to provide additional mechanical protection. However, custom coatings with higher melting points than commercially available Au and Cu might be required. Regardless, fiber-optic sensors are still candidates for spatially distributed temperature measurements since they can be inserted into an embedded metal sheath after CVI.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2025

HDG-1 Fiber Bragg grating data analysis

The main goal of the High dose graphite 1 Advanced test reactor experiment was to study nuclear grade graphite at high fluences. Additional supplementary optical fiber instrumentation was added to this long duration experiment for instrumentation development purposes. The supplementary instrumentation consisted of two pure silica core, fluorine doped cladding optical fibers each etched with 9 fiber Bragg gratings, one fiber being heat treated for 9 hours at 750 C and 16 hours at 750 C, the other being heat treated for 24 hours at 550 C and 48 hours at 650 C. Fiber Bragg gratings are known to have issues of measurement drift when in high temperature and high radiation environments like what is encountered in the Advanced test reactor. At the culmination of this experiment, the optical fibers saw ~1.3E21 n/cm2 total fluence, which is at the highest fluences that fiber Bragg gratings have been studied to date. Reported here is the analysis of this data including radiation induced shift and changes in sensitivity.

46 - INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AN↗

NASA NTRS1987

Mid infrared LHS system packaging using flexible waveguides

As mid IR fiber optic systems are rapidly approaching a reality, so is the feasibility of fiber optic laser heterodyne systems. Laser heterodyne spectroscopy for high resolution monitoring of atmospheric gaseous pollutants is necessarily in the mid IR, the region in which the absorption signature of gaseous species is most prominent. It so happens that the lowest theoretical loss due to Rayleigh-Brillouin scattering also lies in the mid IR. Prospects of highly efficient laser heterodyne systems are thus very good. Such fibers are now beginning to be commercially available, and a test program is being conducted for such fibers with ambient temperature ranging from cryogenic to above room, and stringest mechanical flexibility requirements. Preliminary results are encouraging. A program is being started to explore the possibility of mid IR fiber optic device applications, by taking advantage of this phonon rich region. The potential long interaction length in fibers coupled with predicted extremely low losses point to stimulated Brillouin scattering based devices in the mW range. The generation of backscattered sBs at low laser powers is significant not only as an ultimate power limiting factor for laser transmission in fibers in the mid IR, but also the presence of frequency-shifted multiple order sBs Stokes and antiStokes lines will certainly have severe effect on the laser beats crucial in high resolution heterodyne spectroscopy.

Yu, Chung↗

NASA NTRS1994

Wavelength-division multiplexed optical integrated circuit with vertical diffraction grating

A semiconductor optical integrated circuit for wave division multiplexing has a semiconductor waveguide layer, a succession of diffraction grating points in the waveguide layer along a predetermined diffraction grating contour, a semiconductor diode array in the waveguide layer having plural optical ports facing the succession of diffraction grating points along a first direction, respective semiconductor diodes in the array corresponding to respective ones of a predetermined succession of wavelengths, an optical fiber having one end thereof terminated at the waveguide layer, the one end of the optical fiber facing the succession of diffraction grating points along a second direction, wherein the diffraction grating points are spatially distributed along the predetermined contour in such a manner that the succession of diffraction grating points diffracts light of respective ones of the succession of wavelengths between the one end of the optical fiber and corresponding ones of the optical ports.

Lang, Robert J.↗

NASA NTRS1985

Reusable rocket engine turbopump condition monitoring

Significant improvements in engine readiness with attendant reductions in maintenance costs and turnaround times can be achieved with an engine condition monitoring system (CMS). The CMS provides real time health status of critical engine components, without disassembly, through component monitoring with advanced sensor technologies. Three technologies were selected to monitor the rotor bearings and turbine blades: the isotope wear detector and fiber optic deflectometer (bearings), and the fiber optic pyrometer (blades). Signal processing algorithms were evaluated and ranked for their utility in providing useful component health data to unskilled maintenance personnel. Design modifications to current configuration Space Shuttle Main Engine (SSME) high pressure turbopumps and the MK48-F turbopump were developed to incorporate the sensors.

Hampson, M. E.↗