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International Research & Development Programs Who is doing what in graphite throughout the world Nuclear graphite components Why is graphite so difficult to develop code rules? Unique features of nuclear grade graphite No nuclear graphite standard Brittle material in a pressure vessel code? General graphite behavior and degradation As-fabricated material properties Irradiation behavior Oxidation behavior Molten salt issues
This report documents fiscal year 2026 enhancements to the System Analysis Module (SAM) for modeling fission product transport in liquid-fueled molten salt reactors (MSRs). The work advances three principal areas: noble gas transport, noble metal deposition, and user interface improvements. The noble gas transport capability integrates drift-flux gas transport, Henry’s law two-film interphase mass transfer with pressure-based nucleation suppression, Knudsen-regime pore diffusion into porous graphite with a conjugate salt-graphite interface constraint, built-in material properties, five Sherwood-number mass transfer correlations including three derived from high-fidelity NekRS simulations, and xenon-135 reactivity feedback through SAM’s point-kinetics model. This work also presents a comprehensive verification test suite, including new analytically verified cases for pressure-dependent onset of interphase gas transfer in a stagnant vertical pipe, a postulated FLiBe-graphite Xe extraction permeator, a gravity riser with a fission-product source, and a descending pipe with gas redissolution driven by hydrostatic pressure. A machine learning framework for bubble rise velocity prediction in molten salt systems is developed and benchmarked on molten-salt and diverse aqueous bubble datasets. The best-performing fine-tuned transfer-learning networks achieve an 82% reduction in RMSE relative to the Clift correlation, and is implemented directly in SAM. The noble metal transport capability is developed, including a liquid-wall deposition model and a gas-surface flotation mechanism that transfers insoluble particles entrained by sparging gas to wetted structures. Verification tests and demonstration cases cover the surface deposition, flotation efflux, and flotation shedding. Finally, a new [SpeciesTransport] input structure replaces positional global vectors with selfcontained, order-independent, named species blocks, simplifies the specification of multiphase species and decay chains, and remains fully compatible with existing SAM input files. Together, these developments improve the physical fidelity, verification basis, and usability of SAM for system-level analyses of fissionproduct behavior in MSRs.
Thermal oxidation of nuclear graphite components is highly undesirable because it can cause structural and property degradation that negatively affect a reactor's intended operation. In this work, the body of knowledge of nuclear graphite oxidation is highlighted, including when O 2 , H 2 O, and/or CO 2 are the oxidant. Oxidation conditions relevant to high-temperature gas-cooled reactors (i.e., when oxidation could occur either as an acute or chronic phenomenon) are emphasized. Here, the objective is to summarize graphite oxidation data in a practical and accessible way to inform future research and regulatory requirements. Although each grade of nuclear graphite is different, the oxidation mechanism has underlying commonalities. Although oxidation behavior is grade dependent, the general temperature dependence is well described by a sequence of elementary steps which become rate limiting. Because the regime transition temperature depends on sample microstructure, size, and oxidant supply rate, extrapolating results beyond the experimental range should be done cautiously. Gravimetric oxidation rate measurements generally replicate well. However, caution must be exercised when rates are estimated by other methods or for samples that deviate significantly in size. Air oxidation data for IG-110, NBG-18, and PCEA graphite is critically reviewed to emphasize this point. Despite the amount of experimental data, gaps remain. Sample size and shape effects are not fully explained. Data on the oxidant penetration depth are insufficient. Analytical assessments demonstrate that lower temperature oxidation does not necessarily imply that oxidation is uniform throughout the bulk. Oxidation occurs faster at higher temperature but is more localized to the exposed surface. Paradoxically, at equal mass loss percentage, low temperature oxidation leads to greater property degradation than at high temperature. The isolated effect of oxidation is important; however, a gap remains in the systematic understanding of any potential effect of neutron irradiation on graphite structure and reactivity.
Microreactor designs make use of a coreblock for structural stability allowing for these devices to provide powder generation while being portable and inherently safe. In order to maximize energy output of the microreactors, materials must be able to withstand high temperature without melting and without substantial decreases in mechanical properties. As simultaneous projects looking at steels, graphite, and other materials are on-going, this work package will investigate titanium – zirconium – molybdenum alloy (TZM) as it allows for potentially higher microreactor operating temperatures than traditional reactor materials such as stainless steel. Notably, this alloy was developed in the 1960s for use in rockets and has a very high melting point (2623°C) but is difficult to form, machine and join. With limited needs in aerospace, literature is appropriately sparce in looking at the AM of TZM (examples include [1,2]). However, the properties appear to be an excellent match for the needs of the microreactor coreblock leading to the current project. In addition, small washers form the bulk of TZM parts needed in aerospace while the microreactor community was looking at larger, more complex parts. Therefore, AM of TZM is being explored to enable near – net shape of components with the needed complexity to impact the nuclear energy field.
Microwave-zeolite interactions during direct non-oxidative reactions of methane were studied using three H-ZSM-5 zeolites with different concentrations of Bronsted acid sites. The formation of C 2 and aromatic hydrocarbons increased with increasing surface acidity. When compared to conventional heating, the microwave reaction produced less carbon with higher thermal stability. The increase in diffraction shifts and the decrease in its surface area of microwave-reacted zeolite suggested that the carbon started depositing inside the micropores rather than on the external surfaces. Inhomogeneous carbon deposits with filamentous carbon whiskers were observed under microwave compared to homogeneous spherical carbon deposits on the conventionally reacted sample. The dielectric properties and Raman analysis suggested that the graphitic nature and the thermal stability of deposited carbon increased with zeolite surface acidity under microwave. We believe that this is a very important study for designing microwave active zeolite-based catalysts with a low affinity towards carbon formation.
Lithium-ion batteries (LIBs) are expected to play a crucial role in meeting many of the clean energy-related goals. Due to its electrical properties such as good conductance, chemical inertness, and corrosion resistance, graphite is a very popular anode for LIBs. Traditional methods of producing battery-grade graphite (high purity >99%) include processing naturally mined graphite or manufacturing synthetic graphite via the Acheson process, which converts soft amorphous carbons such as petroleum coke into graphite by subjecting it to high temperature (up to 3000 °C) for prolonged periods of times (3–5 days). However, due to a lack of abundant high purity natural graphite sources, synthetic graphite is the preferred choice for many LIBs. A new synthetic electrochemical graphitization method that subjects the amorphous carbon precursor submerged in a molten salt mixture to a constant cathodic polarization (against a graphitic anode) has been discovered that has significantly lower graphitization temperatures (~800 °C) and reduced graphitization time (3–6 h). Furthermore, the method can accept a higher variety of carbon precursors compared to the Acheson process. A prospective life cycle assessment (LCA) is conducted on this new method and compared against the traditional processes. The laboratory-scale demonstration of the method is used to build an inventory, which through various assumptions is scaled up to a commercial scale. An additional scenario is also considered with a biomass-derived carbon precursor for the graphite. The results from the LCA show that while the laboratory scale process is similar to the Acheson process and natural flake graphite in terms of impact, the scaled-up process is drastically better than the Acheson process in all environmental categories. Using a coconut shell-derived biomass precursor has a higher impact due to its manufacturing in Indonesia, as the Indonesian energy grid is highly fossil fuel dependent. Therefore, the biomass carbon may have a higher impact than petroleum coke dependent on the location of production of biomass-derived carbon black. The LCA has identified the molten salt—CaCl 2 —as a potential hotspot and suggests other salts should be considered. Accordingly, the new method shows promise in this early stage LCA in improving the environmental performance of graphite (and by relation LIBs) and therefore needs to be explored more in terms of its commercial viability.
This project explored how coal and waste coal can be transformed into high-value graphite used in batteries for electric vehicles and power grids. A manufacturing technique that converts coal into carbon foam and subsequently graphite was developed and refined to improve the thermal and mechanical properties of the resulting materials. Cost-effectiveness and environmental impacts were also evaluated. Coal-derived graphite, especially when processed at high temperatures, was shown to perform comparably to commercial graphite in battery tests. Advanced computer simulations were used to model battery behavior and predict long-term performance, demonstrating that coal-based graphite has the potential to support electric vehicle deployment while reducing reliance on imported materials. This work offers a promising pathway for cleaner energy storage solutions and creates economic opportunities for coal-reliant communities by generating new uses for mining byproducts.
ASME Code Development - Nonmetallics slides to include behavior models, licensing & code, graphite R&D Program, As-Fab'd Properties, Mechanisms and Analysis, and Irradiation. Discussion on where these fit into Irradiation behavior, Ceramic Composites, Design, and Component Failure.
Molten salt infiltration in the pore network of nuclear graphite may cause unwanted changes to graphite's local structure and mechanical and thermal properties. A detailed and comprehensive understanding of molten salt intrusion (distribution across sample cross section and penetration depth) is needed to assess its effects. Here, in this work, we report on an improved methodology for the use of neutron imaging (computed tomography) to evaluate salt penetration and distribution of a wide range of graphite grades with diverse microstructures. Neutron tomography data were acquired on the same graphite sample before and after salt intrusion; the 3D reconstructed volumes were digitally co-registered and subtracted. The difference in neutron attenuation coefficient represents direct visualization of FLiNaK (LiF–NaF–KF) salt distribution in the salt-impregnated graphite samples. This improved methodology was applied to investigate the effect of exposure times (12 h and 336 h) and of graphite microstructure when exposed to FLiNaK at 750 °C and 3 bar (gauge) pressure, starting from flowing argon at near atmospheric pressure. The results show that medium-grained and fine-grained graphites evolve to equilibrium at significantly different rates: fast salt uptake in medium-grained graphites produces salt deposits throughout the volume of graphite specimens, whereas salt infiltration in fine-grained graphites is much slower and limited to exposed surfaces.
Experimental discovery of ultralarge elastic deformation in nanoscale diamond and machine learning of its electronic and phonon structures have created opportunities to address new scientific questions. Can diamond, with an ultrawide bandgap of 5.6 eV, be completely metallized, solely under mechanical strain without phonon instability, so that its electronic bandgap fully vanishes? Through first-principles calculations, finite-element simulations validated by experiments, and neural network learning, we show here that metallization/demetallization as well as indirect-to-direct bandgap transitions can be achieved reversibly in diamond below threshold strain levels for phonon instability. We identify the pathway to metallization within six-dimensional strain space for different sample geometries. We also explore phonon-instability conditions that promote phase transition to graphite. These findings offer opportunities for tailoring properties of diamond via strain engineering for electronic, photonic, and quantum applications.
A filtration process of the low cost mesophase pitch developed by Advanced Carbon Products, LLC (ACP) was developed. The mesophase pitch was melt spun into fiber at the University of Kentucky Center for Applied Energy Research (UKY), and converted to carbon fiber. The melt spinning process was moderately stable, but resulted in some void structure in the green fibers. The tensile properties of the resulting carbon fibers, after graphitization heat treatment, were tested yielding a modulus value of approximately 560 GPa or 81 MSI. This demonstrated that a high modulus graphitic carbon fiber is certainly possible from the ACP 20 mesophase pitch. For future work, a better balance between the softening point temperature, the spinning temperature, and filtering must be met to reduce the volatiles generated in the pitch during spinning. This would reduce voids in the fiber, facilitate spinning, and generate finer, higher performance graphitic fiber.
High temperature materials and graphite and composite program review to include: Baseline for unirradiated material properties, ASTM test development, design and construction rules (ASME-based), new fuel matrix mechanical studies, Irradiation damage studies, vender irradiation capsules, graphite supply chain worries, and ceramic composite activities.
This work investigates the role of a carbon nanophase on the local mechanical behavior of nanocarbon metal matrix composites (NCMCs) produced through an electrocharge-assisted process. Nanoindentation experiments on single crystal Al, Al 1350 parent alloys, and Al 1350 NCMCs revealed variable mechanical properties, caused by an interplay between microstructure and graphitic reinforcements. TEM and AFM studies also reveal nanoscale structural changes based on the incorporation of a carbon nanophase. In order to decouple the effects of the aforementioned mechanical behaviors, molecular dynamics nanoindentation simulations were performed on the (111) surface of Al and Al NCMC samples containing semi-infinite graphene nanoribbons to examine the evolution of plasticity over time. Findings indicate that the arrangement of a finite graphene nanophase within a host matrix can alter plasticity mechanisms and therefore yield strength in near-surface mechanical behavior with little effect on elastic properties. Here, this understanding enables further study into tunable bulk properties of Al-based NCMCs while isolating microstructural effects and reinforcement effects of the carbon phase. Such an understanding will lead to application-specific material geometries ranging from highperforming vehicle structures to next-generation electrical devices.
This study presents a comprehensive multiscale analysis to evaluate the influence of moisture on the thermal performance of thermal energy storage systems using magnesium chloride (MgCl 2 ) as the phase-changing material. The system uses graphite foam with 90% relative density to enhance thermal conductivity. The analysis includes thermal conductivity calculations and specific heat capacity for different hydrate phases of MgCl 2 : Anhydrous, Mono, Di, Tetra, and Hexa. These properties were evaluated for the first time using the phonon density of states from Density Functional Theory simulations. Results showed that thermal conductivity decreased, while specific heat capacity increased by a factor of two as the phase changed from anhydrous to hexahydrate. Meso-scale models were created to account for the anisotropy of graphite foam and property variations of the MgCl 2 hydrate phases. Asymptotic Expansion homogenization simulations determined the anisotropic thermal conductivity for all phases. This unique methodology improved simulation accuracy, which matched experimental data for anhydrous MgCl 2 . A parametric study examined various operating conditions and their effect on TES performance. It revealed that higher charging temperatures did not enhance exergy efficiency, but increased discharge mass flow rates improved it due to better heat transfer. Thermal performance evaluated by the exergy efficiency remained consistent across hydrate systems under the tested conditions. Furthermore, the study suggests that this uniformity is linked to missing key data, particularly latent heat and melting point for different hydrates. Overall, it highlights the importance of multiscale effects and accurate material properties in designing and optimizing TES systems.
In this work, an innovative energy storage concept based on the purposeful creation of defects in crystalline material by neutron irradiation is presented. Lattice defects are generated when heavy particles collide with the atoms in a crystal structure, i.e., if the incoming particles have enough energy, recoil atoms are displaced from their initial lattice sites. Most of the displaced atoms will eventually combine with nearby vacancies, but some of them will come to rest in non-ideal locations. The energy held by displaced atoms is called Wigner energy. Lattice defects can migrate and form clusters, and the Wigner energy can be released from these groupings if sufficient activation energy is provided. In the nuclear industry, this effect is well-known since it represented an issue for graphite-moderated reactors. This work presents the conceptual design of an engineering system that exploits this physical process to store the energy of neutrons in advanced reactor concepts. In the first part of the paper, the theoretical performance of an energy storage system based on the Wigner effect is described. Given the lattice properties and the compatibility with the harsh reactor environment, graphite was selected as the candidate material for the irradiation targets. Both experimental data and molecular dynamics simulations confirmed that this system can achieve performance comparable with state-of-the-art batteries in terms of stored energy density. In the second part of the paper, the engineering challenges of this innovative technology and the proposed solutions are described. After defining the optimal irradiation conditions, the different steps of the operation of the proposed energy system (from energy storing to energy harvesting) were defined. Finally, the integration of this concept with advanced reactor designs, i.e., a Sodium-cooled Fast Reactor and a Molten Salt-cooled Reactor, was investigated and the corresponding performance was evaluated.
Baseline Graphite Characterization: Purpose of Baseline, Mechanical Baseline Tests, Physical Properties Tests, Methodology, Baseline progress, Density, Ultimate Tensile Strength, PCEA Ultimate Tensile Strength, Split Disc Tests, Compression Tests, Flexural Tests, and Coefficient of Thermal Expansion.
To achieve a truly closed-loop direct recycling process for lithium-ion batteries, all component materials must be recovered. To date, direct recycling method development has primarily focused on the high-value transition-metal cathode materials, while the inherently lower-value graphite has been challenging to recover in a cost-effective manner. However, end-of-life graphite contains a unique engineered value due to the presence of the solid electrolyte interphase (SEI). Growth of the SEI during the cell's active lifetime stabilizes the electronically reactive graphite surface through an irreversible consumption of Li, and thus necessitates both excess lithiation of the cathode and a costly and time-intensive formation procedure during manufacturing. An optimized pre-formed SEI that capitalizes on existing SEI components from end-of-life batteries has the potential to significantly reduce cathode lithiation requirements and eliminate the critical bottleneck of formation cycling during cell remanufacturing. Further, retaining Li at the anode obviates the need for a separate Li leaching and recovery step, improving the overall efficiency of the direct recycling line. In this work, we present a novel approach to "upcycling" spent graphite through use of tailored chemical treatment to remove adverse (i.e., highly resistive and/or poorly passivating) SEI species while retaining beneficially passivating components. We have explored a rational set of solvents spanning a range of polarity, proticity, and molecular size to evaluate structure-property-performance relationships between applied solvent(s), removed and remaining SEI species, and electrochemical response of the resulting graphite product. Further, we have developed and optimized a robust and holistic analysis procedure that couples symmetric-cell electrochemical testing, multi-modal materials characterization, and advanced electrochemical modeling. These analysis results inform a set of correlative metrics for graphite performance relative to both solvent properties and upcycled SEI composition. We demonstrate effective tunability in the residual SEI composition by varying solvent identity and concentration, and report on several promising solvent systems that achieve comparable or performance to pristine graphite.