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DOE OSTI2017

Post-Irradiation Non-Destructive Analyses of the AFIP-7 Experiment

This paper reports the results and interpretation of post-irradiation non-destructive examinations performed on four curved full-size fuel plates that comprise the AFIP-7 experiment. These fuel plates, having a U-10 wt.%Mo monolithic design, were irradiated under moderate operating conditions in the Advanced Test Reactor to assess fuel performance for geometries that are prototypic of research reactor fuel assemblies. Non-destructive examinations include visual examination, neutron radiography, profilometry, and precision gamma scanning. This article evaluates the qualitative and quantitative data taken for each plate, compares corresponding data sets, and presents the results of swelling analyses. Finally, these characterization results demonstrate that the fuel meets established irradiation performance requirements for mechanical integrity, geometric stability, and stable and predictable behavior.

36 MATERIALS SCIENCE↗

NASA NTRS1986

Transmission electron microscopic examination of phosphoric acid fuel cell components

Transmission electron microscopy (TEM) was used to physically characterize tested and untested phosphoric acid fuel cell (PAFC) components. Those examined included carbon-supported platinum catalysts, carbon backing paper, and Teflon-bonded catalyst layers at various stages of fabrication and after testing in pressurized PAFC's. Applicability of electron diffraction and electron energy loss spectroscopy for identifying the various phases was explored. The discussion focuses on the morphology and size distribution of platinum, the morphology and structural aspects of Teflon in catalyst layers, and the structural evidence of carbon corrosion. Reference is made to other physical characterization techniques where appropriate. A qualitative model of the catalyst layer that emerged from the TEM studies is presented.

Pebler, A.↗

DOE OSTI2019

Core-to-Specimen Energy Coupling Results of the First Modern Fueled Experiments in TREAT

For this study, a series of experiments was conducted in the Transient Reactor Test (TREAT) Facility following a decades-long operational hiatus. A series of physics tests were then performed emphasizing relevant transients for Light Water Reactor (LWR) fuels research. A series of fueled experiments were then conducted using LWR-type sub-length specimens in inert gas capsules with the primary objective to quantify the ratio of nuclear heat deposited in the core to that deposited in the specimens. This type of data can be difficult to measure but is highly important in the design and interpretation of transient tests. Five fueled capsules were irradiated and energy coupling factors (which express the ratio of nuclear heat deposited per mass in the test specimen to that deposited in the reactor core in units of J/gUO 2 MJ TREAT ) were observed ranging from 2.0 to 2.2 over a wide range of transient energies with good agreement between measurement methods.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

NASA NTRS2004

Subscale Testing of Nozzle Ablative Materials in a Supersonic Particle Impingement Environment

Recent efforts to evaluate materials to replace the current NARC rayon used in the nozzle ablative of the NASA's Reusable Solid Rocket Motor (SRM), several tests were developed to look at the performance of supersonic particle impact region of the aft exit cone. It was seen in early testing that some potential candidates did not perform as well as the current NARC based material and so the 24 inch Solid Rocket Motor (SRTM) exit cone design was extended and contoured to induce particle impingement in the aft end. The SRTM testing provided a larger testbed to evaluate the results seen in the Solid Fuel Supersonic Blast Tube. Testing was performed in each test bed on two variants of the final two candidate materials. The materials were a standard prewoven Lyocell, a postwoven Lyocell, an Enka rayon, and Enka rayon processed at a higher carbonization temperature. This paper presents the results of the four materials in the SSBT and the SRTM tests as compared against the NARC baseline. Erosion, char, and plylift results are discussed in detail.

Howse, S.↗

DOE OSTI2022

BISON Validation to In-Situ Cladding Burst Test and High Burnup LOCA Experiments

The process to develop and qualify nuclear fuels for commercial nuclear application requires fundamental material development, characterization, and design; out-of-pile testing on unirradiated materials; integral fuel rod irradiations, testing, and post irradiation examinations (PIEs); and transient analyses. The historical approach depends on the generation of large empirical datasets and series of integral fuel rod irradiations, and this approach ultimately takes approximately 20 years—or sometimes longer—to acquire data through extensive sequential testing. Thus, the qualification and eventual deployment of new fuel systems constitute a long and drawn-out process. However, recent technological advancements have provided researchers the opportunity to perform out-of-cell, in-situ measurements to assess material performance for the duration of the experiment. One such example of this capability is the use of digital image coordination and thermal imaging to assess Zircaloy cladding performance under a simulated loss-of-coolant accident (LOCA) transient condition. In general, the in-situ measurements provide high-fidelity strain, strain rates, and temperature surface maps. This is critical for the United States nuclear industry, which is actively developing a technical basis to support extending the peak rod average burnup from 62 to ~75 GWd/tU and the deployment of accident-tolerant fuel. However, the Nuclear Regulatory Commission, through their research information letter, outlined a number of technical issues for the industry to address before extending burnup. One topic of specific interest is understanding the cladding balloon and rupture geometry during the LOCA heatup phase. Leveraging these advanced in-situ capabilities, this work intends to use insitu data generated from a simulated LOCA in the Severe Accident Test Station at Oak Ridge National Laboratory to better understand high-temperature creep and its impact on Zircaloy balloon and rupture performance. This work used the BISON fuel performance code to compare BISON’s high-temperature creep model predictions to in-situ data and identify limitations and gaps within the model. Additionally, BISON will subsequently be used to simulate relevant high-burnup LOCA tests. The results will be analyzed and compared to the available post-test data in a manner consistent with the approach outlined in the Nuclear Regulatory Commission research information letter.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2021

Effects of knock intensity measurement technique and fuel chemical composition on the research octane number (RON) of FACE gasolines: Part 1 – Lambda and knock characterization

The Research and Motor Octane Number (RON and MON) rate the knock propensity of gasoline in the Cooperative Fuel Research (CFR) engine by comparing the knock intensity of sample fuels relative to that of primary reference fuels (PRF), a binary blend of iso-octane and n-heptane. Important differences exist between standard octane testing and automotive spark ignition (SI) engine knock testing including speed, load, air-to-fuel equivalence ratio (lambda), and knock characterization, which lead to a discrepancy between a fuel’s RON rating and its knock resistance characterized on an automotive SI engine based on knock-limited spark advance. This publication is the first of a set of three publications which modify operating parameters of the RON test method (ASTM D2699) to investigate the effects of these differences with automotive SI engine knock-limited spark advance testing. A fuel’s standard RON is evaluated at the lambda of the highest knock intensity, whereas automotive SI engines typically operate at stoichiometry. Here, we analyze the effects of a stoichiometric RON rating methodology. Additionally, the knock intensity response from the standard CFR knockmeter system is compared to a cylinder pressure oscillation-based knock intensity at several lambda settings. All experiments were performed with a set of seven Coordinating Research Council (CRC) Fuels for Advanced Combustion Engines (FACE) gasolines with approximately 95 RON. The fuel chemical composition impacted the lambda of the highest knock intensity, which resulted in fuel-specific offsets between the standard and stoichiometric RON ratings. The knock system comparison showed significant offsets between cylinder pressure-based and knockmeter-based knock intensity levels.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

NASA NTRS2003

Effects of Non-Uniform Fuel Distribution on Detonation Tube Performance

A pulse detonation engine uses a series of high frequency intermittent detonation tubes to generate thrust. The process of filling the detonation tube with fuel and air for each cycle may yield non-uniform mixtures. Uniform mixing is commonly assumed when calculating detonation tube thrust performance. In this study, detonation cycles featuring idealized non-uniform H2/air mixtures were analyzed using a two-dimensional Navier-Stokes computational fluid dynamics code with detailed chemistry. Mixture non-uniformities examined included axial equivalence ratio gradients, transverse equivalence ratio gradients, and partially fueled tubes. Three different average test section equivalence ratios were studied; one stoichiometric, one fuel lean, and one fuel rich. All mixtures were detonable throughout the detonation tube. Various mixtures representing the same average test section equivalence ratio were shown to have specific impulses within 1% of each other, indicating that good fuel/air mixing is not a prerequisite for optimal detonation tube performance under the conditions investigated.

Perkins, H. Douglas↗

NASA NTRS2003

Effects of Fuel Distribution on Detonation Tube Performance

A pulse detonation engine uses a series of high frequency intermittent detonation tubes to generate thrust. The process of filling the detonation tube with fuel and air for each cycle may yield non-uniform mixtures. Uniform mixing is commonly assumed when calculating detonation tube thrust performance. In this study, detonation cycles featuring idealized non-uniform Hz/air mixtures were analyzed using a two-dimensional Navier-Stokes computational fluid dynamics code with detailed chemistry. Mixture non-uniformities examined included axial equivalence ratio gradients, transverse equivalence ratio gradients, and partially fueled tubes. Three different average test section equivalence ratios were studied; one stoichiometric, one fuel lean, and one fuel rich. All mixtures were detonable throughout the detonation tube. Various mixtures representing the same average test section equivalence ratio were shown to have specific impulses within 1% of each other, indicating that good fuel/air mixing is not a prerequisite for optimal detonation tube performance under conditions investigated.

Perkins, H. Douglas↗

NASA NTRS2011

Mach 0.3 Burner Rig Facility at the NASA Glenn Materials Research Laboratory

This Technical Memorandum presents the current capabilities of the state-of-the-art Mach 0.3 Burner Rig Facility. It is used for materials research including oxidation, corrosion, erosion and impact. Consisting of seven computer controlled jet-fueled combustors in individual test cells, these relatively small rigs burn just 2 to 3 gal of jet fuel per hour. The rigs are used as an efficient means of subjecting potential aircraft engine/airframe advanced materials to the high temperatures, high velocities and thermal cycling closely approximating actual operating environments. Materials of various geometries and compositions can be evaluated at temperatures from 700 to 2400 F. Tests are conducted not only on bare superalloys and ceramics, but also to study the behavior and durability of protective coatings applied to those materials.

Fox, Dennis S.↗

DOE OSTI2016

An analysis method for experiment power in the ATR

The Advanced Test Reactor (ATR) at Idaho National Laboratory (INL) is used for testing and qualification of nuclear fuels and materials. The ATR has been irradiating the lead test assembly (LTA) for the planned Ki-Jang Research Reactor (KJRR) in Korea. Irradiation and subsequent Post-Irradiation Examination (PIE) of the LTA will lead to qualification of the fuel to support licensing activities. Qualification of the LTA requires the experiment to meet specific thermal and burn-up conditions. In particular, plate 20 of the experiment must obtain a heat flux between 137 and 200 W/cm{sup 2} with a target U-235 depletion of 79-84%. Due to the limited instrumentation and burn-up monitoring capabilities, assurance of meeting experiment goals is verified through modelling. In order to validate the experiment model using ATR operating data, a methodology was developed to compare the calculated experiment power with ATR power monitoring instrumentation. This paper discusses the methodology used to quantify the experiment power and uncertainty in the model based on ATR operating conditions. (authors)

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

NASA NTRS1984

Deposit formation and heat transfer in hydrocarbon rocket fuels

An experimental research program was undertaken to investigate the thermal stability and heat transfer characteristics of several hydrocarbon fuels under conditions that simulate high-pressure, rocket engine cooling systems. The rates of carbon deposition in heated copper and nickel-plated copper tubes were determined for RP-1, propane, and natural gas using a continuous flow test apparatus which permitted independent variation and evaluation of the effect on deposit formation of wall temperature, fuel pressure, and fuel velocity. In addition, the effects of fuel additives and contaminants, cryogenic fuel temperatures, and extended duration testing with intermittent operation were examined. Corrosion of the copper tube surface was detected for all fuels tested; however, plating the insides of the tubes with nickel reduced deposit formation and eliminated corrosion in most cases. The lowest rates of carbon deposition were obtained for natural gas, and the highest rates were obtained for propane. Forced-convection heat transfer film coefficients were satisfactorily correlated using a Nusselt-Reynolds-Prandtl number equation for all the fuels tested.

Giovanetti, A. J.↗

NASA NTRS2005

A Materials Compatibility and Thermal Stability Analysis of Common Hydrocarbon Fuels

A materials compatibility and thermal stability investigation was conducted using five common liquid hydrocarbon fuels and two structural materials. The tests were performed at the NASA Glenn Research Center Heated Tube Facility under environmental conditions similar to those encountered in regeneratively cooled rocket engines. Scanning-electron microscopic analysis in conjunction with energy dispersive spectroscopy (EDS) was utilized to characterize the condition of the tube inner wall surface and any carbon deposition or corrosion that was formed during selected runs. Results show that the carbon deposition process in stainless steel tubes was relatively insensitive to fuel type or test condition. The deposition rates were comparable for all fuels and none of the stainless steel test pieces showed any signs of corrosion. For tests conducted with copper tubing, the sulfur content of the fuel had a significant impact on both the condition of the tube wall and carbon deposition rates. Carbon deposition rates for the lowest sulfur fuels (2 ppm) were slightly higher than those recorded in the stainless steel tubes with no corrosion observed on the inner wall surface. For slightly higher sulfur content (25 ppm) fuels, nodules that intruded into the flow area were observed to form on the inner wall surface. These nodules induced moderate tube pressure drop increases. The highest sulfur content fuels (400 ppm) produced extensive wall pitting and dendritic copper sulfide growth that was continuous along the entire tube wall surface. The result of this tube degradation was the inability to maintain flow rate due to rapidly increasing test section pressure drops. Accompanying this corrosion were carbon deposition rates an order of magnitude greater than those observed in comparable stainless steel tests. The results of this investigation indicate that trace impurities in fuels (i.e. sulfur) can significantly impact the carbon deposition process and produce unacceptable corrosion levels in copper based structural materials.

Meyer, M. L.↗

DOE OSTI2021

Gasoline fuels properties for multi-mode operation – Observations in a GDI and the CFR engine

The combustion behavior of five full boiling range RON98 gasoline blends was evaluated for multi-mode operation in a GDI and the CFR octane rating engine. The GDI engine tests were conducted with stoichiometric air-fuel ratio in spark-ignition (SI), and with air-diluted homogeneous charge compression ignition (HCCI) mode. In the CFR engine, the knocking combustion was analyzed under standard RON testing conditions at both peak knocking lambda and stoichiometric air-fuel ratios, whereas compression ignited operation was characterized by utilizing the HCCI number test protocol. Disparate knock limited SI and HCCI combustion behavior was observed for the test fuels, despite four of the fuels having the same RON and octane sensitivity. It was found that knock-limited combustion phasing in the GDI engine did not align well with the RON. However, a detailed comparison of knock-limited SI operation in the GDI and CFR engine revealed that a more appropriate effective RON based on a common knock intensity metric (MAPO) and stoichiometric air-fuel ratio resulted in comparable knock characterization between the two engine platforms. Furthermore, the critical intake air temperature and the critical compression ratio were proposed to characterize knock-limited SI operation, while the minimum intake air heating and compression ratio were used to define a fuel's autoignition propensity for compression ignition operation in the GDI and CFR engine, respectively. Finally, each fuel's characteristic compression ratio needed to obtain knock-limited SI (KLSI) and HCCI operation was used to calculate an effective multi-mode octane number (MM-ON) based on the primary reference fuel blends.

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2016

The impact of interface bonding efficiency on high-burnup spent nuclear fuel dynamic performance

Finite element analysis (FEA) was used to investigate the impact of interfacial bonding efficiency at pellet-pellet and pellet-clad interfaces of high-burnup (HBU) spent nuclear fuel (SNF) on system dynamic performance. Bending moments M were applied to FEA model to evaluate the system responses. From bending curvature, κ, flexural rigidity EI can be estimated as EI = M/κ. The FEA simulation results were benchmarked with experimental results from cyclic integrated reversal bending fatigue test (CIRFT) of HBR fuel rods. The consequence of interface debonding between fuel pellets and cladding is a redistribution of the loads carried by the fuel pellets to the clad, which results in a reduction in composite rod system flexural rigidity. Furthermore, the interface bonding efficiency at the pellet-pellet and pellet-clad interfaces can significantly dictate the SNF system dynamic performance. With the consideration of interface bonding efficiency, the HBU SNF fuel property was estimated with CIRFT test data.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2017

Rubble Fire Multi-Phase Model Development

This report presents multi-phase modeling approaches that are developed for simulating rubble fire scenarios similar to a large-scale rubble pool fire test at Sandia National Laboratories using composite materials and jet fuel. The rubble pool fire test burnt oddly shaped combustible solid objects submerged in liquid fuel. As an intermediate step toward a full scale rubble fire simulation, various model improvement tasks were performed. For modeling solid decomposition, a multi-step degradation model was used for canonical verification problems and the Chemical Percolation for Devolatilization (CPD) approach was implemented. Capabilities of Lagrangian particle approach has been extended such that a group of particles may represent a solid bulk. For gas-liquid interface, the volume of fluid (VOF) technique was implemented and relevant physics were added. The developed tools offer a potential for simulating three-phase (gas, liquid, and solid) combustion applications.

42 ENGINEERING↗

NASA NTRS1977

Effect of Flame Stabilizer Design on Performance and Exhaust Pollutants of a Two-Row Swirl-Can Combustor Operated to Near-Stoichiometric Conditions

Emissions and performance characteristics were determined for two full annulus modular combustors operated to near stoichiometric fuel air ratios. The tests were conducted to obtain stoichiometric data at inlet air temperatures from 756 to 894 K and to determine the effects of a flat plate circular flame stabilizer with upstream fuel injection and a contraswirl flame stabilizer with downstream fuel injection. Levels of unburned hydrocarbons were below 0.50 gram per kilogram of fuel for both combustors and thus there was no detectable difference in the two methods of fuel injection. The contraswirl flame stabilizer did not produce the level of mixing obtained with a flat plate circular flame stabilizer. It did produce higher levels of oxides of nitrogen, which peaked at a fuel air ratio of 0.037. For the flat plate circular flame stabilizer, oxides of nitrogen emission levels were still increasing with fuel air ratio to the maximum tested value of 0.045.

Biaglow, James A.↗

NASA NTRS1977

Gaseous fuel reactors for power systems

Gaseous-fuel nuclear reactors have significant advantages as energy sources for closed-cycle power systems. The advantages arise from the removal of temperature limits associated with conventional reactor fuel elements, the wide variety of methods of extracting energy from fissioning gases, and inherent low fissile and fission product in-core inventory due to continuous fuel reprocessing. Example power cycles and their general performance characteristics are discussed. Efficiencies of gaseous fuel reactor systems are shown to be high with resulting minimal environmental effects. A technical overview of the NASA-funded research program in gaseous fuel reactors is described and results of recent tests of uranium hexafluoride (UF6)-fueled critical assemblies are presented.

Kendall, J. S.↗

NASA NTRS1991

Nuclear thermal propulsion test facility requirements and development strategy

The Nuclear Thermal Propulsion (NTP) subpanel of the Space Nuclear Propulsion Test Facilities Panel evaluated facility requirements and strategies for nuclear thermal propulsion systems development. High pressure, solid core concepts were considered as the baseline for the evaluation, with low pressure concepts an alternative. The work of the NTP subpanel revealed that a wealth of facilities already exists to support NTP development, and that only a few new facilities must be constructed. Some modifications to existing facilities will be required. Present funding emphasis should be on long-lead-time items for the major new ground test facility complex and on facilities supporting nuclear fuel development, hot hydrogen flow test facilities, and low power critical facilities.

Allen, George C.↗