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Considerations for using Privacy Preserving Machine Learning Techniques for Safeguards

In international nuclear safeguards, the International Atomic Energy Agency (IAEA) is tasked with inspecting and verifying nuclear facilities and their activities. Data analytics and machine learning to support inspections require large amounts of data that nuclear facility operators may consider proprietary or sensitive, so the IAEA may not have full access. Allowing computation over private data without compromising its security therefore has value for safeguards inspections and analysis. Privacy-preserving machine learning (PPML) consists of security-focused techniques that allow data analytics and machine learning algorithms to run on sensitive data without revealing it. This includes ideas like homomorphic encryption (HE), secure multiparty computation (SMPC), and secure enclaves. HE allows algorithms and mathematical operations to be conducted directly on the encrypted data instead of first decrypting it. With SMPC, multiple entities collaboratively compute over distributed data such that no party is able to directly view any others’ original data. Secure enclaves allow computation to take place in a separate and heavily blocked-off section of a CPU. Techniques like these allow for several potential use cases in which the security of data is essential. With SMPC, machine learning models can be trained over the input data from multiple entities, resulting in a model that all users can benefit from without leaking the input data from any particular entity. With SMPC or a zero-knowledge proof (ZKP), an algorithm returning some single answer or truth value can be run on someone else’s data without ever needing to see that data, potentially allowing for verification or proof of some underlying question. HE can allow for outsourcing computation on data to a hostile or untrusted environment. Although most of the research in this field resides within the health and financial domains, tools from PPML may have similar applications in nuclear safeguards. Allowing the IAEA to compute over proprietary information, such as process models and raw sensor data using PPML techniques, provides the baseline for running complex analytics without needing direct unencrypted access to the underlying data, maintaining its privacy. Important limitations to consider for these techniques include the efficiency and level of security required. The security of HE and SMPC come at the cost of speed—the significant amount of overhead means that algorithms implemented in these protocols and encryption schemes are slower than when run on plaintext. Additionally, several important parameters determine what techniques or protocols are used based on the security requirements. SMPC protocols may need to be selected for resistance against a party that attempts to deviate from the protocol to distort the result or gain access to additional information, and a protocol secure against these attacks may further increase the overhead of the algorithm.

97 MATHEMATICS AND COMPUTING↗

Performance Evaluation of Comparative Vacuum Monitoring and Piezoelectric Sensors for Structural Health Monitoring of Rotorcraft Components

The costs associated with the increasing maintenance and surveillance needs of aging structures are rising at an unexpected rate. Multi-site fatigue damage, hidden cracks in hard-to-reach locations, disbonded joints, erosion, impact, and corrosion are among the major flaws encountered in today’s extensive fleet of aging aircraft and space vehicles. Aircraft maintenance and repairs represent about a quarter of a commercial fleet’s operating costs. The application of Structural Health Monitoring (SHM) systems using distributed sensor networks can reduce these costs by facilitating rapid and global assessments of structural integrity. The use of in-situ sensors for real-time health monitoring can overcome inspection impediments stemming from accessibility limitations, complex geometries, and the location and depth of hidden damage. Reliable, structural health monitoring systems can automatically process data, assess structural condition, and signal the need for human intervention. The ease of monitoring an entire on-board network of distributed sensors means that structural health assessments can occur more often, allowing operators to be even more vigilant with respect to flaw onset. SHM systems also allow for condition-based maintenance practices to be substituted for the current time-based or cycle-based maintenance approach thus optimizing maintenance labor. The Federal Aviation Administration has conducted a series of SHM validation and certification programs intended to comprehensively support the evolution and adoption of SHM practices into routine aircraft maintenance practices. This report presents one of those programs involving a Sandia Labs-aviation industry effort to move SHM into routine use for aircraft maintenance. The Airworthiness Assurance NDI Validation Center (AANC) at Sandia Labs, in conjunction with Sikorsky, Structural Monitoring Systems Ltd., Anodyne Electronics Manufacturing Corp., Acellent Technologies Inc., and the Federal Aviation Administration (FAA) carried out a trial validation and certification program to evaluate Comparative Vacuum Monitoring (CVM) and Piezoelectric Transducers (PZT) as a structural health monitoring solution to specific rotorcraft applications. Validation tasks were designed to address the SHM equipment, the health monitoring task, the resolution required, the sensor interrogation procedures, the conditions under which the monitoring will occur, the potential inspector population, adoption of CVM and PZT systems into rotorcraft maintenance programs and the document revisions necessary to allow for their routine use as an alternate means of performing periodic structural inspections. This program addressed formal SHM technology validation and certification issues so that the full spectrum of concerns, including design, deployment, performance and certification were appropriately considered. Sandia Labs designed, implemented, and analyzed the results from a focused and statistically relevant experimental effort to quantify the reliability of a CVM system applied to Sikorsky S-92 fuselage frame application and a PZT system applied to an S-92 main gearbox mount beam application. The applications included both local and global damage detection assessments. All factors that affect SHM sensitivity were included in this program: flaw size, shape, orientation and location relative to the sensors, as well as operational and environmental variables. Statistical methods were applied to performance data to derive Probability of Detection (POD) values for SHM sensors in a manner that agrees with current nondestructive inspection (NDI) validation requirements and is acceptable to both the aviation industry and regulatory bodies. The validation work completed in this program demonstrated the ability of both CVM and PZT SHM systems to detect cracks in rotorcraft components. It proved the ability to use final system response parameters to provide a Green Light/Red Light (“GO” – “NO GO”) decision on the presence of damage. In additional to quantifying the performance of each SHM system for the trial applications on the S-92 platform, this study also identified specific methods that can be used to optimize damage detection, guidance on deployment scenarios that can affect performance and considerations that must be made to properly apply CVM and PZT sensors. These results support the main goal of safely integrating SHM sensors into rotorcraft maintenance programs. Additional benefits from deploying rotorcraft Health and Usage Monitoring Systems (HUMS) may be realized when structural assessment data, collected by an SHM system, is also used to detect structural damage to compliment the operational environment monitoring. The use of in-situ sensors for health monitoring of rotorcraft structures can be a viable option for both flaw detection and maintenance planning activities. This formal SHM validation will allow aircraft manufacturers and airlines to confidently make informed decisions about the proper utilization of CVM and PZT technology. It will also streamline future regulatory actions and formal certification measures needed to assure the safe application of SHM solutions.

42 ENGINEERING↗

SolarAPP+ Pilot Analysis: Performance and Impact of Instant, Online Solar Permitting

The National Renewable Energy Laboratory (NREL) led a collaborative effort to develop the Solar Automated Permit Processing Plus (SolarAPP+), a no-cost solar permitting software solution to address residential solar photovoltaic (PV) permitting resource constraints and streamline solar adoption processes among authorities having jurisdiction (AHJs). The SolarAPP+ is an online portal that automates permit plan review, enabling an instant permit approval process for code-compliant residential PV systems. Based on national model building, electrical, and fire codes, the SolarAPP+ automatically performs a compliance check of permit inputs against code requirements and produces an inspection checklist that can be used to verify installation practices, workmanship, and adherence to the approved design. NREL conducted a two-phase pilot with five participating AHJs and 16 solar contractors, spanning from November 2020 through December 2021, evaluating the ability of SolarAPP+ to deliver instant permits and its impact on four critical areas within each AHJ: permit review timelines; solar adoption timelines; AHJ time saved; and inspection results. The pilot confirmed that SolarAPP+ reduced permit review times to less than one day, reduced solar adoption timelines by an average of 12 days, saved an estimated 2,067 staff hours, and had comparable inspection results to those found in traditional permitting. The pilot further identified key lessons for improving SolarAPP+, including ways to streamline SolarAPP+ adoption, development of training resources, and expansion of supported products.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

Non-Destructive In-Process Assessment of Thermal Spray Repairs

This exploratory project, entitled “Non-Destructive In-process Assessment of Thermal Spray Repairs,” evaluated the capabilities and limitations of four non-destructive testing (NDE) technologies for detection of defects in as-sprayed thermal spray coatings: acousto-ultrasonics, vibro-thermography, thermal wave infrared (IR) imaging, and flash IR thermography. The project goal was to identify a single technology suitable for use as an in-process inspection for two common classes of defects in thermal spray coatings, porosity and disbonds. Two rounds of test coupons were fabricated with intentionally seeded defects in AISI 420 stainless steel coatings deposited by twin wire arc (TWA) spray onto gray cast iron substrates. These standardized test coupons allowed the sensitivity of the four NDE methods to be directly compared. The results indicated that the acousto-ultrasonic method will not meet requirements for accuracy, inspection time, and reproducibility, while the vibrothermography method will not meet requirements for integration within remanufacturing cells and process flows. The IR methods, thermal wave imaging and flash thermography, both exhibited acceptable accuracy and reproducibility; however, the former method does not meet the requirement for inspection time. Flash IR thermography met all requirements in the initial round of testing, and that result was confirmed in a second round of testing on samples with a larger, more complex geometry. A final recommendation for further development of flash IR thermography was therefore made based upon i) detection performance, and ii) feasibility of deployment into the target application of resurfacing CAT engine blocks and headers.

36 MATERIALS SCIENCE↗

Modeling and Simulation of Austenitic Welds and Coarse-grained Specimens: Part II

The Pacific Northwest National Laboratory (PNNL) is conducting confirmatory research for the U.S. Nuclear Regulatory Commission (NRC) to evaluate commercially available nondestructive examination (NDE) modeling and simulation software used in the nuclear industry. Simulation results from ultrasonic testing (UT) models can inform the design and qualification of inspection techniques and help interpret inspection results. CIVA is a modeling and simulation package developed by the French Alternative Energies and Atomic Energy Commission (CEA). CIVA was selected for this study because it is readily available and has been used for NDE in the US commercial nuclear power industry. This report is focused on completing the efforts initiated in the previous PNNL report to evaluate UT modeling and simulation performance, reliability, and accuracy in relation to common inservice inspection (ISI) scenarios in nuclear power plants (NPP). This work will be used to provide guidance when establishing methods to perform and evaluate simulations for more standardized model implementation, simulation analysis, and interpretation of results.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

Los Alamos National Laboratory Floodplain Assessment for the TA-72 Guard Post 10 Expedited Vehicle Lane Project

The National Nuclear Security Administration (NNSA), a semi-autonomous agency within the U.S. Department of Energy (DOE), is proposing new construction in lower Sandia Canyon at Technical Area (TA) 72 at the Guard Post 10 vehicle inspection station at Los Alamos National Laboratory (LANL). The proposed project is intended to provide expedited inspection times for vehicles transporting time sensitive loads, such as concrete and asphalt. The project activities within the 100-year floodplain include installation of 1) installation of an expedited vehicle inspection lane, 2) relocation of a 4-strand wire fence, 3) possible relocation of at least one power pole, and 4) a laydown area (Figures 1 and 2).

42 ENGINEERING↗

Advanced Laboratory and Field Arrays: Technical Report for Autonomous Monitoring & Intervention (Task 2)

The goal for this task was to develop software for an autonomous underwater vehicle (AUV) capable of performing inspection, monitoring, and intervention operations in marine renewable energy arrays, employing motion planning and probabilistic navigation methods. Inspection and manipulation tasks were chosen to be applicable to multiple device types without requiring expensive components. Minimal human intervention reduces costs and also improves efficiency. Using AUVs for inspection and monitoring with limited human intervention and low-cost infrastructure is viewed as critical to the strategy for bringing down O&M costs. The final deliverable for this task was to enable a decrease in the time for maintenance and intervention in marine renewable energy arrays by up to 30% versus using tele-operated ROVs.

13 HYDRO ENERGY↗

Plant Disease Detection Technology Assessment

Visual inspections by US Customs and Border Protection agriculture specialists have identified approximately 20,000 regulated, quarantined pests each year in agricultural products entering the United States. Most of these pests identified in the Agriculture Quarantine and Inspection (AQI) program are insects. Many pathogens are difficult to detect in agricultural products, particularly in early stages of infection. New technologies can help to detect plant pathogens and the diseases that they cause. This technology assessment was performed for the US Department of Homeland Security Science and Technology Directorate (DHS S&T) through the Food, Agriculture, and Veterinary Defense (FAV-D) program to identify emerging technologies that could address this hard problem. These emerging technologies differ in their diagnostic sensitivities and specificities, as well as in their measurement time and training requirements. New instruments that detect volatile organic compounds characteristic of plant disease or pathogens could provide a less invasive inspection method. Dogs, which can successfully detect many concealed agricultural products, have also been trained to detect some plant pests and pathogens. Simple immunological tests offer sensitive and specific detection of many pathogens at the point of use. Advanced imaging methods that use AI to sort fruits and vegetables and recognize anomalies at high speeds could be used in cooperation with exporters to improve food quality and reduce pests. Advances in nucleic acid–based detection methods that have become gold standards for confirmatory diagnostics are now making those methods available for faster, point-of-use detection. These new methods should be developed in the context of AQI operational requirements, which apply risk-based sampling protocols to protect agriculture and facilitate commerce and passenger transit.

59 BASIC BIOLOGICAL SCIENCES↗

Status of Eddy Current Developments at INL

Both standard and advanced Light Water Reactor (LWR) fuel systems are composed of fuel pellets enclosed in a metallic cladding. The fuel cladding represents the first containment of the fission products and the first safety barrier. Upon progression of irradiation, the cladding properties deteriorate, mainly due to the pick-up of hydrogen, which causes embrittlement, and the consequence corrosion that reduced the metallic substrate. Those changes in the properties combined with the harsh environment, e.g., fatigue and fretting occurring during operation, might eventually lead to loss of hermeticity. Therefore, it is important to be able to quantify the amount of corrosion taking place and to detect and size structural discontinuity that can promote cladding failure. Eddy current testing is one of the non-destructive methods employed for this purpose. Inspections are carried out using special probes, which are designed and optimized to inspect a tube with well-defined geometrical and physical characteristics, i.e. external diameter, wall thickness, material electric conductivity and magnetic permeability. The inspection goals are mainly twofold: first, the determination of the amount of corrosion by measurement of the external oxide thickness; second, the detection of flaws in the tube wall, ether on the external or the internal surface of the tube. This report summarizes the available capabilities for eddy current testing of LWR fuel claddings, identifies needs and are of developments for testing of ATF claddings.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

Inspecta Technical Report

Sandia National Laboratories (SNL) is in the process of creating Inspecta (International Nuclear Safeguards Personal Examination and Containment Tracking Assistant), an Artificial Intelligence (AI)-powered smart digital assistant (SDA) with robotic capabilities, aimed at enhancing the effectiveness, efficiency, and safety of international nuclear safeguards inspections. This innovative tool is designed to assist inspectors on-site by supporting or automating tasks that are typically mundane, hazardous, or susceptible to errors. In 2021, the development team established the specifications for Inspecta by analyzing International Atomic Energy Agency (IAEA) documents and consulting with former IAEA inspectors and subject matter experts. This process involved aligning in-field inspection tasks with existing commercial or open-source technologies to outline a roadmap for the initial prototype of Inspecta, while also identifying areas needing further research and development. From 2022 – 2024, the focus has shifted to integrating a critical inspection activity, the examination of seals, into an early version of Inspecta. This has involved developing both the software and hardware capabilities necessary for this task. This report outlines the ongoing advancements in Inspecta's functionalities, specifically those supporting the seal examination process.

97 MATHEMATICS AND COMPUTING↗

New Tank Mapping Method Improves Waste Removal Process

Savannah River Mission Completion is the Liquid Waste (LW) contractor at the Savannah River Site (SRS). The LW mission is tasked with treating and disposing of legacy nuclear waste. There are multiple facilities involved in this work, including the Concentration, Storage, and Transfer Facilities (CSTF), the Defense Waste Processing Facility (DWPF), the Salt Waste Processing Facility (SWPF), and the Saltstone Production Facility (SPF). The CSTF includes 43 underground waste tanks used to store and support processing of radioactive liquid waste. Waste removal activities, such as salt dissolution campaigns and sludge agitation, are conducted within the CSTF waste tanks to convert the waste into a form that allows for downstream processing at other LW facilities. While performing these waste removal campaigns, camera inspections are performed to assess the quantity and distribution of the remaining waste within the waste tank (i.e. saltcake or sludge). Understanding the quantity and distribution of the salt/sludge within the waste tanks allows for improved waste removal strategies (e.g. mixing pump operation) and refined safety controls. Typically, several camera inspections are performed during a waste removal transfer to verify the elevation of the visible salt/sludge mounds against the known elevation of the liquid surface. The camera inspection footage must then be interpreted by a trained engineer who will develop a 2-D map that depicts the waste distribution at various elevations within the waste tank. This tank mapping is then used in conjunction with conservative assumptions to evaluate the volume of saltcake or sludge that is present within the waste tank.

Mini, Melany↗

New Tank Mapping Method Improves Waste Removal Process

Waste Tank Mapping Overview • Camera inspections are performed within available tank top risers and used to create waste tank maps – Several camera inspections are performed during waste removal transfers to verify the elevation of the visible salt/sludge mounds against the known elevation of the liquid surface • Tank mappings are used to evaluate the volume and distribution of saltcake or sludge that is present within the waste tank – Allows for refined operating strategies and process safety controls • New tank mapping process creates a standardized approach for accurately defining waste distribution within a waste tank while minimizing the required camera inspection footage – First utilized during the 2023 Tank 22 Sludge Removal Campaign

Mini, Melany [Savannah River Mission Completion (S↗

Fitness For Service Assessment of a Corroded Heat Exchanger

Within the Fermi National Accelerator complex, there exist various water systems that support accelerator operations. One of these systems is extremely vital to the operation of the machine; that is the cooling system. The cooling system consists of nine relatively large heat exchangers that take untreated pond water and use it to cool the process fluid that further cools machine components. Over the 30 years these heat exchangers have been in operation, they have undergone significant material loss on the channels. This material loss, due to various forms of corrosion such as galvanic and microbiologically influenced corrosion (MIC) and possibly others, has deteriorated more than 80% of the nominal wall thickness of some of the exchangers and placed them in a questionable state. ASME FFS-1 (API 579) has been applied to address the condition of the heat exchangers due to their noncompliance with the governing code, BPVC Sec. VIII Div. 1. The assessments encompassed ASME FFS-1 parts 4: General Metal Loss and 9: Crack Like Flaw using level 1, 2, and 3 analysis techniques based on inspection data obtained by API 510 inspections. Level 1 and 2 assessments were deemed unfit for the corroded regions due to their location relative to a major structural discontinuity (channel to tube-sheet joint), so a level 3 analysis was conducted according to ASME Sec. VIII Div. 2 (design by analysis) rules for pressure vessels. Supplemental information included pond water tests to determine an accurate future corrosion allowance due to lacking inspection history. A leak before break (LBB) route was chosen to evaluate the possibility of leaking prior to the onset of failure. The analysis of one heat exchanger shows that the possibility the channel will develop a pinhole leak over 2.5 more years of operation should not be overlooked, but burst was unlikely from operation. The use of fracture mechanics show, that if a through-wall crack were to develop, it would not propagate further than the channel geometry and cause a leak not greater than 35 GPM. Using ASME Section XI Code Case N-705-1, allowing us to operate with a leak until the next outage given certain operating conditions and developing a leak mitigation procedure, this heat exchanger is deemed fit-for-service.

Humenik, Alex [Fermilab]↗

Python Performance Prediction Package for the PGET instrument: User Guide

The Performance Prediction Package (PPP) is a software suite for generating radiation transport results, or leveraging existing transport results, to produce synthetic emission tomography measurements of spent nuclear fuel assemblies. Such synthetic data can be used to mimic specific measurements, and to systematically investigate detection capabilities. Possible uses for the tool include: • Instrument design • Predictive evaluation of observables prior to an inspection visit • Post-measurement assessment of measured data • Evaluation of unusual cases – closed containers with anomalous objects • Sensitivity studies for planning inspections • Sensitivity studies for diversion scenarios • Evaluation of analysis methods A scenario is defined with an assembly type, burnup, and cooling time; as well as assembly rotation angle and position relative to the PGET instrument. Pin-to-pin activity variations or a burnup gradient may be present, but in an inspection scenario these are unlikely to be specified. The measurement will specify a measurement time and a particular detector for detector response, and an optional empirical correction can further adjust the model to better mimic the measurement. The goal is to detect missing pins, or burnup anomalies consistent with a pin substituted with a fresh pin after partial burnup.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗

Measuring 3D Profilometry of SAVY-4000 Nuclear Material Storage Containers: Novacam TubeInspect Capabilities Report

The SAVY-4000 container series is a general-purpose interim storage container for nuclear materials, developed and maintained by Los Alamos National Laboratory (LANL). It is the first vented, general-use nuclear material container to be demonstrated as meeting the requirements outlined in DOE M 441.1-1, the Nuclear Material Packaging Manual. Due to the challenging radiation, thermal, and corrosive storage conditions that the SAVY containers must endure, continuous surveillance techniques are employed to ensure the containers meet all safety standards and specifications. These inspections are typically performed by human operators, who check for issues such as corrosion, O-ring deterioration, corrosion, filter integrity, and potential manufacturing defects. However, human inspections alone are not sufficient, and automated inspection technologies, such as the ATIS system, as well as other automated systems are also utilized. The MicroCam TubeInspect, developed by Novacam Technologies Inc., is designed to address the challenges of understanding how manufacturing variations in the SAVY-4000 container series may affect performance. It is a 3D profilometry measurement system that enables detailed analysis of surface features, including defects, surface roughness, and manufacturing variations. This advanced tool significantly enhances rapid surveillance techniques for both pristine and used containers. In this study, container properties such as surface roughness, thickness, and geometric attributes like circularity are measured for SAVY-4000 containers. Artificially corroded or dented containers are examined to demonstrate the MicroCam's ability to quantify defects. A sensitivity analysis is also conducted, comparing the MicroCam results to those obtained using more precise instruments such as confocal microscopy. This comparison aims to provide valuable insights into container quality, durability, and potential improvements in manufacturing processes.

42 ENGINEERING↗

Inspecta Technical Report

Sandia National Laboratories (SNL) has developed Inspecta (International Nuclear Safeguards Personal Examination and Containment Tracking Assistant), an AI-powered smart digital assistant (SDA) equipped with robotic capabilities. This innovative tool aims to enhance the effectiveness, efficiency, and safety of international nuclear safeguards inspections. Inspecta is designed to assist inspectors on-site by supporting or automating tasks that are often mundane, hazardous, or prone to errors. In 2021, the development team established the specifications for Inspecta by thoroughly analyzing International Atomic Energy Agency (IAEA) documents and consulting with former IAEA inspectors and subject matter experts. This process involved aligning in-field inspection tasks with existing commercial and open-source technologies, thereby creating a roadmap for the initial prototype of Inspecta and identifying areas requiring further research and development. From 2022 to 2025, the focus shifted to integrating a critical inspection activity—the examination of seals—into an early version of Inspecta. This phase has involved the development of both software and hardware capabilities essential for this task. This report outlines the advancements in Inspecta’s functionalities, particularly those that support the seal examination process.

98 NUCLEAR DISARMAMENT, SAFEGUARDS, AND PHYSICAL P↗

Nondestructive Evaluation of Carbon Fiber Reinforced Polymers

The American Society of Mechanical Engineers Boiler and Pressure Vessel Code requires repair and replacement of safety-related piping materials to meet the original Construction Code; however, no construction criteria currently exist for carbon fiber reinforced polymer (CFRP) materials in the nuclear industry. Although nondestructive examination (NDE) techniques for cast and wrought ferritic and austenitic steels are well established, licensees are increasingly deploying novel materials such as CFRP for which assessment of the use of NDE is required, as the inspectability of such materials and the influence of manufacturing processes on inspectability remain insufficiently understood. To address these gaps, Pacific Northwest National Laboratory (PNNL) evaluated the fabrication of several CFRP repair mockups and the effectiveness of NDE methods to support regulatory review of CFRP repairs in nuclear power plant applications. Representative flat-plate mockups containing realistic fabrication defects were manufactured and inspected using manual and automated tap testing, dynamic response spectroscopy (DRS), and ultrasonic testing (UT). The study identified significant fabrication variability, particularly in controlling defect size and epoxy thickness, which strongly influenced defect detectability by NDE methods. Tap testing was effective for shallow defects in thin epoxy configurations but unreliable for thicker repairs and deeper flaws. DRS demonstrated higher sensitivity to dry spots but produced unconfirmed indications for thicker plates, requiring further validation. Conventional UT, particularly at 1.0 MHz, showed the strongest overall capability for detecting a range of defects, although performance degraded with increasing repair thickness and complexity. The results highlight the need to better define critical defect sizes, develop reliable mockup fabrication methods, and validate NDE methods needed to support CFRP repairs.

36 MATERIALS SCIENCE↗

Draft ASME Code Case to qualify L-PBF 316H material for Section III, Division 5 applications

This report documents the AMMT program’s development and submission of a draft ASME Code Case to qualify Laser Powder Bed Fusion (L PBF) Type 316H stainless steel for Section III, Divi-sion 5 Class A and SM high temperature nuclear applications. It summarizes the technical basis, the comprehensive high temperature mechanical test database assembled between 2023–2026, and the proposed code language and qualification framework submitted to ASME. The work was co-ordinated across multiple national laboratories and leverages prior ASME efforts to integrate additive manufacturing into the Boiler & Pressure Vessel Code. The body of the report describes the experimental database and analysis supporting the Code Case: tensile, creep, fatigue, creep fatigue, and thermal aging tests collected from multiple additive manufacturing sites, machine types, and powder lots, with material processed by a solution anneal heat treatment. The dataset — including both full size and subsized specimens and tests oriented parallel and perpendicular to build direction — shows limited tensile anisotropy, tensile properties comparable to wrought 316H, creep strength within the scatter of wrought material, but markedly reduced creep ductility above about 650 °C associated with rapid σ phase formation in L PBF microstructures. The draft Code Case itself prescribes a staged qualification model (manufacturing process qualification, component qualification, and per build witness testing), treats L PBF components as equivalent to Type 316 weld metal for design and inspection, and requires mechanical, chemical, and metallographic controls tied to ASTM/ISO 52946. Key acceptance criteria include tensile tests within a 90% prediction interval of the AMMT dataset, a creep fatigue screening test adapted from ASME Section III, Division 5, Subsection HB, HBB 2800 but with the cycle acceptance reduced to 100 for L PBF material, and double volumetric inspection of production components. The report concludes that the present data support treating L PBF 316H as analogous to conventional fusion weld metal for Division 5 design and inspection, while highlighting important caveats: the σ phase driven loss of creep ductility above ~650 °C, preliminary indications of enhanced creep fatigue sensitivity in some lots, and remaining gaps in long term aging and additional cyclic testing. Recommended next actions include completing outstanding cyclic and long duration creep/aging tests on the solution annealed condition, supporting inclusion of the 316H chemistry and heat treatment in ASTM/ISO 52946, and continuing engagement with ASME and NRC during balloting and review to enable industry adoption.

Messner, Mark C. (ORCID:0000000200404385)↗