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DOE OSTI2021

Development of MCNP Training Modules for Safeguards Practitioners [Abstract]

The Monte-Carlo N-Particle (MCNP) software developed at LANL is the most widely used neutron transport code in the world. It is an essential tool for a variety of applications including detector development and design, nuclear fuel burnup simulation, criticality safety, and nondestructive assay system optimization. For this reason, it is indispensable within the safeguards and materials control & accountability (MC&A) communities. Multiple MCNP training courses have been created and taught over the last several decades by the MCNP development team at LANL, however there are no existing courses that cover specialized topics considered fundamental to NDA and safeguards models. To fill this gap, the MCNP team and Safeguards Science and Technology group at LANL have co-created a set of training modules customized to meet the specialized needs of the safeguards and MC&A communities. The basic modules cover concepts such as NDA system optimization, He-specific and other capture tallies, and tools for improved theoretical understanding. An advanced module was also created to cover topics including variance reduction for active interrogation simulations, use of the LANL MCNPTools post-processor, PTRAC (particle tracking) and list-mode data simulations, and fuel burnup simulations. The training modules teach to the latest and most state-of-the-art MCNP features and tools released by the development team at LANL and are intended to be taught jointly by the developers and safeguards experts. Ultimately, we hope that creation of these modules will serve to capture and convey the safeguards modeling and MCNP expertise at LANL, and that we will be able to share the modules more broadly with the MC&A and safeguards communities.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗

DOE OSTI2017

Microstructural characterization of an irradiated RERTR-6 U-7Mo/AA4043 alloy dispersion fuel plate specimen blister-tested to a final temperature of 500°C

The Material Management and Minimization (M3) Reactor Conversion Program, in the past called the Reduced Enrichment for Research and Test Reactor (RERTR) Program, is developing low-enriched uranium (LEU) fuels for application in research reactors. U–Mo alloy dispersion fuel is one type being developed. Blister testing has been performed on different fuel plate samples to determine the margin to failure for fuel plates irradiated to different fission densities. Microstructural characterization was performed using scanning electron microscopy and transmission electron microscopy on a sample taken from a U-7Mo/AA4043 matrix dispersion fuel plate irradiated in the RERTR-6 experiment that was blister-tested up to a final temperature of 500°C. The results indicated that two types of grain/cell boundaries were observed in the U- 7Mo fuel particles, one with a relatively low Mo content and fission gas bubbles and a second type enriched in Si, due to interdiffusion from the Si-containing matrix, with little evidence of fission gas bubbles. With respect to the behavior of the major fission gas Xe, a significant amount of the Xe was still observed within the U-7Mo fuel particle, along with microns into the AA4043 matrix. For the fuel/matrix interaction layers that form during fabrication and then grow during irradiation, they change from the as-irradiated amorphous structure to one that is crystalline after blister testing. In the AA4043 matrix, the original Si-rich precipitates, which are typically observed in as-irradiated U-Mo dispersion fuel, get consumed due to interdiffusion with the U-7Mo fuel particles during the blister test. Lastly, the fission gas bubbles that were originally around 2 nm in diameter and resided on a fission gas superlattice in the intragranular regions of as-irradiated U-7Mo fuel grew in size (up to ~20 nm diameter) during blister testing.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2022

Fuel Performance Modeling Plan to Support the Advance Gas Reactor Program

This report documents the current status of the fuel performance modeling initiative to support the Advanced Gas Reactor (AGR) program in the development of tristructural isotropic (TRISO) coated fuel particles. A brief summary of the modeling codes that have been developed to support TRISO modeling is included along with a summary of the behavior of fuel particles during irradiation and the modeling used to capture these effects. In addition, this report identifies further modeling and material property needs that have been identified for further development based on experience from previously performed AGR experiments. In general, the remaining activities to support fuel performance modeling for the AGR program include continued AGR experiment support for AGR-3/4 and AGR-5/6/7 as well as modeling improvements identified throughout the course of the program. These modeling improvements can be summarized as the following: Fission product transport Thermomechanical particle behavior Additional modeling needs may be identified during the processing the data collected during the AGR post-irradiation examination (PIE) campaign and may lead to further modeling improvements that are not included in this report.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2019

Characterizing surrogates to develop an additive manufacturing process for U 3 Si 2 nuclear fuel

U 3 Si 2 is considered as an accident-tolerant nuclear fuel candidate due to its promising high uranium density along with its improved thermal properties. The current U 3 Si 2 powder metallurgical fabrication process encompasses numerous process steps with extensive fabrication times. Thus, an additive manufacturing process to fabricate U 3 Si 2 is currently under development to ultimately produce U 3 Si 2 fuel at a lower cost, in a timely and commercially-reliable manner. The current research work seeks to characterize U 3 Si 2 surrogate materials fabricated by a laser synthesis. The characterization results provided novel microstructural data that aided in the early development stages of an additive manufacturing process. For this study, cerium, zirconium, and hafnium, were selected as surrogates based on their thermodynamic properties and crystal structure. As a result, the laser-synthesized samples were characterized by means of scanning electron microscopy (SEM), energy-dispersive X-ray spectroscopy (EDS) along with X-ray diffraction (XRD), where the different phases of formation, morphology, and microstructural features have been analyzed. Laser synthesis showed suitability for alloying Zr-Si and Hf-Si to ultimately form silicide compounds (Zr 3 Si 2 and Hf 3 Si 2 ).

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2020

Design and Development of a High-Efficiency Single Cylinder Natural Gas-Fueled Jet Ignition Engine

The current energy climate has created a push toward reducing consumption of fossil fuels and lowering emissions output in power generation applications. Combined with the desire for a more distributed energy grid, there is currently a need for small displacement, high efficiency engines for use in stationary power generation. An enabling technology for achieving high efficiencies with spark ignited engines for such applications is the use of jet ignition which enables ultra-lean (λ > ~1.6) combustion via air dilution.This paper provides a comprehensive review of the development of a 390cc, high efficiency single cylinder natural gas-fueled jet ignition engine operating ultra-lean. The engine was developed as part of the Department of Energy’s Advanced Research Projects Agency–Energy (DOE ARPA-E) GENSETS program. Design choices for minimizing friction are highlighted as well as test results showing further friction reduction through downspeeding. Extensive hardware optimization of the combustion system has been performed and results are presented for air-flow path optimization and the jet igniter. The efficiency benefits related to enleanment and downspeeding are analyzed using an efficiency loss breakdown based on the First Law of Thermodynamics. Through optimization efforts a peak brake thermal efficiency in excess of 34% was achieved, representing an increase of greater than 20% over the current state-of-the-industry for comparably sized CNG engines.

Peters, Nathan↗

DOE OSTI2022

Grain growth kinetics of the gamma phase metallic uranium

We report metallic uranium is a leading fuel form for sodium cooled fast reactors as an enabling technology of future nuclear energy systems. Mechanistic understanding of fuel behaviors and kinetics under thermodynamic equilibrium and highly non-equilibrium conditions are essential for evaluating fuel performance. It is important to understand and predict the grain and pore evolutions of metallic fuels under thermal and irradiation conditions. However, very limited data are available on the grain growth kinetics and mechanisms of pure gamma phase uranium. In this paper, the pure gamma uranium pellets with different grain structures were fabricated by combining high-energy ball milling and spark plasma sintering. Isothermal annealing tests were performed to investigate the grain growth behavior of the pure gamma phase uranium with different initial grain sizes. A parabolic relationship in grain growth with time was identified for the submicron-sized (374 nm) sample. In contrast, for the nano-sized (137 nm) sample, the grain growth shows a linear relationship with time. The activation energies of grain growth were determined as 199.5 KJ/mol and 80.6 KJ/mol for nano-sized and submicron-sized grain structures, respectively. For the nano-sized sample, the rate-control step of grain growth is dominated by the triple-junction migration, in which the grain boundary triple junction drags the grain growth, leading to a higher activation energy than the bulk diffusion. The dominating mechanism for the submicron-sized sample is grain boundary diffusion. The mechanistic understanding and critical data obtained on the kinetics of pure uranium phases will be useful to evaluate fuel behavior under thermodynamic equilibrium conditions and develop a high fidelity model to predict fuel performance.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2018

Technical Assistance in Fabrication and Testing of MEAs: Cooperative Research and Development Final Report

Altergy's fuel cell cost is highly dependent on expensive purchased membrane electrode assemblies (MEAs), which amount to 42¢/watt in a 5kW system. In order to better compete with other power solutions, the company has identified an MEA breakthrough cost of 20¢/watt to unlock new, major markets for its fuel cell products. Since Altergy presently does not have an accurate cost model for the real costs of these MEAs, it is difficult to know whether the company goal is achievable. Altergy seeks to leverage NREL expertise to reduce cost and improve performance for Altergy's fuel cell products. The objective of this Small Business Voucher (SBV) project therefore will be for NREL and Altergy to work together in three major task areas: 1) demonstrating the fabrication of MEAs at NREL using NREL non-proprietary methods, to the intent of potentially fabricating MEAs at Altergy to reduce product costs; and, 2) creating a cost model to assist Altergy in manufacturing decisions.

30 DIRECT ENERGY CONVERSION↗

DOE OSTI2021

Quantify Sodium Fluoride / Beryllium Fluoride Salt Properties for a Liquid Fueled Fluoride Molten Salt Reactor (CRADA C2018-18168 Final Report)

ThorCon is developing a thermal thorium-uranium fueled molten salt reactor that uses a fuel salt consisting of NaF - BeF 2 - ThF 4 - UF 4 - UF 3 , which uses 19.75% enriched uranium. It is not a breeder reactor but requires regular additions of fissile material. A thorough understanding of the thermophysical properties of the fuel salt at the beginning (BOL) and end (EOL) of its life is critical to establishing its thermal hydraulic behavior and enables ThorCon to design a system with the required natural convection. Experimentally determining the heat capacity and thermal conductivity of the fuel salt will provide data necessary for detailed system design and safety analysis.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2024

Additively Manufactured, Lightweight, Low-Cost Composite Vessels for Compressed Natural Gas Fuel Storage

This project will develop a process to combine AM via direct ink writing (DIW) technology for CFC printing and to use design optimization tools pioneered at LLNL, with advances in resin/composite formulation enabled by chemical and nano-material modification to produce lightweight low-cost CNG tanks. Our approach will yield sub-scale prototype composite pressure tanks equivalent to Type-5 CNG vessel designs that demonstrate a potential cost-benefit advantage. Central to our vision is using agile AM and design based on computationally informed DIW of both short and continuous CF, further coupled with high-performance thermoset polymer matrixes modified by emergent nanomaterials. Our single-stage, multi-material AM technology, combined with a decreased volume fraction of CF and an increased proportion of economically advantaged short fiber, all together drive the reduction in manufacturing time and overall cost. Importantly, reductions in continuous fiber and overall fiber volume fraction will be achieved without detriment to the mechanical strength of the composite vessel. This will be achieved by employing a single process using multi materials grading involving a thermoset resin “ink” modified with aligned nanoplatelets to leverage the efficient tortuous-path gas barrier effect, printed as an inner flexible gas barrier as the initial stage in our manufacturing process before compositionally grading the AM feedstock in real-time to transition to a rigid, structural CF-filled resin. The proposed hybrid construction is projected to achieve pressure ratings at a service range of 2,900–3,600 psi with a 3× burst safety factor comparable to conventional filament-wound composite tanks with an estimated 30–50% reduction in total manufacturing cost.

03 NATURAL GAS↗

NASA NTRS1971

H2 fuel system investigation

Design and development of air breathing engine system for space shuttle vehicle

Collier, W.↗

NASA NTRS2003

Design Considerations of ISTAR Hydrocarbon Fueled Combustor Operating in Air Augmented Rocket, Ramjet and Scramjet Modes

The development and ground test of a rocket-based combined cycle (RBCC) propulsion system is being conducted as part of the NASA Marshall Space Flight Center (MSFC) Integrated System Test of an Airbreathing Rocket (ISTAR) program. The eventual flight vehicle (X-43B) is designed to support an air-launched self-powered Mach 0.7 to 7.0 demonstration of an RBCC engine through all of its airbreathing propulsion modes - air augmented rocket (AAR), ramjet (RJ), and scramjet (SJ). Through the use of analytical tools, numerical simulations, and experimental tests the ISTAR program is developing and validating a hydrocarbon-fueled RBCC combustor design methodology. This methodology will then be used to design an integrated RBCC propulsion system that produces robust ignition and combustion stability characteristics while maximizing combustion efficiency and minimizing drag losses. First order analytical and numerical methods used to design hydrocarbon-fueled combustors are discussed with emphasis on the methods and determination of requirements necessary to establish engine operability and performance characteristics.

Andreadis, Dean↗

NASA NTRS2002

Design Considerations of Istar Hydrocarbon Fueled Combustor Operating in Air Augmented Rocket, Ramjet and Scramjet Modes

The development and ground test of a rocket-based combined cycle (RBCC) propulsion system is being conducted as part of the NASA Marshall Space Flight Center (MSFC) Integrated System Test of an Airbreathing Rocket (ISTAR) program. The eventual flight vehicle (X-43B) is designed to support an air-launched self-powered Mach 0.7 to 7.0 demonstration of an RBCC engine through all of its airbreathing propulsion modes - air augmented rocket (AAR), ramjet (RJ), and scramjet (SJ). Through the use of analytical tools, numerical simulations, and experimental tests the ISTAR program is developing and validating a hydrocarbon-fueled RBCC combustor design methodology. This methodology will then be used to design an integrated RBCC propulsion system thai: produces robust ignition and combustion stability characteristics while maximizing combustion efficiency and minimizing drag losses. First order analytical and numerical methods used to design hydrocarbon-fueled combustors are discussed with emphasis on the methods and determination of requirements necessary to establish engine operability and performance characteristics.

Andreadis, Dean↗

NASA NTRS2013

Peak-Seeking Optimization of Trim for Reduced Fuel Consumption: Flight-Test Results

A peak-seeking control algorithm for real-time trim optimization for reduced fuel consumption has been developed by researchers at the National Aeronautics and Space Administration (NASA) Dryden Flight Research Center to address the goals of the NASA Environmentally Responsible Aviation project to reduce fuel burn and emissions. The peak-seeking control algorithm is based on a steepest-descent algorithm using a time-varying Kalman filter to estimate the gradient of a performance function of fuel flow versus control surface positions. In real-time operation, deflections of symmetric ailerons, trailing-edge flaps, and leading-edge flaps of an F/A-18 airplane (McDonnell Douglas, now The Boeing Company, Chicago, Illinois) are used for optimization of fuel flow. Results from six research flights are presented herein. The optimization algorithm found a trim configuration that required approximately 3 percent less fuel flow than the baseline trim at the same flight condition. The algorithm consistently rediscovered the solution from several initial conditions. These results show that the algorithm has good performance in a relevant environment.

flight optimization↗

NASA NTRS2013

Peak-Seeking Optimization of Trim for Reduced Fuel Consumption: Architecture and Performance Predictions

A peak-seeking control approach for real-time trim configuration optimization for reduced fuel consumption has been developed by researchers at the National Aeronautics and Space Administration (NASA) Dryden Flight Research Center to address the goals of the NASA Environmentally Responsible Aviation project to reduce fuel burn and emissions. The peak-seeking control approach is based on a steepest-descent algorithm using a time-varying Kalman filter to estimate the gradient of a performance function of fuel flow versus control surface positions. In real-time operation, deflections of symmetric ailerons, trailing-edge flaps, and leading-edge flaps of an F/A-18 airplane (McDonnell Douglas, now The Boeing Company, Chicago, Illinois) are controlled for optimization of fuel flow. This paper presents the design and integration of this peak-seeking controller on a modified NASA F/A-18 airplane with research flight control computers. A research flight was performed to collect data to build a realistic model of the performance function and characterize measurement noise. This model was then implemented into a nonlinear six-degree-of-freedom F/A-18 simulation along with the peak-seeking control algorithm. With the goal of eventual flight tests, the algorithm was first evaluated in the improved simulation environment. Results from the simulation predict good convergence on minimum fuel flow with a 2.5-percent reduction in fuel flow relative to the baseline trim of the aircraft.

performance optimization↗

NASA NTRS2013

Peak-Seeking Control For Reduced Fuel Consumption: Flight-Test Results For The Full-Scale Advanced Systems Testbed FA-18 Airplane

A peak-seeking control algorithm for real-time trim optimization for reduced fuel consumption has been developed by researchers at the National Aeronautics and Space Administration (NASA) Dryden Flight Research Center to address the goals of the NASA Environmentally Responsible Aviation project to reduce fuel burn and emissions. The peak-seeking control algorithm is based on a steepest-descent algorithm using a time-varying Kalman filter to estimate the gradient of a performance function of fuel flow versus control surface positions. In real-time operation, deflections of symmetric ailerons, trailing-edge flaps, and leading-edge flaps of an F/A-18 airplane are used for optimization of fuel flow. Results from six research flights are presented herein. The optimization algorithm found a trim configuration that required approximately 3 percent less fuel flow than the baseline trim at the same flight condition. This presentation also focuses on the design of the flight experiment and the practical challenges of conducting the experiment.

flight optimization↗

NASA NTRS2013

Peak-Seeking Optimization of Trim for Reduced Fuel Consumption: Architecture and Performance Predictions

A peak-seeking control approach for real-time trim configuration optimization for reduced fuel consumption has been developed by researchers at the National Aeronautics and Space Administration (NASA) Dryden Flight Research Center to address the goals of the NASA Environmentally Responsible Aviation project to reduce fuel burn and emissions. The peak-seeking control approach is based on a steepest-descent algorithm using a time-varying Kalman filter to estimate the gradient of a performance function of fuel flow versus control surface positions. In real-time operation, deflections of symmetric ailerons, trailing-edge flaps, and leading-edge flaps of an FA-18 airplane (McDonnell Douglas, now The Boeing Company, Chicago, Illinois) are controlled for optimization of fuel flow. This presentation presents the design and integration of this peak-seeking controller on a modified NASA FA-18 airplane with research flight control computers. A research flight was performed to collect data to build a realistic model of the performance function and characterize measurement noise. This model was then implemented into a nonlinear six-degree-of-freedom FA-18 simulation along with the peak-seeking control algorithm. With the goal of eventual flight tests, the algorithm was first evaluated in the improved simulation environment. Results from the simulation predict good convergence on minimum fuel flow with a 2.5-percent reduction in fuel flow relative to the baseline trim of the aircraft.

peak-seeking↗

NASA NTRS2013

Peak-Seeking Optimization of Trim for Reduced Fuel Consumption: Flight-test Results

flight optimization↗

DOE OSTI2020

FY20 Progress Report on FIPD Development and User Support

The DOE Advanced Reactor Technologies program has supported efforts to recover and preserve metallic fuel data generated throughout the past fast reactor R&D programs. Those efforts have focused on establishing databases for information from the experiments conducted during the Integral Fast Reactor program including data generated at EBR-II, FFTF, and TREAT reactors, as well as out of pile transient testing data. These databases are essential for future-licensing activities of metallic fuel based advanced fast reactors. This report describes the EBR-II Fuels Irradiation & Physics Database (FIPD) development, content updates, and user support during the current fiscal year (FY20). Future plans are also provided.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗