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DOE OSTI2025

Helium recovery system at IB3a

The increasing need for optimal and sustainable use of cryogenic resources to support Fermilab’s scientific mission has highlighted the necessity of improving the Laboratory’s helium management practices. An assessment of cryogenic test facilities identified the Technical Division’s Industrial Building 3a (IB3A) as a key site requiring upgrades to integrate a helium recovery system. The IB3A facility is essential for characterizing and testing superconductors, cables, and coils for various R&D projects, including the US High-Luminosity LHC Accelerator Upgrade Project (AUP), Mu2e, and other external collaborations. Currently, the facility relies on 500 L helium Dewars and vents the vaporized helium directly into the atmosphere, leading to significant helium loss. Given the non-renewable nature of helium, recovering and reusing this resource is critical for the sustainability of Fermilab’s operations. To address this challenge, a project has been initiated to connect IB3A to an existing helium purification station and refrigeration system located in another building via a dedicated pipeline pass over the roof of several buildings. This solution will enable the efficient capture of vented helium, its transfer to the purification station, and subsequent liquefaction for reuse in future operations. The project includes a detailed design phase, specifying the pipeline route, flow control mechanisms, and integration with the existing cryogenic infrastructure, followed by phased implementation and commissioning. By implementing this pipeline connection and upgrading IB3A, Fermilab aims to significantly reduce helium waste, lower operational costs, and align with its commitment to sustainability. This initiative provides a model for resource-efficient cryogenic operations and reinforces the Laboratory’s capacity to support its science mission for the long term.

Porwisiak, D. [Fermilab]↗

DOE OSTI2025

Effects of break geometry and orientation on helium-air mixing in simulated reactor cavities of high temperature gas reactors

Here, this study experimentally examined the spatial and temporal variations in air and helium concentrations and temperature fields within simulated reactor cavities of a High Temperature Gas Reactor (HTGR) following helium discharge into an initially air-filled reactor cavity system. Detailed temperature maps were generated using a combination of fiber optics temperature sensor and multiple thermocouple probes within the simulated reactor cavities. The research scenario involved a hypothetical small pipe break in the Reactor Pressure Vessel, resulting in the release of high-temperature helium into the surrounding cavity. A scaled multi-compartment experimental facility, modeled after the General Atomics Modular High Temperature Gas Reactor (GA-MHTGR) design, was constructed for helium and air mixing experiments. Oxygen sensors and thermocouple probes were installed in all five cavities to measure the concentrations of oxygen (or helium) and the temperature distributions of the gas mixture. The experimental findings highlighted the significant impact of the injected helium jet velocity on the gas mixing process and demonstrated how the direction of the helium jet influences the air-helium temperature profiles within the cavities.

Air-ingress↗

DOE OSTI2025

Understanding the effect of minor alloying elements on helium bubble formation in ferritic-martensitic steels

Ferritic-martensitic steels are promising structural materials for advanced nuclear reactors. To minimize long-term radioactivity, reduced-activation ferritic-martensitic steels have been developed by substituting high-activation elements like Ni and Mo with low-activation elements such as W. However, the impact of these alloying modifications on helium bubble formation, which plays a key role in material swelling, remains unclear. Here, in this study, we compared helium bubble formation in ferritic-martensitic steel T91 and reduced-activation ferritic-martensitic steel F82H. Both materials were irradiated with sequential 100 keV, 150 keV, and 200 keV helium ions to a dose of 0.5 dpa and a helium concentration of 9,000 appm at 500°C. The helium bubbles in F82H exhibited a larger average size and a lower density than those in T91, suggesting differences in minor alloying elements may influence the bubble growth. Here, to investigate the effects of these alloying elements, we characterized radiation-induced segregation near bubbles and grain boundaries. Prominent Ni-Mn-Si enriched clusters were found near bubbles in T91, while only Mn-Si enriched clusters were found near bubbles in F82H. In addition, the obvious Cr enrichment near grain boundaries was absent around bubbles in both steels. The different segregation trends among elements revealed the variations in element diffusion mechanisms and the different sink biases between bubbles and grain boundaries. Cr enrichment near grain boundaries is mostly driven by interstitial-mediated diffusion. However, since bubble growth relies on net vacancy flux, vacancy-mediated diffusion plays a dominant role in controlling element segregation near bubbles. Therefore, Cr enrichment was not found near bubbles. Because of preferential vacancy-drag diffusion for Ni, Si and Mn, these elements were enriched near bubbles. Due to the strong binding energies of vacancies with these solute atoms, the vacancy diffusivity can be reduced near these solutes. Therefore, the more prominent Ni-Si-Mn clustered near helium bubbles in T91 lead to stronger suppression of helium bubble growth compared to F82H.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Helium bubble formation in aged plutonium metal at ambient conditions

A model of helium bubble formation is developed that assumes the initial nascent bubbles are generated when two diffusing helium atoms come within a distance of about the interatomic spacing of the plutonium atoms. These nascent bubbles are assumed to be locked in place and grow as additional helium atoms diffuse across their surfaces. Calculations of the helium-bubble number density and sizes as a function of age are compared to experiment. This leads to an inferred helium diffusion coefficient of-the-order of 10 -20 m 2 /s, supports the idea that most of the helium from alpha-decay end up in bubbles, and that previous transmission electron microscopy size estimates are biased low. The energy that helium can transfer to 40-year-old plutonium, upon expansion, is determined to be <0.1 Joules per gram of metal. The model predicts differences between the bubble properties in naturally and accelerated aged plutonium.

36 MATERIALS SCIENCE↗

DOE OSTI2025

The effect of composition on helium bubble nucleation in complex concentrated alloys

Molecular dynamics simulations of helium implantation have been performed in the MoNbTaTi complex concentrated alloy (CCA) to determine the impact of composition on helium clustering and bubble nucleation. It was found that compositions with lower interstitial atomic volume resulted in smaller cluster sizes, higher helium-to-vacancy ratios, and larger migration barriers. As the atomic volume decreases, it is harder to accommodate additional helium in the lattice and for helium to diffuse between interstitial sites, resulting in smaller cluster sizes. In particular, increasing molybdenum directly correlated with a decreased interstitial atomic volume and increased migration barrier. Niobium exhibited the opposite trend, where more niobium in the material resulted in larger interstitial atomic volumes and cluster sizes but lower migration barriers. The atomic volume was determined to be an indicator of the susceptibility of the material to helium bubble growth and could potentially be used as a metric to screen compositions for resistance to helium damage. In this way, properties such as available interstitial volumes could be used to screen materials more rapidly given the vast compositional space of CCAs.

McCarthy, Megan Jeanne [Sandia National Laboratori↗

DOE OSTI2026

Helium co-implantation effects on dislocation loop evolution during in situ ion irradiations of a novel additive-manufactured Fe-9Cr steel alloy

This study examines the impact of helium injection rate on dislocation loop evolution during ion irradiation of a novel, additively manufactured (AM) 9Cr reduced-activation ferritic/martensitic (RAFM) steel. Through in situ transmission electron microscopy ion irradiations and post-irradiation characterization, the effects of simultaneous 1 MeV Kr²⁺ and 12 keV He⁺ ion irradiation at 400°C to 5 dpa with varying helium levels were examined. The findings reveal that helium co-injection significantly increases dislocation loop density, primarily through the formation of small defect features exhibiting contrast and projected morphologies consistent with a⟨100⟩ loops (∼1 nm), while suppressing larger a/2⟨111⟩ loops. The findings underscore the complex interplay among continuously increasing helium content, temperature, and alloy composition in the evolution of dislocation loops under irradiation in RAFM steels. The study highlights the need for further investigation into helium-mediated mechanisms, such as proposed interactions between self-interstitial atoms and helium atoms, to enhance the performance of RAFM steels in advanced nuclear reactors.

ANA2↗

DOE OSTI2025

Helium Incorporation into Scandium Fluoride, a Model Negative Thermal Expansion Material

Scandium trifluoride is a model negative thermal expansion (NTE) material. Its simple structure can be described as an A-site vacant perovskite, and it shows isotropic NTE over a very wide temperature range (up to ~1100 K), due to transverse vibrational motion of the fluoride. Like many framework NTE materials, it undergoes a phase transition at low pressures, adopting a rhombohedral (R3̅c) structure at >0.7 GPa and 300 K in commonly used nonpenetrating pressure media, such as silicone oil. High pressure X-ray diffraction data and gas uptake/release measurements indicate that, on compression in helium above ~200 K, helium is inserted into ScF 3 to form the defect perovskite He x ScF 3 . The incorporation of helium stiffens the structure and changes its phase behavior. At room temperature, complete filling of the structure with helium does not occur until >1.5 GPa. On compression, a cubic perovskite structure is maintained until ~5 GPa. As the pressure was increased to ~9.5 GPa, a further transition occurred at ~7 GPa. The first transition at ~5 GPa is likely to a tetragonal (P4/mbm) perovskite, but the detailed structure of the perovskite phase formed on compression above ~7 GPa is unclear. Cooling down from 300 to 100 K in helium at ~0.4 GPa leads to an approximate composition of He 0.1 ScF 3 . High pressure neutron diffraction measurements, in the temperature range 15–150 K show that the incorporation of helium increases the pressure at which the cubic (Pm3̅m) to rhombohedral (R3̅c) putative quantum structural phase transition occurs from close to 0 GPa to ~0.2 GPa at 0 K.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2024

The impact of helium on plasma-driven hydrogen permeation and implications for direct internal recycling in the fusion fuel cycle

Abstract Metal foil pumps (MFPs) are the leading technology for direct internal recycling (DIR) of hydrogen isotopes from the plasma exhaust in future fusion plants. MFPs rely on the concept of superpermeation, where superthermal H atoms directly absorb into the metal foil, rapidly diffuse, and desorb downstream. To date, studies of superpermeation have predominantly employed either pure hydrogen or in some cases trace levels of impurities. The plasma exhaust is expected to contain just ∼1% helium, but in DIR the source gas would be enriched in helium as hydrogen isotopes are extracted. In this work, we explore the impact of helium on hydrogen superpermeation at low temperature (75 °C–200 °C) using Pd-based foils. To first order, the flux scaled linearly with the hydrogen mole fraction. Stable permeation was observed until the helium fraction reached ∼80%, where the flux began to decline slowly with time. In addition, short term (1–5 min) exposure to pure helium plasma significantly attenuated subsequent hydrogen plasma permeation, and the degree was more dramatic at elevated temperature. This attenuation was correlated with He retention in the foils, which was detected by time-of-flight secondary ion mass spectrometry at low levels (<0.1 at. %) and limited to the near surface (<10 nm). Similar trends were observed among all alloys (Pd, PdAg, PdCu), and the foils were restored to full performance with an Ar + sputter clean. The potential for helium plasma exposure to impact MFP performance under these conditions has not been previously reported, and these findings have significant implications to the design and implementation of practical DIR systems.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2026

Background-Oriented Schlieren Velocimetry of Helium Coolant Flow in Additively Manufactured Channels

High-pressure helium gas cooling is an attractive solution for thermal management of the fusion blanket first wall, as this coolant is chemically and neutronically inert and separable from hydrogenic species. However, due to the low thermal mass of helium, geometric optimization of these channels is required to provide sufficient cooling at manageable flow rates and pumping burdens. Increasingly, analysis and optimization of these coolant channels rely on computational fluid dynamics (CFD) simulations, and these require relevant experimental data for turbulence model validation. Toward this end, a high-pressure helium gas flow visualization system has been employed to image the flow of helium in flow channels with one-sided heating, mimicking the blanket first wall environment. Flow of helium at 4 MPa pressure and flow rates up to 68 g/s (Reynolds number 57 000) is supplied to rectangular channel test sections, with uniform heating applied to the bottom wall of the channel at heat fluxes varied between roughly 50 and 130 kW/m2. A high-speed camera is used to image index of refraction (IOR) gradients in the fluid via background-oriented schlieren (BOS), and temperature and pressure instrumentation are used to characterize thermal-hydraulic performance of each channel. Cross correlation of time-resolved BOS images is then used to calculate time-averaged 2-D helium velocity fields. Flow in additively manufactured (AM) channels is examined in this manner, including both featureless channels and those containing baffling as a heat transfer enhancement. The flow distribution seen in the featureless case differs significantly from that seen in prior simulations, whereas the flow in the baffled case shows the predicted behavior of flow forced along the heated wall. This augmented flow distribution is seen to increase the heat transfer coefficient in the baffled test section. Here, strategies are discussed for ongoing and future validation of these simulations, with the aim of model deployment for blanket cooling design and optimization.

Additive manufacturing↗

DOE OSTI2025

Design Overview of a High-Pressure Helium Flow Visualization Apparatus for Blanket Cooling Studies

Cooling of the fusion blanket first wall remains a significant challenge given the adverse conditions of heat and particle flux encountered near the plasma. Helium emerges as an attractive cooling candidate because of its chemical and neutronic inertness and separability from hydrogenic species (e.g. tritium). Because of the low thermal mass of helium, optimization of these coolant channels is warranted to provide high heat transfer performance at low pumping costs. Increasingly, computational fluid dynamics (CFD) simulations are employed to model and optimize these flow channels, and accompanying experimental data are needed to validate the predictions of these models. To provide the aforementioned experimental data, a high-pressure helium flow visualization upgrade has been designed for the Helium Flow Loop Experiment facility. This apparatus was built to American Society of Mechanical Engineers boiler and pressure vessel standards to withstand operating pressure of 4 MPa and mated to high-pressure glass windows. Seedless flow visualization is performed via high-speed background oriented schlieren (BOS), with image correlation used for time-resolved two-dimensional velocimetry at frequencies in excess of 60 kHz. Rectangular flow channel test articles are additively manufactured via laser powder bed fusion and installed into this visualization apparatus, with one-sided heating supplied by resistive heaters. In conclusion, the chosen test geometries were informed by prior CFD simulations, and the helium flow structures observed via BOS (detachment, recirculation, etc.) will be used for the validation of these accompanying models, in support of the design and optimization of blanket cooling channel configurations.

Helium flow↗

DOE OSTI2025

Helium Bubble Physics Experiments

New results from MST-16 indicate that as plutonium ages at close to ambient temperature and helium ingrows, the number density of bubbles increases only slowly, if at all, and their size distribution shifts towards larger diameters. Helium-containing aged plutonium foams when annealed at high temperatures. We attribute these phenomena to a diffusivity large enough that, after a few years of aging, new decay helium diffuses to extant bubbles rather than nucleating new bubbles, and that during annealing larger bubbles grow at the expense of smaller ones (Ostwald ripening). Bulk swelling results from the fact that the Laplace pressure and therefore the helium density are less in larger bubbles. We develop a simple theory and propose to study these phenomena in aluminum alloyed with 10 B in which successive exposure to reactor thermal neutrons produces a stepwise increase in helium content.

36 MATERIALS SCIENCE↗

DOE OSTI2025

New helium recapture and reliquefier system for Dynamic Nuclear Polarization at UNH.

A new helium recapture and reliquefaction system, consisting of a gas bag, recapture manifold, cooling chiller, cryogenic purifier and, a gas storage cylinder banks, has been installed in the dynamic nuclear polarized target lab at the University of New Hampshire. This new system has the capability to improve the efficiency of our capacity to do target polarization runs by recycling our cryogenic helium which would otherwise be lost during polarization operations. Our helium liquefier is rated upto 40 L/Day under normal full-capacity operations, and is rated for a capacity of 500 liquid liters of helium. I explain the initial installation process followed by a discussion of the challenges with installation, including issues of impurities which appeared during the initial operation of the system. Then I discuss how we overcame these difficulties. Finally, I discuss the function of the system during normal operation and the present situation of the helium recapture and reliquefaction processing in the UNH Lab.

Lama, Chhetra [Univ. of New Hampshire, Durham, NH ↗

DOE OSTI2025

MX precipitate behavior in an irradiated advanced Fe-9Cr steel: Helium effects on phase stability

As part of an ongoing series aimed at optimizing Fe-9Cr reduced activation ferritic/martensitic (RAFM) alloys for fusion energy systems, this study explores MX precipitate behavior under dual-ion irradiations, specifically examining correlations between helium transmutation and irradiation-induced damage. Utilizing single and dual-beam ion irradiation, the research explores the combined effects of helium (10–25 appm He/dpa), temperature (400–600 °C), and damage levels (15–100 dpa) on the microstructural evolution of CNA9 steel, a variant of Castable Nanostructured Alloys (CNAs). The study demonstrates that helium co-implantation hinders radiation-enhanced coarsening of MX-TiC precipitates at 500 and 600 °C, maintaining MX-TiC precipitate stability at moderate damage levels (15 dpa) but failing to prevent complete precipitate dissolution at higher damage levels (≥50 dpa) when irradiated at 500 °C. Here, a generalized precipitate stability model suggests that helium-induced suppression of diffusion alters the balance between recoil resolution and back diffusion for MX-TiC precipitates, enhancing the current understanding of precipitate behavior under damage and transmutation simulated dual-ion irradiation conditions.

Characterization↗

DOE OSTI2025

Operation of helium sub-atmospheric multistage cryogenic centrifugal compressor trains: Part 1 – Steady state modeling and speed ratio selection

Helium cryogenic systems which can provide cooling below the normal boiling point of helium (approximately 4.2 K) are often required by superconducting radio-frequency niobium resonators utilized in modern high-energy particle accelerators. Achieving temperatures below 4.2 K generally involves operating a cryogenic vessel with liquid helium under sub-atmospheric conditions, thereby lowering the saturation pressure and corresponding saturation temperature. Over the last several decades, multi-stage cryogenic centrifugal compressor trains (CC’s) have been operated efficiently and reliably within large-scale cryogenic systems to continuously evacuate helium vapor generated by a device within the vessel, maintaining sub-atmospheric conditions in the vessel while pressurizing the return vapor to above atmospheric conditions. Traditionally, these CC systems have been operated using empirically derived control philosophies and insight gathered from previous operational experience. Recent efforts at the Facility for Rare Isotope Beams (FRIB) have been aimed at the development of a theoretical basis to characterize the operation of multi-stage cryogenic centrifugal compressor train and utilizing predictive model results to generate control parameters. The objective of this research was identifying operational points which adequately balance cryogenic system efficiency, stability, and overall ease of operation. Furthermore, this manuscript provides an overview of the predictive model development, characterization of the FRIB cryogenic centrifugal compressors and implementation of the predicted performance results during steady-state system operation.

Compressor train control↗

DOE OSTI2025

Simulations of the fault current limiting operation of a long-length REBCO CORC ® superconducting cable cooled by helium gas

Conductor-on-round-core (CORC®) cables composed of rare-earth-barium-copper-oxide high-temperature superconducting (HTS) tapes are of great interest for power transmission applications due to their many advantages such as high power density, light weight, and low loss. Closed circulation loops of cryogenic helium gas can be used to cool HTS cables down to low temperatures to significantly improve their current-carrying capacity. Coupled circuit-electromagnetic-thermal finite element simulations implemented in the COMSOL Multiphysics package were developed, validated, and then used for simulating the fault current limiting (FCL) performance and the cooling processes of an 8-layer CORC® cable cooled with a flow of cryogenic helium gas. In the simulations, the temperature dependence of the electrical and thermal properties of all component materials is implemented for improved accuracy. To overcome computational challenges caused by the considerable difference in geometrical scales (i.e. few-µm-thick HTS layers versus 10 m-long HTS cable), the model is divided into two separate simulations. The first simulation is performed on the transverse cross-section of the cable to calculate the electric field, heating power and temperature rise in each component of a CORC® cable during FCL operation. The heating power calculated in the first simulation is transferred to the second model to simulate the cooling of a 10 m-long cable after the fault is cleared. The effect of the helium gas flow rate on the cooling process is also investigated to develop strategic approaches for optimizing cooling systems for HTS cables with FCL capability. The simulations indicated that a 40 ms fault with a voltage drop of 20 V m −1 along the cable can result in a temperature increase from 60 K to about 165 K inside the cable, and it takes about 500 s to cool the cable back to nearly 60 K with a flow of cold helium gas at a rate of 5 g s −1 .

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2026

On the uncertainties in helium generation predictions for fission and fusion alloys

With ongoing advances in fusion and advanced fission reactors, quantifying irradiation effects in materials is critical. Transmutation-induced helium in cladding and structural materials can drive swelling and embrittlement, thereby reducing these components’ lifespans. Yet most studies ignore the considerable uncertainties in predicting helium generation rates. In this work, we created a code wrapper, F-SCATTER, that automatically performs simulations in FISPACT-II. We used this tool to investigate potential variance in helium generation rate, or He/dpa, calculations based on deviations in alloy composition, irradiating neutron flux spectrum, computational methodology, and nuclear data sources. We used 12 wt% Cr HT9 steel as the reference case and observed a 6.5%–98.3% He/dpa spread based on compositional variation within a single chemical specification, a 1.8%–11.5% He/dpa variation upon the incorporation of a 15% artificial uncertainty in flux at each energy, and a He/dpa difference as high as 231% when using ENDF/B-VIII.0 versus TENDL-2021 data libraries. Similar results were found for other prominent iron-based alloys, including Grade 91, castable nano-structured alloy, and 316H—where additional variations exist based on reactor type (e.g. thermal, fast, or fusion) and alloying elements such as carbon, nitrogen, and nickel. Based on the simulated results, we conclude that a significant part of the heat-to-heat variability in swelling responses of Fe-based alloys can be driven by impurity content in alloy compositions, and, therefore, chemical control should be a key element in supply chain design for advanced nuclear energy systems. Furthermore, we provide critical recommendations on best practices for evaluating and reporting helium production and lattice damage rates when computing predictions with multiphysics programs such as FISPACT-II.

FISPACT-II↗

DOE OSTI2025

Modulation of thermal conductivity of iron-doped ß-Ga2O3 by helium-ion irradiation

This study examines the impact of helium-ion irradiation on the thermal conductivity of ß-Ga2O3. A laser-based spatial domain thermoreflectance technique is used to investigate thermal conductivity map for both un-irradiated and irradiated ß-Ga2O3, which are then validated against simulation results derived from density functional theory-based phonon transport simulations. Since helium bubble evolution was ob- served at the nanoscale using transmission electron microscopy, the simulation study was carried out on eight distinct helium-induced sites in ß-Ga2O3. Our findings indicate a reduction in thermal conductivity for the irradiated samples. Experimental results show a significant reduction in thermal conductivity in irradiated samples, with de- creases of approximately 25% along the [100] direction and 40% along [001] directions. Phonon transport simulations closely replicate these findings, particularly when helium occupying interstitial sites, predicting reductions of ˜53% along [100] and ˜50% along [001] directions. This work underscores the role of irradiation-induced microstructural changes in the heat transport properties of ß-Ga2O3 which is crucial for its application in sensor devices in extreme environments.

36 - MATERIALS SCIENCE↗

DOE OSTI2025

Formation and Evolution Simulations of Saturn, Including Composition Gradients and Helium Immiscibility

In this paper, the formation of Saturn is modeled by detailed numerical simulations according to the core-nucleated accretion scenario. Previous models are enhanced to include the dissolution of accreting planetesimals, composed of water ice, rock, and iron, in the gaseous envelope of the planet, leading to a nonuniform composition with depth. The immiscibility of helium in metallic hydrogen layers is also considered. The calculations start at a mass of 0.5 Earth masses and are extended to the present day. At 4.57 Gyr, the model, proceeding outward, has the following structure: (i) a central core composed of 100% heavy elements and molecules, (ii) a region with a decreasing heavy-element mass fraction, down to a value of 0.1, (iii) a layer of uniform composition with the helium mass fraction Y enhanced over the primordial value, (iv) a helium rain region with a gradient in Y, (v) an outer convective, adiabatic region with uniform composition in which Y is reduced from the primordial value, and (vi) the very outer layers where cloud condensation of the heavy elements occurs. Models of the distribution of heavy elements as a function of radius are compared with those derived to fit the observations of the Cassini mission, with rough qualitative agreement. The helium mass fraction in Saturn’s outer layers is estimated to be around 20%. Models are found that provide good agreement with Saturn’s intrinsic luminosity and radius.

79 ASTRONOMY AND ASTROPHYSICS↗