Intermediate energy proton irradiation: rapid, high-fidelity materials testing for fusion and fission energy systems

Fusion and advanced fission power plants require advanced nuclear materials to function under new, extreme environments. Understanding the evolution of mechanical and functional properties during radiation damage is essential to the design and commercial deployment of these systems. The shortcomings of existing methods could be addressed by a new technique - intermediate energy proton irradiation (IEPI) - using beams of 10 - 30 MeV protons to rapidly and uniformly damage bulk material specimens before direct testing of engineering properties. IEPI is shown to achieve high fidelity to fusion and fission environments in both primary damage production and transmutation, often superior to nuclear reactor or typical (low-range) ion irradiation. Modeling demonstrates that high doserates (0.1 - 1 DPA/per day) can be achieved in bulk material specimens (100 - 300 {\mu}m) with low temperature gradients and induced radioactivity. The capabilities of IEPI are demonstrated through a 12 MeV proton irradiation and tensile test of 250 {\mu}m thick tensile specimens of a nickel alloy (Alloy 718), reproducing neutron-induced data. These results demonstrate that IEPI enables high throughput assessment of materials under reactor-relevant conditions, positioning IEPI to accelerate the pace of engineering-scale radiation damage testing and allow for quicker and more effective design of nuclear energy systems.Comment: Revised version. Resubmitted to Materials & Design journal for publicatio

Investigations of Aluminum-Doped Self-Healing Zircaloy Surfaces in Context of Accident-Tolerant Fuel Cladding Research

We present here some important results investigating aluminum as an effective surface dopant for increased oxidation resistance of zircaloy nuclear fuel cladding. At first, the transport behavior of aluminum into reactor grade zircaloy was studied using simple diffusion couples at temperatures greater than 770 K. The experiments revealed the formation of tens of microns thick graded Zr-Al layers. The activation energy of aluminum in zircaloy was found to be ~175 kJ/mol (~1.8 eV), indicating the high mobility of aluminum in zircaloy. Subsequently, aluminum sputter-coated zircaloy coupons were heat-treated to achieve surface doping and form compositionally graded layers. These coupons were then tested in steam environments at 1073 and 1273 K. The microstructure of the as-fabricated and steam-corroded specimens was compared to those of pure zircaloy control specimens. Analysis of data revealed that aluminum effectively competed with zircaloy for oxygen up until 1073 K blocking oxygen penetration, with no traces of large scale spalling, indicating mechanically stable interfaces and surfaces. At the highest steam test temperatures, aluminum was observed to segregate from the Zr-Al alloy under layers and migrate to the surface forming discrete clusters. Although this is perceived as an extremely desirable phenomenon, in the current experiments, oxygen was observed to penetrate into the zirconium-rich under layers, which could be attributed to formation of surface defects such as cracks in the surface alumina layers.Oak Ridge National LaboratoryU.S. Nuclear Regulatory Commissio

Deep Burn Develpment of Transuranic Fuel for High-Temperature Helium-Cooled Reactors - July 2010

The DB Program Quarterly Progress Report for April - June 2010, ORNL/TM/2010/140, was distributed to program participants on August 4. This report discusses the following: (1) TRU (transuranic elements) HTR (high temperature helium-cooled reactor) Fuel Modeling - (a) Thermochemical Modeling, (b) 5.3 Radiation Damage and Properties; (2) TRU HTR Fuel Qualification - (a) TRU Kernel Development, (b) Coating Development, (c) ZrC Properties and Handbook; and (3) HTR Fuel Recycle - (a) Recycle Processes, (b) Graphite Recycle, (c) Pyrochemical Reprocessing - METROX (metal recovery from oxide fuel) Process Development

Enabling a Multi-Purpose High-Energy Neutron Source Based on High-Current Compact Cyclotrons

The current and future need for high-energy neutrons has been a subject of increasing discussion and concern. Immediate applications for such an intense neutron source include medical isotope production, high-energy physics (HEP) research, and for materials development and to support qualification for fission reactors. Also, and of the utmost importance, is the need for such a source to inform critical gaps in our understanding of the transmutation materials science issues facing fusion power reactors. A 14 MeV fusion prototypical neutron source (FPNS) has been a critical, yet unresolved need of the fusion program for more than 40 years. Given the narrowing timeline for construction of pilot and fusion power plants the urgency and necessity of such a neutron source has become increasingly time sensitive. One possibility to address this need is a scaled-down version of IFMIF technology ("IFMIF-Lite"), operating at 125 mA with the beam and target technology leveraging technology developed under the IFMIF/EVEDA program. Within this white paper, a blueprint of necessary R&D to enable a transformational change in both the capital and operating cost of this IFMIF-Lite driver concept is presented. Enabling this transformation is the replacement of the historic RFQ/LINAC components with multiple compact 35+ MeV D+ drivers, based on compact cyclotrons

Deep Burn: Development of Transuranic Fuel for High-Temperature Helium-Cooled Reactors- Monthly Highlights November 2010

During FY 2011 the DB Program will report Highlights on a monthly basis, but will no longer produce Quarterly Progress Reports. Technical details that were previously included in the quarterly reports will be included in the appropriate Milestone Reports that are submitted to FCRD Program Management. These reports will also be uploaded to the Deep Burn website. The Monthly Highlights report for October 2010, ORNL/TM-2010/300, was distributed to program participants on November 29, 2010. This report discusses the following: (1) Thermochemical Data and Model Development; (2) TRU (transuranic elements) TRISO (tri-structural isotropic) Development - (a) TRU Kernel Development, (b) Coating Development; (3) LWR Fully Ceramic Fuel - (a) FCM Fabrication Development, (b) FCM Irradiation Testing

Coated Particle Fuel and Deep Burn Program Monthly Highlights April 2011

The baseline change proposal BCP-FCRD-11026 submitted to change the due date for M21AF080202 'Demonstrate fabrication of Transuranic kernels of Plutonium-239/3.5at%Neptunium-237 using newly installed glove box facilities in ORNL 7930 hot cell complex' from 4/25/11 to 3/30/12 was approved this month. During FY 2011 the CP & DB Program will report Highlights on a monthly basis, but will no longer produce Quarterly Progress Reports. Technical details that were previously included in the quarterly reports will be included in the appropriate Milestone Reports that are submitted to FCRD Program Management. These reports will also be uploaded to the Deep Burn website. The Monthly Highlights report for March 2011, ORNL/TM-2011/96, was distributed to program participants on April 8, 2011. As reported previously, the final Quarterly for FY 2010, Deep Burn Program Quarterly Report for July - September 2010, ORNL/TM-2010/301, was announced to program participants and posted to the website on December 28, 2010. This report discusses the following: (1) Thermochemical Data and Model Development - (a) Thermochemical Modeling, (b) Thermomechanical Behavior, (c) Actinide and Fission Product Transport, (d) Radiation Damage and Properties; (2) TRU (transuranic elements) TRISO (tri-structural isotropic) Development - (a) TRU Kernel Development, (b) Coating Development; (3) Advanced TRISO Applications - Metal Matrix Fuels for LWR; (4) LWR Fully Ceramic Fuel - (a) FCM Fabrication Development, (b) FCM Irradiation Testing; (5) Fuel Performance and Analytical Analysis - Fuel Performance Modeling; and (6) ZrC Properties and Handbook - Properties of ZrC

Deep Burn: Development of Transuranic Fuel for High-Temperature Helium-Cooled Reactors- Monthly Highlights September 2010

The DB Program monthly highlights report for August 2010, ORNL/TM-2010/184, was distributed to program participants by email on September 17. This report discusses: (1) Core and Fuel Analysis - (a) Core Design Optimization in the HTR (high temperature helium-cooled reactor) Prismatic Design (Logos), (b) Core Design Optimization in the HTR Pebble Bed Design (INL), (c) Microfuel analysis for the DB HTR (INL, GA, Logos); (2) Spent Fuel Management - (a) TRISO (tri-structural isotropic) repository behavior (UNLV), (b) Repository performance of TRISO fuel (UCB); (3) Fuel Cycle Integration of the HTR (high temperature helium-cooled reactor) - Synergy with other reactor fuel cycles (GA, Logos); (4) TRU (transuranic elements) HTR Fuel Qualification - (a) Thermochemical Modeling, (b) Actinide and Fission Product Transport, (c) Radiation Damage and Properties; (5) HTR Spent Fuel Recycle - (a) TRU Kernel Development (ORNL), (b) Coating Development (ORNL), (c) Characterization Development and Support, (d) ZrC Properties and Handbook; and (6) HTR Fuel Recycle - (a) Graphite Recycle (ORNL), (b) Aqueous Reprocessing, (c) Pyrochemical Reprocessing METROX (metal recovery from oxide fuel) Process Development (ANL)

Fabrication of neutron absorbing metal hydride entrained ceramic matrix shield composites

With significant improvement in High Temperature Superconductors (HTS), several projects are adopting HTS technology for fusion power systems. Compact HTS tokamaks offer potential advantages including lower plant costs, enhanced plasma control, and ultimately lower cost of electricity. However, as compact reactors have a reduced radial build to accommodate shielding, HTS degradation due to radiation damage or heating is a significant and potentially design limiting issue. Shielding must mitigate threats to the superconducting coils: neutron cascade damage, heat deposition and potentially organic insulator damage due x-rays. Unfortunately, there are currently no hi-performance shielding materials to enable the potential performance enhancement offered by HTS. In this work, we present a manufacturing method to fabricate a new class of composite shields that are high performance, high operating temperature, and simultaneously neutron absorbing and neutron moderating. The composite design consists of an entrained metal-hydride phase within a radiation stable MgO ceramic host matrix. We discuss the fabrication, characterization, and thermophysical performance data for a series of down-selected composite materials inspired by future fusion core designs and their operational performance metrics. To our knowledge these materials represent the first ceramic composite shield materials containing significant metal hydrides