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In this report we present the results on the tensile testing of two FeCrAl alloys developed at Oak Ridge National Laboratory.

Aqueous radioactive wastes from Savannah River Site (SRS) separations and vitrification processes are contained in large underground carbon steel tanks. Inspections made during 2011 to evaluate these vessels and other waste handling facilities along with evaluations based on data from previous inspections are the subject of this report. The 2011 inspection program revealed that the structural integrity and waste confinement capability of the Savannah River Site waste tanks were maintained. All inspections scheduled per SRR-LWE-2011-00026, HLW Tank Farm Inspection Plan for 2011, were completed. Ultrasonic measurements (UT) performed in 2011 met the requirements of C-ESR-G-00006, In-Service Inspection Program for High Level Waste Tanks, Rev. 3, and WSRC-TR-2002-00061, Rev.6. UT inspections were performed on Tanks 25, 26 and 34 and the findings are documented in SRNL-STI-2011-00495, Tank Inspection NDE Results for Fiscal Year 2011, Waste Tanks 25, 26, 34 and 41. A total of 5813 photographs were made and 835 visual and video inspections were performed during 2011. A potential leaksite was discovered at Tank 4 during routine annual inspections performed in 2011. The new crack, which is above the allowable fill level, resulted in no release to the environment or tank annulus. The location of the crack is documented in C-ESR-G-00003, SRS High Level Waste Tank Leaksite Information, Rev.6.

A Heavy Met that is 95% tungsten, 3% nickel and 2% iron and sintered to 100% density and is Ultra High Vacuum (UHV) compatible is proposed for use as the X-ray slit in the Front End Enclosure and the Fixed Mask for the Linac Coherent Light Source (LCLS). The Heavy Met was tested in the LLNL Vacuum Sciences and Engineering Lab (VSEL) to determine its outgassing rate and its overall compatibility with the vacuum requirements for LCLS.

This research program was designed to look at basic radiation damage and effects and mechanical properties in Fe and ferritic alloys. The program scope included a number of materials ranging from pure single crystal Fe to more complex Fe-Cr-C alloys. The range of materials was designed to examine materials response and performance on ideal/model systems and gradually move to more complex systems. The experimental program was coordinated with a modeling effort. The use of pure and model alloys also facilitated the ability to develop and employ atomistic-scale modeling techniques to understand the inherent physics underlying materials performance

Ferrite rods are installed inside the flying-wire cavity of the Recycler Ring and at entrance and exit beam pipes in order to absorb high-frequency electromagnetic waves excited by the beam. However, these rods may also deteriorate the vacuum pressure of the ring. An investigation is made to analyze the necessity of the ferrite rods at the entrance and exit beam pipes.

The purpose of this analysis report is to evaluate and document the inclusion or exclusion of the disruptive events features, events, and processes (FEPs) with respect to modeling used to support the total system performance assessment for license application (TSPA-LA). A screening decision, either ''Included'' or ''Excluded,'' is given for each FEP, along with the technical basis for screening decisions. This information is required by the U.S. Nuclear Regulatory Commission (NRC) at 10 CFR 63.114 (d), (e), and (f) [DIRS 156605]. The FEPs addressed in this report deal with both seismic and igneous disruptive events, such as fault displacements through the repository and an igneous intrusion into the repository. For included FEPs, this analysis summarizes the implementation of the FEP in TSPA-LA (i.e., how the FEP is included). For excluded FEPs, this analysis provides the technical basis for exclusion from TSPA-LA (i.e., why the FEP is excluded). Previous versions of this report were developed to support the total system performance assessments (TSPA) for various prior repository designs. This revision addresses the repository design for the license application (LA).

Tensile testing to provide tensile test data for ASTM A285 steel for application to fracture analysis of Type I and Type II high level waste tanks has been completed. A total of 32 tensile tests were done on 8 heats of steel.

Both the 316L stainless steel and Hastelloy{reg_sign} C-22 gave satisfactory corrosion performance in the simulated test environments. They were subjected to 100 day weight loss corrosion tests and electrochemical potentiodynamic evaluation. This activity supports confirmation of the design basis for the materials of construction of process vessels and equipment used to handle the feed to the LAW-melter evaporator. BNFL process and mechanical engineering will use the information derived from this task to select material of construction for process vessels and equipment.

This report outlines the results of the investigation with emphasis on the measured hydrogen generation rates and a summary of the hydrogen retention and release behavior.

Many experiments have verified the presence of a spin-density wave (SDW) within the Cr spacer of Fe/Cr multilayers and wedges. The authors review the recently-proposed interlayer magnetic coupling mediated by a SDW. Unlike previously proposed mechanisms, this magnetic coupling is strongly temperature-dependent. Depending on the temperature and the number N of Cr monolayers (ML), the SDW may be either commensurate (C) or incommensurate (I) with the bcc Cr lattice.

Creep and creep crack growth behavior of alloy 120 (HR120{trademark}) were studied through the time-dependent fracture mechanics characterization at 871 C (1,600 F). The material was tested under tensile, creep and creep crack propagation conditions to develop an understanding of time-dependent behavior under variable stresses at elevated temperature. The resulting properties were also compared with those of alloy 333 (RA333{trademark}) and alloy (HR160(TM)) previously obtained using the same testing and data processing methods. Results show that at elevated temperature, alloy 120 and alloy 333 had little primary creep while alloy 160 demonstrated significant amount of primary creep. Comparison based on creep energy consumption rate indicates that creep crack growth resistance of alloy 120 is greater than that of alloy 333, but a little less than that of alloy 160.

This report presents the results of a literature review on galvanic corrosion between candidate metals and alloys currently being considered for the waste package containers.

When 55-gal steel drum waste containers fail in service, i.e., leak, corrode or breach, the standard fix has been to overpack the drum. When a drum fails and is overpacked into an 83-gal overpack drum, there are several negative consequences. Identifying waste streams that preferentially corrode steel drums is essential to the pollution prevention philosophy that ``an ounce of prevention is worth a pound of cure.`` It is essential that facilities perform pollution prevention measures at the front end of processes to reduce pollution on the back end. If these waste streams can be identified before they are packaged, the initial drum packaging system could be fortified or increased to eliminate future drum failures, breaches, clean-ups, and the plethora of other consequences. Therefore, a survey was conducted throughout the US Department of Energy complex for information concerning waste streams that have demonstrated preferential corrosion of 55-gal steel drums. From 21 site contacts, 21 waste streams were so identified. The major components of these waste streams include acids, salts, and solvent liquids, sludges, and still bottoms. The solvent-based waste streams typically had the shortest time to failure, 0.5 to 2 years. This report provides the results of this survey and research.

III List of Figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v List of Tables vi Acknowledgements vii

Important properties of iron aluminides have been compiled in order to help engineers and scientists to be able to quickly assess this materials system. This compilation is by no means exhaustive, but it represents a reasonable first effort to summarize the properties of iron aluminides. Considerable care has been, used in assembling the data into tables. However, no guarantee can be made that all the values compiled here are correct; and in case of doubt, or in order to obtain more detailed information, the original sources should always be consulted.

A multi-disciplinary research program was undertaken to address certain fundamental issues relating to corrosion fatigue crack growth in structurally important alloys in aqueous solutions. Focus was placed on austenitic iron-chromium-nickel alloys.

Past decontamination and solvent recovery activities at the Idaho Chemical Processing Plant (ICPP) have resulted in the accumulation of 1.5 million gallons of radioactively contaminated sodium-bearing liquid waste. Future decontamination activities at the ICPP could result in the production of 5 million gallons or more of sodium-bearing waste using the current decontamination techniques of chemical/water flushes and steam jet cleaning. With the curtailment of reprocessing at the ICPP, the focus of decontamination is shifting from maintenance for continued operation of the facilities to decommissioning. As decommissioning plans are developed, new decontamination methods must be used which result in higher decontamination factors and generate lower amounts of sodium-bearing secondary waste. The primary initiative of the WINCO Decontamination Development Program is the development of methods to eliminate/minimize the use of sodium-bearing decontamination chemicals. One method that was chosen for cold scoping studies during FY-93 was abrasive grit blasting. Abrasive grit blasting has been used in many industries and a vast amount of research and development has already been conducted. However, new grits, process improvements and ICPP applicability was investigated. This evaluation report is a summary of the research efforts and scoping tests using the liquid abrasive grit blasting decontamination technique. The purpose of these scoping tests was to determine the effectiveness of three different abrasive grits: plastic beads, glass beads and alumina oxide.

This report presents a re-analysis of an international PISC-II (Programme for Inspection of Steel Components, Phase 2) round-robin inspection results using formal statistical techniques to account for experimental error. The analysis examines US team performance vs. other participants performance,flaw sizing performance and errors associated with flaw sizing, factors influencing flaw detection probability, performance of all participants with respect to recently adopted ASME Section 11 flaw detection performance demonstration requirements, and develops conclusions concerning ultrasonic inspection capability. Inspection data were gathered on four heavy section steel components which included two plates and two nozzle configurations.

A summary of efforts to examine coatings and cladding materials for high-strength austenitic steels is provided. Chromized coatings on 17--14CuMo stainless steel and a modified type 316 (HT-UPS) stainless steel were investigated. Claddings included alloy 671, 690, and an iron-aluminide intermetallic alloy. Structural alloys that were clad included type 304 stainless steel, modified type 316 stainless steel, and modified alloy 800H. The capability of producing co-extruded tubing of the experimental alloys was demonstrated.

The Department of Energy has established specifications for the DWPF product, which require that the DWPF provide estimates of the service life of the canister label, provide assurance that the DWPF canister will be leaktight when shipped, demonstrate that the contents of the canistered waste form will not lead to internal corrosion of the canister. The DWPF has elected to meet these requirements, in part, by characterizing canisters produced in the facility during the Startup Test Program. This includes canisters filled on the pour turntable (normal conditions) and canisters filled on the drain turntable (credible upset conditions expected to be more severe due to higher temperatures). This document identifies the requirements for characterization of the canister fabrication welds and canister labels (characterization of canister closure welds is being performed by Equipment Engineering Section), and for estimation of their service life in DWPF`s Glass Waste Storage Building.

Single-loop electrochemical potentiokinetic reactivation testing of miniaturized (TEM) specimens can provide reliable data comparable to data obtained with larger specimens. Significant changes in electrochemical properties (increased reactivation current and Flade potential) were detected for PCA and type 316 stainless steels irradiated at 200--420[degrees]C up to 7--9 dpa. Irradiations in the FFTF Materials Open Test Assembly and in the Oak Ridge Research Reactor are reported on. 45 figs., 5 tabs., 52 refs.

Objective of this materials program is to conduct R and D on materials for fossil energy applications with focus on longer-term and generic needs of the various fossil fuel technologies. The projects are organized according to materials research areas: (1) ceramics, (2) new alloys: iron aluminides, advanced austenitics and chromium niobium alloys, and (3) technology development and transfer. Separate abstracts have been prepared.

Corrosion monitoring techniques have improved with advances in instrumentation technology and corrosion research. Older techniques, such as coupon immersion, generally provide historical information. The new electrochemical techniques, which have not been used widely at SRS, allow on-line monitoring and correlation with process changes. These techniques could improve the corrosion assessment of the waste tanks to be used for In-Tank Precipitation and Extended Sludge Processing. A task was initiated to place an electrochemical probe into tank 48 for testing the utility of this technique for waste tank applications.

An improved two-step chemical decontamination technique was recently developed at INEL. This memorandum documents the addition of this technology to the SRTC arsenal of decontamination technology. A two-step process using NAOH, KMnO{sub 4} followed by HNO{sub 3} was used for cleaning doorstops (small casks) in the SRTC High Level Caves in 1967. Subsequently, more aggressive chemical techniques have been found to be much more effective for our applications. No further work on two-step technology is planned.

This report provides conceptual designs and design recommendations for installing secondary containment and leak detection systems for three sumps at the Fluorinel and Storage Facility (FAST), CPP-666. The FAST facility is located at the Idaho Chemical Processing Plant (ICPP) at the Idaho National Engineering Laboratory (INEL). The three sumps receive various materials from the FAST water treatment process. This project involves sump upgrades to meet appropriate environmental requirements. The steps include: providing sump modifications or designs for the installation of leak chases and/or leakage accumulation, coating the sump concrete with a chemical resistant sealant (except for sump VES-FT-534 which is already lined with stainless steel) to act as secondary containment, lining the sumps with a primary containment system, and providing a means to detect and remove primary containment leakage that may occur.

The SRS Waste Tanks at the Savannah River Site to be employed in the In-Tank Precipitation (ITP) process are undergoing a structural evaluation in order to define their response to a hypothetical deflagration accident. This report provides mechanical property data to support the structural analyses, and characterizes the impact of mechanical property variability and materials degradation on the failure strain of the primary liner.

An evaluation was undertaken to determine the potential of modified type 310 stainless steel for fossil energy applications. First, alloy performance criteria for components in several emerging technologies were identified. Then, a brief review of existing alloy technology was undertaken relative to performance criteria. Key issues were the tendency for type 310 stainless steel to embrittle due to the formation of intermetallic phases, the poor resistance of type 310 stainless steel to highly sulfidizing environments, the need to examine the strength and ductility of weldments, and the lack of a long-time data base and criteria for setting allowable stress at temperatures in excess of 800{degrees}C. An activity was outlined that would address several of the key issues.

The central focus for this assessment has been to compare the corrosion behavior of two steam generator (SG) tube materials: Inconel 600 TT and Inconel 690 TT from (a) SG operating experience, and (b) laboratory data. The scope and results of the comparisons are summarized in this section. They provide the basis for projecting SG longevity.

Research is being done on transformation plasticity and toughening in steels and on finite-element modeling of transformation toughening in steels. In the analysis of nonuniform flow and constitutive behavior in TRIP steels, a finite-element analysis was performed to model these steels during simple tension tests. Crack-tip metallographic observations have been performed on the precipitation-hardened 31 Ni steel. Experimental alloys under study are discussed. (DLC)

The primary objective of this project is geared toward the substitution of steel media by fracturing silica sand as a grinding media for ultraline coal grinding. The project has been divided into four subgroups for bookkeeping purposes and possible ease of execution. Some of the tasks would be executed simultaneously as overlapping is inevitable. The grouping is as follows: (1) sample procurement, preparation, and characterization; (2) batch grinding tests; (3) continuous grinding tests; and, (4) fracture mechanics. The hardgrove indices for the four coals employed in this work have finally been determined by the personnel at the R and D Center of Drummond Coal Company using 14 [times] 28 mesh feed size materials. The values obtained for the respective coals are given in Table 1.

Through a series of experiments, a new high-speed tapping technique was developed for N/C machining centers. The new technique produces high quality threads in a fraction of the time previously required, using the same equipment. Threads are produced to precise size and depth in a single pass at speeds up to 5000 rpm. Thread sizes ranged from 0.80 UNM (Unified Miniature Thread Series) (0.0315 in. major diameter) to 0.250-20 UN (Unified Screw Threads) in both blind and through-hole applications. The materials tapped included 17-4 PH stainless steel, 300 series stainless steel, and 6061-T6 aluminum. 10 figs.

This report summarizes research conducted by ITI to evaluate the commercialization potential of EG G Mound Applied Technologies' heat treatment process of high strength materials. The remainder of the report describes the nature of demand for maraging steel, extent of demand, competitors, environmental trends, technology life cycle, industry structure, and conclusion. (JL)

During the course of 9{degree} tapered side-bonding resistance upset weld development at Mound, various studies have been conducted to evaluate the effect of yield strength on welds in 304L stainless steel. The results of these studies have concluded that at high yield strengths there may be a minor reduction in the length of Class 2 or better bond. Satisfactory welds have been produced with materials having yield strengths ranging from 36.0 to 141.0 ksi. However, when body yield strengths exceed 80.0 ksi a minor decrease in bond lengths begins. A significant inverse relationship between stem yield strength and bond length was shown to exist. 8 refs., 9 figs., 10 tabs.

Described is the background work performed jointly by the Electric Power Research Institute in the United States, the Central Research Institute of Electric Power Industry in Japan and Nuclear Electric plc in the United Kingdom with the purpose of developing a high-temperature flaw assessment procedure for reactor components. Existing creep-fatigue crack-growth models are reviewed, and the most promising methods are identified. Sources of material data are outlined, and results of the fundamental deformation and crack-growth tests are discussed. Results of subcritical crack-growth exploratory tests, creep-fatigue crack-growth tests under repeated thermal transient conditions, and exploratory failure tests are presented and contrasted with the analytical modeling. Crack-growth assessment methods are presented and applied to a typical liquid-metal reactor component. The research activities presented herein served as a foundation for the Flaw Assessment Guide for High-Temperature Reactor Components Subjected to Creep-Fatigue Loading published separately. 30 refs., 108 figs., 13 tabs.

Planning for storage or disposal of greater-than-Class C low-level radioactive waste (GTCC LLW) requires characterization of that waste to estimate volumes, radionuclide activities, and waste forms. Data from existing literature, disposal records, and original research were used to estimate the characteristics and project volumes and radionuclide activities to the year 2035. GTCC LLW is categorized as: nuclear utilities waste, sealed sources waste, DOE-held potential GTCC LLW; and, other generator waste. It has been determined that the largest volume of those wastes, approximately 57%, is generated by nuclear power plants. The Other Generator waste category contributes approximately 10% of the total GTCC LLW volume projected to the year 2035. Waste held by the Department of Energy, which is potential GTCC LLW, accounts for nearly 33% of all waste projected to the year 2035; however, no disposal determination has been made for that waste. Sealed sources are less than 0.2% of the total projected volume of GTCC LLW.

This memorandum presents experimental data from electrochemical and immersion tests to support the continued use of two sections of nonconforming steel in the Supplementary Safety System. The Reactor Corrosion Mitigation Committee met on May 16, 1991 to evaluate materials that had been installed in the SSS. The materials lacked complete Corrosion Evaluation (CE) and/or Certified Mill Test Reports and had been installed during recent modifications (Project S-4332). Items that lacked proper documentation included AISI Type 304 stainless steel (304) instrument tubing (0.375`` OD) associated with the pressure transmitters and a two-foot section of 304 pipe located on the far side of the system downstream of the pneumatic valves. Cyclic potentiodynamic polarization scans were performed on sensitized and solution-annealed 304 samples in as-mixed and acidified Gd(NO{sub 3}){sub 3}, or ``ink``, solutions at room temperature to determine the susceptibility of 304 to localized corrosion in this environment. No localized attack was observed on the solution annealed or sensitized 304 in the Gd(NO{sub 3}){sub 3} solution. These tests revealed no significant differences in the behavior of the sensitized and solution-annealed 304 in gadolinium nitrate solution. Therefore, localized corrosion of the nonconforming components is not anticipated, and the performance of the nonconforming components shouldmore » not differ from that of corrosion evaluated and certified materials. Previous studies have shown that AISI Type 304L stainless steel (304L) did not pit during a three-month exposure in gadolinium nitrate solutions of pH 2 or 5. These combined results support the continued use of the nonconforming steels until replacement can be made at the next scheduled long shut-down.« less