Successful deposition of thick copper coatings on low carbon steel is a challenge for the Cold Gas Dynamic Spray (CGDS) process if one is to avoid the use of helium as the process gas for the initial pre-coat layer. The issue stems from the presence of accumulated residual stresses, which causes delamination of the weakly bonded coating. Even after exploring different deposition parameters, several copper powders and various steel substrate preparations, copper coating delamination still occurs. The purpose of the current study is to produce copper coatings using only nitrogen as the process gas, while avoiding delamination of the deposited material. To this end, the current work focuses on the study of the effect of steel substrate temperature on particle deposition and adhesion processes. Steel substrates were heated to temperatures between 25°C and 600°C using induction heating and laser. Once the substrate reached the desired temperature, three different copper particle sizes were deposited using the CGDS process. Individual particle impact tests (wipe-tests) were performed to characterize bonded particles and craters from rebounded particles. Further analysis was performed by extracting particles from the surface to understand the effect of substrate temperature and particle size on the particle/substrate deformation and bonding processes. Mechanical adhesion prediction modeling at substrate preheated was also performed to obtain a greater understanding of the bonding mechanism. This prediction is in order to compare with the coating developed with a bond layer coating with helium as process gas and then build the rest of the coating with nitrogen. The experimental results show a significant trend as the substrate temperature increases, indicating proper conditions for enhanced adhesion.

In order to improve the efficiency of dry used nuclear fuel (UNF) storage, reduced reactivity methods are being developed for various reactor types and operating conditions. Sub-criticality must be maintained in the storage configuration and conservative computer simulations are used as the primary basis for loading the storage casks. Methodologies are now being developed to reduce the amount of modeling and computation in order to make conservative assessments of how densely fuel can be packed. The SCALE/TRITON (Standardized Computer Analyses for Licensing Evaluation / Transport Rigor Implemented with Time-dependent Operation for Neutronic Depletion) code system has been used to simulate boiling water reactor (BWR) operating conditions in order to investigate nuclide densities in UNF and how the use of control rod blades affect nuclide densities found in UNF. Rodded and unrodded operating cases for a fuel assembly have been used as bounding cases and are used as reference solutions in a piecewise data approximation methodology (PDA method). A variety of control blade insertion patterns have been used with the PDA method and simulated in TRITON in order to observe trends in nuclide densities with varying control blade use. The PDA method is compared with TRITON simulated data in order to evaluate the validity and accuracy of the PDA method. The PDA method gives very accurate results for fissile nuclides but is insufficient in treating densities as a function of burnup for fission products and fertile nuclides. Predicting nuclide densities from temporally balanced control blade insertion and withdrawal patterns is also a strength of the PDA method. The PDA method, however, is not capable of properly accounting for neutron spectral shifts and the behavior in nuclide densities brought about by the spectral shift or nuclide density saturation. Observing the causes for the shortcomings in the PDA method, a more robust methodology can be developed.

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An electrolytic cell was designed, built, and tested with several proof-of-concept experiments in which Zircaloy material was charged with hydrogen in order to generate zirconium hydride formations. The Electrolytic Charging with Hydrogen and a Thermal Gradient (ECH-TG) system has the ability to generate static 20°C to 120°C temperatures for a H2SO4 and H2O bath for isothermal experiment conditions. This system was designed to accommodate a molten salt bath in future experiments to achieve higher isothermal temperatures. Additionally, the design accommodates a cartridge heater, which when placed on the inside of the sample tube, can be set at temperatures up to 350 °C and create a thermal gradient across the sample. Finally, a custom LABVIEW VI, L2.vi, was developed to control components and record data during experimentation. This program, along with web cameras and the commercial StirPC software package, enables remote operation for extended periods of time with only minor maintenance during an experiment. While proving the concept for this design, 19 experiments where performed, which form the basis for a future parametric study. Initial results indicate formations of zirconium hydrides which formed rim structures between 8.690 +/- 0.982 μm and 12.365 +/- 0.635 μm thick. These electrolytically produced rims were compared with hydrides formed under a previous vapor diffusion experiment via Scanning Electron Microscope (SEM) imaging and Energy dispersive X-ray Spectroscopy (EDS) analysis. While the existing vapor diffusion method formed gradients of zirconium hydride, it failed to produce the gradient in the correct direction and also failed to create a hydride rim. The successful use of the ECH-TG system to create said rim, and some of the methods used to direct that rim to the OD of the tube can be used for future work with the vapor diffusion method in order to create zirconium hydrides of the correct geometry. The procedures and apparatus created for this project represent a reliable method for creating zirconium hydride rim structures.