ORNL-4123.txt

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ORNL-4123
UC-25 — Metals, Ceramics, and Materials

MSRE CONTROL ELEMENTS: MANUFACTURE,
INSPECTION, DRAWINGS, AND SPECIFICATIONS

G. M. Tolson
A. Taboada

OAK RIDGE NATIONAL LABORATORY
CENTRAL RESEARCH LIBRARY
DOCUMENT COLLECTION

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OAK RIDGE NATIONAL LABORATORY

operated by
UNION CARBIDE CORPORATION
for the

’ U.S. ATOMIC ENERGY COMMISSION
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Contract No. W-7405-eng-26

METALS AND CERAMICS DIVISION

MSRE CONTROL ELEMENTS: MANUFACTURE,
INSPECTION, DRAWINGS, AND SPECIFICATIONS

¢. M. Tolson and A. Taboada

JULY 1967

OAK RIDGE NATIONAL LABORATORY
Oak Ridge, Tennessee
operated by
UNION CARBIDE CORPORATION
for the
U.S. ATOMIC ENERGY COMMISSION

ORNL-4123

HEED MARTIN ENERGY RESEARCH LIBRA|

LOCK RIES

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Abstract .

Introduction .

Development of Specification
Component Manufacture
Control Element Assembly .
Summary

Appendix A . . . .

Appendix B . . . . - . .
Appendix C . « « « « + .« =

iii

CONTENTS

and Fabrication Methods .

Page

o o v

11
35
39
MSRE CONTROL EIEMENTS: MANUFACTURE,
INSPECTION, DRAWINGS, AND SPECIFICATIONS

G. M. TolsonT and A. Taboada?

ABSTRACT

The control elements for the Molten Salt Reactor are
Gd,03-A1503 bushings canned in Inconel. The report includes
material selection and development of fabrication methods.
The can was made from fully inspected Inconel closed by four
TIG welds. The Gd203-A1,03 bushings were made by conventional
pressing and sintering methods after a special prereaction
step was used. The bushings were given thermal shock tests,
weighed, dimensionally inspected, and given a final visual
inspection for chips or cracks. As-built drawings, specifi-
cations, and manufacturing procedures are included. By
methods described in this report, 160 MSRE control rod
elements were manufactured.

INTRODUCTTION

The Molten Salt Reactor Experiment (MSRE) is a high-temperature
(675°C) low-pressure (50 psi) system designed to provide a thermal out-
put of about 10 Mw. A fuel mixture of LiF-BeF.-ZrF,-Ur,; is circulated
through a cylindrical 5-ft-diam reactor vessel {containing a graphite
core) to a heat exchanger, where heat is transferred to an unfueled
fluoride salt and then to the atmosphere. The control elements are
Gd,03—30% Al1,03 bushings clad with Inconel as shown in Fig. 1. They are
about 1 1/2 in. long with an inner diameter slightly larger than 3/4 in.
and a wall thickness of about 3/8 in. The MSRE has three control rods,
each of which has 36 control elements strung on a flexible stainless steel
hose to form a 56-in.-long control rod. The flexibility of the control

rod prevents binding due to misaligmment or thermal expansion. Although

1Present Address, Oak Ridge Gaseous Diffusion Plant.

“Present Address, Division of Reactor Development and Technology,
USAEC, Washington, D. C.
UNCLASSIFIED
ORNL-DWG 64-1105R

TOP CLOSURE

BUSHING

BOTTOM
CLOSURE

INNER TUBE

OUTER TUBE

Fig. 1. A Cutaway of an MSRE Control Element.

cooling air will be blown down the inside of the flexible hose and
control element and then back up over the outside of the element, the
element must be designed to withstand the temperature generated at full

power without cooling, about 815°C. )

DEVELOPMENT OF SPECIFICATION AND FABRICATICN METHODS .

To prove the feasibility of the control rcd design, four prototype
elements were manufactured on a research contract with Dresser Products.
The prototype elements differed from the final element in that the pro-
totype pellets were produced by hot pressing and were canned in stainless
steel rather than Inconel. The prototype elements were subjected to
x-ray, penetrant, and dimensional inspection and to testing that included
exposure in a rig3 designed to determine under simulated reactor
conditicns soundness, dimensional stability, and general suitability for

reactor use.

3R. B. Briggs et al., MSR Program Semiann. Progr. Rept., Jan. 31, 1964,
ORNL-3626, pp. 29-31.

In the control-rod testing rig, two canned elements were exposed To
repeated thermal and mechanical shocks. They were examined radiograph-
jcally and dimensionally after 24, 350, and 600 hr of testing that
included approximately 11,000 cycles and 1700 scrams. Holes were made
in one can to expose the Gdz03-Al03 to air for the final 250 hr of
testing.

Dimensions of the metal cans were not altered by the testing. Axial
cracks in the pellets were observed radiographically after the first
cycle, and severe cracks in both the axial and transverse directions were
observed at later stages. However, no crumbling or ratcheting was evident,
and no condition was observed that might affect the nuclear or mechanical
performance of the control rod elements.

Inconel was chosen as a canning material for the poison bushings
because of its high-temperature strength, good weldabllity, and
availability. Inconel was chosen over stainless steel for the following
reasons:

1. TInconel will not catastrophically oxidize, while many stainless
steels will under certain conditions.*

2. TInconel will not stress-corrosion crack.

3. TInconel is more resistant to nitric acid attack than is sensi-
tized stainless steel. Nitric acid can form in radiation fields by
reaction of the nitrogen and water vapor in the air.?

4. If salt should leak into the control element, Inconel would
have better corrosion resistance than stainless steel.

Although there was only a slight possibility that these conditions
might occur, the small cost factor in favor of stainless steel did not
warrant the risk involved.

Boron and boron-containing materials were ruled out as poison mate-

rials, since under certain conditions they react with stainless steel

7. H. DeVan, Catastrophic Oxidation of High-Temperature Alloys,
ORNL-TM-51, (Nov. 10, 1961).

57. J. Stobbs and A. J. Swallow, "Effects of Radiation on Metallic
Corrosion,” Met. Rev. 7(25), 95-131 (1962).

and nickel-base alloys. In addition helium is one of the products when
boron is irradiated, which would require a venting system on the element
or design for high internal pressure. A rare earth oxide was chosen as
the poison material on the basis of work done by ORNL® and Knolls Atomic
Power Laboratory7 and irradiation testing by General Electric on
dysprosium oxide mixtures.®

Since the cross section of dysprosium oxide was not sufficiently
high, the cholce of materials was betwsen Gd»03 and Eus03. Gadolinium
was chosen because 1t was from one-third to one-fourth less expensive
than Eup03. Because pure gadolinium oxide reacts with water in the air,
it was diluted with aluminum oxide. A series of tests was run in boiling
water and water-saturated air at 700°C to determine the aluminum oxide
content needed. Although 20% Alp03 performed satisfactorily, 30% Al1504
was chosen as added protection.

To prevent the "self welding" of the elements during operation, a
preoxidation was specified. It was necessary to perform this operation
on the finished element to avoid contamination of the closure welds.

From experience gained in the manufacture of the prototype control
rods, specifications (Appendix A) and drawings (Appendix B) were prepared.
Quotations were obtained from several control rod manufacturers and were
carefully evaluated. The prime contract for manufacturing the control

elements was awarded to Westinghouse Atomic Power Division.

COMPONENT MANUFACTURE

The top and bottom closures were machined from Inconel bar stock.
The inner and outer tubes were made from tubing drawn to the correct

size. The manufacture and inspection procedures for the Inconel parts

°C. F. leitten, Jr., The Stability of Europium Oxide in Silicon-
Bearing Stainless Steel, ORNL-2946 (Aug. 9, 1960) .

7G. L. Ploetz et al., "Dysprosium Oxide Ceramics," J. Am. Ceram.
Soc. 43, 154—59 (1960).

8F. m. Megerthand and D. L. Zimmerman, VBWR Irradiation of Reactor
Control Materials in Tubes Containing Simulated Defects, GEAP-3927
(June 1963).

B Tt U S N S PR JETER AN i B s e : NENRR T

are given in Appendix A. 1In the case of the tubing, the ORNL Tubing
Specification (JS-81-183, Part II) was rewritten by the vendor, who
added additional manufacturing requirements and purchased the material
from a tubing vendor. The tubing vendor performed the inspection and
certified the material to ORNL specifications. In the case of the bar,
Westinghouse purchased the material to ASTM specification, performed the
necessary inspection, and certified to the ORNL specification (J5-81-183,
Part III). In both cases, the material was inspected by ultrascnic and
penetrant methods as raw stock and examined by penetrant methods after
final machining. All of the raw material had certified chemical analyses
and mechanical properties, and samples of each heat of material were
retained. A flowsheet for cladding components is given in Appendix C,
Procedure 1.

The Gdp03-A1,03 bushings for the prototype control element were hot
pressed, but Westinghouse proposed to manufacture the production bushings
by conventional pressing and sintering. In work performed previously at
ORNL, a chemical reaction occurred at 1650°C, and the pellets became
severely distorted; at 1750°C they melted.® Westinghouse could manufac-
ture bushings that would meet the specifications except that they were
so hygroscopic that they dissolved in boiling water. Experiments at ORNL
showaed that bushings could be made that were not hygroscopic by prereacting
the powder at 1650°C and then pressing and sintering.9 To manufacture a
bushing that would not react with water, Westinghouse used a prereacting
step on all production bushings.

The manufacturing procedure used for the bushing is outlined in
Appendix C, Procedure 2. The process started with mixing the Al;03 and
Gd,05 powder, pressing, and prereacting at 1700°C. The reaction products
were crushed, ball-milled, sized, pressed into bushings, presintered,
and then sintered at 1450°C. Bushings made by this method were boiled
in water for 48 hr without any appreciable weight loss. Fach bushing

was then given a thermal shock test by heating to 1400°C and quenching

9R, B. Briggs et al., MSR Program Semiann. Progr. Rept., July 31,
1963, ORNL 3529, p. 78.

in water. After surface grinding, the bushings were visually inspected
for chips or cracks. Bushings were rejected if they had chips longer
than 1/8 in. or deeper than 1/32 in. Each bushing was weighed and dimen-
sionally inspected with go-no-go gages. The content of Gd,053 was also
determined spectrographically for each batch.

Three bushings were selected for each control element so their
combination would yield the proper stack height and total weight of
Gdz03. The Gdp03 content was computed from the weight of the bushing
and the results of the spectrographic analysis for Gdo03.

Experience showed that even after a 150°C bake, the bushings could
actually release enough gas to bulge the Inconel can during the pre-
oxidation of it. To prevent bulging, it was necessary to outgas the

bushings at 815°C before loading.

CONTROL ELEMENT ASSEMBLY

Before production assembly, welding procedures were written and
qualified for each of the four weld joints required in a control element.
It was necessary that the procedures consistently produce a defect-
free weld with a minimum of 0.20 in. penetration. The weld must not
contain buildup or distort the can sufficiently that the element would
not pass final dimensional inspection. Appendix C, Procedure 3, gives
the welding procedure used, and Fig. 2 shows sections through typical
top and bottom welds. If the outer fop weld was made last, the weld
would blow out due to buildup of gas pressure inside the element. IT
The inner bottom joint was welded last, no difficulty was encountered.
This was probably because less gas was heated during welding as a result
of the configuration of the weld joint (see Fig. 2).

The assembly is described in Appendix C, Procedure 4. After both
top welds were made, the bushings were loaded into the subassembly in
a helium-filled dry box, and the bottom closure was pressed into place.
The final two bottom welds were then made. The element was then dimen-
sionally inspected with go and no-go gages, and, if necessary, excess

weld buildup was removed. An identification number was electro-etched

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Innef Weld

L.

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FRER ' Outér Weld

X » : '. 2 _A;‘:_{:‘é_;.'. . :
_Inner Weld

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Fig. 2. Sections Through Closure Welds on MSRE Control Elements.
Top closure. (b) Bottom closure.

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Fig. 3. Radiographic of MSRE Control Elements, Showing Cracked
Bushings.

into each of the elements, and each part used in the manufacture of
that element was recorded. The element was given a careful visual inspec-
tion, helium leak checked, and inspected at the welds with post-
emulsified fluorescent penetrant. To prevent self-welding of the seg-
ments or components during service, the elements were oxidized by heating
to 927°C. They were then given a final visual and dimensional inspection,
packaged, and shipped.

During receiving inspection at ORNL, radiographic examination
(see Fig. 3) revealed that 51 of the elements contained cracked bushings.
These cracks had developed during welding or during preoxidation. Since
tests on the prototype element showed the bushings would crack during
the first few reactor cycles in any event, the elements were accepted.

The control elements that will be used in the MSRE were run in the
control rod test facility for a total of 2000 cycles. No dimensional
changes were noted. The elements were then put into position in the

MSRE, where they are presently operating.

SUMMARY

By the methods described in this report, 160 MSRE control rod
elements were successfully manufactured. Figure 4 shows a group of the

finished elements.

@10 anon. m Y-55882

" - s S

Fig. 4. Three MSRE Control Elements.

g R ) A R L iy S e L e b et W T

APPENDIX A

Master Specification for the Control Rod Elements for the
Molten Salt Reactor

Tentative Specification for Seamless Inconel Tubing for
Molten Salt Reactor Control Rods

Tentative Specification for Inconel Rods for the Molten
Salt Reactor Control Rod

Tentative Specification for Gadolinium Oxide — Aluminum
Oxide Bushings for Molten Salt Reactor Experiment

13

23

27

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PRI T S Tt SRR e ERpTe

13

MSR CONTROL ROD SPECIFICATION Spvec. No. JS-81-183

METALS AND CERAMICS DIVISION Part T

OAK RIDGE NATTONAL LABORATORY Date: September 21, 1962
Page 1 of 10

Union Carbide Nuclear Company
A Division of Union Carbide Corporation
Oak Ridge, Tennessee

Subject: MASTER SPECIFICATION FOR THE CONTROL ROD ELEMENTS FOR THE

MOLTEN SALT REACTOR

IT.

ITT.

SCOPE

This specification covers the control rod elements for the Molten
Salt Reactor. The element consists of Inconel-clad gadolinium oxide-
aluminum oxide bushing.

REFERENCES

A. JS-81-183, Part II, "Tentative Specification for Seamless Inconel
Tubing for Molten Salt Reactor Control Rods"

B. JS-81-183, Part III, '"Tentative Specification for Inconel Rods
for the Molten Salt Reactor Control Rod"

C. JS-81-183, Part IV, '"Tentative Specification for Gadolinium
Oxide-Aluminum Oxide Bushings for the Molten Salt Reactor
Experiment.

D. ASTM Designation: E 2 — 49 T, "Methods of Preparation of
Micrographs of Metals and Alloys"

E. ASTM Designation: E 3 —58 T, "Methods of Preparation of
Metallographic Specimens"”

F. Mil-C-19874 (Ships), 14 May, 1957, "Military Specification
Cleaning Reguirements for Nuclear Primary Coolant Eqaipment
Including Piping Systems"

G. MET-NDT-4, Revision 2, "Tentative Methods for Liquid-Penetrant
Inspection”

H. Dwg. D-BB-B40600, "MSRE Control Rod Assembly and Details”
MANUFACTURING REQUIREMENTS

The elements shall be manufactured in accordance with ORNL-DWG 64-1104,
64-1107, 64-1108, and 64-1106 and in accordance with this
specification.

14

MSR CONTROL ROD SPECIFICATION Spec. No. J5-81-183
METALS AND CERAMICS DIVISION Part I
OAK RIDGE NATIONAL LABORATORY Date: September 21, 1962

Page 2 of 10

Subject: MASTER SPECIFICATION FOR THE CONTROI: ROD ELEMENTS FOR THE
MOLTEN SALT REACTOR

IV. MATERTALS
Each element shall consist of the following components:

Item ORNL DWG. Specification
No., Component Material No. No. Quantity
1 Bushing  Gd,03—Al1,0;5 64.-1108 MET-RM-C 301 1
2 Inner Tube  Inconel 64-1104 J5-81-183, 1
Part II
3 Outer Tube  Inconel 64-1107 J8-81-183, 1
Part TT
2 Top Closure Inconel 64-1106 JS5-81-183,% 1
Part IT1I
5 Bottom Inconel 64-1106 JS-81-183,% 1
Closure Part TIT

V. WELDING REQUIREMENTS

A. The closures shall be joined to the inner and outer tube by
means of a fusion weld made by the TIG process.

B. All welds shall have a minimum of 0.020-in. penetration and
determined according to Section XI of this specification.

C. The welds shall be tight so that no leak will be detected by
a mass spectrometer calibrated to detect a standard helium
leak of 7 x 10-? std cc/sec at room temperature, as specified
in Section VIIT of this specification.

D. Each closure weld shall be free of surface cracks, surface
porosity, or craters that can be detected visually or with the
aid of dye penetrant as specified in Sections XIV and IX of
this specification.

E. Each weld shall be smooth, bright, and free of contamination
as determined by visual inspection.

VI. WELD QUALIFICATION
A. The welding procedure shall be submitted to the Company for
approval. No qualification will be performed before the
Company has approved the welding procedure.

B. DNo production welding shall be performed before the welding
procedure has been qualified.

*The closure may be manufactured from heavy wall tubing in
accordance with JS-81-183, Part II at the seller's option.

b o Bl ARSI e s . - © e e v o Bt R e S TR, it e G e ) e G e e 4

15

MSR CONTROL ROD SPECTIFICATION Spec. No. JS5-81-183
METALS AND CERAMICS DIVISION Part 1
OAK RIDGE NATIONAL LABORATORY Date: September 21, 1962

Page 3 of 10

Subject:

MASTER SPECIFICATION FOR THE CONTROL ROD ELEMENTS FOR THE
MOLTEN SALT REACTOR

WELD QUALIFICATION (Continued)

C.

D.

The welding procedure shall be gqualified by making three
welds of each type.

The welding parameters on the gualification test shall be
set to give the minimum penetration with the range of
parameters allowed in the procedures.

Qualification welds shall meet the requirements of Section V
of this specification and shall be inspected in accordance
with Sections XIV and IX of this specification.

A1l qualification welds shall be sectioned by the Seller
longitudinally through the weld area at approximately 90-deg
intervals, thus permitting four penetration measurements on
each weld. (One section shall be made at the location where
welding was stopped.) One half of the sample elements shall
be sectioned at the initial closure weld and the remainder at
the final weld. The sections shall be prepared for examination,
metallographically measured, and photographed as specified in
ASTM Designations: E 2 — 49 T and E 3 — 58 T unless other-
wise specified in this specification. The photographs shall
become the property of the Company and shall be delivered with
or prior to final shipment.
1. The sections shall be free of cracks.
5. The sections shall be free of voids, porosity, or inclusions
greater than 0.005 in. in their largest dimension.

VII. INTERNAL ATMOSPHERE

A.

The atmosphere within the welded element shall not exceed
atmospheric pressure by more than 2 psi at room temperature.

The atmosphere within the welded element shall contain at
least 50% He.
16

MSR CONTROL ROD SPECIFICATION Spec. No. J5-81-183

METALS AND CERAMICS DIVISION Part T

OAK RIDGE NATTIONAL LABORATORY Date: September 21, 1962
Page 4 of 10

Subject: MASTER SPECIFICATION FOR THE CONTROL ROD ELEMENTS FOR THE
MOLTEN SALT REACTOR

VITI. IEAK TEST

A. Each element shall be helium-leak tested before penetrant B
inspection or oxidation is performed. Helium-leak testing
shall be carried out in accordance with the following
procedure: .

1. ©Scope: This section applies to the bell-jar method of
testing the assembled, helium-containing elements after the
final closure weld has been accomplished.

2. Reference: The Manufacturer's operating manual for the
particular instrument used in the inspection.

3. Equipment: A mass-spectrograph type, helium-sensitive
instrument, similar to the Veeco Type MS-9 or Consolidated
Engineering Corporation Type 24-110, which includes the
following as incorporated in the instrument or as additions
or modifications:

a. A cold trap (liquid nitrogen or liquid air).
b. A helium-leak source of 7 x 10-? stad ce/sec.

c. An external or auxiliary roughing vacuum pump
connected to the instrument manifold and to the specimen -
or test chamber through a vacuum valve.

d. A throttling or modulating valve between the instru- .
ment manifold and the instrument.

e. A low-pressure supply of helium with a nozzle less
than 1/16 in. in diameter for use in checking for leak-
tight connections.

f. One or more leak-tight chambers, each of which is

capable of accommodating an element for the final closure
weld inspection and having no less than 3/8-in. diametral
clearance between the element and the wall of the chamber.

4. Technical Requirements:

a. The instrument sensitivity shall be such that the
stable signal from the standard leak, as determined in
Section VIIT A5c of this specification, is at least two
times as large as the signals produced by background noise.

17

MSR CONTROL ROD SPECIFICATION Spec. No. JS-81-183

METALS AND CERAMICS DIVISION Part T

OAK RIDGE NATTONAL LABORATORY Date: September 21, 1962
Page 5 of 10

Subject: MASTER SPECIFICATION FOR THE CONTROL ROD ELEMENTS FOR THE
MOLTEN SALT REACTOR

IEAK TEST (Continued)

b. The inspection shall be performed in a force-ventilated
location to facilitate the removal of any helium background.

c. The connecting lines between the test chamber and the
instrument manifold shall be as short as is practical and
should have a minimum inside diameter of 1/2 in. All
connections shall be leak-tight.

d. Care shall be exercised to avoid plugging leaks with
any sealant prior to attempted detection with helium.

e. All assembled elements shall be either helium-leak
tested within 48 hr after the final closure weld is completed
or stored in a helium atmosphere of pressure equal to or
greater than the internal pressure of the element until such
time as they can be helium-leak tested. If an element is to
be retested or if the testing procedure is interrupted, as
in Section VITIIA5-a, -f, and -g of this specification, the
element shall be stored in a helium atmosphere as described
until such time as testing can be completed. No assembled
element shall be allowed to remain in a non-helium atmo-
sphere for more than a total of 48 hr between the time

of its assembly and the completion of helium-leak testing.

5. Testing Procedure:

5. The performance of the leak-detector equipment shall
be verified after each inspection. If at any time this
equipment fails to function properly as described in the
Manufacturer's operating manual, and/or if the sensitivity
as determined in Section VIIIA5c of this specification
decreases below the minimum level prescribed in Section
VIIIA4a, the equipment shall be readjusted to function as
specified and recalibrated, and all elements which have
been inspected during the interim since the last satis-
factory performance verification of the equipment shall
be inspected again.

i
R e N, R T T 1, 1 i A w1 S A < R~

18

MSR CONTROL ROD SPECIFICATION Spec. No. JS5-81-183

METALS AND CERAMICS DIVISION Part T

OAK RIDGE NATTONAL LABORATORY Date: September 21, 1962
Page 6 of 10

Subject:

MASTER SPECIFICATION FOR THE CONTROIL ROD ELEMENTS FOR THE
MOLTEN SALT REACTOR

IEAK TEST (Continued)

b. The element shall be inspected as follows: The
assembled, helium-containing elements shall be inspected
after the final closure weld has been accomplished by
placing the element in the inspection chamber, evacuating
the chamber, and searching for helium leaks as prescribed
in the instrument Manufacturer's operating manual.

c. The instrument shall be calibrated as follows: The
standard leak source (7 x 10-? sta ce/sec) shall be
connected to one end of the test chamber. The opposite
end of the test chamber shall be connected to the manifold,
and the time which is required to produce a signal two
times as large as the background noise shall be measured.
This measurement shall be accomplished while examining a
100% sample from the test chamber and with all valves
between the standard leak source and the helium-sensing
device completely open. This portion of the calibration
shall be continued until the signal from the standard lezk
reaches a stable amplitude. The signal amplitude and
manifold pressure shall be measured at this point.

d. The inspecticn shall be made taking a sample from the
test chamber. All valves between the element and the
helium-sensing device shall be completely open and the

time of inspection shall be no less than one minute and at
least twice as long as the time, as determined in Section
VIIIASc of this specification for that particular method,
required for the standard leak to produce a signal two times
as large as the background noise.

e. The manifold pressure at which the inspection is made
shall be the same as the pressure at which the instrument
is calibrated, as measured in Section VIIIA5c of this
specification.

f. Bxcessive pump-down time shall be indicative of an
external leak. The leak shall be located and corrected
before further testing is accomplished.

19

MSR CONTROL ROD SPECTFICATION Spec. No. JS-81-183

METALS AND CERAMICS DIVISION Part I

OAK RIDGE NATIONAL LABORATORY Date: September 21, 1962
Page 7 of 10

Subject:

MASTER SPECIFICATION FOR THE CONTROL ROD ELEMENTS FOR THE
MOLTEN SALT REACTOR

LEAK TEST (Continued)

IX.

g. During the inspection, any signal which produces an
indication two times as large as the background noise
level shall be indicative of a through path or leak in
the element being inspected and that element shall be
rejected. If more than one assembled element is being
inspected at the time a leak is detected, the elements
shall be inspected again such that the leaking element or
elements are identified and rejected.

h. All rejected, assembled elements shall be disassembled.
Any salvageable parts of the rejected elements may be
reused in the assembly of other elements. A salvageable
item is one that is reinspected and found to conform to
the specification.

PENETRANT INSPECTION OF ELEMENT

Bach element shall be 100% examined for discontinuities by means
of penetrant inspection in accordance with MET-NDT-4, Revision 2.
The process times shall be that listed in Table 2 of NDT-4 for
"All forms with machine finish 125 rms or better.” The penetrant
inspection shall be performed before the elements are oxidized and
before the elements are leak tested.

SURFACE OXIDIZING REQJIREMENTS

A.

The outer surface of the closures shall be oxidized with a
black, adherent high-temperature oxide film to prevent self-
welding of the elements. The entire outer surface of the
element may be oxidized.

The process and procedure utilized by the Seller to provide the
oxide coating on the required surfaces shall be subject to the
Company's approval.

For each oxidizing operation, the Seller shall include a control
sample for testing purposes. The sample shall be material of
identical size and composition to that specified for the closure.
The sample shall be processed with and shall receive the same
treatment as the production parts. The samples shall become

the property of the Company and shall be delivered with or

prior to final shipment.
20

MSR CONTROL ROD SPECIFICATION Spec. No. J5-81-183
METALS AND CERAMICS DIVISTION Part 1
OAK RIDGE NATTONAL LABORATORY Date: September 21, 1962

Page 8 of 10

Subject: MASTER SPECIFICATION FOR THE CONTROL ROD ELEMENTS FOR THE
MOLTEN SALT REACTOR

XI. DESTRUCTIVE TEST OF WELDMENT

A. A sample of 1% of the elements will be selected by the Company's
inspectors. The sample may be selected immediately after
welding or after all nondestructive testing has been performed
at the Seller's option.

B. All the welds on the elements selected for test will be
sectioned, examined, and photographed in accordance with
Section VIF of this specification. The photographs and
sectioned samples shall become the property of the Company
and shall be delivered with or prior to final shipment.

C. The sections shall be free of cracks. The sections shall be
free of porosity or other inclusions greater than 0.005 in.
in their largest dimension.

D. The welds shall show a minimum of 0.020-in. penetration on
all sections.

E. If one or more elements of the 1% random sample are rejected,
then double the number of elements shall be selected for
testing. If one or more of the second group are determined
to be rejectable, then the entire lot will be considered
rejectable and the Seller will be responsible for initiation
of corrective action. After initiation of corrective action,
sampling shall again go into effect as described above.

XITI. DIMENSTIONAL INSPECTION

A, After oxidization, the elements shall be inspected for inside
and outside diameter and length, using the following gages:

Length
Inspection Go Gage No Go Gage of Gage
Ares (in.) (in.) (in.)
1D 0.785 min 0.795 max 1 3/4 min
oD 1.150 max 1.130 min 1 3/4 min

Length 1.578 max 1.547 min
B. The gages shall become the property of the Government.

Any reworking performed on the element to pass the above test
must be approved by the Company.

21

MSR CONTROL ROD SPECTFICATTION Spec. No. JS5-81-183
METALS AND CERAMICS DIVISION Part T
OAK RIDGE NATTONAL LABORATORY Date: September 21, 1962

Page o of 10

Subject:

MASTER SPECTFICATION FOR THE CONTROL ROD ELEMENTS FOR THE
MOLTEN SALT REACTOR

XITT. TDENTTIFICATION AND RECORDS

A.

Tmmediately after assembly, each element shall be given an
identifying number. The number shall be marked on each element
by means of an electrolytic etch.

The Seller shall be responsible for maintaining a complete
record of all materials and process treatments which are
required in the fabrication of the completed element. The
information to be included shall be such as the following:
heat numbers, batch or blend numbers, process numbers, weight
and density of the Gd,03-A1,03, inspection results, test
results, dimensional measurements, and process treatments. A
complete report of all such data on each element shall be
furnished in five copies to the Company prior to shipment of
the completed elements. Additionally, the Seller shall submit
to the Company five copies of certified chemical analyses,
physical properties data, and such other test reports as are
required in the individual component specifications immediately
upon receipt of these or upon completion of fabrication in
his shop.

The maintenance and submission of these records along with a
certificate of compliance that the elements conform to the
requirements of this specification shall be a condition of
acceptance of the elements.

The Seller shall submit to the Company for information any
internal proceduresgs used in the manufacture of the elements
or any specification written for a subvendor, provided the
information is not considered proprietary.

XIV. VISUAL INSPECTION

A.

Each element will be given a careful visual inspection by a
qualified inspector under 100 footcandles Just prior to
shipment.

Any visual indication questioned by the Company's inspector
must be removed. If the element will not meet any provision
of the specification after removal of the indication, the
element shall be rejected. After removal of the indication,
the element will be completely inspected.
22

MSR CONTROL ROD SPECIFICATION Spec. No. JS-81-183

METAIS AND CERAMICS DIVISION Part 1

OAKX RIDGE NATTIONAIL LABORATORY Date: September 21, 1962
Page 10 of 10

Subject: MASTER SPECIFICATION FOR THE CONTROL ROD ELEMENTS FOR THE
MOLTEN SALT REACTOR

VISUAL INSPECTION {Continued)

C. The element shall be free of o0il, grease, dirt, or other
foreign matter as specified in Mil-C-19874%.

XV. SAMPLES

A. Samples from each lot of Inconel material used in the element
shall be furnished by the Seller with or prior to final
shipment.

XVI. FINAL: INSPECTION
Final inspection will be performed at Oak Ridge by the Company.

23

REACTOR MATERIAY, SPECIFICATION Spec. No, JS-81-183
METALS AND CERAMICS DIVISION Part IT

OAK RIDGE NATTONAL LABORATORY Date: September 21, 1962
Page 1 of 4

Union Carbide Nuclear Company
A Division of Union Carbide Corporation
Oak Ridge, Tennessee

Subject: TENTATIVE SPECIFICATION FOR SEAMIESS INCONEL TUBING FOR MOLTEN
SALT REACTOR CONTROL RODS

1. (a) ‘This gspecification covers seamless Inconel tubing for the
control rod elements for the Molten Salt Reactor.

Tubing shall be produced in strict accordance with require-
ments for the specified grade of Tentative Specifications for
Nickel-Chromium-Iron Alloy Seamless Pipe and Tube (ASTM
Designation: A 167 — 61 T) except as modified herein.

ASTM A 167 — 61 T shall be considered part of this specification.
Modifications are arranged under corresponding headings,
sections, paragraphs, and table numbers of that standard.
Additional requirements are given under appropriate headings.

MANUFACTURE
4, (a) The tubes shall be cold-drawn and annealed
CHECK ANALYSIS

6. (b) A check analysis shall be made by the Manufacturer or Seller
on one tube from each lot of finished material.

SPECIAL REQUIREMENTS

15. (a) Ultrasonic testing shall be performed on all tubes as given
below:

(1) Technical Requirements: The tubing shall be inspected at
the completion of the manufacturing process. No drawing
operation shall be accomplished after the ultrasonic inspection.

(2) Inspection Equipment: The instruments and accessory
equipment shall be of the pulse-reflection type with sufficient
sensitivity to distinguish the reference notches as required
during calibration. The transducer employed shall have no
dimension greater than 1 in.
24

REACTOR MATERTIAL SPECTFICATION Spec. No. JS5-81-183

METALS AND CERAMICS DIVISION Part IT

OAK RIDGE NATTIONAL LABORATORY Date: September 21, 1962
Page 2 of 4

Subject: TENTATIVE SPECIFICATION FOR SEAMLESS INCONEL TUBING FOR MOLTEN
SALT REACTOR CONTROL RODS

SPECTAL REQUIREMENTS (Continued)

(3) Calibration Standards: A calibration standard shall be
prepared from tubing taken from the same heat and manufactured
by the same processes as the tubing to be inspected and shall

be free of defects; the tubing used for the calibration standard
shall be the same size as the tubing to be inspected and shall
be in the as-polished condition. A longitudinal reference notch,
1/4 in. long and with a maximum depth of 0.0025 in. (the depth
shall include the highest point of the metal due to upset,
although "deburring' is permitted), shall be machined on the out-
side and inside surfaces of the standard. The notch may be

made by the electric arc discharge method. If both reference
notches are on the same end of the standard, they shall be at
least 120 deg apart. The width of the reference notch shall

not exceed twice its depth. '

(4) Equipment Calibration: TUsing the calibration standard
specified in Section 15 (a) (3), the equipment shall be adjusted
to produce indications the same height from both the inside and
outside reference notches. The rejection alarm shall be
adjusted to signal at the indication of the lesser amplitude.

The equipment shall be calibrated at the same circumferential
speed and rate of translation (feed helix) of the crystal with
respect to the tube shall be the lesser of 3/8 in. per
revolution or 1/2 the crystal or collimator width or diameter.

(5) Inspection Procedure: The material shall be tested for
radial -type defects in both circumferential directions under
identical conditions which are used for calibration of the
equipment.

The equipment shall be recalibrated as specified in Section 15
(a) (3) after the inspection of 10 lengths of tubing or when
any adjustment to the equipment is made.

When significant adjustment of the equipment is required during
the calibration check (any time the inside and outside reference
notches do not present a rejectable signal), the preceding ten
tubegs shall be reinspected in accordance with Section 15 of

this specification.

25

REACTOR MATERTAL SPECIFICATION Spec. No., JS-81-183
METALS AND CERAMICS DIVISION Part IT
OAK RIDGE NATTONAL LABORATORY Date: September 21, 1962

Page 3 of 4

Subject: TENTATIVE SPECIFICATION FOR SEAMLESS INCONEL TUBING FOR MOLTEN

SATT REACTOR CONTROL RODS

SPECIAL REQUIREMENTS (Continued)

(6) Defects and Rejection: All indications of discontinuities
equal to or greater than the lesser indication of the reference
notches as described in Section 15 (a) (3) shall be considered
as defects and shall be rejected. If the defect is reworkable,
i1t may be removed and reinspected ultrasonically. Reworked
material shall conform to the dimensional requirements of this
specification.

(c) The material is intended for use in nuclear applications.

SURFACE FINISH AND WORKMANSHIP

16.

The finished tubing shall be free from oxide or scale and any other
foreign material.

The finished tubing shall be free of cracks, seams, laps, gouges,
tears, or other defects which exceed 0.002 in. Such defects of
less depth which have sharp contours shall be removed at request of
the Company.

Defects may be removed by grinding, provided the wall thicknesses
are not decreased to less than 0.018 in. Ground areas shall have
the same surface finish requirements as unground areas of the tube.
Ground areas shall merge smoothly with the adjacent surface.

MARKTNG

17.

Fach length of tubing shall be marked with the following information:

(1) Specification No. (JS-81-183),

(2) Lot number,

(3) Manufacturer's private identifying mark, and
(4) Heat number.

CERTIFICATION AND INSPECTION

18.

(b) The Seller shall submit to the Company the Manufacturer's
certified statement of compliance that all tubing conforms to
requirements of ASTM B 167 — 61 T and JS-81-183, Part II.
26

REACTOR MATERTAT, SPECIFICATTON Spec. No. J5-81-183
METALS AND CERAMICS DIVISION Part IT
OAK RIDGE NATIONAL LABORATORY Date: September 21, 1962

Page 4 of 4

Subject: TENTATIVE SPECIFICATION FOR SEAMLESS INCONEL TUBING FOR MOLTEN
SATT REACTOR CONTROL RODS

CERTIFICATION AND INSPECTION (Continued)

(c) The Seller shall submit the results of all required tests.
Each test report shall identify form, size, heat number, and
lot number. The following test reports shall be furnished by
the Seller:

(1) Chemical analyses (ladle and check),
(2) Tensile properties,

(3) Hydrostatic test, and

(4) Ultrasonic test.

(e) The Seller shall notify the Company five days in advance of
date set for test in order that the Company's inspector may be
present to witness ultrasonic inspection, to review test
reports, to check dimensions, and to visually inspect the
tubing.

27

REACTOR MATERTAL SPECTFICATION Spec. No. JS-81-183

METALS AND CERAMICS DIVISION Part TITT

OAK RIDGE NATTONAL LABORATORY Date: September 21, 1962
Page 1 of 3

Union Carbide Nuclear Company
A Division of Union Carbide Corporation
Oak Ridge, Tennessee

Subject: TENTATIVE SPECTFICATION FOR INCONEL RODS FOR THE MOLTEN SALT
REACTOR CONTROL ROD

SCOFE

This specification covers Inconel centerless-ground rods for the
Molten Salt Reactor.

The rods shall be produced in strict accordance with requirements

of the Tentative Specification for Nickel-Chromium from Alloy Rod

and Bar (ASTM Designation: B 166 — 61 T) except as modified

herein. ASTM B 166 — 61 T shall be considered part of this specifi-
cation. Modifications are arranged under corresponding headings,
sections, paragraphs, and table numbers of that standard. Additional
requirements are given under other appropriate headings.

MANUFACTURER

4. (a) The rod shall be hot-worked, annealed, and centerless-ground.

(b) Dimensional requirements are at the Seller's option. Finished
parts must be in accordance with Dwg. D-BB-B40600.

SAMPLES FOR CHEMICAL ANALYSIS

6. (b) A check analysis shall be made by the Manufacturer or Seller on
each lot of finished material.

SPECIAL REQUIREMENTS

16. (a) An ultrasonic test will be performed as follows:

1. The reference standard shall consist of two 1/16-in.-diam
flat-bottomed holes positioned at least 2 in. apart, one of
which shall be drilled to a depth of one-fourth of the bar
diameter and the other to a depth of three-fourths of the bar
diameter; a 1/32-in.-diam hole drilled to a depth of at least
3/4 in. into the end of the standard, parallel to the axis,
and at a distance of one-fourth of the bar diameter from the
axis; and a notch 0.005 in. in depth (of optional cross
section) cut parallel to the longitudinal axis.

2. The reference standard shall be made from bar material
similar to the bars under test in size, type, temper, form,
and surface finish.

3. All surfaces, except the ends, shall be scanned in a cir-
cumferential direction with a minimum overlap of 50% of the
crystal width and at a surface speed not to exceed 6 in./sec.
28

REACTOR MATERTIAL SPECIFICATION Spec. No. JS-81-183
METALS AND CERAMICS DIVISION Part II1
OAK RIDGE NATTONAL LABORATORY Date: September 21, 1962

Page 2 of 3

Subject: TENTATIVE SPECTFICATION FOR INCONEL RODS FOR THE MOLTEN SALT
REACTOR CONTROL ROD

SPECTAL REQUIREMENTS (Contirued)

L. The transducer shall be no larger than 3/4 in. in diameter.

5. The equipment shall be calibrated with the use of the
appropriate reference standard. Clear indications shall be
demonstrated from the flat bottom of each radial hole, from -
the side of the hole parallel to the axis, and from the side

of the reference notch. The response from the hole parallel

to the axis shall be discernible when the hole is rotated
approximately 90 deg from the crystal position. IT adequate
indications from all notches and holes can be demonstrated with

s single test setup, this shall be considered sufficient for

the required inspection. However, it may be necessary to make
separate inspection setups and calibrations to achieve the
specified sensitivity for a particular reference standard. The
amplitude of the back surface reflection at a reduced-sensitivity
setting shall be noted for determination of differences in
ultrasonic attenuation properties in the test material as com-
pared to the reference standard. The equipment shall be
calibrated at the same speed and rate of translation that will

be used for the inspection.

6. The maximum indication from any detected discontinuity

shall be related to the reference defect which is most nearly
comparable in regard to cross-sectional position and with the
reference and detected discontinuities being, as near as practi-
cal, the same distance from the transducer. Bars containing
discontinuities which produce indications equal to or greater
than the proper reference defect, after consideration of
differences in ultrasonic attenuation properties between the
standard and the test material, shall be rejected.

WORKMANSHIP AND FINISH

17. All defects shall be explored for depth. When the depth encroaches
on the minimum specified dimensions, the bar shall be rejected.

St ke Ere R LR e A 5 - iy i 5 R T LT T FR e ERTE TR CE N P
29

REACTOR MATERIAL SPECIFICATION Spec. No. JS-81-183

METALS AND CERAMICS DIVISION Part ITIT

OAK RIDGE NATIONAL LABORATORY Date: September 21, 1962
Page 3 of 3

Subject:

TENTATIVE SPECIFICATION FOR INCONEL RODS FOR THE MOLTEN SALT
REACTOR CONTROL ROD

CERTIFICATION AND INSPECTION

18.

(o)

(e)

The Seller shall submit to the Company the Manufacturer's
certified statement of compliance that all bars conform to the
requirements of ASTM B 169 — 61 and JS-81-183, Part III and
shall attach certified reports of results of all required
tests.

Each test report shall adequately identify the material as to
form, size, and heat number. The following reports shall be
furnished by the Seller:

(1) Chemical analyses (ladle and check),
(2) Tensile properties, and
(3) Ultrasonic test.

The Seller shall notify the Company five days in advance of
date set for the test in order that the Company's inspector
may be present to witness the ultrasonic and fluid-penetrant
tests, to check dimensions, to visually inspect the bars, and
to review the test reports.
30

NUCLEAR REACTOR SPECIFICATION Spec: JS-81-183, Part IV
METALS AND CERAMICS DIVISION Date: September 3, 1964
OAK RIDGE NATTONAIL LABORATORY Rev. No:

Page: 1 of 5

Union Carbide Nuclear Company
A Division of Union Carbide Corporation
Oak Ridge, Tennessee

Subject: TENTATIVE SPECIFICATION FOR GADOLINIUM OXIDE - ATUMINUM
OXIDE BUSHINGS FOR MOLTEN SALT REACTOR EXPERIMENT

I. GSCOFE:

This specification covers gadolinium oxide - aluminum oxide
(Gd203 - A1,05) bushings for use in control rods for nuclear
reactors.

II. REFERENCES:
ORNL Dwg. 64-1108.
III. MANUFACTURING REQUIREMENTS:

Individual gadolinium oxide - aluminum oxide (Gd,03 - A1,03) bushings
and stacks of bushings ready for canning shall be manufactured in
accordance with this specification.

IV. DEFINITIONS:

A. A lot of gadolinium oxide power consists of all Gd»04 powder
identified by the same lot number.

B. A lot of aluminum oxide powder consists of all Al,053 powder of
the same grade designation received at the same time.

C. A blend lot consists of all A1,05 - Gd,03 powder and recycles
sintered or green material which are mixed together at the
same time for pre-reacting. -

D. A pressing lot consists of all shapes pressed from a blend lot
to the same green density range.

E. A sintering lot consists of all shapes pushed through the
sintering furnace at the same time.

V. CHEMICAL COMPOSITION:

A. Starting aluminum oxide powder shall be 99.9% minimum purity
based on ignited weight and aluminum oxide content.

B. Starting gadolinium oxide powder shall be of 99.9% purity
based on ignited weight and rare earth content.

31

NUCLEAR REACTOR SPECIFICATION Spec: JS8-81-183, Part IV
METALS AND CERAMICS DIVISION Date: September 3, 1964
OAK RIDGE NATTIONAL LABORATORY Rev. No:

Page: 2 of 5

Union Carbide Nuclear Company
A Division of Union Carbide Corporation
Oak Ridge, Tennessee

Subject: TENTATIVE SPECIFICATION FOR GADOLINIUM OXIDE - ATUMINUM
OXIDE BUSHINGS FOR MOLTEN SALT REACTOR EXPERIMENT

V. CHEMICAL COMPOSITION: (Continued)

C. Finished shapes ready for canning shall consist primarily of
Al203 and Gd,03 or compounds thereof and shall have a completion
of 65—74 wt % Gd,03.

VI. DENSITY:

A. For purpose of density calculations, the following parameters
shall be used:

Theoretical density of Al,03 - 3.96 gm/cc
Theoretical density of Gdp0; - 7.407 gm/cc
Theoretical density 30% A1,03 - 70% Gdp,03 - 5.873 gm/cc
Theoretical density 29% A1,0, - 71% Gd,05 - 5.914 gm/cc
Theoretical density 28% Al,03 - 72% Gdy03 - 5.955 gm/cc

B. The sintered bushings shall have a minimum density of 95% of
theoretical.

C. A stack of bushings ready for canning shall have dimensions
falling within the envelope defined by ORNL-Dwg. 64-1108 and
shall weigh a minimum of 41.100 gms.

D. The total Gdp03 content of the stack shall be computed by
multiplying the stack weight by the average analyzed Gd,O3
content. The analyzed Gdp03 content is that obtained by analysis
of sintered bushings from each blend lot (Par. 9.b.3). If more
than one blend lot is represented in a stack of bushings, the
Gd203 content shall be computed for each bushing and the results
then summed to get the total stack Gd,03 content.

In either case the minimum total stack Gd,03 content shall be
no less than 28.770 gms.
32

NUCLEAR REACTOR SPECIFICATION Spec: JS-81-183, Part IV
METALS AND CERAMICS DIVISION Date: September 3, 1964
OAK RIDGE NATTIONAL LABORATORY Rev. No:

Page: 3 of 5

Union Carbide Nuclear Company

A Division of Union Carbide Corporation

Oak Ridge, Tennessee

Subject: TENTATIVE SPECIFICATION FOR GADOLINIUM OXIDE - ATUMINUM

OXIDE BUSHINGS FOR MOLTEN SALT REACTOR EXPERIMENT

Vil.

VIIT.

IX.

DIMENSIONS:

A. Not more than three bushings may be stacked to make an
assembly (stack) falling within the envelope defined Dy ORNL-
Dwg. 64-1108.

B. TIndividual bushings and stacks of bushings shall be shown in
ORNL-Dwg. 64-1108.

SURFACE FINISH AND CONDITION:

Chipping on the inner and outer cylinder surfaces shall not exceed
5% of the inner and outer cylindrical surface areas, respectively.
Chipping on the surface of each end of the bushings shall not
exceed 5% of the surface area of one end of the bushings. No
chipped area shall be greater than 1/16 in. in largest lateral
dimension nor greater than 1/32 in. deep. The finished material
shall be free of cracks.

TEST REQUIREMENTS:

A, Non-Destructive

1. Visual - All bushings shall be subjected to visual inspec-
tion under direct daylight-type fluorescent lighting of at
least 100 footcandles to insure conformance with this
specification.

2. Dimensional - All individual bushings shall be subjected
to dimensional inspection to determine conformance with
wall thickness variation requirements set forth in ORNL-
Dwg. 64-1108.

A1l stacks of bushings shall be subjected to dimensional
inspection to determine conformance with overall envelope
dimensions set forth in ORNL-Dwg. 64-1108.

3. Weight - All stacks of bushings shall be weighed to deter-
mine conformance with stack weight requirements set forth
under "Density'" above.

B. Destructive

1. A sample of each lot of aluminum oxide powder shall be
analyzed to determine conformance with purity set forth
under "Chemical Composition."

33

NUCLEAR REACTOR SPECIFICATION Spec: JS-81-183, Part IV
METALS AND CERAMICS DIVISION Date: GSeptember 3, 1964
OAK RIDGE NATTIONAIL LABORATORY Rev. No:

Page: 4 of 5

Union Carbide Nuclear Company
A Division of Union Carbide Corporation

Oak Ridge, Tennessee

Subject:

TENTATIVE SFECIFICATION FOR GADOLINIUM OXITE - AIUMINUM
OXIDE BUSHINGS FOR MOLTEN SALT REACTOR EXPERIMENT

IX. TEST REQUIREMENTS: (Continued)

2.

A sample of each lot of gadolinium oxide powder shall be
analyzed to determine conformance with purity set forth
under 'Chemical Composition".

Two sintered bushings from each blend lot (one each from
two different sintering lots) shall be broken into quarters
and two opposite quarters analyzed separately to determine
the Gdo03 content. The remaining quarters shall be
forwarded to the Company for check analysis.

X. CERTIFICATION AND INSPECTION:

A,

The Seller shall submit to the Company the certified statements
and reports required in Section 10 (b) of this specification.

Statements that the material complies with requirements of this
specification shall accompany the test reports which shall
include the following results:

1.

11 B LS UL T A8

.

Chemical analyses on starting virgin aluminum oxide powder
and starting virgin gadolinium oxide powder.

Chemical analyses on sintered bushings.
Visual inspection of sintered bushings.
Results of GO-NO GO ID and OD bushing inspection.

Individual heights and summation of heights of bushings in
each stack.

Bushing stack weight.

Remaining gquarters of sintered bushings Section 2.b.3. shall
be identified and supplied to the Company for check analysis.

The Seller shall notify the Company five (5) days in advance
of date set for starting of production testing in order that
Company's inspector may be present to witness testing.
34

NUCLEAR REACTOR SPECIFICATION Spec: JS5-81-183, Part IV
METALS AND CERAMICS DIVISION Date: September 3, 1964
OAK RIDGE NATIONAL LABORATORY Rev. No:

Page: 5 of 5

Union Carbide Nuclear Company
A Division of Union Carbide Corporation
Oak Ridge, Tennessee

Subject: TENTATIVE SPECIFICATION FOR GADOLINIUM OXIDE - ATUMINUM
OXIDE BUSHINGS FOR MOLTEN SALT REACTOR EXPERIMENT

XI. THERMAL CYCLE TEST:

A. A thermal cycle test shall be performed by the Seller on each
bushing from a temperature of 1475 * 25°F to room temperature
in 10 sec. The method of thermal cycling shall be as follows:

1. Heat Gd,03 - Al,03 bushings in air in a furnace operating
at 1475 t 25°F for at least the time necessary for the
bushings to approach the same color as the interior of the
furnace as judged by eye. As an alternative, bushings may
be placed in a cold or a warm furnace and both furnace and
bushings raised in temperature to a furnace temperature of
1475 * 25°F before bushings are removed (next step).

2. Remove bushings from furnace one at a time and quench
immediately in a container of cold tap water. Allow bushings
to remain in water for at least 1/2 min.

3. Dry bushings by air drying and/or heating for a minimum of
one hour at 25C°F or higher in air.

4, Inspect bushings for cracks.

Any bushings having cracks shall be rejected.

Fig.
Fig.
Fig.
Fig.

0 1 O W

APPENDIX B

Bushing and Bushing Stack Dimensions
Dimensions of Inner Tube
Dimensions of Outer Tube

Assembly and Closure of Control Element

37
37
38
38
Sl o 50

e

irs

gzt

LY.

S

prs

37

UNCLASSIFIED
ORNL - DWG 64 ~4108

0.010 MAX. PERMISSIBLE
" UARIATION IN WALL THICKNESS

—— 108025553 0D —==—

! |
|
| |
! |
I
. 1.315 MIN. | |
1.330 NOM. MAX, | |
l (SEE NOTE) | |
| | |
\ ! |
I 1 | A | |
| I | 04 TO | |
| { || 07 NoM | l
[ | I
i '<o.84o 1008 ID4
INDIVIDUAL BUSHING BUSHING STACK

NOTE:
TOTAL LENGTH SHALL BE DETERMINED BY THE DIMENSION
OF THE MINIMUM LENGTHS OF EACH BUSHING IN STACK. BUSHING
MINIMUM LENGTH TO BE DETERMINED BY INDICATING OUTER
PERIPHERY OF EXPOSED FLAT FACE OF BUSHING LYING ON FLAT
FACE, USING EQUIPMENT SIMILAR TO STARRETT BENCH GAGE NO.652.

DIMENSIONS ARE IN INCHES

Fig. B-1. Bushing and Bushing Stack Dimensions.

UNCLASSIFIED
ORNL -DWG 64 -1107

I I i | 1140 0D B
REF.
—_—
11465 NOM. DIMENSIONS ARE IN INCHES.
TOLERANCE: +0.002 U.0.S. NOTE:
0D AND ID TO BE CONCENTRIC NO SURFACE DEFECTS GREATER
WITHIN 0.002 TIR. THAN 0.002 DEEP PERMITTED

REMOVE ALL BURRS

Fig. B-2. Dimensions of Outer Tube.

38

UNCL ASSIFIED
ORNL-DWG 64-1104

et 4 537 NOM, ————— =]

DIMENSIONS ARE IN INCHES.

OD AND ID TO BE CONCENTRIC NOTE:
WITHIN 0.002 TIR. NO SURFACE DEFECTS GREATER
THAN 0.002 DEEP PERMITTED

Fig. B-3. Dimensions of Inner Tube.

UNCL ASSIFIED
ORNL-DWG 64-1106

ID TO GO OVER
0785 MANDREL ; NOT-GO
OVER 0795 MANDREL —s=

TOP

CLOSURE—% % %&W;mm!m'r:un.mm«mnfaf%
1 fi 1

LENGTH TO GO IN
1.578 GAP; NOT-GO

IN 1547 GAP
6d,0,~A1,05 ||
~—=—[NNER TUBE BUSHING —*
OUTER
TuBe — | L
P e )
\\BOTTOM - o -—
CLOSURE | Ut
BORE; NOT ~GO
THRU 1430 BORE
DIMENSIONS ARE (N INCHES. vH3
BEFORE WELDING FINISHED ASSEMBLY
NOTE :

MACHINING OF WELDS TO MEET DIMENSIONS PERMITTED PROVIDED
THAT WELD METAL IS NOT MACHINED BELOW THE LEVEL OF SUR-
ROUNDING UNMELTED METAL AND THAT METAL IS NOT MACHINED.

Fig. B-4. Assembly and Closure of Control Element.

APPENDIX C

Westinghouse's Manufacturing Procedure for Cladding Components

Westinghouse's Welding Procedure for MSRE Control Elements

Westinghouse's Manufacturing Procedure for the Gd,03—Al,03 Bushings.

Westinghouse Assembly Procedure for the MSRE Control Elements

. 41
. 42

4'7

. 50
PRy

Inconal
Tubing,
Large

Westinghouse's Manufacturlng Procedure

41

for Cladding Components

Inconel
T\Jbing’
Small

(Purchase to Spec. AFD-ORL-105)

Inzpect

Sample to ONNL

Retainer sample

dimensions at
ends, sample
Cut off Cut off
4 !
Degreasn Degrease
Ingpect. Inspect-
Dye Penetrant, Dye Pcnetrant,
Dimenaions, Pimensions,
Surface Surface
Defects Defects
rid i
Clean - Clean =
Degrease Deprease

Wash Jn Alcutox

+ hot waler

Rinse in .ot
water

Alcohol dehydrate
(if necessary)
Air Dry

Wash in Alconox

+ hot water

liinge in hot
water

Alcohol dehydrate
(if necessary)
Mr Dry

Inconel Nar Stoek
(Purchase to AST!"-B-166-61T)

Centerless
Orind
Sample to OR!L
o Retainer sample
Inspect Sample to
analytical
b 4
Machine

Upper ring lower ring

Inspect- Inspect~

Dye Penetrant, Dye Penetrant,

Dimensions, DMdmensions,

Surfece Surface

Defects Defects
Clean ~ Clean ~
Degrease Degrease
Wash in Alconox Wash in Alconox
+ hot water + hot water
Rinse in hot Rinse in hot
water water
Alcohol dehydrate Alcohol dehydrate
(1f necessary) (if necessary)
Air Dry Ailr Dry

To Assemrbly
42

Westinghouse's Welding Procedure

for MGRE Control Elements

Four welds will be made on each control element assembly. The top welds will be

made using copper chills. The control element assembly will be positioned in two
different planes to make the top closures. The inner weld will be made first and
the electrode will be positioned as shown:

Top Ingide Weld Top Outeide Veld
Toroh Torch
& ™~

Copper
Chill

T Out

Rigg Electrode Tub:r O

\ ;,//Innar Tube \ — —Flectrode

Copper -[l

cmu\ — l
Outer | = : ‘\fi?fig
\ Copper ’_______';i:::fl‘! o I\Inner

chill e Tube

43

On the bottom ring the outer weld will be made first, Chills will be used to make
both welds. The electrode will be positioned as shown:

I.

II.

Bottom Outside Weld

/ Torch

Bottom
Electrode Ring

/Copper chill
Copper

Chill \
¢ | |

Outer Tube —_—

!
Eiogg /v \ner Tube

NOTE: The electrode will be positioned over the I.,D. of the
bottom closure just as it is shown for the 0.D.

VWelding Specifications

The following parsmeters have been found to produce welds of desired width
and penetration with acceptable characteristics. Where a range occurs,
the operator may adjust settings within the range piven., ihere settings
are marked fixed, the operator will not make any changes without specific
englneering approval.

Welding Operating Parameters

A. Velding Current

1. Top Closure o Lh=Sh amperes (range)
2, Bottom Closure « 30-hO amperes (range)
Bo

Ce

De

Eo

Go

H,

4y

Weldirg Voltage

1. Top Closure - 80.5-11 Volts (range)

2, Bottom Closure - 8,5-11 Volts (range)

Rotational Speed

1, Top Closure inside weld - 11,2 sec./rev. (fixed)
2. Tcp Closure outside weld - 11,2 sec./rev, (fixed)
3. DBottom Closure inside weld - 11,2 sec./rev. (fixed)
. Bottom Closure outside weld - 12,2 gec./rev. (fixed)
Weld Time

1. Bottom Closure outside weld - 15.5 sec., (fixed)

2. Bottom Closure inaside weld - 13 sec., (fixed)

3. Top Closure outside weld - 15 sec. (fixed)

he Top Closure inside weld - 13 gec. (fixed)
Tall Tine

1., Bottom Closure outside weld - 3.1 sec., (fixed)

2. Bottom Closure inside weld - 2,25 sec. (fixed)

3. Top Closurs outside weld - 2.25 sec., (fixed)

b, Top Closure inside weld - 20,25 sec. {fixed)

Arc Gap

Arc gap fixed before welding with

Vickers Welder Control

automatic head at - 0,025 in.

l, Are Control - 10 (fixed)
2. Current Control - 90 (fixed)
3. Switches
a. Panel - Off (fixed)
b, Hi-frequency/manual - Hi-frequency (fixed)
c. Current - Remote (fixed)
d. Voltage - Remote (fixed)
e. Polarity - Straight (fixed)

Vickers Welder Remote Control

1.

Arc Control - 910 (range) use for small changes in

welding current.

2. Current Control (use outer calibration only)

8o DBottom Closure outside weld
b, Bottom Closure inside weld
¢. Top Closure outside weld

Top Closure

inside weld

- 200 - 505 (range)
- 2.0 ~» 5.5 (range)
« 6,0 « 9.5 (range)
- 6,0 = 9.5 (range)

45

I, Slope Control

l. Top Current Dial - O=3 (range)
20, Top Time Dial v 0-3 (range)
3s Bottom Current Dial - 0~5 (range)
he Bottom Time Dial - 1-5 (rango)
S« Switches
a. Start Slope - Up (fixed)
b. Start and Tail - On (fixsd)
co Start and Tail - Tail Slope Only (fixed)
do Tail Slope - Down (fixed)

Jo Control Panel Internal Settings for Automatic Head

1, Stability -— 3.2 (fixed)
2o Mamal Speed Control . 1.5 (fixed)
3. Start Compensator - 0 (fixed)

he AC/DC Arc Switch DC Are (fixed)

Ko, Remote Control Arc Voltage

1. Bottom Closure outside weld - 0.7 = 1,0 (Range)
2. 3ottom Closure inside weld - 0,7 = 1.0 (Range)
3. Top Closure outaide weld - 0.7 = 1,0 (Range)
h. Top Closure inside weld - 0,7 = 1,0 (Range)

L. Hi-Frequency Oscillator

l. Dial -~ 70 - 100 (Range)
2. AC/DC Switch - DC (fixed)
3. On/Off Switch - On (fixed)

Mo Inert Gas

1. Purity - Welding prade (fixed)
2. Flow - 10 CFH of He*
10 CFH of Ar

# Flow of each gas 1s to be adjusted with the other gas
flowing, Gases are in approximately a 50-50 ratio.

e Electrode

1l. Material -~ 2% Thoriated Tungsten, centerleas ground (fixed)
2, Size - 1/16" diameter (fixed)
3, Point Rounded

L. Projection
from Nozzle 1/16" - 1/h" (range)
0,

Nozzle

l. Material
20 Size

Ceramic
3/8" opening

46

47

Westlnghouse's Manufacturing Procedure

for the GAd,05—-A1,03 Bushings

Gdy04 Powder Al.0. Powder
2 3
F.5.5. Size & F.S.S8. Size
Inspect Customer Sample Insnect Custamer Sample
Analytical Sample pec Anelytical Sample
Retainer Sample Retainer Sample
v v
Mix by
splitii
& rgcanbigfng
Water and binder- l
water golution ’ Vet Mix
4
Gramilate
Dry 80 to 100°C
Grarmlate
Dry

Overnite, 1700°C in

PmrtICt Hp or cracked WNHj
Crush Jaw crusher

48

Pulverize

p

D
Magnatigy Treatment

HC1 1leach

wash and filter 2 hrs, naninal

3 to 4 N HC1,

Wet Magnetic Treat

2 w/o Carbo L0OO
1 w/o PVA

Ball .Hill

L8 hrs. or as required to give particle

L

Sample

Wet Mix

size < 5 _AL,

d— s ey e ohiees

80 to 100°C

Gramilate

I

Dry

.

Weigh Individual

Charges

Presas

Air, 2 hrs. min,
at 700-86000C

Sinter

L hrs. 1400°C - 1500°C
Cracked "1!3

W e A A S e e

49

Chemistry Samnle

- Sample - Visual
Dimensions

Ingpect

:

Haat to 175 + 250F,
Thermal Shock Tegt quench in cold tap water
<
OD Grind

Wash and Air Dry

I

ID Grind
if necessary
p| Make Stacks
and Inspect
Inspect -

End Grind Individual Length
If necessary, > OD, ID Envelope
to make stack Bake = 1B 1
height. a t ] 0:)'51.,'“ o Wall Thickness

& Variation
Soundness
Chips
4

Stack Weigh

To Assembly
50

Westinghouse Assembly Procedure

for the MSRE Control Elements

Bottom Sealing

Cleaned Cleaned
Baked Quter Inner Top Sealing
Gds 03—Al,03 rings (large) (small) Ring Ring
tube tube
Clean \\ / "’,//f////I//’
Welding —| Assemble
Chill
'L_ OD and ID
WélEJ welds at top
Y For porosity and
Inspect blow holes
[ID Weld Expand |
Identify
Put in
— | Helium-filled | -
dry-box
A
IAssemble
¥
Remove from
b dry-box
Store
Helium-filled
container Y OD and ID
- —| Weld welds at bottom
GO-NO-GO
— Weld OD and ID-
D Weld [ GO-N0O-GO Length

Expand

A A i e b s

51

Visual for weld
Inspect and surface defects

I

Helium Leak
Test

l

Dye Penetrant
Inspect

Clean

Minimum 1 hr at
Oxidize 1700 to 1800°F, air cool

'

Identify

 §

Dimension GO-NO-GO for
Inspect ID, OD and Length

1

Visual
Inspect

Package Check Records

Y
40-42.

72.
73.
T4 .
75.
76.
77
78.
79.
80.
81.
82.
83.
84—355.

53

ORNL-4123
UC-25 — Metals, Ceramics, and Materials

INTERNAL DISTRIBUTION

Central Research Library 44, A, P,
ORNL — Y-12 Technical Library 45, H. G.
Document Reference Section 46, R. E.
Laboratory Records Department 47. G. B.
Laboratory Records, ORNL R.C. 48. H. E.
ORNL Patent Office 49, C. K,
G. M. Adamson, Jr. 50. C. J.
J. W. Arendt (K-25) 51, J. A.
R. J. Beaver 52. M. W.
H. Beutler 53, A. E.
G. E. Boyd 54. C. E.
Ji Young Chang 5564, G. M.
W. H. Cook 65. T. N.
F. L, Culler 66. A, M.
J. E. Cunningham 67. W. J.
D, E. Ferguson 68. M. L.
J. H Frye, Jr. 69. M. B.
V. 0. Haynes 70. A. R.
M. R. Hill 71. J. A,
C. BE. Larson
FXTERNAL DISTRIBUTION

D. F. Cope, RDT, SSR, AEC, Oak Ridge National

A, Giambusso, AEC, Washington

J. L. CGregg, Bard Hall, Cornell University

W. J. Larkin, AEC, Oesk Ridge Operations

T. W. McIntosh, AEC, Washington

H. M. Roth, AEC, Oak Ridge Operations

J. Simmons, AEC, Washington

W, L. Smally, AEC, Oak Ridge Operations

E. E. Stansbury, University of Tennessee

D. K. Stevens, AEC, Washington

J. A. Swartout, Union Carbide Corp., New York
A. Taboada, AEC, Washington

Litman

MacPherson
MacPherson

Marrow

McCoy, Jr.

McGlothlan

McHargue

Parsons (K-25)
Rosenthal

Richt

Segsions

Tolson

Washburn

Welinberg

Werner

Winton

Bever (consultant)
Kaufmann (consultant)
Krumhansl (consultant)

Laboratory

Given distribution as shown in TID-4500 under Metals, Ceramics,

and Materials Category (25 copies — CFSTI)