Extending Lifetime of Sensors and Electronics by In-Operando Rejuvenation

Statement of the problem being addressed: Nuclear reactor sensors and electronics degrade due to neutron fluence, high temperatures, and ionizing radiation, causing signal loss, reduced accuracy, delayed responses, and higher maintenance costs, affecting safety and efficiency, especially in reactor cores. The DOE's Advanced Sensor and Instrumentation (ASI) program focuses on developing reliable, long-lasting, cost-effective sensors for real-time monitoring of reactor cores, coolant loops, and plant systems. Despite advancements in radiation-resistant materials, performance degradation in nuclear reactor environments remains a challenge, driving up costs. Recovery methods like rapid thermal and laser annealing restore functionality but require removing devices from the reactor, limiting practicality. This highlights the need for durable sensors and in-situ recovery techniques to extend device lifetimes in harsh nuclear environments. General statement of how this problem is being addressed: Our team proposed to use Electron-Wind Force (EWF) annealing technique using electropulsing to rejuvenate metal and semiconductor sensors and electronics. This method employs high-current, short pulses that avoid significant heating, instead using high-momentum electrons to repair irradiation-induced defects and relieve thermoelastic stress. The process restores degraded components in seconds without removal from the reactor, enabling longer in-core operation and sustained performance. Highly localized and efficient, the technique requires only two electrodes and wires for remote operation in confined spaces, allowing seamless integration with existing systems for in-situ annealing. By enabling sensors to operate closer to the reactor core, this innovation promises enhanced measurement accuracy and significant reductions in operational and maintenance costs. What is to be done in Phase I: Phase I aims to demonstrate in-situ electric wind force (EWF) annealing for temperature sensors and semiconductor electronics at the PSU Breazeale reactor. The project will assess its effectiveness in reversing radiation and high-temperature damage through parametric experiments and computational modeling. High-temperature radiation-resistant thermocouples (e.g., Molybdenum-niobium from Idaho National Lab) and Rad-Hard Electronics (e.g., wide bandgap devices for DOE discrete active electronics sensors) will be exposed to temperatures up to 500°C, 10 Mrad cobalt-60 gamma radiation per cycle, and neutron irradiation of 10¹4 n/cm² at 1 MeV per cycle, with 5 to 10 radiation-anneal cycles. Extensions will focus on identifying critical parameters rather than full optimization, depending on time and resources. The project will also evaluate the technology’s applicability across various reactor concepts and fuel cycle applications and develop methods for in-situ performance evaluation to ensure the long-term reliability of sensors and electronics in nuclear environments. Commercial applications and other benefits: Radiation-hardened sensors and rejuvenation services are vital for industries like nuclear power, research reactors, and space missions. The in-operando EWF device can cut maintenance costs in nuclear facilities, saving billions annually. It also enables in-situ welding stress relief, reducing manufacturing costs and improving product lifespan, especially in space-constrained environments.