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Laser Direct Manufacturing of Nuclear Power Components

Laser Direct Manufacturing of Nuclear Power Components. Dr. Jyotsna Iyer , Dr. Scott Anderson , Gautham Ramachandran, Georgina Baca, Scott Heise, Dr. Slade Gardner 3 November 2014.

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Laser Direct Manufacturing of Nuclear Power Components

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  1. Laser Direct Manufacturing of Nuclear Power Components Dr. Jyotsna Iyer, Dr. Scott Anderson, Gautham Ramachandran, Georgina Baca, Scott Heise, Dr. Slade Gardner 3 November 2014 Acknowledgment: “This material is based upon work supported by the Department of Energy , Office of Nuclear Energy, Idaho Operations, under Award Number DE-NE0000542” Disclaimer: “This report was prepared as an account of work sponsored by an agency of the United States Government. Neither the United States Government nor any agency thereof, nor any of their employees, makes any warranty, express or implied, or assumes any legal liability or responsibility for the accuracy, completeness, or usefulness of any information, apparatus, product, or process disclosed, or represents that its use would not infringe privately owned rights. Reference herein to any specific commercial product, process, or service by trade name, trademark, manufacturer, or otherwise does not necessarily constitute or imply its endorsement, recommendation, or favoring by the United States Government or any agency thereof. The views and opinions of authors expressed herein do not necessarily state or reflect those of the United States Government or any agency thereof.”

  2. Nuclear Energy in the U.S. • 104 reactors in the U.S. providing 20% of our electricity • 4 new plants under construction in U.S., >60 globally, >150 on order • Current Light Water Reactors (LWR) cost $10B-$12B/unit • Costly on-site construction • Next generation Small Modular Reactors (SMR) estimated $800M-$2B/unit • DOE SMR program funding ~$400M • B&W and NuScale selected for concept development • Factory fabrication, rapid installation • Advanced materials and manufacturing are significant industry drivers Advanced/Affordable Manufacturing methods are key enablers for competing in $700B global market

  3. DOE Nuclear Energy Enabling Technologies (NEET) Advanced Manufacturing Methods (AMM) LM CE&T Energy IPT funding cost-share and supporting industry engagement and growth opportunities Net-Shape Manufacturing Demo Articles built in <18 hours, no assembly/joining required – Fuel rod spacer grids manufactured using 316L SS and Inconel600

  4. Background for Alternate Nuclear MaterialsSelection N13137-02 Fuel Assembly Fuel RodCutaway FuelPellets N13137-01 1400 Fuelrod Very High Temperature Reactor 1200 Superficial-Water-Cooled Reactor Clad Gas Fast Reactor 100 Lead fast Reactor Spacergrid Molten Salt Reactor 800 Temperature (°C) 600 Fuelpellet 400 Sodium Fast Reactor Generations II-III 200 UO2MOX 0 0 50 100 150 200 Displacements Per Atom (dpa) Water flow

  5. Table of Comparison Criteria for Selection of Alternative Nuclear Materials Comparison criteria Alternate Nuclear Materials BASELINE: Traditional ferritic/martensitic steels (HT-9) or later generations of F/M steels OPTION 1: ODS steels to examine effect of direct manufacturing methods on nanoscale oxide domains OPTION 2: Inconel 800 series of materials to study the effect of processing parameters offered by direct manufacturing methods to improve performance under irradiation OPTION 3: Among the refractory alloys, the Mo (TZM) alloys. These have a high operating temperature window and also, the most information on irradiated material properties • Low neutron absorption • Elevated temperature mechanical properties • Creep resistance • Long-term stability • Compatibility with reactor coolant • Resistance to irradiation-induced damage (greater than 200 dpa) • Radiation hardening and embrittlement • Void swelling • Creep • Helium-induced embrittlement • Phase instabilities Based on customer feedback at Technical review, materials down-selected to 316SS, ODS steels and Inconel alloys

  6. Material Down selection for DM Demonstration • Alloys: Inconel 600, Inconel 718, Incoloy 800, 316L SS, ODS Steels • Oxides: Yttrium, Cerium - Mix of nano- & micron- sized oxide particles selected for mixing 3 x 3 Grid 10 x 10 Grid 10 x 10 Grid • Emerging literature in Austenitic ODS alloys • Development of Austenitic ODS Strengthened Alloys for Very High Temperature Applications (http://energy.gov/sites/prod/files/2013/09/f2/Stubbins_Austenitic%20ODS%20NEUP.pdf) • Synthesis and Characterization of Austenitic ODS alloys (http://www.mme.iitm.ac.in/murty/?q=node/96)

  7. Process Parameter Variation During Part Fabrication – Inconel 600

  8. Process Parameter Effect on Fabricated Part Density – Inconel 600 Laser power of 195W makes the fabricated article almost insensitive to scan speed

  9. Process Parameter Effect on Fabricated Part Density – Inconel 718 Laser power of 165W most consistent for Inconel 718; more scatter in density data

  10. Microstructure Characterization QCML manufactured 56 of Inconel 600 samples Fourteen were selected Five samples were selected for microstructure characterization Sample #12 was selected for mounting in both the x-y & z directions for a total of six samples Metallography Procedure Mount/ grind/ polish Micrograph (photographs) Scanning Electron Microscopy (SEM) Etch Micrograph SEM Samples produced at the higher speed rate and lower power demonstrate more voiding based micrographs

  11. Backscattered Electron Imaging of Sample 600-195-1400 Top Bottom Middle • BSE imaging revealed the solidification/grain microstructure • Microstructure appeared similar in the three locations examined • No titanium nitride particles were detected (titanium nitride particles are typically found in wrought material) • Black areas in images are voids

  12. Microstructure Comparison of Inconel 600 Bar Stock Sample vs Additive Manufactured Sample • QCML manufactured 56 of Inconel 600 samples • Fourteen were selected • Five samples were selected for microstructure characterization Metallography procedure • Mount/ grind/ polish • Micrograph (photographs) • Scanning Electron Microscopy (SEM) • Etch • Micrograph • SEM Inconel 600: Sample 500X BSE 10kV not etched Inconel 600: Bar Stock Sample 500X BSE 10kV not etched Noticeable Grain Structure differences due to manufacturing process

  13. Examination of Microstructure of Edge Transition Top Edge: Terminating Side (a) a) Inconel 600 Micrographs show (b) top edge (c) transitions (d) interior of sample at 500X (b) Top Edge:500X Side Terminating Side (c) Top Edge Transition: 500X Side Initiating Side (d) Away from edge: 500X

  14. Test Coupons Ready for Mechanical Testing • This build layout produces 45 test coupons in a single build at 1100mm/s and 195W • The test coupons are cylinders with 0.5" diameter by 3" length.  • 15 cylinders are in horizontal orientation • 15 cylinders are in vertical orientation • 15 cylinders are at 45 degrees with respect to the horizontal. Inconel 600 longitudinal, transverse, and 45deg specimen blanks after LDM Samples heat treated (900C for 1-2hr) to remove after fabrication to prevent warping

  15. Next Steps • Mechanical & microstructural characterization of test coupons for Alloy 600 • Test specimen build for Alloy 718, Alloy 800 • Characterization of Alloy 718 & Alloy 800 test specimens • Test coupon build for Alloy 718 & Alloy 800 • Mechanical & microstructural characterization of test coupons for Alloy 718 & Alloy 800 • ODS steel mechanical blending & trial runs

  16. Back up slides

  17. Metallurgy of AM Technologies • Weldable alloys are readily manufactured via AM • Titanium alloys, stainless steels, alloy/tool steels, nickel-based alloys (Inconel), cobalt-based alloys • Enables unique control of microstructure • Very fine grain sizes due to high solidification rates • Can produce microstructures not possible using conventional manufacturing methods • Equivalent or superior mechanical properties to wrought alloys

  18. Material Down Selection for DM Demonstration • Mix of nano- and micron- sized oxide particles selected for mixing with 316SS • Emerging literature in Austenitic ODS alloys • Development of Austenitic ODS Strengthened Alloys for Very High Temperature Applications (http://energy.gov/sites/prod/files/2013/09/f2/Stubbins_Austenitic%20ODS%20NEUP.pdf) • Synthesis and Characterization of Austenitic ODS alloys (http://www.mme.iitm.ac.in/murty/?q=node/96)

  19. Literature Notes for Austenitic ODS Steel Composition • (http://energy.gov/sites/prod/files/2013/09/f2/Stubbins_Austenitic%20ODS%20NEUP.pdf)

  20. Several Inconel 600 samples were metallographically cross-sectioned and polished • Examination of microstructure on sample 600-195-1400 was conducted using backscattered electron imaging (BSE) • Sample was not yet etched • BSE images were taken in the three locations shown below Optical Image of Polished Cross-Section Sample 600-195-1400 Top Mid Bot ~ 1cm Mt 14.046

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