Presentation is loading. Please wait.

Presentation is loading. Please wait.

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

Similar presentations


Presentation on theme: "Laser Direct Manufacturing of Nuclear Power Components Dr. Jyotsna Iyer, Dr. Scott Anderson, Gautham Ramachandran, Georgina Baca, Scott Heise, Dr. Slade."— Presentation transcript:

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-NE ” 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 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) Contract: DE-NE POP: 36 months, GFY13 - GFY15 DOE Team: Alison Hahn (HQ), Jack Lance (HQ), Bradley Heath (HQ) LM Team: Gautham Ramachandran, Dr. Scott Anderson, Dr. Jyotsna Iyer, Georgina Baca, Scott Heise, Dr. Slade Gardner Dr. Eric Faierson, Quad City Manufacturing Laboratory ScopeHIGHLIGHTS Purpose: Position U.S. to compete in $B international market for nuclear power via enabling technology that significantly reduces development and operational costs and manufacturing lead time for nuclear reactors Project Objectives: Demonstrate >50% cost and schedule reduction using additive manufacturing methods. Develop, advanced radiation tolerant alloys via nanophase modification during additive manufacturing for reduced life cycle costs. Technical Approach Build manufacturing demonstrations of complex parts demonstrating design flexibility and shortened design-to-manufacturing cycles Employ nanophase alloy modification via Laser Direct Manufacturing (LDM) to create enhanced radiation tolerance in the components Demonstrate the cost and schedule benefits through case studies and business case analyses Net-Shape Manufacturing Demo Articles built in <18 hours, no assembly/joining required – Fuel rod spacer grids manufactured using 316L SS and Inconel600 LM CE&T Energy IPT funding cost- share and supporting industry engagement and growth opportunities

4 4 Background for Alternate Nuclear Materials Selection N Generations II-III Sodium Fast Reactor Molten Salt Reactor Gas Fast Reactor Lead fast Reactor Superficial-Water-Cooled Reactor Very High Temperature Reactor 1400 Temperature (°C) Displacements Per Atom (dpa) N Fuel Rod Cutaway Fuel Pellets Fuel Assembly UO 2 MOX Clad Fuel pellet Fuel rod Spacer grid Water flow

5 5 Table of Comparison Criteria for Selection of Alternative Nuclear Materials Comparison criteria 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 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 Based on customer feedback at Technical review, materials down-selected to 316SS, ODS steels and Inconel alloys

6 6 Material Down selection for DM Demonstration 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)http://www.mme.iitm.ac.in/murty/?q=node/96 Alloys: Inconel 600, Inconel 718, Incoloy 800, 316L SS, ODS Steels Oxides: Yttrium, Cerium - Mix of nano- & micron- sized oxide particles selected for mixing 10 x 10 Grid 3 x 3 Grid

7 7 Process Parameter Variation During Part Fabrication – Inconel 600

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

9 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 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 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 11 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 Bottom Middle Top Backscattered Electron Imaging of Sample

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

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

14 14 Test Coupons Ready for Mechanical Testing Inconel 600 longitudinal, transverse, and 45deg specimen blanks after LDM Samples heat treated (900C for 1-2hr) to remove after fabrication to prevent warping 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.

15 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 16 Back up slides

17 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 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_Au stenitic%20ODS%20NEUP.pdf) Synthesis and Characterization of Austenitic ODS alloys (http://www.mme.iitm.ac.in/murty/?q=node/96)http://www.mme.iitm.ac.in/murty/?q=node/96

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

20 SPACE SYSTEMS COMPANY Preliminary Examination of ; Mt JAB STAR Labs 20 Several Inconel 600 samples were metallographically cross-sectioned and polished Examination of microstructure on sample was conducted using backscattered electron imaging (BSE)  Sample was not yet etched  BSE images were taken in the three locations shown below ~ 1cm Top Mid Bot Optical Image of Polished Cross-Section Sample Mt


Download ppt "Laser Direct Manufacturing of Nuclear Power Components Dr. Jyotsna Iyer, Dr. Scott Anderson, Gautham Ramachandran, Georgina Baca, Scott Heise, Dr. Slade."

Similar presentations


Ads by Google