3D Metal Printing Application to Nuclearenergy.mit.edu/wp-content/uploads/2017/02/3-1.-Bolger... ·...
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3D Metal Printing Application to Nuclear Fran Bolger ([email protected]) Manager, New Product Introduction GE Hitachi Nuclear Energy January 31, 2016
Transcript of 3D Metal Printing Application to Nuclearenergy.mit.edu/wp-content/uploads/2017/02/3-1.-Bolger... ·...
3D Metal Printing Application to Nuclear
Fran Bolger ([email protected])
Manager, New Product Introduction
GE Hitachi Nuclear Energy
January 31, 2016
21/31/20173D Printing for Nuclear - Topical Workshop on New Cross-cutting Technologies for Nuclear Power Plants,
MIT
21/31/20173D Printing for Nuclear - Topical Workshop on New Cross-cutting Technologies for Nuclear Power Plants,
MIT
Topics of Discussion
• 3D Metal Printing “Additive Manufacturing” Overview
• Materials Qualification
• Challenges
31/31/20173D Printing for Nuclear - Topical Workshop on New Cross-cutting Technologies for Nuclear Power Plants,
MIT
31/31/20173D Printing for Nuclear - Topical Workshop on New Cross-cutting Technologies for Nuclear Power Plants,
MIT
Additive (3D Printing) Process
Post Processing (HIP, Heat Treat, Machining, etc.)
Direct Material Laser Melting (DMLM)
41/31/20173D Printing for Nuclear - Topical Workshop on New Cross-cutting Technologies for Nuclear Power Plants,
MIT
51/31/20173D Printing for Nuclear - Topical Workshop on New Cross-cutting Technologies for Nuclear Power Plants,
MIT
51/31/20173D Printing for Nuclear - Topical Workshop on New Cross-cutting Technologies for Nuclear Power Plants,
MIT
Value of Additive/3D Metal Printing
Speed of Delivery: Condensed supply chain enables quick response to emergent needs
• No tooling required: fast turnaround time
Design for Performance: Fewer manufacturing limitations allow new designs
• Design-driven manufacturing as opposed to manufacturing-constrained design
Enhanced chemistry control: Powder atomization Low Cobalt
61/31/20173D Printing for Nuclear - Topical Workshop on New Cross-cutting Technologies for Nuclear Power Plants,
MIT
61/31/20173D Printing for Nuclear - Topical Workshop on New Cross-cutting Technologies for Nuclear Power Plants,
MIT
When to Apply Additive
• Functional Prototypes
• Design for Performance Enhancement where conventional manufacturing is difficult or not possible
• Weight Reduction
• Geometric Features Enable Enhancements
• Cost reduction for complex multi-component assemblies
• High-value Products for low volume, specialized or unique components
71/31/20173D Printing for Nuclear - Topical Workshop on New Cross-cutting Technologies for Nuclear Power Plants,
MIT
71/31/20173D Printing for Nuclear - Topical Workshop on New Cross-cutting Technologies for Nuclear Power Plants,
MIT
Unique Design Development Process
• Example: Enhanced Fuel debris filter: prevent fretting of fuel rods
– 3D allows making a new design
– Only way to make it
– Can quickly make prototype for evaluation
– Iterate on the design
– Quickly build for actual in-plant trial
Key concern remains: Can I use the materials to
put a prototype into a plant?
81/31/20173D Printing for Nuclear - Topical Workshop on New Cross-cutting Technologies for Nuclear Power Plants,
MIT
Additive Materials Qualification Program
91/31/20173D Printing for Nuclear - Topical Workshop on New Cross-cutting Technologies for Nuclear Power Plants,
MIT
91/31/20173D Printing for Nuclear - Topical Workshop on New Cross-cutting Technologies for Nuclear Power Plants,
MIT
DOE Program - CFA-15-8309Environmental Cracking and Irradiation Resistant Stainless Steel by Additive Manufacturing
Objective: Evaluate the stress corrosion cracking susceptibility, corrosion fatigue, and irradiation resistance of the additively manufactured 316L stainless steel in nuclear environment.
Participants: GEGR (Lou - PI), ORNL (Muth), U of M (Was), GEH (Connor, Horn)
Activities: Study DMLM material nanostructure and optimize the material. Proton irradiation at 2 MeV to a dose in the range 5-10 dpa.
101/31/20173D Printing for Nuclear - Topical Workshop on New Cross-cutting Technologies for Nuclear Power Plants,
MIT
101/31/20173D Printing for Nuclear - Topical Workshop on New Cross-cutting Technologies for Nuclear Power Plants,
MIT
DOE Program - CFA-16-10393Irradiation Testing of LWR Additively Manufactured Materials
Objective: Perform full irradiation / PIE on structural materials produced by DMLM
Participants: GEH (Horn - PI), INL (NSUF facility)
Activities: Obtain microstructural characterization, mechanical properties, stress corrosion crack growth data for un-irradiated Type 316L and IN 718 (GEH) and corresponding irradiated data to 1 dpa (INL at the ATR)
111/31/20173D Printing for Nuclear - Topical Workshop on New Cross-cutting Technologies for Nuclear Power Plants,
MIT
111/31/20173D Printing for Nuclear - Topical Workshop on New Cross-cutting Technologies for Nuclear Power Plants,
MIT
Top View 2 Top View 2
Cross-section View 4 Cross-section View 4
1
2
3 4
Building
Direction
As-built Stress
Relief
121/31/20173D Printing for Nuclear - Topical Workshop on New Cross-cutting Technologies for Nuclear Power Plants,
MIT
121/31/20173D Printing for Nuclear - Topical Workshop on New Cross-cutting Technologies for Nuclear Power Plants,
MIT
Top View 2 Top View 2
Cross-section View 2 Cross-section View 4
1
2
3 4
Building
Direction
Anneal HIP+Anneal
Good density, low porosity
100% Austenitic
Grain size 5 or finer
Microstructure similar to wrought
131/31/20173D Printing for Nuclear - Topical Workshop on New Cross-cutting Technologies for Nuclear Power Plants,
MIT
131/31/20173D Printing for Nuclear - Topical Workshop on New Cross-cutting Technologies for Nuclear Power Plants,
MIT
Tensile and Charpy Properties
Good ductility (>40%El)
Good yield strength
20
40
60
80
100
120
140DMLS 316L (Vertical)DMLS 316L (Horizontal)Wrought 316LNitronic 50
UTS 0.2% YS Elongation
Stre
ss, k
si o
r Elo
ngat
ion,
%
HIP+Anneal
0
20
40
60
80
100
120
140
Vertical 0 degree 45 degree
Orientation
Toug
hnes
s (ft-
lb)
HIP+Anneal
Typical charpy toughness for
annealed 316L @RT: 65~100 ft-
lb
AM 316L mechanical properties similar to Wrought
316L
Challenges
151/31/20173D Printing for Nuclear - Topical Workshop on New Cross-cutting Technologies for Nuclear Power Plants,
MIT
151/31/20173D Printing for Nuclear - Topical Workshop on New Cross-cutting Technologies for Nuclear Power Plants,
MIT
Inspection Challenges
• Complex geometry = complex inspection
• Only simplest parts can be UT inspected
• Computed Tomography (CT) scan can be used for dimensional validation
• Produce test specimens as part of each build
Cut up, SEM, and mechanical testing of selected complete parts
• EPRI leading CFA-16-10169 team for In-situ monitor Integrated Computational Materials Engineering (ICME) and
In-situ Process Monitoring for Rapid Qualification of Components Made by Laser-Based Powder Bed Additive Manufacturing (AM) Processes for Nuclear Structural and Pressure Boundary Applications
161/31/20173D Printing for Nuclear - Topical Workshop on New Cross-cutting Technologies for Nuclear Power Plants,
MIT
161/31/20173D Printing for Nuclear - Topical Workshop on New Cross-cutting Technologies for Nuclear Power Plants,
MIT
Standards & Regulatory Challenge
Approved ASTM Specifications
• Additive Manufacturing Stainless Steel Alloy (UNS S31603) with Powder Bed Fusion
• Additive Manufacturing Nickel Alloy (UNS N07718) with Powder Bed Fusion
ASME Code Case – code application is not intended however this level of approval is generally accepted
BWRVIP-84 – EPRI BWR Vessel and Internals Program is working on guidelines for “Qualification of Advanced Processes”
171/31/20173D Printing for Nuclear - Topical Workshop on New Cross-cutting Technologies for Nuclear Power Plants,
MIT
171/31/20173D Printing for Nuclear - Topical Workshop on New Cross-cutting Technologies for Nuclear Power Plants,
MIT
Part Performance Challenges
Although a multiplicity of features can be 3D printed, the performance must be tested or simulated
• Testing representative of nuclear operating conditions can be expensive
• CFD simulation is challenged for the areas of greatest opportunity
– Steam separator for ΔP/efficiency optimization
– Fuel spacer for CPR performance optimization
Conclusions
191/31/20173D Printing for Nuclear - Topical Workshop on New Cross-cutting Technologies for Nuclear Power Plants,
MIT
Conclusions
• DMLM process provides and excellent opportunity for nuclear metals application as has been shown for other industries
• Materials qualification is progressing well
• Challenges to inspection, standards, and performance optimization
