Development of a 316L SS Code Case Using Powder Metallurgy ...
18
© 2021 Electric Power Research Institute, Inc. All rights reserved. www.epri.com Development of a 316L SS Code Case Using Powder Metallurgy-Hot Isostatic Pressing David Gandy Sr. Technical Executive, Nuclear Materials [email protected] August 24-25, 2021 GAIN-EPRI-NEI AMM Qualification Workshop
Transcript of Development of a 316L SS Code Case Using Powder Metallurgy ...
PowerPoint Presentation© 2021 Electric Power Research Institute,
Inc. All rights reserved.w w w . e p r i . c o m
Development of a 316L SS Code Case Using Powder Metallurgy-Hot Isostatic Pressing
David Gandy Sr. Technical Executive, Nuclear Materials [email protected]
August 24-25, 2021
Why Consider Powder Metallurgy To Produce Nuclear Components?
Enables predictable production schedules to be met by eliminating casting quality issues – Minimize repairs & enhance weldability (control of residuals)
Eliminates inspectability issues (homogenous microstructure) Enables manufacture of large, complex components using “Near-Net
Shape” technologies
Enables new alloys systems & “controlled” chemistries Alternate supply route for long-lead time components
– Reduces manufacturing and delivery times. Production of smaller, individual heats (lots) as opposed to several ton
heats (in NNS form or as ingots)
Technology Gaps/Barriers (in 2011-12)
Sizes/shapes for “near-net shaped” components only recently reached a point for consideration – Not currently tailored for the compositions/alloys currently of most interest to the
industry.
ASME Boiler and Pressure Vessel Code currently did not allow the use PM produced components for the desired applications. – ASTM A988-11 – Hot Isostatically-Pressed Stainless Steel Flanges, Fittings, Valves,
and Parts for High Temperature Service – ASTM A989-07 -- Hot Isostatically-Pressed Alloy Steel Flanges, Fittings, Valves, and
Parts for High Temperature Service
Feasibility Demonstration --12-inch Valve Body Fabrication
Type 316L Stainless Steel Valve Body
Near-Net Shaped
1716 lbs
Annealed condition
316L SS Valve Body Assessment --Inspectability
Manual and Automated UT Scans Performed
EDM Flaws Installed @ 6 locations around Flange
Results • Reflectors adequately detected and sized
even thru thick (>5-inches) portions of flange
• Compared to cast 304L SS calibration blocks, the 316L PM/HIP material exhibited superior inspectability.
• No significant challenges for the UT inspection process
316L SS Valve Body Assessment --Homogeneous Microstructure
500X Photos from 3 different orientations. Isolated carbide particles were present. No porosity
ASTM Grain Size = 6-7
Element Valve Body 316L Specification
Carbon 0.019 0.030 max Manganese 0.99 2.00 max Phosphorus 0.006 0.045 max Sulfur 0.005 0.030 max Silicon 0.73 0.75 max Nickel 12.10 10.00 – 14.00 Chromium 17.25 16.00 – 18.00 Molybdenum 2.52 2.00 – 3.00
316L SS Valve Body Feasibility
Results very encouraging: – Good inspectability – Good tensile, yield, elongation, ROA, hardness, properties – Homogenous microstructure, grain size is right – No porosity – Outstanding toughness
Decided to move on to manufacture 3 valve bodies – Goal: Develop ASME Code Case & Data Package – Assess machinability & weldability
EPRI Report No. 1025491 Manufacture of Large Nuclear and Fossil Components Using Powder Metallurgy and Hot Istostatic Processing Technologies (publicly available).
ASME Code Case Development
1000F (& stress/strain curves) Toughness Fatigue Weldment Properties
Table of Contents
2.1 Chemical Composition 2.2 Tensile Requirements 2.3 Heat Treatment 2.4 Hardness Requirement
3. Properties of 316L PM/HIP Components 3.1 Chemical Compositions 3.2 Grain Size Measurements 3.3 Hardness Measurements 3.4 Drawings and Images 3.5 Microstructure 3.5.1 Heat 814520 3.5.2 Heat 815111 3.6 Density 3.7 Inclusion Content 3.8 Toughness 3.9 Tensile Properties (70-1000°F) 3.10 Yield Stress-strain Curves
4. Weldment Properties of S31603 (316L) Manufactured Components 4.1 Welding Consumables 4.2 Welding Parameters 4.3 Joint Geometry 4.4 Macro and Microstructure 4.5 Hardness Profiles 4.6 Tensile Properties 4.7 Bend Results
5. References 6. Suggested Reading
Appendix A – Additional Test Property Data for Heat 33836-01A
Appendix B – ASME Stress Allowable Values
316L Stainless Steel --Powder Metallurgy/HIP
2011
2010
2011
500X
• Good tensile/yield properties • Good toughness • No Porosity, homogenous microstructures • Good Fatigue properties • Inspection, near forging quality
ASME Code Case N-834 & Data Pkg, plus NRC Review— Sect III-Approved Sept 2013
courtesy Rolls-Royce
ASTM 988
Tensile & Yield Strength – 316L SS (for Code Case)
Calculated Stress Allowable Values & Fatigue Data
Courtesy of Rolls-Royce
© 2021 Electric Power Research Institute, Inc. All rights reserved.w w w . e p r i . c o m12
316L SS Mechanical Properties ROA ~ >68%; Elong. > 40% (Room temp) Charpy Impact: >122 ft-lbs (3 orientations) Inclusion content (per ASTM E45): zero, (3 orientations) Density measurements: No porosity observed (3 orientations)
500X100X
316L Weldments for Code Case
GTAW
SMAW
Weldment Tensile & Hardness Results
Room Temperature Tensile Test Values for Each Weldment
Process Specimen TS (ksi) TS (MPa) YS (ksi) YS (MPa) Elong. in 2" (%) Fracture Location
SMAW 2 94.7 653.1 60.8 419.3 27.5 Weld 5 95.1 655.9 60.4 416.6 28.0 Weld 7 94.1 649.0 58.4 402.8 28.0 Weld
GTAW 2 83.9 578.6 51.2 353.1 36.0 Base 5 84.2 580.7 50.7 349.7 38.5 Base 7 84.8 584.8 52.9 364.8 39.0 Base
SMAW GTAW
Process
Specimen
SMAW
2
94.7
653.1
60.8
419.3
27.5
Weld
5
95.1
655.9
60.4
416.6
28.0
Weld
7
94.1
649.0
58.4
402.8
28.0
Weld
GTAW
2
83.9
578.6
51.2
353.1
36.0
Base
5
84.2
580.7
50.7
349.7
38.5
Base
7
84.8
584.8
52.9
364.8
39.0
Base
© 2021 Electric Power Research Institute, Inc. All rights reserved.w w w . e p r i . c o m15
Summary
Data Package developed – 2010-12. Code Case N-834 Approved in Sept 2013. Subsequently recognized by NRC under a
Reg. Guide. Used dozens of times since for production of
nuclear components (>$1M documented savings by one organization).
More recently we are using the Code Case as a guiding document for preparation of a new Appendix to BPV-III for PM-HIP.
Leading to New Industry: Installation of ATLAS-HIP, a 3.55m (140” diameter) HIP unit.
Acknowledgements
John Shingledecker, EPRI John Siefert, EPRI Walt Sperko, Sperko Engineering Lou Lherbier & Dave Novotnak, Carpenter John Sulley, Rolls Royce Tyco Valves & Controls
Together…Shaping the Future of Electricity
Small Modular Reactor Upper Head--Example
~44% scale Single monolithic structure A508 Class 1, Grade 3 27 penetrations 1650kg (3650lbs); 1270mm (50
inches) diameter Next, 2/3-scale head Need larger HIP Vessel -- ATLAS
Photographs courtesy of EPRI and NuScale Power
DOE Project: DE-NE0008629
Why Consider Powder Metallurgy To Produce Nuclear Components?
Technology Gaps/Barriers (in 2011-12)
316L SS Valve Body Assessment --Homogeneous Microstructure
316L SS Valve Body Feasibility
ASME Code Case Development
Tensile & Yield Strength – 316L SS (for Code Case)
Calculated Stress Allowable Values & Fatigue Data
316L SS Mechanical Properties
Weldment Tensile & Hardness Results
Development of a 316L SS Code Case Using Powder Metallurgy-Hot Isostatic Pressing
David Gandy Sr. Technical Executive, Nuclear Materials [email protected]
August 24-25, 2021
Why Consider Powder Metallurgy To Produce Nuclear Components?
Enables predictable production schedules to be met by eliminating casting quality issues – Minimize repairs & enhance weldability (control of residuals)
Eliminates inspectability issues (homogenous microstructure) Enables manufacture of large, complex components using “Near-Net
Shape” technologies
Enables new alloys systems & “controlled” chemistries Alternate supply route for long-lead time components
– Reduces manufacturing and delivery times. Production of smaller, individual heats (lots) as opposed to several ton
heats (in NNS form or as ingots)
Technology Gaps/Barriers (in 2011-12)
Sizes/shapes for “near-net shaped” components only recently reached a point for consideration – Not currently tailored for the compositions/alloys currently of most interest to the
industry.
ASME Boiler and Pressure Vessel Code currently did not allow the use PM produced components for the desired applications. – ASTM A988-11 – Hot Isostatically-Pressed Stainless Steel Flanges, Fittings, Valves,
and Parts for High Temperature Service – ASTM A989-07 -- Hot Isostatically-Pressed Alloy Steel Flanges, Fittings, Valves, and
Parts for High Temperature Service
Feasibility Demonstration --12-inch Valve Body Fabrication
Type 316L Stainless Steel Valve Body
Near-Net Shaped
1716 lbs
Annealed condition
316L SS Valve Body Assessment --Inspectability
Manual and Automated UT Scans Performed
EDM Flaws Installed @ 6 locations around Flange
Results • Reflectors adequately detected and sized
even thru thick (>5-inches) portions of flange
• Compared to cast 304L SS calibration blocks, the 316L PM/HIP material exhibited superior inspectability.
• No significant challenges for the UT inspection process
316L SS Valve Body Assessment --Homogeneous Microstructure
500X Photos from 3 different orientations. Isolated carbide particles were present. No porosity
ASTM Grain Size = 6-7
Element Valve Body 316L Specification
Carbon 0.019 0.030 max Manganese 0.99 2.00 max Phosphorus 0.006 0.045 max Sulfur 0.005 0.030 max Silicon 0.73 0.75 max Nickel 12.10 10.00 – 14.00 Chromium 17.25 16.00 – 18.00 Molybdenum 2.52 2.00 – 3.00
316L SS Valve Body Feasibility
Results very encouraging: – Good inspectability – Good tensile, yield, elongation, ROA, hardness, properties – Homogenous microstructure, grain size is right – No porosity – Outstanding toughness
Decided to move on to manufacture 3 valve bodies – Goal: Develop ASME Code Case & Data Package – Assess machinability & weldability
EPRI Report No. 1025491 Manufacture of Large Nuclear and Fossil Components Using Powder Metallurgy and Hot Istostatic Processing Technologies (publicly available).
ASME Code Case Development
1000F (& stress/strain curves) Toughness Fatigue Weldment Properties
Table of Contents
2.1 Chemical Composition 2.2 Tensile Requirements 2.3 Heat Treatment 2.4 Hardness Requirement
3. Properties of 316L PM/HIP Components 3.1 Chemical Compositions 3.2 Grain Size Measurements 3.3 Hardness Measurements 3.4 Drawings and Images 3.5 Microstructure 3.5.1 Heat 814520 3.5.2 Heat 815111 3.6 Density 3.7 Inclusion Content 3.8 Toughness 3.9 Tensile Properties (70-1000°F) 3.10 Yield Stress-strain Curves
4. Weldment Properties of S31603 (316L) Manufactured Components 4.1 Welding Consumables 4.2 Welding Parameters 4.3 Joint Geometry 4.4 Macro and Microstructure 4.5 Hardness Profiles 4.6 Tensile Properties 4.7 Bend Results
5. References 6. Suggested Reading
Appendix A – Additional Test Property Data for Heat 33836-01A
Appendix B – ASME Stress Allowable Values
316L Stainless Steel --Powder Metallurgy/HIP
2011
2010
2011
500X
• Good tensile/yield properties • Good toughness • No Porosity, homogenous microstructures • Good Fatigue properties • Inspection, near forging quality
ASME Code Case N-834 & Data Pkg, plus NRC Review— Sect III-Approved Sept 2013
courtesy Rolls-Royce
ASTM 988
Tensile & Yield Strength – 316L SS (for Code Case)
Calculated Stress Allowable Values & Fatigue Data
Courtesy of Rolls-Royce
© 2021 Electric Power Research Institute, Inc. All rights reserved.w w w . e p r i . c o m12
316L SS Mechanical Properties ROA ~ >68%; Elong. > 40% (Room temp) Charpy Impact: >122 ft-lbs (3 orientations) Inclusion content (per ASTM E45): zero, (3 orientations) Density measurements: No porosity observed (3 orientations)
500X100X
316L Weldments for Code Case
GTAW
SMAW
Weldment Tensile & Hardness Results
Room Temperature Tensile Test Values for Each Weldment
Process Specimen TS (ksi) TS (MPa) YS (ksi) YS (MPa) Elong. in 2" (%) Fracture Location
SMAW 2 94.7 653.1 60.8 419.3 27.5 Weld 5 95.1 655.9 60.4 416.6 28.0 Weld 7 94.1 649.0 58.4 402.8 28.0 Weld
GTAW 2 83.9 578.6 51.2 353.1 36.0 Base 5 84.2 580.7 50.7 349.7 38.5 Base 7 84.8 584.8 52.9 364.8 39.0 Base
SMAW GTAW
Process
Specimen
SMAW
2
94.7
653.1
60.8
419.3
27.5
Weld
5
95.1
655.9
60.4
416.6
28.0
Weld
7
94.1
649.0
58.4
402.8
28.0
Weld
GTAW
2
83.9
578.6
51.2
353.1
36.0
Base
5
84.2
580.7
50.7
349.7
38.5
Base
7
84.8
584.8
52.9
364.8
39.0
Base
© 2021 Electric Power Research Institute, Inc. All rights reserved.w w w . e p r i . c o m15
Summary
Data Package developed – 2010-12. Code Case N-834 Approved in Sept 2013. Subsequently recognized by NRC under a
Reg. Guide. Used dozens of times since for production of
nuclear components (>$1M documented savings by one organization).
More recently we are using the Code Case as a guiding document for preparation of a new Appendix to BPV-III for PM-HIP.
Leading to New Industry: Installation of ATLAS-HIP, a 3.55m (140” diameter) HIP unit.
Acknowledgements
John Shingledecker, EPRI John Siefert, EPRI Walt Sperko, Sperko Engineering Lou Lherbier & Dave Novotnak, Carpenter John Sulley, Rolls Royce Tyco Valves & Controls
Together…Shaping the Future of Electricity
Small Modular Reactor Upper Head--Example
~44% scale Single monolithic structure A508 Class 1, Grade 3 27 penetrations 1650kg (3650lbs); 1270mm (50
inches) diameter Next, 2/3-scale head Need larger HIP Vessel -- ATLAS
Photographs courtesy of EPRI and NuScale Power
DOE Project: DE-NE0008629
Why Consider Powder Metallurgy To Produce Nuclear Components?
Technology Gaps/Barriers (in 2011-12)
316L SS Valve Body Assessment --Homogeneous Microstructure
316L SS Valve Body Feasibility
ASME Code Case Development
Tensile & Yield Strength – 316L SS (for Code Case)
Calculated Stress Allowable Values & Fatigue Data
316L SS Mechanical Properties
Weldment Tensile & Hardness Results
