Laser Direct Manufacturing of Nuclear Power Components Dr. Jyotsna Iyer, Dr. Scott Anderson, Gautham...
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Transcript of Laser Direct Manufacturing of Nuclear Power Components Dr. Jyotsna Iyer, Dr. Scott Anderson, Gautham...
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.”
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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
100
200
300
2010 2020 2030 2040
Gigawatt s- electr ic
Current reactors, 40 years Current reactors, 60 years
New capacity being considered 4 Builds per year starting 2021
Generating capacity with 80-year life
02050
Advanced/Affordable Manufacturing methods are key enablers for competing in $700B global market
DOE Nuclear Energy Enabling Technologies (NEET) Advanced Manufacturing Methods (AMM)
Contract: DE-NE0000542POP: 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 GardnerDr. Eric Faierson, Quad City Manufacturing Laboratory
Scope HIGHLIGHTS
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
(Unsintered powder)
Laser Melting
Sintered powder
Completed Layer
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
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Background for Alternate Nuclear Materials Selection
N13137-01
Generations II-IIISodium Fast Reactor
Molten Salt Reactor
Gas Fast Reactor
Lead fast Reactor
Superficial-Water-Cooled Reactor
Very High Temperature Reactor
1400
Tem
per
atu
re (
°C)
1200
100
800
600
400
200
0
0 50 100 150 200
Displacements Per Atom (dpa)
N13137-02
Fuel RodCutaway
FuelPellets
Fuel Assembly
UO2
MOX
Clad
Fuelpellet
Fuelrod
Spacergrid
Water flow
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
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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)
• 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 10 x 10 Grid 3 x 3 Grid
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Process Parameter Variation During Part Fabrication – Inconel 600
Specimen size Scan speed Laser powerInconel 600 1cmX2cmX1cm 1100mm/s 195W Standard EOSInconle 718 1cmX2cmX1cm 1200mm/s 195W Standard EOS
1cmX2cmX1cm 1000mm/s 195W 180W 165W 150W1cmX2cmX1cm 900mm/s 195W 180W 165W 150W1cmX2cmX1cm 800mm/s 195W 180W 165W 150W1cmX2cmX1cm 1200mm/s 195W 180W 165W 150W1cmX2cmX1cm 1400mm/s 195W 180W 165W 150W
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Process Parameter Effect on Fabricated Part Density – Inconel 600
Laser power of 195W makes the fabricated article almost insensitive to scan speed
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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
Notes:Power (W) Speed (mm/s)
4 600_150_1400 8.235 150 1400
10 600_180_1400 8.299 180 1400
11 600_195_800 8.384 195 800
12 (a) 600_195_1100 8.37 195 1100Sample #12 was selected to be mounted in both the x-y & Z planes (long)
12 (b) 600_195_1100 8.37 195 1100Sample #12 was selected to be mounted in both the x-y & Z planes (trans)
14 600_195_1400 8.346 195 1400
Proces ParametersSample # Sample name Micrograph (100X) Density (g/cm3)
Samples produced at the higherspeed rate and lower power demonstrate more voiding based micrographs
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 600-195-1400
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• 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
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Examination of Microstructure of Edge Transition
(c) Top Edge Transition: 500X
Top Edge: Terminating Side
Terminating Side
Initiating Side
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
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
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
Alloy Procurement StatusInconel 600 250lbs in-houseInconel 690
Inconel 718 250lbs in-houseInconel 625
Incoloy 800Purchased from Carpenter - expected ship date 9/17
Incoloy 800H
316 SS316Ti SS
316L SS In-house
304 SSCorrect particle size not available
ODS Steels
Oxide list downselected - further details being worked out
T91
• 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)
SPACE SYSTEMS COMPANYPreliminary Examination of 600-195-1400; Mt 14.046
8-7-14 JAB STAR Labs 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
~ 1cm
Top
Mid
Bot
Optical Image of Polished Cross-SectionSample 600-195-1400
Mt 14.046