Materials and Manufacturing, Opportunities and … · Opportunities and Constraints, in New Nuclear...
Transcript of Materials and Manufacturing, Opportunities and … · Opportunities and Constraints, in New Nuclear...
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Materials and Manufacturing,
Opportunities and Constraints,
in New Nuclear Build
J.B. Borradaile, R.M. Mitchell, H.R. Dugdale (Rolls-Royce)
10 April 2014
Sustainable Nuclear Energy Conference
9-11 April 2014, Manchester
Agenda
10 April 2014
• Introduction to Rolls-Royce Capability
• Design, Structural Integrity and Reliability
• Safety Classification of Components
• HIP in the Nuclear Industry: A Case Study
• Development of HIP Nickel Based Alloys Capability
• Conclusions
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Rolls-Royce has supplied nuclear
PWR plant and nuclear services for
over 50 years supporting civil and
naval applications
Trusted to Deliver Excellence
Rolls-Royce is a global business
providing integrated power systems for
use on land, at sea and in the air.
3
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10 April 2014
Nuclear Sector business locations
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Design Process
In-Service Modification
Configuration Management
Maintenance of Design Intent
Design Definition (creation) Design Definition (verification)
STAGE 1 Preliminary Concept Definition
STAGE 2 Full Concept definition
STAGE 3 Product Realisation
STAGE 4 Production & In-service Support
STAGE 5 Continuing In-Service Support
STAGE 6 End of life disposal
STAGE 0 Innovation & Opportunity Selection
Component Design - GQP C.4
Product Change Control - GQP C.1.4
Customer requirements and key drivers + Research and Capability requirements/ investment
Statement of Requirements + Preliminary Concept Design Scheme
Full Concept Design Scheme + Draft Design Substantiation Report + Definition of Material Requirements
Final Reference Design Scheme + Design Substantiation Report + Manufacturing Drawings + Manufacturing, installation, testing and commissioning procedures
Verification of manufacturing, Installation, testing and commissioning procedures + DSR Review
Revalidation and Inspection + Maintenance and Upkeep + DSR Review
Lay-up + Surveillance
Product Introduction and Lifecycle Management - GQP C.1.8
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Design Intent
Requirements
No unacceptable
defects introduced
during welding
No environmentally
assisted cracking in-
service
No defect initiation
Stage in Life
Cycle
Design
Weld location and
geometry (ease of
welding / inspection)
Material selection Geometry and
surface finish
specification
Manufacture
Weld procedures and
welder qualification
Heat treatment
control/stress relief
Process controls
and inspection
Commission
-
Plant fill procedure
-
In-service
Control of
maintenance
requiring welding
Environmental
controls (operational
and maintenance)
Operation within
design envelope
Design Intent
Maintenance of
Design Intent
Environment
Stress Material
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Nuclear Safety Principles
10 April 2014
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•Proven Engineering Practices:
Nuclear power technology is to be based on engineering
practises which are proven by testing and experience
•Equipment Qualification:
Safety components and systems shall be chosen which
are qualified for the environmental conditions
•Continuous Improvement:
Operating organisations and designers shall seek to
improve safety standards and safety performance in
present and future plant. Techniques such as
maintaining excellent material condition and component
performance shall be employed
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• ASME recognises different levels of importance of each component.
• It requires provision of a level structural reliability relative to the safety importance of the individual component (Class 1, 2 or 3).
• ASME does not provide guidance on the selection of a specific classification to assign a component.
It is the owner’s responsibility through provision of the Design Specification, to provide an appropriate classification for components.
ASME Classes
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• Compliance with design codes such as ASME allows a structural reliability of ~10-5/year to be claimed, based on failure statistics from non-nuclear pressure vessels.
• For those components with intolerable consequences of failure (uncontained release of fission products to the public) it needs to be demonstrated that failure is incredible, which in the UK is defined as a failure rate <10-7/year.
• Consequently, a higher safety classification and demonstration of reliability is required for a catastrophic failure mode of the Reactor Pressure Vessel, compared with other Class 1 primary circuit components, with less severe consequences of failure.
• This introduces the concept of Incredibility of Failure or IoF.
Safety Classification
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IoF Concept Multi-Layered
Major principle in Nuclear Safety is Defence in Depth, provision of multiple layers of protection
Some components it is not possible to provide this defence by physical means
For these Incredibility of Failure (IoF) needs to be demonstrated, retaining the principle of Defence in Depth, through application of appropriate experience, testing, analysis and monitoring
Conceptual Defence in Depth – based on leg element structure UK Technical Advisory Group on Structural Integrity of High Integrity Plant
TAGSI
GOOD DESIGN & MANF
TESTING FAILURE ASSESSMENT
FORWARNING of FAILURE
DEFENCE IN DEPTH
SEGREGATION DIVERSITY
REDUNDANCY
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NSRP Safety Classifications
System,
Structure,
Component,
Classification
Consequences of Failure
Approximate
Failure rate /
annum
ASME III Code
Classification
Consequence of
Failure
IoF
Failure leads inevitably to
fuel failure and uncontained
fission product release <10-7 Class 1 Catastrophic
High Integrity Failure would inevitably lead
to fuel failure 10-6 Class 1 Major
Safety
Critical
Failure would lead to a
demand for a safety system
to operate to prevent fuel
failure
10-5 Class1 Serious
Safety
Related
In combination with other
failures (including operator
error ) failure would lead to
the demand for a safety
system
10-4
Class 2 Minor
Non-Safety Failure would only lead to
reduced plant availability 10-3 Class 3 Negligible
Procedure is DETERMINISTIC – probabilistic studies may be used to support the deterministic calculations
ASME III
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Stages in the Procedure
Assess Damage Tolerance Step 2
Determine Risk Category Step 3
Identify Structural Integrity requirements
Step 4
Define Component Safety Classification
Step 1
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1 2 3 High upper shelf toughness
High tearing resistance
(e.g. TIG)
Intermediate upper
shelf toughness
(e.g. MMA, Sub.Arc)
Transition toughness
Limited tearing resistance
Non-welded components Welds with simple
geometry and easy
access for welding
and NDE
Welds with complex geometry and
difficult access for welding and NDE
Within stress limits
Secondary stresses low
Stress relieved welds
Within stress limits
Non-stress relieved
ductile welds
Dissimilar ductile
welds
Structural
discontinuity
Gross structural discontinuity
Rapid temperature changes
Non-stress relieved non-ductile
welds
Dissimilar non-ductile welds
Known well understood
degradation mechanism
Judgements/uncertainties
resolved by
surveillance/monitoring
programmes
FUF<0.4
0.4<FUF<0.8
Moderate crack
growth
Degradation
mechanism that
results in reduction in
toughness but no
failure mode
FUF>0.8
High crack growth
Degradation mechanism that brings
about a change in failure mode
Material failure mode
Likelihood of significant defects
Loading/ Stress level
Degradation mechanism
Score
Assessment of Damage Tolerance
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Ranking of Damage Tolerance
Sum the Damage Tolerance scores
Damage Tolerance Total Score
High (H) 4
Medium (M) 5 to 8
Low (L) 9 to 12
Use Damage Tolerance Ranking in Conjunction With Consequence of Failure Ranking
Matrix of Potential risk
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A A B C C
A B C C C
B C C C C
IoF HI SC SR NS
Low (9-12)
Medium (5-8)
High (4)
Safety Classification (Consequences of Failure)
Damage Tolerance
• ASME Class 1
• 4 legged approach (Required)
• SMI (ASME V) + review of credible defects
• MAI to support a defect tolerance assessment
• R6 target reserve factors
• ASME Class 1
• 4 legged approach (required for cat A, recommended for cat B)
• SMI (ASME V)
• R6 sensitivity study
• ASME Class 1
• ASME Class 2 (SR), Class 3 (NS)
• 4 legged approach (useful)
• SMI (ASME V)
CATEGORY A CATEGORY B CATEGORY C
SMI (Standard Manufacturing Inspections) - Confirm quality
MAI (Manufacturing Acceptance Inspections) – Qualified inspections that target defects of structural significance and supports the fracture assessment
Matrix of Potential Risk and Structural Integrity Requirements
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Examples
High Quality Butt Weld in Large Diameter Austenitic Stainless Steel Reactor Coolant Boundary Piping A postulated gross failure of this weld could result in fuel failure based on the assumption that a catastrophic failure would not be isolable or protectable. Consequence is Fuel Failure - Safety Classification is High Integrity Material failure mode = 1 Likelihood of defects = 2 Loading/stress level = 2 Degradation mechanism = 1 Total score` = 6 Damage Tolerance is Medium. The location is therefore in Risk Category B. Risk Category B welded location, has the following structural integrity requirements: Compliance with ASME III Code Class 1 Design and Fabrication requirements (including SMI) R6 defect tolerance sensitivity study TAGSI safety case structure
High Quality Butt Weld in Small Diameter Austenitic Stainless Steel Reactor Coolant Boundary Piping A postulated gross failure of this weld would not result in fuel failure as it could be protected by emergency core cooling system. Failure is protected - Safety Classification is Safety Critical Material failure mode = 1 Likelihood of defects = 2 Loading/stress level = 2 Degradation mechanism = 1 Total score` = 6 Damage Tolerance is Medium. The location is therefore in Risk Category C. Risk Category C welded location, has the following structural integrity requirements: Compliance with ASME III Code Class 1 Design and Fabrication requirements (including SMI)
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Safety Classification Summary
• The traditional approach to safety classification was to designate all safety significant components as ASME III Class 1.
• IAEA and UK safety assessment principles for nuclear plants require components to be classified based on their safety functions and then designed and constructed to achieve the required reliability level.
• A safety classification process has been developed which has five levels; the highest two levels, High Integrity and IoF require additional demonstration of reliability than can be gained from strict compliance with ASME III Class 1 rules.
• A multi-legged structural integrity case is adopted for those components that require high reliability demonstration ie High Integrity/IoF using the UK Technical Advisory Group on the Assessment of High Integrity Nuclear Plant (TAGSI) format.
• The two specific areas where the ASME III Class 1 requirements may need to be exceeded to achieve the additional reliability demonstration are: • Explicit demonstration of defect tolerance
• Validation of inspection techniques to demonstrate that tolerable size of defects (plus an appropriate margin) can be reliability detected and characterized.
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• Initial step is to produce powder metal of desired composition. Molten metal is poured through ring of high pressure inert gas nozzles. This breaks up molten stream into fine droplets which rapidly solidify within the atomisation tower.
• Powder is then sieved to desired size distribution, which limits segregation and inclusion size.
• A low alloy steel can is filled with the powder, degassed and sealed. The filled can is then subjected to a high temperature (>1100 C) and pressure (>100 MPa) for a number of hours until powder fully consolidated, along with a shrinkage of ~ 30%.
• Can is removed by machining or pickling
Advanced Nuclear Manufacturing Case Study : Hot Isostatic Pressing (HIP) of powder metals
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Why HIP?
Attractive manufacturing route for NSRP components, able to provide protection against manufacturing route obsolescence, improved mechanical properties, better control of defects and more reproducible results.
Microstructures are isotropic, equiaxed with a small grain size, properties not normally achieved in heavy section components. This helps facilitate ultrasonic NDE examination - Additionally, inclusions are small and more benign compared to forgings.
Turnaround times and costs can be reduced when compared to large forgings.
Complex shapes can be created, which enables weld removal from the design, simplifying construction and NDT requirements
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Introduction: Advantages of HIPping
• Fine, equiaxed grain size
• Improved inspectability
• Material cleanliness
• Repeatability
• Geometric complexity (near-net shapes)
• Cost
• Batch sizes
• Lead time
10 April 2014 Rolls-Royce Proprietary Information
Introduction: HIP in the Nuclear Industry
Fine, equiaxed grain size
Improved inspectability
Material cleanliness
Repeatability
Geometric complexity (near-net shapes)
Cost
Batch sizes
Lead time
•10 April 2014
21
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RR Nuclear HIP Strategy Background
To satisfy the Nuclear Safety Principles a gradual
introduction strategy for HIP NSRP components
evolved
This included proving the technology for specific
applications, and development of the
specification, procurement and justification
experience.
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CAT A Components - Conceptual Strength in Depth
Multi-legged structure (TAGSI 4 leg approach)
LEG 1
Interpolation of
experience
(Design and
Manufacture)
LEG 2
Functional
Testing
LEG 3
Failure Analysis
LEG 4
Forewarning of
Failure
• Multifaceted, based on experience and sound
engineering practice
• Tolerant to defects and fault conditions.
• Strength of the case is judged by the strength and
independence of each leg
• For introduction of HIP, both Leg 1 and Leg 3 needed
to be stronger
• Leg 3 is required to be strong for IoF and HI components
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Gradual Introduction Strategy
Demonstrate by mechanical testing to recognised standards that HIPped material is equivalent to wrought form
Obtain manufacturing and in-service experience of the technology through HIP of non-pressure boundary components
Further develop manufacturing and in-service experience pf the technology by applying it to leak limited pressure boundaries of isolable components
Further develop manufacturing and in-service experience of the technology by applying it to isolable pressure boundary components
Apply technology to un-isolable pressure boundary components
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Gradual Introduction Strategy
Demonstrate by mechanical testing to recognised standards that HIPped material is equivalent to wrought form
Obtain manufacturing and in-service experience of the technology through HIP of non-pressure boundary components
Further develop manufacturing and in-service experience of the technology by applying it to leak limited pressure boundaries of isolable components
Further develop manufacturing and in-service experience of the technology by applying it to isolable pressure boundary components
Apply technology to un-isolable pressure boundary components
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Gradual Introduction Strategy: Tensile properties of HIP and wrought 316L
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0
100
200
300
400
500
600
700
21.1 37.8 93.3 148.9 204.4 260 315.6 371.1 426.7 482.2 510
MP
a
Temperature °C
0.2% Proof HIP
0.2% Proof Wrought
UTS HIP
UTS Wrought
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Gradual Introduction Strategy
Demonstrate by mechanical testing to recognised standards that HIPped material is equivalent to wrought form
Obtain manufacturing and in-service experience of the technology through HIP of non-pressure boundary components
Further develop manufacturing and in-service experience of the technology by applying it to leak limited pressure boundaries of isolable components
Further develop manufacturing and in-service experience of the technology by applying it to isolable pressure boundary components
Apply technology to un-isolable pressure boundary components
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HIPing of hard-wearing Stellite 6 (Co-base) and Tristelle 5183 (Fe-
base) bars and HIP bonding of inserts to austenitic 304LE and
Monel 4070 small-bore globe valves since 1994
Rolls-Royce (nuclear) applications of HIP
HIPped Stellite/Tristelle
Seat machined from bar
Seat HIPped to valve body billet
Final machining
Replaced oxy-acetylene deposit of Stellite
Reduced non-conformance and removed bottleneck in route
HIPped seat provided better grain structure and in-service longevity
Rolls-Royce data – Proprietary & Confidential Information
28
Proceedings of PVP-2005, PVP2005-71711
HIPped back seat
HIPped main seat
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Implementation of HIP
•10 April 2014
29
Manufacture and bonding of HIP Stellite 6 hard facings
onto valves
Oxy-acetylene Stellite 6 deposit on stainless steel
x100
HIPped Stellite 6 powder bonded onto stainless steel
x100
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Gradual Introduction Strategy
Demonstrate by mechanical testing to recognised standards that HIPped material is equivalent to wrought form
Obtain manufacturing and in-service experience of the technology through HIP of non-pressure boundary components
Further develop manufacturing and in-service experience of the technology by applying it to leak limited pressure boundaries of isolable components
Further develop manufacturing and in-service experience of the technology by applying it to isolable pressure boundary components
Apply technology to un-isolable pressure boundary components
Rolls-Royce Proprietary Information
Rolls-Royce data – Proprietary & Confidential Information
31
HIPped Stainless Steel 316L Omega Seals
Omega seals are welded to main
component assembly
No discernible difference between
wrought/HIPped welded material
HIP offers smaller defect sizes and an
ability to supply small quantities at
acceptable cost and lead-time
Over 500 omega seals manufactured,
with over 200 in-service. Proceedings of ICAPP 2008 Paper 8110
Gradual Introduction Strategy
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HIPped 316L stainless steel machined and welded omega seals.
Gradual Introduction Strategy
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Microstructure of Forged and HIPped 316L
Forging (ASTM No. 2) HIPped powder (ASTM No. 5)
Type 316L structures (x100)
Omega seal was first stainless steel HIP application, high level of material cleanliness required
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Gradual Introduction Strategy
Demonstrate by mechanical testing to recognised standards that HIPped material is equivalent to wrought form
Obtain manufacturing and in-service experience of the technology through HIP of non-pressure boundary components
Further develop manufacturing and in-service experience of the technology by applying it to leak limited pressure boundaries of isolable components
Further develop manufacturing and in-service experience of the technology by applying it to isolable pressure boundary components
Apply technology to un-isolable pressure boundary components
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Full size Tee piece in Type 316L ~ 2 tons
Destructively tested, isotropic mechanical properties confirmed
Production components were introduced onto nuclear plant
First use of HIP in a Primary Circuit pressure retaining application
Gradual Introduction Strategy
Isolable PC boundary – Tee piece 2009
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Isolable PC boundary – Tee piece 2009
Previously, forging of the Tee had
used a three ram press and closed
die process
Typical issues experienced included
large grain structures and surface-
breaking defects
HIP proved an attractive alternative
In addition to project savings, HIP
offered advantages in both
mechanical properties and improved
inspectability
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• HIP pipework in 304LE austenitic
stainless steel enables elimination
of a number of large bore and
small bore stub connection welds.
• Development work produced a
stable and reproducible technique
• HIP pipework sections have also
been introduced onto plant
• Current requirement to machine
bore rules out elbows and
diameters where access cannot be
gained
Gradual Introduction Strategy
Isolable PC boundary – HIP Pipework
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Gradual Introduction Strategy
Valve Body and Cylinder Demonstrators
Valve body and cylinder technology demonstrators manufactured from Type 304LE powder.
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Gradual Introduction Strategy
Pump Bowl Demonstrator
Thickest section component
produced to date
Traditionally sand cast
No inclusions above 15 μm reported
Grain size ASTM grade 5
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Gradual Introduction Strategy
Demonstrate by mechanical testing to recognised standards that HIPped material is equivalent to wrought form
Obtain manufacturing and in-service experience of the technology through HIP of non-pressure boundary components
Further develop manufacturing and in-service experience of the technology by applying it to leak limited pressure boundaries of isolable components
Further develop manufacturing and in-service experience of the technology by applying it to isolable pressure boundary components
Apply technology to un-isolable pressure boundary components
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ASME Code Case N-834
In November 2011, a code case submission for
the use of HIP Type 316L austenitic stainless
steel on nuclear plant was made to ASME boiler
and pressure vessel committee.
Code case was approved on October 22, 2013
It was the opinion of the committee that, ASTM
A988/A988M-11 UNS S31603 may be used for
Section III, division 1, subsection NB, Class 1
components in construction
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Future Nuclear HIP Strategy
10 April 2014 Rolls-Royce Proprietary Information
The Development of HIPped Nickel Based Alloys
10 April 2014
43
• Interest in developing HIP Alloy 625 began in 1990
• Research programme examined both the potential of the HIP process and the opportunity to make use of new materials.
• Alloy 625 was identified as having the potential to offer benefits to a wide range of plant applications
• HIP process is especially relevant to alloys like Alloy 625, the same properties that make it appealing to a designer also made it difficult to fabricate and machine
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Development of HIP NBA: Valve Production
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• Single experimental project to demonstrate the feasibility of producing an Alloy 625 valve using HIP
• Design offers a degree of complexity without being overambitious
• Opportunity to combine a number of production stages into one:
Body machining
Seat installation
Addition of stubs
Fitting of liner
• Three sections:
Optimisation of HIP process
Production of valve bodies
Rig testing of completed valve
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Development of HIP Valve: Parameters
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Particle Size Distribution
0
5
10
15
20
25
30
<45 45-75 75-106 106-180 180-250 250-420 >420
Particle Size Range (μm)
% o
f P
art
icle
s
Element C Si Cr Ni Fe Mo Nb Mn P S Co Al Ta N O
Composition
% 0.02 0.37 21.3 59.3 4.36 9.3 3.53 0.33 0.15 0.007 0.04 0.003 1.05 0.108 0.021
Temperature (°C) Pressure (MPa) Time at Temperature
(°C)
1120 103 4
1160 103 3
1200 103 4
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Development of HIP Valve: Optimisation of HIP
Parameters
• Effect of HIP temperature on mechanical properties
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Development of HIP Valve: Valve Production
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• Three valve bodies produced
• Can design optimisation
• Rig testing considered successful
• Major departure from conventional method of producing component
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Development of HIP Valve: Material
Characterisation
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• Tensile test results compared with ASME wrought data
0
100
200
300
400
500
600
700
800
900
1000
0 100 200 300 400 500 600
Temperature °C
Str
ess M
Pa Wrought 0.2% proof
Wrought UTS
HIP 0.2% proof
HIP UTS
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Development of HIP Valve: Material Characterisation
10 April 2014
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• Fracture toughness values were lower than expected
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Development of HIP Valve: Material Characterisation
10 April 2014
50
• Results from rotating beam specimens are comparable to wrought material, whilst those from cantilever bend tests are superior
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Development of HIP Valve: Project Conclusions
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• Project was determined to have successfully demonstrated the feasibility of producing a valve using the HIP process
• Significant reduction in the number of production stages
• Mechanical properties of Alloy 625 require more work
• Extensive development work required to transition valve from prototype to production part
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Further Development of NBA
10 April 2014
52
• Interest in the HIPping of NBA has recently been ignited
• Development of Alloys 690 and 625
• Basic test programme aiming to characterise materials and optimise HIP parameters
• Material properties are compared to their wrought equivalents: regulatory requirements
• Aiming to manufacture HIP NBA components for plant applications
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Further Development of NBA: Alloy 625
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53
• University of Birmingham programme
• Production of 15 kg HIP bars
• Small powder size: 45 ± 15 μm
• HIP Conditions: 1160°C, 103 MPa for 240 mins
• Heat Treatments are being studied
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The Development of HIPped Alloy 625: Mechanical Properties
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0
100
200
300
400
500
600
700
800
900
1000
0 100 200 300 400 500 600
Temperature (°C)
UT
S (
MP
a) HIP UTS
Wrought ASME UTS
HIP 0.2% proof
Wrought ASME 0.2% proof
• Tensile tests showed favourable mechanical properties when compared with wrought ASME data
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The Development of HIPped Alloy 625: Mechanical Properties
Sample Vickers
(H v0.3)
Brinell Rockwell
1 260 Equivalent
Brinell
hardness
10 mm C
ball 3000
kgf (HB)
Equivalent
Rockwell
hardness
150 kgf
(HRC)
2 275
3 281
4 265
5 266
6 260
7 281
8 267
9 276
10 271
Average 270 H v0.3 257 HB 25 HRC
Temperature L T
RT 84 106
RT 96 108
RT 92 102
RT 103 103
RT 105 105
RT 96 119
• Favourable hardness and Charpy impact test results
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HIP Development of NBA: Alloy 625 MA
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HIP Case Study Summary
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57
HIP powder processing has become a valuable manufacturing
technique
The use of stainless steel HIPped components has been
extensively validated through both laboratory and prototype
component testing
Work is beginning to optimise the HIPping of Inconel alloys,
including Alloy 625
The methodology established for taking HIP stainless steel
components from design phase up to component safety case will
be key for the introduction of other HIPped materials onto plant
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Sizewell B (Gen III size) Naval Propulsion Equivalent
RPV Steam
Generator
Pressuriser Reactor
Coolant
Pump
RPV
Steam
Generator Pressuriser RCP
Size Matters: Propulsion components are significantly smaller than land based plant
Rolls-Royce Proprietary Information
• HIP has been demonstrated for applications on Naval Propulsion
Plant .
• An ASME Code Case has been achieved for the use of HIP Type
316L austenitic stainless steel on Class 1 components.
• HIP advantages include inspectability of the component, control of
defects, batch sizes, lead times and are not only metallurgical.
• There is no reason that HIP should not be used on Civil Plant and
Small Modular Reactors with their requirement for increased
production rates may provide the impetus
Conclusions
Rolls-Royce data – Proprietary & Confidential Information
59
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