Additive Manufacturing for Nuclear Components

George Pabis Craig Gramlich

December 5th, 2018

Acknowledgment and Disclaimer

Acknowledgment: This material is based upon work supported by the U.S. Department of Energy, Office of Science under Award Number DE-SC0015902.

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.

Agenda

• NovaTech Overview • AM Ideology • Accomplishments • Results • Future Tasks

3December 5, 2018 NovaTech Proprietary 2018

1 3 5 7 9 11 13 15 17

Series1

OVERVIEW – General InformationOVERVIEW – General Information

Founded in 1994, NovaTech is located in Lynchburg, Virginia

35 Employees, 27,500 ft2 Facility

Sales of $9.3 M (2016), Small Business Classification, S-Corporation

Quality Assurance Program Compliant with ASME NQA-1 and 10CFR50 App. B

Registered with US Dept. of State (ITAR) and US/Canada Joint Certification Office

Sales ($M)

00 02 04 06 08 10 12 14 16

Nuclear

Defense

Industrial

4December 5, 2018 NovaTech Proprietary 2018

NNUUCCLLEEAARR –– EEnnggiinneeeerriinngg

SMALL MODULAR REACTOR SYSTEM DESIGN

Contract lasted 4 yearsSupport the initial design studies beginning in 2008– Provided conceptual and preliminary design – Safety and support system design, analyses and documentation – Fuel mechanical design and testing – Fabrication and testing of fuel assembly and CRA prototypes – Component design and seismic analyses – Provided economic assessment for non-electric power applications – Provided design support for non-utility applications – NRC technical briefings during pre-application – Technical and topical reports – Drafting DCD sections – Review of specific licensing issues (10 CFR 50.62, 10 CFR 50.54(hh)(2), EA-12-049, etc)

December 5, 2018 NovaTech Proprietary 2018 5

NNUUCCLLEEAARR –– EEnnggiinneeeerriinngg

FUEL DESIGN

Contract lasted 2 years Varied from 5-10 engineers Work preformed remotely at NovaTech but travelled to support testing and meetings Work included • Design and analysis of skeleton • control rod assemblies • axial power shaping rods • burnable poison rods • primary and secondary neutron sources

Generated and checked production drawings Supported the final design review.

MMAAJJOORR CCUUSSTTOOMMEERR LLIISSTT

Aerojet American Ordnance AREVA BWXT BAE Systems Battelle Memorial Lab. Cadence Medical Day & Zimmermann DE Technologies Department ofDefense Department of Energy Dominion Power Duke Energy EPRI Flowserve

TVA NASA Nuclear Fuel Services NuScale Sandia National Lab. Savannah RiverCompany Siemens Energy Southern Company TerraPower US Army – ARDEC Vagts Engineering Inc. Westinghouse Electric

AM Ideology

• Use existing AM processes as if they were commonplace. • Replace existing fuel assembly components.• Add performance enhancing features. • MUST ADD VALUE.

SBIR Methodology

• Start with components that havewell established powder materials(Stainless Steel and Inconel) – Top & Bottom Nozzles – Holddown Springs

• Define design requirements • Rapidly fabricate prototypes thatshow potential based on analysis • Test designs • Iterate

DOE SBIR Awards

• Phase II Awards – Bottom Nozzles – Holddown Springs – Accident Tolerant Control Rods

• Phase I Awards – BWR Lower Tie Plates – Accident Tolerant Spacer Grids – NDT Techniques for TRISO Fuel

Bottom Nozzle

• Phase I Accomplishments – 3D printed eight bottom nozzle 5X5 prototypes out ofInconel-718 – Age hardened and inspected Inconel-718 parts – Designed and fabricated a prototype fuel rod lowerend cap – Successfully tested the fuel rod locking mechanism– Performed tensile tests, flow tests, and debris filtering tests – Submitted Technical report summarizing 2016 Phase IResearch

Bottom Nozzle

• Phase I – AM Build Example

12 December 5, 2018 NovaTech Proprietary 2018

Bottom Nozzle

• Tensile Testing – Yield Strength – Ultimate Strength – Elongation – Conclusion: Materialproperties of 3D printed

Minimum Inconel-718 meet minimum Properties material requirements.

Bottom Nozzle

Tunable Flow

Reactor Conditions

Bottom Nozzle

• Fuel Rod Locking – Designed to replace the lower end grid • Removes lower end grid and a fuel rod failure initiation point

– Integral to the bottom nozzle grillage • Allows for longer fuel rod

– Room for more fuel or plenum volume

– Locks fuel rod axially – Provides anti-rotation feature – Reconstitutable – Designed for single setup machining • Lathe turning + wobble broaching

– Successfully tested to 30 lb pull force

Bottom Nozzle • Debris Filter Testing – Tested all filter designs twice for debris resistance – Small holes and torturous pathsare the most effective filters– AM fabricated designs are highlyeffective at debris filtering

Bottom Nozzle

• Phase II Objectives – Full Scale Flow Loop Testing • Partnership with Framatome

– Predictive CFD Modeling – HIFR irradiation testing – Further Hone Design Features• Debris Filtering • Fuel Rod Locking • Part consolidation

Bottom Nozzle

• Full Scale Flow Loop Testing – Verify Phase I testing • Pressure Drops • Debris Filtering • FA fit-up • Fuel Rod Locking

– Measure Fuel Rod Wear

Bottom Nozzle

• Predictive CFD Analysis

Standard Path Part H Part A

Standard Path – 150 GPM Pressure Drop = 1.53 psi

Part H – 150 GPM Pressure Drop = 4.75 psi

Part H – 60 GPM Pressure Drop = 0.93 psi

Part B Path – 145 GPM Pressure Drop = 9.36 psi

Bottom Nozzle

• HIFR Irradiation Testing – 24 specimens – Inconel-718 – 60x1019 n/cm2

• ~6 dpa

– 2020

Holddown Springs • Phase I Accomplishments – FEA simulation of spring rates – 3D printed five different Holddown Spring Designs – Age hardened and inspected Inconel-718 parts – Performed load-deflection tests to failure – Submitted Technical report summarizing 2017 Phase I Research

Holddown Springs

• Design – 3-Leaf Westinghouse 17x17 spring replacement – Tunable to different fuel assembly and reactor designs – Minimize Upper Core Plate wear – Reduce rework – Evaluate potential Upper Nozzle / Holddown Spring Design Interface – Reduce number of parts

Holddown Springs

• Phase I – AM Build Example

Holddown Springs

• FEA Simulation – Predict Spring Rates – Predict Deflection Shape – Guide design beforemanufacture– Stress states

Holddown Spring

• Load-Deflection Testing – Failure Modes – Deflected Shape – Verify analytical models

0 0.5 1 1.5 2

Load-Deflection 5b

Part 4a

0 0.5 1 1.5 2 2.5 3

Load-Deflection 4a

Compress 1

Release 1

Compress 2

Release 2

Copmress 3

Release 3

Compress 4

Release 4

Compress 5

Release 5

Part 3a

0 0.5 1 1.5 2 2.5 3

Load-Deflection 3a

Compress 1

Release 1

Compress 2

Release 2

Copmress 3

Release 3

Compress 4

Release 4

Compress 5

Release 5

Holddown Springs

• Phase II Objectives – Top nozzle interface enhancement– Optimize successful Phase I designs– Fatigue Testing – SCC testing – Fuel Bundle Assembly

Summary• NovaTech is excited to be involved with this transformative technology.

• We are using additive manufacturing to fabricate: – Bottom Nozzles – Holddown Springs – Top Nozzles – BWR Lower Tie Plates

• As we look to the future, we see: – More fuel assembly components being additively manufactured – Further Part consolidation – Faster fabrication times – Reduced costs

Additive Manufacturing for Nuclear Components · Design and analysis of skeleton ... – Performed...

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