Enclosure 2: Additive Manufacturing Presentation. · 2017-06-20 · ENCLOSURE 2 M170149 Additive Manufacturing Presentation Non-Proprietary Information – Class I (Public) INFORMATION

ENCLOSURE 2

M170149

Additive Manufacturing Presentation

Non-Proprietary Information – Class I (Public)

INFORMATION NOTICE

Enclosure 2 is a non-proprietary version of the Additive Manufacturing Presentation from Enclosure 1, which has the proprietary information removed. Portions that have been removed are indicated by open and closed double brackets as shown here [[ ]].


General Aspects ofAdditive Manufacturing(Open Session)

Presenters: Felipe Betancor, Edison Engineer – Additive ManufacturingMyles Connor, Lead Materials EngineerFrancis Bolger, New Product Introduction Manager

June 7th, 2017

1


Safety Moment:Questioning Attitude

• Why?• Avoid dependence on unsubstantiated

assumptions or opinions

• When?• At all times!

• How?• Consider “what-if’s”• Stop when unsure

June 7, 2017Aspects of Additive Manufacturing2


Aspects of Additive ManufacturingTopics of Discussion for Open Session

• Introduction

• General Electric and Additive Manufacturing

• The 3D Printing Process

• Applications of Additive Manufacturing in Nuclear Industry

• Show and Tell

• Looking Forward



IntroductionSynopsis and Meeting Objectives

Additive Manufacturing (AM) is the process of building 3D objects by adding layer-upon-layer of material under computer control.• AM Variants: Technique; Material; Building Method• Direct Metal Laser Melting (DMLM)

Objectives of Meeting

• Provide an overview of DMLM and why it is important for the nuclear industry.

• Present GEH’s current DMLM knowledge base, qualification strategy, and regulatory acceptance path.

• Obtain NRC’s perspective on the adequacy of the plan.



Industrial Solutions Plainville, CT

AMWGreenville, SC

LEAP Fuel Tip Production Auburn, AL

CATAPittsburgh, PA

GE Aviation Cincinnati, OH

Energy ConnectionsBielsko-Biala, Poland

Innovation CenterIstanbul, Turkey

Adv. Mfg. CenterDetroit, MI

Global Research CenterNiskayuna, NY

Avio AeroCameri, Italy

Building a Global Additive NetworkCustomer Experience CenterMunich, Germany



GE’s Grasp in Additive Manufacturing

Over $3B InvestedOver 10 Years of R&D

Center for Additive Technology Advancement

Advanced Manufacturing Works

GE Aviation Additive Manufacturing Production Center



Source: EPRI.com

Source: genewsroom.com

Source: Energy.gov

Source: designnews.com

Source: optics.org

Source: metal-am.com



DMLM Description


Additive (3D Printing) ProcessDirect Metal Laser Melting (DMLM)

Powder Bed


Intricate Designs that conventional

manufacturing processes cannot achieve

Reference: Within Labs, UK

Reference: metalbot.org


Before and After DMLMGas Atomization: Powder Development Post-Processing: Heat Treatment

• Powder Chemistry

• Powder Size

• Stress Relieving

• Hot Isostatic Pressing (HIP)

• Solution Annealing12

3

4



Value and Benefits• Speed of Delivery

• Rapid Prototyping• On-Demand Parts Reduced Inventory• Obsolete Parts Scan, Model, Print• Emergent Parts Outage Demand

• Design for Performance• Geometric Freedom Performance Enhancements• Weight Reduction

• Cost Reduction• Low Volume Parts• Complex Multi-Component Assemblies

• Enhanced Chemistry Control • Alloy Control Favorable to Nuclear Environment

Cos

t

Complexity


Additive ManufacturingTraditional Manufacturing

Area of Opportunity


Already Demonstrating Success



LEAP Engine Nozzle Story

Video: https://youtu.be/rMzVSbNebCg



Delivering Results

Five Years of Dedicated Research, Optimization, and Development

Material Properties for AM 316L and IN718 Consistently Met or Surpassed Reference Properties

from Wrought Material

Significant Work Towards Demonstrating Successful Part Implementation Has Yielded Promising Results

Successfully Issued ASTM StandardUpdating EPRI Guidance for Reactor Internal Materials

Developing and Implementing Quality Assurance Requirements



Application Examples

Channel Fastener

Fuel Bundle Debris Filter

AVS Compliant Spring

FMCRD Labyrinth Seal



Channel Fastener

Fuel Bundle Debris Filter



AVS Compliant Spring



Fine Motion Control Rod Drive (FMCRD) Labyrinth Seal




Looking Forward

Ensure Safety and

Compliance

Identify Applications

Validate Material

Properties

Develop Expertise

Control Quality

Evolve AM Landscape


Questions?

20GEH Nuclear Energy: Additive Manufacturing

6/7/2017


Thank you. This marks the end of the Open Session.


General Aspects ofAdditive Manufacturing(Closed Session)

1

Presenters: Felipe Betancor, Edison Engineer – Additive ManufacturingMyles Connor, Lead Materials EngineerFrancis Bolger, New Product Introduction Manager

June 7th, 2017


June 7, 2017Aspects of Additive Manufacturing

2

Aspects of Additive ManufacturingFocus of Closed Session

• Deep Dive into Material Testing Results

• AM Process Qualification/Control

• Regulatory Acceptance

• Future Work

Objectives of Closed Session

• Provide an overview of DMLM and why it is important for the nuclear industry.

• Present GEH’s current DMLM knowledge base, qualification strategy, and regulatory acceptance path.

• Obtain NRC’s perspective on the adequacy of the plan.


Principles of Material Quality


3


Outline


4

• Microstructure Characterization• Mechanical Properties• Irradiation Testing• Qualification and Process Control• Inspection and Validation Processes

Chemistry +

ProcessingMicrostructure



5Aspects of Additive Manufacturing

AM 316L Virgin

Powder

AM 316L Product

316L Standard

C 0.018 0.019 ≤ 0.020S 0.002 0.003 ≤ 0.020N 0.10 0.09 0.060-0.10O 0.03 0.03Mn 1.41 1.27 ≤ 2.00P <0.030 <0.030 ≤ 0.030Si 0.50 0.50 ≤ 0.75Cr 17.3 17.0 16.0-18.0Ni 10.3 10.5 10.0-14.0Mo 2.29 2.16 2.00-3.00Cu 0.07 0.07B <0.010 <0.010Co 0.04 0.04 ≤ 0.050

Powder CharacterizationSupplier: [[ ]]Process: Gas AtomizedSize: -325 mesh 16 μm

Powder/Product Chemistry

Non-Proprietary Information – Class I (Public)Top View 2 Top View 2

Cross-section View 4 Cross-section View 4

1

2

3 4

Building Direction

As-built Stress Relief


6


Top View 2 Top View 2

Cross-section View 2 Cross-section View 4

Anneal HIP + Anneal

Good Density Low Porosity 100% Austenitic Grain Size 5 or Finer Microstructure Similar to Wrought


7

1

2

3 4

Building Direction




Microstructure Characterization

Aspects of Additive Manufacturing

Strain: AM 316L (Electron Backscatter Diffraction Spectroscopy)

[[

]]




Microstructure Characterization

Aspects of Additive Manufacturing

AM 316L to Wrought 316L Comparison

Wrought 316LAM 316L


Outline


10

• Microstructure Characterization• Mechanical Properties• Irradiation Testing • Qualification and Process Control• Inspection and Validation Processes



3/1/2017

Committed to Reliability and Quality

Mechanical Testing:• Tensile• Charpy• Fatigue• Toughness• SCC

[[

]]

]]

[[


Mechanical Properties


12

Tensile Testing: Ultimate Tensile Strength

[[

]]




13

Tensile Testing: Yield Stress

[[

]]




14

Tensile Testing: Elongation and Reduction of Area

[[

]]




15

Charpy Test

Typical Charpy toughness for annealed 316L @ RT: 65~100 ft-lb

[[ ]]

]]

[[




16

Fatigue Test for AM 316L

Fatigue Performance meets design limits.Machining and Surface Treatment Improve Life.

[[

]]


Surface Roughness


17

Design Principles

• Due to layer by layer build, the melt profile goes [[ ]] layers deep [[ ]]

• Top most layer exposed to least amount of heat• Down facing surfaces come out rougher than up

facing surfaces due to melt profile of the laser• There is no over melt in up facing surfaces

[[

]]


Surface Roughness


18

Surface Considerations

As-built surface finish significantly coarser than traditionally machined parts

Can be compensated for in most cases; must be accounted for in design phase

• Design to requirements ,(i.e. airflow, fluid flow, LCF/HCF, etc…) not solely based on past “normals”

Straight from the machine (as-built), parts will have:• [[ ]] RA [micro-inches]on the top facing surface (upskin)• [[ ]] RA on side walls• [[ ]] RA on down facing surfaces (downskins)

[[

]]




19

Fracture Toughness: AM 316L

Positive and Consistent Fracture Toughness Response

Build

Dire

ctio

n [[

]]

[[]]




20

Stress Corrosion Cracking: Crack Growth Rate

Continued SCC and IASCC In Progress

[[

]]


Outline


21

• Microstructure Characterization• Mechanical Properties• Irradiation Testing• Qualification and Process Control• Inspection and Validation Processes

Courtesy: University of Michigan



22

Irradiation PropertiesParameter 2 MeV Proton 5 MeV Fe++

Dose (dpa) [[

Temperature (○C)

Damage rate (dpa/s)

Beam current ( A) ]]Irradiation stage

Example of temperature distributionTemperature = 360 ± 4 ◦C for 2 MeV proton irradiation



23

Irradiation Properties


[[

]]



24

Irradiation Properties


]]

[[ Comparison to wrought data in progress…

Preliminary results show AM 316L performing as good (or better?) than wrought 316L

Tensile and SCC Coupons schedule for INL ATR irradiation starting 3rd Qrt 2017



25

Let’s Take A Break


Outline


26

• Microstructure Characterization• Mechanical Properties• Irradiation Testing • Qualification and Process Control• Inspection and Validation Processes


Process Quality


27

Ensuring Robustness and Repeatability

Process Specification:• Pre-build Calibration• Laser Power and Size• Travel Speed and Path• Laser Dwell Time• Layer Thickness• Build Atmosphere• Pre-Heat Temperature

Powder Specification:• Traceable PO’s• Power Composition• Powder Size• Powder Reuse Procedure

Heat Treatment Spec:• Time• Temperature• Atmosphere

Material Specification:• Product Chemistry• Mechanical Properties

• Coupons on each plate• Embedded Serialization• Traceability to build

Input ControlProcess Control Output Control


Qualification and Quality Control Strategy


28

Industry Standards and GEH Programs

GEH QAPD NEDO-

11209-A

10CFR50 App B

NQA-1

GS-R-3

GEH Internal Reviews

KTA-1401

ISO 9001


Outline


29

• Microstructure Characterization• Mechanical Properties• Irradiation Testing • Process Control Description• Inspection and Validation Processes


Inspection and Validation


30

• Comparison to Wrought Properties- Industry Standards- GE Reference Databooks (Historic)

• Test Coupons with Each Print

• NDE Challenges

• Other Possible Techniques- [[

]]

[[

]]

[[

]]


Regulatory Acceptance


31


Reactor Internals

Non Internal

Fuel Bundle Component

Non-Code Code Safety Non-SafetyLead Use

BWRVIP-84

Approval

Code-Case Approval

Implementation

GEH Internal Fabrication Quality Approval and Customer Documentation

Customer Approval

GEH Materials Baseline (Powder Spec, Machine Parameters, ASTM Specification Compliance, Post-Treatment,

Mechanical Test Data, Technical Report, GEH Internal Approval)

Application Quality Requirements

10 CFR 50.59

Justification and Evaluation (LUA

Report)

Target Applications

Target Requirements

Regulatory Touchpoints


32


ASTM Standard Compliance


33

ASTM 3184 - 16

• Additively Manufactured UNS S31603.

• Ensure Mechanical Properties Compliance.

• Requires Manufacturing Plan to control input, processing, outputs.

• Requires test plan with acceptance criteria including tensile test specimens (X,Y,Z direction).

• Supplier and Purchaser decide on adequacy of control elements.


Elements of Quality Documentation for example AM Application


34

BWRVIP 84 Technical Basis Report will contain• [[

]]

LUA Report (e.g. debris filter) will contain• Material quality details (as

described for BWRVIP 84)• Specific part dedication,

including:o [[

]]


Dedication Procedure for example AM Application


35

Commercial Grade, Safety Related Component• Supplier of AM Parts Treated as Non-Safety Supplier (For Now).

• Responsible Design Engineer Provides Justification of Equivalency between Performance of Part and Test Coupon On Same Plate.

• Steps Need to Be Taken to Ensure All Parts are traceable to the common build plate.

• Inspection Techniques [[ ]] Must Be Vetted.

• Follow Regulatory Requirements:• 10 CFR 50 Appendix B• EPRI NP-5652• EPRI TR- 102260


Current and Future Activity


36


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 (Rebak - PI), ORNL (Muth), U of M (Was), GEH (Connor)

• Activities: Study DMLM material nanostructure and optimize the material. Proton irradiation [[ ]]to a dose in the range [[ ]].


37


DOE Program - CFA-16-10393Irradiation Testing of LWR Additively Manufactured Materials

• Objective: Perform full irradiation / PIE on structural materials produced by DMLM

• Participants: GEH (Connor - 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 [[ ]] (INL at the ATR)


38


GEH Additive Timeline2017 Materials Qualification PlanComplete unirradiated materials testing on 316L and IN718Complete proton/ion irradiation of 316L (U. of Michigan)Initiate neutron irradiation of 316L and IN718 (INL’s ATR)Print and “qualify” representative nuclear componentComplete CFA-15-8309 report to DOE

2018+ Materials Qualification PlanIssue Lead Use Next Generation Debris Filter Report (TBD)Issue BWRVIP 316 technical basis report (TBD)BWR reactor deployment of 316L parts (TBD)Complete PIE mechanical testing on 316L and IN718


39


Summary


40

• DMLM parts will provide value for nuclear application

• When fabricated and treated in a controlled manner, DMLM material exhibits adequate properties for nuclear application

• Within the existing regulatory framework, DMLM material can be qualified for use


Questions?


6/7/2017

Non- Proprietary Information – Class I (Public)

Documents

Enclosure 2: Additive Manufacturing Presentation. · 2017-06-20 · ENCLOSURE 2 M170149 Additive Manufacturing Presentation Non-Proprietary Information – Class I (Public) INFORMATION