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The US Division of Power (DoE)’s Oak Ridge Nationwide Laboratory (ORNL) has accomplished profitable testing of two 3D printed chrome steel capsules within the Excessive Flux Isotope Reactor (HFIR).
Supported by the DoE’s Workplace of Nuclear Power’s Superior Supplies and Manufacturing Applied sciences program, the venture concerned fabricating the capsules at ORNL’s Manufacturing Demonstration Facility (MDF) utilizing laser powder mattress fusion (LPBF) and 316H chrome steel.
This materials is being assessed for its suitability in nuclear environments resulting from its energy at excessive temperatures, corrosion and radiation resistance, and compliance with stringent security requirements.
“As we show the reliability of those printed parts, we’re taking a look at a future the place additive manufacturing may grow to be normal apply in producing different crucial reactor components,” mentioned Ryan Dehoff, Director of the MDF at ORNL.
Additive components examined for sturdiness
As soon as fabricated, the capsules have been assembled and certified by ORNL’s Irradiation Engineering group. They have been then positioned inside HFIR, the place they underwent a month-long irradiation cycle. After testing, each capsules have been retrieved absolutely intact, demonstrating their structural integrity and efficiency beneath excessive circumstances.
These experimental capsules are designed to carry pattern supplies throughout irradiation, appearing as each containment boundaries and strain vessels. HFIR’s intense neutron surroundings, among the many highest on this planet, supplies researchers with the flexibility to check supplies and fuels beneath practical reactor circumstances.
Historically, irradiation capsules require customized designs and specialised supplies, making the event course of each time consuming and costly. ORNL researchers are exploring additive manufacturing as a sooner, more cost effective various that additionally affords better flexibility in design.
“Additive manufacturing will develop my group’s toolset to develop revolutionary experiments to help this crucial want,” mentioned Richard Howard, a gaggle chief within the Nuclear Power and Gasoline Cycle Division at ORNL.
Earlier this yr, ORNL 3D printed and examined a chrome steel rabbit capsule utilizing LPBF, marking the primary time AM was utilized to such a nuclear part. After being assembled, sealed, and inserted into HFIR, the capsule withstood almost a month of irradiation and remained absolutely intact. A post-irradiation evaluation is deliberate for winter to additional consider its efficiency and potential future makes use of.
Demonstrating enhanced reactor efficiency utilizing 3D printed components
Additive manufacturing is altering how the nuclear sector designs, maintains, and helps crucial gear, making the method extra adaptable, environment friendly, and dependable beneath strict regulatory requirements.
Final yr, Westinghouse Electrical Firm used 3D printing to develop a brand new filtering backside nozzle geared toward enhancing gas meeting efficiency in Pressurized Water Reactors (PWRs). Built-in into 4 lead take a look at assemblies on the Joseph M. Farley Nuclear Plant, the design particularly focused particles fretting, a key contributor to gas rod leakage.
Having used 3D printing, engineers have been in a position to create extra refined geometries that restricted the scale of particles coming into the reactor. Throughout testing, the nozzles demonstrated a 30% enhance in resistance to clutter, highlighting the potential of AM to improve reactor part reliability.
Elsewhere, researchers on the Korean Atomic Power Analysis Institute efficiently used a mixture of 3D printing and CNC machining to supply a 30 kg safety valve to be used in a nuclear reactor. The valve featured intricate inside cooling channels and met the stringent necessities for ‘Class 1’ nuclear security classification.
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Featured picture exhibits 3D printed chrome steel capsules. Picture through ORNL.
