advanced manufacturing processes for the nuclear industry · copyright © twi ltd 2018 drivers:...

Copyright © TWI Ltd 2018

Professor Chris Dungey

Advanced Manufacturing Processes for the Nuclear Industry

1


▪ Drivers

▪ Manufacturing processes

Additive Manufacturing

Hot Isostatic Pressing

Advanced Welding

▪ Summary

Scope

Courtesy EDF

NEC Nov 2018 CD 2


▪ Nuclear Strategy

To support de-carbonisation of power supply

Cost reduction

Safety – Quality – Delivery

Importance of ONR code compliance

Serial/modular/digital manufacture

SMR

Establishing effective collaborations at home and overseas on R&D and innovation

Drivers

NEC Nov 2018 CD 3


‘Small’ Modular Reactors

TWI are a strategic provider of R&D and Manufacturing services:• Materials• Welding • Inspection

NEC Nov 2018 CD 4


▪ Traditional

Casting

Forging

Weld fabrication

▪ Emerging technologies for Nuclear Power Plants



Advanced Welding – power beams

Manufacturing processes

NEC Nov 2018 CD 5



NEC Nov 2018 CD 6


Additive Manufacture

LMD: ‘Cylindrical’ component manufacture • 97% materials usage• 7hrs to build from powder c.f. 26wks

from solid

• >1.5m diameter parts• Wall deviation from CAD

± 0.3mm• Surface finish 15-20µm

RA• Wall thickness 0.84µm ±

0.1µm


Additive manufacturing

SLM Fuel spacer grid (Zr)

• AM has the potential for significant lead time and cost savings

NEC Nov 2018 CD 8

WAAM

Courtesy Westinghouse



NEC Nov 2018 CD 9


Large Components for Power Generation – PM-HIP

Large 316L SS Valve Bodies

Tee-Section courtesy Rolls-Royce

Grade 91 (Creep strength enhanced ferritic steels)Valve Bodies

SMR Access Port

NEC Nov 2018 CD 10

Courtesy of DOE/EPRI


Advanced Welding Processes

NEC Nov 2018 CD 11


Local vacuum EB mobile seal

NEC Nov 2018 CD


Local Vacuum EB weldingCommercialisation

65mm (wt), 3m length 1.8m, diameter <10minutes

NEC Nov 2018 CD 13


Local vacuum EB and Laser Welding

NEC Nov 2018 CD


Maintenance and repair

NEC Nov 2018 CD 15


In-bore laser welding for repair

NEC Nov 2018 CD 16


Laser decommissioning

NEC Nov 2018 CD


▪ Drivers: Cost and safety drivers

▪ New technologies developed and being implemented


HIPping

Advanced Joining

▪ Regulatory codes adapting to these technologies with input from industry and R&D community

Summary

NEC Nov 2018 CD 18

advanced manufacturing processes for the nuclear industry · copyright © twi ltd 2018 drivers:...

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