Advanced Manufacturing To Enable The Next Generation of Nuclear Plants

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Outline
§ Background
§ Development/Demonstration of 4 Advanced Manufacturing/
Fabrication Technologies
§ 2/3-Scale SMR Manufacturing/Fabrication – Phase 1
§ Component Assembly
§ Applicability to Advanced Reactors -- Summary
2
© 2018 Electric Power Research Institute, Inc. All rights reserved.
Vessel Manufacture and Fabrication
§ What if it only took 12 months to produce a reactor
pressure vessel?
§ What if you could perform an entire SMR RPV girth
weld in less than 60 minutes?
§ What if you could manufacture an entire SMR head in
< 3 months with no vessel dissimilar metal welds?
§ What if you could eliminate the need for in-service
examinations of girth welds?
§ What if you could perform vertical welds to join rolled
plates without subsequent embrittlement concerns? Representative Model
of NuScale Power
Reactor Vessel
3
Enabling the Next Generation of Nuclear Plants
-Scope
§ Manufacture Major Critical Components to

Assemble a 2/3-Scale SMR Reactor Pressure
Vessel
§ Jointly Funded Collaboration
– EPRI, Nuclear AMRC, DOE, NuScale Power
§ Others
– Synertech-PM, Sheffield Forgemasters, Sperko Photograph provided
Engineering, Carpenter, ORNL, etc. courtesy: NuScale Power
DOE Project: DE-NE0008629

What Once Took Weeks,
We Can Now Do In Hours…
4
Advanced Manufacturing
-Objectives
§ Rapidly Accelerate the Deployment of SMRs

§ Develop/Demonstrate New Methods for
Manufacture/ Fabrication of a Reactor
Pressure Vessel (RPV) in <12 months
§ Eliminate 40% from the cost of an SMR
RPV, while reducing the Schedule by
18 Months
200mm Electron Beam Weld
5
Electron Beam (EB) Welding
Why EBW?
§ One-pass welding!
§ No filler metal required.
§ EBW can produce welds w/ minimal HAZ
§ Nuclear-AMRC, TWI, Rolls-Royce & EPRI 65mm (thick) x 3m length x 1.8m diameter
have demonstrated in-chamber and/or local Welding time: <10 minutes
vacuum on thick section alloys Photograph provided courtesy: TWI (UK)
– Enables field/shop welding!

§ RPV girth welds (110mm thick) in <60 min
Inspection, Costs?
§ Huge savings in welding costs
(again, one pass welding)
§ Potential to eliminate in-service inspection!
Photograph provided courtesy: Nuclear AMRC (UK)
6
Powder Metallurgy-Hot Isostatic Pressing (PM-HIP)
Why PM-HIP?
§ Near-net shape and complex components
(reduces materials cost and machining)
§ Alternate supply route, shorter turn-around
Steam Separator
§ Considerable EPRI/Industry development over Inlet Swirler
last 7 years.
Large 316L SS Valve Body
§ Ideal for multiple penetration applications
(RPV or CNV head) vs expensive forgings
Inspection, Costs?
§ Homogeneous-Excellent inspection
characteristics
§ Costs roughly equivalent to forging
§ Eliminates need for welds in some applications.
3700 lb BWR nozzle Partial RPV Ring Section
7
Elimination of Welds via Heat Treatment
--Resetting the Clock
How?
§ Perform chamber EB weld of sub-assemblies
§ Localized Solution HT, quench; normalize; temper
§ Resulting microstructure is same as base metal
§ Fracture toughness comparable to base material !"#+$%=0 #&'(
Inspection, Costs?
§ Perform fabrication inspection prior to and following
initial solution HT, plus N&T
§ Following HT, no weld is visible
§ Potentially no weld inspection required at 10 year EB Weld after Heat Treatment
intervals WCL microstructure @ 500X
8
Diode Laser Cladding
Why DLC?
§ Robotic machine welding
§ High deposition rates
§ Significantly reduces cladding thickness
required (~4mm)
Inspection, Costs?
§ Lbs. (or kg) of material required is significantly Diode Laser Cladding equipment
reduced since thinner layers can be applied. setup (courtesy of N-ARMC)
§ No machining after cladding required
9
Project Tasks
1. Lower Reactor Assembly
2. Upper Reactor Assembly
3A. Thick Section EBW Development
3B. Local Vacuum EBW Development
4. Diode Laser Cladding Development
5. Elimination of DMWs—for Nozzle
Applications
6. Elimination of In-Service Inspection via
Solution Heat Treatment
7. ASME BPVC Code Development Representative Model
of NuScale Power
8. ORNL Mechanical and Metallurgical Reactor Vessel
Testing
10
2/3rds Scale Small Modular Reactor • EPRI
Manufacture/Fabrication • Nuclear-AMRC
• US DOE
• NuScale Power
11
2017-18 Scope/Schedule
Fabrication
§ EB Welding Development (Task 3A)
§ Diode Laser Cladding Development (Task 4--partial)
§ Lower RPV Assembly (Task 1)
Manufacturing & Fabrication

§ Lower Head (Synertech PM-HIP)
§ Lower RPV Flange Shell (SFEL forged)
§ Two Flanges (SFEL forged)
§ Upper Flange Shell (Synertech PM-HIP) Lower RPV Assembly
12
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Lower Assembly
Lower Flange Shell Mockup EB Weld -- ~6 ft (1.82m) Lower head to Lower Flange Shell
diameter (Note, mockup is upside down) (again, upside down)
Completed in 47 minutes
15
Upper Flange Shell – Four sections and flange
Vertical Welding of Sections Circumferential Girth Weld to Attached Flange
16
Task 2—Upper Reactor Assembly
--2019-2020
4. RPV Top Head

– Manufacture via PM-HIP in two halves
– EBW halves together, annealed, Q&T
– DLC completed top head
5. RPV PZR Shell

– Forged Section
Representative Model
of NuScale Power
6. Steam Plenum Reactor Vessel
– PM-HIP & EBW together
17
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Upper Head (Stamped Inner
& Outer Capsule Shells)
19
44% Upper Head Demonstration - Laser Machining
Laser machining of the penetrations to Machining complete for outer capsule

attach CRD nozzles
20
Capsules for CRD Tubes Mounted in Upper Head
Upper head at 40% scale is ~2370 lbs

At full scale, ~ 21,000 lbs.
21
Capsules for Upper Head Completed and Ready for
Powder Filling
Solid nozzles will be bored after HIP

and heat treatment
Note “fill stems” on top of upside
down upper head capsule
22
Upper Head– Hot Degassing & Crimping of Fill Stems
Following Degassing, All Fill Stems are Crimped

and Welded Shut. Now Ready for HIP
Hot Degassing of Powder Filled Upper Head
23
Small Modular Reactor
Upper Head
§ ~44% scale
Photographs courtesy of EPRI
§ A508 Class 1, Grade 3 and NuScale Power
§ 27 penetrations
§ 1650kg (3650lbs); 1270mm (50
inches) diameter
§ Next, 2/3-scale head
§ Need larger HIP Vessel -- ATLAS
DOE Project: DE-NE0008629
24
Lower Head – One-Half Section
25
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Lower Head—Stamped Capsule Sections
Inner Capsule Shell
HIP Modeling—Shows Lower Head inside of the

Finished Capsule
Final part: ~4300 lbs (1950 kg) @ 2/3rds scale;
Full Scale is ~11,000lbs (1/2 section) (4990kg)
Outer Top Capsule Shell
27
One half lower head under construction
3/8-inch (9.5mm) thick lower head construction;

~70-inches (1780mm) diameter (2/3rds scale) Note: Two reactor internals support structures
are included for each RPV head half
28
Completed Capsule for Lower Head
One-half of Lower Head. Note Support Legs inside One-half of Lower Head Read for Powder Filling
of the Structure
29
Custom Rack Build for the One-Half Lower Head Section
§ Custom rack required due to size

of existing HIP furnaces in USA.
§ 1.67m (66 inches) diameter in
USA; 2m (78.5 inches) in Japan
§ Must be stood upright in custom
rack/frame
§ Remember, this is a non-
symmetrical component in one-
half section.
30
Custom Rack Build for the One-Half Lower Head Section
31
Lower Head Inserted Into HIP Vessel and Final Component
32
One-Half Lower Head HIP’ed & Dimensioned
33
Project Status (August 2018)
§ Work packages developed for:
– EBW, DLC, Machining, PM-HIP, Heat Treatment, etc.
– Flange welding, head welding, vertical welding, circumferential welding
– Lower assembly
§ Steam plenum access port completed (EPRI ANT)
§ 44% diameter (50-inch) A508 top head completed (EPRI ANT)
§ Forgings for flanges, PZR shell, lower RPV section, and HT completed
§ One-half section A508 lower head, completed
§ EBW & DLC development underway @ Nuclear AMRC
§ Heat treatment development underway soon.
34
Applicability to Advanced Reactors -- Summary
§ Must change the way we manufacture RPVs to be cost

competitive!!!
§ Four technologies will have direct applicability:
– PM-HIP -- for higher alloyed components; eliminate long lead-time
forgings; improve inspectibility
– EB Welding – significantly reduced welding time; for difficult to join
components
– Diode Laser Cladding – robotic cladding of vessels; difficult
materials
– Re-setting the Clock – elimination of welds via heat treatment;
eliminates in-service inspection
35
Together…Shaping the Future of Electricity
36
Four SA508, Grade 3 Class 2 Forgings Produced
§ PZR Shell
§ Lower RPV “Flange”
§ Lower RPV Shell
§ Upper RPV Transition Shell “Flange”
§ Primary HT performed.
Forging for Two Flanges
37
Flange and Shell Forgings
38
Flange and Shell Forgings
39

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CDA.1$#D(3.12?.

§ Manufacture Major Critical Components to

DOE Project: DE-NE0008629

§ Rapidly Accelerate the Deployment of SMRs

200mm Electron Beam Weld

– Enables field/shop welding!

Manufacturing & Fabrication

Vertical Welding of Sections Circumferential Girth Weld to Attached Flange

4. RPV Top Head

5. RPV PZR Shell

Laser machining of the penetrations to Machining complete for outer capsule

Upper head at 40% scale is ~2370 lbs

Solid nozzles will be bored after HIP

Following Degassing, All Fill Stems are Crimped

DOE Project: DE-NE0008629

Inner Capsule Shell

HIP Modeling—Shows Lower Head inside of the

3/8-inch (9.5mm) thick lower head construction;

§ Custom rack required due to size

§ Must change the way we manufacture RPVs to be cost

Forging for Two Flanges

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