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ORNL is managed by UT-Battelle, LLC for the US Department of Energy
Nuclear Reactor – Current state, challenges and future needs from materials perspective
Nov 21, 2019
Kurt TerraniTCR Technical Director
22
Outline
• Current status
• Towards high dose
• Towards high temperature
• What is TCR?
• Opportunities in advanced manufacturing
– Advanced processing and designs
– new approach to qualification
Zinkle, Snead, Annu. Rev. Mater. Res. 2014. 44:241–67
33
40
50
60
70
80
90
100
1970 1980 1990 2000 2010
1920 1930 1940 1950 1960 1970 1980 1990 2000 2010 2020
304SS
IN 600
316SSA286
17-4 PHA302B
X750 Zr-2IN 800
Zr-4
IN 690
A533B Zirlo & M5
US Electricity >10% Nuclear
US Nuclear Capacity FactorHits 90%
RPV Embrittlement Concerns Confirmed
Fuel Failure Rate ~1ppm
Fuel Failure Rate = 0
Zero Failure By 10 Initiative
FukushimaChernobyl
TMI-2
Core StructureHigh StrengthSteam GeneratorRPVCladding
A Timeline
No new materials after
1970s
44
It has been 40 years since a non-LWR reactor was started up in the United States
• New nuclear energy is associated with high costs and long timelines with large uncertainty
• Few if any technological advances in design, materials, sensing, and qualificationapproach have been brought to bear since the 1970s
FFTF core, HEDL
55
Towards high dose
66
Basic Definitions
• Structural materials are those that are primarily responsible to bear a load and maintain geometry with specific strength or strain requirements
• Radiation stability for nuclear structural applications is defined as the ability of the material to limit its dimensional change to an acceptable design envelope and to withstand degradation in mechanical properties as a function of irradiation dose
time + stress + temperature + radiation
77
Realization of radiation tolerant materials relies on three distinct strategies• Immobile point defects
• Crystal structure with intrinsic resistance (BCC)
• High density of recombination centers (surfaces)
1%/dpa
30 nm
Zinkle, Snead, Annu. Rev. Mater. Res. 44 (2014) 241–67
S.J. Zinkle & G.S. Was, ActaMater. 61(2013) 735
C. Massey et al., Acta Mater. 166 (2019)
FeCrAl ODS
88
Towards high temperature
99
High temperature operation requires microstructural stability and creep resistance • Fine precipitates in metal alloys
• Refractory metals
• Ceramics (CMCs)
D. Hoelzer et al., J. Nucl. Mater. (2020)
-12
-10
-8
-6
-4
-2
0
1.4 1.6 1.8 2 2.2 2.4 2.6 2.8 3
550ºC - OFRAC
600ºC - OFRAC
700ºC - OFRAC
800ºC - OFRAC
650ºC - 316 SS
650ºC - 316LN SS
650C - X6CrNiTi18-10 SS
Lo
g [
(s-1
)]
. min
Log [ (MPa)]
550ºC
600ºC700ºC800ºC
650ºC
650ºC
CVD-SiC RB-SiC
1010
What is TCR?
1111
Reliable,
available, and
low-cost clean
energy
facilitated using
modern
technology
Rapidly
demonstrate
application of
advanced
manufacturing
to build and
deploy an
efficient nuclear
energy system
VisionMission
Transformational Challenge Reactor is committed to an
audacious timeline to build and operate a 3D-printed
reactor core
Enable adoption of technologies by U.S. nuclear
industry and regulator
Phase IIIPhase IIPhase IFeb
2019
Feb
2021
Feb
2023
Jan
2025
Nuclear Demo
1212
Opportunities in advanced manufacturing- Advanced processing and designs
1313
How is the design approach different with TCR?
Identify issues
Measure properties
model
Identify l imitations
Manufacture core structure
Manufacture fuel
Manufacture moderator
consolidate
Using CAD software with topology
optimization to arrive at complex geometries
• fundamental design and manufacturing principles
• Physical, component, regulatory constrains
1414
3D printing of nuclear-grade SiC in complex geometries
Binder jet printing
chemical vapor infiltrationCAD model
1cm
1515
Design optimization via parallel modeling, manufacturing, and testing
Temperature [°C]0 200 400 600 800 1000
Th
erm
al con
du
ctivity [
W/m
-K]
0
5
10
15
20
25
30
35
40
unirradiated
0.001 dpa
0.01 dpa
0.1 dpa
10 dpa
1 dpa
increasing dose
K. Terrani, B. Jolly, M. Trammell, “3D printing of high-purity silicon carbide” J. Am. Cer. Soc., (2019) DOI: 10.1111/jace.16888
1616
Opportunities in advanced manufacturing- New approach to qualification
1717
Is it possible to exploit Advanced Manufacturing to deliver a new approach to qualification?
Conform to feedstock
quality requirements
Conform to manufacturing
quality requirements
Conform to examination
quality requirements
pass pass
pass
Qualified component
Rejected
failure
Conventional Qualification Scheme
Collect feedstock
data
Collect spatially selective data
throughout manufacturing
Data repository Qualified component
Rejected component
Trained data analytics
Collect environmental
data during manufacturing
provide live feedback to manufacturing
Instantaneously ascertain quality
New Qualification Scheme
1818
Fins to hold fuel and conduct heat
Lid to be welded on top
Cooling channels
TCR fuel cladding concept
Monitoring to assess quality during advanced manufacturing (in situ)
1919
Establishing links between in situ and ex situ data
25 mm
50 mm
75 mm
100 mm
125 mm
150 mm
175 mm
Err
or d
ete
cti
on
ra
te (
un
itle
ss)
y100 110 120 130 140
800
850
900
950
1000
Tem
per
atu
re (°C
)Hoop Stress (MPa)
Laser 1
Laser 2
Line Defect
No Defect
y
1 5 50 500
600
800
1000
1200
1400
Tem
per
atu
re (°C
)
Hoop Stress (MPa)
Laser 1Laser 2Line DefectNo Defect
20% CW 316 - SSA 316 - S20% CW 316 - C20% CW 316 - GCFR
5-5.6°C/s
2020
A new approach to qualification is warranted and possible
Collect
feedstock
data
Collect spatially
selective data
throughout
manufacturing
Data repository
Train data analytics framework
Collect
environmental
data during
manufacturing
Collect
performance
data
Manufacturing data (input)testing data
(output)
2121
Summary
• Nuclear energy advancement requires new materials, manufacturing methods, and approaches to qualification
• Advanced nuclear energy systems require materials that can withstand higher dose and temperature regimes. Strategies for radiation tolerance and classes of materials that offer high temperature operation capability are known.
• Advanced manufacturing when performed in parallel with design and testing allows for an agile and informed development process
• In situ data during additive manufacturing have the potential to provide a new paradigm for critical component qualification
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