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Appendix B - Workshop Slides
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Issue date:	05/06/2021
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RIL 2021-03 NRC WORKSHOP ON ADVANCED MANUFACTURING TECHNOLOGIES FOR NUCLEAR APPLICATIONS Part II - Workshop Slides Date Published: Draft April 2021 Prepared by:

A. Schneider M. Hiser M. Audrain A. Hull Research Information Letter Office of Nuclear Regulatory Research

Disclaimer This report was prepared as an account of work sponsored by an agency of the U.S. Government. Neither the U.S. Government nor any agency thereof, nor any employee, makes any warranty, expressed or implied, or assumes any legal liability or responsibility for any third partys use, or the results of such use, of any information, apparatus, product, or process disclosed in this publication, or represents that its use by such third party complies with applicable law.

This report does not contain or imply legally binding requirements. Nor does this report establish or modify any regulatory guidance or positions of the U.S. Nuclear Regulatory Commission and is not binding on the Commission.

NRC Public Workshop on Advanced Manufacturing Technologies for Nuclear Applications Matthew Hiser and Mark Yoo Office of Nuclear Regulatory Research December 7, 2020 1

Outline

NRC Activities on Advanced Manufacturing Technologies (AMTs)

- 5 Primary Technologies

- Technical and Regulatory Preparedness

- Communications and Knowledge Management

Public Workshop

- Overview and Approach

- Summary of Sessions

- Organization and Logistics 2

2 B-1

Advanced Manufacturing Technologies

Techniques and material processing methods that have not been:

- Traditionally used in the U.S. nuclear industry

- Formally standardized/codified by the nuclear industry

Key AMTs based on industry interest:

- Laser Powder Bed Fusion (LPBF)

- Direct Energy Deposition (DED)

- Electron Beam Welding

- Powder Metallurgy Hot Isostatic Pressing (PMHIP)

- Cold Spray 3

3 Laser Powder Bed Fusion

Process:

- Uses laser to melt or fuse powder particles together within a bed of powder

- Generally most advantageous for more complex geometries

Potential Applications Schematic of LPBF process*

- Smaller Class 1, 2 and 3 components, fuel hardware, small internals

https://www.osti.gov/pages/servlets/purl/1437906 4

4 B-2

Directed Energy Deposition

Process:

- Wire or powder fed through nozzle into laser or electron beam

- Fundamentally welding using robotics/ computer controls Schematic of DED process*

Potential Applications

- Similar to LPBF, although larger components due to faster production and greater build chamber volumes

https://www.osti.gov/pages/servlets/purl/1437906 5

5 Powder Metallurgy - Hot Isostatic Pressing (PMHIP)

Process:

- Metal powder is encapsulated in a form mirroring the desired part

- The encapsulated powder is exposed to high temperature and pressure, densifying the powder and producing a uniform microstructure

- After densification, the capsule is removed, yielding a nearnet shape component where final machining and inspection can be performed

Potential Applications

- All sizes of Class 1, 2 and 3 components and reactor internals

- EPRI / DOE focused on use with electronbeam welding to fabricate NuScale reactor vessel 6

6 B-3

Electron Beam Welding

Process:

- Fusion welding process that uses a beam of high velocity electrons to join materials

- Single pass welding without filler metal

- Welding process can be completed much more quickly due to deep penetration

Potential Applications

- For welding medium and large components, such as NuScale upper head 7

7 Cold Spray

Process:

- Powder is sprayed at supersonic velocities onto a metal surface and forms a bond with the part

- This can be used to repair existing parts or as a mitigation process Schematic of cold spray process*

Potential Applications

- Mitigation or repair of potential chlorideinduced stress corrosion cracking (CISCC) in spent fuel canisters

- Mitigation or repair of stress corrosion cracking (SCC) in reactor applications

https://www.army.mil/article/148465/army_researchers_develop_cold_spray_system_transi 8 tion_to_industry 8

B-4

NRC Action Plan

NRC activities related to AMTs have been organized and planned through the AMT action plan (Rev. 1 in June 2020 ML19333B980) with the following objectives:

- Assess the safety significant differences between AMTs and traditional manufacturing processes, from a performancebased perspective.

- Prepare the NRC staff to address industry implementation of AMT fabricated components through the 10 CFR 50.59 process.

- Identify and address AMT characteristics pertinent to safety, from a risk informed and performancebased perspective, that are not managed or addressed by codes, standards, regulations, etc.

- Provide guidance and tools for review consistency, communication, and knowledge management for the efforts associated with AMT reviews.

- Provide transparency to stakeholders on the process for AMT approvals.

9 9

Action Plan - Rev. 1 Tasks

Task 1 Technical Preparedness

- Technical information, knowledge and tools to prepare NRC staff to review AMT applications

Task 2 Regulatory Preparedness

- Regulatory guidance and tools to prepare staff for efficient and effective review of AMTfabricated components submitted to the NRC for review and approval

Task 3 Communications and Knowledge Management

- Integration of information from external organizations into the NRC staff knowledge base for informed regulatory decisionmaking

- External interactions and knowledge sharing, i.e. AMT Workshop 10 10 B-5 5

1/6/2021 Technical Preparedness Activities

Subtask 1A: AMT Processes under Consideration

- Perform a technical assessment of multiple selected AMTs (Laser Powder Bed Fusion, Directed Energy Deposition, PMHIP, EBwelding, and Cold Spray)

- Gap assessment for each selected AMTs vs traditional manufacturing techniques

Subtask 1B: NDE Gap Assessment

- Assess the state of technologies in the testing and examination of AMTs

- Will inform staff decisions related to use of NDE on AMTfabricated components

Subtask 1C: Microstructural and Modeling

- Evaluate modeling and simulation tools used to predict the initial microstructure, material properties and component integrity of AMT components

- Identify existing gaps and challenges that are unique to AMT compared to conventional manufacturing processes 11 11 Regulatory Preparedness Activities

Subtask 2A: Implementation using the 10 CFR 50.59 Process

- Provide guidance and support to regional inspectors regarding AMTs implemented under 50.59

Subtask 2B: Assessment of Regulatory Guidance

- Assess whether any regulatory guidance needs to be updated or created to clarify the process for reviewing submittals with AMT components

- Complete: ML20233A693

Subtask 2C: AMT Guidance Document

- Develop a report which describes the generic technical information to be addressed in AMT submissions

- Public meeting discussing initial framework was held July 30, 2020: https://www.nrc.gov/pmns/mtg?do=details&Code=20200816

- Meeting summary can be found here: ML20240A077 12 12 B-6 6

1/6/2021 Communications and KM Activities

Subtask 3A: Internal Interactions

- Internal coordination with NRC staff in other areas (e.g., advanced reactors, dry storage, fuels)

Subtask 3B: External Interactions

- Engagement with codes and standards, industry, research, international

Subtask 3C: Knowledge Management

- Seminars, public meetings, training, knowledge capture tools

Subtask 3D: Public Workshop

Subtask 3E: AMT Materials Information Course

- Internal NRC staff training 13 13 Workshop Overview

Location/Dates: Virtual, December 710, 2020

Website: https://www.nrc.gov/publicinvolve/conferencesymposia/amt workshop.html

Motivation:

- Increasing industry interest and plans to implement AMTs for nuclear applications

Replacement components in operating nuclear power plants and in initial construction of small modular and advanced reactors.

- NRC must be prepared to efficiently and effectively regulate and respond to industry submittals that apply AMTs for both operating and future plants.

Participants

- Vendors, utilities, EPRI, NEI, DOD, DOE (incl. labs), NIST, NASA, regulators (other U.S. government, international) 14 14 B-7 7

1/6/2021 Workshop Approach

Goal is to have an interactive workshop with multiple opportunities for dialogue

- Q&A / discussion periods to end each session as well as secondary Teams chat following most presentations

Objectives:

- Discuss ongoing activities related to AMTs, including nuclear industry implementation plans, codes and standards activities, research findings, and regulatory approaches in other industries

- Inform public of NRCs activities and approach to approving use of AMTs

- Determine, with input from nuclear industry stakeholders and other technical organizations, areas where NRC should focus to ensure safe implementation of AMTs 15 15 Workshop Sessions

Session 1 - Practical Experience Related to Implementing AMTs

- Nuclear and nonnuclear industry experience with various AMTs

Session 2 - Plans and Priorities for AMT Implementation in Commercial Nuclear Applications

- Nuclear industry plans and interests for using AMTs in NRC regulated applications

Session 3 - Performance Characteristics of AMT-Fabricated Components

- AMTspecific information related to processing and product performance 16 16 B-8 8

1/6/2021 Workshop Sessions

Session 4 - Approaches to Component Qualification and Aging Management

- Nuclear and nonnuclear perspectives on qualification of AMT components

Session 5 - Codes and Standards Activities and Developments

Session 6 - Regulatory Approaches for AMTs

- Nuclear, nonnuclear, and international regulatory approaches

Session 7 - Research and Development of AMTs

- Information on key research programs and specific research projects related to AMTs 17 17 Workshop Organization

WebEx will be used for the primary presentations and discussion sessions

- Please place questions in the chat window during the presentation and we will address as many as possible in the allotted time

- If you would like to ask your question verbally, please indicate through the chat, so that you can be upgraded temporarily to a panelist to be able to use audio functions

A secondary Microsoft Teams link will be provided after most presentations to allow presenters to field additional Q&A for 20 minutes

- Simply click the link provided in the WebEx chat window to join the Teams chat and ask additional questions to the presenter.

18 18 B-9 9

B-10 B-11 B-12 B-13 B-14 B-15 B-16 B-17 B-18 B-19 1/6/2021 ENGIE Experience with Additive Manufacturing and Related Nuclear Applications US NRC Workshop on Advanced Manufacturing Arne CLAES Technologies for Nuclear Applications Steve NARDONE 7 December 2020 1

ENGIE Experience with Additive Manufacturing and Related Nuclear Applications Additive Manufacturing @ ENGIE ENGIE Qualification Approach for Laser Powder Bed Fusion Process Implementation of qualification approach to tackle ENGIE obsolescence challenges 7 December 2020 ENGIE Experience with Additive Manufacturing and Related Nuclear Applications 2 2

B-20 1

1/6/2021 Additive Manufacturing

@ ENGIE 7 December 2020 ENGIE Experience with Additive Manufacturing and Related Nuclear Applications 3

3 ENGIE Laborelec In a nutshell

ENGIE Laborelec is a leading expertise and research center in electrical power technology.

Founded in 1962, the company has over 55 years experience in the power sector.

ENGIE Laborelec is a cooperative company with ENGIE and independent grid operators as shareholders.

Our competencies cover the entire electricity value chain: generation, transmission & distribution, RES, storage, usage of the energy for the industry and other end-users.

We put a strong focus on the energy transition and the 3Ds : decentralization, decarbonization and digitalization.

We offer specialized services, R&D and global solutions in each of these domains, to companies in all parts of the world.

7 December 2020 ENGIE Experience with Additive Manufacturing and Related Nuclear Applications 4 4

B-21 2

1/6/2021 ENGIE Electrabel in a nutshell 7 December 2020 ENGIE Experience with Additive Manufacturing and Related Nuclear Applications 5 5

This webinar deals exclusively with the Laser Powder Bed Fusion process Local fusion of successive metal powder layers using a high energy laser.

Simple facts Production of 10mm-cube using 50µm-layer thickness requires:

200 meters of scanned lines !

200 layers !

Fast and local welding process with high heating/cooling cycles 7 December 2020 ENGIE Experience with Additive Manufacturing and Related Nuclear Applications 6 6

B-22 3

1/6/2021 Additive Manufacturing as key enabler for operational excellence Launch of ENGIE AM Expertise Centre in late 2015 Laboratories

> Materials laboratories

> Non-destructive testing (inspection & qualification)

> AM Powder lab Fe-, Ni-, Al-based AM powders (Ti) AM Machine Material Capabilities Expertise Materials Technology

> QA/QC of inspection campaigns

> Implementation in industrial > Multidisciplinary projects for thermal/nuclear environment O&M on power plants

> Obsolescence management ENGIE Assets > Maintenance plan optimisation and revision in ENGIE assets Foster industrialization

> Tackle obsolescence issues Certification Project

> Functionality-driven approach > Technological bricks: feedstock / Process /

> Validation & Implementation Industry- AM Material Performance of high-end applications with driven Certification > Materials certificates 3.1 & 3.2 high qualification standards approach > Proactive approach before release of future EN 13445 Part 14 7 December 2020 ENGIE Experience with Additive Manufacturing and Related Nuclear Applications 7 7

1st AM valve body (non-safety classified pressure retaining part)

Key milestones in high-end applications @ ENGIE installed in nuclear power station Redesign & Validation of Commissionin radio-frequency antenna g 3rd machine Commissioning 2nd machine & Powder Lab Radio-frequency design NUCOBAM:

by ENGIE Nuclear components based on Additive Manufacturing 2015 2016 2017 2018 2019 2020 Commissioning 1st machine 1st AM part for robot inspection in nuclear primary circuit AM Facility Qualification 1st Qualification of static part by Lloyds Register

& Field Testing in ENGIE Installation of pressure CCGT regulation valve part in ENGIE CCGT 5,10 and 20-year qualification of 3D printed Production & delivery of 12 terminal blocks for safety parts from 10 days to 49 hours5.671296e-4 days 0.0136 hours 8.101852e-5 weeks 1.86445e-5 months function purpose Flow Swirler for condenser air Powder Lab, Facility and extraction pump, obsolete part produced material 7 December 2020 ENGIE Experience with Additive Manufacturing and Related Nuclear Applications 8 8

B-23 4

1/6/2021 Additive Manufacturing Product Quality High-Level Overview Process Reproducibility

From machine to machine (same SLM brand)

From machine to machine (different SLM brand)

Process Repeatability

Consistent product quality from build job to build job

Powder management, storage and reuse Process Stability

Consistent product quality throughout the build height Process

Consistent product quality on the entire build plate Qualification

Process parameters optimization

Sensitivity analysis

Transferability from coupons to industrial part 7 December 2020 ENGIE Experience with Additive Manufacturing and Related Nuclear Applications 9 9

NUCOBAM: NUclear COmponents Based on Additive Manufacturing Horizon 2020 Nuclear Fission and Radiation Protection Research Context: State-of-the-art nuclear design codes and assessment procedures do not take into consideration the Additive Manufacturing Technologies Objectives:

Establish a qualification methodology for AM nuclear components to be proposed for standardization and to be communicated to nuclear design code committees Develop a manufacturing plan that ensures and demonstrates process stability, repeatability and reproducibility that meet nuclear quality standards Demonstrate that laser powder bed fused material performance meets qualification Gate Valve DN25 Debris Filtering requirements (ex-core pressure component from fuel Demonstrate that in-core AM use case meets its safety-related function and operational retaining application) assembly (in-core part) requirements Assess the operational performance of ex-core AM components regarding safety-related function and operational requirements Disseminate and prepare the exploitation of results with nuclear industries and regulatory bodies in support to codification and industrialization of AM Key information:

Project Duration: 48 months (Oct. 2020 - Sept. 2024)

Total Budget: 3,9M AM machines: Laborelec (SLM500), CEA (SLM280), VTT (SLM125) and AMRC (AM250) 7 December 2020 ENGIE Experience with Additive Manufacturing and Related Nuclear Applications 10 10 B-24 5

1/6/2021 ENGIE Qualification Approach for Laser Powder Bed Fusion Process 7 December 2020 ENGIE Experience with Additive Manufacturing and Related Nuclear Applications 11 11 What can go wrong along the whole value chain ?

7 December 2020 ENGIE Experience with Additive Manufacturing and Related Nuclear Applications 12 12 B-25 6

1/6/2021 Challenges for production of high-end components and large productions runs 177h print time Ensuring process stability, quality &

reproducibility over the long term for large production runs:

Large components Heavily-loaded build platform 0,5m FATAM Project https://www.sim-flanders.be/project/fatam-icon 7 December 2020 ENGIE Experience with Additive Manufacturing and Related Nuclear Applications 13 13 What can go wrong along the whole value chain ?

Ensuring process stability, quality & reproducibility over the long term for large production runs :

Influence of powder batch Powder storage & recycling Influence of build location Influence of build height Transferability from coupons to industrial part From build job to build job 7 December 2020 ENGIE Experience with Additive Manufacturing and Related Nuclear Applications 14 14 B-26 7

1/6/2021 Material Feedstock for Laser Powder Bed Fusion Standardization & acceptance criteria Sample Thief Hall flow, Carney flow Semi-automatized tapped density method producing compaction and apparent density curve as a function of number of taps for a SLM metal powder Particle Morphology by Scanning Electron Microscopy Sample Divider Automated measurements of dynamic angle Particle Size Mechanical Semi-quantitative chemical analysis Archimedes of repose, providing cohesive index and Distribution by Sieving by Scanning Electron Microscopy density testing flowing angles for different shearing stresses Laser Diffraction Metal Powder Characterization New Metal Powder Rheometer, shear based on ASTM F3049-14 Characterization Methods cell, wall friction 7 December 2020 ENGIE Experience with Additive Manufacturing and Related Nuclear Applications 15 15 What can go wrong along the whole value chain ?

Influence of build location & build height Large quality discrepancy for heavy-loaded platform without careful machine fine-tuning, even with optimal laser process parameters 7 December 2020 ENGIE Experience with Additive Manufacturing and Related Nuclear Applications 16 16 B-27 8

1/6/2021 Process Stability Challenge: Homogeneous properties over the platform !

Large quality discrepancy for heavy-loaded platform without careful machine fine-tuning, even with optimal laser process parameters A

B Impact testing 136 J vs. 16 J A B 7 December 2020 ENGIE Experience with Additive Manufacturing and Related Nuclear Applications 17 17 Process Stability Challenge: Homogeneous properties over the platform !

Charpy V-notch toughness values over the build platform using optimized laser process parameters 87 70 61 66 32 54 74 49 75 47 79 76 69 54 61 GAS 73 77 89 47 35 FLOW 73 33 52 60 45 76 71 85 78 49 65 65 92 64 39 61 82 56 35 42 58 47 50 25 27 40 49 33 23 24 Charpy V-notch toughness in Joule 7 December 2020 ENGIE Experience with Additive Manufacturing and Related Nuclear Applications 18 18 B-28 9

1/6/2021 Process Stability over build height & Process Transferability Full height samples Big blocks Process Stability Process Qualification Consistent product Transferability from quality throughout coupons to industrial the build height part 107 108 104 109 108 110 109 103 115 128 104 111 104 135 140 100 102 114 133 76 113 106 87 121 55 112 111 109 112 118 107 106 97 118 99 111 118 112 142 85 106 108 111 114 132 104 102 110 116 130 yield strength(MPa) tensile strength(MPa) elongation (%) reduction of area (%)

average 434 571 45.8 59.9 stdev 18 26 6.5 11.1 7 December 2020 ENGIE Experience with Additive Manufacturing and Related Nuclear Applications 19 19 Process Stability over build height & Process Transferability Microstructure Before gas flow upgrade After gas flow upgrade Built direction Built direction After gas flow upgrade and corresponding parameter optimisation, the visible melt pools after etching seem to be less pronounced and more homogeneous insize 7 December 2020 ENGIE Experience with Additive Manufacturing and Related Nuclear Applications 20 20 B-29 10

1/6/2021 ENGIE Certification Project Successful ENGIE Facility and Powder Lab Certification by Lloyds Register on 10.09.2019 Technological bricks:

Feedstock Process AM Material Performance Material certificates 3.1 & 3.2 Proactive approach before release of future EN 13445-14 7 December 2020 ENGIE Experience with Additive Manufacturing and Related Nuclear Applications 21 21 ENGIE Certification Project Certification of stainless steel 316L powder feedstock & our Our Main Goal Laborelec Powder Lab Achieving ENGIE AM Facility Qualification & Material Certification Validation of SLM500 equipment at ENGIE Fabricom Zwijndrecht Material Certificate linking Powder Batch, Machine/Process & Formed Certification of produced Material stainless steel (mechanical performance)

Delivery of material certificate 3.1 or 3.2 for 316L material under Lloyds Register label 7 December 2020 ENGIE Experience with Additive Manufacturing and Related Nuclear Applications 22 22 B-30 11

1/6/2021 Additive Manufacturing Product Quality and Control Off-line / non-destructive Material properties determine inspectability for UT and EC New manufacturing technology leads to unique challenges and material properties Codes and regulations require inspection of critical components BenchmarkAM material against industry-standard materials (forging and casting)

Industry-standard material Fabrication of Ultrasound testing Calculate material standardized blocks with properties reference defects AM material Eddy current testing Benchmark against industry standard Young modulus Signal to noise Absorption Sound velocity Anisotropy Electrical conductivity 7 December 2020 ENGIE Experience with Additive Manufacturing and Related Nuclear Applications 23 23 Qualification approach to tackle ENGIE obsolescence challenges Non-safety classified pressure retaining part installed in nuclear power station 7 December 2020 ENGIE Experience with Additive Manufacturing and Related Nuclear Applications 24 24 B-31 12

1/6/2021 Problem Statement Tackling obsolescence in NPP - CW-VV0592 in KCD3 Outage Unit 3 at Doel NPP Voluntary test of non-safety pressure relief valves in secondary circuit Disassembly of the valve showed corrosion and damage Obsolescence status: unknown

Non-safety related

Body was never on stock

Low install base (1 location)

Considered solutions

Order original body Valve appeared obsolete

Equivalent stock replacement No equivalent model on stock

Order new equivalent model Lead time 24 weeks (> outage deadline)

Reverse Engineering & Metal Additive Manufacturing 7 December 2020 ENGIE Experience with Additive Manufacturing and Related Nuclear Applications 25 25 Reverse Engineering incorporating Metal Additive Manufacturing Redaction of Test Specs & Post-processing Destructive Testing on Obsolescence Dossier Sacrificial Valve Generation of 3D Manufacturing Functional Testing Model Plan & Printing on Industrial Valve 7 December 2020 ENGIE Experience with Additive Manufacturing and Related Nuclear Applications 26 26 B-32 13

1/6/2021 Reverse Engineering incorporating Metal Additive Manufacturing 7 December 2020 ENGIE Experience with Additive Manufacturing and Related Nuclear Applications 27 27 Reverse Engineering incorporating Metal Additive Manufacturing Process stability, reproducibility 7 December 2020 ENGIE Experience with Additive Manufacturing and Related Nuclear Applications 28 28 B-33 14

1/6/2021 Reverse Engineering incorporating Metal Additive Manufacturing Process stability, reproducibility 7 December 2020 ENGIE Experience with Additive Manufacturing and Related Nuclear Applications 29 29 Reverse Engineering incorporating Metal Additive Manufacturing 7 December 2020 ENGIE Experience with Additive Manufacturing and Related Nuclear Applications 30 30 B-34 15

1/6/2021 Qualification approach to tackle ENGIE obsolescence challenges Safety classified terminal blocks for Belgian nuclear power station 7 December 2020 ENGIE Experience with Additive Manufacturing and Related Nuclear Applications 31 31 CNT Qualification & Obsolescence Nuclear Qualification of Electrical Equipment: Qualification of 3D printed terminal blocks Obsolescence Terminal Block Geometry for Production Additive Manufacturing Qualification by Terminal Block Build Preparation Tractebel/Laborelec Design (ongoing) 7 December 2020 ENGIE Experience with Additive Manufacturing and Related Nuclear Applications 32 32 B-35 16

1/6/2021 CNT Qualification & Obsolescence Nuclear Qualification of Electrical Equipment: Qualification of 3D printed terminal blocks Build Preparation Qualification by Tractebel/Laborelec (ongoing) 12/3/2020 CNT Qualification & Obsolescence 33 33 Any Questions ?

7 December 2020 ENGIE Experience with Additive Manufacturing and Related Nuclear Applications 34 34 B-36 17

1/6 /2 0 2 1 RollsRoyces Introduction of HIP Nuclear Components US N R C Workshop on Advanced Manufacturing December 2020 Presenter - John Sulley RollsRoyce Associate Fellow RollsRoyce P L C PO BOX 2000, Derby 21 7XX, United Kingdom The information in this document is the property of RollsRoyce plc and may not be copied or communicated to a third party, or used for any purpose other than that for which it is supplied without the express writtenconsent of RollsRoyce plc.

© 2020RollsRoyce This information is given in good faith based upon the latest information available toRollsRoyce plc, no warrantyorrepresentation is given concerning such information, NoClassification which must not be taken as establishing any contractual or other commitmentbinding upon RollsRoyce plc or any of its subsidiary or associated companies.

Export Control: Not Listed (31stJuly2020) 1 01 HIP Process Overview Agenda 02 Why HIP?

03 Approach 1

04 Previous Applications

- Stainless Steel 05 New Developments

- Low Alloy Steel Pressure Vessels

1/6 /2 0 2 1 1.Inert gas atomisation to produce powder.

HIP Process Overview 2.Sheet metal capsules filled 3.Capsules subjected to high with powder.

4.Can pickled or isostatic pressure and high machined off. temperature to obtain full

Export Control: Not Listed (31stJuly2020) 3 Project:

LeadTime Reduction No tooling development required, thincan Why HIP? encapsulation welding of mild steel Cost Reduction Scrap/rework elimination Material quantity closer to final shape Machining reduction closer to final shape Product:

2 Material Quality Improvements Cleaner material, no aligned inclusions Homogeneous Isotropic Improved properties can be achieved due to smaller grain size Smaller defect sizes (sieving size)

NonDestructive Examination Improvement - Sensitivity increase due to:

Homogeneous material structure

1/6 /2 0 2 1 Enable a Project to adopt the technology by:

Establishing a robust Method of Manufacture (MoM)

Approach - understanding of variability. Ensuring risks are appropriately mitigated.

To provide data in order to produce a generic/base level justification - UK TAGSI fourlegged structure.

Additional, specific application data may still be required.

Approach Dimensionally inspected to show geometry can be achieved.

NDE examination and destructive examination. Units cut up for material microstructural assessment and property testing.

3 Near Nett Shape? Some benefits, but design for inspectability was key consideration.

1/6 /2 0 2 1 Independent industry survey Incremental approach Approach NonPressure Boundary Pressure Boundary - Leak Limited Pressure Boundary - Isolable Pressure Boundary Unisolable Material equivalence striven for.

ASME code case - N834

References:

ICAPP 088110, 2008 [1]

ICONE2461106, 2016 [2]

1/6 /2 0 2 1 Applications Valve HardFaced Seats

Reference:

ICONE2461106, 2016 [2]

Reference:

ICAPP 088110, 2008 [1]

1/6 /2 0 2 1 Applications ThickWalled Pressure Vessel Section 600 590 580 570 UTS (N/mm2) 560 550

Reference:

540 530 520

[3]

ICAPP 099389, 2009 510 500 Sample

Reference:

PVP201278115, 2012 [4]

1/6 /2 0 2 1 Applications Pipework

Reference:

AMEE2012, Jan1819, 2012 [5]

160 Yield Strength(N/mm )

2 150 140 130 120 110 50 Near Su rface 100 200 Bu ried 300 HIP Section Thickness (mm)

Reference:

PVP201278115, 2012 [6]

1/6 /2 0 2 1 Acknowledgments Our customer for funding the work conducted on Stainless Steel HIP products presented on the previous slides.

Low Alloy Steel (LAS) Pressure Vessels with ThickSection Electron Beam Welding (TSEBW) 8 Supported by:

The information in this document is the property of RollsRoyce plc and may not be copied or communicated to a third party, or used for any purpose other than that for which it is supplied without the express writtenconsent of RollsRoyce plc.

© 2020RollsRoyce This information is given in good faith based upon the latest information available toRollsRoyce plc, no warrantyorrepresentation is given concerning such information, No Classification which must not be taken as establishing any contractual or other commitmentbinding upon RollsRoyce plc or any of its subsidiary or associated companies.

Export Control: Not Listed (31stJuly2020) 16 B-44

1/6 /2 0 2 1 RollsRoyces New Development - LAS Vessels Project FAST Applying HIP and TSEBW

Reduce vessel manufacturing cost & leadtime Alternative supply chain to mitigate fragility 9

Improve material quality Possibility to reduce inservice inspections

1/6 /2 0 2 1 TSEBW Process Overview &

Structural Advantages ICONE28-POWER2020-16035

Reference:

ICONE28POWER2020 16035, 2020 [7]

Proof of concept TSEBW for HIPed SA508 Pressure & thermal cyclic testing HIPed test pieces Manufacture of a Small Vessel Demonstrator (SVD) and hydrostatic Completed LVD for UK Powder filling process testing component qualification testing Manufacture of two Large Vessel Demonstrator (LVD) sections Manufacture of a Ring Section Demonstrator (RSD) and thermal cyclic testing 10 Full material property testing programme ASME code case submission 2018 2019 2020 2021

Reference:

20 B-46

1/6 /2 0 2 1 Justification Approach

© 2020 RollsRoyce 21 No Classification Export Control: Not Listed (31stJuly2020) 21 Poor toughness, oxidisation of powder, poor quality powder Key Technical Risks Oxide Decoration at Prior Particle Boundaries 11

Reference:

ICONE28POWER2020 16035, 2020 [7]

1/6 /2 0 2 1 Can failure during HIP cycle Key Technical Risks Can Unconsolidated Powder Can

Reference:

ICONE28POWER2020 16035, 2020 [7]

Powder Particle Ligament between powder particles

© 2020 RollsRoyce 23 No Classification Export Control: Not Listed (31stJuly2020) 23 Cracking during quench -hydrogen/poor toughness Key Technical Risks 12 Achieving geometry - reducing amount of machining

Reference:

ICONE28POWER2020 16035, 2020 [7]

1/6 /2 0 2 1 Progress Billets & Basic Material Testing

References:

ICO NE28P OWER2020 16035, 2020 [7]

ICONE271021, 2019 [8]

Reference:

ICONE28POWER2020 16035, 2020 [7]

1/6 /2 0 2 1 Progress SVD Design &

Manufacture

Reference:

ICONE28POWER2020 16035, 2020 [7]

1/6 /2 0 2 1 Progress EBW

© 2020 RollsRoyce 29 No Classification Export Control: Not Listed (31stJuly2020) 29 Largescale HIP vessel - max dia in Europe = 1.6m Capability Largescale EB chamber Requirements Improving toughness level -ideally equivalent to forged, oxygen for Deployment control High quality can manufacture - prevention of can failure 15 Good quality powder manufacture, low oxygen level, morphology, but at a competitive price, and with reliable, short delivery time - need to ensure competitiveness to forging.

ASME Code Case - Completion of future full material test programme

Reference:

ICONE28POWER2020 16035 [7]

1/6 /2 0 2 1 Acknowledgments Project FAST is part funded by the UK Department for Business, Energy & Industrial Strategy as part of the UK £505m Energy Innovation Programme.

1/6 /2 0 2 1 Thank you 33 Any Questions?

17

1/6/2021 APPROVED FOR PUBLIC RELEASE U.S. ARMY COMBAT CAPABILITIES DEVELOPMENT COMMAND -

ARMY RESEARCH LABORATORY Cold Spray Technology and Experience in Army Applications Matt Siopis DISTRIBUTION STATEMENT A: Approved for CCDC-Army Research Labs Public Release; Distribution Unlimited 07 DEC 2020 APPROVED FOR PUBLIC RELEASE 1

APPROVED FOR PUBLIC RELEASE COLD SPRAY OVERVIEW Cold spray is an AM process that incorporates a heated high-pressure gas such as He or N2 together micron sized particles of a metal, ceramic and/or polymer into a gun fitted with a De Laval rocket nozzle designed such that the particles exit at supersonic velocities and consolidate upon impacting a suitable surface to form a coating or a near-net shaped part.

Main Gas Stagnation Pressure 100-1,000 psi Gas Temperature 0-1000ºC Main Gas Flow Rate 30-100 CFM High Powder Feed Rates >10 lbs/hr Particle Velocity 300-1500 m/s Particle Size 10-75 m diameter APPROVED FOR PUBLIC RELEASE 2 2

B-54 1

1/6/2021 APPROVED FOR PUBLIC RELEASE METALLIC BONDING IN COLD SPRAY

Materials compatibility enables increased bond strength (bond layers, encapsulated powders, etc.)

Surface contamination requires higher surface expansion (strain) to achieve bonding (oxides, hydroxides, chemisorbed layers, etc.)

High plastic strain of both surfaces improves bonding

Material jetting from interface can eliminate or further breakdown surface contamination High Plastic Strain High Strain Rate Jetting Material Compatibility APPROVED FOR PUBLIC RELEASE 3 3

APPROVED FOR PUBLIC RELEASE Solidification Thermodynamic Particle Acceleration Particle Impact Modeling & Simulation Chemistry Degassing Microstructure Pressure Porosity Manufacturing process Heat Treating Particle Size Temperature Microstructure Particle Size and Blending Morphology Nozzle Geometry Interface Geometry Milling Mechanical Properties Substrate Preparation Hardness Motion Control Wear Mechanicals Powder / Powder Powder / Material Cold Spray Post-Processing Material Selection Processing Characterization Process Characterization APPROVED FOR PUBLIC RELEASE 4 4

B-55 2

1/6/2021 APPROVED FOR PUBLIC RELEASE POWDER PROCESSING Key Considerations ARL Team Developments

Mechanical properties (hardness, flow

Development of thermal treatments to degas, stress, etc.) homogenize, solution treat, over-age, or anneal powders

Grain structure

Processes to cost effectively clad powders to develop

Phase distribution Cold Sprayable cermets, control chemistry, and improve

Surface cleanliness (oxide/hydroxide) DE of certain material blends

Powder size distribution

Development of fluidized bed processes and equipment

Morphology (clad, layered, etc.) on the laboratory and small production scale to perform

Thermal processing

Degassing

Particle sizing Modeling and Testing

Worked with Supplier to commercialize powder processing techniques developed

Thermodynamic phase modeling

FEA Modeling

Single particle impact testing

Surface characterization

Conductivity testing

Microtrac and other PSD evaluation and separation

Thermal processing APPROVED FOR PUBLIC RELEASE 5 5

APPROVED FOR PUBLIC RELEASE Cold Spray Powder Development - WIP Coatings What makes a high quality Cold Powder Blends have achieved Spray coating approximately 375-450 HV The Cold Spray process achieves particle hardness deposits with bonding through a process of high velocity moderate to high wear impact and plastic deformation resistance and the best impact Powders used in Cold Spray must contain a properties Mechanical Blend soft plastic phase in order to properly consolidate when the powder undergoes plastic deformation Spray Dried or agglomerated To create hard coatings, a significant quantity of hard phase is required in the and sintered powders have coating achieved the highest hardness For high toughness coatings less hard ranging from 800 - 1300 HV phase is required while interparticle depending on composition Spray Dried and Sintered bonding is critical Materials Selection Methods of Combination Design optimized clad Hard Phases Soft Phases Blending agglomerate powders show the Tungsten Carbide Chrome Carbide Nickel Stainless Steel High Energy Milling best overall properties including

Iron Based Hard powders Cobalt Chrome Powder Plating higher DE, good toughness, and

Tantalum Niobium Bronze Small-Large Powder excellent wear performance

Copper-Nickel Combined Processing Granulation Spray Dried + Coated Spray Drying / Agglomeration APPROVED FOR PUBLIC RELEASE 6 6

B-56 3

1/6/2021 APPROVED FOR PUBLIC RELEASE Current State of Development with WIP Coatings WIP-C1 and WIP-C2 These deposits are being rolled out into several applications and have by far the most robust set of data and spray conditions of all WIP materials Vendors have been set up to produce this material commercially for easier procurement Deposits have been demonstrated with both helium and nitrogen with good quality Deposits can be machined by milling, turning, or grinding WIP-F1 This material is very similar to WIP-C1 and C2 but is completely iron based for applications where EH&S concerns about nickel based deposits may be present More work needs to be done to characterize the properties, especially wear performance, of this material Once further data is developed scale-up of this material to production quantities will follow the process for WIP-C1 and C2 WIP-W1 This material has the greatest potential for direct chrome replacement in most applications The data generated has shown excellent wear and Deposits must be ground, but can be ground with SiC or diamond All powders have been produced using production robust processes All coatings can be applied in line of site applications as well as in features as small as 1.8 - 2 inches APPROVED FOR PUBLIC RELEASE 7 7

APPROVED FOR PUBLIC RELEASE ID NOZZLE DEVELOPMENT Single injection design for use with Dual injection design carbide nozzle with carbide insert

1.8 in minimum bore, 0.5 standoff

1.5 in minimum bore, 0.5 Dual injection design with standoff integral Co-Cr nozzle

1.5 in minimum bore, 0.5 standoff Single injection design for spraying aluminum Single injection large bore design

1.8 in minimum bore, 0.5 standoff

4 in minimum bore, 0.5 standoff APPROVED FOR PUBLIC RELEASE 8 8

B-57 4

1/6/2021 APPROVED FOR PUBLIC RELEASE WIP-C1 TECHNICAL DATA

Sprayable with N2 or He

1.5%-3% porosity with N2

<1% porosity with He

Suitable for many substrates

HRC 30-55 steels

Stainless

Monel

Copper-Nickel

Similar or better wear performance than Cr plating

Suitable for high impact conditions Measured Porosity: <0.5%

Substrate Lug Shear Strength (ksi) 17-4PH ~20 High Hardness Steel ~20-25 4340 40.6 (He), 28 (N2) 4330V 38.3 APPROVED FOR PUBLIC RELEASE 9 9

APPROVED FOR PUBLIC RELEASE BRADLEY TURRET MOUNT

Turret mount wears over time

Becomes out-of-round

Repair technology provides:

- Cost savings

- Improved Warfighter readiness APPROVED FOR PUBLIC RELEASE 10 10 B-58 5

1/6/2021 APPROVED FOR PUBLIC RELEASE BRADLEY TURRET MOUNT

Cold spray can be used to re-establish new drawing dimensions

Improved wear performance reduce lifecycle sustainment costs APPROVED FOR PUBLIC RELEASE 11 11 APPROVED FOR PUBLIC RELEASE LETTERKENNY BALL SCREW ACTUATOR With Cold Spray process minimal masking or complicated tooling required!!

Damaged Cr-plating removed by machining operation APPROVED FOR PUBLIC RELEASE 12 12 B-59 6

1/6/2021 APPROVED FOR PUBLIC RELEASE Porosity measurement 0.44 +/-

Blend Region 0.13%

Complete bonding along entire interface

Deposition process was performed 0 . 2 5 N o min a l Mac h i n e t o s q u a r e e d g e with WIP-BC1 followed by WIP-C1 1.0 0 0 0

Lug Shear testing was performed 0.9 0 0 0 on 4340 (40-44HRC) which closely 3 .1000 2 .9 0 0 0 3 .10 0 0 2 .9 0 0 0 represents part material R0.06 2 5 1.5 0 0 0 1.0 0 0 0

Results 28 ksi bond strength 0 .5 0 0 0 0 . 1 2 5 N o m i n a l o r 0 . 5 X D e p o s it W i d t h Mi n i m u m 0 .3 7 5 0 0.1250 0.06 2 5 APPROVED FOR PUBLIC RELEASE 13 13 APPROVED FOR PUBLIC RELEASE CANDIDATE REPAIR COMPONENT Surface wear due to adhesive/abrasive wear Sheet metal masking created to protect pocket APPROVED FOR PUBLIC RELEASE 14 14 B-60 7

1/6/2021 APPROVED FOR PUBLIC RELEASE Repair material applied (blue texture) beyond blue-print dimensions Edge of hole receded due to wear.

cold-spray deposit Point cloud scan overlaid on blue-print CAD APPROVED FOR PUBLIC RELEASE 15 15 APPROVED FOR PUBLIC RELEASE BALLISTIC ARMOR REPAIR 0.045 (1.1 mm)

Cold Spray Coating APPROVED FOR PUBLIC RELEASE 16 16 B-61 8

1/6/2021 APPROVED FOR PUBLIC RELEASE COLD SPRAY BALLISTIC PERFORMANCE

Bar chart shows the percentage of ballistic performance restoration indexed to 100% of base metal.

Repair depth 1mm onto thinned 6.3 mm thick HH steel for a 12 x 12 panel with full coverage.

Using armor piercing (AP) rounds and fragment stimulating projectile (FSP) rounds.

APPROVED FOR PUBLIC RELEASE 17 17 APPROVED FOR PUBLIC RELEASE BLEND AND FILL ARMOR REPAIR COLD SPRAY BLEND REPAIR BALLISTIC RESULTS VS BASELINE 120.0%

98.6%

100.0% 97.5% 96.9% 98.1% 96.1%

80.0%

60.0%

40.0%

20.0%

0.0%

Circular Blend Blend Geometry 1 Blend Geometry 1 Blend Geometry 2 Blend Geometry 2 Frontside Frontside Backside Frontside Backside

Repairing pockets yielded similar performance

Confined delamination area

Improved Cost Reduction Near repair CP and PP hit did not induce delamination. 18 APPROVED FOR PUBLIC RELEASE 18 B-62 9

1/6/2021 APPROVED FOR PUBLIC RELEASE THANK YOU!

APPROVED FOR PUBLIC RELEASE 19 19 B-63 10

1/6/2021 NAVSEA Additive Manufacturing Program Overview NRC Public Workshop on Advanced Manufacturing Dr. Justin Rettaliata NAVSEA 05T, AM Technical Warrant Holder 7 Dec 2020 Statement A: Approved for Release. Distribution is unlimited 1

Additive Manufacturing Why AM?

Increase readiness through production of obsolete or long-lead items

Enhance capabilities through mission-tailorable solutions and employment of designs not otherwise possible

Maintain operational availability through good enough production at the point-of need Key Initiatives

Develop specifications and standards necessary to incorporate AM components for surface and subsurface applications

Engage fleet and leverage logistics databases to ID priority components

Prototype the digital infrastructure to securely store and share files

Published policy for installing equipment onboard submarines

Working closely with industry on identification and approval of components for AM.

Statement A: Approved for Release. Distribution is unlimited 2 2

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1/6/2021 NAVSEA AM Lines of Effort

Tech Authority o Technical publications for multiple AM processes o Guidance enabling equipment deployed surface and subsurface o AM approval processes o Materials database DSO valve installed on CVN75

Digital o File securing/transiting/storage strategy, including parts repository o Apollo Lab: Surface fleet able to reach back electronically to CONUS engineering support o Explore topology optimization and generative design o Development of digital manufacturing enclave

Afloat/Undersea Deployment o Explore how to deploy and integrate advanced/additive manufacturing equipment surface and subsurface o Install AM equipment on 8 platforms in 2019 o Provide in-service engineering support

Logistics integration o Incorporate components into logistics databases to enable part provisioning, tracking and buy or print decisions

Innovation challenges o Scale propulsor production; rapidly deployable manufacturing capability Statement A: Approved for Release. Distribution is unlimited 3 3

Tech Authority Products

NAVSEA AM Guidance released August 2018 o Guidelines for use of polymeric materials aboard ship (fire, smoke, and toxicity Part Risk Assessment Boxes requirements)

Yellow: Part received by NAVSEA, in

Powder Bed Fusion Technical Publication published - 21 Jan 2020 process of risk assessment

Directed Energy Deposition Technical Publication - Q2 FY21 Green: Low criticality, can be

Establishing framework for qualifying critical polymer machines and approved waterfront or shipboard components and installed

Develop Technical Data Package for AM components Blue: Part requires NAVSEA HQ

Performing machine assessment for new metal AM systems going to NSYs and review and approval NSWCs

Engage Standard Development Organizations with industry for AM processes Red: Part cannot or should not be produced via additive manufacturing;

Establishing methodology to qualify vendors for metal AM production will inform S&T strategy Powder Bed Fusion Process Directed Energy Deposition Process Material Extrusion Additive Friction Stir Ensuring repeatable, reliable production of AM components organically and from industry Statement A: Approved for Release. Distribution is unlimited 4 4

B-65 2

1/6/2021 Logistics Integration

Motivation: Growing application space for AM across the Naval Enterprise requires supply chain Integration

Goal: Datadriven AM part identification using automated logistics, supply and maintenance data

Approach: Leverage existing databases and policies to integrate AM into the supply chain to promote improved agility, lower response times minimize brittleness

Current Roadmap:

Establish cataloging and provisioning guidelines for AM parts

Logistics database and search for evaluating AM mission impact and readiness

Establish procedures for traceability of shipboard AM components at all levels; risk assessment and management Statement A: Approved for Release. Distribution is unlimited 5 5

Logistics Integration

Provisioning for AM Components

Temporary AM Part Allowance Parts List (APL) set up for AM TDPs as NSNs get assigned

4 AM parts routed for provisioning review

NSN Assignment of AM Components

Federal Cataloging Committee (FCC) Interim plan for identifying AM part at the reference level of NSN

Interim policy requires DLA to provide a list of AM NSNs to the services at a minimum monthly cadence

Mission Impact Analysis

Integrating NAVSUP N25 Price Fighters AM cost/part tool into the TDP development process to provide a more accurate projected AM part cost Integrating AM components into the Navy supply system Statement A: Approved for Release. Distribution is unlimited 6 6

B-66 3

1/6/2021 NAMPIE Events

Naval Additive Manufacturing Part Identification Exercises (NAMPIE)

Organized and supported by greater NAVSEAcommunity

Objective: Identify candidate AM parts onboard ships and influence creation of associated technical data packages (TDPs) for fleet utilization

Increase exposure to AM

Build database of AM parts

Began as small data gathering sprint/AM showcase

Grew into large scale multifaceted event Photo Courtesy: navy.mil Integrating AM components into the Navy supply system DISTRIBUTION A. Approved for public release: distribution unlimited 7 7

Technical Data Packages/Approval

Engage fleet and leverage logistics databases to ID priority components

Interim process established for digitally sharing files

NAVSEA AM TDP format established

DON COVID-19 facemask AM TDP (top left)

Supporting attachments within TDP promote repeatable AM parts

Risk categorization box DON COVID19 nonsurgical facemask AM TDP approach for AM TDPs

Yellow = Triage Submitted For Approved Low Risk Received Tech

Green = Low risk Approval Applications Authority Approval

Blue = Moderate-high risk Applications have been Delegated to local Approved TDP which submitted for technical authority specifies materials and

Red = Not AM capable at this time assessment. (Chief Engineers - printers Waterfront or Ship).

DISTRIBUTION A. Approved for public release: distribution unlimited 8 8

B-67 4

1/6/2021 Additive Manufacturing Part Reporting Guidance

Current tracking of AM part demand, AM parts produced is manual (reported via Excel spreadsheet and email/handcarry hard drive)

New approach takes advantage of established processes and systems with sailor and shipyard experience - OMMSNG and Automated Work Notification (AWN)

Reporting as maintenance provides traceability and time metrics to support logistics tracking without further burdening sailors

Proposed process is being piloted with USS MAKIN ISLAND. Additional pilot will initiate with an AWN ship after MKI pilot completes. Results will be used to update reporting process outlined in guidance update NAVSEA Gui dance SEA05T Routing EC D: 2K/WN JAN21 Codified Data Entry SEA06 AM Part Request SEA04 NAVSUP JFMM BoD AM Info Automated data collection Statement A: Approved for Release. Distribution is unlimited 9 9

Afloat Advanced Manufacturing Overview Afloat Advanced Manufacturing Strategy AM Process Shipboard Afloat AM Program of R&D and Process Refinement Investigation Installations Record Surface Ship Polymer AM Sub Polymer AM Surface Metal AM Results to Date

8 Surface Ship Installations (FY19/20)

3 Sub Kits Delivered and one requested (FY20)

1 FDRMC Rota Installation (IOC FY19, FOC FY20)

50+ Sailors Trained

3 Underways Supported CAT2 CASREP for Satellite IP

AIRPAC Requested SOW to fund additional CVN Antenna Installations Night Ops Porthole Covers Light Bracket Bridge Statement A: Approved for Release. Distribution is unlimited 10 10 B-68 5

1/6/2021 Afloat Advanced Manufacturing Metal AM

Test candidate hybrid metal wire directed energy deposition (DED) and CNC systems

Develop a requirements document and installation plan for shipboard installation

Identify appropriate platform for FY21 install

Preliminary R&D on melt pool effects from motion and vibration

Development of preliminary SOPs and operator training/familiarization Polymer AM

Development of four AM packages for installation aboard CVNs

Model development for vibration and motion effects on machines and materials o Influence of ship motion on printer components o Influence of shipboard vibration on printer components and parts and development of mitigation strategies

Offgas testing at NASA White Sands Test Facility o Determining emission products, amounts, and rates from processing thermoplastic with AM equipment Apollo Lab

Provide continued reachback support for deployed equipment Statement A: Approved for Release. Distribution is unlimited 11 11 Afloat Advanced Manufacturing Capabilities Updated Polymer Equipment Tier 1 - Desktop Polymer

Noncritical shipboard repair applications and some NAVSEAapproved critical applications with corresponding technical data package

Polymer desktop printer, laptop with design and AM processing software, reverse engineering kit and maintenance/feedstock sustainment for 1 year Tier 2 - Industrial Polymer

Suitable for noncritical and critical shipboard repair applications

Expands to high temperature and engineeringgrade plastics and composites

Polymer desktop printer, engineeringgrade (PEEK, PEKK, ULTEM, etc.) polymer printer, composite polymer printer, design and software suite (desktop / laptop computers)

Leverages lessons learned from over 2 years of shipboard installation support while also continuing R&D to expand critical polymer applications

Expands shipboard printable materials to higher strength engineering plastics and polymer composites

All equipment must be "hatchable", either whole or disassembled, to enable installation Statement A: Approved for Release. Distribution is unlimited 12 12 B-69 6

1/6/2021 Cybersecure Digital Manufacturing Enclave

BLUF: Advanced Manufacturing capabilities on operational platforms is isolated and sub optimal, due to inability to network AM computers or equipment. The development of a dedicated network enclave with a controlled interface to DoN networks will facilitate an appropriate security posture, enabling efficient utilization of AM capabilities.

Notional Schedule:

Domain Specific Tailoring 18 Guide Routing Aug Q3

Prototype enclave (shore)

FY21

Evaluate enclave during 2123 HacktheMachineAtlanta March

Enclave installation (afloat) CY FY21 The DME will enable the secure transfer of Advanced Manufacturing Data between Ship and Shore to facilitate distributed manufacturing Statement A: Approved for Release. Distribution is unlimited 13 13 B-70 7

1/6/2021 U.S. Nuclear Industry Perspectives on Advanced Manufacturing Technologies Hilary Lane December 7, 2020

About the Nuclear Energy Institute (NEI)

The Nuclear Energy Institute is the industrys policy organization, located in Washington, DC

Provides a unified industry voice on generic regulatory, policy, and technical matters

Its broad mission is to foster the beneficial uses of NEI President and CEO nuclear technology in its Maria Korsnick many forms.

B-71 1

1/6/2021 In Collaboration with our Members:

Working Groups Task Forces Committees 1,800 global member representatives serving on 140 committees, working groups and task forces (i.e. Advanced Manufacturing Task Force)

Supporting Partners

B-72 2

1/6/2021 94 reactors at 55 plant sites across the country KEY Nuclear power plant site

Continuum of Innovation Advanced Fuels Micro-Reactors Advanced Non-LWRs TerraPower OkloAurora 2020 2025 2030 2035 Large Light Water Small Modular Reactor

Gas cooled

Liquid metal

Molten salt Vogtle 3 & 4 NuScale

B-73 3

1/6/2021 Delivering the Nuclear Promise - Achieved!

Costs in 2019 dollars ($/MWh)

Realized Cost Category Reduction Goal 2012 Costs 2019 Costs Reductions Fuel $7.97 $6.15 $1.81 (23%)

Capital $12.19 $5.71 $6.48 (53%)

Operations $24.41 $18.55 $5.86 (24%)

Total Generating $13.36 (30%) $44.57 $30.41 $14.15 (32%)

The U.S. nuclear industry achieved the DNP goal.

n

©20©2200N20ucNleucalreaErnEenregrygyInIsntsittiututete 77 Source: Electric Utility Cost Group 7

2019 total generating costs decreased nearly $2.50/MWh 2019 costs compared to 2018:

Capital Fuel 5.71

Total generating costs decreased by 6.15

$2.49/MWh (7.6% reduction)

Total

Operations costs decreased by Generating

$1.57/MWh (7.8% reduction)

Cost:

30.41

Capital costs decreased by

$0.61/MWh (9.6% reduction)

Fuel costs decreased by Operations 18.55 $0.32/MWh (4.9% reduction)

B-74 4

1/6/2021 The Big 3 AMT Good Candidate APPLICATIONS FOR BOTH THE CURRENT For:

FLEET AND ADVANCED REACTOR DESIGNS Long lead time components

Less labor; automated High value Cost

Less material; less waste components Complex geometries Obsolete parts

Reduced lead times; some up to 90% Mitigation work Schedule High T environments Reduced weight

Excellent inspectibility Localizing the supply Quality

Excellent material properties

Homogenous chain True Nth-of-a-kind And more

NEIs Advanced Manufacturing Task Force

Broad membership to include:

Advanced Reactor designers/developers

Suppliers / manufacturers

Utilities

Law and consulting firms

EPRI

DOENE and DOE National Laboratories

Universities

Nonprofits

1/6/2021 Advanced Manufacturing Technologies of Interest

1) Laser Powder Bed Fusion

2) Powder Metallurgy - Hot Isostatic Pressing (PM-HIP)

3) Electron Beam Welding (EBW)

4) Cold Spray

5) Directed Energy Deposition (DED)

6) And many others

1/6/2021 First of a Kind (FOAK) Prototype Work Courtesy: EPRI Courtesy: Kairos

developers DOE National Suppliers/

Laboratories Manufacturers Focus on The Big 3

+ Deploy EPRI Utilities

1/6/2021 Continued Dialogue Needed Advanced Reactor designers/

developers DOE National Laboratories Suppliers/

Manufacturers NRC Focus on The Big 3

+ Deploy SDOs EPRI Utilities

ASME Sec. III Code Case- Submitted Aug. 2019

Laser Powder Bed Fusion (316L)

ASME Special Committee on Advanced Manufacturing (formed 2017)

Draft Pressure Technology Book:

1/6/2021 Where to go next?

DEVELOPMENT & INTEREST IN THE FOLLOWINGAREAS

More fuel assembly focus (current fleet)

Advanced reactor fuels

Non-pressure boundary parts

Pressure boundary parts (i.e. near net shape head)

Replacement of obsolete parts

New alloys

Dont forget about plastics!

And more Industry research & collaboration continues!

1/6/2021 Additional Takeaways

Utilize the OPEX from other industries (aerospace, defense, etc.) to the extent practicable; dont re-invent the wheel

New-to-nuclear countries are looking to the U.S. to pave the way in AMT deployment

Continue frequent dialogue amongst stakeholders (industry, NRC, SDOs, etc)

Communicate, Communicate, Communicate!

- Looking to NRC for a streamlined approach in line with their efforts to become a modern, risk-informed regulator**

=

Innovate & Thrive

1/6/2021 Thank you Questions:

hml@nei.org

1/6/2 0 2 1 Vision of Advanced Manufacturing Technology (AMT) Use in the Nuclear Industry Marc Albert, Senior Technical Leader Advanced Nuclear Technology malbert@epri.com David Gandy, Senior TechnicalExecutive Nuclear Materials NRC Workshop on Advanced Manufacturing Technologies for Nuclear Applications December 710, 2020 w w w . e p ri . c o m © 2020 Electric Power Research Institute, Inc. All rights reserved. Date: Add submission date and/or revision date & #

1 Outline - Roadmapping EPRIs Vision to Deploy AMTs Advanced Manufacturing Technologies (AMT) Roadmap Additive Manufacturing Roadmap Additive Manufacturing for Obsolete and Replacement Components 1

EPRI R&D Methodology to Deploy AMTs

2 B-82

1/6/2 0 2 1 EPRI AMT Roadmap - Background and Genesis Advanced Value Added

- Numerous AMTs of interest for nuclear where is the value/need?

Near net shapes, complex geometries (reduced machining and waste)

Flexibleproduction, improved time to market Improved material properties (in certain cases) = improved reliability Applicability

- ALWRs and Repair/Maintenance of operating plants

- Extends to advanced plants (SMRs, nonLWRARs)

Deployment Timeline: Industry Needs

- TRL level, lack of standards, reactor type applicability, ASME acceptance, regulatory approval Compliments/refines NEI Regulatory Acceptance of AMM in Nuclear Energy Roadmap & Technical Report 3 w w w . ep r i. co m © 2020 Electric Power Research Institute, Inc. All rights reserved.

3 EPRI AMT Roadmap - Structure Aligns with Approach to Codifying New Manufacturing Methods

- Dec. 8 discussion from GE-Hitachi Understanding AMTs and Applicability of Each and EPRI during NRC AMT Workshop

- Component size often dictates AMT to beused Review of LWR Component Opportunities for Powder MetallurgyHIP (3002005432)

ALWR Primary System Candidates for Advanced Manufacturing Methods (Q1 2021)

SMR Candidate Components for Advanced Manufacturing Methods (2021)

Easily extends to advanced plants (SMRs, nonLWR ARs)

- Process parameters and their impacts on properties (e.g., microstructure, etc.) 2 Demonstrationsof the AMTs at Scale

- Understand applicability, advantages/disadvantages,proveout implementation Development of ASME Data Packages and Code Cases to Support Implementation of CertainAMTs Development/Compilation of Environmental Effects for Regulatory Approval 4 w w w . ep r i. co m © 2020 Electric Power Research Institute, Inc. All rights reserved.

4 B-83

1/6/2 0 2 1 Size Often Dictates Advanced Manufacturing Process Laser Powder Bed Fusion Direct Energy Deposition Additive Manufacturing: Additive Manufacturing: Powder MetallurgyHIP:

5 Candidate AMT Processes for Nuclear Components Powder MetallurgyHot Isostatic Pressing: PMHIP

- ~4 ft (1.2m) diameter Larger HIP allowing ~ 10ft (3.05m) diameter, est. completion 2023/24 Directed Energy Deposition AM:DEDAM

- < 500 lb. (227kg) max.

Powder Bed Fusion AM: LPBF orEBPBF

- ~75 lb. (34kg) max.

3 Advanced CladdingProcesses:

- e.g., diode laser cladding, hot wire laser welding, friction stir additive, cold spray & laser assisted cold spray,PMHIP

- Further development/qualificationneeded Electron Beam Welding:EBW

- For large components (RPVs, SGs, pressurizers, fusion components, etc.)

Other AMTs of interest not included with the roadmap:

6 B-84

1/6/2 0 2 1 Three AMT Roadmaps Primary Pressure Boundary Reactor Internals Other components (Class 1) Components (Obsolete parts, Classes 2 & 3, etc.)

Courtesy of Photo credit:

Westinghouse Electric CompanyLLC Fred List - ORNL, US DOE Courtesy of Westinghouse Electric CompanyLLC Courtesy of Siemens Power &Gas Courtesy of US NRC 7 w w w . ep r i. co m © 2020 Electric Power Research Institute, Inc. All rights reserved.

7

1. Primary Pressure Boundary (Class 1) Roadmap Roadmap includes an initial sizing study to identify candidate components

- Many large LWR Class 1 components exceed limitationsof certain AMTs. 16 BWR Feedwater Inlet Nozzle (LAS)

Developments identified are specific to: size groups/processes/materials 4

- Larger Class 1 components can be manufacture using PM/HIP Demonstration pieces of LWR components already produced 316L already accepted by ASME, but other alloys require qualification testing and ASME approval

- Smaller Class 1 components may be produced by DEDAM or Powder BedAM Process development, qualification testing, ASME approval shown Few Class 1 components candidates for Powder Bed AM (size limitation) 8 w w w . ep r i. co m © 2020 Electric Power Research Institute, Inc. All rights reserved.

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1/6/2 0 2 1 Advanced Recently Completed Research Focus Area Component Groups 2019 2020 2021 2022 2023 2024 2025 +

Projects Value ALWR and Large LAS Component Comparison SMRs Sizing ARs Sizing study for candidate components Manufacturing Component Sizing Between study for Size Study PM/HIP (need DCD first)

Manufacturing candidate Techniques components Innovative Manufacturing Roadmap -

Process for NPP Components via PM DOE Adv Manufacturing SMR Mfg &Fabrication Advanced Material Manufacturing HIP Demonstration (EBW, PMHIP, DLC, AM)

Large Components Alloy Code Development

(~4 to 7.25 ft dia.) Alloy Code Development (508) ASME Code Case for LAS (for ARs)

Class 1 Pressure PM/HIP Construction/Commisioning Large HIP FurnaceATLAS Prototype Demonstration/Testing Modeling of Large HIP Structures Boundary PostIrradiation of PMHIP and EBW Parts ASME Code Cases Test 316HSS/A690/304SS 316HSS/A690/304/304LSS Medium Components

(<4' dia., > 500 lb) Code Case 316L 1 Develop Bimetal components2 PM/HIP ASME Approval of Bimetal Components DEDAM Demonstration Testing Small Components Develop DEDAM Standards

(< 500 lb) PM/HIP or (support ASMESpecial Completed Project DEDAM Committee on AM)

Additive Manufacturing Strategic Focus Area Procurement Spec Code Case for DEDAM 316H DEDCode Case Roadmap is Active Project 316L SS(supporting KIWG) Development Magnified on Scoped Project Additive Manufacturing Strategic Focus Area AM QualificationRegulatory 316L SS Data Packageand Code Alloy 718, 690 or other Code Case following 2 slides Very Small Components (<75lbs)

Case Confirm AM Powder Bed AM with HIP or Concept no HIP Procurement Specification Process Process Development/Demonstration Selection Study Advanced Cladding Footnotes: Processes 3 Code Qualification/Approval

1. Applicable to all PM/HIP componentsizes Mechanical Advanced Mechanical Connection

2. LAS Nozzle/SS SafeEnd Connections Methods

3. Diode Laser Cladding development is partof EPRI Electron Beam DOE Adv Manufacturing SMR Mfg &Fabrication No PreheatASME and Advanced ManufacturingDOE Mfg. & Fabrication Welding Demonstration (EBW, PMHIP, DLC, AM) Regulators PostIrradiation of PMHIP and EBW Parts Demonstration project.

9

1. Primary Pressure Boundary (Class 1) Roadmap - upper half Recently Completed Research Focus Area Component Groups 2019 2020 2021 2022 2023 2024 2025 +

Projects Value Comparison ALWR and SMRs Large LAS Component Between Sizing study for ARs Sizing study for candidate components (need Component Sizing Size Study PM/HIP Manufacturing candidate DCD first)

Techniques components Innovative Advanced Material Manufacturing Manufacturing Process for NPP Components via DOE Adv Manufacturing SMR Mfg & Fabrication Demonstration PMHIP (EBW, PMHIP, DLC, AM)

Large Components Alloy Code Development (for

(~4 to 7.25 ft dia.) Alloy Code Development (508) ASME Code Case for LAS ARs)

PM/HIP Construction/Commisioning Large HIP FurnaceATLAS 5 Prototype Demonstration/Testing Modeling of Large HIP Structures PostIrradiation of PMHIP and EBW Parts ASME Code Cases Test 316HSS/A690/304SS 316HSS/A690/304/304LSS Medium Components

(<4' dia., > 500 lb) Code Case 316L1 Develop Bimetal components2 PM/HIP ASME Approval of Bimetal Components Footnotes:

1. Applicable to all PM/HIP componentsizes

2. LAS Nozzle/SS SafeEnd

3. Diode Laser Cladding development is part of EPRI Advanced ManufacturingDOE Mfg. & Fabrication Demonstration project.

10 B-86

1/6/2 0 2 1

1. Primary Pressure Boundary (Class 1) Roadmap - lower half Recently Completed Research Focus Area Component Groups 2019 2020 2021 2022 2023 2024 2025 +

Projects Advanced Material DEDAM Demonstration Manufacturing Testing Develop DEDAM Standards Small Components (support ASME Special Completed Project (< 500 lb) PM/HIP or Committee on AM)

DEDAM Additive Manufacturing Strategic Focus Area Procurement Spec Code Case for DEDAM 316L 316H DED Code Case Active Project SS(supporting KIWG) Development Scoped Project Additive Manufacturing Strategic Focus Area AM QualificationRegulatory Very Small 316L SS Data Package and Code Components (<75lbs) Alloy 718, 690 or other Code Case Case Powder Bed AM Confirm AM with HIP or no HIP Concept Procurement Specification Process Selection Process Development/Demonstration Study Advanced Cladding Processes 3 Code Qualification/Approval Mechanical Connections Advanced Mechanical Connection Methods DOE Adv Manufacturing SMR Mfg & Fabrication No PreheatASME and Electron Beam Welding Demonstration (EBW, PMHIP, DLC, AM) Regulators PostIrradiation of PMHIP and EBW Parts Footnotes:

2. LAS Nozzle/SS SafeEnd

3. Diode Laser Cladding development is part of EPRI Advanced ManufacturingDOE Mfg. & Fabrication Demonstration project.

11

2. Reactor Internals Roadmap Internals Roadmap generally follows similar pattern set for Class 1

- Up front sizing study Some significant differences:

- No low alloy steel components

- Fuel Hardware and Control Rod Drive components (unique shapes and materials)

- High strength Nibase alloys and cobaltfree alloys 6 Interaction with ASME is limited for Internals Roadmap

- Only core support structures require ASME approval

- Interaction with NRC may be required for some Safety Related Internals

- Other internals: free to use ASTM, AMS, etc. or no standard at all (a potential case for fuel hardware or control rod drive components) 12 w w w . ep r i. co m © 2020 Electric Power Research Institute, Inc. All rights reserved.

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1/6/2 0 2 1 Research Advanced Recently Completed Research Focus Area Task/Component 2019 2020 2021 2022 2023 2024 2025 +

Projects Groups ALWR and SMRs Manufacturing Sizing study for ARs Sizing study for candidate components Sizing Study candidate (need DCD first) components Roadmap - Large Internals Note: PMHIP of Reactor Internals are covered by Class 1 Pressure BoundaryRoadmap Reactor Internals

(~4 to 7.25 ft dia.) PM/HIP Advanced Material Manufacturing Medium Internals

(<4' dia., >50 lb)

PM/HIP DEDAM Demonstration Testing Small Internals Develop DEDAM Standards

(< 500 lb)

(support ASME Special Roadmap is PMHIP/DED AM/Powder Committee on AM)

Magnified on Bed AM2 Additive Manufacturing Strategic Focus Area Procurement Spec following 2 slides Code Case for DEDAM 316L SS(supporting KIWG) 316H DED Code Case Development Build/Test AM Demonstration Components (Includes X750/718/725)

Fuel Hardware Additive Manufacturing Strategic Focus Area AM Qualification/Standards Development (inc. thin parts)

Completed Powder Bed 316L SS Data Package and Code Confirm AM with HIP or no Project AM2 Case HIP Procurement Spec Active Project Footnotes:

Process Selection Study

1. Applicable to all PM/HIP Internals sizes Control Rod AM/DED and/or PM/HIP Process Demonstration/Testing Drive

2. Powder Bed AM < 75 lb Scoped Project Components (Includes Co Replacement Process Qual/Standards Alloys) Development 13 w w w . ep r i. co m © 2020 Electric Power Research Institute, Inc. All rights reserved.

13

2. Reactor Internals Roadmap - upper half Research Recently Research Focus Area Task/Component 2019 2020 2021 2022 2023 2024 2025 +

CompletedProjects Groups ALWR and SMRs Sizing studyfor ARs Sizing study for candidate components Sizing Study candidate (need DCD first) components Advanced Material Manufacturing Large Internals Note: PMHIP of Reactor Internals are covered 7 by Class 1 Pressure Boundary Roadmap

(~4 to 7.25 ft dia.)

PM/HIP Medium Internals

(<4' dia., > 500 lb)

PM/HIP Footnotes:

1. Applicable to all PM/HIP Internals sizes

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1/6/2 0 2 1

2. Reactor Internals Roadmap - lower half Research Recently Completed Research Focus Area Task/Component 2019 2020 2021 2022 2023 2024 2025 +

Projects Groups DEDAM Demonstration Testing Advanced Material Develop DEDAM Standards (support ASME Special Committee on AM)

Additive Manufacturing Strategic Focus Area Procurement Spec Manufacturing Code Case for DEDAM 316L 316H DED Code Case SS(supporting KIWG) Development Build/Test AM Demonstration Components Fuel Hardware (Includes X750/718/725)

(inc. thin parts) Additive Manufacturing Strategic Focus Area AM Qualification/Standards Development Completed Project Powder Bed AM2 316L SS Data Package and Code Case Confirm AM with HIP or no HIP Procurement Spec Active Project Process Selection Study Control Rod Drive AM/DED and/or PM/HIP Process Demonstration/Testing Scoped Project Components (Includes Co Replacement Process Qual/Standards Alloys) Development Footnotes:

1. Applicable to all PM/HIP Internals sizes

15

3. All Other Components Roadmap

--Obsolete Parts, Class 2 & 3, etc.

Primary Pressure Boundary and Reactor Internals Roadmaps fully address needs of Other Componentscategory

- e.g., ASME acceptance of a process/material for Class 1 immediately applicable to Class 2 & 3

- Other Components Roadmap may not be required 8

Sizing study to identify potential AMM candidate components still required

- Complicated by the broad range of components in this category Potentially different materials of interest

- Many likely Class 2 & 3 components and steam generator shell/internals

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1/6/2 0 2 1 Examples of Candidate AMM Components Primary Pressure Boundary Reactor Internals Other Components 17 w w w . ep r i. co m © 2020 Electric Power Research Institute, Inc. All rights reserved.

17 AMM Roadmap - Summary Two Roadmaps will likely cover >95% of components

- Primary pressure boundary (Class 1) Roadmap

- Reactor Internals Roadmap Roadmaps are focused on LWRs, ALWRs and SMRs 9

- Easily expanded to ARs in future Roadmap development generated based on component size/materials Central feature of each is ASME BPVC standards development & regulatory approval 18 w w w . ep r i. co m © 2020 Electric Power Research Institute, Inc. All rights reserved.

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19 AM Roadmap Contents Discuss stateoftheart applications of additive manufacturing technologiesfor metallic materials.

Discuss industry specifications and standards for AM

- Current documents

- Major documents in the pipeline

- Availability and applicability to the nuclear power industry 10 Identify key concerns for AM use in nuclear power applications Assessment of gaps in qualifying additive manufacturing techniques for AM components to be used in the nuclear power industry Develop a roadmap for additivemanufacturing

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1/6/2 0 2 1 Motivations for AM Adoption in Nuclear Industry Complex geometries not previously practical

- Example: novel fuel assembly debris filters Photo Credit: Westinghouse Reduce cost to build complex Photo Credit: Fred List/ORNL, Electric Company, LLC U.S. DOE, Framatome geometries

- Examples: valve bodies, Transformational Challenge Reactor Simplify inventory management

21 Motivations for AM Adoption in Nuclear Industry (contd)

Increase reliability and decrease part count with integrated assemblies

- Example: thimble plug assembly Simplify supply chain

- Reduce number of active qualified vendors Photo Credit: Westinghouse Electric Company, LLC 11 Manufacture inkind replacements for obsolete parts

- Example: fire protection pump impellers Other motivations Photo Credit: NEI, Siemens, Krko

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1/6/2 0 2 1 AM Roadmap Research Focus Technical Topic Priority Area EPRI Report: 3002018276 Type 316L Materials-Related Gaps Additive Manufacturing Alloy 718 Material Development and ASME Code Case AM Marketplace Alloy 625 Priorities Materials Ti64 ELI Grade 23

- AM Marketplace Materials Alloy X

- NonAM Marketplace Materials Alloy 690 Materials-Related Type 316H

- Feedstock Quality Guidelines Gaps Alloy 617

- Fatigue Data Materials Not in Zirconium Alloys AM Marketplace

- SCC and IrradiationData AISI 4340 Feedstock Quality Guidelines Process Related Gaps Materials-Related Gaps Fatigue Data for As-Printed Surfaces

- ASME PTB Guideline for DED PBF Guidelines

- Industry consensus regarding minimum essential DED Guidelines parameters for each AM process Process-Related Essential Parameters

- Heat Treatment Effects (HIP andSA) Gaps DED Process Parameter Effects Heat Treatment Reqm'ts NonDestructive ExaminationRelated Gaps Technical Bases for

- Technical Basis for Defect Acceptance Criteria Defect Acceptance Criteria

- NDE Improvements for AM Parts NDE Improvements for AM Parts

- Guidelines for NDE of DED Parts Completed Project NDE-Related Guidelines for NDE of DED Parts

- Insitu RealTime Build Health Monitoring Gaps ASME Code NDE Active Project Inspection Scope In-Situ Real-Time Recommended Practices for Purchases AM Scoped Project Build Health Monitoring Parts Purchasing AM Concept Procurement Gaps 23 w w w . ep r i. co m © 2020 Electric Power Research Institute, Inc. All rights reserved. Manufactured Parts 23 Additive Manufacturing To Support Spare and Replacement Items 12 Marc H. Tannenbaum Technical Executive 24 w w w . ep r i. co m © 2020 Electric Power Research Institute, Inc. All rights reserved.

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1/6/2 0 2 1 Overview Range of available materials Wide range of technologiesand methods

Ceramics

Binder Jetting

Glass

Directed Energy Deposition (DED)

Laser Powder Bed Fusion(PBF)

Sand

Material Extrusion / Fused Deposition

Metals (wire, powder, sheet) Modeling (FDM)

Polymers

Material Jetting

Reinforced polymers

Sheet Lamination

VAT Photopolymerization Various replacementitem Many non-structural, applications non-pressure-retaining applications Manufacturing Rapid prototyping Fewer barriers to use inplant parts ondemand Creating tooling applications 25 w w w . ep r i. co m © 2020 Electric Power Research Institute, Inc. All rights reserved.

25 Benefits to spare and replacement items IMPROVED SIGNIFICANT replacement cost reductions for low-volume parts item designs and complex assemblies 13 ENHANCED ability to establish SHORTER design suitability of proposed lead-times replacement i tems 26 w w w . ep r i. co m © 2020 Electric Power Research Institute, Inc. All rights reserved.

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1/6/2 0 2 1 Obsolescence Instead of building to meet a design, smart manufacturing technologies build from a design Certain aspects of conformance with design Additive are inherentManufacturing in the processes Supply Process - Obsolescence Traditional Additive Manufacturing Manufacturing Fused Deposition Modeling

Mold $10,000s

Scan + Build $100s ea. (no min)

Component run $1,000 ea. (100min)

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1/6/2 0 2 1 EPRI Advanced Manufacturing Research Focus Area GOAL &VALUE Identify, develop, qualify and implement more economical manufacturing technologies that enable:

Higher Quality Components l Reduced Lead Times l Alternative Supply Chains l Cost Competitiveness Additive Manufacturing Advanced Manufacturing Advanced Welding Demonstration Project Techniques PMHIP EB Welding Adaptive Feedback Welding ANT +

WRTC 316L LPBF Code Case & Data Package (submitted to ASME August 2020) Modular InChamber EBW DLC Heat Treat Additive Manuf. Roadmap for Nuclear Applications (Q4 2020)

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1/6/2 0 2 1 SMRs and ARs Factory Manufacture/Fabrication Modular Construction

- Have to get it right this time Smaller unit size is ideal for factory production Economy of scale Must bring to bear new manufacturing and fabrication technologies to be costeffective.

Reference:

Bailey, J., Whats Nu and Whats Next, April 2017.

31 Advanced Reactor Manufacturing/Fabrication MicroReactors

- Heat pipe reactors will use AMTs to produce core GEN IV Reactors

- Rely heavily on nickelbased alloys and complex cooling geometries.

16

- HIP provides economic avenue to producenickel based components

- Eliminates welds and minimizes machining due to near netshape

- Cladding of complex alloys(Moly or other)

32 B-97

1/6/2 0 2 1 What Is Required To Bring These Technologies Forward For SMR, Micro-Reactor, or AR Applications?

Code Data Packages (mechanical, microstructural, welding data)

ASME or RCCM Code acceptance Regulatory Acceptance Corrosion Testing Irradiation Studies Clearly separate pressure retaining applications from structural applications 33 w w w . ep r i. co m © 2020 Electric Power Research Institute, Inc. All rights reserved.

33 Summary - EPRI Vision of AMT Use in Industry Advanced Manufacturing Technologies Roadmap

- ALWRs Easily extends to advanced plants (SMRs, nonLWR ARs)

- Two Roadmaps will likely cover >95% of components

- Development generated based on component size/materials

- Central feature of each is ASME BPVC standards development & regulatory approval 17 Additive ManufacturingRoadmap

- Assesses key concerns/gaps for AM use in nuclear power applications

- Develops a roadmap for AM to address the gaps identified Additive Manufacturing for Obsolete and Replacement Components EPRI R&D to Deploy AMTs Whats Next 34 w w w . ep r i. co m © 2020 Electric Power Research Institute, Inc. All rights reserved.

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35 18 B-99

1/6/2021 Utility Perspective on Implementing on Advanced Manufacturing Technologies in LWRs Lee Friant, PhD Sr. Staff Engineer Exelon Nuclear 1

Utility View of New Technologies - Inertia Governing Law:

Newton's first law states that every object (read Nuclear Utility) will remain at rest or in uniform motion in a straight line unless compelled to change its state by the action of an external force.

1 NRC Workshop on AMT 12/7-12/10/2020 2

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1/6/2021 External Forces Driving New Technology in Nuclear Cost Savings Purchase Price Maintenance Radiological Dose Lack of Availability Obsolescence/Supplier out of business Too long lead time to deliver Only off-shore suppliers (unknown quality)

Corrects long-standing problem/reliability/safety issue with an existing component design Material failures; e.g., cracking, erosion, corrosion, wear, etc.

Regulatory Compliance 2 NRC Workshop on AMT 12/7-12/10/2020 3

How Can Advanced Manufacturing Technologies Address Nuclear Utility Needs?

Cost Savings Not likely initially, but lower Life-cycle Cost Lack of Availability Ability to reverse engineer components 3-D print of one-off items Corrects long-standing problem/reliability/safety issue to prevent /mitigate failures Upgrade to non-susceptible base metal Surface Repair / Apply protective coating 3 NRC Workshop on AMT 12/7-12/10/2020 4

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1/6/2021 AMT Implementation Barriers Lack of Utility familiarity with AMTs unique capabilities/limitations EPRI, NEI (Task Force) and NRC are addressing this gap Lack of ASTM Standards/ASME Codes for AMTs ASME Sub-committee formed; first one submitted for review Will take years to obtain design allowables and to develop and adopt standards for all AMTs Need to borrow/adopt from other Industries e.g., Powder Metallurgy and Electron Beam Welding are mature technologies outside of Nuclear Regulatory framework under development Structural ASME Class 1, 2 and 3 Components will have to wait unless NRC permission granted through ASME Code relief process 4 NRC Workshop on AMT 12/7-12/10/2020 5

Where Can AMTs be Implemented at Utilities Near-term?

Replacement and/or Repair of Non-Code Components Non-structural Non-pressure retaining No safety impact (based on 10CFR 50.59 Screening)

Exelon example: Westinghouse Thimble Plugging Device made by Laser Powder Bed Fusion (installed in plant in Spring 2020)

Coatings for Corrosion / Oxidation Prevention Exelon examples:

Full length Cold Spray accident tolerant coating on 16 Fuel Rods (installed in plant in Spring 2019)

Cold Spray of Titanium/Titanium Carbide for Crevice Corrosion Mitigation in spare flanged Salt water piping components (Flow Element, 11/20 and Nozzle Check Valve, 12/20).

PWR Steam Drum, In-situ Cold Spray of Primary Moisture Separators for Flow Accelerated Corrosion (FAC) Mitigation (2015, 2021 to 2024).

Balance of Plant Applications at Nuclear Plants Turbine components (e.g., blades) 5 NRC Workshop on AMT 12/7-12/10/2020 6

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1/6/2021 PWR Steam Generator Steam Drum Access to Primary Moisture Separators Top Down View of Swirl Vanes and Riser Barrel FAC No Close-up FAC of Vane and Riser Barrel Wall 6 www.nucleartourist.com 7

Lessons Learned From AMT Implementation Suppliers developed AMTs then shopped around to interested Host utilities Utility personnel unprepared to accept AMT due to lack of technology familiarity (e.g., critical characteristics such as porosity, toughness, etc.), lack of Procurement and Design Specifications and Code precedent Start with simple geometries (rods, tubes, pipes, etc.)

Most AMT hardware doesnt lend itself to in-plant applications; pick components which are new or spares that can be fabricated / refurbished off-site Cold Spray shows promise for in-plant repair applications Need to educate and coordinate large number Stakeholders to implement any AMT Leveraged DOE Funding - AMT not realized at Exelon without DOE support! Thanks!

7 NRC Workshop on AMT 12/7-12/10/2020 8

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1/6/2021 It Takes a Team Effort..

Many Stakeholders needed to be coordinated and engaged to implement AMT; at Exelon these included:

Design and Strategic (Plant) Engineering (outside reactor vessel) / Reactor and Fuels Engineering (inside reactor vessel)

Procurement Engineering Supply Chain Programs Engineering Non-destructive Examination / In-Service Inspection Maintenance Warehouse / Shipping Machine / Weld Shop Regulatory Assurance Planning / Work Management Finance Corporate and Site Leadership 8 NRC Workshop on AMT 12/7-12/10/2020 9

Takeaways Set realistic objectives and timetables Implementing a first-of-a-kind AMT application is a challenge and requires patience and perseverance; be prepared for a lot of questions, meetings, emails and hand holding After the AMT process qualification and all the Nuclear infrastructure to accept AMT is in place, the 2nd implementation is easy.

Exelon example: Cold Spray of 1st Salt Water Component: ~ 3 yrs; 2nd component: 2 weeks 9 NRC Workshop on AMT 12/7-12/10/2020 10 B-104 5

1/6/2 0 2 1 Westinghouse Non-Proprietary Class 3 © 2020 Westinghouse Electric Company LLC. All Rights Reserved. 1 WAPP-11867 WESTINGHOUSE ADVANCED MANUFACTURING DEVELOPMENT AND IMPLEMENTATION EFFORTS U.S. NRC Workshop on Advanced Manufacturing Technologies for Nuclear Applications December 7, 2020 Clint Armstrong: armstrcb@westinghouse.com Advanced Manufacturing Subject Matter Expert Westinghouse Global Technology Office 1

WAPP-11867 Westinghouse Advanced Manufacturing Program Objectives Improve industry competitiveness, through the development and implementation of advanced manufacturing technologies

Drive cost reductions in component manufacturing

Enable new products and services that provide innovative customer solutions

Leverage collaborative development and external funding sources 1

2 2

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WAPP-11867 ADDITIVE MANUFACTURING DEVELOPMENT EFFORTS 3

WAPP-11867 Additive Manufacturing (AM) Objectives Exploiting the Benefits of Additive Manufacturing Technologies

Producing components with: Powder Bed Fusion (PBF), Binder Jetting (BJ),

and Directed Energy Deposition (DED) AM technologies

Complex components required for performance gains

Advanced reactor components - eVinci, LFR

Obsolete and high value / lead-time components

Tooling / jigs / fixture, prototypes, mockups 2 Enabling AM for Nuclear Component Construction

Leading material development & testing for in reactor use, including irradiation and PIE of 316L, 718 and Zirc-2

Parameter development and material testing for 304L, 17-4 PH, Haynes 230 & 282, MS1, AFA and FeCrAl ODS alloys

Supporting the development of ASTM and ASME codes and standards 4

4 B-106

WAPP-11867 ASME Engagement - L-PBF AM 316L Code Case FIRST ASME CODE CASE SUBMITTAL FOR ADDITIVEMANUFACTURING Laser-PBF AM 316L Code Case

Submitted the Section III Code Case for L-PBF AM in August

- ASME Record 20-254

- Requesting implementation ASTM F3184-16 with addition requirements, for Section III, Division 1, Subsection NB/NC/ND, Class 1, 2 and 3 components construction

- Presented Code Case and Data Package at the Section III MF&E Sub-Committee and AM Special Committee

EPRI consolidated the 316L AM Data Package to support the AM Code Case

- AM test components were supplied by Westinghouse, Rolls-Royce, ORNL, Auburn University and Oerlikon

- EPRI coordinated material testing and analysis

- Funded under DOE NEET-1 AMM Program (DE-NE0008521) 5 5

WAPP-11867 Reactor Ready Component Development Efforts AM COMPONENT INSTALL IN COMMERCIAL NUCLEAR REACTOR CORE Advanced Manufacturing Kaizen - Dec. 2014

Project initiated for development of AM reactor ready component Thimble Plugging Device (TPD) selected as first component to test in core 3

Low risk component, moderate complexity

Produced hybrid 304/316L TPD

Manufacturing qualification.....2017-2018

Production units2018-2019

Delivered Byron 1....Spring 2020 6

6 B-107

WAPP-11867 Fuel Debris Filtering Bottom Nozzle Development AM Benefits:

Improved debris filtration

- BWR Testing: Up to 100% debris capture in testing

Reduced pressure drop AM Development:

Multiple complex designs / features enabled by AM

Significant mechanical and performance testing

PWR: LUAs in Fall 2021

BWR: LUAs in Spring 2022 7

WAPP-11867 Fuel Spacer Grid Development Efforts AM Benefits:

Stronger support of fuel rods

Improved mixing characteristics Additive Manufacturing of Spacer Grids for Nuclear Reactors

$1.25M, 3 year, ARPA-E Funded Project

Collaborative effort with Carnegie Mellon University 4

Primary Tasks Include:

Establish baseline capability

Enable low-cost fabrication

Improve the spacer grid quality and performance

Improve spacer grid performance

Exploring potential opportunities for redesign of spacer grid geometries 8

8 B-108

WAPP-11867 Innovation Projects eVinci' Microreactor

Utilizing of Design for Manufacturability approach and developing Adv Mfg technologies, where appropriate

Primary Heat Exchanger (PHX), heat pipe end plugs and fittings, and small parts and structural components are the leading candidates Salem Thermal Shield Flexure

Completed topology and AM optimization efforts

Successfully complete fatigue testing of topology optimized AM flexure eVinci is a trademark or registered trademark of Westinghouse Electric Company LLC, its affiliates and/or its subsidiaries in the United States of America and may be registered in other countries throughout the world. All rights reserved. Unauthorized use is strictly prohibited. Other names may be trademarks of their respective9owners.

WAPP-11867 Replacement Parts Replacement Parts Identification Efforts

Currently working to identify, demonstrate and qualify AM applications

Data and expert review for application down-selection

Development of detailed estimates / business cases for top candidates

Utilizing laser scanning and reverse engineering 5

software to develop editable 3D models for obsolete parts 10 10 B-109

WAPP-11867 Tooling Immediate benefit from tooling applications

Lower the costs and improve performance Improved safety for operators

Reduction of leak points

Two hands touch control

Ergonomic designs resulting in less fatigue injuries 11 11 Westinghouse Non-Proprietary Class 3 © 2020 Westinghouse Electric Company LLC. All Rights Reserved.

WAPP-11867 HOT ISOSTATIC PRESSING (HIP)

DEVELOPMENT EFFORTS 6

12 12 B-110

WAPP-11867 Hot Isostatic Pressing (HIP) Development Efforts NEER Project (Innovate UK-funded): Completed in May 2018

Focused on reusable tooling, HIP development and demonstration of nuclear components, and UK supply based development

Produced demonstration components

Reactor Vessel Internals (RVIs): Quickloc Upper Support Assembly

Control Rod Drive Mechanisms (CRDMs): Guide Funnel Extension

Valves: 4 Motor Operated Gate Valve Body Producing Prototypes / Mockups for Next Generation Plants Completing Cost-Benefit Analysis for Reactor Coolant Loop Components Collaborating on Auburn led DOE AMM funded project

3 year, $1M effort focused on HIP of dissimilar metal joints, materials, and modeling 13 13 Westinghouse Non-Proprietary Class 3 © 2020 Westinghouse Electric Company LLC. All Rights Reserved.

WAPP-11867 ADVANCED WELDING AND COATING DEVELOPMENT EFFORTS 7

14 14 B-111

WAPP-11867 Advanced Welding and Coating Development Efforts Collaborating on welding development efforts

Hot wire laser welding (HWLW)

Hybrid laser GMAW

Laser welding of irradiated materials

Laser metal deposition for component repair

Cold Spray & Plasma Arc Spray Using emergent technologies to solve fabrication and repair challenges and reduce manufacturing costs

RCP, RVI and CRDM cost reduction opportunities

Module fabrication

Weld distortion reduction and modeling

In-field component repair 15 15 Westinghouse Non-Proprietary Class 3 © 2020 Westinghouse Electric Company LLC. All Rights Reserved. 16 WAPP-11867 8

Westinghouse Westinghouse

@WECNuclear wecchinanuclear Electric Company Electric Company westinghousenuclear.com 16 B-112

1/6/2021 Framatome Additive Manufacturing Overview Applications, Challenges and Progress Thomas Genevés - R&D Engineer - AMT, Framatome Technical Center Chris Wiltz - Design to Cost / Design to Manufacture Manager, Fuel Advanced Manufacturing Technologies Workshop December 7, 2020 1 Framatome Additive Manufacturing Overview - Applications, Challenges and Progress - AMT Workshop- December 7, 2020 1

Overview Background of Framatomes AMT Development and Progress 2014: Rapid Prototyping Stereolithographic (Resin) Printing Polymer product production for fast and cheap prototyping investigations Investigation of potential applications, limitations and opportunities 2015 - 2018: Material, Processes and Application Development Additional equipment procurement and broad technology application evaluation Cooperative activities with external companies and researchfacilities 2019 - 2020: Industrial and Nuclear Advanced Manufacturing Technologies (AMTs) Application and Qualification Material evaluation programs Irradiation performance evaluations Specification, design and manufacturability experience Lead component introduction Framatome Additive Manufacturing Overview - Applications, Challenges and Progress - AMT Workshop- December 7, 2020 2 2

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1/6/2021 General Practices and Uses of AMT Manufacturing Methods, Equipment and Examples Framatome identifies the value of AMT in maximizing for: Product Complexity SLM Optimized component and tool design Functional addition / enhanced repair LMD Lower product cost with faster application Debris Filter In supporting implementation of WAAM these techniques, a global development approach to AMT was engaged: Machining Tool Development of design skills PWR Upper Internals Materials characterization Function Addition on Heavy Components Study of defects and adequate NDE Size Determination of qualification approaches Framatome Additive Manufacturing Overview - Applications, Challenges and Progress - AMT Workshop- December 7, 2020 3 3

General Practices and Uses of AMT (cont.)

Manufacturing Methods, Equipment and Examples Framatome Equipment Design and Prototyping Methods (Polymers):

Filament Fused Deposition Tooling, Gaging, Inspection Stereolithographic Printing and Manufacturing Equipment Directed Energy Deposition Cooperative Equipment Service, Packaging and Replacement Parts Methods (Metals):

Powder Bed Fusion Direct Metal Melting/Energy Test Hardware Deposition Cold Spray Coating Wire Arc Additive Manufacturing In-Reactor (Direct Energy Deposition) Components Framatome Additive Manufacturing Overview - Applications, Challenges and Progress - AMT Workshop- December 7, 2020 4 4

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1/6/2021 Industry Observations and Nuclear Industry Evaluation Perspective - Applying AMT Effectively in the Nuclear Industry Relatively New Technology Application in the Nuclear Industry but Widely Applied in Industries - High and Low Technology High Technology: Aerospace, Medical, Automotive, Military Low Technology: Business Machines, Consumer Products Technology to market quicker in non-nuclear industries - Also high risk/conservative More diverse materials and advanced manufacturing methods Innovation and Development Critical Market Drivers Nuclear Industry Does Have Success with Similar Manufacturing Technology Transfers and Starting Materials Example: Machined Cast Brazed/WeldedMetal Injection Molding Adoption of Additional Inspection and Quality Control Technologies Examples: Real-time Void Detection and Machine Learning Large Upside with a Quick, Broad and Efficient Implementation Framatome Additive Manufacturing Overview - Applications, Challenges and Progress - AMT Workshop- December 7, 2020 5 5

Nuclear Fuel Related Activities and Progress Development, Qualification and Application Material Behavior Under Reactor Operating Conditions Goal: Obtain material irradiation experience and obtain behavior and response data to support licensing approval for additive manufactured component application and compare with out of reactor evaluation results Initiated in 2016 with focus on 316L stainless steel and nickel based Alloy718 Various parameters or responses evaluated through analysis of samples placed in the active region (neutron field with coolant interaction) of a commercial nuclear power plant Mechanical Corrosion Surface Condition and Geometric Material Integrity / Metallography Three configurations of material segment types tested in Material Test Rods (MTRs)

Standard, Cylinder and Universal Framatome Additive Manufacturing Overview - Applications, Challenges and Progress - AMT Workshop- December 7, 2020 6 6

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1/6/2021 Nuclear Fuel Related Activities and Progress Development, Qualification and Application (cont.)

Material Behavior Under Reactor Operating Conditions (cont.)

Test samples manufactured using Selective Laser Melting and placed in Material Test Rods for irradiation testing Universal Cylinder Standard Test Sample Orientation in MTR Segment - Multiple Segments in Multiple Rods Samples to be analyzed after 1, 3 and 5 cycles of operation Three Sample Set #1 Sample Set #1 Sample Set #2 Sample Set #2 Sample Set #3 Sample Set #3 Sample Sets (1 Cycle) Hot Cell (3 Cycles) Hot Cell (5 Cycles) Hot Cell Inserted Removed Examination Removed Examination Removed Examination 2019 2020 2021/22 2022 2023/24 2024 2025/26 Framatome Additive Manufacturing Overview - Applications, Challenges and Progress - AMT Workshop- December 7, 2020 7 7

Nuclear Fuel Related Activities and Progress Development, Qualification and Application (cont.)

Fuel Assembly Component Implementation - Channel Fastener Goal: Gain experience, demonstrate competency and introduce in reactor nuclear fuel assembly components produced using additive manufacturing Accomplished in collaboration with Oak Ridge National Laboratory and TVA as part of the Transformational Challenge Reactor (TCR) program Full scope basic product development and implementation project accomplished Design modification and control for Direct Metal Laser Melting (Powder Bed Fusion) AM technique

- Drawings, product specifications, material specifications, inspection requirements, etc.

Additive manufacturing process/configuration control and optimization - Product manufacturability Qualification and quality control establishment for manufacturing process and final product Licensing and commercial operation of a safety related fuel assembly component in reactor Four channel fasteners completed and delivered to TVA for Spring 2021 insertion in Browns Ferry Nuclear Power Plant - Unit 2 (Cycle 22) for three cycles of operation Full pre-irradiation characterizations accomplished - Dimensional, mechanical, chemical and NDE Framatome Additive Manufacturing Overview - Applications, Challenges and Progress - AMT Workshop- December 7, 2020 8 8

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1/6/2021 Nuclear Fuel Related Activities and Progress Development, Qualification and Application (cont.)

Fuel Assembly Component Implementation - Channel Fastener (cont.)

Anticipated post-irradiation examination plan beginning in 2023 - To be finalized Poolside visual examination after each cycle of operation Hot cell examinations - visual, dimensional, metallography, tensile tests, fraction toughness, etc.

Direct Metal Laser Melting Manufacturing Process - Directed EnergyDeposition Edge of Manufacturing via adding (melting together) thin layers of 316L powder from a solid base plate upward Base Plate Secondary Unmelted Machining Unmelted Powder Bed Powder and Heat Final (Multiple Thin Layers) Removed Treatment Assembly Melted Powder Layer Powder/Metal Layer (Component Build-up) Melting Laser Framatome Additive Manufacturing Overview - Applications, Challenges and Progress - AMT Workshop- December 7, 2020 9 9

Nuclear Fuel Related Activities and Progress Development, Qualification and Application (cont.)

Direction Forward for Additive Manufacturing Application Near Term - Additional Experience and Industrial/Commercial Application Feedback Completion of reactor operation material behavior evaluationprograms Introduction of additional existing fuel assembly components produced using additive manufacturing technologies and materials as additional PWR and BWR fuel assembly lead type programs

- 316L stainless steel and nickel based Alloy 718 material applications Technology influenced product boundary conditions and performance enhancement capabilities Product Innovation and Additive Manufacturing Technology Application Optimization Fuel Lower Debris Filters Fuel Upper Grids and Filters Tooling and Reactor Components Goal: Industrial product delivery beginning in 2026 Framatome Additive Manufacturing Overview - Applications, Challenges and Progress - AMT Workshop- December 7, 2020 10 10 B-117 5

1/6/2021 Questions, Comments and/or Opinions Framatome Additive Manufacturing Overview - Applications, Challenges and Progress - AMT Workshop- December 7, 2020 11 11 Thank You!

Framatome Additive Manufacturing Overview - Applications, Challenges and Progress - AMT Workshop- December 7, 2020 12 12 B-118 6

1/6/2021 Any reproduction, alteration, transmission to any third party or publication in whole or in part of this document and/or its content is prohibited unless Framatome has provided its prior and written consent.

This document and any information it contains shall not be used for any other purpose than the one for which they were provided. Legal action may be taken against any infringer and/or any person breaching the aforementioned obligations.

13 Framatome Additive Manufacturing Overview - Applications, Challenges and Progress - AMT Workshop- December 7, 2020 13 13 B-119 7

1/6/2021 Advanced Manufacturing with Advanced Materials for Nuclear Applications ROBERT OELRICH Fuels and Materials Performance, National Security Directorate, PNNL NRC Public Workshop on Advanced Manufacturing - December 7-10, 2020 IR# PNNLSA158421 Workshop on Advanced Manufacturing Technologies for Nuclear Applications December 7, 2020 1 1

Advanced Materials with Advanced Manufacturing Additive Manufacturing: Components are now being introduced into commercial LWRs PWR thimble plug assembly installed at Exelons Byron Unit 1 in Spring 2020 BWR channel fasteners to be installed at Browns Ferry in Westinghouse - PBF Thimble Plug Spring 2021 Source: World Nuclear News May 5, 2020 Advanced Manufacturing: Accident Tolerant Fuel (ATF) coated cladding also being introduced in PWRs and BWRs GNF Armor-coated Zirconium at Plant Hatch Framatome EATF Chromium-coated M5 into Vogtle 2 Westinghouse EnCore Chromium-coated GE ArmorCoated Cladding Framatome/TVA/ORNL TCR - AM Channel Fasteners rods in Byron 2 Source: Power Magazine April 1, 2018 Source: ORNL Press Release October 19, 2020 Workshop on Advanced Manufacturing Technologies for Nuclear Applications December 7, 2020 2 2

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1/6/2021 Advanced Materials with Advanced Manufacturing The combination of Additive Manufacturing flexibility with advanced materials can result in innovation that was previously unachievable.

Additive Industry Benefits:

Advanced Materials Manufacturing

Higher Safety Margins

Complex Geometry Game

More Favorable Economics Changing

Thermal Performance

Improved Heat Transfer Innovation

Strength and Ductility

Enhanced Accident Survivability

Debris Filtering

Corrosion Resistance

Enabling of Advanced Reactor

Anisotropic Mechanical Concepts

Wear Resistance Properties Workshop on Advanced Manufacturing Technologies for Nuclear Applications December 7, 2020 3 3

Advanced Materials with Advanced Manufacturing Advanced Manufacturing Complex geometries not possible with traditional manufacturing Material and weight savings Materials: SS 316L, Inconel 718, Zirconium, Titanium & Aluminum alloys Advanced Materials Improved thermal and mechanical properties Enhanced radiation, wear and corrosion resistance Materials: new alloys, carbides, nitrides, MAX phase, ceramics, ODS steels Advanced Manufacturing with Advanced Materials Functionally Graded Materials (FGM)

Applications of some new non-traditional reactor materials New components for advanced reactors (unrestricted by existing environments and configurations)

Workshop on Advanced Manufacturing Technologies for Nuclear Applications December 7, 2020 4 4

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1/6/2021 Advanced Materials with Advanced Manufacturing Advanced Manufacturing (AM) can be useful for direct component Advanced Enhanced Material Advanced replacement, and/or to implement Performance Reactor evolutionary improvements in SiC Fuel Cladding Components performance or weight Gen IV+ Fuel &

Rx components However, costs may not justify AM for high volume parts or for long Carbides, Nanomaterials qualification processes Materials Cr Coated Nitrides, MAX PhaseCoatings Functionally Cladding GradedMaterials Strongest opportunities may be for (FGM) totally new concepts for future Fuel Assembly advanced reactor components which Existing BWRChannel Fasteners Spacer Grids Complex may not be constrained by pre- Reactor PWR Thimble Debris Filter Geometries existing requirements: enveloping Proven Components Plug Assemby Components geometry, thermal and other environmental conditions, licensing Proven Manufacturing Advanced bases, etc Workshop on Advanced Manufacturing Technologies for Nuclear Applications December 7, 2020 5 5

Advanced Materials with Advanced Manufacturing Additive Manufacturing introduces new variables that must be Selective Laser Melting (SLM) controlled throughout the development and qualification cycle.

Selective Laser Parameters Sintering (SLS)

Energy, speed of deposition Direct Metal Powder Bed Laser Sintering Fusion (PBF)

(DMLS)

Thermal conditions, temperature gradients, solidification Laser Metal velocities, localized annealing rates Fusion (LMF)

Powder characteristics Electron Beam Melting (EBM)

Alloys, impurities Additive Manufacturing Direct Material Properties Manufacturing (DM)

Isotropic/Anisotropic performance LaserEngineered Net Shaping Strength, Ductility Advanced Manufacturing (LENS)

Direct Metal Directed Energy Production Rates Deposition (DED)

Deposition (DMD)

Surface Finish Wire and Arc Additive Cold Spray Manufacturing Microstructure ATF Coated (WAAM)

Claddings Composition Homogenity Physical Vapor Deposition Laser Metal Deposition (LMD)

Workshop on Advanced Manufacturing Technologies for Nuclear Applications December 7, 2020 6 6

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1/6/2021 Advanced Manufacturing in the Development Process There are at least three separate opportunities to introduce Advanced Manufacturing into the development and qualification process 2 Enable rapid Optimization for Final prototyping Manufacturing Qualification Prototyping Testing 1 Enhance 3 Help to optimize Conceptual Design production (e.g.

Development Cycle minimize weight, optimize costs and energy)

Concept R&D Redesign Workshop on Advanced Manufacturing Technologies for Nuclear Applications December 7, 2020 7`

7 Advanced Manufacturing in the Development Process The many forms of Advanced Manufacturing introduces new flexibility into the development and qualification process. Also, AM technology continues to evolve at a fast pace.

Technology can outpace the qualification and licensing process.

Traditional certification and qualification processes need to be improved.

To retain the most flexibility from AM, consider qualifying material and irradiation performance as much as possible based on material characterization - specific AM technology can/will evolve.

Type: Powder Bed Fusion, Direct Energy

Microstructure: grain

Tensile Strength, Deposition, etc. size, orientation Hardness

Processing

Defect

Isotropic/Anisotropic Advanced parameters: Energy Material behavior characteristics, Performance Manufacturing Deposition, Temp Characterization dislocations

Chemical, SCC, &

Gradient,

Chemistry and IASCC resistance Solidification Velocity, Alloying, Impurities

Fatigue Life Impurities Dynamic - AM Technology Durable - Materialbased Performance Workshop on Advanced Manufacturing Technologies for Nuclear Applications December 7, 2020 8 8

B-123 4

1/6/2021 Advanced Manufacturing in the Development Process Evolving AM technology can disrupt material performance, jeopardizing the qualification process.

Define and control basic material characteristics early in the process.

Also inform regulators in advance of new technology as early as possible.

Optimization for Final Postdeposition Manufacturing Qualification grain recovery actions, heat treatments, Prototyping Testing Proton/Ion Advanced Irradiation Predictive surface finishing, Modelling Development Cycle Define Material Characteristics Concept R&D Redesign Workshop on Advanced Manufacturing Technologies for Nuclear Applications December 7, 2020 9 9

Advanced Manufacturing in the Development Process The third AM, Advanced Modelling, supports Additive Manufacturing and Advanced Materials Additive Manufacturing can enable rapid prototyping in the testing phase However, it also introduces additional variables into the prototyping/testing process So, empirical modelling and qualification can be much more challenging Advanced modelling can be utilized to better predict and control the governing AM parameters influencing the product performance Finally, with so much more computer-based modelling earlier in the development cycle, Cyber Security becomes even that much more critical to protect Intellectual Property.

Material Selection

Atomic and MesoScale Modelling Conceptual Design

IonProton Beam Irradiation Additive Manufacturing Prototyping

Solid Modelling

Calibration

ThermoMechanical Modelling

Validation

Computational Fluid Dynamics Workshop on Advanced Manufacturing Technologies for Nuclear Applications December 7, 2020 10 10 B-124 5

1/6/2021 Case Study - Accident Tolerant Fuels ATF coated cladding development represent a similar qualification and licensing challenge as other AM development programs Material properties are heavily dependent upon new but controllable process parameters, such as temperature, speed, carrier gas, energy of deposition, impurities Critical to understand and control desired microstructure characteristics, not just process parameters Qualification and licensing based on fundamental material properties, not simply deposition process parameters Key modelling and material characterization must be brought forward in the process Workshop on Advanced Manufacturing Technologies for Nuclear Applications December 7, 2020 11 11 Case Study - Accident Tolerant Fuels IL TROVATORE:

An international collaboration with strong academic input & industrial support Beneficiaries: 28 from Europe, 1 from the US, and 1 from Japan External Expert Advisory Committees:

Scientific Advisory Committee End Users Group (Oelrich member)

Standardization Advisory Committee (ASTM/C28, CEN/TC 430, ISO/TC 85)

Workshop on Advanced Manufacturing Technologies for Nuclear Applications December 7, 2020 12 12 B-125 6

1/6/2021 Case Study - Accident Tolerant Fuels Goal: Help to address the global societal & industrial need for improved nuclear energy safety by optimizing and validating select ATF cladding material concepts in an industrially relevant environment (i.e., under neutron irradiation in PWR-like water in the BR2 research reactor)

Candidate ATF Cladding Material Concepts:

SiC/SiC composite clads, different concepts Coated clads (e.g., Cr-coated zircaloys); innovative coating materials: MAX phases, doped oxides GESA surface-modified clads ODS-FeCrAl alloy clads Workshop on Advanced Manufacturing Technologies for Nuclear Applications December 7, 2020 13 13 Case Study - Accident Tolerant Fuels Goal: Help to address the global societal & industrial need for improved nuclear energy safety by optimizing and validating select ATF cladding material concepts in an industrially relevant environment (i.e., under neutron irradiation in PWR-like water in the BR2 research reactor)

Candidate ATF Cladding Material Concepts:

SiC/SiC Composite Clads Coated & SurfaceModified Clads SiC/SiC composite clads, different concepts ODSFeCrAl Clads Coated clads (e.g., Cr-coated zircaloys); innovative coa ting materials: MAX phas es, doped oxides GESA surface-modified clads 2 nm Al2O3 ODS-FeCrAl alloy clads Ti2AlC 1 m 50 m 400 nm 300 nm GESA Clad Surface Modification e

FeCrAlcoated 200 µm DIN 1.4970SS December 4, 2020 14 14 B-126 7

1/6/2021 Case Study - Accident Tolerant Fuels The accelerated development of nuclear materials entails:

Interconnectivity of applicationdriven material design, material production and material performance assessment in applicationrelevant conditions Development of reliable highthroughput material screening tools, e.g., use of ion/proton irradiation to assess radiation tolerance; select modelling approaches (atomic scale, FE, etc.) to predict inservice material behavior 15 Case Study - Accident Tolerant Fuels Predictive modelling Material Performance Material Demonstration Assessment in Industrially Relevant Accelerated Development of MAX PhaseBased input Conditions feedback (mechanical properties, materials compatibility with coolant, (neutron irradiation in Material Design primary coolant) radiation tolerance) materials optimized feedback feedback materials Material Production Screening Property Interactions Innovative Nuclear (tailored composition, irradiations requirements with coolant Material Licensing microstructure, (ions/protons)

(market uptake) layout/configuration)

Optimum Composition (Zr,Cr)Based MAX Phase Solid Solutions Materials for the ATF Cladding Application Material Design: Basic Considerations c pristine Minimize cracking by Minimize cracking by GB GB Maximize radiation Ti3SiC2 Phase Purity Grain Size a

(3.4 dpa, 735C)

Texture (Nb0.85,Zr0.15)4AlC3 c Cr2AlC 20 µm differential swelling irradiated anisotropic swelling Denuded zone 0.5 m defect annihilation 2 µm December 4, 2020 16 a

16 B-127 8

1/6/2021 In conclusion Ensure the value proposition (business case) up front: safety and economics Balance potential benefits against realistic risks of new materials and processes Introducing AM to existing parts without advanced materials may not justify costs of development and qualification Seek successful collaboration approaches between industry, DOE, national labs, and NRC Leverage prior qualification of first-of-a-kind AM processes, materials, and modelling Apply lessons learned from ATF coated cladding development and qualification Coated cladding workshop at PNNL Plan well in advance for a successful qualification process NRC AMT Application Guidance Apply advanced predictive technology, including atomic and meso-scale modeling and in-situ testing Meet with regulators early in cycle to share new technologies and qualification bases as early as possible Workshop on Advanced Manufacturing Technologies for Nuclear Applications December 7, 2020 17 17 Thank you for your attention Workshop on Advanced Manufacturing Technologies for Nuclear Applications December 7, 2020 18 18 B-128 9

1/6 /2 0 2 1 Additive Manufacturing Justification and Implementation Dave Poole, Additive Manufacturing Engineering Manager Bill Press, Technical Specialist December 2020

Agenda 01 Implementation Strategy Substitution > Enhanced Substitution > Onewaychoice 02 The Lead Application Primary Circuit Manual Globe Valve 03 Justification Strategy Beyond code multilegged TAGSI approach 1

04 Where next?

Robust production, new applications and R&T 05 Questions and discussions

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1/6 /2 0 2 1 01 Implementation Strategy The Additive Manufacturing Team will be the RollsRoyce Nuclear and Defence centre of competence for additive manufacture; delivering improvements to cost, quality & delivery through innovative & effective implementation of additive manufacturing technology

In the beginning Capability Current state Ist EOS M2xx Series L P B F Development 7x EOS M2xx Series L P B F system (single laser) installed in systems supported by two teams Technology readiness levels -

2008. - Manufacturing Engineering manufacturing and materials and Operations.

Background Single engineer parttime only Increasing experience of parts Lead applications in full Rig parts, visualisation on rigs in representative production.

assemblies, rapid tooling environments Focussed AM teams also in Developing knowledge and Significant materials testing Materials and Design experience of L PB F programmes - predominantly Engineering departments.

316L and A625.

Materials development and laser 1st single laser replacement in parameter DoEs Increased capacity (people and 2021 NEW multilaser system.

machines) as demand rose A lot of internal marketing, quickly. New facility to be commissioned demonstrations and commodity in 2021 including post 2 discussions! Lead application identified and processing capability.

taken through formal gated review process. Focussed R&T programmes.

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1/6 /2 0 2 1 Implementation Strategy

02 The Lead Application High volume manual globe valve Safety critical Pressure boundary 3

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1/6 /2 0 2 1 Manual Globe Valve (15, 25 & 50mm NB) 316 Stainless Steel Body &Bonnet Tristelle 5183 Main and Back Seats (hardfacings)

High Production Volume Pressure Boundary SafetyCritical

Traditional MoM

1. Rough Machine Wrought Billet

2. Tristelle 5183Insert (Hot Isostatic Press (HIP) bar)

3. Stainless Steel Plug

4. Assemble &HIP Bond Insert to Body 4

5. Rough Machine to Form Valve Seat

6. Machine to CompleteFinal Form

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1/6 /2 0 2 1 LPBF MoM LaserPowder Bed Fusion (LPBF)

Technology produces 316body near net shape and Tristelle insert.

Post AM, single HIP cycle bonds insert, forms properties of both alloysandstress relieves.

Phase 1-Substitutiononly Nochange to design configuration/geometry Nochange to materialtypes Nochange to product finish (all surfaces machined)

Method of Manufacture Powder is evacuated from pockets and L P B F inserts added 5

1/6 /2 0 2 1 Leadtime Reduction Materials Removal of a HIP cycle AM material properties What are the Reduced machining steps meet specification and timescales requirements benefits? Materials types applicable to broad product range Still at Phase 1-simple substitutiononly. Cost Reduction Phase 2-Enhanced Simplification of Quality Assurance substitution manufacturing method Quality assurance of programmes will deliver Removal of extensive metallic powder and further benefits to cost machining operations product (control anddelivery. Reduced raw material samples/HIP bond inventory specimens)

Inprocess monitoring Justification ofas Collaboration Innovation builtsurfaces RollsRoyce leading on AM with key partners across Encapsulation principle exchange programme patent - exploitation opportunities against broad product range

© 2020RollsRoyce 11 OFFICIAL Not Export Control Listed 11 03 Justification Strategy Beyondcode approach to justification based on TAGSI multilegged structure: design and manufacture, functional testing, failure analysis &

forewarning of failure.

6

1/6 /2 0 2 1 Design Justification Strategy

Manufacture Mechanical, metallurgical&

corrosion testing 7

Fatigue Tristelle 5183 to 316 St St Bond Line

1/6 /2 0 2 1 Leg 1 Design &

Manufacture Contour residualstress measurement of valve body Destructive mechanical strain relief technique

Manufacture Shear load test 316St St to Test Piece Geometry Tristelle 5183bondline.

Withstand beyond highest in service loadingsapplied.

8 Test Setup

1/6 /2 0 2 1 50mm MGV Bonnet 15mm MGV Body Leg 1 Design &

Manufacture Volumetric ondestructive testing -

radiography Surface visual examination Current Method - Wrought/HIP bar examined using Ultrasonic Testing AM Method - Radiographic Testing based on nearnetshape and startofLife defect characterisation Defect characterisation by expert elicitation used to guide inspection technique and inspection acceptance criteria

Manufacture Production Requirements:

WeldabilityTrials Canopy Weld Trials Pipework Stub Trials 9

Machining, grinding, plating methods trialled

1/6 /2 0 2 1 Comparison Production Test Type Description Component Size Wrought Valve Test 15mm Leg 2 - Functional & Standard Hydro Body only 25mm No Yes Performance Testing 50mm 15mm Valve Half Open Full Assembly No Yes 50mm Hydrostatic 15mm Valve Closed Full Assembly No Yes 50mm Ultimate Ultimate Pressure Body only 50mm only Yes No Hydrostatic Test 15mm Cold Full Assembly No Yes 50mm 15mm Performance Hot Full Assembly No No 50mm 15mm Repeat Cold Full Assembly No No 50mm Endurance Hot Full Assembly 15mm only No No Shock Cold Full Assembly 50mm only Yes No Fatigue Thermal Shock Full Assembly 50mm only Yes No

Performance Testing Wrought and AM MGV Bodies Postburst Test 10 Ultimate Pressure Tests Explore full capability of AM pressure boundary on MGVbody

>2000bar applied without failure Representative material strain rates

1/6 /2 0 2 1 Leg 2 - Functional &

Performance Testing Shock LoadingTests Shock test to assess integrity of key MGVregions during shock event Three test orientations on both AMand WroughtMGVs Pre and post test functional checks successful on each MGV

Performance Testing HOT IN C O L D IN 11 Thermal FatigueTest ASMEIII, Appendix II assessment used to specify extended thermal cycle test 2x AMand 1x Wrought MGV tested Valves functionally tested after extended life simulation

1/6 /2 0 2 1 Leg 3 - Failure Analysis Design, hydrostatic and level A conditions assessed for limiting valve location Fatigue assessment using cycling counting method and static shock assessment L e g 1- Material test data confirms analysis inputs remain appropriate L e g 2 - Functional/performance testing provides further assurance in theoretical analysis

© 2020RollsRoyce 23 OFFICIAL Not Export Control Listed 23 Leg 4 - Forewarning FMEA Review of Failure System Hydrostatic and Valve Functional Tests Inservice Inspections External for evidence of corrosion/EAC Internal for evidence of bond line corrosion and condition of seat contact line 12 Potential for additional volumetric NDE inservice (Remote RT, Phased Array UT)

Development of Techniques ALARP study

1/6 /2 0 2 1 04 Where Next?

Increasing applications across plant Strategic alloy development Facility commissioning Increased size, capacity and build speed

316L/LN NEUTRAL NEGATIVE C ADVANCED

(*INTEGRALHARDFACINGS) UNASSESSED S Q THERMAL C BARRIER S Q P D LPBF Component SG SECONDARY P D Strategy SEPARATOR (625)

S C

Q C

S C

Q AM VALVE DESIGNS*

S Q C

C P D P D P D Commodities engaged on S Q ADVANCED C S Q THERMAL PRIMARY CIRCUIT S Q opportunities for AMto deliver P D MCP JOURNAL BARRIER RELIEF VALVE* P D PADS benefits MCP THRUST P D C

AM HEAT BIV EXCHANGER PADS S Q DESIGNS C C C P D S Q S Q S Q P D DP C E L L BODY C

13 C O ST P D P D C S Q TORQUE NONRETURN C VENT &DRAIN S Q TAKER* VALVES* P D STRATEGIC QUALITY VALVE* C C S Q C S Q P D S Q AM TEES &

S Q REDUCER ASSY C PUMP P D P D S Q IMPELL ERS P D P D THROTTLE C MCP BEARING PERFORMANC E DELIVERY MCP JOURNAL PADS P

MANUAL GLOBE VALVE*

D S

C Q

VALVE* S P D Q LINKAGE*

OTHER RT POCKET C C P D C S Q S Q C S Q SNUBBERS S Q P D C P D C P D P D CORE PARTS (ZR)

S Q S Q TEES & REDUCERS SG SECONDARY STATOR BODY SEPARATOR (LAS)

1/6 /2 0 2 1 Materials WORLDCLASS AMFACILITY Strategically selected alloys 15x48m Cleanroom 316LN, In625, In690, In713, C263, FV520, Duplex & Self contained modular H282 cleanroom to prevent Same powder input for all contamination from components = reduced entering the process C omponents inventory and hazardous substance escape to Valves Operations fac tory Tee and Reducers Installations 2x fulltime operators Heat Exchangers required to run cell up Stators to 6x LPBF systems - all Pumps data and machine health Cellular etc etc etc !!

monitoring remotely Selfcontained manufacturing cell for AM includes de powdering, WEDM, polishing, powder Agile Capacity handling & storage, 7x singlelaser systems GOM scan inspection 2020 transitioning to . . .

Up to 6x multilaser systems by 2030 Hybrid DED included for largescale AM (up to 2000kg)

1/6 /2 0 2 1 Thank you 29 15 B-143

1/6/2 0 2 1 Fatigue and Mechanical Properties of Laser Powder Bed Fusion 316L Stainless Steel Steve Attanasio, Chelsea Snyder, and Tressa White Naval Nuclear Laboratory - Schenectady, NY NRC workshop on Advanced Manufacturing December 7-10, 2020 The Naval Nuclear Laboratory is operated for the U.S. Department of Energy by Fluor Marine Propulsion, LLC, a wholly owned subsidiary of Fluor Corporation.

Steven.Attanasio@unnpp.gov (518) 395-7566 1

Naval Nuclear Propulsion Program:

AHistory of Success 1

Over 80 Nuclear-Powered Ships Over 167 Million Miles Safely Steamed 2

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1/6/2 0 2 1 Naval Nuclear Laboratory(NNL)

Research Laboratory Sites NNL - Bettis Laboratory Pittsburgh, PA NNL - Knolls Laboratory Schenectady, NY Two Laboratory Sites:

Headquarters for NNL Operations Centers for Design and Engineering Laboratory, Testing and Experimental Facilities Operated by FMP 3

Naval Nuclear LaboratoryExpertise NNPP Reactor and Propulsion Plant Designs, Equipment, and Support Require Expertise In:

Acoustics

Materials Science

Reactor Engineering

Instrumentation & Control 2

Power Electronics and Distribution

Experimental Engineering

Scientific Computations

Information Technology 4

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1/6/2 0 2 1 NNL Interests in Metal Additive Manufacturing (AM)

The capabilities of metal AM processes have spurred changes to fabrication methods in industries such as aerospace and medical

More modest changes to date in other areas such as the nuclear industry

Prospective benefits include manufacturing and performance gains

Delivery time, hard-to-source parts, part consolidation, improved design

Tooling, rapid prototyping, repairs, hard-to-fabricate parts, tailored design Materials of interest include 316L SS and Alloy 625 Components of interest include valves and pump hardware 5

Laser Powder Bed Fusion(L-PBF)

L-PBF 316L contains long grains and crystallographic texture in the build direction due to epitaxial growth across layers Epitaxial Growth Laser Direction 3 Build Direction Build up Direction 50 m 6

6 B-146

1/6/2 0 2 1 Build Parameters and Chemistry for 316L Build Naval Nuclear Laboratory (NNL) Build External Vendor (EV) Build 20 m layer 40 m layer EOS M290 EOS M290 Hot Isostatic Press (HIP) Hot Isostatic Press (HIP)

Porosity - Witness cylinder <0.05% Porosity - Witness cylinder <0.03%

NNL ASTM F3184 ASTMA182 EV As-Built Bar Stock As-Built Test Block 7

7 Microstructure Grain Sizing X-Y X-Z

Similar grain size and structure between builds

Precipitate size and locations (primarily along grain boundaries) similar between builds

Texture was stronger in the NNL build Build Direction Grain Size 19.5 m Grain Size 25 m 4 Texture Aspect Ratio 3.4 Aspect Ratio 3.4 Microstructure NNL EV oxides Build Direction Build Direction 500 m IPF-Z 50 m 8

8 B-147

1/6/2 0 2 1 Tensile Testing ASTM A182 for Room Temp ASTM A182 for Room Temp Specimen Orientations ASTM A182 for Room Temp ASTM A182 for Room Temp Fractography 9

9 Tensile Testing

Minimal difference in properties between witness coupon and body specimens 5

10 10 B-148

1/6/2 0 2 1 Charpy Impact Toughness ZX/ZY 45o XZ/YX Secondary Electron Microscopy (SEM) images of lowest energy fracture surfaces NNL EV Wrought Testing according to ASTM E23-16b 11 11 480oF Air Fatigue Crack Growth Testing Wrought AM NNL EV Wrought 6

Heat tint more difficult to see in AM material ZX/ZY - Open Symbols XZ/YZ - Closed Symbols Testing according to ASTM E647-151 Temperature: Precrack 70 oF air, Test 480 oF air Stress Ratio: Precrack R = 0.1, Test R=0.3 Clip gage compliance method used ASME Boiler and Pressure Code,Section XI, Article C-8410 for Austenitic Steels 12 12 B-149

1/6/2 0 2 1 Fracture Toughness Wrought 500 ZX XZ C-L 400 KJQ (ksiin) 300 200 100 0

ZX/ZY XZ/YZ Wrought NNL EV Testing according to ASTM E1820-17a 70F, air Precrack to 0.55 a/W, 0.6T C(T) specimens Partially side-grooved (10% total) prior to precrack and then further side-grooved prior to test (additional 10% total) 13 13 Fracture Toughness E1820 ValidityCriteria

High toughness performance made it ASTM E1820 -17a: Section A9.6.4, A9.6.6.6 difficult to meet all validity requirements and therefore qualify KQ as KIc.

Only Z orientations failed ASTM E1820 -17a: Section 9.1.5.2 Load-Disp Curve 7 5000 Not enough qualified data points (Region A or B) 4000 ASTM E1820 -17a: Section A8.3.1, A9.10.1, A9.10.2 Load (lbf) 3000 2000 75%

1000 All AM specimens, no wrought failed 0

0.00 0.05 0.10 0.15 0.20 Only Z orientations failed Displacement (inch) Rear face (apredicted) at the last unloading differed from physical post-test crack extension (ap) by more than 0.15ap for crack extensions less than 0.2bo, and 0.03bo thereafter. Maximum J-integral capacity was exceeded, thickness and initial ligament < 10 JQ/Y 14 14 B-150

1/6/2 0 2 1 Summary

Similar microstructure and properties were observed across vendors and when comparing test blocks to components

Orientation effects caused by deposition process could be traced back to microstructural differences and texture in material

Despite orientation effects, AM material performed as good as or better than wrought material

Satisfactory performance of AM material gives confidence in qualification of methods for component fabrication and use of this material in applications 15 15 8

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1/6/2 0 2 1 National Aeronautics and Space Administration Impact of Powder Supply Variation on Mechanical Properties for Additive Manufacture of Alloy 718 Christopher Kantzos NASA John H. Glenn Research Center at Lewis Field Cleveland Ohio NRC Workshop on Advanced Manufacturing, Dec 2020 www.nasa.gov 1 1

National Aeronautics and Space Administration 1

www.nasa.gov 2 2

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1/6/2 0 2 1 National Aeronautics and Space Administration Space Launch System - Heavy Lift Launch Vehicle -

Requires four RS-25 engines to lift core stage RS-25 Affordability Initiative 33% Reduction in Cost

> 700 Welds Eliminated

> 700 Parts Eliminated 35 AM Opportunities www.nasa.gov 3 3

National Aeronautics and Space Administration Motivation NASA Marshall

Standardization is needed for consistent evaluation of Standard 3716 AM processes and parts in critical applications. POC: Doug Wells

Powder feedstock variability is a major unknown.

Chemistry and Size distribution are essential

Atomization Process?

2

Supplier Variation?

Variations within AMS Chemistry specification?

Objectives

Obtain comprehensive industry supplier-to-supplier comparison to understand and identify the feedstock controls important to SLM Alloy 718 www.nasa.gov 4 4

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1/6/2 0 2 1 National Aeronautics and Space Administration Approach: Survey wide range of off-the-shelf Alloy 718 powders ID Cut Atomization Gas 16 total powders acquired

Supplier-to-supplier A1 Supplier 1, Powder 1 15-45 Gas Ar

Lot-to-lot A2 Supplier 1, Powder 2 10-45 Gas Ar

Gas and rotary atomized A3 Supplier 1, Powder 3 10-45 Gas Ar

Ar and N cover gas B1 Supplier 2, Powder 1 15-45 Rotary Ar

Cut Size

Once Reuse C1 Supplier 3, Powder 1 15-45 Gas N D1 Supplier 4, Powder 1 16-45 Gas Ar Standard ~10-45 µm SLM cuts D2 Supplier 4, Powder 2 11-45 Gas Ar (8 powders) E1 Supplier 5, Powder 1 10-45 Gas N Standard ~15-45 µm SLM cuts E2 Supplier 5, Powder 2 10-45 Gas N (6 powders) F1 Supplier 6, Powder 1 15-45 Gas Ar F2 Supplier 6, Powder 2 10-45 Gas Ar Undersized / oversized cuts G Supplier 7: 4 cuts G2:11-45 G3: 16 -45 Gas Ar

- G1: 0-22 Did not build H1 Supplier 8, Powder 1 10-45 Gas Ar

- G4: 45-90 Did not build well www.nasa.gov 5 5

National Aeronautics and Space Administration Majority of powder compositions within AMS 5664 chemistry specification B1 low C, E1 high C, low Al 3

www.nasa.gov 6 6

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1/6/2 0 2 1 National Aeronautics and Space Administration Particles are all highly regular spheroids from all suppliers; Show distinct differences in roughness, fines, & agglomeration Powders with higher percentage of fines and agglomeration more prone to unplanned stops www.nasa.gov 7 7

National Aeronautics and Space Administration Processing Details NASA MSFC Concept Laser M1 machine:

Custom Build Parameters

Customized SLM 718 parameters for MSFC RS-25 projects

10 cm height

Layer thickness: 30 µm

Snap off construction; no stress relief

Continuous scan strategy plus

HIP: >1100 C hot isostatic press contours

AMS 5664 heat treat schedule Visible refill lines 4

Two microstructure bars

Green-state bar inherent to the process

HIP + heat treated bar post process response Small box configuration

Eight Mechanical Test Specimens requires start /stop to

Two Tensile specimen refill piston with powder 3.125 Height

Six High Cycle Fatigue specimens Green-state Planned restarts

Six Flammability specimens met bar www.nasa.gov 8 8

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1/6/2 0 2 1 National Aeronautics and Space Administration Microstructure and Grain Size ID Gas Mean Dia Avg Grain

- Number basis distributions are more sensitive to fines; Volume basis typically A1 Ar 27.2 70.0 +/- 5.5 Recrystallized reported. A2 Ar 9.1 57.3 +/- 3.6 Recrystallized

- There was poor flow and extensive caking in A3 Ar 21.1 74.4 +/- 12.2 Recrystallized many of these powders: 6 powders would B1 Ar 12.8 67.9 +/- 8.6 Recrystallized not flow in Hall or Carney Cup C1 N 30.9 35.9 +/- 4.5 Anisotropic

- Powders with higher percentage of fines and D1 Ar 25.1 52.5 +/- 3.6 Recrystallized agglomeration more prone to unplanned stops E1 N 25.3 21.5 +/- 1.3 Anisotropic

- Characterized melt pool depth, porosity, E2 N 31.6 +/- 5.0 Anisotropic nitrides, carbides fraction E2R N 19.5 +/- 3.6 Anisotropic

- Typical as-fabricated porosity less than F1 Ar 24.9 88.8 +/- 12.3 Recrystallized 0.5 vol. % and post HIP/HT porosity less G2 Ar 16.4 63.2 +/- 6.0 Recrystallized than 0.05 vol. % G3 Ar 27.0 71.2 +/- 6.4 Recrystallized Standard ~10-45 µm SLM cuts G4 Ar 72.9 39.2 +/- 5.7 Recrystallized Standard ~15-45 µm SLM cuts Undersized / oversized cuts H1 Ar 32.0 40.9 +/- 2.3 Partially Recrystd www.nasa.gov 9 9

National Aeronautics and Space Administration Mechanical Property Evaluation Screen room temperature mechanical behavior As-Fabricated (AF) vs. Low Stress-Ground (LSG) Surface Conditions

One tensile test per surface condition

Strain control up to 2% then stroke control at equivalent strain rate 5

Three HCF tests per surface condition at 20 Hz and R= -1

Targeted 1 million cycle averages, Runouts above 10 million

Stress amplitudes of 271 MPa (40 ksi) for AF and 464 MPa (67 ksi) for LSG All mechanical testing performed after HIP (1160 C) + Soln (1065 C) +

Precipitation Aging (760 C, 650 C) www.nasa.gov 10 10 B-156

1/6/2 0 2 1 National Aeronautics and Space Administration Room Temperature Tensile Meets Minimum Standard AMS 5664E spec.

UTS YS 0.2% YS Low Stress 0.2% YS As-fabricated UTS (ksi) UTS (ksi)

Offset (ksi) Ground Offset (ksi)

B1 200.5 171.1 B1 208.8 179.3 Avg 183.5-195.5 151.6-165.4 Avg 193.4-203.6 160.8-165.4 E1 (Low Al, Hi C) 178.8 144.9 E1 (Low Al, Hi C) 185.0 150.6 www.nasa.gov 11 11 National Aeronautics and Space Administration Room Temperature High Cycle Fatigue Low stress ground compares well to literature Statistical analysis shows two populations: C1 & B1 had highest lives, G4 and E2 the lowest 6

As Fabricated has less scatter, but 40% lower stress for comparable life Only H1 lot was significantly different, with higher lives www.nasa.gov 12 12 B-157

1/6/2 0 2 1 National Aeronautics and Space Administration Room Temperature High Cycle Fatigue As-built Surface Low Stress Ground Fine grained specimens often had improved fatigue performance www.nasa.gov 13 13 National Aeronautics and Space Administration Fatigue Crack Initiation Sites As fabricated: Incidence of surface failures was significantly higher for AF surfaces due to stress concentrators associated with SLM surface asperities 7

Low Stress Ground:

More internal initiation sites www.nasa.gov 14 14 B-158

1/6/2 0 2 1 National Aeronautics and Space Administration Powder and Build Quality Summary

Majority of powder compositions within AMS 5664 chemistry specification (E1out)

Powders evaluated are distinct - similar in that particles are highly regular spheroids; differences in N; Particle Size Distributions; degree of agglomeration and surface roughness

Optimized SL M parameters for 718 yielded high quality builds with low porosity and full recrystallization across many distinct powder lots

Compositional differences had strongest impact on SLM 718 microstructure High N and C contents form TiN-nitrides and MC carbides on GBs that suppresses recrystallization during HT 400 ppm N content a good rule of thumb cutoff to ensure equiaxed grain distribution

As-Fabricated surfaces met minimum tensile strength except for E1 which was chemically out-of-spec

Low stress ground surface produced high cycle fatigue lives comparable with literature

Fatigue strength reduced 40 percent for as-fabricated surface www.nasa.gov 15 15 National Aeronautics and Space Administration (In-Progress) Phase 2: Downselection

Five powder lots selected for a further investigation: B1, C1, G2, G3, H1 ID Cut Atomization Gas Note

Powder, chemistry, and microstructure analysis Low C/N, B1 15-45 Rotary Ar V. Smooth

Expanded Mechanical Testing High N, C1 15-45 Gas N 8

- Cryogenic and Elevated Temperature Tensile Narrow PSD

- Room and Elevated Temperature High Cycle Fatigue G2 11-45 Gas Ar Good PSD

- Creep G3 16-45 Gas Ar Good PSD

- Crack Growth and Fracture Toughness Moderate N,

- Broader As-built and Ground Surface Flammability H1 10-45 Gas Ar High Fines www.nasa.gov 16 16 B-159

1/6/2 0 2 1 National Aeronautics and Space Administration Round 2 Mechanical Testing (On-Going) - Tensile www.nasa.gov 17 17 National Aeronautics and Space Administration Round 2 Mechanical Testing (On-Going) - Fatigue 9

www.nasa.gov 18 18 B-160

1/6/2 0 2 1 National Aeronautics and Space Administration Round 2 Mechanical Testing (On-Going) - Creep Expected Life Ratio of 1 = Life matches Brinkman prediction. B1.2 lives are falling below while G2.2 and G3.3 are meeting or exceeding.

Colors correspond to test temperature; Symbol shapes represent build batches www.nasa.gov 19 19 National Aeronautics and Space Administration Phase 3: Powder Recyclability

One powder lot selected for a further investigation: G2

Recycling Study: 50 builds reusing powder

1. Virgin powder sieved -270/+500

2. Complete build

3. Leftover powder sieved again to -270/+500

4. Recycled powder is blended with as much virgin powder necessary to complete next build

5. Repeat steps 2-4 49 times for a total of 50 builds 10

Builds included

- 8 cubes for microstructural/defect analysis

- 4 bars for mechanical testing.

Horizontal test bars to keep build short

Lattice Fences to increase laser-powder interaction

Everything HIPed and heat treated www.nasa.gov 20 20 B-161

1/6/2 0 2 1 National Aeronautics and Space Administration Powder Recyclability: Powder

Powder showed increase in dark particles suggesting oxidation

Particle size did not change significantly, though percentage of oversized powder increased Build 3 Build 50 www.nasa.gov 21 21 National Aeronautics and Space Administration Powder Recyclability: Powder

Flowability significantly improved after build 1

Measured using Revolution rotating drum technique

-30%

11

-18%

www.nasa.gov 22 22 B-162

1/6/2 0 2 1 National Aeronautics and Space Administration Powder Recyclability: Chemistry

Chemistry measured using ICP-AES and combustion based techniques

Significant increase in oxygen from build 1 (virgin powder) to build 50 (220 ppm to 530 ppm)

Other elements quite stable Build Al Cr Fe Mo Nb Ni Ti Si C1 C2 S1 S2 N1 N2 O1 O2 1 0.45 18.85 18.06 3.09 5.11 53.38 0.94 0.0240 0.0237 0.0020 0.0016 0.0263 0.0263 0.0285 0.0215 0.0220 2 0.45 18.82 18.06 3.10 5.15 53.37 0.93 0.0237 0.0234 0.0021 0.0021 0.0305 0.0305 0.0296 0.0248 0.0245 5 0.45 18.78 18.04 3.10 5.15 53.41 0.94 0.0230 0.0227 0.0019 0.0014 0.0316 0.0316 0.0308 0.0229 0.0252 10 0.44 18.83 18.03 3.09 5.12 53.42 0.93 0.0229 0.0231 0.0021 0.0020 0.0301 0.0301 0.0293 0.0351 0.0319 23 0.44 18.79 18.06 3.09 5.12 53.44 0.93 0.0221 0.0231 0.0021 0.0013 0.0308 0.0308 0.0308 0.0385 0.0361 50 0.44 18.83 18.05 3.08 5.12 53.40 0.94 0.0220 0.0221 0.0015 0.0017 0.0299 0.0299 0.0296 0.0546 0.0516 www.nasa.gov 23 23 National Aeronautics and Space Administration Powder Recyclability: Surface finish

Surface finish somewhat worse with notable increase in oxidation

Surface roughness anomalies seem unrelated to extent of recycling 12 www.nasa.gov 24 24 B-163

1/6/2 0 2 1 National Aeronautics and Space Administration Powder Recyclability: Defects

Increase in defects found internally, though a lot of scatter

For quantitative analysis particles with area<50m2 (diameter<8m) ignored 250 um Number Density of Particles Area Fraction of Particles Particle Size 8 0.14 30

as-built

as-built

as-built Average Equivalent Spherical Diameter (m) 7 0.12

HIP

HIP 25

HIP Particle Number Density (#/mm²)

6 0.1 20 Area Fraction (%)

5 0.08 4 15 0.06 3

10 0.04 2

5 1 0.02 0 0 0 0 10 20 30 40 50 0 10 20 30 40 50 0 10 20 30 40 50 Buld Number Buld Number Buld Number www.nasa.gov 25 25 National Aeronautics and Space Administration Powder Recyclability: Defects

A lot of defects confirmed to be Al/Ti oxides 13 www.nasa.gov 26 26 B-164

1/6/2 0 2 1 National Aeronautics and Space Administration Powder Recyclability: Microstructure Virgin Powder 50th build Build direction Overlaying Image Quality map, along with grain boundaries in black www.nasa.gov 27 27 National Aeronautics and Space Administration Powder Recyclability: Microstructure Virgin Powder 50th build Build direction 14 Average Grain Diameter: 77um Average Grain Diameter: 69um Twin Grain Boundary Area: 60% Twin Grain Boundary Area: 27%

Grain sizes are similar. Virgin Powder slightly larger, but significantly more twins www.nasa.gov 28 28 B-165

1/6/2 0 2 1 National Aeronautics and Space Administration Powder Recyclability: Microstructure Virgin Powder 50th build Build direction Grain Orientation Spread shows the orientation variation within a grain. Un-recrystallized (as-built) grains show high GOS. The recycled powder (with high 0 1 2 3 4 5 oxide volume fraction) recrystallizes poorly. GOS www.nasa.gov 29 29 National Aeronautics and Space Administration Powder Recyclability: Summary

Mechanical testing results soon to come (tensile and fatigue)

Both the powder and printed parts pick up Oxygen with increased reuse.

This manifests in the surface finish, and in ~10 um oxide particles in the bulk.

15

Significant impacts on microstructure and extent of recrystallization during HIP + HT

Reused powder leads to less recrystallized microstructures with fewer twin boundaries.

www.nasa.gov 30 30 B-166

1/6/2 0 2 1 National Aeronautics and Space Administration 31 31 National Aeronautics and Space Administration As Fabricated Surface Finish Evidence of pre-existing flaws, surface cracking 16 www.nasa.gov 32 32 B-167

1/6/2 0 2 1 Effect of Plasma Spheroidization on the Corrosion Performance of Additively Manufactured 316L Stainless Steel Department of Mechanical Engineering Unites States Naval Academy Annapolis, MD Prof R.J. Santucci, Prof Elizabeth Getto, Prof Michelle Koul CAPT Brad Baker, CDR Jon Gibbs, Prof Rick Link, Midn 1/C Andrew Shumway, Midn 1/C Jordan McLaughlin 1

Motivation

316L stainless steel is essential to U.S. Naval applications from ship parts to weapon systems.

Additive manufacturing (AM), the stepwise construction of a part layer by layer, is used extensively with 316L and shows promise for use in the Navy. 1 2

B-168

1/6/2 0 2 1 Additive Manufacturing (AM)

Process AM AlSi10Mg specimen, etched cross section, M.

Krishnan, PhD Thesis, Politecnico di Torino; 2014 Inconel 600 specimen, EBSD of single track, Nicolas D. Hart, CAPT Brad W.

SLM: Fraunhofer Institute for Machine Tools and Forming Technology Baker, US Naval Academy Non-equilibrium solidification can result in microstructures that differ significantly from wrought materials The same is true for the unique processing strategy employed with AM 3

Additive Manufacturing (AM)

AM Processing:

With so many degrees of freedom in selecting processing variables, it is important to gain a 2 mechanistic understanding of each variable From: Aboulkhair et. al., Additive Manufacturing 1-4 (2014) 77-86 4

B-169

1/6/2 0 2 1 Motivation It is critical to determine the effects of AM on the properties of stainless steel parts: Microstructure, Strength, and Corrosion Resistance.

Melia, Corrosion Science, 2019 Shamsujjoha, Met. And Mat.

Trans. A, 2018 5

Motivation NSWC Corona has provided two separate 316L base powders to compare, one normal and one spheroidized, to make the particles more regular Plasma Treated Untreated or Plasma Spheroidized 3 Corona Spheroidization Treatment Normal Spheroidized

?

Specifically, what is the role of powder morphology?

6 B-170

1/6/2 0 2 1 Additive Manufacturing (AM)

From: Meier et. al., Jour. of Mat. Proc. Tech. 266 (2019)484-501 Hypothesis:

If the treatment increases the spheroidicity and tightens the size distribution of the powder, then

Layer recoating will improve

Powder packing will improve

Final Properties will improve 7

Plasma Spheroidization Process http://www.tekna.com/spheroidization-systems General process used to spheroidize the powder 4

Normal and Spheroidized 316L powder provided by NSWC Corona

Powder morphology changes?

Chemical composition for 316L is retained after treatment?

8 B-171

1/6/2 0 2 1 Powder Morphology Characterization Powder becomes more spherical after treatment Size distribution largely invariant Spheroidized powder exhibits satellite artifacts on surface Virgin Virgin Normal Spher.

100 µm 9

Powder Elemental Characterization Weight Percent Powder Mo Cr Mn Fe Co Ni Bulk composition is relatively Normal 1.91 18.39 2.46 62.99 1.15 13.10 unchanged - still SS316L Spheroidized 2.04 18.63 1.79 63.29 0.00 14.25 5

Atomic % Normal to Spheroidized Normal Treated 1.2 1

20 µm 0.8 0.6 0.4 0.2 Mn 0

Virgin -0.2 Fe Cr Ni Mo Virgin Normal -0.4 Spher.

-0.6

-0.8 10 B-172

1/6/2 0 2 1 Print Microstructure Characterization Normal 4000 Print Orientations Normal

Phase identification

Vertical Top of Vertical Bar 3500 Bar Middle of Vertical Bar relatively

Tilted Diffraction Intensity (a.u.)

Bottom of Vertical Bar

(Near) Horizontal 3000 homogenous throughout the bar 2500 Offset Applied (for this print 2000 direction, XY face) 1500 Offset Applied

Printing does not 1000 introduce detectable (200)

(111) (220) (311) ferrite (222) 500 0

20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95100 Diffraction Angle (o2) 11 Print Microstructure Characterization Spheroidized 4000 Print Orientations Top of Vertical Bar

Phase identification

Vertical Spherodized 3500 Bar Middle of Vertical Bar relatively

Tilted Bottom of Vertical Bar homogenous Diffraction Intensity (a.u.)

(Near) Horizontal 3000 Offset Applied throughout the bar 2500 (for this print 6 2000 Offset Applied direction, XY face) 1500

Printing does not (200) introduce detectable (111) (220) (311) 1000 (222) ferrite 500 0

20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95100 Diffraction Angle (o2) 12 B-173

1/6/2 0 2 1 Print Microstructure Characterization Normal Spheroidized Print Orientations

Vertical

Tilted

(Near) Horizontal 1 mm

Few macro pores overall for vertical print orientation

Normal powder qualitatively has fewer defects or pores 13 Print Microstructure Characterization Normal Spheroidized Print Orientations

Vertical

Tilted

(Near) Horizontal 7

1 mm

Many more large pores and defects with normal powder

Difference much more obvious than for Vertical build 14 B-174

1/6/2 0 2 1 Print Tensile Properties Print Orientations

Vertical

Tilted

(Near) Horizontal All dimensions in inches

ASTM E8 - Standard Test Methods for Tension Testing of Metallic Materials

Elastic Strain Rate of 3 x 10-5 /s -

displacement control

Elongation at fracture taken at 10% load drop from maximum load 15 Print Tensile Properties Normal Spheroidized Print Orientations

Vertical

Tilted

(Near) Horizontal 8

The Ultimate Tensile Strength of the printed normal (83 ksi) and spheroidized (80 ksi) powder samples is similar

The Yield Strength of the printed normal (72 ksi) powder sample is slightly higher than the spheroidized (66 ksi) powder sample

The results for the spheroidized powder samples are less variable 16 B-175

1/6/2 0 2 1 Print Tensile Properties Normal Spheroidized Print Orientations

Vertical

Tilted

(Near) Horizontal

The Ultimate Tensile Strength is similar (at 75 ksi) for both the printed normal and spheroidized powder samples

The Yield Strength of the printed normal (69 ksi) powder sample is slightly higher than the spheroidized (64 ksi) powder sample

The results for the spheroidized powder samples are less variable 17 Print Corrosion Testing Pitting initiates and propagates

Testing conducted in 0.6 M Pitting will NaCl solution initiate but not propagate

Wrought and AM (as-printed and polished) are evaluated 9

Potentiodynamic and Potentiostatic Testing Pitting will not initiate or propagate

As-printed surface native Polished oxide is passivating 18 B-176

1/6/2 0 2 1 Print Corrosion Testing Pitting initiates and 8x10-7 propagates 1000 2 Passive Current Density, iPass (A/cm )

Pitting will Electrode Potential, E (VSCE) 800 initiate but not Wrought I pass 6x10-7 propagate Norm I pass 600 400 EBreakdown 4x10-7 ERP Pitting will not 200 initiate or OCP propagate 2x10-7 0 All 1200 Grit Surface Finish

-200 0

0 50 100 150 200 250 300 350 400 Potentiostatic Hold Potential (mVSCE)

The passive window is extended for AM

The stable film passive dissolution samples compared to wrought kinetics are similar between wrought and

All critical potentials are more positive for the printed normal powder samples the AM samples compared to wrought 19 Thank you Questions?

10 20 B-177

1/6 /2 0 2 1 Linking 3D Microstructural Analysis of Additive Manufactured 316L to Performance and Properties in LPBF 316L Dave Rowenhorst US Naval Research Laboratory david.rowenhorst@nrl.navy.mil Aeriel Murphy-Leonard NRC/NRL Post-doc very soon to Ohio State University aeriel.murphy-leonard.ctr@nrl.navy.mil adleonard.821@gmail.com NRC Workshop on Advanced Manufacturing Technologies for Nuclear Applications 8 Dec 2020 DISTRIBUTION STATEMENT A. Approved for public release: distribution unlimited.

1 Outline

Brief introduction to the NRL ICME approach to AM

3D Serial Sectioning Analysis: Qualitative to Quantitive

- Why Serial Sectioning?

- Automated Serial Sectioning

3D Analysis of 316L LPBF 1

- Defect characterization and grain initiation

- Localized crystallographic orientation

- Grain Boundary Character Distribution

Conclusions DISTRIBUTION STATEMENT A. Approved for public release: distribution unlimited. 2 2

B-178

1/6 /2 0 2 1 Agile ICME AM Data Flow Synthetic Microstructures Design and Validation Integration and Optimization Localized to Global Mechanical Response Prediction DISTRIBUTION STATEMENT A. Approved for public release: distribution unlimited. 3 3

1 10 3D techniques for 2

µ-CT 10 materials characterization Mechanical Serial Sectioning 3

10 Femto-Second Laser Serial Sectioning 4

10 Serial sectioning is the method that can: 5µm Field of View (m) 5 10 Capture very large volumes 6 2

10

(~1mm3)

Atom Probe Tomography 7 FIB Sectioning 10 At a relatively high resolution eTomography (1m) for a wide class of 10 8 materials.

9 10 20nm 10 10 10 9 8 7 4 3 2 1 10 10 10 10 10 6 10 5 10 10 10 10 Resolution (m)

DISTRIBUTION STATEMENT A. Approved for public release: distribution unlimited. 4 4

B-179

1/6 /2 0 2 1 Robotic Serial Sectioning System (RS3D)*

Inspired by Mike Uchic (AFRL) LEROY system Good artists copy, great artists steal Pablo Picasso 24 Hour, 7 Days/week operation, automated polishing, automated electron imaging.

Kuka six axis robot to transfer sample between devices RoboMet automatic polishing w/ 8 polishing pads, ultra sonic cleaning, two etching stations.

Controlled material removal from 0.2 - 10 micron using well developed material preparation techniques.

Mira Tescan SEM that allows for full automation of controls/data collection 5 SE/EBSD/EDS/BSE...

5 316L AM Build Special Thanks to Mike Kirka: ORNL 316L PBF on an SLM 280 15 x 15 x 15 mm cubes 30µm layers ; 67° Raster Direction Rotation Hatch distance: 0.12mm 175W @750mm/sec 3

DISTRIBUTION STATEMENT A. Approved for public release: distribution unlimited. 6 6

B-180

1/6 /2 0 2 1 Automated Serial Sectioning 308 Sections, 1.44µm spacing 2-step polish: 1µm diamond; 0.04 SiO2 BSE/SE: (0.586µm/px) 2048x2048 EBSD: 2x2 Montage 0.75µm/px ~ 1600 x1600 Every Kikuchi Pattern saved, post-indexed

~2.5 hrs/section (30min removal/cleaning) 1110 µm Total data set ~10TB. 10 sections/day Image stacks aligned BSE - translations EBSD - high-order polynomials for stitching Ane for stack alignment Final dataset: 994 x 1110 x 444 µm3

>10,000 Grains in the volume Build Direction DISTRIBUTION STATEMENT A. Approved for public release: distribution unlimited. 7 7

Automated Serial Sectioning 308 Sections, 1.1µm spacing 2-step polish: 1µm diamond; 0.04 SiO2 BSE/SE: (0.586µm/px) 2048x2048 EBSD: 2x2 Montage 0.75µm/px ~ 1600 x1600 Every Kikuchi Pattern saved, post-indexed

~2.5 hrs/section (30min removal/cleaning)

Total data set ~10TB. 10 sections/day 4

Image stacks aligned BSE - translations EBSD - high-order polynomials for stitching Ane for stack alignment Final dataset: 994 x 1110 x 339 µm3 30,000 Grains in the volume 1,800 pore defects DISTRIBUTION STATEMENT A. Approved for public release: distribution unlimited. 8 8

B-181

1/6 /2 0 2 1 Porosity using mechanical serial sectioning Spherical equivalent radius (m) 0.28 % Volume Fraction Pores (consistent with large area optical microscopy)

Largest pores are irregular in shape and have features that are much below the resolution of tomography.

200µm BSE Image 9

9 0 00 0 167 0 333 0 500 0 666 0 833 1 00 Pore Reconstruction D. J. Rowenhorst, L. Nguyen, A. D. Murphy-Leonard, and R. W. Fonda. Characterization of microstructure in 200 400 600 300 800 0 additively manufactured 316l using automated serial sectioning. Current Opinion in Solid State and Materials 0 (µm)

Science, page 100819, Jul 2020. DOI: 10.1016/j.cossms.2020.100819 150 DInscribed Irregular Shapes Spherical Shapes 200 120 l =

DCaliper 90 Count is advantageous over sphericity 400 in that is does not require Build Direction 60 measurement of surface area.

30 5

600 250 0 Lower 0 0.2 0.4 0.6 0.8 1.0 detect on l m t Irregular Shapes (Sphere ratio) Spher cal Shapes 200 All Pores 800 150 Count Irregular Pores -> LOF 100 1000 - Elongation along the recoater direction

- LOF pores are denser in particular layers 50 0

10 100 DISTRIBUTION STATEMENT A. Approved for public release: distribution unlimited. Cal per m 10 10 B-182

1/6 /2 0 2 1 0 00 0 167 0 333 0 500 0 666 0 833 1 00 Pore Periodicity 400 200 400 600 300 800 Raster Rotation (deg) 0 0 (µm) Laser Raster Directions Rotate 67° per layer 300

- Assume that the large porosity peak aligns with a 0° 200 200 rotation.

- There appears to have some correlation with a periodicity 100 of 2, but not .

400 0 Build Direction 0.010 0.008 Void Fraction Angular Delta (AU) 600 3000 Period ~160µm 0.006

= 2 periodicity 0.004 2000 800 periodicity 0.002 0

1000 0 500 1000 Distance along BD(m) 1000 0

Delta 0 Plot frequency power spectrum (FFT amplitude)

Void Fraction Power (AU) 7 6x10 Delta 0, 180 (Plot offset +200) for density and angular delta from 0° and 0,180° Porosity Density for a 67° series.

4x107 The 0° angular delta shows the same Gas Flow 2x107 periodicity, but not the 180°.

0 0 0.005 0.010 0.015 Freq (m)-1 DISTRIBUTION STATEMENT A. Approved for public release: distribution unlimited. 11 11 Pores and Grain Nucleation 200 400 600 800 300 0 Black - 3D Reconstruction of pores 0 (µm)

Points - location of the first time a grain appears in the build direction: Grain Initiation Site (GIS)

Used a variation of the DBScan cluster search for the GIS sites:

Red - Clustered GIS 200 Blue - Unclustered GIS GIS clusters are more homogeneously distributed through the build layers.

400 Some correlation of clusters with LOF pores.

Build Direction 4500 Partial Distribution of grains lengths 4000 Complete along the build direction.

600 3500 6 54% grains only exist for a single AM layer.

3000 13% exist for more than 3 Layer 1 Layer 2 Layer 3 2500 Number 800 layer (>90 m) 2000 1500 1000 1000 500 0

0 30 60 90 120 150 180 210 240 270 300 Grain Height along BD (m) -1000 DISTRIBUTION STATEMENT A. Approved for public release: distribution unlimited. 12 12 B-183

1/6 /2 0 2 1 (a) (b) 200 400 600 800 300 0

0 (µm)

Pores and Grain 200 Nucleation a) Reconstruction of 400 largest GIS clusters.

Build Direction 600 b) The largest GIS with (c) associated LOF pore 800 c) Second largest GIS -

no associated pore 1000 found DISTRIBUTION STATEMENT A. Approved for public release: distribution unlimited. 13 13 Columnar - like growth 7

Build Direction Qualitative observation: grain branches align along <001>

DISTRIBUTION STATEMENT A. Approved for public release: distribution unlimited. 14 14 B-184

1/6 /2 0 2 1 Single Grain Textures - BD ll [011]

Y BD Z

DISTRIBUTION STATEMENT A. Approved for public release: distribution unlimited. 15 15 Single Grain Textures - BD ll [111]

(001)

(111) Oriented Grains Can poorly align three (1)directions with 8 the raster directions.

Y BD Z

DISTRIBUTION STATEMENT A. Approved for public release: distribution u nlimited. 16 16 B-185

1/6 /2 0 2 1 Single Grain Textures - BD ll [001]

(001)

(001) Oriented Grains Have only one direction that is aligned with the thermal gradients, More dicult for sideways growth keeping the profile thinner.

Y BD Z

DISTRIBUTION STATEMENT A. Approved for public release: distribution unlimi ted. 17 17 Local Orientation MRD Want to determine the crystallographic orientation of the branches.

00 31 62 93 12 5

- Calculate a distance transform for the object

- Use a watershed transform to label domains of similar shape

- Calculate the principle moment of inertia for the maximum distance with each watershed domain.

- Take the largest direction as the vector direction of that local piece of the grain. 9

- Use the average orientation of the watershed domain to calculate the local crystallographic direction.

Large Ellipsoids are associated with the trunk and not representative of the branch alignment. Filter out any domains that are part of a channel that is > 40µm diameter.

Full Volume Analysis (Represents 90% of the volume)

DISTRIBUTION STATEMENT A. Approved for public release: distribution unlimited. 18 18 B-186

1/6 /2 0 2 1 Grain Boundary Interface Texture All interfaces 5° [100] 5 - 60° [100] 3 - 60° [111]

0.5 5.80.0 2.0 0.4 3.5 1.4 5.0 vs (100)

T /x AM 316 0.7 1.90.0 0.3 0.7 0.0 5800 4.5 Traditional 316 Thermal Gradient DISTRIBUTION IBUTION STATEMENT A. Approved for ppublic release:

release:

distribution distribution unlimited.lic unlimited. 19 19 Conclusions New advances in automation have made large scale serial sectioning a feasible process, allowing for direct visualization of the 3D structures formed during AM processing.

Incredibly useful for initial conditions of simulations and modeling

Essential for validation of simulation and modeling 10 In 316L PBF material has a complex columnar growth. The grains are larger than expected, and contain complex shapes and branching features.

The sample textures are a function of preferred growth directions aligning with raster directions and the local morphology reflects the crystal symmetry.

This directional solidification structure leads to an elimination of 3 boundaries within the AM 316L Grain Boundary Character Distribution.

20 20 B-187

1/6 /2 0 2 1 21 11 B-188

1/6/2021 The Effects of Post-Processing on Mechanical Properties and Corrosion Behavior of AM 316L Stainless Steel Richard Fonda, Scott Olig, David Rowenhorst, Jerry Feng, Adelina Ntiros, Beth Stiles, Krystaufeux Williams, Roy Rayne, and Charles Hart US Naval Research Laboratory Codes 6350 and 6130 Supported by NRL and the NAVSEA Technology Office Cross Platform Systems Development (CPSD) Program DISTRIBUTION A: Approved for public release, distribution is unlimited 1

Objective Objectives: Systematically determine the microstructure, corrosion behavior, and mechanical properties of AM 316L stainless steel in the as-built and post-processed conditions Approach: Take advantage of the outstanding capabilities and expertise in microstructural characterization and corrosion behavior at NRL:

- Advanced 2D and 3D microscopy techniques

- Corrosion testing

- Mechanical property testing NRC Advanced Manufacturing, 08 Dec 2020 2 2

B-189 1

1/6/2021 316L AM Steel is NOT Stainless

As-built 316L sample does not exhibit any passivity

AM sample corrodes three orders of magnitude faster than wrought sample at -100mV 316L Stainless Steel Cyclic Polarization Tests 0.30 Negligible Passivation Pitting corrosion Region corrosion 0.20 0.10 316 L wrought Potential (V) 0.00 316 L AM

-0.10

-0.20

-0.30 1.00E-09 1.00E-08 1.00E-07 1.00E-06 1.00E-05 1.00E-04 1.00E-03 1.00E-02 Current (A)

Polarization response comparison, Courtesy Dr. J. Moran 6130 NRC Advanced Manufacturing, 08 Dec 2020 3 3

Porosity in As-Built Material Both LOF and gas porosity present Enhanced porosity between fill and border scans NRC Advanced Manufacturing, 08 Dec 2020 4 4

B-190 2

1/6/2021 Depth Effects of Corrosion

No passivity at the as-built surface

Passivity improves with distance from surface NRC Advanced Manufacturing, 08 Dec 2020 5 5

As-Built Microstructure Standard L-PBF Appearance NRC Advanced Manufacturing, 08 Dec 2020 6 6

B-191 3

1/6/2021 Samples

As-Received Sample:

- 316L Stainless Steel

- EOS M270

- Stress Relief: 790 °C, 1 h

Additional Heat Treatments:

500 °C, 1h 1100 °C, 1h 700 °C, 1h 1200 °C, 1h 800 °C, 1h 1300 °C, 1h 900 °C, 1h 1300 °C, 15h 1000 °C, 1h

HIP Treatments15 ksi (100 Mpa):

1000 °C, 3h 1100 °C, 3h 1200 °C, 3h NRC Advanced Manufacturing, 08 Dec 2020 7 7

Microhardness Variations

Heat treat for 1 hour1.157407e-5 days 2.777778e-4 hours 1.653439e-6 weeks 3.805e-7 months at various Temps Slight decrease up to 800 °C Steeper decrease above 800 °C NRC Advanced Manufacturing, 08 Dec 2020 8 8

B-192 4

1/6/2021 Changes in Cell Structure No Fine Cell Fine Cell Structure Structure

Cell structure evident below 800 °C

Associated with higher strength and better corrosion resistance

Completely absent at 900 °C and above NRC Advanced Manufacturing, 08 Dec 2020 9 9

Grain Evolution Recovery / Fully Recrystallization Recrystallized No Fine Cell Fine Cell Structure Structure

Recovery / Recrystallization occurs from 1000-1200 °C

Difficult to discern from IPF maps NRC Advanced Manufacturing, 08 Dec 2020 10 10 B-193 5

1/6/2021 Recrystallization Recovery / Fully Recrystallization Recrystallized No Fine Cell Fine Cell Structure Structure 900

Recovery / Recrystallization occurs from 1000-1200 °C

More evident in Geometrically Necessary Dislocation maps

Three characteristic temperature regimes NRC Advanced Manufacturing, 08 Dec 2020 11 11 Evolution with Temperature NRC Advanced Manufacturing, 08 Dec 2020 12 12 B-194 6

1/6/2021 Corrosion of Bulk AM 316L

Passive behavior of build interior up to 800 °C

Corrosion is enhanced / passivity lost above 800 °C NRC Advanced Manufacturing, 08 Dec 2020 13 13 Corrosion of Bulk HIP AM 316L

Enhanced corrosion rate after HIP

Passive / non-passive behavior retained NRC Advanced Manufacturing, 08 Dec 2020 14 14 B-195 7

1/6/2021 Effect of T on Porosity Fraction

Heat treatments alone do not change pore volume fraction

HIP treatments reduce pore volume fraction by ~2/3 NRC Advanced Manufacturing, 08 Dec 2020 15 15 Effect of HT on Pore Morphology As-received 1100 °C, 1 hr 1200 °C, 1 hr

No effects at <1000 °C

Initial rounding of pore corners at 1100 °C

No gross changes in pore shape <1300 °C

Follows recrystallization behavior 1300 °C, 1 hr 1300 °C, 15 hr NRC Advanced Manufacturing, 08 Dec 2020 16 16 B-196 8

1/6/2021 Effects of HIP on Porosity As-Built HIP 1.0 mm 0.75 mm LOF pores removed by HIP; small pores remain NRC Advanced Manufacturing, 08 Dec 2020 17 17 New Build Parameters Further analysis of four characteristic structures

EOS M290 at JHU-APL

EOS StainlessSteel 316L

Porosity <0.1%

Parameters

Power: 195 W

Laser Speed: 1083 mm/s

Layer thickness: 0.02 mm

Hatch Distance: 0.09 mm

Stripe width: 5 mm

Stripe overlap: 0.12 mm NRC Advanced Manufacturing, 08 Dec 2020 18 18 B-197 9

1/6/2021 Characteristic Microstructures As-Built Annealed Recrystallized HIPed 100 µm 100 µm As-Built 900 °C, 1h 1200 °C, 1h HIP: 1204 °C, 4h Fine cell structure No cell structure No cell structure No cell structure As-built grain As-built grain 70% recrystallized Fully recrystallized structure structure grain structure grain structure Few precipitates Few precipitates Fine precipitates Fine precipitates NRC Advanced Manufacturing, 08 Dec 2020 19 19 Tensile Testing

YS decreases with processing temperature

All samples exceed 316L specifications NRC Advanced Manufacturing, 08 Dec 2020 20 20 B-198 10

1/6/2021 Tensile Testing

UTS shows only slight decrease with Temp

All samples exceed 316L specifications NRC Advanced Manufacturing, 08 Dec 2020 21 21 Elongation

Elongation increases with processing temp

Vertical samples more ductile than horizontal NRC Advanced Manufacturing, 08 Dec 2020 22 22 B-199 11

1/6/2021 Rotate Bending Fatigue

Fatigue life degrades with recrystallization

- Vertical sample orientation (along BD)

- Evolution from vertical grains to equiaxed grains with 111 underlying precipitates 011 AB 001 900 °C 1200 °C HIP 100 µm NRC Advanced Manufacturing, 08 Dec 2020 23 23 Corrosion at Transverse Surface

AM has better passivity than the wrought 316L

HIP sample has transients in passivation regime

- reflect individual isolated corrosion events (precipitates?)

Difference in OCP due to defects/matrix comp?

No loss of passivity >800°C

Due to low porosity?

NRC Advanced Manufacturing, 08 Dec 2020 24 24 B-200 12

1/6/2021 Corrosion at Build Plane

Generally similar to transverse surface

More transients observed in HIP sample

- Leads to earlier breakdown of surface (ppts?)

NRC Advanced Manufacturing, 08 Dec 2020 25 25 Onset of Crevice Corrosion

Delayed onset from AB 900°C 1200°C due to coarsening of microstructure scale

Accelerated CC of HIP condition: precipitates?

HIP 900 °C 1200 °C As-Built NRC Advanced Manufacturing, 08 Dec 2020 26 26 B-201 13

1/6/2021 Summary

Corrosion enhanced at surface due to porosity

Three distinct microstructural regimes:

As-Built < 800 °C < Annealed < 1200 °C < Recrystallized

Microhardness decreases with increasing temperature

Porosity fraction does not evolve with temperature

- HIP reduces porosity by ~2/3 by closing LOF pores

Yield Strength: ~3x the 316L specification

- decreases with processing temperature

UTS: slight decrease due to recrystallization/ppt

Elongation: increases with processing temperature

RB Fatigue: ~100x decrease with recrystallization

Corrosion: HIP-induced precipitation causes increased frequency of transients and rapid onset of crevice corr.

Crevice corrosion resistance improves at 900 °C & 1200 °C

All AM structures exceed 316L specifications for YS, UTS, and elongation NRC Advanced Manufacturing, 08 Dec 2020 27 27 Thank you!

NRC Advanced Manufacturing, 08 Dec 2020 28 28 B-202 14

1/6/2021 PROCESS VALIDATION FOR AM Daniel Porter, PhD Division of Applied Mechanics Office of Science and Engineering Laboratories Center for Devices and Radiological Health U.S. Food and Drug Administration December 2020 OSEL InfoClear #DAM6715 OSEL Accelerating patient access to innovative, safe, and effective medical devices through bestintheworld regulatory science 1

Disclaimer The mention of commercial products, their sources, or their use in connection with materials reported herein is not to be construed as either an actual or implied endorsement of such products by the Department of Health and Human Services.

OSEL Accelerating patient access to innovative, safe, and effective medical devices through bestintheworld regulatory science 2

B-203 1

1/6/2021 Speaker Bio Dr. Daniel Porter currently is a Regulatory Scientist at the U.S. FDAs Division of Applied Mechanics researching the properties of additively manufactured (AM) lattice structures and AM facemask sealing efficacy. Dr. Porter also has experience as a Lead Reviewer in the Office of Orthopedic Devices (OHT6) within the Center of Devices and Radiological Health at the U.S. FDA. He holds a Bachelor and Master of Science in Mechanical Engineering from the University of Louisville (UofL). He completed nearly two years of internships at Sandia National Laboratories in New Mexico where he researched gas chromatography technologies for national security applications. Dr. Porter received his Ph.D. in Mechanical Engineering from UofL where he studied vibrational energy harvesting, MEMS technology, and AM. He completed his postdoctoral position at Southern Methodist University (SMU) in Dallas, Texas where he studied AM of ultraviolet industrial silicone and thermally curable medical grade silicone.

OSEL Accelerating patient access to innovative, safe, and effective medical devices through bestintheworld regulatory science 3

Overview of Presentation

Introduction & Motivations

Hypothetical Case Study Intro

Device Design & Draft Labeling

Process Workflow

Software Workflow

Material Control

PostProcessing

Monitoring Activities

WorstCase AM Selection

Ending Remarks 4

OSEL Accelerating patient access to innovative, safe, and effective medical devices through bestintheworld regulatory science 4

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1/6/2021 CDRH Snapshot 1900 18k Medical Device 183k EMPLOYEES Manufacturers Medical Devices On the U.S. Market 22k /year 570k Proprietary Brands 1.4 MILLION /year Premarket Reports on Submissions medical device including supplements 25k adverse events and and amendments Medical Device Facilities malfunctions Worldwide OSEL Accelerating patient access to innovative, safe, and effective medical devices through bestintheworld regulatory science 5

Introduction

AM Guidance released December 5th, 2017.

Intended to help stakeholders address AM aspects in regulatory submissions*.

Gives a broad overview of considerations for AM.

Does not include biological, cellular, or tissuebased products in AM.

6 OSEL Accelerating patient access to innovative, safe, and effective medical devices through best intheworld regulatory science 6

B-205 3

1/6/2021 FDA Guidance Documents

Represent FDA's current thinking on a topic

Do not create or confer any rights for or on any person

Do not bind FDA or the public

Allow you to use alternative approaches if the approach satisfies the requirements of the applicable statutes and regulations OSEL Accelerating patient access to innovative, safe, and effective medical devices through bestintheworld regulatory science 7

Motivation Up to ~2016 U.S. Submissions

Submissions using AM appear to be increasing.

More stakeholders new to AM technology.

Powder Bed Fusion (PBF) appears to be dominant currently.

Would like to provide a hypothetical case study on one example of how to use the U.S. FDA AM Guidance.

Ricles 2018. Regulating 3Dprinted medical products.

https://stm.sciencemag.org/content/10/461/eaan6521 8

OSEL Accelerating patient access to innovative, safe, and effective medical devices through bestintheworld regulatory science 8

B-206 4

1/6/2021 Some Things to Keep in Mind

Not all considerations are mentioned.

Not stating what minimum activities/criteria are for submissions.

No guarantee that this fictitious submission would be cleared.

- Data is absent in this presentation.

9 OSEL Accelerating patient access to innovative, safe, and effective medical devices through bestintheworld regulatory science 9

Hypothetical Case Study 510(k) Submission

Subject Submission: K19ABCD

Predicate Submission: K17EFGH

Sponsor: Subject Company

Sponsor: Predicate Company

Device: Subject Bone Support System

Device: Predicate Bone Support System

- Patient Matched Bone Plate

Adults

- Adults

- Long Bones VS

Long Bones

Product Code: HRS, 21 CFR 888.3030

Product Code: HRS, 21 CFR 888.3030

Technology: Traditional Subtractive

Technology: Powder Bed Fusion Manufacturing

- Energy Source: Laser

Material: Ti6Al4V ELI (ASTM F136)

- Material: Ti6Al4V (ASTM F292414)

Similar Indications for Use 10 OSEL Accelerating patient access to innovative, safe, and effective medical devices through bestintheworld regulatory science 10 B-207 5

1/6/2021 Device Design Patient matched bone plate

Frontal angle 1

Anterior angle 2

Total length L1

Partial shaft length L2

Minimum plate thickness b

Patient matched spline surface

Radial curvature oc Minimum feature size ~=0.7 mm (AM Guidance §V.A)

Understand and describe critical features (AM Guidance §VI.A)

All input variables have validated limits (AM Guidance §V.B)

Understand allowable dimensional tolerances (AM Guidance §VI.C) 11 OSEL Accelerating patient access to innovative, safe, and effective medical devices through bes tintheworld regulatory science 11 Representative Sacrificial Long Configuration Test Coupon Short Configuration Config 2 Config 1 Subject Company presents data showing that Sacrificial coupons are representative of the final, finished device (AM Guidance §VI.D.2).

12 OSEL Accelerating patient access to innovative, safe, and effective medical devices through bestintheworld regulatory science 12 B-208 6

1/6/2021 Draft Labelin g

(AM Guidance §VII)

Labeling indicates patient matched

Patient identification number

Design iteration number (AM Guidance §V.B.2

Patients anatomy location )

Expiration date (AM Guidance §V.B.1)

Other(s) 13 OSEL Accelerating patient access to innovative, safe, and effective medical devices thr ough bestintheworld regulatory science 13 Process Workflow AM Guidance, pg 8/31 14 OSEL Accelerating patient access to innovative, safe, and effective medical devices through bestintheworld regulatory science 14 B-209 7

1/6/2021 Software Workflow Start Validated Validated AM Patient Scan / Matching Patient Matched Position and Machine Print Job File Segmentation Software Bone Plate Info Orientation Settings Bone Plate Build Path Generation Validated CAD/STL File Design &

Envelope Sacrificial Test Coupon

Considers build volume placement, laser power, speed, path, etc. (AM Guidance §V.C.2).

If new software/firmware or changes to software/firmware then the Subject Company understands:

- Revalidation may be needed (AM Guidance §V.F.2) .

- Consult When to Submit a 510(k) for a Change to an Existing Device. 15 OSEL Accelerating patient access to innovative, safe, and effective medical devices through bestintheworld regulatory science 15 Position and Orientation Patientmatched surface Worstcase Z orientation YZ,Max Y

Build Plate Z

YZ,Min Y Build Plate Subject Devices Sacrificial Test Coupon Validated Orientations (AM Guidance §V.F.4)

No worstcase position Build supports on nonpatient matched face (AM Guidance §V.C.2.ii) from OQ/PQ 16 OSEL Accelerating patient access to innovative, safe, and effective medical devices through bestinth eworld regulatory science 16 B-210 8

1/6/2021 Material Control

Virgin Ti6Al4V powder from supplier, with certificate of analysis.

Subject Company verifies virgin powder (AM Guidance §V.D.1):

- Particle size distribution.

- Chemical constituency (ICPAES, combustion, inert gas fusion).

Mixes powder in ratio (used:virgin) 1:1.

Validated storage protocol under inert gas (argon).

OQ/PQ showed nonconformance to ASTM F292414 after 9 reuse/mixes (i.e. sieves).

- Process is repeatable.

- Safety factor > Will only reuse/mix (i.e. sieve) powder up to 6 times.

17 OSEL Accelerating patient access to innovative, safe, and effective medical devices through bestintheworld regulatory science 17 Material Control Powder Reuse Subject Companys Powder Handling Routine Refreshed Load/ Used Used Build Powder (n)

Powder Allowed

+1 Reuse reuses 6 Store until Virgin Sieve/

current feedstock Powder mix is exhausted Start at reuse 1 Conveying the powder handling routine is important!

Will not mix powder from differing lots.

18 OSEL Accelerating patient access to innovative, safe, and effective medical devices through bestintheworld regulatory science 18 B-211 9

1/6/2021 Material Control Powder Reuse Hypothetical data from Subject Companies OQ/PQ E8 tensile coupons.

Chemical constituency charts as a function of powder reuse also important.

Potential worst-case powder reuse 19 OSEL Accelerating patient access to innovative, safe, and effective medical devices through bestintheworld regulatory science 19 PostProcessing Powder Removal Device Removal

Devices and representative test coupons both Ti-6Al-4V Blast & Sanding Ultrasonication & Machining /

go through postprocessing. Cleaning Engraving

Subject Company decides to discuss the Oven Drying Passivate / Clean

/ Dry detrimental effect of the HIP process (AM Hot Isostatic Residual Powder Guidance §V.E). Press Test Post-Processing

Residual powder test performed on final finished devices (AM Guidance §VI.E and

§VI.F). Final, finished components

- Has specified acceptance criteria.

20 OSEL Accelerating patient access to innovative, safe, and effective medical devices through bestintheworld regulatory science 20 B-212 10

1/6/2021 Residual Powder Analysis

Subject company decides to use USP <788> to evaluate residual powder with 788s acceptance criteria.

Uses Method 2, Microscopic Particle Count.

- Particle size distribution

Size < 10 m

10 m Size 25 m Substitute representative porous

25 m Size volume if there was one.

- Morphology

Acceptance criteria, assume 1 mL equivalent container volume.

- 12 particles actual count (Size 10 m)

- 2 particles actual count (Size 25 m) Device is not porous.

Need better residual powder standards.

21 OSEL Accelerating patient access to innovative, safe, and effective medical devices through bestintheworld regulatory science 21 Monitoring (Verification) Activities The Subject Company also does not want to create a new worstcase

In situ monitoring (Oxygen sensors, etc.)

Visual inspections

3D metrology scan - subject device Final Finished Bone Plate FMEA

2x per build tensile specimens & Test Coupons No

1x density cubes In Situ Mechanical/ Test Coupons

Single cycle 4point bend (ASTM F38217) Monitoring Chemical Verification Visual Inspections Accept/

- sacrificial coupon Reject? Final Finished

- Verify loaddisplacement curve Bone Plate Yes

Chemical verification - sacrificial coupons 3D Scan Final Finished &

Verification Packaging,

- ICPAES Labeling, &

Packaged Device

- Combustion Sterilization

- Inert Gas Fusion Final Testing 22 OSEL Accelerating patient access to innovative, safe, and effective medical devices through bestintheworld regulatory science 22 B-213 11

1/6/2021 WorstCase Selection (AM)

Subject Company decides to also consider what is worstcase in regards to the AM process

Build location dependence

- Negligible

Build orientation dependence

- YZ,Max

Powder reuse/mixing (sieve) dependence

- Reuse #6 AM Component(s) to Performance Test

Laser power, speed, path dependence

- Locked down. Tolerances known and monitored. WorstCase Selection w/Data

Residual powder and Robust

- None identified Rationale

Other (device size selection, etc.)

23 OSEL Accelerating patient access to innovative, safe, and effective medical devices through bestintheworld regulatory science 23 Ending Remarks

Just one example of how to use the AM Guidance.

- Many ways to address AM considerations for a premarket submission.

AM is a broad technology, and we only look at LPBF here.

- Potentially different considerations with other technologies.

Should also defer to any devicespecific Guidance Document(s) or special controls Guidance Document(s) for premarket requirements.

Highlevel overview.

No performance data presented here for the subject or predicate device.

24 OSEL Accelerating patient access to innovative, safe, and effective medical devices through bestintheworld regulatory science 24 B-214 12

1/6/2021 Thank You For Your Attention Questions?

AdditiveManufacturing@fda.hhs.gov 25 OSEL Accelerating patient access to innovative, safe, and effective medical devices through bestintheworld regulatory science 25 B-215 13

1/6/2021 NRC Technical Assessment of Additive Manufacturing - Laser Powder Bed Fusion Meg Audrain Office of Nuclear Regulatory Research December 8, 2020 1

Outline

Background on Advanced Manufacturing

NRC Technical Assessment - Laser Powder Bed Fusion (LPBF)

- Background, ranking of significance

- LPBF Generic Considerations

- Material Specific Considerations

- Codes and Standards Gap Assessment

Conclusions 2

2 B-216 1

1/6/2021 Advanced Manufacturing Technologies

Techniques and material processing methods that have not been:

- Traditionally used in the U.S. nuclear industry

- Formally standardized/codified by the nuclear industry

NRC Focus based on industry interest

- Laser Powder Bed Fusion (LPBF)

- Direct Energy Deposition (DED)

- Electron Beam (EB) Welding

- Powder Metallurgy Hot Isostatic Pressing (PMHIP)

- Cold Spray 3

3 Action Plan - Rev 1 Tasks

Task 1 Technical Preparedness

- Technical information, knowledge and tools to prepare NRC staff to review AMT applications

Task 2 Regulatory Preparedness

- Regulatory guidance and tools to prepare staff for efficient and effective review of AMTfabricated components submitted to the NRC for review and approval

Task 3 Communications and Knowledge Management

- Integration of information from external organizations into the NRC staff knowledge base for informed regulatory decisionmaking

- External interactions and knowledge sharing, i.e. AMT Workshop

ML19333B980 4 4

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1/6/2021 NRC Technical Assessment LPBF 5

Laser Powder Bed Fusion

Process:

- Uses laser to melt or fuse powder together in bed of powder

- Generally most advantageous for more complex geometries

Potential Applications

- Smaller Class 1, 2 and 3 components, fuel hardware, small internals https://www.osti.gov/pages/servlets/purl/1437906 6

6 B-218 3

1/6/2021

Background

Based on a technical information and gap assessment written by ORNL for the NRC

NRC technical assessment provides regulatory perspective and highlights key technical information

Fulfills the NRC Action Plan Task 1A deliverable to describe:

- Differences between AMT/conventional component

- Safety significance of the differences

- C&S gaps 7

7 Ranking of Significance

Importance - impact on final component performance

- High - significant impact on component performance

- Medium - moderate impact on component performance

- Low - minimal impact on component performance

Knowledge/Manageability - how well understood and manageable is issue?

The overall impact to plant safety is a function of component performance and the specific component application 8

8 B-219 4

1/6/2021 LPBF Generic Differences 9

Medium Importance

Machine Process Control

- Definition: Software controlling the scan strategy of the LPBF machine and the machine calibration to reliably fabricate components

- Manageable with Quality Assurance (QA) including appropriate calibration

Build Process Management and Control

- Definition: Includes monitoring parameters during fabrication using environmental sensors, insitu monitoring, and evaluating the effects of build interruptions.

- Manageable with QA and the use of in situ monitoring and environmental sensor data 10 10 B-220 5

1/6/2021 Medium Importance

Witness Specimens

- Definition: Test specimens that are fabricated concurrently with enduse components and used to provide confirmation of build quality and product performance

- Well established to detect events that may result in component rejection (e.g., delamination)

Residual Stress

- Definition: Residual stresses form during the LPBF build process and can lead to warping, cracking, and delamination if not properly managed

- There is significant knowledge on residual stress, including how to manage it through postprocessing or NDE 11 11 High Importance

Powder Quality

- Definition: Important characteristics of the powder, such as composition and size distribution, and how it is managed in the production process prior to the build process (e.g., sieving, reuse, storage, contamination).

- Can be challenging to manage and the effects on final product performance are material specific

Post Processing

- Definition: Includes methods used (e.g., HIP, heat treatments) to improve material properties and performance by increasing density and reducing porosity

- Should make material properties and performance more homogeneous and similar to conventional forged materials

- Heat treatments are commonly done for LPBF and conventional materials and are fairly wellunderstood

- HIP is wellestablished method but less commonly used for conventional materials where porosity is not a significant issue 12 12 B-221 6

1/6/2021 High Importance

Local Geometry Impacts

- Definition: The geometry of the component and the heat transfer characteristics from the product build directly affect local microstructure (e.g., grain size and orientation), which can affect material properties and performance, including SCC susceptibility

- Can be managed through postprocessing and sampling /

witness specimens to measure the impacts

Porosity

- Definition: The size, distribution, and total volume of voids and pores in the LPBF component

- May have smaller size and higher density than forged materials

- There is knowledge on how to manage porosity both in the build process and through postprocessing 13 13 High Importance

Heterogeneity and Anisotropy

- Definition: Different properties in the build direction due to the nature of the layerbylayer build process. Impacts the microstructure and generally creates poorer properties between build layers

- Significant difference from conventional materials and can have a significant impact on product performance if not addressed in the design and fabrication process

- Generally wellunderstood but requires specific measures to manage such as sampling methodology or postprocessing 14 14 B-222 7

1/6/2021 Material Specific Differences 316L Stainless Steel 15 Low Importance

Tensile Properties

- Refers to the ultimate tensile and yield strength of the material

- Not a common failure mode in nuclear components and no more likely in LPBF materials due to their similar or superior tensile properties 16 16 B-223 8

1/6/2021 Medium Importance

Fatigue

- Refers to the initiation and propagation of cracks due to cyclic loading with or without environmental effects playing a significant role in the process.

- Can lead to component failure, however, its generally addressed conservatively through design standards and has not generally led to many safetysignificant failures or flaws

Weldability/Joining

- Refers to the ability to successfully weld a material to another component without unacceptable defects

- Should not impact component performance if welding Code requirements can be developed 17 17 High Importance

Initial Fracture Toughness

- Low fracture toughness can lead to brittle component failure

- Limited data on 316L have shown significantly lower initial fracture toughness depending on postprocessing than similar forged materials

Thermal Aging, SCC and Irradiation Effects

- Limited data on 316L

- Representative data is important to demonstrate material behavior

- Post processing is expected to make material properties and performance similar to conventional forged materials 18 18 B-224 9

1/6/2021 High Importance

Weld integrity

- Refers to the properties and performance of the weld and surrounding heataffected zone

- Welds can be a location of degradation and may behave significantly differently with LPBF materials

- Understanding this behavior is important to inspection and aging management 19 19 Codes and Standards Gaps

Materialspecific criteria for powder recycling and sieving

Assessments of microstructural and material property heterogeneity

- Should also consider the positive impact of post processing, such as HIP, on heterogeneity

Datadriven requirements for number, location and orientations of witness specimens

Weld integrity and weldability including pre and postweld heat treatments 20 20 B-225 10

1/6/2021 Conclusions

First of the AMT Technology Assessment and Gap Analysis Reports will be public shortly

- NRC has developed a companion technical assessment with an NRC perspective that will be made public at the same time

Additional AMTspecific reports for DED, Cold Spray, EB Welding and PM HIP will be published in 2021 21 21 B-226 11

1/6/2021 PM-HIP and Electron Beam Welding Development for Nuclear Applications David W. Gandy Sr. Technical Executive, Nuclear Materials NRC Advanced Manufacturing Virtual Workshop December 710, 2020 w w w . ep r i . c o m © 2020 Electric Power Research Institute, Inc. All rights reserved.

1 Overview

Background

Advanced Manufacturing/Fabrication Technologies

- DOE Projects: DE-NE0008629 and DE-NE0008846 Powder Metallurgy-Hot Isostatic Pressing Electron Beam Welding Development Modular In-Chamber Electron Beam Welding Summary 2 w w w . ep r i . co m © 2020 Electric Power Research Institute, Inc. All rights reserved.

2 B-227 1

1/6/2021 Objectives - SMR Advanced Manufacturing Project Rapidly accelerate the deployment of SMRs Develop/Demonstrate new methods for manufacture / fabrication of a RPV in < 12 months Eliminate 40% from the cost of an SMR RPV, while significantly reducing the schedule Primary Advanced Methods:

Representative Model of NuScale Power

- PMHIP Reactor Pressure Vessel Copyright NuScale Power

- Electron Beam Welding

3 Powder Metallurgy-Hot Isostatic Pressing Why PMHIP?

Nearnet shaped Subsea Manifold.

components Courtesy: Sandvik Homogenous microstructure

- Ease of inspection!

40 diameter HIP Vessel Elimination of welds Courtesy: Isostatic Forge International 46 months lead times typical Ideal for multiple penetration applications (RPV or CNV head) vs expensive forgings Large Bore Valve NNS Reactor Coolant Pump (courtesy Roll-Royce) Impeller (courtesy Framatome 3600lb BWR Nozzle and Albert & Duval) 4 w w w . ep r i . co m © 2020 Electric Power Research Institute, Inc. All rights reserved.

4 B-228 2

1/6/2021 Small Modular Reactor Upper Head--Example

~44% scale Single monolithic structure Photographs courtesy of EPRI A508 Class 1, Grade 3 and NuScale Power 27 penetrations 1650kg (3650lbs); 1270mm (50 inches) diameter Next, 2/3scale head Need larger HIP Vessel ATLAS DOE Project: DE-NE0008629 5 w w w . ep r i . co m © 2020 Electric Power Research Institute, Inc. All rights reserved.

6 B-229 3

7 Electron Beam (EB) Welding Why EBW?

Onepass welding!

No filler metal required.

EBW can produce welds w/ minimal HAZ NuclearAMRC, TWI, RollsRoyce & EPRI have 110mm (thick) EB Weld demonstrated inchamber and/or local Photograph provided courtesy: Nuclear AMRC (UK) vacuum on thick section alloys

- Enables field/shop welding!

RPV girth welds (110mm thick) in <60 min Inspection, Costs?

Huge savings in welding costs (up to 90%)

Potential to eliminate inservice inspection coupled with heat treatment!

8 B-230 4

1/6/2021 Electron Beam Welding 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)

9 Each One-half Lower Reactor Head ~6500lbs One-half lower headArticle 4. (2950 kg) x 70 inches @

10 B-231 5

12 B-232 6

13 RPV Shell and Flange Shown Inside of Modular EBW Chamber (in gold)

Lower Flange Shell Mockup EB Weld -- ~6 ft (1.82m) diameter (Note, mockup is upside down)

14 B-233 7

16 B-234 8

17 EB Generator and Slide attached to the vacuum chamber Slide Assembly High Voltage Cable Vacuum Chamber EB Generator 18 w w w . ep r i . co m © 2020 Electric Power Research Institute, Inc. All rights reserved.

18 B-235 9

20 B-236 10

22 B-237 11

23 Summary Advanced Manufacturing/Fabrication Technologies

- Reviewed DOE Projects: DE-NE0008629 and DE-NE0008846

- Targets rapid acceleration for deployment of SMRs!

Powder Metallurgy-Hot Isostatic Pressing

- Near-net shaped components; ease of inspection; shorter lead times; scale to larger parts Electron Beam Welding Development

- Rapid; single pass; thick section, highly repeatable Modular In-Chamber Electron Beam Welding

24 B-238 12

25 Task 4--Design Vacuum Seals for Modular Ring Sections

--AMRC Lead Individual ring sections will be produced (Task 6) from >1.5 in. (>38.1 mm) thick carbon steel.

A flange will be attached to both the upper and lower extremities of the ring section via welding to achieve a good junction between two modules.

A tight fit is achieved at the junction between the two modules through two engineered vacuum seals.

A sensor will be positioned between the two vacuum seals to allow vacuum tightness to be checked

- before pumpdown

- and monitoring during pumping to detect any leaks extremely important in EBW activities.

26 B-239 13

1/6 /2 0 2 1 Cold Spray Process Details and Nuclear Applications December 8, 2020 Ken Ross And Jack Lareau PNNL-SA-158431.

Workshop on Advanced Manufacturing Technologies for Nuclear Applications 1

Solid Phase Processing Involves the application of a high shear strain during metals synthesis or fabrication, to produce high-performance microstructures in alloys, semi-finished products and engineered assemblies, without melting the constitutive materials.

1 Friction Stir Processes ShAPE' UHV Cold Spray Solid Phase Processing Capabilities at PNNL Workshop on Advanced Manufacturing Technologies for NuclearApplications December 8, 2020 2 2

B-240

1/6 /2 0 2 1 Cold Spray: Description

High Pressure/velocity cold spray

Solid phase deposition process

Particles are propelled at Mach 1-4

Typically particle size is 20 - 50m

Carrier gas is typically nitrogen or helium

Impact energy causes extreme plastic deformation creates grain refinement and metallurgical bonds Substrate: Stainless steel Powder: Inconel 625 Carrier Gas: Helium Deposition rate: 350g/min Note:

Arc welding is .25lbs/min =113.4 g/min Video courtesy of Plasma Giken Workshop on Advanced Manufacturing Technologies for NuclearApplications December 8, 2020 3 3

Cold Spray: Process Details

Extreme plastic deformation when particle impacts substrate produces a highly refined grain structure Energy of a single particle deformation is so low and happens so quickly that Grain structure of atomized particles prior detrimental heat affected zones are to and immediately after impact 2

avoided. -courtesy of VRC Metal Systems

As particles are deposited a mixtures areas of extreme to low plastic deformation develop Video: Simulation of particle deformation during high velocity cold spray

-courtesy of VRC Metal Systems Workshop on Advanced Manufacturing Technologies for NuclearApplications December 8, 2020 4 4

B-241

1/6 /2 0 2 1 Cold Spray Microscopy

No heat affected zone!

Cold

Cold sprayed material is highly cold worked Sprayed SS Highly deformed with areas of dynamic recrystallization 316 and nano-sized grains at particle interfaces

Base metal near the cold sprayed interface is severely deformed, extensive slip lines are visible as indicated by arrows below.

100 m 250 m Workshop on Advanced Manufacturing Technologies for NuclearApplications December 8, 2020 5 5

What Makes Good Cold Spray Best properties are typically achieved under the following conditions:

A high-pressure/velocity cold spray system is used.

High pressure systems operate at pressures typically ranging from 300 to 1,000 PSI and typically produce particle velocities ranging from 800 to 1400 m/s 3

Helium is used as the carrier gas.

Surface preparation is done correctly.

The correct material is selected for the application.

Powder is processed correctly.

Sieving powder to remove fines.

Drying powder.

High-pressure cold spray coating of commercially pure nickel sprayed (left side) at PNNL Workshop on Advanced Manufacturing Technologies for NuclearApplications December 8, 2020 6 6

B-242

1/6 /2 0 2 1 CISCC Mitigation and Repair

The US DOE and NRC determined microstructural degradation and residual stresses produced by fusion welds in austenitic DCSS canisters put the fusion weld areas at high risk for CISCC.

Cold spray provides a corrosion barrier and can produce compressive residual stresses in the coating and directly beneath

Removes two of the three conditions required for CISCC

Applications

New canister with factory coatings over welds and HAZ

Repair and mitigation using portable cold spray equipment Workshop on Advanced Manufacturing Technologies for NuclearApplications December 8, 2020 7 7

Hanford Applications Hanford Tank Farms Hanford Cs/Sr Capsules

Repairs needed to extend the life of

Modified Commercial DCSS built by corroding tanks NAC

PNNL executed an extensive repair

300 year design life process technology evaluation and

Cold spray will be applied over all down selection welds during fabrication 4

Cold spray scored highest PNNL proposed this concept to the project stakeholders at CH2M Hill + NAC

PNNL successfully developed and and continues to provide technical demonstrated feasibility of cold spray guidance as a repair process on laboratory coupons in relevant material system (mild steel)

Workshop on Advanced Manufacturing Technologies for NuclearApplications December 8, 2020 8 8

B-243

1/6 /2 0 2 1 Common Failure Modes in Nuclear Plant Components

Over the past 50 years, several failure modes for nuclear plant components have been detected Acid and caustic cracking Fatigue (the primary mechanism addressed in ASME Code)

Hydriding and oxidizing fuel rods Crevice corrosion Pitting corrosion Flow assisted corrosion (FAC) and cavitation Mechanical wear

Several base materials have been affected Carbon steel (pressure vessels and piping)

Stainless steel (piping and storage tanks)

Ni based alloys (inconel welds and base metal)

Zirconium based materials (fuel rods and assembly structures)

Workshop on Advanced Manufacturing Technologies for NuclearApplications December 8, 2020 9 9

Cold Spray Mitigation-Corrosion Resistance

For corrosion resistance, appropriately selected cold spray coatings provide a barrier between the base metal and corrosive or erosive environment

Demonstrated powders for corrosion or erosion protection Commercially Pure nickel (CPNi) (corrosion)

Stainless steel 316 (corrosion or erosion) 5 Titanium-Titanium Carbide (Crevice corrosion)

Inconel 625 (corrosion or erosion)

Advantages over welding No heat affected zone (HAZ)

No tensile residual stresses Workshop on Advanced Manufacturing Technologies for NuclearApplications December 8, 2020 10 10 B-244

1/6 /2 0 2 1 Cold Spray Mitigation: FAC

FAC in part caused by fracturing oxide layers in two phase flow conditions with carbon steel

Stainless of inconel coatings would eliminate the oxide layer deterioration

Welding repairs introduces new problems with heat affected zones

Cold spray of a high alloy coating could prevent FAC Note: This has not been tried to date, but related work on cavitation and flow erosion has demonstrated high potential for this approach Workshop on Advanced Manufacturing Technologies for NuclearApplications December 8, 2020 11 11 Examples of Stainless Steel Corrosion

Chloride cracking

Crevice Corrosion 6

Workshop on Advanced Manufacturing Technologies for NuclearApplications December 8, 2020 12 12 B-245

1/6 /2 0 2 1 Examples of Carbon Steel Degradation

Flow Assisted Corrosion

Boric Acid Corrosion of Carbon Steel Workshop on Advanced Manufacturing Technologies for NuclearApplications December 8, 2020 13 13 Westinghouse LWR Fuel Cladding

Cold sprayed Chromium on Optimized ZIRLO

Irradiation testing Byron Unit 2 Cycle 22 7

Improved Economics Safety Reliability Asfabricated microstructure of cold spray chromium coating on Optimized ZIRLO cladding (a). Microstructure of cladding tube following oxidation in steam at 1200°C for 20 minutes https://www.euronuclear.org/archiv/topfuel2018/fullpapers/TopFuel2018A0145 fullpaper.pdf Workshop on Advanced Manufacturing Technologies for NuclearApplications December 8, 2020 14 14 B-246

1/6 /2 0 2 1 CP Ni Ultrasonic Transducer

Cold Spray for online

EMAT reflections form 6 mm monitoring reflectors

Ni cold spray coatings are magnetostrictive

Can be used as a permanently installed electromagnetic acoustic transducer (EMAT)

Austenitic stainless steel is not suitable by itself for EMATs

On-line ultrasonic monitoring of pre-existing cracks is possible Workshop on Advanced Manufacturing Technologies for NuclearApplications December 8, 2020 15 15 ASME Code Aspects

Anticipated nuclear applications of cold spray are non-structural in nature Anticipated coating thicknesses are on the order of 1-2% of component thickness (no fatigue credit)

Corrosion resistant layers and hard-facing are allowed

This avoids the large hurdles of Code acceptance Section II specifies material properties to be used for structural evaluation 8 Section III specifies design criteria for pressure retaining structuresSection XI specifies inspection and repair Cold spray is a mitigation technique rather than a defect repair Inspectability must be maintained Code relief would be required for inspection interval or technique changes Mitigation techniques have been addressed in Code Cases, as required Workshop on Advanced Manufacturing Technologies for NuclearApplications December 8, 2020 16 16 B-247

1/6 /2 0 2 1 Regulatory Aspects

NRC regulatory requirements are diverse, but manageable

Anticipated cold spray applications may fall under 10CFR50.59 requirements 10CFR50.59 allows plants to make engineering judgement to approve many applications NUREG 1927 discusses the use of corrosion resistant coatings to extend component life for spent fuel storage canisters

Technical justification reports would be required for many applications Demonstrate the process works to correct issue Has no adverse unintended consequences Does not affect other Code requirements (inspection, dimensional fit up, surfacefinish)

Workshop on Advanced Manufacturing Technologies for NuclearApplications December 8, 2020 17 17 Technical Justifications

Application specific technical reports could be used to document efficacy of cold spray

Several ASTM standards and military standards are available for guidance

Required coating characteristics should be addressed Porosity 9

Adhesion Corrosion and/or erosion resistance Surface finish Radionuclide activation considerations Thermal and mechanical constraints Other application specific attributes Workshop on Advanced Manufacturing Technologies for NuclearApplications December 8, 2020 18 18 B-248

1/6 /2 0 2 1 Acknowledgments Sponsors

Department of Energys office of Nuclear Energy

Department of Energys office of Environmental Management Collaborators

VRC Metal Systems

Army Research Laboratory

Exelon

Westinghouse

University of Wisconsin Madison

Penn State Applied Research Laboratory

Sandia National Laboratory Workshop on Advanced Manufacturing Technologies for NuclearApplications December 8, 2020 19 19 10 Thank you Workshop on Advanced Manufacturing Technologies for NuclearApplications 20 20 B-249

1/6/2 0 2 1 Cold Spray Mitigation &

Repair for Nuclear Applications KYLE W. JOHNSON, VRC METAL SYSTEMS NRC AMT WORKSHOP 2020 This material is based upon work supported by the Government under Contract No(s). DE-SC0017855 & DE-SC0017229. Any opinions, findings and conclusions or recommendations expressed in this material are those of the author(s) and do not necessarily reflect the views of theGovernment.

1 VRC Metal Systems

Cold Spray Equipment Manufacturer and Commercialization Partner, specializing in process development for Repair, Additive Manufacturing, Coating, and Joining applications.

Veteran Owned Small Business Established in 2012 focused primarily on DoD applications.

Headquartered in Rapid City, South Dakota. 3 US locations.

63 Full Time Staff 1 2

2 B-250

1/6/2 0 2 1 Problem - Seawater Corrosion

Corrosion of structural steels in military and industrial applications is a widespread problem

Cost to the US Navy:

2025% of total maintenance costs Corrosion mitigation and remediation -

Estimates as high as $4B Annually

Cost to Nuclear Energy:

Corrosionrelated causes of partial LWR outages $5M/year

Corrosionrelated causes of zero power LWR outages

$665M/year

Contribution of corrosion to LWR operation and maintenance (O&M) $2B/year

[1]

[1] Griesbach, T. J., Gordon, B. M., Materials aging management programs at nuclear power plants in the United States, Second International Symposium on Nuclear Power Plant Life Management, Shanghai, China, October 1518, 7007.

3 Stainless Steel Materials for Seawater Service Wrought Cast

Common Austenitic Grades 304L CF3

304 & 316 most common industrial wrought steels 304 CF8

CF series most commonly used cast stainless steel 304H CF10 316 CF8M

Cast Austenitic grades can contain up to 40% Ferrite, AL6XN CN3MN although higher levels of Ni and C stabilize Austenite in highly alloyed steels Alloy 20 CN7M 2

Even the most corrosion resistant grades are susceptible to

Stress Corrosion Cracking

Crevice Corrosion

Solution: Cold Spray Corrosion Mitigation 4

B-251

1/6/2 0 2 1 Solution - Cold Spray Corrosion Mitigation

Applied at Low Temperatures

Coatings can be applied as low as 400 °C

Dense and Highly Adherent

Less than 1% porosity and greater than 10ksi adhesion typical

Can be applied with Nitrogen for cost sensitive applications

Pure Metals (e.g. CPNi), Alloys (e.g. 316L) and Metal Matrix Composites (e.g. Ni / CrC) can be sprayed with high Deposition Efficiency.

Cold Spray contains crack retarding compressive residual stresses

Resists stress corrosion cracking

Corrosion Control Coatings typically nonstructural,

[2]

allowing quicker implementation.

[2] Parsi, A., Lareau, J., Gabriel, B., Champagne, V., Cold Spray Coatings for Prevention and Mitigation of Stress Corrosion Cracking, 2013 CSAT Workshop, Worcester, MA, 1819 June2013.

5 Solution - Cold Spray Corrosion Mitigation Cold Sprayed Nickel

Typical Cold Spray coatings exhibit porosity less than 1%.

Dependent on material and processing parameters

Polished cross section - No particles 3 can be seen

Etched cross section shows particle boundaries

Significant flattening observed 6

B-252

1/6/2 0 2 1 Case Study - Cold Spray CISCC Mitigation

Long term onsite is now being considered.

Large Existing Fleet Made from welded 304SS Known for susceptibility to SCC

Chlorineassisted SCC threshold in austenitic stainless steel as low as 80100 MPa

304 stainless steel girth welds are likely sites for initiation and propagation of SCC

Dry Canisters not readily maintainable

Difficult to inspect and repair

Potential for CISCC environment to form, especially near seawater [3]

Canister removal and replacement or repair costly

Cold Spray Corrosion Resistant Coatings with Compressive Residual Stresses Offer an Ideal Solution to CISCC Mitigation.

[3] Haigh, R.D.; Hutchings, M. T.; James, J. A. ; Ganguly, S.; Mizuno, R.; Ogawa, K.; Okido, S.; Paradowska, A.M. and Fitzpatrick, M. E. (2013). Neutron diffraction residual stress measurements on girth welded 304 stainless steel pipes with weld metal deposited up to half and full pipe wall thickness. International Journal of Pressure Vessels and Piping, 101 pp. 1-11.

7 Case Study - Cold Spray CISCC Mitigation

ASTMG36 Boiling MgCl testing Uncoated 304L

Very effective cracking of 304 and 316 Stainless

Boiling point of 140 °C assures cracking efficacy.

MgCl Concentration Increased to achieve 140 °C

Samples welded to create tensile residual 4 stresses.

Coated 304L

Uncoated and Cold Spray Coated Samples tested

Samples exposed for 24 hours2.777778e-4 days 0.00667 hours 3.968254e-5 weeks 9.132e-6 months

Extensive and deep CISCC on Uncoated 304L

No cracking observed on Coated 304L 8

B-253

1/6/2 0 2 1 Case Study - Cold Spray CISCC Mitigation The Challenge Can the Cold Spray solution be applied in a difficultto access application?

YES!

Cold Spray Mitigation coatings have been demonstrated in laboratory mockup canisters and in field conditions.

Coatings can be applied within Overpack from a modified inspection crawler.

Demonstrations have been performed in laboratory and field environments for vertical canisters using upper vent access.

Mockup demonstrations include straightvent & stepped vent access and direct overpack placement designs.

Field demonstrations have been performed on an ISFISI.

9 Case Study - Cold Spray CISCC Mitigation 5

10 B-254

1/6/2 0 2 1 Case Study - Cold Spray CISCC Mitigation

Cold Spray CISCC Mitigation has been successfully deployed on an active ISFSI within a commercial vertical canister system.

Developed with and approved by customer.

Independently analyzed and verified.

Commercial Grade Dedication Process

Deployed within a heated test canister

Integrated into LongTerm Inspection and Mitigation Plan Inspect Thickness Stability Adhesion Porosity Tensile Strength ability Capability Tech. Obj. Y Y > 10 ksi <2% > 36 ksi > 0.100 in.

Result Y Y > 11.2 ksi 0.6 % 40.6 ksi 0.103 in.

11 Case Study - Seawater Crevice Corrosion Mitigation Crevice corrosion plagues even the most seawater corrosion resistant materials

Especially prevalent in quiescent or slowmoving seawater & brackish water.

Cold Spray offers the ability to apply extremely crevice corrosion resistant materials to isolate 6 structural materials.

Example Seawater Handling Check Valve

CN3MN - Cast SS, High Mo

Crevice Corrosion on flange faces

Casting Defects can lead to pitting and Leakage. 1 2

12 B-255

1/6/2 0 2 1 Case Study - Seawater Crevice Corrosion Mitigation For this application, Focus on Nitrogensprayed coatings on AL6XN

High Nickel Materials with hard phase blend

Titaniumbased coatings and hard phase blends Commercially Pure Titanium (CPTi) best performer in ASTM G192 repassivation crevice corrosion tests.

A59/CRC on AL6XN C276/CRC on AL6XN CPTi on AL6XN CPTi/TiC on AL6XN 0.05% Porosity 0.75% Porosity 1.00% Porosity ~1.00% Porosity

+10 ksi Glue +10 ksi Glue 4.61 ksi Adhesion +10 ksi Glue 13 Case Study - Seawater Crevice Corrosion Mitigation

LongTerm Seawater Exposure Crevice Corrosion Testing

Candidate Materials Tested on AL6XN Substrates with Crevice Formers

LongTerm Exposure to Chesapeake Bay water, silt, and organic matter.

10 May 2019 - 36 cold sprayed sampled + 9 controls installed

10 Sept. 2019 - Half of the sample set pulled for inspection

3 Feb. 2020 - Remainder of sample set pulled for inspection 7

No Crevice or Galvanic Corrosion observed in CPTi materials AL6XN C276 / CrC Alloy 59 / CrC CPTi CPTi / TiC 14 B-256

1/6/2 0 2 1 Case Study - Seawater Crevice Corrosion Mitigation

Application of Tibased coating for crevice corrosion resistance

Excellent adhesion to AL6XN, low porosity, equivalent or higher hardness, no crevice corrosion

Qualification Plan developed with and approved by customer

Adhesion, Porosity, Hardness, Deposition Efficiency

Additional testing for impact resistance, thermal cycling, and salt fog galvanic to ensure no cracking, spallation, or corrosion will occur in the application.

Deposition Impact Thermal Salt Fog Adhesion Porosity* Hardness Efficiency Resistance Cycling Galvanic Tech. Obj. > 10 ksi <1% None > 50% No Cracking No Spallation No Corrosion Result > 11.3 ksi 0.73 % 188 HV 62% Pass Pass Pass

Porosity of Metal Matrix between Carbide Hard Phases 15 Case Study - Seawater Crevice Corrosion Mitigation

Cold Spray Tibased coating applied to the flange and internal surfaces.

Coating application performed at VRC Spray Operations Facility, Box Elder, SD.

Before After 8 16 B-257

1/6/2 0 2 1 Case Study - Seawater Crevice Corrosion Mitigation

Cold Spray Application Process

1. Apply targeted cold spray nonstructural fill to crevice sites and blended defects.

Hand Application

2. Apply uniform cold spray coating robotically. + Targeted Fill

3. PostMachine, as necessary. Less Uniform

4. Repeat for all component sections.

Applicable to various seawater handling components.

Process travelers and quality control processes Robotic Application developed and maintained. + Uniform Coating Conformally builds defects Witness Coupons collected and tested.

Results within Acceptance Criteria Outlet Flange Section 17 Conclusions

High Pressure Cold Spray can be used to generate coatings of extremely corrosion resistant materials at low temperatures.

Compressive residual stresses present in the coating help prevent stress corrosion cracking.

Cold Sprayed coatings can be applied in critical applications to protect sensitive materials in corrosive environments, key points:

Material Selection is Critical!

Process Parameter development, process control, and inprocess monitoring are important to achieve 9 desired coating performance and quality assurance.

Select applications that make sense for cold spray

High Value, Temperature Sensitive Components for Critical Applications

Applications where InSitu restoration / mitigation is necessary

Potential Future Applications

High Capacity, High Level Waste Tanks

InSitu Dimensional Restoration of Steam Erosion in Secondary Systems 18 B-258

1/6/2 0 2 1 Thank You!

DOE SBIR Program Sponsors South Dakota School of Mines & Technology John Orchard, Prasad Nair, Bharat Jasthi & Team

& Sue Lesica Southern California Edison Exelon Generation Allen Williams & SONGS Team Lee Friant Electric Power Research Institute Robotic Technologies of Tennessee Jeremy Renshaw & Jonathan Tatman Jamie Beard & Andrew Braynt Pacific Northwest National Lab Ken Ross & Jack Lareau 19 10 B-259

1/6/2 0 2 1 Laser Glazing Of Cold Sprayed Coatings For The Mitigation Of Stress Corrosion Cracking In Light Water Reactor (LWR)Applications A. M. Stutzman, P. E. Albert, E. W. Reutzel, D. E. Wolfe, Penn State University B. Alexandreanu, Argonne National Laboratory A. K. Rai, R. S. Bhattacharya, UES Inc.

NRC Workshop on Advanced Manufacturing Technologies for Nuclear Applications, Virtual, December 710, 2020 Research sponsored by the Office of Science (STTR), THE U.S. DEPARTMENT OF ENERGY Contract No. DESC0004356, Program Manager Sue Lesica 11/30/2020 1 1

Background

Nickelbased Alloy 600 and its associated weldments Alloys 82/182 have commonly been utilized as structural material for the light water reactor (LWR) components

LWR components operate in harsh environment and may be subject to degradation; a major form of degradation is stress corrosion cracking (SCC)

Compromises safety and reliability of reactors Reduces operational life 1

Different approaches can be taken to mitigate SCC for improved safety, reliability and enhanced operational life of the reactors

a. Replace degraded components as the need arises (expensive)

b. Insitu repair of degraded components and welds 11/30/2020 2 2

B-260

1/6/2 0 2 1 Objectives and Approach

1. Develop and demonstrate the potential of a hybrid process of cold spray (CS) and laser glazing to mitigate stress corrosion cracking of Alloy 600 and associated weldment Alloy 182 material in a simulated pressurized water reactor (PWR) environment Use alloys known to be SCC susceptible, Alloy 600 and Alloy 182 (a weldment prototypic of those used in nuclear industry was produced for this program)

Use SCCresistant Alloy 690 for coating

2. Develop a method to quantify the effect of the hybrid process on SCC growth in Alloy 600 or Alloy 182 Use interrupted crack growth rate (CGR) testing in simulated reactor environment to measure SCC CGRs prior and after the application of the hybrid process 11/30/2020 3 3

SCC Mitigation - Test Plan

Coat SCCprone materials (A600 and A182) with SCCresistant material (A690) by CS

Posttreat coating with laser glazing to further densify and smooth out surface Enhanced corrosion protection Repair unsealed cracks in the substrate beneath the CS coating 2

Analyze fusion zone area (depth, width) as a function of laser glazing parameters (power, traverse speed)

Evaluate effectiveness of the hybrid treatment SCC crack growth rate (CGR) testing using realistic samples and environments 11/30/2020 4 4

B-261

1/6/2 0 2 1 Cold Spray Alloy 690 powder (1045µm), Carpenter Powder Products, Bridgeville, Pa CS Equipment: Impact Innovations ISS5/11 11/30/2020 5 5

Cold Spray - Parameter Optimization (Microstructure)

Resulting microstructure vs. parameters 3

11/30/2020 6 6

B-262

1/6/2 0 2 1 Cold Spray - Parameter Optimization (Porosity)

Resulting porosity vs. parameters 500C/40bars 800C/50bars Avg. Porosity = 2.434+/-1.404 Avg. Porosity = 0.116+/-0.041 11/30/2020 7 7

Cold Spray - Optimized Parameters Parameter Value

Powder CPP 690/-325 mesh + 10 m

Gas type and flow rate Nitrogen/97 m3/Hr

Gas temperature & pressure 800C/50 bars

Powder feed rate/vibration 2.0 and 1.5 RPM/60%

4

carrier gas flow rate 3.0 m3/Hr

Substrate material/dimensions Alloy 600/2.2 x 12 x 0.25

Spray distance 25 mm

Coating spec 100, 150 and 200 m

Blast grit/pressure/distance 46 grit alumina/60 psi/20.0

Spray direction Along the 12 direction

Robot speed 1000 mm/s

Step size 1.0 mm 11/30/2020 8 8

B-263

1/6/2 0 2 1 Laser Glazing of CS Coating of A690 onA600

Single pass verse multipass laser trials were compared to see the impact on fusion zone (depth and width) 11/30/2020 9 9

Single Pass Laser Glazing

Cross sectional fusion zone area increases with increasing laser power

Cross sectional fusion zone area increases with decreasing traverse velocity 5

11/30/2020 10 10 B-264

1/6/2 0 2 1 Multiple Pass Laser Glazing

Cross sectional fusion zone area increases with increasing laser power

Cross sectional fusion zone area increases with decreasing traverse velocity

Cross sectional fusion zone area for multiple pass shows on average larger areas relative to single pass 11/30/2020 11 11 Adhesion Testing for Selected Cold Sprayed and Laser Glazing Parameters Example Layout of Adhesion Slugs, Testedin Sets of Four (4)

As Cold Sprayed Adhesion Slugs A690 Schematic 2.2 6

2.2

2.2x2.2x0.25

Wire EDM four (4), 1.0 buttons from 2.2 square

Adhesion strength was nearly the same regardless of grit blasting the surface prior for non laser glazed samples

Adhesion did increase in laser glazed samples where the surface was initially grit blasted 12 12 B-265

1/6/2 0 2 1 Further Evaluation - CT Specimen Geometry

Practice laser glazing runs were made on machined grooves on a piece spanning three materials:

without A690 powder (grooves 16) and with A690 (grooves 712)

The machined grooves were matched in terms of depth and width of the CT specimen A182 A600 A533 11/30/2020 13 13 Further Evaluation - CT Specimen Geometry

Treated (a) A600, (b) A182 and (c) A533 to determine depth and width of the fusion zone with and without Alloy 690 powder (a)

(b) 7 (c) 11/30/2020 14 14 B-266

1/6/2 0 2 1 Evaluation of Effectiveness of HybridTreatment SCC CGR Testing Sequence

1) SCC growth was first induced in a compact tension (CT) test specimen of Alloy 600 or Alloy 182 exposed to a high temperature water environment, and an initial SCC CGR is measured. Target crack depth was 0.5 mm.

2) Then, the CT specimen is removed from the test to allow for the hybrid treatment to be applied. Due to the notch geometry, we were not able to CS the crack. To demonstrate repair feasibility (fill and seal the crack), powder was laid and laser glazed 11/30/2020 15 15 Evaluation of Effectiveness of HybridTreatment SCC CGR Testing Sequence

3) The groove on both sides (A and B) and the notch were treated with the hybrid treatment.

4) The specimen is reintroduced into the same environment, and under the same loading, and a new SCC CGR is measured If the hybrid treatment is effective at mitigating SCC, the SCC crack is sealed, and 8

the SCC CGR measured after the application of the treatment is reduced vs. the CGR measured prior to the treatment One specimen (A600ST1) was destructively examined posttest, whereas two specimens (A600ST2 and A182ST2) were not destructively examined posttest; the intent is to conduct fatigue CGR testing to determine whether the response is consistent with Alloy 600, 690, 182 or not - further substantiating the effectiveness of the repair 11/30/2020 16 16 B-267

1/6/2 0 2 1 SCCCGR Test Before Hybrid Treatment (A600ST1)

Test was initiated with fatigue precracking and transitioned to SCC growth in the primary water environment Alloy 600 Heat NX131031 Alloy 600 Heat NX131031 Specimen A600-ST-1 10 -7 Simulated P W R W ater at 320°C 10 -9 Simulated P W R W ater at 325°C Best-Fit Curve for A600 CGR a i r + 4.4 x 10 -7 (CGR air ) 0.33 95th 10 -8 Experimental CGR (m/s) 90th 10 -10 75th Percentile CGRenv (m/s)

(MRP-55) 10 -9 25th 10 -10 10 -11 10 -11 C G R env 600 (NUREG-4667) 10 -12 A600-ST-1 A690-ST-1 10 -12 10 -12 10 -11 10 -10 10 -9 10 -8 10 -7 10 15 20 25 30 35 40 45 CGR air Ni-weld alloys (m/s) Stress Intensity K (MPa*m 1/2 )

11/30/2020 17 17 SCCCGR Test Before And After Hybrid Treatment (A600ST1)

Specimen A600ST1 specimen was processed with Alloy 690 powder and laser glazing (200 W, 12.7 mm/s:30IPM)

Initial SCC CGR resumed shortly after the treatment Hybrid Treatment 9

11/30/2020 18 18 B-268

1/6/2 0 2 1 A600ST1: Posttest Examination

Post test examination suggests that the crack did not seal -

particularly the side grooves of the CT specimen 11/30/2020 19 19 A600ST1: Posttest Examination

Post test examination found areas that did seal, however, the side grooves remained open

Findings informed treatment of the subsequent Specimen A690TS2 10 11/30/2020 20 20 B-269

1/6/2 0 2 1 CGR Test Before Hybrid Treatment (A600ST2)

As before, test was initiated with fatigue precracking and transitioned to SCC growth in the primary water environment.

Identical cyclic and SCC CGR response 11/30/2020 21 21 A600ST2 - Prereinsertion Examination

Prereinsertion examination suggests that the crack did seal Groove A 11 Notch Groove B 11/30/2020 22 22 B-270

1/6/2 0 2 1 A600ST2: SCC CGR Response Before and After the Hybrid Process

Specimen A600ST2 was processed using two laser glazing steps:

500 W at 25.4 mm/s followed by 300 W at 25.4 mm/s

Growth did not reinitiate cracking in 1200 h (FOI > 220 assuming detection limit 5 x 1013 m/s)

Hybrid Treatment 11/30/2020 23 23 Alloy 182 SCC CGR Testing

Two SCC CGR tests were conducted on Alloy 182 (Specimens A182TS1 and A600TS2)

Both tests were initiated with fatigue precracking and transitioned to SCC growth in the primary water environment.

10-7 Alloy 182 double-J Heat 869644 Alloy 182 double-J Heat 869644 Simulated PWR Water at 320°C Simulated PWR Water at 320°C 10-9 10-8 Best Fit Curve for Alloy 182 75th Percentile (MRP-115)

CGRair + 0.018 (CGRair)0.78 Experimental CGR (m/s) 10-10 25th 12 10-9 CGRenv (m/s) 10-11 10-10 10-12 10-11 CGR env weld (NUREG-6921) A182-TS-1 A182-TS-1 A182-TS-2 A182-TS-2 10-12 10-13 10 20 30 40 50 10-12 10-11 10-10 10-9 10-8 10-7 Stress Intensity K (MPa*m1/2)

CGRair Ni-weld alloys (m/s) 11/30/2020 24 24 B-271

1/6/2 0 2 1 SCCCGR Test Before And After Hybrid Process (A182TS1)

Initial test on Alloy 182 (Specimen A182TS1). Processed with 2 laser glazing steps that were successful for Alloy 690 (500 W at 25.4 mm/s followed by 300 W at 25.4 mm/s)

As with A690TS2 previously, decision was made to further adjust laser parameters 11.90 45 Hybrid Alloy 182 double-J Heat 869644 Specimen A182-TS-1 11.88 Simulated PWR Water at 320°C 40 Treatment Period 5 Period 6 11.86 Crack Length (mm) 3.3 x 10-11 m/s 2.9 x 10-11 m/s 35 24.5 MPa m0.5 24.5 MPa m0.5 Constant load Constant load 11.84 30 Kmax (MPa m0.5)

Crack Length 11.82 25 11.80 Kmax 20 11.78 15 200 400 600 800 1000 Time (h) 11/30/2020 25 25 Optimized Laser Glazing Parameters in Alloy 182 Weld (A182TS2)

As before, optimized laser glazing parameters for Alloy 182 (Specimen A182TS2), notch and both side grooves were included

Three laser glazing steps were used (IG interdendritic morphology in the weld may not be as uniform as that of the base metal)

Laser Power Travel Shielding Focus Head Spot Setting Speed Gas Standoff Size Comments 13 (watts) (IPM) (L/min) (mm) (mm) 500 60 25 18.62 1 preheat to 400 C side A, A690 powder added 500 60 25 18.62 1 preheat to 400 C side B, A690 powder added 500 60 25 18.87 1 preheat to 400 C side Notch, A690 powder added 11/30/2020 26 26 B-272

1/6/2 0 2 1 A182TS2 - Prereinsertion Examination

Pretest examination suggests that the crack did seal Groove A Notch Groove B 11/30/2020 27 27 SCCCGR Test Before And After Hybrid Process (A182TS2)

Optimized, three laser glazing parameters were used on Alloy 182 Specimen A182TS2 (FOI = 14, not as high as the one for the base metal, suggests crack morphology plays a role) 12.90 Alloy 182 double-J Heat 869644 12.80 Specimen A182-TS-2 Hybrid 60 Simulated PWR Water at 320°C Treatment 14X Period 4 12.70 1.1 x 10-10 m/s 50 Crack Length (mm) 28.0 MPa m0.5 14 Constant load Period 5 12.60 8.4 x 10-12 m/s Crack Length 28.0 MPa m0.5 40 Kmax (MPa 12.50 Constant load m0.5) 12.40 30 12.30 Kmax 20 12.20 200 400 600 800 1000 1200 1400 1600 Time (h) 11/30/2020 28 28 B-273

1/6/2 0 2 1 Summary

1. Alloys 600 and 182 weld were selected as the SCCprone substrate materials. Alloy 690, an alloy with superior resistance to SCC was selected as the repair material.

2. CS processing parameters were optimized to fabricate denser and highly adherent coatings of Alloy 690 powders. The adhesion strength of the coating with the substrate was determined and found to be very high (>8140PSI).

3. Several laser processing tests were conducted on uncoated and CScoated alloy substrates to determine optimal conditions for the repair (sealing) of underlying cracks at a given depth/dimension.

4. Using the optimized laser and CS parameters, hybrid treatments were further adapted and optimized for the compact tension (CT) specimen geometry used in SCC CGR testing and sharp cracks

5. A method to quantify the effectiveness of the hybrid process to seal the cracks, thus mitigating SCC growth in Alloys 600/182 was developed: interrupted crack growth rate (CGR) testing to measure SCC CGRs prior and after the application of the treatment

6. SCC CGR testing have shown that under optimal conditions, the hybrid treatment sealed the crack, and substantial reductions in CGR of 220x in Alloy 600 and 14x in Alloy 182 were achieved for test durations of ~1000 hours demonstrating the feasibility of the lasercold spray hybrid process to mitigate SCC.

11/30/2020 29 29 Future Work

1. Utilize repaired A600ST2 and A182TS2 specimens to conduct fatigue CGR testing to determine whether the response is consistent with Alloy 600, 690, 182 or not - further substantiating the effectiveness of the repair.

2. Utilize cold spray and/or hybrid treatment to develop coatings for corrosion resistance and/or tritium permeation in molten salt environment of advanced 15 high temperature reactors (AHTRs) 11/30/2020 30 30 B-274

US NRC Workshop on Advanced Manufacturing Westinghouse AM Thimble Plugging Device /

Advanced Debris Filtering Bottom Nozzle Implementation Process David Huegel, Fuel Product Technical Lead 1

Agenda

Westinghouse AM Objectives

Advanced AM Components

Reactor Ready Component

Licensing of AM TPD

Advanced AM Debris Filter Bottom Nozzle 2

2 B-275 1

Westinghouse AM Objective

Westinghouse is using the AM process to produce high quality

/ high performance fuel products for use in commercial nuclear reactors.

Westinghouse has performed significant testing, designing, prototype building, verifying design characteristics, validating material properties, etc. to ensure that the AM process is fully understood and thus can be safely used for producing fuel components for use in commercial reactors.

AM Provides Significant Benefits Relative to Existing Manufacturing Methods 3

Advanced AM Components - Bottom Nozzles Numerous Advanced AM Component designs have been developed and tested by Westinghouse and are close to being implemented via Lead Test Assembly Programs

Advanced AM debris filtering bottom nozzle created

Low Pressure drop

Improved filtering performance

Improved structural support via use of Alloy 718 AM Optimizes performance 4

4 B-276 2

Reactor Ready Component Project

Kaizen Event Held to Select Demonstration Component - Dec 2014

- Thimble Plugging Device (TPD) selected as the first AM Fuels component to be placed in a commercial reactor as a demonstration component

- Low risk component, moderate complexity, fully contained in guide thimble tubes.

- AM TPD is equivalent in Form, Fit and Function as existing TPD.

Completed testing, analysis, quality assurance, manufacturing qualification, licensing, etc. to support one production AM TPD

Working with Exelon, the AM TPD was delivered for the Byron Unit 1 Spring 2020 Outage via 10CFR50.59 5

Westinghouse AM Testing and Analyses Summary

Westinghouse performed significant work to support the AM components, including for the first application of the AM TPD.

- 2015-2017: Mech. Testing of AM test specimens irradiated in MIT reactor

- 2016-2018: Autoclave Testing of AM Type 316L SS and AM Alloy 718

- 2015-2019: AM Thimble Plugging Device (TPD) testing

Extensive testing of the AM TPD including in comparison to the current TPD design

Density Evaluation of AM Type 316L SS

Defect evaluation via dye penetrant testing for AM TPD

Microstructure Evaluation for presence of voids or porosity

- 2019: US NRC Issues Action Plan for AMTs including request for a candidate AM component for which W offered the AM TPD.

- May 2019: Westinghouse met with NRC at W Rockville offices and covered all aspects of the development, design, manufacture, quality assurance/control, licensing, etc. of the AM TPD.

6 6

B-277 3

Mechanical Testing Irradiated AM Specimens

Unirradiated and irradiated tensile testing of AM 316 SS and Alloy 718 materials inside WEC hot cell.

Room Temp and elevated Intact irradiated quad held with Temp (i.e., 572°F) tensile hot cell grips prior to separation into 4 individual miniature testing of ~50 AM 316SS tensile specimens specimens and ~50 AM Alloy 718 specimens.

Extensive unirradiated Video monitor and irradiated materials displaying in-cell camera live feed evaluations completed.

7 7

Mechanical Testing - AM 316 SS Performance Irradiated AM Specimen SX51 US NRC AMT Action Plan:

Testing performed to assess irradiation and aqueous environment effects on the performance of AMTs.

8 8

B-278 4

Manufacturing Validation Process

Three confirmatory AM TPD builds were created utilizing the same AM machine, same lot of material and same process parameters. Each of these builds included witness specimens and tensile bars.

Two builds were destructively tested along with the witness specimens to establish consistency of the witness specimen results.

US NRC AMT Action Plan:

Discusses the need to investigate state-of-the-art modeling and simulation tools being developed to predict AM microstructure and properties of AMT materials, to provide a path for validating the acceptability of AMT components similar to the use of witness specimens and lot testing.

9 9

Westinghouse AM TPD Testing Mechanical Testing of AM TPDs:

Mechanical testing was performed for the existing and the AM TPDs. Testing included axial pull tests, lateral bending tests and baseplate weld integrity tests.

Performance of the AM TPD was consistent with the existing TPD.

All TPD mechanical design criteria satisfied.

NRC AMT Action Plan:

- Testing should address differences between AMTs and traditional manufacturing processes from a performance-based perspective. Focus should be on those performance characteristics pertinent to safety that deviate from traditional manufacturing requirements.

10 10 B-279 5

ASTM E-8 Tensile Specimen Testing

ASTM E-8 Tensile specimens cut from AM TPD

Tensile testing performed on resulting ASTM E-8 Tensile specimens.

ASTM specimens from X and Y cylinders Z Specimens from Z cylinder US NRC AMT Action Plan: and from select AM rodlets

Performance criteria for the AMT component may include physical properties, mechanical properties, dimensionality, functionality, and reliability.

Westinghouse AM TPD Testing Additional Testing and Evaluation:

Dye Penetration Testing:

Dye penetrant testing was performed on the complete AM TPD and there were no observed defects.

Microstructure Evaluation:

Cylinders were created from the AM Rodlets and were cut in half and polished and examined at 50x magnification and found to be free of voids or porosity.

Density Evaluation:

Cylinders were created from the AM Rodlets and were evaluated for density and were determined to be consistent with wrought 316L Stainless Steel material.

US NRC AMT Action Plan:

Adequate information to demonstrate whether inspection and non-destructive examination (NDE) techniques are sufficient to assess the condition of AMT-fabricated components, and in particular for the types of defects that can compromise the safe performance of the component and can accelerate degradation of the component during service.

12 12 B-280 6

Manufacturing Verification Process

ASME NQA-1-2008: Requirement 3 - 300 Design Process states the following:

- (2) specify required inspections and tests and include or reference appropriate acceptance criteria

Westinghouse Product Spec. (PDTPAM00) for AM TPD

- Process Plan, Manufacturing Qualification, Safety related Properties

Product identification, Chemical composition, mechanical properties, grain structure density, etc.

Design is controlled consistent with 10 CFR 50 Appendix B

US NRC AMT Action Plan:

Consistent with 10 CFR Part 50 Appendix B requirements, each processing step is to be performed using a quality assurance procedure with appropriate documentation. Critical processing parameters will be identified along with the parameter values and a technical basis for the values. The compliance with requirements of the pertinent processing standard shall be confirmed in an appropriate manner, such as process logs, inspection, and testing.

AM TPD Implemented using 50.59 Process

Equivalent in form, fit, and function with minor changes which screen out - no adverse impact on the design function

No changes to design and safety criteria

The AM process does not adversely affect the manner in which any plant design function is performed or controlled.

There are no system design or operation changes.

This activity does not involve a safety analysis methodology change.

This activity does not involve a test or experiment.

This activity does not require any Technical Specification (TS) changes.

14 14 B-281 7

Post Irradiation Evaluation of AM TPD

Post Irradiation Examination (PIE)

- Westinghouse currently plans on performing inspections of the AM TPD which will include detailed visual inspections with a high-resolution camera system as well as performing drag tests.

US NRC AMT Action Plan:

Although there is nothing specific regarding PIEs, Subtask 2C: AMT Guidance Document mentions that a report will be created to be used as a resource for staff reviews of AMTs and includes the topic of "In-Service Inspection" 15 15 Westinghouse Non-Proprietary Class 3 © 2020 Westinghouse Electric Company LLC. All Rights Reserved.

AM Advanced Debris Filter Bottom Nozzle

Full size AM Advanced Debris Filter Bottom Nozzle

- Reduced pressure drop

- Improved Filtering capability

Pursuing the licensing of Lead Test Assembly AM Bottom Nozzles (4 to 8) using the 50.59 process.

Coordinating with the NRC to ensure licensing approach is acceptable.

Licensing support will include GSI-191 testing to demonstrate acceptability of design 16 16 B-282 8

Summary

Westinghouse has invested significant time and effort thoroughly evaluating the Additively Manufactured process for application to fuel components for a commercial reactor.

Material and Mechanical Property Testing concluded that AM Properties are consistent with conventional wrought material.

First reactor ready component (AM TPD) installed in Byron Unit 1 in the spring of 2020.

Westinghouse continues to pursue through testing and development of advanced AM components following guidance provided in the US NRC Action Plan on AMTs.

Questions

?

18 18 B-283 9

1/6 /2 0 2 1 316L Stainless Steel Manufactured via Laser Powder Bed Fusion Additive Manufacturing Data Package & Code Case D. Gandy, S. Tate, M. Albert (EPRI)

C. Armstrong (Westinghouse)

U.S. NRC Workshop on Advanced Manufacturing Technologies for Nuclear Applications December 9, 2020 DOE Project:

1 A Few Attributes of LPBF-AM Attractive for pressure retaining applications across the power, chemical, process, and pulp & paper industries, etc. including:

1. Speed to produce a final part/component

2. Capability to produce multiple parts using identical parameters with little or no variance between the parts

3. Ability to monitor/capture build conditions throughout the build process

4. Ability to produce structural parts with optimized support / features, enabling lighter and/or stronger components 1

2 B-284

1/6 /2 0 2 1 AM Qualification for Nuclear Applications

--ASME Data Package Development DOE Project: DENE0008521 EPRI lead Five organizations involved

- RollsRoyce

- Westinghouse

- ORNL MDF

- Auburn University

3 AM Qualification for Nuclear Applications

--ASME Data Package Development 2 Types of machines

- EOS, Renishaw 4 sets of processing parameters 4 different 316L powder heats 3 different components (next slide)

Components are >8inches in diameter and ~0.5 inch thick Different build environments argon and nitrogen 2 Two conditions: HIP and SA; SA only EOS M290 System Vertical control/witness samples included Courtesy: Westinghouse /

4 B-285

1/6 /2 0 2 1 AM Qualification for Nuclear Applications

--ASME Data Package Development Class 300 Forged Gate Valve Body Ring Flange End Connection Straight Pipe Tee 8Ø x 2bore x 4OD x 1/2T 8.5Ø x 1.5T x 2 bore 8-1/4W x 4-1/8T 5 www.epri.com © 2020 Electric Power Research Institute, Inc. All rights reserved.

5 3

6 B-286

7 4

8 B-287

9 Chemical Composition of 316L SS Powder 5

10 B-288

12 B-289

1/6 /2 0 2 1 Pipe Tee Section - Auburn U.

13 Ring Flange End Connection - Westinghouse 7

14 B-290

15 HIP & Solution Annealed Solution Annealed only 8

16 B-291

17 Charpy Impact Results - Solution Anneal only 9

18 B-292

20 B-293

1/6 /2 0 2 1 Yield and Tensile Strength as a Function of Temperature Note: Shift (lower) in Westinghouse Yield and Ultimate Strength between 260°C (500°F) and 287.8°C (550°F), is due to the transition from Z to XY direction specimens See slide 14 for specimen layout and slides 19 and 20 for associated tensile results 21 www.epri.com © 2020 Electric Power Research Institute, Inc. All rights reserved.

22 B-294

23 Summary Three components, 5 builds performed

>0.50inch thick components (for testing)

All builds provide acceptable microstructural and mechanical properties

- HIP and Solution annealed

24 B-295

1/6 /2 0 2 1 Draft ASME Section III Code Case for LPBF AM 316L Submitted to Section III MF&E subcommittee for August 2020 Code Week

- Record # 20254

- Section III, Division 1 - Subsection NB/NC/ND, Class 1, 2 and 3 Components Standard ASME approach of calling out ASTM material / process spec and adding clarifications and additional requirements

- ASTM F318416 is base spec for LPBF 316L

- Significant clarification required due many requirements are left open to be agreed upon by the component supplier and purchaser Proposes use of HIP (per ASTM F318416 section 13, Condition C) plus Solution Anneal (per ASTM F318416 section 12.2, Condition B)

25 Draft ASME Section III Code Case for LPBF AM 316L (Cond)

Design stress intensity values and the maximum allowable stress values are included in the code case Tables 1(1M) and 2(2M)

Feedstock powder: Recert after 10 uses and max powder size of 100um Manufacturing plan: requiring documentation of essential process parameters Witness specimens, in 2 limiting locations: tensile (4x), hardnes (1x),

microstructure (Z & XY, 100X & 500X), chemistry (1x, 1st and last build only)

UT and RT per the subarticle of NB/NC/ND2500 applicable to the product 13 form being produced Components shall be pressure tested per NB6000 Neutron dose <7x1020 n/cm2 (E > 1 MeV) for designlife 26 www.epri.com © 2020 Electric Power Research Institute, Inc. All rights reserved.

26 B-296

1/6 /2 0 2 1 Next Steps AM 316L Code Case Routing

- David Gandy has been appointed project manager for the code case

- EPRI is completing weld testing & weldment data will be added to the data package

- The code case will go through ASME commenting, editing and balloting

- It will likely be routed to Section II (Materials) and potentially Section IX (welding) for review Additional Code Cases

- Directed energy deposition (DED) for valve production (Korean WG)

- Westinghouse is looking to collaborate on material testing, analysis, data package consolidation and code case submittals Currently producing 718 Ni Alloy, 304 SST, 174 PH, MS1, Haynes 230 and select high temperature alloys with LPBF ASME Interactions

28 B-297

1/6 /2 0 2 1 Acknowledgements US Department of Energy Tansel Selekler, Dirk Cairns-Gallimore, Isabella van Rooyen ORNL & UTKORNL Industry Suresh Babu, UTKORNL David Poole, RollsRoyce Fred List, ORNL Dane Buller, RollsRoyce Caitlin Hensley, UTKORNL Thomas Jones, RollsRoyce Kevin Sisco, UTKORNL Thomas Pomorski, Penn United Amy Godfrey, UTKORNL Technologies Serena Beauchamp, UTKORNL Brian Bishop, Oerlikon Xiao Lou, Auburn University 29 www.epri.com © 2020 Electric Power Research Institute, Inc. All rights reserved.

29 Backup Materials:

30 B-298

32 B-299

34 B-300

36 B-301

1/6/2021 Certification of the First Powder Bed Fusion Component in the US Naval Nuclear Propulsion Plant Tressa White, James Carter1, Steven Attanasio, Chelsea Snyder, William DePoppe, James Eliou Naval Nuclear Laboratory 1Huntington Ingalls Industries, Standard Navy Valve Yard The Naval Nuclear Laboratory is operated for the U.S. Department of Energy by Fluor Marine Propulsion Corporation, LLC, Tressa.White@unnpp.gov a wholly owned subsidiary of Fluor Corporation (518) 395-7925 1 1

Purpose

First attempt to make AM hardware suitable as a pressure boundary component for submarine propulsion plant operation.

Step through manufacturing and inspections to identify administrative or technical roadblocks.

Familiarize designers, pressure equipment safety, and quality groups with new material form.

Main Steam Condenser 2

2 B-302 1

1/6/2021 316L Material Processing NNL External Vendor 20 µm standard 40 µm proprietary EOS M290 EOS M280 HIP Cycle

>1900°F, 2 hr, min.

As-built As-HIPd 3

3 Acceptance Testing

Geometric equivalence

ASTM A182 strength, ductility, composition, and intergranular attack resistance

Density

Fatigue Crack Growth Rate Screening

Charpy & Fracture Toughness Screening

Weldability

Hydrostatic Test

Shock & Vibration Test

Prototypic Steam Test Certification testing happened in parallel with a large materials development program.

4 4

B-303 2

1/6/2021 Tensile Summary ASTM F3184 (L-PBF)

& ASTM A182 (forged)

MIL-DTL-23195 (forged) 5 5

Process Knowledge Gained

NNL Build 1 had many interruptions due to balling and excess powder supply.

Microscopy, radiography, &

mechanical data suggest the build was successfully recovered each time.

6 6

B-304 3

1/6/2021 Process Knowledge Gained

NNL Build 1 had many interruptions due to balling and excess powder supply.

Microscopy, radiography, &

mechanical data suggest the build was successfully recovered each time.

Part Witness Part appears stronger and less ductile than witness coupons, though differences were small.

7 7

Impact Energy & ToughnessSummary J-integral testing at room temperature also revealed high toughness of L-PBF materials

(>2600 in-lb/in2 or >455 kJ/m2).

8 8

B-305 4

1/6/2021 Fatigue Crack Growth at elevatedtemp.

9 9

AM Weldability Trial: autogenousGTA Bead on plate at same conditions AM plate Increased penetration in AM material, likely due to increased O content (540ppm vs. <10ppm)

Autogenous welding acceptable for strainer assembly.

10 10 B-306 5

1/6/2021 AM Weldability Trial: wire-fedGTA Dimpling Oxide floaters along edge to be ground 8 long butt joints using AWS-ER316L wire Welded in accordance with NAVSEA procedure AM-to-AM Weld Plate Control Weld AM (vert) to AM (horiz) AM (vert)

Plate to plate AM (horiz) to plate to plate Weldable? none Radiography &

Penetrant none Indications?

Tensile Strength 81 & 81 ksi 90 & 92 ksi 83 & 83 ksi 92 & 93 ksi (558 MPa) (621 & 634 MPa) (573 MPa) (634 & 641 MPa)

--failure location AM (vert) Weld AM (vert) Weld 20% Bend no defects Charpy HAZ > 100 ft-lbs (>136 J) propagation along epitaxy

> 150 ft-lbs

>150 ft-lbs (>203 J) propagation across epitaxy 11 11 Component Testing Prototypic Steam Shock & Vibration Simulate 1000s of start-up / Expose DSOs to typical fleet shock shutdown cycles and 100s of hot loads and worst case vibration operational hours. Parts did not frequencies while pressurized. Parts exhibit cracking or erosion. did not leak and were not damaged.

Proof Test Pressurized to >4.5 times the ASME Group 2.2 maximum allowable working pressure (2160 psig) before leaking at gasket.

12 12 B-307 6

1/6/2021 Summary

A focused, case-basis certification plan and final data package was approved by NAVSEA.

Approved in August.

Installed in September.

Steaming in October.

Subsequently ran a multi-site Design Challenge to encourage adoption by design engineers.

13 13 B-308 7

1/6/2021 On the Development of Federal Aviation Administration Fatigue and Damage Tolerance Framework for Metal AM Parts Presented at:

NRC Workshop on Advanced Manufacturing Technologies - Session 4 December 9, 2020 Presented by:

Dr. Michael Gorelik FAA Chief Scientist and Technical Advisor for Fatigue and Damage Tolerance 1

BLUF (bottom line upfront)

All the existing rules apply to AM

Need to consider unique / AM-specific attributes, especially for high-criticality components

Leverage industry and regulatory experience with other relevant material systems More on this topic in Dec. 10th presentation

Leverage public standards Federal Aviation 2 Administration 2

B-309 1

1/6/2021 Example: Moving Towards Safety-critical AM Parts Federal Aviation 3 Administration 3

State of Industry Need to mature F&DT framework for AM Today Level of Criticality Fracture-critical Static Time Federal Aviation 4 Administration 4

B-310 2

1/6/2021 C. R. Smith, Tips on Fatigue, Dept. of the Navy, 1963 Federal Aviation 5 Administration 5

System-Level View of F&DT Discipline Design &

Analysis Material Testing Data Fatigue

& DT QA and Mfg.

Controls Fleet Mgmt.

Maint. NDI and Repairs All elements of the system are essential to ensure safety Federal Aviation Administration 6

B-311 3

1/6/2021 Two Types of Anomalies that may result in life debit Rogue (rare) Inherent Anomalies Anomalies Examples: Examples:

Melt-related defects

Porosity in castings (hard alpha) in Ti

NMEs (non-metallic

Machining induced inclusions) in PM alloys Surface vs. Volume Federal Aviation 7 Administration 7

Categories of Anomalies by Location Surface Considerations

Crack initiation vs. propagation

Defect types Near-surface

NDI detectability

Size distribution

Frequency of occurrence

Effect of post-processing Sub-surface

Near-surface scan pattern (for PBF)

Photo credits: S. Jha et al, Fatigue Life Prediction OF Additively Manufactured Ti-6Al-4V, MS&T 2019, Portland, OR.

Federal Aviation 8 Administration 8

B-312 4

1/6/2021 Example: Porosity vs. Scan Speed Ref: N.T. Aboulkhair et al, Reducing porosity in AlSi10Mg parts processed by selective laser melting, Additive Manufacturing 1-4 (2014), pp. 77-86 Scanning speed Populations of AM defects can be a strong function of process parameters, and may need to be re-assessed if the process has changed Federal Aviation 9 Administration 9

Anomalies Characterization Methods

NDI (CT, Digital X-ray, UT)

Fractography

Serial sectioning Photo credits: V. Sundar et al, Microsc. Microanalysis 24 (Suppl 1), 2018, pp.554-555.

Key Outputs:

Can be combined in the

Size Distribution form of exceedance curves

Frequency of occurrence*) (see, for example, FAA AC 33.14-1 or AC 33.70-2)

) Typically, more challenging to quantify Federal Aviation Administration 10 B-313 5

1/6/2021 NDI Considerations for AM

Current lack of validated and quantified NDI capabilities for flaw detection in metal AM parts

Effective two-way dialogue is needed between the NDI and F&DT (fatigue and damage tolerance) communities of practice Focus on the largest flaw that can be missed, not the smallest flaw that can be found F&DT NDI Community Community of Practice of Practice

What types of defects

What are the quantifiable need to be detected? detection capabilities for

What is the range of a given class of defects defect sizes that need (QNDI)?

to be reliably detected?

Federal Aviation 11 Administration 11 Example: Cross-Committee Collaboration (SDO-level)

Federal Aviation 12 Administration 12 B-314 6

1/6/2021 Detection Capability vs. Flaw Size Distribution pdf

Relative position of these curves, as Flaw Size well as critical flaw POD Distribution size, are crucial to the understanding Critical Flaw of the Size effectiveness of F&DT framework

Needs to be

? assessed for each type of AM anomaly a

Federal Aviation 13 Administration 13 Residual Stress (RS) Considerations Measurement / modeling Unfavorable residual stresses capabilities for beneficial resulting from manufacturing engineered residual process may significantly stresses continue to reduce components safe life advance (by 10x or more), as well as DT capabilities Existing F&DT assessment tools can largely account for the presence of residual stresses Federal Aviation Administration 14 B-315 7

1/6/2021 Example: RS in Aluminum Forgings the detrimental effects of tensile RS can be mitigated and/or managed during design by establishing and imposing appropriate requirements for their location, spatial distribution and magnitude, and for the inclusion of their effects during design structural analyses.

Federal Aviation 15 Administration 15 Example - Smarter Testing (BCA)

Use of advanced analysis techniques using fundamental (coupon-derived) inputs can lead to reduced quantities of program-led mid-level structural tests, reducing airplane development costs and risks.

AM presents new challenges for certification in that there are no traditional validated analysis methods suited to the arbitrary and organic nature of many AM parts Credits: S. Chisholm et al, Smarter Testing Through Simulation for Efficient Design and Attainment of Regulatory Compliance, Boeing, Presented at 30th ICAF Symposium - Kraków, 5 - 7 June 2019.

Federal Aviation 16 Administration 16 B-316 8

1/6/2021 Example: Location-Specific Properties Build Direction Each area encircled in red has a different orientation with respect to the build direction, and thus may have different local properties Federal Aviation 17 Administration 17 Part Zoning Considerations for AM

Many Interpretations exist

Zones can be defined based on:

- Criticality of failure mode, inspectability, population of defect species, design margin, microstructure, residual stress, etc.

- Somewhat similar to zoning of structural castings

Level of analysis for each zone may vary from simplified / conservative (e.g. safety factors) approach to more accurate / less conservative (e.g. probabilistic DT) assessment for higher criticality parts / zones

Two main attributes of the proposed approach:

Flexibility (only use necessary level of complexity)

Ability of perform quantitative assessment (when needed)

Federal Aviation 18 Administration 18 B-317 9

1/6/2021 Example: Smarter Testing (BCA) - cont.

Fatigue and damage tolerance considerations currently pose significant challenges to the use of AM parts on airplane structures.

The presence of inherent material defects randomly distributed throughout the volume, which may be below the threshold of detectability, means that due consideration has to be given to size effects and the possibility of cracks not always nucleating where they would ordinarily be expected

The solution to these challenges for AM structural applications may lie in the application of probabilistic fatigue analysis methods Credits: S. Chisholm et al, Smarter Testing Through Simulation for Efficient Design and Attainment of Regulatory Compliance, Boeing, Presented at 30th ICAF Symposium - Kraków, 5 - 7 June 2019.

Federal Aviation 19 Administration 19 Excerpts from 14 CFR 33.70

WHY: Industry data has shown that manufacturing-induced anomalies have caused about 40% of rotor cracking and failure events

WHAT: 33.70 rule requires applicants to develop coordinated engineering, manufacturing, and service management plans for each life-limited part

- This will ensure the attributes of a part that determine its life are identified and controlled so that the part will be consistently manufactured and properly maintained during service operation Engineering The probabilistic approach to Plan damage tolerance assessment is one of two elements necessary to appropriately assess damage Service Manufacturing Management tolerance. Plan Plan AC 33.70-1, GUIDANCE MATERIAL FOR AIRCRAFT ENGINE LIFE-LIMITED PARTS REQUIREMENTS, 7/31/2009.

Federal Aviation 20 Administration 20 B-318 10

1/6/2021 AM Part Zoning and Probabilistic DT

AM parts are uniquely suited for Lack of Fusion Gas Porosity zone-based evaluation

Concept is similar to zoning considerations for castings

however, modeling represents a viable alternative to empirical casting factors One Assessment Option - PFM *)

) PFM - Probabilistic Fracture Mechanics

Reference:

M. Gorelik, Additive Manufacturing in the Context of Structural Integrity, International Journal of Fatigue 94 (2017), pp. 168-177.

Federal Aviation 21 Administration 21 Increasing Recognition of the Probabilistic DT for AM Federal Aviation 22 Administration 22 B-319 11

1/6/2021 Special Topics

Seeded defects studies

Bi-modal fatigue distributions in AM Federal Aviation 23 Administration 23 Example: Seeded Defects Study in Weldments (circa 1975)

Federal Aviation 24 Administration 24 B-320 12

1/6/2021 Generation of Seeded Defects in AM Coupons J. Beuth et al, Process mapping for qualification across multiple direct metal additive manufacturing processes, 24th Notional P-V Map International SFF Symposium - An Additive Manufacturing Conference, SFF 2013.

Increasing severity of defects Absorbed Power (W)

Acceptable process range Process sweet spot Deliberate manipulation of process parameters can alter both severity and Velocity (in/min) type of AM anomalies Ref: M. Gorelik, Considerations for Qualification of AM Aircraft Components of High Criticality, ASTM Symposium on Fatigue and Fracture of AM Materials, Nov. 2017, Atlanta, GA.

Federal Aviation 25 Administration 25 On the Bi-Modal Fatigue Distributions Credits: S. Jha et al, Fatigue Life Prediction OF Additively Manufactured Ti-6Al-4V, MS&T 2019, Portland, OR.

Challenge - availability of small crack data for AM Federal Aviation 26 Administration 26 B-321 13

1/6/2021 Summary

Expect rapid expansion of AM in Aviation and increase in the levels of AM parts criticality

Good progress is being made by the F&DT community of practice in application to metal AM However, most areas are still work in progress

Continued focus is important, through a combination of funded R&D, standardization, technical interchange meetings, and collaborative efforts

Potential areas for collaborative efforts:

- Development of public standards for F&DT and NDI of AM

- Seeded defects studies effect of defects

Reference:

M. Goreliks ASTM 2017 AM Symposium presentation

- Development of Lessons Learned best practice documents and databases (longer-term)

Federal Aviation 27 Administration 27 Discussion Dr. Michael Gorelik Chief Scientist, Fatigue and Damage Tolerance Aviation Safety Federal AviationAdministration michael.gorelik@faa.gov (480) 284-7968 Federal Aviation 28 Administration 28 B-322 14

1/6/2 0 2 1 Accelerating Quality Certification of Critical Components with Additive Manufacturing Vincent Paquit, PhD Lead - Energy Systems Analytics group TCR Lead - Digital/Manufacturing/Testing Workshop on Advanced Manufacturing Technologies for Nuclear Applications Session 4 - Approaches to Component Qualification and Aging Management ORNL is managed by UT-Battelle, LLC for the US Department of Energy This work has been authored by UT-Battelle, LLC, under Contract No. DE-AC05-00OR22725 with the U.S. Department of Energy 1

Scientific drivers

Certification of AM components by conventional methods eliminates the business case for AM components

Limited understanding of local 1 and global processing state for additive manufacturing Develop new certification methodologies for manufacturing technologies 2

2 B-323

1/6/2 0 2 1 Conventional Approach 3

3 Path to Certification Use data analytics and machine learning to intentionally design components with location specific 2 control of microstructure 4

4 B-324

1/6/2 0 2 1 Smart Manufacturing Approach ORNL has developed a technology agnostic data analytics framework for manufacturing.

A four-steps data driven approach toward processes optimization, and qualification, and certification of manufactured parts Step 1: Understanding the process Step 2: Optimizing the process Step 3: Feedback loop for self-optimization/correction Step 4: Certifying and qualifying components 5

5 TCR will demonstrate that an agile development approach can be applied to accelerate deployment.

An agile approach breaks with traditional linear development models to exercise an iterative, dynamic development process. 3

The approach lends itself to complex projects in which a large, multidisciplinary team works together closely to complete a product.

6 6

B-325

1/6/2 0 2 1 Digital Platform for Manufacturing Advanced manufacturing technologies produce valuable datasets at every stage of the manufacturing workflow. Collecting, structuring, and analysis such data is paramount to understanding, optimizing and validating the manufacturing process.

IT Infrastructure Voxelized Parts Data Producers Digital Clone Data Workflow

Wired network Sensor data Unified Data Architecture

WiFi network

IoT

Storage systems

HPC systems

Embedded Systems Cybersecurity Digital Thread 7

7 database visualization D 4 5 1 8 autonomous design goal: B improvements AI AI TC 9 6 3 2 R C predict performance AI 8

design & testing rapid iteration use-simulation Digital 2

in-situ & sectioning meta part digital thread subtractive data data anomaly metrology Thread registration detection heat treat process physics, A additive 4 planning, & simulation feedstock AI process parameters CAD design feedstock additive heat treat metrology subtractive sectioning testing operation operation operation operation operation operation 1 2 8 3 9 new parts new parts characterization & created 2 4 5 6 2 2 2 created 8 recycling timeline maintenance &

8 calibration timeline 8

B-326

1/6/2 0 2 1 Augmented Intelligence for Advanced Manufacturing Deep Learning Machine Learning etc. DL ML vs.

features % %

etc. data truth AI dog ca ca t do g bik e t bik e A B C D AI driven design 2025 AI ML performance prediction for arbitrary geometries TCR ML performance prediction for specific geometry AI anomaly visualization Value Added 2020 DL anomaly detection descriptive diagnostic predictive prescriptive ML anomaly detection CV anomaly detection AI Complexity 9

9 Web-Based Interface and API Makes Data Accessible LDAP authentication Metadata search Upload form Data viewer 5 10 10 B-327

1/6/2 0 2 1 Additive Technologies & Parts Laser Powder Bed Blown Powder Binder Jet 11 11 BeAM - Blown Powder LWIR camera Chamber monitor Stereo 20 MP Strobe Visible cams

& LED Imaging system (a) 6 provides:

10 9

- real time 360 8 measurement 7

- 3D geometry 6 dimensions 5

- 3D strain 4 measurement, 3

- thermal 2 measurement 1 a

12 12 B-328

1/6/2 0 2 1 Anomaly Detection incomplete spreading

1. Detect and classify any anomalies recoater hopping

2. Localize anomaly detections super-elevation recoater streaking

3. Register sensing modalities part damage and debris Critical layer Attempt to re-spread the powder log file scan path

4. Perform process interventions

5. Fully machine agnostic solution 13 13 AI workflow and transfer learning data curation one layer of powder bed data mask of pixel locations MWIR visible spreading spreading global network Manual data annotation

Training the machine learning algorithm from scratch localization

100,000,000+ labeled pixels network 7

MWIR visible fusion fusion (x,y) contextual UNet 14 Dynamic Segmentation Convolutional Neural Network 14 B-329

1/6/2 0 2 1 Approach: classification results Input image Classification results 15 15 Peregrine 8

AI software for real-time 3D print monitoring

Main platform for most of the TCR data analytics activities

Commercial copyright license available

Publication DOI:

10.1016/j.addma.2020.101453 16 16 B-330

1/6/2 0 2 1 Process Correlation Campaign For Properties Predictions Standard Cluster Build 0.1 Layout Data Correlation Mechanical properties Creep properties 2,784 SS-J3 specimens Location Specific Sample Extraction 17 17 Achieving Uniform Material Properties through Data Analytics and AI Scattered mechanical Micrographs testing results Base Melt Theme Top Horizontal Bottom Horizontal 9

Top Horizontal Beam Current Profile Z Height Bottom Horizontal Layer Time Geometry with varying cross section and printing time per layer Micrographs 18 Modified Melt Theme 18 B-331

1/6/2 0 2 1 Relevance and impact Solar Turbines TCR

Objective: Fabricate near net-shaped SGT5-400F airfoil with

Objective: Develop a digital platform and associated no surface breaking cracks from a high gamma prime Ni- processes to couple data analytics with design and base superalloy manufacturing data for use in rapid prototyping and quality evaluations of manufactured products.

Successfully tested on August 25th 2020 Digital Platform / Quality Assurance Manufactured Mercury 50 Gas Turbine Engine component CT Data Near-IR AI for CT reconstruction and defect detection Sensor In-situ and Ex-situ In-situ & AI correlation 19 development 19 Framatome, TVA, Oak Ridge National Laboratory to load first 3D-printed component in commercial reactor The fuel assembly channel fasteners were printed at ORNL using additive-manufacturing 10 techniques, also known as 3D printing, as part of the lab's Transformational Challenge Reactor Program and installed on ATRIUM 10XM fuel assemblies at Framatomes nuclear fuel manufacturing facility in Richland, Washington.

Framatome website (Dec 2020) 20 20 B-332

1/6/2 0 2 1 Questions?

Contact:

paquitvc@ornl.gov 21 11 B-333

1/6 /2 0 2 1 PNNL-SA-158418 Inservice Inspection Considerations for AMT Components Joel Harrison 1

Advanced Manufacturing Techniques

AMT has gained significant attention and success in several industries Aerospace, automotive, medical, consumer products, and energy

ASME Code and the nuclear power industry is yet to fully embrace AMT The nuclear industry could benefit from precision replacement components that are 1 difficult to obtain due to a reduction or loss of supply chain capabilities AMT components must meet quality and regulatory requirements The NDE methods employed during ISI of the existing nuclear fleet have evolved over more than 40 years into an established practice with strong technical and regulator backing There are several papers and reports on NDE of AMT components but none related to ISI 2

2 B-334

1/6 /2 0 2 1 ASME Section XI

Draft published in 1968

First Edition published on January 1, 1970 Entire document was 42 pages with only 24 devoted to ISI requirements

Compared to 2019 Edition - 676 pages

Rules for Inservice Inspection of Nuclear Power Plant Components Does not cover component fabrication NDE or plant construction/Repair Replacement NDE These issues are addressed in ASME Section III 3

3 ASME Section XI

Currently no discussion regarding ISI of AMT fabricated components within Section XI NDE Committees

Only one Code Case, N-834, has been adopted in ASME Section III, Division 1 PM-HIP of 316L Stainless Steel 2 EPRI Report 1025491, May 2012

ASMEs Board on Pressure Technology Codes and Standards (BPTCS) and Board on Nuclear Codes and Standards (BNCS)

Convened Special Committee on Use of Additive Manufacturing for Pressure Retaining Equipment Scheduled to meet quarterly during ASME Code Week 4

4 B-335

1/6 /2 0 2 1 Thoughts Regarding ISI of AMT Components

Are AMT fabricated components comparable to conventionally fabricated methods?

Without investigation, how can we know for sure?

Such information will help define inspection volumes and intervals and provide the basis for the development of aging management programs

How will proprietary AMT processes and manufacturing methods be standardized?

Can it be anticipated that considerations for most ISI of AMT components would overlap with those of conventional components?

5 5

Thoughts Regarding ISI of AMT Components

An AMT component may contain no welds, so the inspection volume cannot be defined in terms of weld regions.

What is the relevant inspection volume?

How is a piping component welded to a valve body or piping elbow fabricated by an AMT process defined? 3

Can critical defects, once defined, be detected with current NDE technology?

What will be the NDE resolution requirements?

Can NDE techniques be validated without destructive testing?

Will the grain structure of the AMT components interfere with UT detection?

6 6

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1/6 /2 0 2 1 Section XI IWA-220 Applicable NDE Methods

Visual VT, VT-1, VT-2, VT-3

Surface Liquid Penetrant, Magnetic Particle, Eddy Current

Volumetric Radiography, Ultrasound, Eddy Current, Acoustic Emission 7

7 Section XI Examination Requirements - Visual

Class 1 components identified in Section IWB-2500 4

8 8

B-337

1/6 /2 0 2 1 Visual Examination

Early AMT fabrication attention in the nuclear power industry has been on pump and valve housings.

Visual examinations should be relatively straight forward provided:

Anticipated flaw types have been determined Critical flaw size & acceptance standards have been defined 9

9 Section XI Examination Requirements - Surface &

Volumetric

Class 1 components identified in Section IWB-2500 5

10 10 B-338

1/6 /2 0 2 1 Section XI Examination Requirements - Surface &

Volumetric

Class 1 components identified in Section IWB-2500

Examination volumed defined in reference to a weld 11 11 Surface & Volumetric Examination

Surface A important factor for surface examinations is surface finish. Will AMT components surface finish be conducive to surface examinations?

Volumetric 6

Volumetric examinations for inservice inspection are predominantly performed with ultrasound Single sided exams - pipe to AMT valve or pump Pump & Valve components are typically a casting Pipe to AMT fabricated elbow in place of a CASS elbow Appendix VIII Considerations 12 12 B-339

1/6 /2 0 2 1 Summary

Advanced Manufacturing Technologies offer a potential benefit to the existing nuclear power fleet in fabricating replacement components.

AMT could possibly reduce a utilitys repair/replacement costs.

If existing Codes & Standards are to be used for AMT components, research must be performed in order to ensure AMT equivalency with conventionally fabricated components.

NDE methods and techniques applicable to AMT components must be validated through performance demonstration.

ASME Code approval process is very long. If the industry is optimistic about utilizing AMT components a Section XI Committee should begin investigating possibilities.

13 13 7

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1/6/2 0 2 1 NIST Perspectives on Additive Manufacturing Standards Landscape Shawn Moylan shawn.moylan@nist.gov Intelligent Systems Division Engineering Laboratory National Institute of Standards and Technology (NIST)

December 9, 2020 MSAM 1

Role of Additive Manufacturing Standards

Standards can be used for (among others):

specifying requirements

communicating guidance and best practices

defining test methods and protocols

documenting technical data

accelerating adoption of new technologies

enabling trade in global markets 1

ensuring human health and safety

Government regulatory agencies and certifying bodies may reference publicly available standards in their regulations and procedures

Standards development in the U.S. is conducted through voluntary participation and consensus MSAM 2

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1/6/2 0 2 1 NIST Influence on Additive Manufacturing Standards

Identify consensus needs and priorities for standards

Workshops, industry meetings, outreach events, etc.

Conduct measurement science research to develop technical basis for standards

Draft content / starting point for development of documentary standards

Serve on standards committees

Leadership roles

Technical standards development

Strategic planning / big picture view

Support the coordination, facilitation, and communication among standards groups MSAM 3

Example NIST Measurement Science Research in Support of AM Standards Methods to characterize metal powder Methods enabling insitu process monitoring

Dimensional - mechanical - thermal - and control to robustly predict part quality powder bed density - powder condition for

Process metrology - signature analysis -

recyclability uncertainty quantification - AM GCode for Methods to characterizebuilt machine control materials Reference data identifying correlations

Mechanical - microstructure - porosity

- density - post processing to enable intelligent controller design

Process parameters Process signatures Exemplar data Part quality

Round robin studies - variability analyses

- powder/process/material relationships Additive ManufacturingMetrology 2 Testbed (AMMT)

Reference data to be used by modeling AM information systems community to improve model inputs architecture, including metrics, and validate model outputs information models, and

Temperature - Microstructure - Residual validation methods Stress Public AM Material Database Preprocess and postprocess test

AM schema/ database - populated methods to characterize with round robin data performance and assess part quality Product definition andtolerance

Machine performance characterization -

representation (GD&T) for AM XCT of AM parts NIST AM AM design rules and their Test Artifact fundamental principles MSAM 4

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1/6/2 0 2 1 Multiple Standards Bodies are Relevant to Additive Manufacturing

ASTM Committee F42 on Additive Manufacturing Technologies

ISO Technical Committee 261 on Additive Manufacturing

SAE Aerospace Material Specifications for Additive Manufacturing (AMSAM)

ASME Y14.46 on Geometric Dimensioning & Tolerancing NIST Contributes to (GD&T) Requirements for Additive Manufacturing All of These Efforts

ASME B46 Project 53, Surface Finish for AM

AWS D20 on Additive Manufacturing

ISO TC184 / SC4, STEPbased data representation for AM

<others - the AM Standards Landscape continues to grow!>

MSAM 5

Challenges Due to the Growing AM Standards Landscape

Increased risk of duplication of efforts and overlapping content

Potential for inconsistencies or even contradictions

Conflicting standards create ambiguity and confusion 3

Increased requirements for communication and coordination

Increased needs for liaisons

Limited resources available for standards development MSAM 6

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1/6/2 0 2 1 Additive Manufacturing Standards Collaborative (AMSC)

Purpose:

coordinate and accelerate development of additive manufacturing standards consistent with stakeholder needs and facilitate growth of the additive manufacturing industry

AMSC launched in March 2016 following two planning meetings

Facilitated by American National Standards Institute (ANSI) through cooperative agreement with America Makes; experts from many industry sectors identified AM standards gaps and priorities

Standardization Roadmap for Additive Manufacturing /

AMSC Standards Landscape, Version 2.0 (June 2018) www.ansi.org/amsc Identifies published and in-development standards and specifications, assesses gaps, makes recommendations for priority areas where there is a perceived need for additional standardization MSAM 7 7

Additive Manufacturing Standards Collaborative (AMSC)

Open Gaps in Standards Landscape High Medium Low Section (02 years) (25 years) (5+ years) Total Design 4 15 6 25 Precursor Materials 1 4 4 10 Process Control 4 8 4 16 4 Postprocessing 0 4 3 7 Finished Material Properties 3 1 0 4 Qualification & Certification 4 8 3 15 Nondestructive Evaluation 2 4 2 8 Maintenance & Repair 0 7 1 8 Total 18 51 24 93 65 gaps need Research & Development MSAM 8 8

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1/6/2 0 2 1 ASTM Committee F42 on Additive Manufacturing Technologies Quick facts

Formed: 2009

Current Membership: 1000+ members (Over 30% outside the US)

Standards: 30+ approved, 45+ in development (Jointly with ISO)

Meet twice a year, next meeting: March 2021, Colorado School of Mines

Global Representation, including: Argentina Germany Norway Switzerland Australia India Puerto Rico Taiwan Austria Italy Russian Federation United Kingdom Belgium Japan Singapore United States Canada Korea South Africa China Mexico South Korea http://www.astm.org/COMMITTEE/F42.htm Czech Republic Netherlands Spain France Nigeria Sweden MSAM 9

ASTM Committee F42 Structure Standards under the jurisdiction of F42 (https://www.astm.org/COMMIT/SUBCOMMIT/F42.htm )

Subcommittees address specific segments within the general subject area covered by the technical committee.

F42.01 Test Methods - Jesse Boyer, Pratt & Whitney 8 Subcommittees and Focus

F42.04 Design - David Rosen, GA Tech

F42.05 Materials and Processes - Frank Medina, UTEP/Tim Shinbara, AMT Test Methods

F42.06 Environment, Health, and Safety - Francoise Richard, P&W Canada Data

F42.07 Applications - Shane Collins, Additive Industries Design 5

F42.08 Data - Alex Kitt, EWI ASTM F42

F42.90 Executive - John Slotwinski, JHU/APL Committee US TAG to ISO

F42.90.05 Research and Innovation - Matt Donovan, Jabil TC 261 Materials &

Processes

F42.91 Terminology - Klas Boivie, Sintef

F42.95 US TAG to ISO TC 261 - Stacey Clark, US Army EHS Terminology Applications MSAM 10 B-345

1/6/2 0 2 1 SubCommittee F42.07 on Applications F42.07 Applications F42.07.01 F42.07.02 F42.07.03 F42.07.04 F42.07.05 F42.07.06 F42.07.08 F42.07.09 F42.07.07 Aviation Spaceflight Medical/ Transportation Maritime Electronics Oil/Gas Consumer Construction Biological & Heavy Machinery (Charles Park, (Rick Russell, (Open) (Alireza Sarraf, (Sam Ruben, Lakshmi (Open)

Boeing) NASA) (Rod McMillan, (Sergio Sanchez, Lam Research) Mighty Building) Jyotshna, Baker J&J and Matthew Jabil) Hughes DiPrima, FDA)

Scope The development of standards for additive manufacturing in a variety of industryspecific applications, settings, & conditions.

The work of this subcommittee will be coordinated with other F42 subcommittees, ASTM technical committees, and national/international organizations having mutual or related interests.

MSAM 11 ASTM: AM Footprint Across Committees

Breadth

More than 20 AM relevant Committees

1000+ standards applicable to AM

2000+ technical experts

Collaboration 6

PSDO - ISO TC261 (CEN TC438)

MOU & Membership - America Makes

MOU - SME

Liaison Agreement - 3MF

Strategic Relationships - NIST, NASA, FAA, FDA, DOD, .

MSAM 12 B-346

1/6/2 0 2 1 ISO Technical Committee 261 on Additive Manufacturing

TC261 Working Groups established for:

WG1 - Terminology

WG2 - Processes, Systems, and Materials

WG3 - Test Methods and Quality Specifications

WG4 - Data and Design

WG6 - Environment, Health, and Safety

JWG10 (with ISO TC44) - AM in Aerospace Applications

JWG11 (with ISO TC61) - AM for Plastics https://www.iso.org/committee/629086.html MSAM 13 ISO TC 261: Participating (P) and Observing (O) Members 7

Blue: 23 Participating Member Countries Orange: 9 Observing Member Countries

+ 26 liaisons with other ISO technical committees for cooperation MSAM 14 B-347

1/6/2 0 2 1 Formal Agreement Established between ASTM F42 and ISO Technical Committee 261

Formal collaboration established between ASTM and ISO (first of its kind!) for joint development of AM standards

Results in duallogo ISO and ASTM standards (same content, no need for future harmonization)

Guiding principles and specific procedures for how ASTM and ISO will cooperate and work together are defined in the Joint Plan for Standards Development MSAM 15 Some Details of the F42 / TC261 Collaboration

New Work Items offered to the partner body

If accepted, draft standards developed by Joint Groups and reviewed by both organizations

Parallel ASTM and ISO ballots o ISO/TC 261: "Draft International Standard" (DIS) ballot; 3month balloting cycle, an FDIS ballot may be needed 8 o ASTM F42: Final balloting; 30days balloting cycle

Editorial changes are allowed; comments resulting from ASTM balloting can be submitted into the ISO balloting process

Separate (new) fasttracking process allowed within ISO

Publication, copyright, and commercial arrangements MSAM 16 B-348

1/6/2 0 2 1 ISO TC261 / ASTM F42 - Guiding Principles for Standards Development 01 Trusted One set of AM standards to be used all over the world 02 Similarity Common roadmap and organizational structure for AM standards 03 Dont reinvent the wheel Use and build upon existing standards, modified for AM when necessary 04 Partnerships Emphasis on joint standards development, colocated meetings, etc.

MSAM 17 SAE International: Aerospace Material Specifications for Additive Manufacturing (AMSAM)

Committee Scope To develop and maintain aerospace material and process specifications for additive manufacturing...

9 MSAM 18 B-349

1/6/2 0 2 1 SAE AMSAM By the Numbers - October 2020 16 Standards

Established in 2015 to develop and maintain aerospace 2 Data Submission Guidelines material and process specifications for additive manufacturing 14 Metals AMS Published

Membership is representative of global aerospace sector 2 Nonmetals AMS Published and supply chains 30 Works in Progress

Assists U.S. Federal Aviation Administration in developing 5 in revision guidance for AM certification 500+ Members 24 Countries Biannual meetings include both North American and European locations MSAM 19 AMSAM Committee - Top Level AMSAM Chair: Dave Abbott ViceChair: Dan Reeves Secretary: Hallee Deutchman 10 AMSAMM AMSAMP AMSAMR Chair: Hector Sandoval Chair: Chris Holshouser/Paul Jonas* Chair: Dave Abbott Metals Subcommittee Non-Metals Subcommittee Repair Applications Subcommittee Each subcommittee includes both Materials and Process technical tracks MSAM 20 B-350

1/6/2 0 2 1 Current SAE Specification Framework Aerospace Material Specification Process Specification Feedstock Material Specification Feedstock Process Specification

Hierarchical framework

Defines requirements and establishes controls

Framework combines Performance-based and Pseudo-prescriptive (establish controls and provide substantiation)

Control = Quality + Consistency MSAM 21 ASME Y14.46 Standards Committee

ASME Y14.462017, Product Definition for AM

Geometric Dimensioning & Tolerancing (GD&T) requirements that are unique to additive manufacturing

freeform complex surfaces; internal features; lattice structures; support structures; asbuilt assemblies; builddirection dependent properties; multiple / functionallygradient materials, etc.

GD&T: the language for communicating geometric tolerance specification and design intent from designers to manufacturing / quality engineers 11 MSAM 22 B-351

1/6/2 0 2 1 ASME B46 Project 53 Surface Finish for AM

Composed of surface metrology experts associated with ASME B46: Classification and Designation of Surface Qualities

White paper and preliminary work item for surface attributes and corresponding characterization methods relevant to components made with additive manufacturing

Several open research questions remain; no consensus at this time; associated standards are in early phase of discussion /

development

For example: typical surface characterization parameters (such as Ra, arithmetic average of roughness profile) may not be the best Sample surface map approach for describing complex AM surfaces MSAM 23 Other Related ASME Standards Activities ASME Y14 Committee ASME Special Committee On Use

Y14.412019, Digital Product ASME ModelBased Enterprise (MBE) Of Additive Manufacturing For Definition Data Practices

Rules, guidance, and examples for the Pressure Retaining Equipment

Y14.472019, Model creation, use, and reuse of modelbased

To develop a technical baseline Organization Practices datasets, data models, and related to support development of a

Y14.48, Universal Direction and topics within a ModelBased Enterprise proposed BPTCS standard or Load Indicators (in development)

Starting point: guideline addressing the MBE Standards Recommendation pressure integrity governing ASME Manufacturing and Report (Dec 2018): direction, the construction of pressure 12 Advanced Manufacturing (MAM) activities, priorities, organization, retaining equipment by Standards Committee roadmap for standards process additive manufacturing

New subcommittee on Additive processes.

Manufacturing ASME B89.4.23 Committee ASME Verification and Validation (V&V) Committee

Performance Evaluation ASME Committee on Digital

V&V 50, Computational Modeling for Advanced of Computed Tomography Engineering / Big Data / Digital Manufacturing (launched in 2016) Systems Transformation (forming in 2021)

MSAM 24 B-352

1/6/2 0 2 1 AWS D20 on Additive Manufacturing

AWS D20.1/D20.1M:2019, Specification for Fabrication of Metal Components using Additive Manufacturing

Requirements for repeatable production of metal AM components

Processes: powder bed fusion (PBF) and directed energy deposition (DED)

Feedstock: metal powder and wire

Contents:

Design Requirements for AM Components

Fabrication Requirements

AM Machine and Procedure Qualification

Inspection Requirements

AM Machine Operator Performance Qualification

Acceptance Requirements First revision in process: multiplelaser systems; inprocess monitoring /

adaptive feedback; updates to PBF powder requirements; updates to PBF qualification variables; inspection test artifact requirements MSAM 25 NIST Perspectives on AM Standards

NIST continues to support and influence AM standards development through measurement science research and service on standards committees

Contributions to more than 40 AM standards activities across several standards bodies

Multiple leadership roles, including with ANSI Additive Manufacturing Standards Collaborative

NIST Motivations / Future Vision:

High quality, technically accurate standards

Usable and high impact standards that meet stakeholder needs

Integrated and cohesive set of standards: consistent, noncontradictory, nonoverlapping 13

No duplication of effort

Use of existing standards, modified for AM when necessary

Coordination, communication, and cooperation are essential to achieve this vision and to drive consensus standards that enable trade in global markets

AM users, standards bodies, vendors, technology providers, regulatory agencies, etc. all play a role

Challenges continue to grow due to technology advancements and rapidlychanging environment

Much progress and cooperation todate; definitely successes to build upon!

e.g., AMSC interactions; multilogo standards; AM standards structure; many liaisons; terminology YoMuSrAMideas,participation, expertise, and help are welcomed and appreciated!

26 B-353

1/6/2 0 2 1 Questions and Discussion

Contact:

Kevin Jurrens kevin.jurrens@nist.gov MSAM 27 Key References for AM Standards Landscape

AMSC, AM Standardization Roadmap and AM Standards Landscape: https://www.ansi.org/amsc

ASTM F42: https://www.astm.org/COMMITTEE/F42.htm

ASTM AM Center of Excellence: https://amcoe.org/

ISO TC261: https://www.iso.org/committee/629086.html

SAE: https://www.sae.org/works/committeeHome.do?comtID=TEAAMSAM

SAE AM Data Consortium: https://www.saeitc.com/amdc

AWS D20: https://www.aws.org/standards/committee/d20committeeonadditivemanufacturing2 14

ASME Y14.46: https://cstools.asme.org/csconnect/CommitteePages.cfm?Committee=100749850

ASME MBE Standards Recommendations Report: http://go.asme.org/MBEreport

MMPDS: https://www.mmpds.org/

CMH17: https://www.cmh17.org/HOME/AdditiveManufacturing.aspx

Workshop Proceedings, Strategic Guide for AM Data Management and Schema: https://amcoe.org/rd publications MSAM 28 B-354

1/6/2021 ASME Criteria for Powder Bed Fusion Additive Manufacturing ASME Special Committee on Additive Man George Rawls Advisory Engineer SRNL NRC Advanced Manufacturing Workshop December,3 2020 1

ASME Criteria for Powder Bed Fusion Additive Manufacturing

What is Additive Manufacturing

Additive Manufacturing (AM) - a process of joining materials to make objects from 3D model data, usually layer upon layer, as opposed to subtractive manufacturing methodologies.

Subtractive Manufacturing - making objects by removing material (for example, milling, drilling, grinding, etc.) from a bulk solid to leave a desired shape.

Subtractive Additive Additive + Subtractive Application will require additive joined to non-additive 2

B-355 1

1/6/2021 ASME Criteria for Powder Bed Fusion AdditiveManufacturing

Additive Manufacturing Technologies Powder Bed Fusion Direct Energy Deposition Powder Bed Fusion Process 3

ASME Criteria for Powder Bed Fusion AdditiveManufacturing

The ASME Special Committee has produced a final draft documentproviding Criteria for Pressure Retaining Metallic Components Using AdditiveManufacturing.

The document is intended to provide criteria on the materials, design, fabrication, examination, inspection, testing and quality control essential to be addressed in any proposed standard for the construction of metallic pressure retaining equipment using powder bed fusion additive manufacturing.

The additive manufacturing criteria document addresses the follow areas.

Scope

Production Builds

Additive Manufacturing Specification

Chemistry Testing

Materials

Mechanical Property Testing

Thermal Treatment

Metallographic Evaluation

Powder Requirements

Referenced Standards

Additive Manufacturing Design Requirements

Definitions

Additive Manufacturing Procedure

Records

Additive Manufacturing Procedure Qualification

Quality Program

Qualification Testing of Additive Manufactured Components 4

4 B-356 2

1/6/2021 ASME Criteria for Powder Bed Fusion AdditiveManufacturing

Scope

- These criteria address the construction of pressure retaining equipment using the Additive Manufacturing (AM) Powder Bed Fusion process using both Laser and Electron Beam energy sources.

- Hybrid construction incorporating AM components joined (Welded or Brazed) to non-AM components is acceptable. Additive manufactured components joined to other AM components or non-AM components shall follow the requirements for the applicable ASME Construction Code or Standard.

- The pressure design for components shall follow the requirements of the applicable ASME Construction Code or Standard.

- The maximum design temperature shall be at least 50°F (25° C) colder than the temperature where time-dependent material properties begin to govern for the equivalent wrought ASME material specification, as indicated in ASME Section II, Part D [15.1].

- The minimum design temperature shall follow the requirements for the applicable ASME Construction Code or Standard.

5 5

ASME Criteria for Powder Bed Fusion AdditiveManufacturing

Materials

- Material for the purpose of this specification is defined as the additively manufactured component in its final heat-treated condition.

- The Additive Manufacturer shall select a listed wrought ASME material specification from ASME Section II for the component material.

- The requirements for chemical composition, grain size, hardness, final heat treatment and mechanical properties shall be identical to the requirement of the ASME material specification. Valve Body Fabricated Using Powder Bed Fusion AM Courtesy of Emerson

The AM Committee basically followed the same criteria for materials that was used in the codification of component fabricated using the powder metallurgy 6

6 B-357 3

1/6/2021 ASME Criteria for Powder Bed Fusion AdditiveManufacturing

Thermal Treatment

- The final heat treatment requirements applied to the AM material shall be identical to those applied to the ASME material specification.

- Additional intermediate thermal treatment is acceptable.

Intermediate thermal treatment may include stress relief, hot isostatic pressing or other thermal processing.

- When intermediate thermal treatment is performed ASTM F3301 [15.2] may be used as guidance.

- When hot isostatic pressing is performed ASTM A988

[15.3] or ASTM A1080 [15.4] may be used as guidance.

- All material testing shall be performed on material specimens in the final heat-treated condition ASME material specification. Schematic of the Hot Isostatic Pressing Process 7

7 ASME Criteria for Powder Bed Fusion AdditiveManufacturing

Design

- In addition to the design requirements of the ASME Construction Code or Standard the following design requirements apply for components produced using the powder bed fusion AM process.

- Any material produced during the AM build that is specified as cosmetic material shall not be credited as load bearing material in the stress analysis. Sacrificial Supports

- Fatigue critical surfaces shall be designed to be accessible for Courtesy of Rolls- Royce liquid penetrant examination.

- Surfaces interfacing with sacrificial supports shall be fully accessible for removal of supports and for liquid penetrant examination.

- The effect of any support that will not be removed following the AM build shall be included in the stress analysis.

Permanent Supports 8

8 B-358 4

1/6/2021 ASME Criteria for Powder Bed Fusion AdditiveManufacturing

Additive Manufacturing Procedure

- Additive Manufacturing Procedure

The Additive Manufacturer shall prepare an Additive Manufacturing Procedure.

The AM Procedure shall address applicable process variables.

The Additive Manufacturer shall complete sufficient qualification builds and produce sufficient material qualification specimens to support a 95% confidence that 99% of the produced material is in accordance the ASME material specification.

The Additive Manufacturer shall identify the locations of limiting material conditions for each energy source.

Material Qualification Specimens forAdditive Manufacturing Procedure Qualification Courtesy of Emerson 9

9 ASME Criteria for Powder Bed Fusion AdditiveManufacturing

Additive Manufacturing Procedure Qualification

- Limiting material conditions for each energy source.

Radial Distance From Energy Source Overlap Zone

% Elongation Gas Flow Overlap Zone Overlap Zone Perimeter of Build Volume Radial Distance From Energy Source Courtesy of Emerson 10 10 B-359 5

1/6/2021 ASME Criteria for Powder Bed Fusion AdditiveManufacturing

Qualification Testing of Additive Manufactured Components

- Fabricated components shall be subjected to qualification testing.

- Correlation between the samples and the actual component.

Prototype Testing Requirements Prototype Test Number of Prototypes Test Criteria Proof 1 Section 9.12 Fatigue 2 to 5 Section 9.13 Material Properties 1 Sections 12-14 Toughness 1 Construction Code

Locations for Material Qualification Specimens for Component Qualification Build Location Description Minimum Samples CQ1 Locations of limiting material conditions identified 2 per Energy Source during the procedure qualification.

CQ2 Thinnest pressure retaining feature in the 1

component CQ3 Highest stressed location in the component 1 11 11 ASME Criteria for Powder Bed Fusion AdditiveManufacturing

Production Builds

- First 10 Production Builds

- A vertically oriented witness specimen shall be constructed over the total height of the build volume at a minimum of 2 locations of limiting material conditions determined during procedure qualification for each energy source.

- Witness specimens shall be subdivided when required to meet the requirement of ASTM E8.

- All tensile specimens from each energy source shall be tested.

12 12 B-360 6

1/6/2021 ASME Criteria for Powder Bed Fusion AdditiveManufacturing

Production Builds

- Production builds greater than 10 with all tensile samples conforming.

- One vertically oriented witness specimen for each energy source shall be constructed to the height required to capture the limiting material location determined from the data for the first 10 production build cycles for each energy source.

- The location of the single tensile specimen shall be at the limiting location within the witness sample identified during the first 10 production build cycles.

- The single tensile specimen from each energy source shall be tested.

13 13 ASME Criteria for Powder Bed Fusion Additive Manufacturing

Examination Requirements for AM Components

- The current ASME Construction Codes examination.

Computed Tomography

- Computed tomography is needed to provide full volumetric examination of AM Components.

- Section V is developing a new article for the 2021 edition CT Pipe Scan EMS Corp for computed tomography.

Move to Real Time Monitoring of Flaws During an AM Build.

Defect Acceptance Criteria for Load-Bearing AM Parts

- Fatigue Analysis of AM Parts Comparison of Infrared Thermography and Computed Tomography Results 14 14 B-361 7

1/6/2021 ASME Criteria for Powder Bed Fusion AdditiveManufacturing

Path Forward

- The intent is to publish the ASME Criteria for Powder Bed Fusion Additive Manufacturing as a Pressure Technology Book (PTB) for use as a reference document for additive manufacturing Code Cases or incorporation of additive manufacturing into construction codes.

- It will also serve as the baseline for future development of an ASME AM standard by an ASME Standards Committee.

ASME has submitted a Project Initiation Notification with ANSI stating that they will develop a standard for additively manufactured pressure equipment.

15 15 ASME Criteria for Powder Bed Fusion Additive Manufacturing QUESTIONS 16 16 B-362 8

1/6/2 0 2 1 Approach to Codifying New Manufacturing Methods (e.g., PM-HIP, LPBF, EBW)

Brian Frew Consulting Engineer, Materials and Chemistry, GEH David W. Gandy, Sr. Technical Executive, Nuclear Materials,EPRI NRC Advanced Manufacturing Virtual Workshop December 710, 2020 www.epri.com © 2020 Electric Power Research Institute, Inc. All rights reserved.

1 Outline Whats missing today from the Code?

What are the gaps that need to be addressed?

What alloys need to be qualified?

Four manufacturing methods reviewed herein: 1

- Powder metallurgyhot isostatic pressing

- Cold spray welding/cladding

- Laser powder bed fusionadditive manufacturing

2 B-363

1/6/2 0 2 1 Powder Metallurgy-Hot Isostatic Pressing (PM-HIP)

Whats missing today from the Code?

- Permitted by several Code Cases (see next slide What alloys need to be qualified?

https://www.materials.sandvik/enus/products/hotisostaticpressed

- Alloy 600M (N5802) hipproducts/productionprocess/

- Alloy 625

- Alloy 690

- Alloy 718

3 ASME Code Cases ASME Code Cases

- CC N834 - 316L SS (nuclear)

- CC 2770 - Grade 91 (fossil)

- B31.1 CC ApprovedGrade 91

- Section VIII CC - Div. 1 and 2 29Cr6.5Ni 2MoN (S32906)Duplex SS 2 Incorporation ASTM A988, A989, and B834 into ASME Section II Section IIAppendix 5

This CC initiated by Sandvik 4 www.epri.com © 2020 Electric Power Research Institute, Inc. All rights reserved.

4 B-364

1/6/2 0 2 1 Powder Metallurgy-Hot Isostatic Pressing (PM-HIP)

What are the gaps that need to be addressed?

- Material standards: Additional ASTM specifications need to be developed for Ni base alloys and low alloy steel (A 508 equivalent)

- Code Cases: Needed for the additional alloys

- Environmental data: stress corrosion cracking needs to be developed for Nibase alloys

- Low Alloy Steels: welding acceptability needs to be confirmed.

- Fracture toughness: Needed for low alloy steels

- Irradiation Data -Some data under development by EPRI/INL.

5 Powder Metallurgy-Hot Isostatic Pressing (PM-HIP)

Near term needs

- Low Alloy steel (A 508 equivalency)

Material specification Section III Code Case

- Nickel Base Alloys Alloy 600M, 625, 690, 718 3 Code Cases Longer term

- Grade 91

- Type 316H

- Alloy 617

6 B-365

1/6/2 0 2 1 Cold Spray Additive Manufacturing Technique results in a mechanical bond

- Repair of existing material

7 Cold Spray Additive Manufacturing Whats missing today from the Code?

- Process is not recognized by the Code What alloys need to be qualified?

- Austenitic stainless steel

- Alloy 625 4

- Alloy 690

- Alloy 718

8 B-366

1/6/2 0 2 1 Cold Spray Additive Manufacturing What are the gaps that need to be addressed?

- Material Standard necessary

- Material sampling plan for mechanical properties

- Process qualification requirements not covered by Section IX

- RT is typically used for castings

- UT examination for bond

9 Laser Powder Bed Fusion-Additive Manufacturing Whats missing today from the Code?

- LPBFAM is not currently addressed by ASME or NRC.

- ASME BPTCS/BNCS Special Committee on AM for Pressure Retaining Equipment is currently assembling a Guidelines for Control of PBF processes to fabricate and test AM pressureretaining components.

- Each ASME Book Section will then need to incorporate the guidance into the appropriate Book (I, III, VIII, etc.) for application 5

- DRAFT Code Case for 316L SS LPBFAM submitted to BPVIII (by Westinghouse/EPRI)

What alloys need to be qualified?

- Stainless steels: 316L, 304L, 316H, 709, 174PH

- Nickelbased alloys: 617, 625, 690, 725, X750, Alloy X

- Titaniumbased alloys: Ti6Al4V

- Zirconiumbased alloys: Zircaloys?

10 B-367

1/6/2 0 2 1 Laser Powder Bed Fusion-Additive Manufacturing What are the gaps that need to be addressed?

Materials Properties Gaps Processing Gaps

- Time dependent and independent - ProcessingEstablish essential materials properties variables (next slide)

- Fatigue (smooth and as deposited) - HIP vs noHIP application and properties properties

- Fracture toughness properties

- Irradiation and thermal aging NDE Gaps properties - Defect acceptance criteria

- SCC properties

- Detection limits

11 Laser Powder Bed Fusion-Additive Manufacturing Essential Variables may include:

Laser power Gas flow and gas composition Exposure time Recoater blade type Point distance Beam focus distance Scanning speed Layer thickness 6 Hatch spacing or hatch distance Stripe width Scan strategy Pulse characteristics Beam diameter Overview of LPBFAM deposition on a substrate plate Energy density 12 www.epri.com © 2020 Electric Power Research Institute, Inc. All rights reserved.

12 B-368

1/6/2 0 2 1 Electron Beam Welding

- List of Pertinent ASME Docs for EBW of Thick Section ComponentsSection III NB4311 Types of Processes Permitted

- Any process used shall meet the records required by NB4320 NB4320 Welding Qualifications, Records and Identifying Stamps NB5277 Examination of EB WeldsSection IX 110mm (thick) EB Weld QW215 Electron Beam Welding and Laser Beam Welding

- WPS qualification test coupons shall be prepared w/ the joint geometry duplicating that to be used in production.

- If the production weld is to include a lapover (completing the weld by rewelding over the starting area of the weld, as a girth weld), such lapover shall be included in the WPS qualification test coupon.

- The mechanical testing requirements of QW451 shall apply.

QW260 - Essential Variable Procedure Specifications (WPS) for Electron Beam Welding QW451 - Procedure Qualification Thickness Limits and Test Specimens

13 Electron Beam Welding Whats missing today from the Code?

- EBW is already permitted for nuclear pressure retaining components under Section III, NB4311 and Section IX QW215.

7 Photograph provided courtesy:

Nuclear AMRC (UK)

What alloys need to be qualified?

- No preheat on low alloy steel (SA 508 Class 12) - see next slide.

14 B-369

1/6/2 0 2 1 Electron Beam Welding What are the gaps that need to be addressed?

- EBW is performed in a vacuum chamber, thus moisture/hydrogen is not present and not an issue.

- For Low Alloy Steels, welding without preheat will need to be qualified and codified.

- Irradiation Data - US & UK Naval programs have this information. Some data under development by Purdue/EPRI/ATR.

- Longterm Thermal Embrittlement - Same, US & UK Naval programs

- Residual Stress Data - Collaborative project (EPRI, U. of Manchester, Nuclear AMRC developed data). Also, TWI.

- Operator Qualification - Difficult to convert conventional welder to EBW operators.

CNC machinists can often be converted to EBW operators.

15 Summary - Major Gaps Powder metallurgyhot isostatic pressing

- Limited material acceptance (Nuclear)

- Material data

- Size limitations Cold spray welding/cladding

- Not accepted currently by ASME BPVC

- Additional alloys, Process qualification, NDE gaps 8

Laser powder bed fusionadditive manufacturing

- Not accepted currently by ASME BPVC

- Additional alloys, processing gaps, NDE gaps Electron beam welding

- No preheat (in vacuum)

- Irradiation and longterm thermal embrittlement

16 B-370

17 9

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1/6 /2 0 2 1 Driven byDriven Driven by America Makes Efforts Relevant to AM for Nuclear Applications 9 December 2020 Brandon D. Ribic, PhD.

Technology Director, America Makes Brandon.Ribic@ncdmm.org Approved for Public Release, Unlimited Distribution AmericaMakes.us 1 1

Driven by Overview The three core activities of the Institute are:

Develop Additive Manufacturing Technology:

Projects, Innovation, Technology Transfer, Implementation

Accelerate Human Capital Development:

Workforce, Education, Training, Outreach

Maintain Collaborative Ecosystem:

Government, Membership, Community 1 These focus areas are enabled by:

Operations: Run by a not-for-profit organization with a lean and collaborative structure

Technology: A dynamic advanced manufacturing technology including the core AM technologies as well as supporting technologies like the digital thread, standards, etc.

Communications: Spreading the word to government, members, stakeholders, community Approved for Public Release, Unlimited Distribution AmericaMakes.us 2 2

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1/6 /2 0 2 1 Driven by Collaboration Drives Our Strategic Focus Focus and strategy is documented within the Technology Roadmap Swimlane CTE Design Bio-Inspired Design & Manufacturing

Application/process agnostic Design Product & Process Design Aides/Apps

Informed by not only end users Material Material Property Characterization Material Next-Gen Materials Material Additive Manufacturing Tech Data Packages Process Multi-Material Delivery & Deposition Systems Multitude of interconnected technical Process Next-Gen Machines considerations Process Process Temperature Gradient Control Value Chain Advanced Sensing & Detection Methods

TRL 4-7 Value Chain Cost & Energy Driver Analysis/Modeling

Address risk and maturation Value Chain Digital Thread Integration Value Chain Intelligent Machine Control Methods

Assess performance/function Value Chain Rapid Inspection (Post-Build)

Value Chain Repair Technologies Value Chain Standards/Schemas/Protocols Roadmap is a data model AM Genome Benchmark Validation Use Cases AM Genome Model-Assisted Property Prediction

Integral to institute operation AM Genome Physics-Based Modeling & Simulation

Connects research efforts to roadmap taxonomy

Identifying needs/opportunities

Charting progress

Organizes lessons learned Approved for Public Release, Unlimited Distribution AmericaMakes.us 3 3

Driven by Roadmap Advisory Group Teresa Clement Brian Thompson Steven Floyd Thierry Marchione Raytheon GE Additive Northrop Grumman Caterpillar Technologies Brian.Thompson1 Floyd, Steven J Marchione_Thierry_A Teresa.Clement Steven.Floyd@ngc.com

@ge.com @cat.com

@Raytheon.com Federico Sciammarella Prabir Chaudhary 2 Anil Chaudhary MxD Education and Applied Optimization federico.sciammarella Consulting LLC.

anil1@ao.com @mxdusa.org prabir.chaudhury

@gmail.com Craig Brice Ray Xu Frank Medina Colorado School of Rolls-Royce Corp.

UTEP Mines Ray.Xu@Rolls-fmedina@utep.edu craigabrice@mines.edu Royce.com Approved for Public Release, Unlimited Distribution AmericaMakes.us 4 4

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1/6 /2 0 2 1 Driven by Addressing Technology Gaps to Strengthen Domestic Supply Chain Image Courtesy Quintus Technologies Supply Chain Design Performance Post- Inspection/ Cost & Rate

& Sourcing & Durability Processing & NDE Finishing Key Additive Manufacturing Technology Focus Areas Strengthen Warfighter Capability Needs Approved for Public Release, Unlimited Distribution AmericaMakes.us 5 5

Driven by Previous and Current Applications 3

Image courtesy DARPA Image courtesy DARPA http://www.optisurf.com/index.php/mirror- Image credits: Dr. Beth Ripley and Timothy Prestero mounts-for-high-precision-optics/

Approved for Public Release, Unlimited Distribution AmericaMakes.us 6 6

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1/6 /2 0 2 1 Driven by Merits of Additive Manufacturing for Nuclear Applications Design

Filtering

Thermal management

Vibration/shock

Part consolidation

Tooling, jigs, and brackets Materials & Process Lu et al. AOI2 Wireless High-Temperature Sensor Network for Smart Boiler Systems.

2020

Tailored material chemistries and microstructures for performance Image Courtesy of Westinghouse Shielding/passivation Mechanical performance Thermophysical properties

Multi-material Metal, polymer, ceramic, composite Part count reduction Embedded sensors

Repair, cladding, hard facing GE Hitachi 2017

Reverse engineering Adaptive distributed manufacturing base Image Courtesy of Nuclear AMRC

Adaptable and readily adjusts to iterative/evolving product definition

Single article production lots are tolerable

Lead time reduction Image Courtesy of Additive Composite Approved for Public Release, Unlimited Distribution AmericaMakes.us 7 7

Driven by Design GD&T of metals, polymers, composites Structure DfAM

Guides, process selection aides, and apps

Product development and qualification Structural Optimization

Including lattice structures Materials and data play a vital role Performance Bogard et al., Integrated Turbine Component Cooling Designs Facilitated by Additive Manufacturing and Optimization.2019.

4 Design for:

Life limited applications Chyu, To, and Kang., Integrated Transpiration and Lattice Cooling Systems Developed

Complex parts/assemblies by Additive Manufacturing with Oxide-Dispersion Strengthened Alloys. 2017.

Anisotropic materials

Multi-material

Multi-process

Multi-physics Manufacturability Validation and vetting manufacturability and product equivalence to known designs Approved for Public Release, Unlimited Distribution AmericaMakes.us 8 8

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1/6 /2 0 2 1 Driven by Material Material Types

Ti, Ni, Al Process

Polymers

Composites Evaluation of austenitic, ferritic, or PH stainless steels

Beyond 718 and 625 nickel alloys Pedigreed materials allowable data sets Service life modeling - probabilistic approaches Structure

Dissimilar materials

Elevated temperature Chyu, To, and Kang., Integrated Transpiration and Lattice Cooling Systems Developed by Acharya et al., Computational Tools for Additive Manufacturing of Tailored Microstructure and

Various degradation mechanisms Additive Manufacturing with Oxide-Dispersion Strengthened Alloys. 2017.

Properties. 2020.

Materials which improve system performance

Certified as-built

Recycling

Methods for AM materials development Properties Functional testing for equivalence Feedstock production capability Dryepondt et al., AM of Nickel Components and Joining of Dissimilar Metal Welds.2020.

Approved for Public Release, Unlimited Distribution AmericaMakes.us 9 9

Driven by Process Advancements in controls, software, and hardware Control

Geometric, microstructural, and performance (quality) enhancements Multi-laser/multi-deposition

Larger build volumes

Increased productivity

Expanded capacity/capability Maintenance &

Calibration New capabilities can come with new challenges 5

Increased degrees of freedom for operators

Scan path optimization tools/methods

Process control methods and validation

Repeatability Expanded Transferability between different machine platforms Capability Process calibration methods and tools

Equipment maintenance Approved for Public Release, Unlimited Distribution AmericaMakes.us 10 10 B-376

1/6 /2 0 2 1 Driven by Value Chain Physical limits of sensing and inspection Qual/

technologies Cert

Probability of detection

Overcoming complexity Sourcing and acquisition technology Business case analysis

Understanding value proposition of AM Cost Novel test methods needed

Validation Cybersecurity Rapid inspection Digital Digital twins which account for: Capability

Manufacturability

Multiple manufacturing operations

Product variability/quality control Approved for Public Release, Unlimited Distribution AmericaMakes.us 11 11 Driven by AM Genome Physics-based predictive tools Tools

Track geometry

Surface finish and lack of fusion

Distortion/residual stress Experimental validation Methods Machine learning/artificial intelligence 6

Structure and performance prediction Reduced demand for physical experimentation 10 95% C.I.

samples and testing truefunction surrogate prediction 5

f(x)

Optimization New AM materials development 0

-5 0 2 4 6 8 10 x

Senvol.com Approved for Public Release, Unlimited Distribution AmericaMakes.us 12 12 B-377

1/6 /2 0 2 1 Driven by Scaling AM Technology for Nuclear Applications Demand volume for nuclear application components exhibits potential for considerable benefit from AM Reliability and familiarity with product performance and materials behavior must be addressed to insure expanded adoption

Repeatability and transferability of manufacturing capability will be important

Supply chain resilience = potential for lead time reduction Inspection is a critical component of nuclear product certification and may not deter broader application of the technology

May not always be true, now is the time to explore Continued exploration and documentation of productivity and lead time improvements gained by AM

DED vs. GMAW

Repair and prototyping before super-critical applications - crawl, walk, run mentality

Refined cost modeling Compatibility with legacy sub-systems, assemblies, or manufacturing operations

New materials may not exhibit same compatibilities or behaviors Some cost and lead time savings may come immediately

Like for like replacement of legacy designs/material forms

Often realization of performance or unique benefits requires development, testing, data and investment Approved for Public Release, Unlimited Distribution AmericaMakes.us 13 13 Driven by Regulation and Standards These appear to be encouraging times for advanced manufacturing in nuclear industry

AMT Application Guidance Draft Framework June 2020 10CFR 50.55a(z)(1)

Equivalency according to ASME Code Section III design allowables

This is a challenging and evolving topic within AM industry which is impact no just nuclear industry 10CFR 50.55a(z)(2)

Functional testing has served as a meaningful method to determining product function in a relevant operating environment 7

Aerospace Direction and recommendation of guidance mirrors much of the AM industries understanding The guidance suggests now is a great time to get engaged with SDOs and share your needs with broader community

Opportunity to benefit your organization and your industry

Standards development requires data and perseverance

Change requires time and effort

There has been much learned about AM, but additional effort is required Take advantage of opportunities to connect with your peers and learn from others

Sharing information (familiarity with the technology) tends to reduce barriers to entry and uncertainty Approved for Public Release, Unlimited Distribution AmericaMakes.us 14 14 B-378

1/6 /2 0 2 1 Driven by Future Opportunities Additive has demonstrated value proposition for nuclear applications

These benefits build upon prior lessons learned across various (but similar) industries

Expansion of technologys recognized value Operating conditions and materials offer reasonable transition opportunities With expanded familiarity, additional validated design tools and methods are likely to follow Capture of key lessons learned will serve as the foundation for workforce development and new standards

R&D, materials data, and functional (performance based) testing will play a key role Successful demonstration of lower risk components can continue to serve as useful opportunities to bolster industrys familiarity with the technology

Scale and expand adoption for a variety of applications It is important to recognize the value of collaboration

Sharing (pre-competitive) lessons learned will allow the nuclear industry to focus on application specific challenges rather than redeveloping AM best practices from scratch

Accelerate primary focus/efforts to product evaluation and performance monitoring (terminology adopted from AMT Application Guidance Draft Framework)

Approved for Public Release, Unlimited Distribution AmericaMakes.us 15 15 Driven by When America Makes America Works 8 AmericaMakes.us @AmericaMakes /AmericaMakes Approved for Public Release, Unlimited Distribution AmericaMakes.us 16 16 B-379

1/6/2021 www.astm.org Recent Progress on ASTM AM Standardization and R&D Efforts U.S. NRC Workshop on Advanced Manufacturing Technologies for Nuclear Applications December 9th, 2020 www.astm.org Dr. Mohsen Seifi

Director, Global Additive Manufacturing Programs, ASTM International, Washington DC, USA

Adjunct Faculty, Case Western Reserve University, Cleveland, OH, USA 1

Introduction

ASTM has significant history with Nuclear Industry

ASTM Committee E10 on Nuclear Technology formed in 1951 - approximately 150members

75+ published Standards

ASTM Committee C26 on Nuclear Fuel Cycle formed in 1969 -approximately 150 members

175+ published Standards

Introducing the ASTM Additive Manufacturing Center of Excellence

Founded in 2018 - aimed to accelerate ASTM standardization activities and fill some of the skill gaps

Supporting F42 Additive Manufacturing Committee and other technical committees relevant to AM

Objectives

ASTM and its AM CoE is here to listen!

Understand challenges and opportunities presented at the workshop

Participated at ANS/NEI Advanced Reactor Standards and Codes Virtual Workshop Presentations, June 23, 2020

Identify where ASTM efforts are already providing solutions that can immediately add value & present solutions

Consider next steps:

How can the ASTM support beyond this workshop and work with U.S. NRC and nuclear industry?

2 2

B-380 1

1/6/2021 ASTM Nuclear Pedigree

E10 - Nuclear Technology & Applications:

C26 - Nuclear Fuel Cycle:

To promote the advancement of nuclear science and technology and the safe application of To develop consensus standards for, and promote commercialization of, nuclear fuel cycle, energy, including endoffuelcycle activities such as decontamination and decommissioning materials, products and processes

Standardizing measurement techniques and specifications for:

Provide internationally accepted standards which facilitate the commerce;

Radiation effects worker safety; public and environmental health; and regulatory

Dosimetry, including materials response compliance within the Nuclear Fuel Cycle.

Instrument response

Determination of radiation exposure

Fuel burnup

All aspects of the nuclear fuel cycle are included with emphasis on

Nuclear fuel

Reactor materials processing

Standardizing the nomenclature and definitions used

Analysis

Disposal/disposition technologies and applications.

Maintaining a broad expertise in the application of nuclear science and

Nuclear fuel cycle activities of both the commercial nuclear industry and the technology, especially the measurement of radiation effects from defense community fall within the scope of this committee.

environments of nuclear reactors, charged particle accelerators, indigenous space, spacecraft, and radioisotopes.

The work of the Committee(s) will be coordinated with other ASTM International committees and national and international organizations

Sponsoring scientific and technical symposia, workshops, and having mutual interest.

publications in the Committee's fields of specialization.

3 3

ASTM Nuclear Pedigree Roadmap published in 2012

This roadmap identifies top priorities and opportunities in the commercial nuclear energy sector that:

Encompass the objectives of NESCC Task Group on Standards Prioritization;

Build on the results of the ASTM nuclear survey and Nuclear Standards Workshop (described further in this roadmap); and

Manage gaps in the underlying technology and standards based on their significance to the NESCC goals.

The roadmap is of importance to ASTM International because it provides:

The formation of a self-sustaining nuclear energy focal point within ASTM;

The strengthening of alliances with other societies and international organizations;

An increased understanding of the nuclear energy sector and how to effectively contribute to this industry through the actions of ASTM technical committees;

The identification of gaps in current and emerging technologies and related standards; Download at: https://www.astm.org/portals/nuclear_roadmap.pdf 4 4

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1/6/2021 ANS/NEI Advanced Reactor Standards and Codes Virtual Workshop, June 2020

Purpose of the workshop:

Facilitate discussions on needs for codes/standards

Recommended actions:

Conduct gap analysis

Development of standards that were identified high priority for this sector

Many more https://www.ans.org/file/1716/2/NEI ANS%20Advanced%20Reactor%20Codes%20&%20Standards%20Workshop%20Presentations.pdf 5

5 New Sub-Committee on Applications More background on ASTM F42: See Shawn Moylan presentation earlier today.

F42.07 Applications Nuclear/

Energy?

F42.07.01 F42.07.02 F42.07.03 F42.07.04 F42.07.05 F42.07.06 F42.07.08 F42.07.09 F42.07.07 Aviation Spaceflight Medical/ Transportation Maritime Electronics Oil/Gas Consumer Construction Biological & Heavy Machinery (Charles Park, (Rick Russell, (Open) (Alireza Sarraf, Lakshmi (Open)

(Sam Ruben, Boeing) NASA) (Rod McMillan, (Sergio Sanchez, Lam Research) Mighty Building) Jyotshna, Baker J&J and Matthew Jabil) Hughes DiPrima, FDA)

Scope The development of standards for additive manufacturing in a variety of industry-specific applications, settings, & conditions.

The work of this subcommittee will be coordinated with other F42 subcommittees, ASTM technical committees, and national/international organizations having mutual or related interests.

6 6

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1/6/2021 ASTM AM Footprint:

Collaborative nature

Partnership with ISO TC261 (& CEN TC438): Agreement since 2011

Strategic Relationships:

America Makes: MoU since 2013

Government agencies: NIST, NASA, FAA, FDA, DoD, U.S. NRC, etc.

Other groups: MMPDS (MoU), CMH17, etc.

AM Center of Excellence partnership:

AU, EWI, MTC, NIAR, NASA, NAMIC

Certification bodies:

SEI (ASTM Subsidiary)

UL: MoU to develop AM Safety standard (UL3400)

TUV SUD: MoU to develop joint programs

Other SDOs: More background on ASTM F42: See Shawn Moylan presentation earlier today.

ASME, AWS, SAE, etc.

7 7

The Impact of Standards

Recent Key Standards/Drafts for AM

Installation, Operation, and Performance Qualification for Production (ISO/ASTM 52930)

Best Practices for Metal Powder Bed Fusion Process to Meet Critical Applications (ISO/ASTM 52904)

Qualifying machine operators of LB-PBF machines and equipment used in aerospace applications (ISO/ASTM 52942)

Feedstock materials technical specifications on metal powder (WK62190)

Standard Guide for In-Situ Monitoring of Metal AM Parts (WK62181)

How ASTM Standards interact

See example Quality System in slide 9 8

8 B-383 4

1/6/2021 Snapshot of ISO/ASTM Standards (partial list) 9 9

An example Quality System Leveraging ASTM/ISO Standards How are you supposed to utilize these standards?

Credit: Shane Collins, F42 Note: Not inclusive of all Standards 10 10 B-384 5

1/6/2021 Guidelines for Installation, Operation and Performance Qualification (LB-PBF)

ISO/ASTM 52930

Ballot ended in April, currently available as ASTM F3434-20

Covers the key elements for Process Validation

Installation Qualification:

Equipment design & validation: FAT/SAT, Installation conditions, environmental operating limits, calibration

Operational Qualification:

Show the relationship of the input variables to the measured output for the specific combination of equipment with specific parts produced

KPVs, control of variability, optimal processing parameters

Performance/Part Qualification:

Validation vs requirements, Failure modes, Production Controls, In Process monitoring, data to be collected This guideline addresses IQ, OQ, and PQ issues directly related to the AM machine and connected equipment.

Scenarios requiring Revalidation: Physical facility, personnel, process and material issues are

Software/firmware updates, installation of additional components, repair/replacement of included to the extent necessary to components, changes to location/environment support machine qualification 11 11 Process Characteristics and Performance:

Practice for Metal Powder Bed Fusion to Meet Critical Applications

ISO/ASTM 52904

Released in June 2020

Covers the control of machines (Laser and Electron Beam) and process required to meet critical applications such as aerospace components

Feedstock Batches:

Powder container requirements, CoC, approval of material suppliers, feedstock material specification, guidance on used powder

Qualification:

Pre-build checks, periodic preventative maintenance, machine/process/part qualification

Manufacturing Plan:

Plan to detail the steps required for the PBF process, including pre-build check records, machining stock added, part nesting, reference parts etc.

The requirements contained in 52904 are applicable for

Guidance on Configuration Control of digital data and software control production components and mechanical test specimens using powder bed fusion (PBF) with both laser and electron beams.

12 12 B-385 6

1/6/2021 Material Standards:

316 L as an example

Covers AM components made from Electron Beam and Laser Powder Bed

Provides Minimum Tensile Properties

Similar to machined forgings & wrought

This specification intended to be used by both the Purchaser and the Producer of AM Material

Serves as a link to other key standards (testing, quality, terminology, etc.)

13 13 NDT Standards led by E07 committee on NDT Relevant standards:

ASTM E3166 - Guide for Nondestructive Testing of Metal Additively Manufactured Metal Aerospace Parts After Build

ASTM WK62181 - Standard Guide for InSitu Monitoring of Metal AM Aerospace Parts

ASTM WK56649 Additive Manufacturing NonDestructive Testing and Evaluation Standard Guideline for Intentionally Seeding Flaws Metallic Parts

ISO/ASTM JG59 DTR 52905 Standard Guideline for Defect Detection in Metallic Parts 1

4 14 B-386 7

1/6/2021 ASTM AM Center of Excellence (CoE)

- Overview of AM R&D portfolio and their impact on AM standards portfolio

- New program development in workforce development

- Expansion of inperson workshops attracting over 300 AM professionals in Paris, Virginia and Texas

- AM CoE's COVID19 response

- And more 15 15 ASTM AM Center of Excellence (CoE)

Why ASTM create the AM CoE?

About the CoE Rationale: Mission

Critical need to support accelerate development of globally accepted AM standards due to large gaps The Center bridges standards development

Critical need to educate the next generation of AM with R&D to better enable efficient development of:

professionals and implementation of standards

Standards

Education and training and Objective:

Certification and proficiency testing programs

To coordinate and conduct R&D that supports AM standards development

To support related education, training and other programs Expected outcome: AM standards via committees and Vision standards related products and services The Center facilitates collaboration and

Reducing timetomarket

Increasing widespread adoption coordination among government, academia, and industry to:

CoE relation with respect to F42 Committee: F42

Advance AM standardization membership and other committees can leverage AM CoE as a

Expand ASTM Internationals and our partners platform to conduct research that can fill gaps in ongoing capabilities.

standardization efforts 16 16 B-387 8

1/6/2021 Role of AM CoE with respect to F42 ASTM Committee F42 Dedicated to AM and has technical subcommittees focused on the development of consensus-based standards. This is happening in partnership with ISO TC261.

ASTM AM CoE A collaborative partnership among ASTM and organization representing government, industry, and academia that conducts strategic R&D to advance standards across all aspects of AM in addition to develop E&WD and Certification Programs.

Create strong national and

AM CoE is a platform that international industry F42 members can tap into Platform to conduct research to fill Focal point

AM CoE houses and Global hub for governmentuniversity for F42 for standard facilitates AM R&D partnerships; gaps in the AM standards. AM innovation members and related R&D generation to support to support

Develop education, training, AM

AM CoE is also a platform global standardization activities standardization proficiency testing, and community open for other ASTM efforts certification programs; and technical committees to utilize resources.

Host ASTM committee related events, workshops, and symposia.

17 AM CoE R&D: High Priority Areas AM CoE R&D Themes

1. Defined based on the CoE R&D input of the AM CoE Areas Design, Feedstock AM Qualification R&D team materials processes/ AM Data, and (Testing, Post Testing (NDT, etc.) 2. Shortterm Modeling Reuse) Process 3. Highlyfocused

4. Highpriority (linked to AMSC roadmap and Committee F42)

Topics are crosslinked to create synergy! 5. Aligned with America Makes projects

6. Coordination/collabora tion with NIST, other agencies F42.07 Applications F42.01 F42.04 F42.05 F42.06 F42.07 F42.08 Test Methods Design Materials and Environment, Applications Data Processes Health, and Safety 18 18 B-388 9

1/6/2021 AM CoE R&D Projects (Rounds 1 & 2)

R&D Projects Round 1: 20182019 (5 projects)

Post Processing (Surface finishing and LB-PBF Process Qualification Characterization)

Feedstock (Powder quality guide) Polymer AM Test Specimen Design Mechanical Testing of Metal AM Round 2: 20192020 (9 projects)

Standardization of Data Pedigree LB-PBF Process Qualification - Phase II Design Guide for Post-Processing Polymer AM Design Value Tests Powder Spreadability Dynamic Testing of Polymer AM Rapid Quality Inspection In-process Monitoring Specimen (RQIS)

Design Guides for AM Processes https://www.amcoe.org/projects ASTM International Information - Distribution limited- Please do not share without prior written approval 19 19 Research to Standardization

1. Work item 2. Draftunder 3. Editorial support 4. Undergoing balloting scoping and development and preballot and final approval of a registration standard WK49229*

WK65937*

WK62867 WK66029 WK65929 WK72172 WK66030 WK66682 WK73444 TBD WK71393 WK71391 WK71395 WK73340 Approved:

WK74390 ASTM F3413 - 19

Existing Work Items Status Key:

1. Work item scoping and registration

2. Draft under development

3. Editorial Support and PreBallot

4. Undergoing Balloting and Final approval as a standard ASTM International Information - Distribution limited- Please do not share without prior written approval 20 20 B-389 10

1/6/2021 3rd Round of Projects 2020 Request for Ideas The idea solicitation process was expanded to all ASTM members as a membership benefit Over 60 ideas were received during the survey Submissions addressed a wide range of challenges in AM that members face, including:

Design, Data, and Modeling Feedstock Processes and Post processing AM Testing Inspection and Qualification Project selection process Ideas were evaluated by the F42.90.05 team AM CoE Partners are developing SOWs Projects will start in October 2020 ASTM International Information - Distribution limited- Please do not share without prior written approval 21 21 3rd Round of Projects Summary of Ideas Over 60 ideas were received during the RFI Standard data formats and Recycling & reuse guidelines Calibration and maintenance Test methods and specimen Guidance for acceptance terminology to enable for powders and resins of AM machines; particularly designs for mechanical testing criteria of surface finish in exchange of data between Methods for evaluating multilaser systems Guidelines for implementation fatiguecritical applications organizations and across contamination (e.g. chemical, Guidance for use of post and use of witness testing Guidance for acceptance process steps moisture) of metal powders processing methods (e.g. hot Test methods for evaluating criteria based on size, type, Definition of minimum viable Methods for evaluating isostatic pressing, wet lattice structures and location of defects data packages for process feedstock variability chemical support removal) Guidelines for nondestructive Framework for quality control steps Material standards specifically Process safety guidance and evaluation in an environment with Data processing techniques to for additive manufacturing considerations (e.g. fume, multiple AM machines improve visualizations and applications safety incident database) Guidance for implementation, usefulness Material safety guidance and Methods for manufacturing analysis, and use of inprocess Benchmark datasets for considerations multimaterial/functionally monitoring data for calibration of models and graded components qualification simulations ASTM International Information - Distribution limited- Please do not share without prior written approval 22 22 B-390 11

1/6/2021 3rd round of R&D Projects Lead Project Title Material Topic Specimen Design for Compression Testing of Metallic Lattice Structures Common Data Exchange Format (CDEF) for Powder Characterization Metal Powder Feedstock Recycling and Sampling Strategies Material Metal Recycling and ReUse of Polymer Powders Polymer Miniature Tensile Specimens for Additive Manufacturing Ceramic Topic VolumeTraceability (VT) Development in Porosity Characterization with XCT for Design, Data, Integrity and Quality Assurance of AM Parts & Modeling Feedstock Development of Specification for Maraging Steel Processes &

PostProcesses Thermal Tolerance Test for LBPBF Process Parameters Testing Continuation of AM Polymer Projects (Design Value and Dynamic Testing)* Qualification

Continuation of projects initiated in2019 23 23 Other notable efforts AAPT (Advancing Additive Manufacturing ATRQ (Advanced Tools for Rapid Qualification) Post-Processing Techniques)

Total Federal Funding: ~$1M Total Federal Funding: ~$800K SLAM CORE TEAM ChrisHolshouser Program Manager RachaelAndrulonis Royal Lovingfoss ShaunFreed,PhD Andrew Hanson Alex Kitt, PhD Tasks: 1, 3, 4, 5, 6 Tasks: 1, 2, 3, 4,5 Tracy Albers, PhD NimaShamsaei, PhD Cameron Rogers Nicholas Tsolas, PhD Tasks: 1, 2, 4, 5 Tasks: 1, 2, 3, 4, 5 REQUIREMENTS AND TECHNICAL INPUT Government Review Board Technical Steering Committee Task 1: DoD Requirements All Tasks: Technical input throughout program Problem Statement: Service life predictive tools for Problem Statement: lack of best practices for post-application specific characterization do not exist for polymer processing of AM components AM materials exposed to harsh environmental conditions Objective: determine and enable the use of quantitative Objective: Quantify service life of AM polymer parts used in mechanical performance debits for both as-built and HIPed harsh/severe field environments thin-walled components and components with narrow flow channels Standard transition phase has defined in both projects - multiple work items has been registered 24 24 B-391 12

1/6/2021 New Project Call Mechanism New Call for Projects (CFP) mechanism allowing nonAM CoE partners to receive support to conduct targeted R&D projects Objectives Allow the AM community to participate in Research to Standardization initiative Evaluate the possibility of bringing on additional partners to the AM CoE team, to further accelerate standard development in AM PROPOSAL DUE NOVEMBER 24, 2020 SELECTION ANNOUNCEMENT JANUARY 2021 Review by F42.90.05 (Research and Innovation) is in ANTICIPATED START DATE MARCH 2021 progress 25 25 Research & Development Public R&D Roadmap Objectives Communicate the goals and current progress of the AM CoEs R&D program Provide a common vision for AM R&Ds future for the AM community to work toward 26 B-392 13

1/6/2021 AM Data Management and Schema Collaborative workshop with America Makes Workshop held December 2019 Two-day event: 20 technical talks, panel, roadmapping session Objective:

Identify challenges, gaps, and pain points Discuss solutions Build a momentum

Gaps and Challenges: Participants brainstormed gaps and challenges in small groups and voted on the highest priorities for the AMcommunity.

Potential Solutions: Participants brainstormed solutions to the priority gaps and challenges from the previous exercise and again voted on the highest priority solutions for the AM community.

Detailed Action Plans: Participants worked in small groups to develop detailed action plans for the highest priority solutions by identifying major tasks, milestones, stakeholder roles, and resource requirements.

27 27 Data - Highest Rated Gaps Formation of F42.08: Sub-committee dedicated to data Data Acquisition ASTM WK72172: New Practice for Additive manufacturing --

Potential for manual data entry to lead to human error General principles -- Overview of data pedigree Data Security The standard identifies classes of AM data (buckets), important terms for data that fit within those buckets, and relationships that exist between the buckets.

Data traceability/integrity/provenance

Protection of intellectual property (IP) Balloting completed, negative comments are being addressed (Tech contact: Yan during data sharing Lu, NIST)

Data Practices 37 Gaps Common Data Exchange Format (CDEF)

Minimum viable data packages Facilitates data sharing among data management systems, Will be registered in

Common terms and semantics for data definition Nov. 2020 (Lead org: EWI)

Data Management ASTM WK73978: New Specification for Additive Manufacturing

The need for unique, unified data identifiers (e.g., - Data Registration bar codes, alphanumeric tags, etc.) for AM data This standard practice comprises actions that users need take to Data Use register datasets and store them in a repository.

Correlating data to part performance Several other data related activities at F42 ISO/ASTM joint

Format or presentation mode of data groups such as JG64, JG67, JG70, JG7 28 28 B-393 14

1/6/2021 Highest Rated Action Plans Summarized gaps and challenges with respect to Data in AM, and provided solutions and action plans Common Data Dictionary (Underway: WK72172)

To standardize data elements that are collected during an AM process Common Data Exchange Format (Underway: work item to be registered next month)

A neutral and open data format that simplifies data exchange between data management systems that have built the appropriate translators.

Automated Data Acquisition To reduce human error, and enable application of advanced analytics Minimum Viable Datable Package To correlate key AM variables to part performance Public Use Cases To understand the ROI of the AM Data Ecosystem (Qual./Cert., Supply Chain, R&D)

Download at: https://amcoe.org/rdpublications 29 29 Other Initiatives/Activities In-Process Monitoring Project Assessment of State-of-the-Art of In-Process Control and In-Situ Monitoring for Additive Manufacturing Conducted literature review of available monitoring technique Evaluated TRL/MRL level Conducted survey (20+ experts in North America and Europe)

Report to be published for public before end of the year Data structure a primary concern Variation between companies constrains High spatial resolution sensor data produces development of universal acceptance criteria very large volumes of data Standardization of data simplification will be Real time data processing is challenging and necessary for allowance in expensive certification/qualification Clearance from NASA Parameterization reduces data volume for to publish Soon.

analysis and storage, but loses fidelity 30 30 B-394 15

1/6/2021 Other Initiatives/Activities NASA-ASTM Cooperative Agreement This cooperative agreement will be the basis to expand the AM CoE and NASAs evolving partnership Three-year contract Formalize collaboration aimed at supporting projects identified by NASA for the AM CoE execution First project Qualification framework for laser beam powder bed fusion (LB-PBF)

AM processes One of the largest impediments to the growing implementation of AM into many applications.

Need to standardize process qualification that ultimately contribute to robust data generation, collection and specification 31 31 Other Initiatives/Activities AM Cyber Security Training Project America Makes Open Project Call ASTM and Auburn University: AM Cyber Security training Security is a critical gap for digital manufacturing-related technologies The contribution ensures the creation of new curricula and programs to train the AM industry in the subject and help ensure the integrity and security of the entire value chain 32 32 B-395 16

1/6/2021 ASTM ICAM 2020: 5th event in a row 18 Symposium topics linked to ASTM technical committees

1. Structural Integrity

2. i4.0 3.

4.

Feedstock Microstructure 11

5. NDE AM related

6. InSitu Monitoring/Control topics

7. Fatigue

8. Mechanical testing

9. General topics

10. Ceramics

11. Polymers

1. Construction

2. Maritime and Oil & Gas

+Nuclear 7 3.

4.

Electronics Medical Application 5. Aviation and Spaceflight

/Energy? 6. Transportation/Heavy Machinery topics

7. Defense 33 ASTM Perspective on AM Standardization

- AM technologies continue to rapidly evolve across several industry sectors

- We continue to see evolution of applications in the energy sector including nuclear, renewables, oil/gas, etc.

- ASTM continues to support closure of standardization gaps by relying on key roadmaps, industry needs, coordination, etc.

- We believe in developing agile and innovative solutions as the needs of industry continue to evolve

- Opportunities exist to accelerate standardization

- Role of government agencies by defining standard deliverables in project calls is key

- ASTM will actively participate in research to standardization projects

- No need to reinvent the wheel and duplicate efforts

- ASTM continues to collaborate and coordinate with other active bodies and open to new collaborations (example is interaction with ISO)

- Ultimately, what drives the industry forward in terms of implementation is the quality and utility of the standards that are coming out 34 34 B-396 17

1/6/2021 Q&A Thank you for your attention!

Dr. Mohsen Seifi mseifi@astm.org www.amcoe.org 35 35 Appendix

List of standards from ASTM and ISO 36 36 B-397 18

1/6/2021 List of Published standards (As of 07/2020) 15 Standards published by ASTM Only 10 Standards published by ISO/ASTM ASTM F297113 Standard Practice for Reporting Data for Test Specimens Prepared by Additive ISO/ASTM5290015 Standard Terminology for Additive Manufacturing General Principles Terminology1, 2 Manufacturing ISO/ASTM5290116 Standard Guide for Additive Manufacturing General Principles Requirements for ASTM F304914 Standard Guide for Characterizing Properties of Metal Powders Used for Additive Purchased AM Parts Manufacturing Processes ASTM F300114 Standard Specification for Additive Manufacturing Titanium6 Aluminum4 Vanadium ELI ISO/ASTM5291516 Standard Specification for Additive Manufacturing File Format (AMF) Version 1.

(Extra Low Interstitial) with Powder Bed Fusion ISO/ASTM5291018 Additive manufacturing Design Requirements, guidelines and recommendations ASTM F3091/F3091M14 Standard Specification for Powder Bed Fusion of Plastic Materials ISO/ASTM5290219 Additive manufacturing Test artifacts Geometric capability assessment of additive ASTM F312214 Standard Guide for Evaluating Mechanical Properties of Metal Materials Made via Additive manufacturing systems Manufacturing Processes ISO/ASTM5292113(2019) Standard Terminology for Additive ManufacturingCoordinate Systems and Test ASTM F292414 Standard Specification for Additive Manufacturing Titanium6 Aluminum4 Vanadium with Methodologies Powder Bed Fusion ASTM F305614e1 Standard Specification for Additive Manufacturing Nickel Alloy (UNS N06625) with Powder ISO/ASTM5290719 Additive manufacturing Feedstock materials Methods to characterize metallic powders Bed Fusion ISO/ASTM52911119 Additive manufacturing Design Part 1: Laserbased powder bed fusion of metals ASTM F305514a Standard Specification for Additive Manufacturing Nickel Alloy (UNS N07718) with Powder Bed Fusion ISO/ASTM52911219 Additive manufacturing Design Part 2: Laserbased powder bed fusion of polymers ASTM F318416 Standard Specification for Additive Manufacturing Stainless Steel Alloy (UNS S31603) with ISO/ASTM5290419 Additive Manufacturing Process Characteristics and Performance: Practice for Metal Powder Powder Bed Fusion Bed Fusion Process to Meet Critical Applications ASTM F318716 Standard Guide for Directed Energy Deposition of Metals ASTM F321317 Standard for Additive Manufacturing Finished Part Properties Standard Specification 4 Standards published by ISO for Cobalt28 Chromium6 Molybdenum via Powder Bed Fusion ISO 172962:2015 Additive manufacturing General principles Part 2: Overview of process categories and feedstock ASTM F330218 Standard for Additive Manufacturing Finished Part Properties Standard Specification for Titanium Alloys via Powder Bed Fusion ISO 172963:2014 Additive manufacturing General principles Part 3: Main characteristics and corresponding test methods ASTM F331818 Standard for Additive Manufacturing Finished Part Properties Specification for AlSi10Mg with Powder Bed Fusion Laser Beam ISO 172964:2014 Additive manufacturing General principles Part 4: Overview of data processing ASTM F330118a Standard for Additive Manufacturing Post Processing Methods Standard Specification ISO 275471:2010 Plastics Preparation of test specimens of thermoplastic materials using mouldless technologies Part 1:

for Thermal PostProcessing Metal Parts Made Via Powder Bed Fusion1, 2 General principles, and laser sintering of test specimens ASTM F333520 Standard Guide for Assessing the Removal of Additive Manufacturing Residues in Medical Devices Fabricated by Powder Bed Fusion 37 37 List of Under Development standards (continued) 20 Standards currently under development: ASTM ASTM WK66029 New Guide for Mechanical Testing of Polymer Additively Manufactured Materials ASTM WK66030 Quality Assessment of Metal Powder Feedstock Characterization Data for Additive Manufacturing ASTM WK67454 Additive manufacturing Feedstock materials Methods to characterize metallic powders ASTM WK69371 Standard practice for generating mechanical performance debits ASTM WK69731 New Guide for Additive Manufacturing NonDestructive Testing (NDT) for Use in Directed Energy Deposition (DED) Additive Manufacturing Processes ASTM WK71391 Additive Manufacturing Static Properties for Polymer AM (Continuation)

ASTM WK71393 Additive manufacturing assessment of powder spreadability for powder bed fusion (PBF) processes ASTM WK71395 Additive manufacturing accelerated quality inspection of build health for laser beam powder bed fusion process ASTM WK48549 AMF Support for Solid Modeling: Voxel Information, Constructive Solid Geometry Representations and Solid Texturing ASTM WK72172 Additive manufacturing General principles Overview of data pedigree ASTM WK65937 Additive Manufacturing Space Application Flight Hardware made by Laser Beam Powder Bed Fusion Process ASTM WK69730 Additive Manufacturing Wire for Directed Energy Deposition (DED) Processes in Additive Manufacturing ASTM WK69732 Additive Manufacturing Wire Arc Additive Manufacturing ASTM WK72317 Additive Manufacturing Powder Bed Fusion Multiple Energy Sources ASTM WK72457 Additive manufacturing processes Laser sintering of polymer parts/laserbased powder bed fusion of polymer parts Qualification of materials ASTM WK66637 Additive Manufacturing Finished Part Properties Specification for 4340 Steel via Laser Beam Powder Bed Fusion for Transportation and Heavy Equipment Industries ASTM WK67583 Additive Manufacturing Feedstock Materials Powder Reuse Schema in Powder Bed Fusion Processes for Medical Applications ASTM WK70164 Additive Manufacturing Finished Part Properties Standard Practice for Assigning Part Classifications for Metallic Materials ASTM WK71891 Additive Manufacturing of Titanium6 Aluminum4 Vanadium ELI (Extra Low Interstitial) with Powder Bed Fusion for Medical Devices ASTM WK66682 Evaluating Postprocessing and Characterization Techniques for AM Part Surfaces 38 38 B-398 19

1/6/2021 List of standards (continued)

ISO/ASTM WD529262 Additive manufacturing Qualification principles Part 2: Qualification of machine operators for metallic parts production for PBFLB 45 Standards currently under development: ISO/ASTM ISO/ASTM WD529263 Additive manufacturing Qualification principles Part 3: Qualification of machine operators for metallic parts production for PBFEB ISO/ASTM 529031 Additive manufacturing Material extrusionbased additive manufacturing of plastic materials Part 1: Feedstock materials ISO/ASTM WD529264 Additive manufacturing Qualification principles Part 4: Qualification of machine operators for metallic parts production for ISO/ASTM DIS529032 Additive manufacturing Standard specification for material extrusion based additive manufacturing of plastic materials DEDLB Part 2: Process Equipment ISO/ASTM WD529265 Additive manufacturing Qualification principles Part 5: Qualification of machine operators for metallic parts production for ISO/ASTM DTR52905 Additive manufacturing General principles Nondestructive testing of additive manufactured products DEDArc ISO/ASTM CD TR52906 Additive manufacturing Nondestructive testing and evaluation Standard guideline for intentionally seeding flaws in parts ISO/ASTM PWI 52927 Additive manufacturing Process characteristics and performance Test methods ISO/ASTM AWI 52908 Additive manufacturing Postprocessing methods Standard specification for quality assurance and post processing of ISO/ASTM PWI 52928 Powder life cycle management powder bed fusion metallicparts ISO/ASTM NP 52930 Guideline for installation Operation Performance Qualification (IQ/OQ/PQ) of laserbeampowder bed fusion equipment for ISO/ASTM AWI 52909 production manufacturing Additive manufacturing Finished part properties Orientation and location dependence of mechanical properties for metal powder bed fusion ISO/ASTM CD 52931 Additive manufacturing Environmental health and safety Standard guideline for use of metallic materials ISO/ASTM PWI 529113 Additive manufacturing Technical design guideline for powder bed fusion Part 3: Standard guideline for electronbased ISO/ASTM WD 52932 Additive manufacturing Environmental health and safety Standard test method for determination of particle emission rates powder bed fusion of metals from desktop 3D printers using material extrusion ISO/ASTM NP 52933 Additive manufacturing Environment, health and safety Consideration for the reduction of hazardous substances emitted ISO/ASTM PRF TR52912 Additive manufacturing Design Functionally graded additive manufacturing during the operation of the nonindustrial ME type 3D printer in workplaces, and corresponding test method ISO/ASTM PWI 529131 Additive manufacturing Test methods for characterization of powder flow properties for AM applications Part 1: General ISO/ASTM PWI 52934 Additive manufacturing Environmental health and safety Standard guideline for hazard risk ranking and safety defense requirements ISO/ASTM NP 52935 Additive manufacturing Qualification Principles Qualification of coordinators for metallic parts production ISO/ASTM PWI 52914 Additive manufacturing Design Standard guide for material extrusionprocesses ISO/ASTM WD529361 Additive manufacturing Qualification principles Laserbased powder bed fusion of polymers Part 1: General principles, ISO/ASTM WD 52916 Additive manufacturing Data formats Standard specificationfor optimized medical image data preparation of testspecimens ISO/ASTM WD 52917 Additive manufacturing Round Robin Testing Guidance for conducting Round Robin studies ISO/ASTM PWI 52937 Additive manufacturing Qualification principles Qualification of designers for metallic parts production ISO/ASTM CD TR52918 Additive manufacturing Data formats File format support, ecosystem and evolutions ISO/ASTM DIS52941 Additive manufacturing System performance and reliability Standard test method for acceptance of powderbed fusion machines for metallic materials for aerospace application ISO/ASTM WD 529191 Additive manufacturing Test method of sand mold for metalcasting Part 1: Mechanical properties ISO/ASTM DIS52942 Additive manufacturing Qualification principles Qualifying machine operators of laser metal powder bed fusion machines and ISO/ASTM WD 529192 Additive manufacturing Test method of sand mold for metalcasting Part 2: Physical properties equipment used in aerospace applications ISO/ASTM PWI 529201 Additive manufacturing Qualification principles Part 1: Conformity assessment for AM systemin industrial use ISO/ASTM PWI 529431 Additive manufacturing Process characteristics and performance Part 1: Standard specification for directed energy deposition using wire and beam inaerospace applications ISO/ASTM WD 529202 Additive manufacturing Qualification principles Part 2: Requirements for industrial additive manufacturing sites ISO/ASTM PWI 529432 Additive manufacturing Process characteristics and performance Part 2: Standard specification for directed energy deposition ISO/ASTM DIS52921 Additive manufacturing General principles Standard practice for part positioning, coordinates and orientation using wire and arc in aerospaceapplications ISO/ASTM PWI 52922 Additive manufacturing Design Directed energydeposition ISO/ASTM PWI 529433 Additive manufacturing Process characteristics and performance Part 3: Standard specification for directed energy deposition ISO/ASTM PWI 52923 Additive manufacturing Design decisionsupport using laser blown powder in aerospace applications ISO/ASTM PWI 52944 Additive manufacturing Process characteristics and performance Standard specification for powder bed processes in aerospace ISO/ASTM DIS52924 Additive manufacturing Qualification principles Classification of part properties for additive manufacturing of polymer applications parts ISO/ASTM DIS52950 Additive manufacturing General principles Overview of data processing ISO/ASTM DIS52925 Additive manufacturing Qualification principles Qualification of polymer materials for powder bed fusion using a laser ISO/ASTM PWI 52951 Additive manufacturing Data packages for AMparts ISO/ASTM WD 529261 Additive manufacturing Qualification principles Part 1: Qualification of machine operators for metallic parts production 39 39 B-399 20

1/6/2 0 2 1 NASA activities and perspectives on standardization in the AM certification process:

NASASTD6030 and beyond Douglas Wells NASA Marshall Spaceflight Center Douglas.N.Wells@nasa.gov United States Nuclear Regulatory Commission Public Meeting (Virtual)

Workshop on Advanced Manufacturing Technologies for Nuclear Applications November 710, 2020 1

1 Contents of Discussion

Overview of selected standardization activities

Within Agency - NASASTD6030 development

Review of status

Key concepts

Supporting Standards Development Organizations (SDOs) 1

ASTM CoE R&D in LBPBF Process Qualification

Considerations for critical, but uninspectable AM hardware

Cooperative work with FAA on DARWIN code development for AM applications 2

2 B-400

1/6/2 0 2 1 Motivations for Agency Standards NASA has been motivated to develop internal standards for AM to provide for a complete and common foundation while industry standards (and standards of practice) evolve.

NASA AM standards have the following intent:

To provide a consistent methodology for AM on NASA projects

To define a complete and integrated approach to AM hardware implementation

To ensure NASA visibility into the introduction of additively manufactured hardware

To allow for awareness and evaluation of risk with AM implementation 3

Statement A: Approved for public release; distribution is unlimited.

3 New Agency Document Structure MSFCSTD3716 Fundamental Requirements NASASTD6032 NASASTD6030 AM AM Appendix B Standard for Standard for Crewed Aero Noncrewed 2

Tailoring Requirements for:

Guidelines MSFCSPEC3717 Process definition, QMPs NASASPEC6033 NASAHDBK6034 Requirements for:

Equipment and facility AM Spec for Handbook process control Equipment to AM and Standards Facilities 4 4

B-401

1/6/2 0 2 1 AM Certification: Governing Principles

Understanding and Appreciation of the AM process

Integration across disciplines and throughout the process

Discipline to define and follow the plan

Have a plan

Integrate a Quality Management System (QMS)

Statistical

Build a foundation Process

Equipment and Facility Control (SPC) Rationale

Training Qualified Metallurgical Qualified for

Process and machine qualification Process Part Process (QPP)

Qualified

Material Properties / SPC (QMP) AM parts Material

Plan each Part Properties

Design, classification, Preproduction articles Suite (MPS)

Qualify and lock the part production process

Produce to the plan - Stick to the plan 5

5 Applicable Materials and Technologies in NASASTD6030 3

Adaptive technologieswhere process parameters change based on active feedback during the manufacturing processare not allowed without a tailored, pointdesign methodology. 6 6

B-402

1/6/2 0 2 1 NASASTD6030 AM Part Classification 7

7 Material Engineering Equivalence Statistical process controls are important in sustaining certification rationale

Statistical / Engineering equivalency evaluations substantiate design values and process stability build tobuild a) Process qualification b) Witness testing 4 c) Integration to existing material data sets d) Preproduction article evaluations

Equivalency of material performance is an anchor to the structural integrity rationale for additively manufactured parts 8

8 B-403

1/6/2 0 2 1 Standardizing AM Process Qualification One example of NASAs involvement in the AM SDO landscape.

Welldefined process qualification standards remain a clear gap in the AM standards framework

This gap impedes the diversification and responsiveness of AM part suppliers when qualification requirements are unique to each purchaser Many fundamental concepts that define AM process qualification remain undetermined

Terminology - What nomenclature is used to describe the process?

Scope - What is within the scope of process qualification?

Intent - What should the final outcome of a successful process qualification consist of?

Rigor - How detailed and thorough should a process qualification be? Same for all parts?

Application - How will a process qualification standard fit into the bigger picture of the AM standards framework?

9 9

Standardizing AM Process Qualification Core fundamentals of the project approach remain the same:

1. Develop consensus within the ASTM CoE community regarding minimum requirements for the qualification of L-PBF machines and processes. 5

2. Establish a standard set of procedures, test methods, and evaluations used to establish L-PBF qualification based on fundamental objectives.

3. Establish quantitative and/or qualitative metrics applicable to each evaluation to define successful machine and process qualification.

4. Conduct development and round-robin-style trials of the qualification evaluations and associated metrics.

5. Establish a set of recommendations to appropriate F42 sub-committees for standards implementation.

10 10 B-404

1/6/2 0 2 1 Standardizing AM Process Qualification Thermal Challenge Build for Process Box Confirmation (Auburn University)

Subset of Process Qualification Standardization

Objective: confirm candidate parameter set is well centered in the process box.

Develop standard parts or part design philosophy

Challenge the AM process box through geometry, and potentially scan pattern

Not used in defining process box during parameter development

Needs to be able to work with fixed, black box parameter sets from OEMs 11 11 Assessment of Noninspectable Critical Parts

Risk level in AM parts for space applications continues to accelerate rapidly

Need methodologies to assess damage tolerance (DT) in critical parts that, through mass or complexity, significantly limit or preclude traditional nondestructive inspection

Challenges in work:

Integration tools for deterministic or probabilistic DT assessment 6

DARWIN software through Southwest Research Institute

Projects complimentary to similar FAA efforts

Part zoning methodologies/considerations

AM defect characterization

Inherent

Rogue / process escapes

Leveraging NDI simulation to understand limits of coverage

Practical use of process data on a perpart basis

In situ monitoring data

Qualification of in situ monitoring systems 12 12 B-405

1/6/2 0 2 1 Conclusions

1. NASA remains intently interested in standardization for AM

Working Agency (public) standards as well as with multiple SDOs

Standards for AM process qualification remains a focus

2. NASA has nearterm challenges regarding risk management of high criticality parts with limited postbuild structural integratory verification

Working on integrated methods to utilize all available data (traditional NDE, inprocess data) and assessment techniques (zoning, probabilistic assessments, ) to manage risk 13 13 7

B-406

1/6/2021 Development of AWS D20.1/D20.1M, Specification for Fabrication of Metal Components using Additive Manufacturing Jessica Coughlin AWS D20 Committee Chair 1

AWS D20 COMMITTEE ON ADDITIVE MANUFACTURING

Charter: Create a standard containing requirements for fabricating metal components using AM that, when adhered to, will result in the repeatable production of metal AM components that meet functional requirements

Result: AWS D20.1/D20.1M:2019, Specification for Fabrication of Metal Components using Additive Manufacturing 2

B-407 1

1/6/2021 AWS D20.1/D20.1M - PROCESSES COVERED 3

AWS D20.1/D20.1M - COMPONENT CLASSIFICATION AWS D20.1 contains graded requirements for qualification and inspection based on the classification of the AM component. (1.4)

Class A - Critical application. A component whose failure would cause significant danger to personnel, loss of control, loss of a system, loss of a major component, or an operating penalty.

Class B - Semicritical application. A component whose failure would reduce the overall strength of the equipment or system or preclude the intended functioning or use of equipment, but loss of the system or the endangerment of personnel would not occur.

Class C - Noncritical application. A component whose failure would not affect the operation of the system or endanger personnel.

4 B-408 2

1/6/2021 AWS D20.1/D20.1M:2019 CLAUSES 1 General Requirements 2 Normative References 3 Terms and Definitions 4 Design Requirements for Additively Manufactured Components 5 Additive Manufacturing Machine and Procedure Qualification 6 Additive Manufacturing Machine Operator Performance Qualification 7 Fabrication 8 Inspection 5

AWS D20.1/D20.1M:2019 ANNEXES A Additive Manufacturing Qualification Records B Informative References C Examples of Standard Qualification Build Designs for Powder Bed Fusion D Suggested Format for Fabrication Records E Process Flowcharts for Producing Components using AWSD20.1/D20.1M F Requesting an Official Interpretation on an AWS Standard Also contains: Commentary on the Specification for Fabrication of Metal Components using Additive Manufacturing 6

B-409 3

1/6/2021 AWS D20.1/D20.1M DESIGN REQUIREMENTS - CLAUSE 4 The Engineer is required to design and define component requirements to ensure compliance with all functional and system requirements. Responsibilities include:

Develop or obtain appropriate material property requirements to satisfy the component design. (4.2)

Design witness specimens for Class A and Class B PBF component builds. (4.3)

Define component classification level, final dimensions, process restrictions, postprocessing requirements, etc. (4.4) 7 AWS D20.1/D20.1M MACHINE AND PROCEDURE QUALIFICATION - CLAUSE 5 As in the welding industry, qualification is achieved through the successful fabrication, inspection, and testing of material representative of the production component.

Procedure Qualification Record (PQR) and Machine Qualification Record (MQR) required to document variables used during qualification builds.

(5.1.1) Example records for each process provided in Annex A.

Additive Manufacturing Procedure Specification (AMPS) must be qualified prior to fabrication of production components. Includes: AM process, component classification, build model file name, all applicable build platform, feedstock, machine, environment, build parameters, and postprocessing information. (5.1.2) 8 B-410 4

1/6/2021 AWS D20.1/D20.1M MACHINE AND PROCEDURE QUALIFICATION 9

AWS D20.1/D20.1M PBF MACHINE QUALIFICATION PBF machine qualification requires a standard qualification build with 54 tension test specimens (minimum), representative of the component in the following ways:

Thick and thin specimens shall be (support structure not shown) fabricated to represent a range of component feature geometries. (5.2.1.1)

Specimen orientations shall include tensile axis within the XY plane, along the Zaxis, and at 45° from the Zaxis. (5.2.1.2)

Specimens shall encompass the build volume to be used during component fabrication. (5.2.1.2)

Dimensional inspection features shall be included in the build. (5.2.1.1) 10 B-411 5

1/6/2021 AWS D20.1/D20.1M DED MACHINE QUALIFICATION DED machine qualification requires a standard qualification build from which a minimum of 9 tension test specimens can be removed.

The build shall provide material with heat sink conditions representative of the component, with vertical and horizontal plane conditions at a minimum. (5.2.2.1)

Dimensional inspection features shall be included in the build. (5.2.2.1)

Three additional tension test specimens required across interface for components with integrated build platform. (5.2.3.2) 11 AWS D20.1/D20.1M AM PROCEDURE QUALIFICATION For PBF and DED components, AM procedure qualification requires fabrication and testing of a preproduction test build, which shall:

Be fabricated from the same build file as will be used for the production component (i.e., shall have identical geometry to the production component, including witness specimens). (5.2.3)

Undergo the same postprocessing steps (e.g., surface finishing, thermal processing) as will be used for the production component. (5.2.3)

Be fabricated using the same parameters as will be used for the production component, aside from changes within qualified limits. (5.2.3) 12 B-412 6

1/6/2021 AWS D20.1/D20.1M QUALIFICATION LIMITS AWS D20.1 lists all qualification variables for PBF (Table 5.2) and DED (Table 5.3) processes, along with the changes to each variable that require requalification of the AM machine (M), AM procedure (P), or both (Q).

Sections include Build Design, Material, Machine, Environment, Heat Source Characteristics, Deposition Characteristics, a n PostProcessing. d 13 AWS D20.1/D20.1M MACHINE OPERATOR PERFORMANCE QUALIFICATION - CLAUSE 6 AM machine operators must be capable of repeatedly fabricating acceptable AM components. Qualification is achieved through training, practical examination, and a completion of a demonstration build (6.3).

Training topics include (6.3.2.1):

Feedstock material storage, safety, and setup.

Cleaning requirements and environmental controls.

Machine calibration, preventative maintenance, and safety.

Loading of qualified build parameters.

Running and monitoring AM build cycles.

Recording AM build cycle data.

Common build defects, their causes, and means of prevention.

Recovery from planned and unplanned build interruptions.

14 B-413 7

1/6/2021 AWS D20.1/D20.1M FABRICATION OF AM PARTS - CLAUSE 7 Clause 7 identifies various fabrication controls requirements

Digital control plan (7.2)

Preproduction maintenance checklist (7.3)

Equipment calibration control plan (7.3.1)

Identification and traceability controls (7.4.1)

Cleaning (7.4.2.1)

Build platform dimensions (thickness, surface finish, parallelism) (7.4.2.2)

Feedstock specification and powder recycling (7.4.2.3)

Feedstock change plan (7.4.2.4)

Preheat and interpass temperature controls (7.5)

Contamination control (7.6.1)

Gas specification (7.6.2) 15 AWS D20.1/D20.1M FABRICATION OF AM PARTS Clause 7 identifies various fabrication controls requirements

Use of qualified AMPS (7.7)

Planned and unplanned build interruptions (7.8)

Inprocess adjustments or modifications (7.9, 7.13)

Witness specimens (7.10)

Component identification (7.11)

Build acceptance (7.12)

Postbuild processing (7.14)

Records requirements (7.15) 16 B-414 8

1/6/2021 AWS D20.1/D20.1M INSPECTION OF AM PARTS - CLAUSE 8 Clause 8 contains inspection, testing, and acceptance requirements for qualification builds, production components, and witness specimens:

Qualification of inspection personnel. (8.1)

Nondestructive examination (NDE) requirements and acceptance:

Visual examination (8.2.1), dimensional examination (8.2.2), penetrant testing (PT) (8.2.3), magnetic particle testing (MT) (8.2.4), radiographic testing (RT) (8.2.5), density testing (8.2.6)

Destructive evaluation requirements and acceptance:

Tension testing (8.3.1), metallographic examination (8.3.2), chemical analysis (8.3.3) 17

AWS D20.1/D20.1M:2019 provides comprehensive design, qualification, fabrication, and inspection requirements for metal components using PBF and DED AM processes.

Extensive testing and evaluation are required to ensure that AM parts will be produced with acceptable, repeatable properties.

Potential material variability related to build orientation, thickness, and surface roughness demonstrates the importance of testing material representative of component features.

Standardized test article builds using representative material provide a repeatable means for detecting quality concerns and sources of microstructural and mechanical property variability.

CONCLUSIONS 18 B-415 9

1/6/2 0 2 1 NRC Regulatory Approach for Advanced Manufacturing Technologies Carolyn Fairbanks Office of Nuclear Reactor Regulation December 10, 2020 1

Techniques and material processing methods

Not traditionally used in the U.S.

nuclear industry

Not formally standardized/codified Advanced by the nuclear industry Manufacturing

Initial AMTs based on industry interest: 1 Technologies

Laser Powder Bed Fusion (LPBF)

Direct Energy Deposition (DED)

Cold Spray

Electron Beam Welding

Powder Metallurgy - Hot Isostatic Pressing (PM-HIP) 2 2

B-416

1/6/2 0 2 1 Action Plan, Rev. 1 - Tasks

Task 1 Technical Preparedness

Technical information, knowledge and tools to prepare NRC staff to review AMT applications

Task 2 Regulatory Preparedness

Regulatory guidance and tools to prepare staff for efficient and effective review of AMTfabricated components submitted to the NRC for review and approval

Task 3 Communications and Knowledge Management

Integration of information from external organizations into the NRC staff knowledge base for informed regulatory decisionmaking

External interactions and knowledge sharing, i.e. AMT Workshop 3

3 Subtask 1A: AMT Processes under Consideration

Perform a technical assessment of selected AMTs (Laser Powder Bed Fusion, Directed Energy Deposition, PM HIP, EBwelding, and Cold Spray)

Gap assessment for each selected AMTs vs traditional manufacturing techniques Subtask 1B: Inspection and NDE Technical

Assess the state of technologies in the testing and examination of AMTs Preparedness

Will inform staff decisions related to use of NDE on AMTfabricated components Activities Subtask 1C: Modeling and Simulation of Microstructure and Properties 2 (Task 1)

Evaluate modeling and simulation tools used to predict the initial microstructure, material properties and component integrity of AMT components

Identify existing gaps and challenges that are unique to AMT compared to conventional manufacturing processes

Survey of Modeling and Simulation Techniques for Advanced Manufacturing Technologies:

Volume I - Predicting Initial Microstructures (ML20269A301)

Volume II Predicting Material Performance from Material Microstructure 4

4 B-417

1/6/2 0 2 1 Subtask 2A: Implementation using the 10 CFR 50.59 Process

Provide guidance and support to regional inspectors regarding AMTs implemented under 50.59 Regulatory Subtask 2B: Assessment of Regulatory Guidance Preparedness

Assess whether any regulatory guidance needs to be updated or created to clarify the process for reviewing submittals with AMT Activities components

Complete: ML20233A693 (Task 2) Subtask 2C: AMT Guidelines Document

Develop guidelines which describe the generic technical information to be addressed in AMT submissions

Public meeting discussing initial framework was held July 30, 2020 https://www.nrc.gov/pmns/mtg?do=details&Code=20200816

Meeting summary: ML20240A077 5

5

Industry identified 10 CFR 50.59 as the regulatory path for initial AMT components at U.S. NPPs.

Staff performed a preliminary review of the 50.59 Implementation process for changes to use AMT components.

Using the 10 CFR 50.59

In-depth development based on consensus inputs from many NRC counterparts.

Process -

3 Background Multiple rounds of review & comment from regulatory and technical subject matter experts in (Subtask 2A) the Regions, NRR, and RES; and from OGC attorneys.

Staffs review expanded to address technical QA criteria for design control & procurement in addition to 50.59. 6 6

B-418

1/6/2 0 2 1 Purpose of the Draft Paper

Document staff review of how a change to use an AMT component could be implemented at a plant under QA controls and the 10 CFR 50.59 process.

Changes in the facility made without prior Implementation application for NRC review & approval.

Using the 10 CFR

Focus is 10 CFR Part 50, Appendix B and 50.59 Process - 10 CFR 50.59 requirements and guidance.

Purpose & Status Status (Subtask 2A)

The NRC requests comments from the public on the draft document for AMT Subtask 2A, Implementation of QA Criteria

& 10 CFR 50.59 for AMT Components.

FRN - scheduled publication Dec. 10, 2020. Document 2020-26845; Docket ID NRC-2020-0253.

Public meeting planned for January 2021. 7 7

Assessment of Regulatory Guidance (Subtask 2B)

Standard Review Plan (SRP) provides regulatory guidance to NRC technical reviewers regarding a large range of core regulatory areas.

Focused on SRP sections and regulatory guides applicable to material 4 engineering reviews.

Staff concluded that there were no impediments in current regulations or regulatory guidance that were reviewed.

Future consideration of updating existing regulatory guidance or developing additional regulatory guidance may help improve the efficiency and effectiveness of the staffs review and provide clearer expectations to the applicants for AMT submittals with regards to material properties and functions.

Complete: ML20233A693 8

8 B-419

1/6/2 0 2 1

Develop a report providing guidelines AMT which describe the generic technical information to be addressed in AMT Application submissions.

Guidelines

Public meeting discussing initial Framework framework was held July 30, 2020:

https://www.nrc.gov/pmns/mtg?do=det (Subtask 2C) ails&Code=20200816.

Meeting summary: ML20240A077.

Framework document has evolved further into a draft document.

Future public comment period, public meeting on the draft document.

9 9

The draft framework provides a starting AMT point for discussion on potential guidance regarding the use of AMTs.

Application

AMTs include techniques and material Guidelines processing methods not traditionally used in Framework the US nuclear industry that have yet to be formally standardized by the nuclear (Subtask 2C) 5 industry and approved by the NRC (e.g.,

ASME Code, topical report).

AMTs can include new ways to fabricate or join components, surface treatments, or other processing techniques to provide a performance or operational benefit.

10 10 B-420

1/6/2 0 2 1

Framework and associated guidelines must be sufficient and flexible.

Currently there are two conventional paths to demonstrating that an AMT component is acceptable General and will fulfill its intended function.

- Equivalency Approach: attributes of the AMT Review component meet or exceed the original design and performance requirements. (e.g., equal to or Philosophy greater than tensile, yield, fracture toughness, SCC resistance).

- Design Modification: Provide technical justification for changing existing requirements. For example, the original material provided significant margin compared to what is necessary for the component to meets its intended function.

11 11

10 CFR 50.59 and QA/design controls

- Subtask 2A of AMT Action Plan, rev.1

- Draft 2A document will be available for public comment Dec. 10, 2020

- FRN Document Number 2020-26845 Regulator - Docket ID NRC-2020-0253 y

License amendment (Technical Specification change, etc.)

6 Pathways

10 CFR 50.55a Codes and Standards

- (z) Alternatives to codes and standards

(1) Acceptable level of quality and safety

(2) Hardship without a compensating increase in quality and safety 12 12 B-421

1/6/2 0 2 1

An applicant must demonstrate that the AMT component provides an acceptable level of quality and safety.

- Meets the same design requirements as an ASME component.

- Example: An AMT component material is not 10 CFR produced using an approved ASME Code material specification and is not equivalent to the 50.55a(z)(1) original code material.

Meets ASME Code Section III design allowables

Fulfills the material requirements in the design (e.g., tensile, yield, fracture toughness)

Fulfills the intended function of the component 13 13

An applicant must demonstrate that compliance with the specified requirements would result in hardship or unusual difficulty without a compensating increase in the level of quality and safety.

Example: ASME Code Class 2 or 3 pump can no longer remain in service due to a degraded pump case housing component.

The OEM is no longer in business 10 CFR

A suitable Code compliant component will take several months or longer to procure 50.55a(z)(2) 7

The AMT component material is not equivalent to the original material

The AMT component does not meet the original design requirements

The AMT component will fulfill the intended function of the component

The AMT component may be acceptable if the licensee demonstrates that the AMT component/part fulfills its intended safety function. Risk insights may also be considered.

14 14 B-422

1/6/2 0 2 1 The process flow chart in Appendix A to the AMT Application Guidelines Framework document, along with definitions and short descriptions, describes a holistic approach to the qualification and performance considerations for any system, structure, or safety significant component (SSC), including the Process underlying material and fabrication process.

The flow chart is intended to cover a broad range of AMTs Flow and be a guide which outlines the types of information that could be included in a licensees request to facilitate the NRCs review.

Chart

Depending on the AMT process used, some of the information in the flow chart may not be necessary.

The focus of the information should be on those unique attributes associated with AMT qualification and performance compared to conventionally manufactured SSCs.

The application may leverage relevant aspects of ASME and ASTM standards that prescribe certain testing requirements for conventionally manufactured items.

15 15 8

16 B-423

1/6/2 0 2 1 AMT-Specific (Initial 5 AMTs) Generic Technical Regulatory Guidelines (Subtask 1A) (draft for FRN p ublic comment)

Technical Draft Technical Context Guidelines Letter Report Document Document LPBF LPBF LPBF Technical Draft Technical Context Guidelines Letter Report Document Document DED DED DED Technical Draft Subtask 2C Technical Final Guidance Context Guidelines Draft Generic Letter Report for Initial AMTs in Document Document Guidelines for Cold Spray Rev. 2 of AMT Cold Spray Cold Spray AMTs Action Plan Technical Draft Technical Context Guidelines Letter Report Document Document PM-HIP Spray PM-HIP PM-HIP Legend Technical Draft Technical Context Guidelines Contractor-developed Letter Report Document Document EBW EBW EBW NRC Staff-developed 17 Questions Acknowledgements: 9 AMT Project Team: NRR - Carolyn Fairbanks, Bob Davis, Isaac Anchondo-Lopez; RES - Matt Hiser, Mark Yoo AMT Technical Advisory Team: NRR - Allen Hiser, Dave Rudland; RES - Rob Tregoning AMT Steering Committee: NRR - Hipo Gonzalez; RES

- Steve Frankl, Raj Iyengar NRC Staff: Meg Audrain, Chris Sydnor, Dave Beaulieu, Dong Park, Dan Widrevitz 18 18 B-424

1/6/2 0 2 1 Regulatory point of view on additive manufacturing for nuclear facilities (Originally presented in Additive manufacturing in nuclear energy applications - Energiforsk webinar 23.9.2020)

Ville Rantanen, Martti Vilpas, Pekka Vlikangas

[VRa, MV, PVa]

1 10.12.2020 19 Content

The Finnish Nuclear Facilities in brief

Legal framework and guidelines from regulator 10

Regulator oversight of additive manufacture

Discussion of conventional standards in relation to additive manufacture 2

20 B-425

1/6/2 0 2 1 Finnish Nuclear Facilities in Brief

Operating NPPs

- Loviisa LO1/LO2

- Olkiluoto OL1/OL2

NPP under construction

- Olkiluoto OL3

NPP in construction licensing phase

- Hanhikivi FH1

LLW & MLW repositories

Spent fuel disposal facility under construction

Research reactor FiR in decommissioning

Uranium extraction, Terrafame, Talvivaara 21 Finnish nuclear legislation and safety requirements Nuclear Energy Act

nuclear energy utilisation shall be safe; licensee is Consti-responsible for safety, other principal safety reqs (including tution security and onsite emergency preparedness)

Nuclear Energy Decree

administrative details for licensing and regulatory oversight Laws,

radiological acceptance criteria Decrees STUK Regulations Mandatory for

mandatory requirements for Nuclear safety, Emergency safety preparedness, Nuclear security, Nuclear waste management, Safety of Mining and Milling Practices for Producing Uranium STUK 11 and Thorium Regulations

general principles, fundamental technical requirements etc.

YVL Guides

status as Reg. Guides in USA Guidance YVL Guides

detailed technical requirements, acceptable practices, for safety guidance for licenseeSTUK interaction, STUKs oversight Standards

Detailed guidance to fulfil and follow contractual issues in Industrial industry Standards level quality 4 MlJ 22 B-426

1/6/2 0 2 1 Evolution of the Finnish YVL Guides from 1975 NPP design principles Today YVL Guides (47) in (5) groups

General design principles of a nuclear

Group A: Safety management of a nuclear facility (12) power plant, 1976

- 55 criteria

Group B: Plant and system design (8)

- Based on 10CFR50, AppendixA

Group C: Radiation safety of a nuclear facility and (US.NRC regulations) environment (7)

Group D: Nuclear materials and waste (7)

YVL 1.0 Safety criteria for design of

Group E: Structures and equipment of a nuclear facility nuclear power plants, 1982 (revised (13, 12 published, 1 pending) 1996)

YVL 2.0 Systems design for nuclear https://www.stuk.fi/web/en/regulations/stuk-s-regulatory-power plants, 2002 guides/regulatory-guides-on-nuclear-safety-yvl-

YVL B.1 Safety design of a nuclear power plant, 2013 (revised 2019) 5 23

Background

Additive manufacturing (AM) is a new promising solution to fabricate complexly shaped components from great variety of industrial materials.

AM has been already used in manufacturing for e.g. aviation industries showing that acceptable quality and safety can be reached for demanding applications with optimised processes and parameters.

AM has been applied also in nuclear sector including e.g. nuclear fuel components, pump impellers, 12 nozzle debris filters and other complexly shaped parts. It is applicable also for composite structure optimisation through multi-material fabrication.

One important benefit of the AM is the possibility to produce additional spare/replacement parts which are already obsolete (not any more available).

[Esitys, Esittjnnimi]

6 10.12.2020 24 B-427

1/6/2 0 2 1 Regulator oversight of additive manufacture (AM) (1/3)

Oversee the reliability of AM processing and quality of parts

- Compare AM to conventional manufacture

Detailed standards concatenate design, materials, manufacture, inspection and testing as well as quality management and qualification protocols for personnel

Lack of standards shall be compensated by R&D and testing

- The structural performance of AM parts, including required inspections

Mock-ups in-line with safety classification

- The service performance and aging degradation of AM parts

In-line with Aging Management plan starting from design through the whole life cycle of the nuclear facility

[Esitys, Esittjnnimi]

7 10.12.2020 25 Regulator oversight of additive manufacture (AM) (2/3)

SFS-EN ISO/ASTM 52910:2019, overall strategy for AM Issues in YVL Guides

Safety classification

Design documentation

Description of organisation 13

Supervision of manufacture

Quality control

Commissioning

Control during plant operation

[Esitys, Esittjnnimi]

8 10.12.2020 26 B-428

1/6/2 0 2 1 Regulator oversight of additive manufacture (AM) (3/3)

Follow the development of codes and standards for AM

- Analogy between traditional standards and AM standards

- Benchmarking between traditional and AM processes

- Basic thinking for AM manufacture (SFS-EN ISO/ASTM 52910:2019) vs. safety requirements

Follow research and international development of AM

- Finnish safety research program SAFIR combine AM-technology, quality and safety thinking

- International R&D, including co-op. with e.g. aviation industry etc.

Gradual implementation of AM to Nuclear facilities

- Starting from lower level safety classified systems and components

- References from nuclear facilities abroad are appreciated

[Esitys, Esittjnnimi]

9 10.12.2020 27 Conventional standards vs. AM 1/2 Commonly used for NPPs Questions to AM standards

Detailed standards for design:

Design:

- PED, ASME for reactor, primary and main - How AM is introduced in detailed circulation systems and containment design standards?

- ASCE for earthquake resistance to nuclear

Selection criteria between AM and facilities conventional manufacture

- KTA liner structures of radioactive fuel - How design criteria are set and pools ensured? 14

Analysis / testing methodology

- PED, EN-ISO, Finnish Building Code

Design margins / robustness (RakMK) conventional steel and concrete structures

- RCC codes are under development for common European usage

Advanced coordination between nuclear design codes and EN-ISO standards 10 28 B-429

1/6/2 0 2 1 Conventional standards vs. AM 2/2 Commonly used for NPPs Questions to AM standards according to design requirements

Materials:

Materials:

- KTA, ASTM, EN-ISO for concrete, steel, welds - Standards not as specific as conventional

- ASTM, EN-ISO for coatings against radiation standards?

Manufacture / Execution:

Manufacture

- PED, ASME - Not as specific as conventional

- KTA, RCC-M, EN-ISO, RakMK standards?

- How manufacture is related to design and material standards?

Inspection and testing:

Inspection and testing

- ASME, ASTM, KTA, EN-ISO

- How inspections and testing is related to materials and manufacture?

Quality management:

- EN-ISO 9001:2015

Quality management

ISO 19443-2018 for supply chain management

IAEA 50-C-Q nuclear safety related quality

- Are there any AM standards?

management 11 29 Consideration needs

Additional/continuous development work is still needed to ensure the quality of AM components for nuclear applications:

- Qualification requirements stipulated for nuclear and radiation safety

- Further development of applicable standardisation

- Certification and qualification requirements for AM manufacturers

- Qualification of the AM processes applied

- Approval of the AM filler materials 15

- Qualification of testing technology and personnel (NDT/DT)

- Paying attention to Safety Culture as well as QA/QC

These actions shall be supported with applicable R&D work

Class EYT would be a reasonable starting point

In higher safety classes ( 3 2 1 ) the Graded Approach principle shall be followed

Pressure boundary components would need special attention (Pressure equipment legislation & PED)

[Esitys, Esittjn nimi]

12 10.12.2020 30 B-430

1/6/2 0 2 1 13 31 FDA REGULATORY APPROACH FOR ADDITIVE MANUFACTURING Matthew Di Prima, PhD 16 Division of Applied Mechanics Office of Science and Engineering Laboratories Center for Devices and Radiological Health U.S. Food and Drug Administration 10 December 2020 OSEL Accelerating patient access to innovative, safe, and effective medical devices through bestintheworld regulatory science 32 B-431

1/6/2 0 2 1 Disclaimer The mention of commercial products, their sources, or their use in connection with materials reported herein is not to be construed as either an actual or implied endorsement of such products by the Department of Health and Human Services.

OSEL Accelerating patient access to innovative, safe, and effective medical devices through bestintheworld regulatory science 33 Speaker Bio Dr. Matthew Di Prima is a Materials Scientist in the US Food and Drug Administrations Office of Science and Engineering Laboratories, housed in the Center for Devices and Radiological Health. His areas of research are investigating how the additive manufacturing process can alter material properties, the interplay between corrosion and durability testing, and explant analysis. Along with his research duties, he is the 17 head of the Additive Manufacturing Working Group which is spearheading efforts across the Agency to address how this technology affects medical devices and other regulate medicalproducts OSEL Accelerating patient access to innovative, safe, and effective medical devices through bestintheworld regulatory science 34 B-432

1/6/2 0 2 1 Outline

FDA and Medical Device Regulations

- Device Classification

- Regulatory Controls

- Submission Types

How this is applied to AM

- Cleared AM Medical Devices

- Patient Matched Devices

- Anatomical Models OSEL Accelerating patient access to innovative, safe, and effective medical devices through bestintheworld regulatory science 35 FDAs Mission

Protecting the public health by assuring that foods (except for meat from livestock, poultry and some egg products which are regulated by the U.S. Department of Agriculture) are safe, wholesome, sanitary and properly labeled; ensuring that human and veterinary drugs, and vaccines and other biological products and medical devices intended for human use are safe and effective

Protecting the public from electronic product radiation 18

Assuring cosmetics and dietary supplements are safe and properly labeled

Regulating tobacco products

Advancing the public health by helping to speed product innovations This equals ~25% of consumer spending in the US www.fda.gov/AboutFDA/Transparency/Basics/ucm194877.htm OSEL Accelerating patient access to innovative, safe, and effective medical devices through bestintheworld regulatory science 36 B-433

1/6/2 0 2 1 CDRHs Role

Regulates medical devices and radiationemitting products

Evaluate safety and effectiveness of medical devices

- Before and after reaching market

Assure patients and providers have timely, continued access to safe, effective, and highquality medical devices OSEL Accelerating patient access to innovative, safe, and effective medical devices through bestintheworld regulatory science 37 CDRH Snapshot 1900 EMPLOYEES 18k Medical Device Manufacturers 183k Medical Devices On the U.S.Market 22k /year 570k Proprietary Brands 1.4 MILLION /year 19 Premarket Reports on Submissions medical device including supplements 25k adverse events and and amendments Medical Device Facilities malfunctions Worldwide OSEL Accelerating patient access to innovative, safe, and effective medical devices through bestintheworld regulatory science 38 B-434

1/6/2 0 2 1 Medical Device, defined

Instrument, apparatus, machine, implant, in vitro reagent, including component, part, or accessory

Diagnoses, cures, mitigates, treats, or prevents disease or condition

Affects structure or function of body

Doesnt achieve purpose as a drug

Excludes certain software functions

- data storage, administrative support, electronic patient records Section 201(h) of FD&C Act OSEL Accelerating patient access to innovative, safe, and effective medical devices through bestintheworld regulatory science 39 Device Regulations

21 Code of Federal Regulations (CFR): Parts 8001050

- 800861: crosscutting device requirements

Example: 812 Investigational Device Exemption

- 8621050: devicespecific requirements 20

Example: 876 Gastroenterology and Urology Devices

21 CFR: Parts 199

- general medical requirements that also apply to medical devices OSEL Accelerating patient access to innovative, safe, and effective medical devices through bestintheworld regulatory science 40 B-435

1/6/2 0 2 1 Device Classification

Based on device description and intended use

Determines extent of regulatory control

Class I, II, or III

- increases with degree of risk

Product Codes: threeletter coding to group similar devices and intended use OSEL Accelerating patient access to innovative, safe, and effective medical devices through bestintheworld regulatory science 41 How to determine classification

Classification is defined under Code of Federal Regulations (e.g. 21 CFR 888.3350)

(a)Identification: A hip joint metal/polymer semiconstrained cemented prosthesis is a device intended to be implanted to replace a hip joint. The device limits translation and rotation in one or more planes via the geometry of its articulating surfaces. It has no linkage acrossthejoint. This generic type of device includes prostheses that have a femoral component made of alloys, such as cobaltchromiummolybdenum, and an acetabular resurfacing 21 component made of ultrahigh molecular weight polyethylene and is limited to those prostheses intended for use with bone cement (888.3027).

(b) Classification. ClassII.

This language is specific, slight changes in device design/function can change the regulation and therefore the classification

If your device is not in the CFR, you have to request a designation and classification from the FDA, 513(g)

OSEL Accelerating patient access to innovative, safe, and effective medical devices through bestintheworld regulatory science 42 B-436

1/6/2 0 2 1 Classes of Medical Devices Class Risk Controls Submission I Lowest General

Exempt*

510(k)

II Moderate General and

510(k)*

Special (if available)

Exempt III Highest General and

PMA PMA

More common submission requirement of this Class OSEL Accelerating patient access to innovative, safe, and effective medical devices through bestintheworld regulatory science 43 General Controls: Examples Control Regulation Brief Description (21 CFR Part)

Labeling 801 provide information for users Medical Device Reporting 803 report devicerelated injuries and deaths Establishment Registration 807 register business with FDA 22 Device Listing 807 identify devices Quality System 820 ensure safe, effective finished devices Adulteration FD&C Act 501 provide device not proper foruse Misbranding FD&C Act 502 provide false or misleading labeling FD&C Act = FederalFood Drug, and Cosmetic Act OSEL Accelerating patient access to innovative, safe, and effective medical devices through bestintheworld regulatory science 44 B-437

1/6/2 0 2 1 Special Control

Specific to Class II devices

Usually for wellestablished device types

Found in (b) Classification of regulation

-example: 21 CFR 876.5860(b)

OSEL Accelerating patient access to innovative, safe, and effective medical devices through bestintheworld regulatory science 45 21 CFR 876.5860 High permeability hemodialysis system

(a) Identification. A high permeability hemodialysis system is a device intended for use as an artificial kidney system for the treatment of patients with renal failure, ...

(b) Classification. Class II. The special controls for this device are FDA's:

- (1) "Use of International Standard ISO 10993 'Biological Evaluation of Medical Device Part I: 23 Evaluation and Testing,' "

- (2) "Guidance for the Content of 510(k)s for Conventional and High Permeability Hemodialyzers,"

- (3) "Guidance for Industry and CDRH Reviewers on the Content of Premarket Notifications for Hemodialysis Delivery Systems,"

- (4) "Guidance for the Content of Premarket Notifications for Water Purification Components and Systems for Hemodialysis," and

- (5) "Guidance for Hemodialyzer Reuse Labeling."

OSEL Accelerating patient access to innovative, safe, and effective medical devices through bestintheworld regulatory science 46 B-438

1/6/2 0 2 1 Special Controls: Examples

Design, Characteristics or Specifications

Testing

Special Labeling

Guidance Documents OSEL Accelerating patient access to innovative, safe, and effective medical devices through bestintheworld regulatory science 47 Premarket Submission Types

Investigational Device Exemption (IDE)

Premarket Notification (510(k))

Premarket Approval Application (PMA) 24

De Novo

Humanitarian Device Exemption (HDE)

OSEL Accelerating patient access to innovative, safe, and effective medical devices through bestintheworld regulatory science 48 B-439

1/6/2 0 2 1 AM and Device Manufacturing

Generally, manufacturing method does not change regulatory classification or regulatory controls

This allows AM products to use existing regulatory pathways

- The majority of AM devices have been cleared through the 510(k) pathway todate

- Predicate devices can be AM or nonAM

- Generally, we dont expect the technological characteristics of the devices [to] raise different questions of safety and effectiveness1

- I.E., a spine cage is a spine cage and a bone plate is a bone plate 1 FDA Guidance Benefit Risk Factors to Consider When Determining Substantial Equivalence in Premarket Notifications (510(k)) with Different TechnologicalCharacteristics OSEL Accelerating patient access to innovative, safe, and effective medical devices through bestintheworld regulatory science 49 AM 510(k) Submissions

FDA Guidance Technical Considerations for Additively Manufactured Medical Devices details premarket submission expectations

For a 510(k) submission, we are looking for the worst case AM condition to be determined in order to ensure subject device performance is substantially equivalent to the predicate 25

This is different from most nonAM submissions as material performance can be assessed separately from the manufacturing process

- In most cases purchasing controls and an understanding of tooling/postprocessing effects are sufficient to address materialperformance

- For AM controlling only the feedstock and understanding the tooling/post processing effects are not generally sufficient to address materialperformance OSEL Accelerating patient access to innovative, safe, and effective medical devices through bestintheworld regulatory science 50 B-440

1/6/2 0 2 1 AM 510(k) Submissions - Establishing Worst Case Build Conditions

Build location

- Establish the worst case build location or that all build locations have comparable mechanical properties

Build orientation

- If multiple build orientations are used, which will have theworst mechanical properties

Feedstock reuse

- For AM processes that reuse feedstock, what is the reuse scheme and is there a worstcase feedstock condition in terms of performance and variability

Residual feedstock in lattice/porous structures

- How residual feedstock material is removed from lattice/porous structures and what is the worst case for residual feedstock in final device OSEL Accelerating patient access to innovative, safe, and effective medical devices through bestintheworld regulatory science 51 Evidence of this working: 510(k) Cleared 3D Printed Devices

Patient matched implants

Orthopedic devices

- Skull plate - Hip Cups

- Maxillofacial - Spinal Cages K121818 implants OsteoFabby OPM - Knee trays K102975 http://www.accessdata.fda.gov/c drh_docs/pdf12/K121818.pdf Novation Crownby Exatech http://www.accessdata.fda.gov/cdrh_docs 26

Patient matched surgical guides

Dental /pdf10/K102975.pdf

- Craniofacial - Temporary bridges

- Knee - Reconstructive surgery support

- Ankle K120956 VSP by Medical K102776 Modeling eDENT TemporaryResin http://www.accessdata.fda.gov/cd rh_docs/pdf12/K120956.pdf by DeltaMed GmbH http://www.accessdata.fda.gov/c drh_docs/pdf10/K102776.pdf OSEL Accelerating patient access to innovative, safe, and effective medical devices through bestintheworld regulatory science 52 B-441

1/6/2 0 2 1 Cleared 510(k) AM Products (2010 - 2016)

OSEL Accelerating patient access to innovative, safe, and effective medical devices through bestintheworld regulatory science 53 AM Device Adverse Events 2014 27 59 productrelated adverse events for additive manufactured devices based on 836 reports to the Manufacturer and User Facility Device Experience (MAUDE) database in2014 OSEL Accelerating patient access to innovative, safe, and effective medical devices through bestintheworld regulatory science 54 B-442

1/6/2 0 2 1 Patient Matched Devices

Pairing 3D imaging (CT, MRI, optical scanning) with AM printing for personalized medical devices

- Implants

- Anatomical models

Incorporating virtual surgical software allows for personalized cutting guide and tools

Regulatory challenge is that there is no longer a discrete device to assess, instead we are looking at a design envelope OSEL Accelerating patient access to innovative, safe, and effective medical devices through bestintheworld regulatory science 55 Examples of Patient Matched Devices 28 K133809: K121818: K122870:

http://www.oxfordpm.com/news/articl http://www.oxfordpm.com/news/article/2 http://www.conformis.com/c e/201408 01302 ustomizedknee 19_oxford_performance_materials_rec 18_osteofab_patient_specific_cranial_devi implants/products/itotal/

eives_fda_clearance_for_3d_printed_os ce_receives_510k_approval_

teofab_patient _osteofab_implants_ready_for_us_market http://www.accessdata.fda.go specific_facial_device.php _and_beyond.php v/cdrh_docs/pdf12/K122870.

pdf http://www.accessdata.fda.gov/cdrh_d http://www.accessdata.fda.gov/cdrh_d ocs/pdf13/K133809.pdf ocs/pdf12/K121818.pdf OSEL Accelerating patient access to innovative, safe, and effective medical devices through bestintheworld regulatory science 56 B-443

1/6/2 0 2 1 Patient Matched Regulatory Approach

Not Custom Devices

- Devices meeting the regulatory definition of custom devices are exempt from pre market review

- §V.E of FDA Custom Device Exemption Guidance explains why patient matched device generally dont meet the custom devicerequirements

Treating the design envelope as the device design requirements

- Design envelopeneeds to be validated for the intended use

- For 510(k)eligible devices, substantial equivalence needs to be shown for the worst cases OSEL Accelerating patient access to innovative, safe, and effective medical devices through bestintheworld regulatory science 57 AM Anatomic Models

Intended Use of the Anatomic model is key to determine if they are considered medical devices

Diagnostic Use makes a model a medical device (i.e., the model will affect diagnosis, patient management, or patient treatment)

- Models used to make a diagnosis based on examination or a physical measurement of structural 29 changes from the 3D model

- Using the model to size and/or select a device or surgical instrument based on a comparison, fitting, or measurements with the model

- Using the model to determine whether a specific surgical procedure may be viable OSEL Accelerating patient access to innovative, safe, and effective medical devices through bestintheworld regulatory science 58 B-444

1/6/2 0 2 1 AM Anatomic Model Regulatory Approach

A 3D printed patientspecific anatomic model that is intended for diagnostic use is, in essence, a physical representation of a digital 3D model that is produced by medical image analysis software.

The software used to generate the 3D printed models based on medical images, will be regulated. There needs to be evidence that the 3D printed models are of equivalent accuracy to the digital 3D models (segmented volumes).

The goal is not to have to clear every individual 3D printed model, or the 3D printers.

Instead, FDA will clear software capable of generating diagnostic quality 3D printed anatomic models that has been tested and validated on a set of 3D printers based on the performance needed for the intended use and anatomy (i.e., orthopedic, cardiovascular, neurological, etc.).

OSEL Accelerating patient access to innovative, safe, and effective medical devices through bestintheworld regulatory science 59 Summary of AM Regulatory Approach

Existing FDA regulatory pathways and controls have been sufficient to handle the AM medical devices that we have reviewed

Existing product performance requirements/predicate comparisons have generally been sufficient to ensure safety and efficacy

- One product specific test standards has been developed to address fatigue concerns 30 in AM acetabular (hip) cups

- Ongoing research to evaluate adequacy of lattice/porous standardsfor AM Products

Currently working to develop a framework to handle the adoption of AM technologies by hospitals and other points of care.

OSEL Accelerating patient access to innovative, safe, and effective medical devices through bestintheworld regulatory science 60 B-445

1/6/2 0 2 1 Thank You For Your Attention Questions?

AdditiveManufacturing@fda.hhs.gov 30 OSEL Accelerating patient access to innovative, safe, and effective medical devices through bestintheworld regulatory science 61 Federal Aviation Administration Regulatory Considerations for AM and Lessons Learned for Structural Alloys 31 Presented at:

NRC Workshop on Advanced Manufacturing Technologies - Session 6 December 10, 2020 Presented by:

Dr. Michael Gorelik FAA Chief Scientist and Technical Advisor for Fatigue and Damage Tolerance 62 B-446

1/6/2 0 2 1 BLUF (bottom line upfront)

All existing FAA rules apply to AM

Leverage experience with other relevant material systems and historical lessons learned

However need to consider unique / AM-specific attributes, especially for high-criticality components

Increasing role of public standards

Increasing role of Computational Materials / ICME The same message as in 12/09/20 presentation Federal Aviation 2 Administration 63 FAA Regulatory Documents SDOs Rules 14 CFR Part XX Means of Compliance (MoC) 32 Policies Advisory Circulars Issue Papers General Memoranda Federal Aviation 3 Administration 64 B-447

1/6/2 0 2 1 H.R. 302 FAA Reauthorization Act of 2018 SEC. 329. PERFORMANCE-BASED STANDARDS.

The Administrator shall, to the maximum extent possible and consistent with Federal law, and based on input by the public, ensure that regulations, guidance, and policies issued by the FAA on and after the date of enactment of this Act are issued in the form of performance-based standards, providing an equal or higher level of safety.

Federal Aviation 4 Administration 65 Engagement with SDOs and Consortia A partial list America Makes AMSC AIA AMC KART MMPDS FAA 33 AWS CMH-17 SAE ASTM SDOs Consortia / WGs Federal Aviation 5 Administration 66 B-448

1/6/2 0 2 1 Some AM-Specific Attributes

Characterization and role of inherent (and rogue) material anomalies / defects

Each individual category has

Anisotropy been encountered in other material systems

Location-specific properties

Unique nature of AM - all of

Residual stresses these categories apply

High process sensitivity / large number of controlling parameters

Effects of post-processing (HIP, heat treatment, surface improvements, )

Material-specific NDI considerations

Effect of surface conditions

Susceptibility to environmental effects Federal Aviation 6 Administration 67 FAA Regulatory Environment (driven by different product types)

Small Engines and Transport Airplanes Propellers Airplanes (14 CFR Part 23)

(14 CFR Parts 33, 35)

(14 CFR Part 25) 34 Rotorcraft (14 CFR Parts 27, 29)

Federal Aviation 7 Administration 68 B-449

1/6/2 0 2 1 14 CFR Part 25 Regulations - Materials (Transport Category Aircraft)

§ 25.613 Material Strength Properties and Design Values a) Material strength properties must be based on enough tests of material meeting approved specifications to establish design values on a statistical basis.

b) Design values must be chosen to minimize the probability of structural failures due to material variability.

d) The strength, detail design, and fabrication of the structure must minimize the probability of disastrous fatigue failure, particularly at points of stress concentration.

Federal Aviation 8 Administration 69 14 CFR Part 25 Regulations - Special Factors (Transport Category Aircraft)

§ 25.619 Special Factors The factor of safety prescribed in § 25.303 must be multiplied by the highest pertinent special factor of safety prescribed in §§ 25.621 (Casting Factors) through 25.625 for each part of the structure whose strength is 35 a) Uncertain; b) Likely to deteriorate in service before normal replacement; or c) Subject to appreciable variability because of uncertainties in manufacturing processes or inspection methods Federal Aviation 9 Administration 70 B-450

1/6/2 0 2 1 Excerpts from 14 CFR 25.571 (Transport Category Aircraft)

§ 25.571 Damagetolerance and fatigue evaluation of structure (a) General. An evaluation of the strength, detail design, and fabrication must show that catastrophic failure due to fatigue, corrosion, manufacturing defects, or accidental damage, will be avoided throughout the operational life of the airplane.

Federal Aviation 10 Administration 71 AC 29-2C on Flaw Tolerance (Transport Category Rotorcraft)

To determine types, locations, and sizes of the probable damages, considering the time and circumstances of their occurrence, the following should be considered:

- Intrinsic flaws and other damage that could exist in an as-manufactured structure based on the evaluation of the details and potential sensitivities involved in the specific manufacturing work processes used.

36

The flaw sizes to be considered should be representative of those which are likely to be encountered during the structures service life resulting from the manufacturing, maintenance, and service environment.

An analysis may be used combining the distribution of likely flaw sizes, the criticality of location and orientation, and the likelihood of remaining in place for a significant period of time.

Federal Aviation 11 Administration 72 B-451

1/6/2 0 2 1 AC 29-2C on Inspections (Transport Category Rotorcraft)

The specific inspection methods that are used to accomplish fatigue substantiation should be:

- Compatible with the threats identified in the threat assessment, paragraph f.(5), and provide a high probability of detection in the threat assessment and their development, under the operational loads and environment.

Federal Aviation 12 Administration 73 Excerpts from 14 CFR 33.70 (Aircraft Engines)

WHY: Industry data has shown that manufacturing-induced anomalies have caused about 40% of rotor cracking and failure events

WHAT: 33.70 rule requires applicants to develop coordinated engineering, manufacturing, and service management plans for each life-limited part

- This will ensure the attributes of a part that determine its life are 37 identified and controlled so that the part will be consistently manufactured and properly maintained during service operation Engineering The probabilistic approach to Plan damage tolerance assessment is one of two elements necessary Service to appropriately assess damage Manufacturing Management Plan tolerance. Plan AC 33.70-1, GUIDANCE MATERIAL FOR AIRCRAFT ENGINE LIFE-LIMITED PARTS REQUIREMENTS, 7/31/2009. Federal Aviation 13 Administration 74 B-452

1/6/2 0 2 1 History is a Vast Early Warning System Norman Cousins Lessons Learned What Not to What to Do? Do?

Federal Aviation 14 Administration 75 Relevant Material Technologies - Examples

Structural Castings

- Empirical life management system (design knock-downs, NDI acceptance criteria etc.)

- Effect of material anomalies understood, but not well quantified

Powder Metallurgy (PM)

- Gave rise to PM-specific fatigue and DT methodologies, explicitly accounting for the presence of inherent material anomalies

Forgings 38

- Process controls (lessons learned), advanced NDI

- Location-specific microstructure and residual stresses

Welding Plan to leverage

- Highly process-sensitive regulatory experience

- Susceptible to manufacturing anomalies with other process-sensitive material

- Defects detectability challenges systems Federal Aviation 15 Administration 76 B-453

1/6/2 0 2 1 Lessons Learned Powder Metallurgy (PM)

Effect of defects may not be well understood for new technologies

Transition from well-controlled development environment to full-scale production may introduce new failure modes

Solution: development of adequate process controls, NDI and PM-specific life management system explicitly accounts for material anomalies (via probabilistic fracture mechanics)

Outcome: Several decades of successful field experience Federal Aviation 16 Administration 77 Lessons Learned Structural Castings

Empirical - effects of material anomalies are not well understood or quantified no explicit feedback loop to process controls and QA

No means to assess / quantify risk 39

May be overly conservative in some cases Federal Aviation 17 Administration 78 B-454

1/6/2 0 2 1 Question Can we do better for AM..?

Performance = f (microstructure l anomalies population)

Federal Aviation 18 Administration 79 Example: Modeling Framework for Castings Linking Modeling Tools to Predict Stress/Strain, Fracture and Fatigue Life Simulate Casting Process Courtesy of Prof. C. Beckermann (U. of Iowa) and Porosity Design Requirements (Strength)

Casting solidification model Porosity Postprocessing Results Nodal values of FEA Code for FEA porosity for use in Directly Measure Porosity FEA as a field variable FEA Model run using elastic CT scan properties as function of porosity data Multiaxial fatigue life porosity field, and porous metal prediction using location plasticity to predict fracture specific fatigue properties as a 40 function of local porosity Fatigue Postprocessing Region Analysis for Fatigue of concern Tools Analysis with porosity FEA postprocessing code to generate locationspecific (nodal) fatigue property data Design Requirements (Fatigue)

R. A. Hardin, C. Beckermann, Integrated design of castings: effect of porosity onmechanical performance, IOP Conference Series: Materials Science and Engineering, Vol. 33, 2012. Federal Aviation 19 Administration 80 B-455

1/6/2 0 2 1 AM Part Zoning and Probabilistic DT

AM parts are uniquely suited for Lack of Fusion Gas Porosity zone-based evaluation

Concept is similar to zoning considerations for castings

however, modeling represents a viable alternative to empirical casting factors One Assessment Option - PFM *)

) PFM - Probabilistic Fracture Mechanics

Reference:

M. Gorelik, Additive Manufacturing in the Context of Structural Integrity, International Journal of Fatigue 94 (2017), pp. 168-177.

Federal Aviation 20 Administration 81 Design Allowables Considerations

Generation of design allowables is contingent upon mature material and process specifications

Cross SDOs and WGs collaboration is essential 41 PIM = Process Intensive Materials Federal Aviation 21 Administration 82 B-456

1/6/2 0 2 1 Material Allowables vs. Design Values

Top 2 curves -

bulk material allowables

Bottom (red) curve - design values Credit: M. Shaw (GE Additive), presented at the 2018 Joint FAA - EASA Workshop on Q&C of Metal AM Parts, Wichita, KS, Aug. 2016.

Federal Aviation 22 Administration 83 Part vs. Coupon Properties Purpose-built Finished Coupon AM Part 42 Property of Interest Property of Interest This understanding can be enabled by physics-based ICME models Federal Aviation Administration 23 84 B-457

1/6/2 0 2 1 Example: Industry Lessons Learned Developed by AIA RoMan Working Group for conventional (i.e. subtractive) manufacturing processes

Leveraged industry experience to reduce the likelihood of manufacturing-induced defects

Emphasizes the role of real-time process monitoring systems Federal Aviation 24 Administration 85 Recent Developments

Consortia / SDOs / Industry engagement

R&D

2020 FAA-EASA Workshop on Q&C of AM 43 (appendix)

Federal Aviation 25 Administration 86 B-458

1/6/2 0 2 1 Examples of External Engagements (Consortia and WGs)

AIA AM WG MMPDS Emerging ETTG Technologies Task Group Volume 2

Guidance

Data Federal Aviation 26 Administration 87 AIA AM Working Group Report: 2/28/20 Recommended Guidance for Certification of AM Component https://www.aia-aerospace.org/report/certification-of-am-component/

44 Federal Aviation 27 Administration 88 B-459

1/6/2 0 2 1 AIA AM Working Group Report (cont.)

Federal Aviation 28 Administration 89 MMPDS and Additive Manufacturing MMPDS Efforts to Address Emerging Metallic Process Intensive Materials (PIM)

MMPDS recognizes the need to be proactive and keep pace with the rapid development of Emerging Metallic Structures Technologies by industry, e.g., Additive Manufacturing (AM), Friction Stir Welding (FSW) that are considered PIM.

Several efforts of PIM were presented to the MMPDS for allowables development but were found not to be compatible with current handbook procedures. Extensive amount of standardization efforts need to take place before design values for PIM can be considered for 45 inclusion in the current handbook.

General agreement within the MMPDS to create two Volumes:

Volume I - Current handbook for traditionally produced Materials.

Volume II - Properties for PIM ,e.g., Additive Manufacturing (AM),

Friction Stir Welding (FSW).

Emerging Technology Task Group (ETTG) was established to develop processes and procedures best suited to derive and publish design information for PIM Volume II.

Federal Aviation Administration 90 B-460

1/6/2 0 2 1 Emerging Technologies Task Group (ETTG) and its Working Groups Data Generation & Materials & Machines Certification &

Applications Qualification S. Cordner (NASA) & P.

D. Hall (Battelle) & A. Sodouri (Nork Titanium) R. Grant (FAA) & P.

Steevens (Boeing) Guerrier (MOOG)

ETTG - Michael Gorelik (FAA) & Sam Cordner (NASA)

Data Submission Specification Content Outline an approach to Guidelines -9.2 Requirements -9 Further Showing -10 Data Analysis -9.5 Material Qualification -9 OEM & Component or 10 Supplier perspectives Design Philosophy -1 & 9 Machine Qualification -9 Part Qualification -10 Acceptance/Equivalence or 10 Testing -10.5 SPC Requirements -10 Influence Factors -1 SPC Methods -10.10 Federal Aviation Administration 91 MMPDS Interaction with SDOs and Working Groups SAE

AM Material and Process Specs (AMS-AM)

Use of MMPDS data analysis tools for spec min values ASTM AWS Testing Specs

Welding Specs AM Material Specs

AM Specs Signed MOU with Battelle 46 CMH-17 AM WG AIA AM WG Cross-coordination to explore Developing best synergies and streamline practices for Q&C communication between two of metal AM parts groups Federal Aviation Administration 92 B-461

1/6/2 0 2 1 R&D - Internal / External

Development of material databases (joint with DoD and NASA) - JMADD

Seeded defects studies - effect of defects

Understanding of process variability drivers

Round-robin studies

NASA ULI (University Leadership Initiative)

Probabilistic DT framework for AM (collaboration with NASA, USAF and NAVAIR)

CM4QC Steering Group - see next slide Federal Aviation 32 Administration 93 Example: Development of Computational Materials (CM) Capabilities for Metal AM Co-organizers: NASA and FAA DRAFT 47 Government Industry Academia NIST Boeing Carnegie Mellon AFRL LockheedMartin / Sikorsky UTSA Sandia NL Raytheon / P&W Vanderbilt NAVAIR GE Aviation Penn State Membership ORNL Spirit Aerosystems Northwestern Army Aviation Honeywell Aerospace Howmet Aerospace SwRI NorthrupGrumman Textron Aviation / Bell Federal Aviation Administration 94 B-462

1/6/2 0 2 1 Summary

What worked well historically to reduce the rate of failures induced by material /

manufacturing anomalies a three-prong approach:

Improved better capability to Manufacturing prevent anomalies Process Controls Improved Enhanced Life Inspection Management Plan Methods (including DT) better capability better capability to to find anomalies design for anomalies Federal Aviation 34 Administration 95 Discussion 48 Dr. Michael Gorelik Chief Scientist, Fatigue and Damage Tolerance Aviation Safety Federal AviationAdministration michael.gorelik@faa.gov (480) 284-7968 Federal Aviation 35 Administration 96 B-463

1/6/2 0 2 1 APPENDIX Federal Aviation 36 Administration 97 3rd Joint FAA - EASA AM Workshop November 2-6, 2020 Workshop Demographics 16 Countries over 300 participants Austria Belgium Workshop Participation Brazil Canada 7% France 3%

Germany 49 Academia Italy Industry 28%

Netherlands Machine makers Norway 57% Government Poland SDOs and NonProfit Portugal 5%

Singapore Spain Sweden UK https://www.faa.gov/aircraft/air_cert/step/events/2020_additive_mfg_workshop/ US Federal Aviation 37 Administration 98 B-464

1/6/2 0 2 1 Workshop Evolution 2018 2020 2020 Workshop (joint FAA-EASA workshops)

First virtual workshop

More balanced international participation 2019 Workshop

More than 2x increase in participation

Continued breakout sessions

Continued breakout sessions

Significant participation from

Focus on new technical operators, Tier 2/3/ suppliers developments, not and machine makers 2018 Workshop

Clear signs of Q&C framework organizational updates

Highly diverse industry

First joint FAA - EASA maturation and common demographics workshop technical approaches

Big focus on standardization

First workshop with parallel

Leveraged Machine Makers -

breakout sessions End Users knowledge transfer workshop

Continued focus on Q&C

Tracking of the key industry trends (in the Q&C context)

Gradual increase in the industry demographics by segment Federal Aviation 38 Administration 99 Agenda at a Glance

Opening remarks:

- Ms. Di Reimold, Deputy Director of Policy and Innovation Division, FAA

Keynote - SpaceX

- Dr. Charlie Kuehmann, VP of Materials Engineering and NDE

- Mr. Will Heltsley, Vice President of Propulsion Engineering

22 presentations from the industry, government, academia and SDOs / Consortia / WGs 1. Low Criticality AM Parts

3 Breakout Sessions 2. F&DT and NDI Considerations

3. Knowledge transfer between

Standardization Day machine makers and end users 50

Regulatory Panel Federal Aviation 39 Administration 100 B-465

1/6 /2 0 2 1 QA and QC Tools for Metal AM and implementing them in EU NUCOBAM project Pasi Puukko VTT Technical Research Centre of Finland Ltd.

AMT Workshop, 7-10 December, 2020 23.9.2020 VTT - beyond the obvious 1

Rationale We need to ensure that Additively Manufactured components are build defect free and fit for purpose consistently and reliably.

This is true for every industry, but specially for those in which 1

components are safety critical as some applications of nuclear energy are.

AM enables manufacturing of complex geometries and one-off components which brings added challenges to quality assurance.

23.9.2020 VTT - beyond the obvious 2 2

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1/6 /2 0 2 1 General approach for AM qualification

to ensure that the general process is controlled and repeatable and can produce components within quality requirements Process Qualification

This includes: Machine, Powder, Operator In-process Monitoring

to ensure that a particular part can be printed within quality requirements given a certain design Component and use requirements AM Qualification Component Quality

to ensure that every single part is printed within quality requirements. And if it is not, that defects Destructive NDT Individual are properly detected and the non-conformity Testing Part QC properly recorded.

23.9.2020 VTT - beyond the obvious 3 3

Principle for Design values 2

Source: Recommended Guidance for Certification of AM Components -

09/12/2020 VTT - beyond the obvious AIA Additive Manufacturing Working Group 4

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1/6 /2 0 2 1 EU NUCOBAM project 23.9.2020 VTT - beyond the obvious 5 5

EU NUCOBAM Project

Additive Manufacturing (AM) will allow nuclear industry:

to tackle component obsolescence challenges

to manufacture and operate new components with optimized design in order to increase reactor efficiency and safety

NUclear COmponents Based on Additive Manufacturing aims at:

developing the qualification process

provide the evaluation of the inservice behavior allowing the use of additively 3

manufactured components for nuclear installations Demonstrators (316L):

Coordinator: CEA, PierreFrançois GIROUX

Partners: 12 from 6 countries + EU JRC

Total Project Cost: ~4 M

Duration: 4 years (10/20209/2024)

7 Work Packages Valve block body 6

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1/6 /2 0 2 1 Workpackages:

WP1 Methodology for AM qualification standardization CEA focus on establishment of a qualification methodology for AM components and on reviewing the existing standards and qualification processes WP2 AM process qualification VTT aim to create a general methodology for qualifying LPBF process for nuclear energy industry applications so that components manufacture by LPBF meet the quality expectations and design functions WP3 Qualification as processed: NDE & mechanical properties vs microstructure - Naval Group focus on nondestructive tests and characterization as manufactured to ensure the capability to decide of the qualification as processed 7

Workpackages WP4 Inpile Behaviour of Additively Manufactured Samples (IBAMS)

FRAMATOME deal with the description of the sample sets, irradiation conditions (fluence, temperature), microstructure characterization, determination of the mechanical properties and documentation WP5 Performance assessment of excore user case: valve component ENGIE Tractebel assess the operational performance of excore valve component that 4

will be produced by LPBF process WP6 Dissemination and exploitation EDF ensure dissemination and then exploitation, by reaching out to industry, standardization and regulatory bodies WP7 Project Management CEA ensure effective coordination and management to monitor the progress of the project towards its planned objectives 8

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1/6 /2 0 2 1 WP2 Objective To create a general methodology for qualifying L-PBF process for nuclear energy industry applications so that components manufacture by L-PBF meet the quality expectations and design functions. The study of machine-to-machine variations in properties will be studied.

Advanced quality control methods will be evaluated with the objective of increasing safety by detecting defects during production and ensure batch consistency.

Demonstration components and test coupons to be tested in other WPs will be manufactured.

12/10/2020 VTT - beyond the obvious 9

WP2 focuses on different variation sources Improved Process Stability

High process stability within same platform (same manufacturing batch).

5 Improved Process Repeatibility

High process repeatability from build to build on same equipment (different batch).

Improved Process Reproducibility

High process reproducibility from build to build on different equipment 12/10/2020 VTT - beyond the obvious 10 B-470

1/6 /2 0 2 1 Some challenge related to LB-PBF QA & QC Qualification procedures are laborous and require lot of experimental trials In-process Monitoring Due the differences between the machines - results are not directly transferable AM Component Quality Complex geometrics poses challenges for utilizing Destructive NDT Testing conventional non-destcructive technologies (NDE)

Destructive testing does not fit very well for single component testing Results of in-process monitoring are open to interpretations 23.9.2020 VTT - beyond the obvious 11 11 Destructive Testing 6 23.9.2020 VTT - beyond the obvious 12 12 B-471

1/6 /2 0 2 1 Witness samples and microstructural microscopy

Mechanical testing following recognized standards

Specially useful for process qualification

Usefulness reduced for component qualification and for single part quality control 23.9.2020 VTT - beyond the obvious 13 13 Small Punch Testing

Allows scooping small samples from critical areas

Can complement standard methods for process and component qualification

Can be used as a more cost alternative for batch QC

EN 10371 Small Punch Test Method for Metallic Materials to be voted in October 2020.

7 23.9.2020 VTT - beyond the obvious 14 14 B-472

1/6 /2 0 2 1 Non-Destructive Examination 23.9.2020 VTT - beyond the obvious 15 15 NDI Technology applied to AM: gaps Geometrical complexity

AM has practically no geometry-related limitations New defect types

Porosity: no reliable, cheap and easy-to-use method exists.

8 New materials

Elastic anisotropy: Several ultrasound related problems New reference standards are required

NDI devices must be calibrated using known defects No POD data

Without POD methodology, the actual reliability of inspection cannot be determined 23.9.2020 VTT - beyond the obvious 16 16 B-473

1/6 /2 0 2 1 Applicability of NDI to AM NDI Technique Geometry Complexity Group Comments 1 2 3 4 5 Visual Testing Y Y P(c) NA NA Liquid Penetrant Testing Y Y P(a) NA NA Magnetic Particle Testing Y Y P(a) NA NA Only for ferromagnetic materials Leak Testing P P P P P Screening for containers, valves etc.

Eddie Current Testing Y Y P(c) NA NA Ultrasonic Testing / Phased Array Y Y P(b) NA NA Quantitative methods are possible for GCG 1 Ultrasonic Testing Alternate & Direct Current Y Y P(c) NA NA Potential Drop Process Compensated Y Y Y Y Y Screening, size restrictions Resonance Testing Radiographic Testing Y Y P(d) NA NA Computed Tomography Y Y Y Y Y Restrictions how small defects are detectable

-focus Computer Tomography Y Y Y Y Y Size restrictions for sample 23.9.2020 VTT - beyond the obvious 17 17 So, what NDE method to use?

CT/uCT is the method of choice currently as is the only method capable of handling complex geometries. But it is not a perfect solution:

Trade-off between resolution / sample size / 9 equipment performance

For quality control quite expensive and time consuming technology For GCG1-2 parts, other methods can still have a major role:

Advantages in cost

Possibilities for in-service inspection.

23.9.2020 VTT - beyond the obvious 18 18 B-474

1/6 /2 0 2 1 In-Process Monitoring 23.9.2020 VTT - beyond the obvious 19 19 AM Process Monitoring

Detected process variations not necessarily linked to a specific defect.

Can be used for AM process qualification leading to reduced NDT requirements

As it is done simultaneously while manufacturing: it might reduce system downtime. 10

There are several process monitoring types commercially available:

Basic process and environmental sensors (oxygen level, gas flow rate..)

Powder bed monitoring

Thermal signatures monitoring o Off-axis, platform scale field-of-view (usually with IR/near-IR-cameras) o On-axis, high spatial and temporal resolution (usually with photodiodes)

Currently no closed-loop control available.

23.9.2020 VTT - beyond the obvious 20 20 B-475

1/6 /2 0 2 1 Off-axis thermal monitoring Spatter landing at the left hand side parts Thermal camera FLIR A655sc at VTT Experimental material, non-optimal powder size & parameters caused excessive spattering 23.9.2020 VTT - beyond the obvious 21 21 Example of Melt Pool Monitoring 11 23.9.2020 VTT - beyond the obvious 22 22 B-476

1/6 /2 0 2 1 Summary General models for AM qualification procedures exist In-process Monitoring

- the challenge is to implementing them on different AM industrial domains and different requirements Component Quality EU NUCOBAM project aims to develop and implement Destructive Testing NDT qualification procedures for Nuclear Industry There is no single magic bullet to ensure quality on a component

Combination of in-process monitoring, NDT and destructive testing can support our efforts.

23.9.2020 VTT - beyond the obvious 23 23 12 Pasi Puukko @VTTFinland www.vtt.fi pasi.puukko@vtt.fi

+358 40 5251 684 24 B-477

1/6/2 0 2 1 DOE Transformational Challenge Reactor Program US NRC Workshop on Advanced Manufacturing Technologies for Nuclear Applications Kurt A. Terrani, Ph.D.

Director - Transformational Challenge Reactor December 10, 2020 ORNL is managed by UT-Battelle, LLC for the US Department of Energy 1

TCR is bringing to bear additive manufacturing (AM) and artificial intelligence (AI) to deliver a new approach Using AI to navigate Leveraging AM Exploiting AM Using AI to assess an unconstrained to arrive at high- to incorporate critical component design space and performance integrated and quality using in situ realize superior materials in complex distributed sensing manufacturing performance geometries in critical locations signatures 1

tcr.ornl.gov 2

2 B-478

1/6/2 0 2 1 Navigating the unconstrained deigns space offered by AM presents performance opportunities parameter space search to find optimized cooling channel design Tmax = 687 C, = 119 C Tmax = 622 C, = 78 C Core P = 0.56 psi Core P = 1 psi 3

3 Leveraging AM to arrive at high-performance radiation tolerant ceramic materials in complex geometries computer-aided design 3D printed shell 2

4 fully densified 4

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1/6/2 0 2 1 Codification of metal additive manufacturing with a focus on powder bed methodologies was pursued in 2020 5

5 Incorporating sensors into critical structure via AM to harvest operational data and facilitate health monitoring Integrated instrumentation Conventional instrumentation 3

Embedded sensor sheathes in additively manufactured stainless steel and silicon carbide 6

6 B-480

1/6/2 0 2 1 Applying the current approach for quality certification of critical components derived via AM is procrustean Instantaneously Conform to Conform to Conform to Trained data analytics ascertain quality feedstock pass manufacturing pass examination quality quality quality Data repository Qualified requirements requirements requirements component pass Collect Collect spatially failure Collect environmental selective data Rejected Qualified feedstock throughout Rejected data during component data manufacturing manufacturing component provide live feedback to manufacturing data anomaly properties predict design registration detection visualization performance improvements A B C D AI AI AI AI rapid iteration Digital Thread 7

7 Extensive testing, including exposure to displacement damage inducing neutrons, are a core part of TCR Typical HFIR irradiation capsule for metals Typical HFIR irradiation capsule for ceramics 4

Roughly 25 capsules irradiated in 2020: SiC, YHx, 316L, Inc 718 8

8 B-481

1/6/2 0 2 1 316L microstructure after additive manufacturing and prior to irradiation Build direction (Z) 9 (M. Gussev, T. Lach, ORNL) 9 The dislocation cells in AM 316L are tenacious, affect creep behavior of the material, and only disappear above 950°C 5

750°C/1h 800°C/1h 900°C/1h 550°C 275 MPa 10 (M. Li, ANL) 10 B-482

1/6/2 0 2 1 Evolution of the dislocations in the AM, annealed, and wrought 316L govern their response under deformation 11 T.S. Byun, ORNL) 11 Concluding Thoughts

TCR aims to harness advanced in manufacturing and computational science to deliver materials and components for advanced nuclear energy systems Special Issue 6 Additive Manufacturing

The goal is to develop and for Nuclear Energy demonstrate high TRL to facilitate Applications industrial adoption tcr.ornl.gov 12 12 B-483

1/6/2 0 2 1 Advanced Methods for Manufacturing Program Overview Isabella J. van Rooyen NRC Public Workshop on Advanced Manufacturing National Technical Director: Advanced Methods for Manufacturing (AMM)

Dirk Cairns-Gallimore December 7-10, 2020 DOE-NEET-AMM Federal Program Manager 1

Office of Nuclear Energy: Mission Pillars

Advance nuclear power to meet the nation's energy, environmental, and national security needs.

Resolve technical, cost, safety, security and regulatory issues through research, development and demonstration.

1 Existing Fleet Advanced Fuel Cycle Global Reactor Pipeline Infrastructure Competitiveness 2

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1/6/2 0 2 1 Office of Nuclear Energy NE-1/2 Nuclear Energy Assistant Advisory Secretary Committee NE-20 for Nuclear Energy Chief Operating Chief Technology Officer Officer NE-3 NE-4 NE-5 NE-6 NE-8 Nuclear Nuclear Fuel Reactor Fleet and Advanced Reactor International Idaho Spent Fuel &

Infrastructure Cycle and Deployment Nuclear Energy Operations Waste Programs Supply Chain

Advanced Reactor Demonstration Program Demos Policy and Office Disposition Deputy Assistant Secretary: Alice Caponiti Cooperation NE-51 NE-52 Office of Nuclear Energy Technologies Office of Advanced ReactorDeployment Suibel Schuppner Tom Sowinski Enabling Technologies Team University and Competitive Research Reactor Optimization and Modernization Team Advanced Reactor Development Team

Advanced Sensors and Instrumentation (ASI) Team

Light Water Reactor Sustainability

Sodium-Cooled Fast Reactor

Advanced Methods for Manufacturing (AMM)

Nuclear Energy University Program

Advanced Small Modular Reactor R&D

Gas-Cooled High-Temperature Reactors

Nuclear Energy Advanced Modeling and Simulation (NEUP)

Integrated Energy Systems (IES)

Molten Salt Reactors (NEAMS)

Integrated University Program (IUP)

Nuclear Cyber Security (NCS)

Microreactors

Nuclear Science User Facilities (NSUF)

Research Reactor Infrastructure (RRI)

Advanced Reactors Safeguards (ARS)

National Reactor Innovation Center (NRIC)

Transformational Challenge Reactor (TCR)

Small Business Innovation Research

Risk Reduction (SBIR) and Small Business

Advanced Reactor Regulatory Development Technology Transfer (STTR)

Gateway for Accelerated Innovation in Nuclear (GAIN) Advanced Nuclear Industry Funding Opportunity (Industry FOA)

Technology Commercialization Fund (TCF) 3 Office of Reactor Fleet and Advanced Reactor Deployment Mission (NE-5)

Vision - Be a catalyst for the commercialization of NE-sponsored research, development and demonstration products

Mission - Integrate NEs research investments to achieve a productive and balanced portfolio of competitive and crosscutting research, development, and demonstration (RD&D) and research infrastructure to enable expansion of the U.S. commercial nuclear industry 2

Objectives

- Full and effective integration of NE RD&D planning, execution and oversight

- Systematic management of NE investments in research capabilities

- Alignment of NEs RD&D programs with industry-identified technical and regulatory needs

- Accelerate the introduction of innovative technologies into the marketplace through multiple mechanisms 4 energy.gov/ne 4

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1/6/2 0 2 1 Advanced Methods for Manufacturing (AMM)

Vision

To improve and demonstrate the methods by which nuclear equipment, components, and plants are manufactured, fabricated, and assembled by utilizing state of the art Fuel tubes produced by cold spray methods Goal

To reduce cost and schedule for new nuclear plant construction

To make fabrication of nuclear power plant (NPP) components faster, less expensive, and more reliable GEH BWR fuel bundle w/debris filter insert 5

5 energy.gov/ne 5

Connections of AMM program to other R&D programs, NRC, Industry NEAMS ART ASI GAIN 3

NSUF &

NMDQi TCR IES NE-4

- VTR

-TREAT 6 energy.gov/ne 6

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1/6/2 0 2 1 Stakeholder Engagement (Customers)

Internal DOE Supported Programs

Advanced Reactors

LWRS

Other elements of NEET Industry Connections

NEI

USNIC

EPRI

IFOA

Fuel Vendors External Governmental Programmatic Synergies/Overlaps

NRC

EERE

NIST

DoD The Goal is for DOE-NE to be the nexus for AMM development and leadership 7 energy.gov/ne 7

FY21 Objectives and Priorities

Increase stakeholder participation (Industry, DOE offices, Standards, NRC, National laboratories etc.)

Leverage the impact of research work and understand how the technology can 4 potentially be adopted & commercialized

Continue to reevaluate strategic intent and identify gaps, needs

Increase collaboration with DOE programs (identify cross cutting similar needs)

Establish direct funded project(s)

Re-evaluate Strategy 8 energy.gov/ne 8

B-487

1/6/2 0 2 1 Communication Surveys Conferences E-mail contact list Outreach presentations NEI workgroups Publications 9 energy.gov/ne 9

Addressing Challenges Competitively selected projects via Consolidated Innovative Nuclear Research (CINR) & Industry FOA

Open to universities, national laboratories and Industry

R&D and irradiation/PIE projects funded

FY 21 work scopes

MODULAR ADVANCED MANUFACTURING APPROACHES

NEW ADVANCED MANUFACTURING TECHNOLOGIES FOR QUALIFICATION 5 AND CERTIFICATION TO ACCELERATE LICENSING

IRRADIATION TESTING OF MATERIALS PRODUCED BY INNOVATIVE MANUFACTURING TECHNIQUES

- AMM Qualification Workshop

GAIN-EPRI-NEI

Develop an integrated approach to the AMM qualification process for materials and components 10 energy.gov/ne 10 B-488

1/6/2 0 2 1 AMM Focus Areas: FY2021 11 energy.gov/ne 11 Evaluate AMM Program Award Impact DRAFT (NEET Awards 2011-2019)

AMM Techniques Materials 6

Courtesy Subhashish Meher 12 energy.gov/ne 12 B-489

1/6/2 0 2 1 Evaluate AMM Program Award Impact DRAFT (NEET Awards 2011-2019)

AMM Techniques Materials LPBF Courtesy Subhashish Meher 13 energy.gov/ne 13 Gaps or Technology Challenges

Performance data in nuclear environments

How do we measure or gauge applications of new advanced manufacturing methods?

Technology readiness level

Qualification routes

Standards/Codes

Risks

Determining requirement & performance specifications for different manufacturing process domains 7

How do we measure & communicate the impact of our research (especially earlier TRL)?

Cybersecurity in:

Digital Engineering

Machine Learning approaches

Big Data/Artificial Intelligence Applications

Automated Manufacturing

In-situ monitoring

Embedded sensor 14 14 B-490

1/6/2 0 2 1 High Impact Materials & Manufacturing Technology Challenges

Design approaches for manufacturing

More qualified materials are needed by reactor developers to allow for design flexibility and to meet performance targets.

Optimized process modeling and AI

Interface design

Residual stresses relationships to design features

Topology optimization

Develop and qualify high strength, corrosion and radiation resistant materials for molten salt reactors

Accelerate qualification (new paradigm?)

Verification of quality & validation of modeling tools: specific manufacturing process modeling

New material discovery (or is it adoption of lessons learned from other disciplines)

High-throughput testing and characterization

Verification of quality & validation of modeling tools: specific manufacturing process modeling

Acceptance protocols for high temperature reactor components fabricated by advanced manufacturing methods

Integrated shared databases

Compact Heat Exchangers

Develop scientific understanding of processing-properties relation for enhanced diffusion bond properties

Large component fabrication and welding, Size limitations (Scalability - size, volume)

Sensors:

Radiation tolerant sensors

Miniaturization of sensors

Integrated manufacturing processes

Thermal barrier coatings: Interface designs to prevent scaling, functional materials, isolation 15 15 CURRENT AMM NEET PROJECTS HIP Cladding and Joining to Manufacture Large Dissimilar Metal Structures for Modular and GEN IV Xiaoyuan Lou Reactors (Project awarded FY 21) Auburn University Fiber Sensor Fused Additive Manufacturing for Smart Component Fabrication for Nuclear Energy Kevin Chen (Project awarded FY 21)

University of Pittsburgh Diffuse Field Ultrasonics for In Situ Material Property Monitoring During Additive Manufacturing Using Christopher M. Kube the SMART Platform Pennsylvania State University (Project awarded FY 21)

Machine Learning-based Processing of Thermal Tomography Images for Automated Quality Control of Alexander Heifetz Additively Manufactured Stainless Steel and Inconel Structures Argonne National Laboratory Development of Innovative Manufacturing Approach for Oxide-Dispersion Strengthened (ODS) Steel Kumar Sridharan 8 Cladding Tubes using a Low Temperature Spray Process University of Wisconsin Integrated Computational Materials Engineering (ICME) and In-situ Process Monitoring for Rapid David Gandy & Marc Albert Qualification of Components Made by Laser-Based Powder Bed AM Processes for Nuclear Structural Electric Power Research Institute and Pressure Boundary Applications Integrating Dissolvable Supports, Topology Optimization, and Microstructure Design to Drastically Albert To Reduce Costs in Developing and Post-Processing Nuclear Plant Components Produced by Laser- University of Pittsburgh based Powder Bed Additive Manufacturing All-position Cladding by Friction Stir Additive Manufacturing Zhili Feng Oak Ridge National Lab Laser Additive Manufacturing of Grade 91 Steel for Affordable Nuclear Reactor Components Stuart Maloy Los Alamos National Lab 16 energy.gov/ne 16 B-491

1/6/2 0 2 1 Additive Manufacturing Projects - Code Case Integrated Computational Materials Engineering & In-Situ Process Monitoring for Rapid Qualification of Components Made by Laser-based Powder bed Additive Manufacturing Processes for Nuclear Structural Award Number: DE-NE0008521 Award Dates : 10/2016 to 06/2020 PI: David Gandy Team Members: ORNL, Westinghouse, Rolls-Royce

Working with ASME Special Committee on Additive Manufacturing and BPVIII to develop and submit Data Package and Code Case (with Westinghouse)

ASME Special Committee has drafted Guideline document for AM welding of 316L SS.

Data Package finalized

Code Case submitted August 2020 17 17 Non-Destructive Testing 9

18 18 B-492

1/6/2 0 2 1 Development of Innovative Manufacturing Approach for ODS Steel Cladding Tubes using a Low Temperature Spray Process Kumar Sridharan University of Wisconsin 19 19 CURRENT AMM INDUSTRY PROJECTS IFOA Scope: Advanced manufacturing, fabrication and construction techniques for nuclear parts, components, and full-scale plants, or integrated efforts that could positively impact the domestic nuclear manufacturing enterprise Establishment of an Integrated Advanced Manufacturing and Data Science Driven Paradigm for Scott Shargots 10 Advanced Reactor Systems BWXT Small Modular Reactor Pressure-vessel Manufacturing & Fabrication-technology Development (sole David Gandy sourced) Electric Power Research Institute EPRI: Modular In-Chamber Electron Beam Welding Capability (Large Thick Section Components) David Gandy Electric Power Research Institute Advancing and Commercializing Hybrid laser Arc Welding (HLAW) for Nuclear Vessel Fabrication, Brian Farnsworth Including Small Modular Reactors (SMR) Holtec Manufacturing 20 energy.gov/ne 20 B-493

1/6/2 0 2 1 SMR RPV Manufacturing & Fabrication Technology Development SMR Reactor Pressure Vessel Manufacturing & Fabrication Technology Development - EPRI (10/01/2017 - 09/30/2021)

Overall industry goal is to produce a code-acceptable SMR Reactor Pressure Vessel (RPV) within 12 months 18-month schedule reduction 40% cost reduction R&D project objective is to manufacture the major components for a 2/3 scale (44 long x 6 in diameter) NuScale RPV utilizing:

Powder Metallurgy/ Hot Isostatic Processing (PM/HIP) Mockup EB weld of Electron Beam Welding lower head Diode Laser Cladding Cryogenic Machining Partners include EPRI, the UKs Nuclear Advanced Manufacturing Research Center (NAMRC), Carpenter Powder Products, Synertech, TWI, Sheffield Forgemasters, Sperko Engineering and others 21 21 CURRENT AMM SBIR PROJECTS Real Time NDE During 3D Manufacturing Araz Yacoubian LER Technologies Additive Manufacturing of BWR Lower Tie Plates and other Fuel Assembly Components Lauren Gramlich Novatech Additive Manufacturing of SMR Holddown Springs and Upper Nozzle Interfaces George Pabis Novatech NovaTech printed Lower Tie plate concept E, Inconel & SS 11 NovaTech design for a hold down spring that takes advantage of the capability of AM to produce complex geometries 22 energy.gov/ne 22 B-494

1/6/2 0 2 1 CURRENT AMM NEET NSUF PROJECTS Janelle Wharry Irradiation Studies on Electron Beam Welded PM-HIP Pressure Vessel Purdue University Jeffrey King Irradiation-Performance Testing of Specimens Produced by Commercially Available AM Colorado School of Mines Nanodispersion Strengthened Metallic Composites with Enhanced Neutron Irradiation Tolerance Ju Li Massachusetts Institute of Technology Enhancing Irradiation Tolerance of Steels via Nanostructuring by Innovative Manufacturing Techniques Mary Lou Dunzik-Gougar Idaho State University Haiming Wen Missouri University of Science and Technology Performance of SiC-SiC Cladding and Endplug Joints under Neutron Irradiation with a Thermal Gradient Christian Deck (Recap of Project) General Atomics Chase Cox Irradiation Testing of Materials Produced by Additive Friction Stir Manufacturing (Recap of Project) Aeroprobe Corporation 23 energy.gov/ne 23 Irradiation Performance Testing of Specimens Produced by Commercially Available Additive Manufacturing Techniques 12 Jeffrey King Colorado School of Mines 24 energy.gov/ne 24 B-495

1/6/2 0 2 1 Enhancing irradiation tolerance of steels via nanostructuring by innovative manufacturing techniques ECAP G91 Haiming Wen (Missouri S&T) 25 energy.gov/ne 25 What Next?

Update Strategic Plan Mining previous awards Implement FY21 priorities 13 26 26 B-496

1/6/2 0 2 1 FIRST NAME LAST NAME ORGANIZATION Marc Albert EPRI/AMM Marsha Bala INL/AMM Program Lori Braase GAIN Dirk CairnsGallimore DOENE John Carpenter LANL/AMM Technical Team Jason Christensen INL/AMM Regulatory David Gandy EPRI/AMM Ed Herderick OSU/AMM Technical Team Ryan deHoff ORNL/Secure & Digital Manuf Teresa Krynicki GAIN Hillary Lane NEI/AMM Kun Mo ANL/Adv Manuf Everett Redmond NEI/GAIN Sarah Roberts INL/AMM Support Andrew Sowder EPRI/GAIN Isabella Van Rooyen INL/AMM NTD Ali Zbib PNNL/AMM Technical Team Industry input on needs and qualification approaches will form the basis for the AMM Roadmap in 2021 and Implementation Plan.

Lori.braase@inl.gov Program Manager GAIN 27 27 Contact Information Dirk Cairns-Gallimore: AMM DOE federal program manager dirk.cairns-gallimore@nuclear.energy.gov 14 Dr. Isabella van Rooyen: AMM program National Technical Director Isabella.vanrooyen@inl.gov For more program information, including recent publications:

www.energy.gov/ne SMR Reactor Pressure Vessel (EPRI)

Onehalf lower head: Forge and electron bean weld 28 28 B-497

1/6/2 0 2 1 Questions?

29 energy.gov/ne 29 15 B-498

1/6 /2 0 2 1 WE START WITH YES.

RAPID QUALIFICATION OF NEW MATERIALS Creep rate (hrs-1)

USING MODELING AND 200 MPa180 MPa SIMULATION 160 MPa 140 MPa 120 MPa 100 MPa MARK MESSNER 80 MPa 60 MPa Argonne National Laboratory Time (hrs)

NRC Workshop on Advanced Manufacturing Technologies for NuclearApplications December 2020 1

ACCELERATING QUALIFICATION OF NEW (AMT)

MATERIALS Overview of the key challenges in rapid qualification of new materials and qualifying AMT materials, focusing on high temperature reactors:

- AMTs

Expect higher variability compared to conventional processing

Manufacturers/vendors have greater control over process

Limited data on nuclear materials 1

- High temperature materials

Long-term properties control design, short term tests provide limited information

Limited test data on AMT materials Three key tools for using modeling and simulation to accelerate qualification:

- Tool 1: Physically-based models

- Tool 2: Staggered qualification test programs

- Tool 3: Uncertainty quantification through statistical inference One vision of how these tools could be used to accelerate the qualification of a new AMT material 2

2 B-499

1/6 /2 0 2 1 WHAT ARE THE CHALLENGES QUALIFYING AM MATERIALS IN GENERAL?

Creep at same Variability in AM material properties is much Wrought 316L conditions AM 316L greater than for conventional wrought/cast 300 m material - more akin to welds

- Less understood processes

- Many processing parameters controllable by users

- Wide variety of technologies

- Manufacturing likely to occur at a number of smaller sites, rather than at large, central production facilities AM methods often result in significant material property variations within a single build We want a process that can take advantage of the AM material good, bad, or just different?

flexibility of AM processes - not trying to simply 3D print conventional material AM creep specimens courtesy UW Madison 3

3 WHAT ARE THE CHALLENGES QUALIFYING MATERIALS FOR HIGH TEMPERATURE SERVICE?

At high temperatures long-term, time-dependent material properties control design:

- Creep strength and ductility

- Creep-fatigue life

- Thermal aging characteristics

- Environmental degradation Creep cavitation 2 Short-term tests might tell you very little about (INL) important long-term properties Statistical variation in mechanical properties tends to be high, even for well-controlled Seam pipe failure at coal power station traditional wrought material processes (Viswanathan and Weld resilience can be challenging Stringer, 2000)

Very little long-term mechanical test data on AM material for properties relevant to high temperature design HRSG tube failure 4 (EPRI, 2005) 4 B-500

1/6 /2 0 2 1 TOOL #1: PHYSICALLY-BASED MODELS

Physically-based model: model the physical mechanisms that underlie a process

Opposed to an empirical model correlating data to outcome

Types of physically-based models:

Microstructural model: (some of) the model parameters are measurable microstructural characteristics

Multiscale model: hierarchical model propagating physical descriptions of processes on smaller length scales to higher length scales How physically-based models can improve property predictions and accelerate qualification:

1. Direct link to microstructure: connection to in-situ process monitoring and process models

2. Better chance of accurate extrapolation: physics remains the same regardless of lengths scale, time scale, environmental conditions 5

5 AN EXAMPLE OF HOW PHYSICALLY-BASED MODELING CAN SPEED QUALIFICATION Wrought Grade 91 Creep rate (hrs-1) 200 MPa180 MPa 160 MPa 140 MPa 120 MPa 3 Grain bulk: 100 MPa Grain boundaries: 80 MPa

Solid finite elements

Interface-cohesive formulatio n 60 MPa (tet10) (DG method)

Constitutive model

Constitutive model captures:

captures:

Cavity nucleation

Dislocation-mediated creep on

GB diffusion mediate d Calibration data: Time (hrs) void growth BCC slip systems Kimura (2009) at 160, 140, 120, and Experimentally

Bulk plasticity

Isotropic diffusion- (=dislocation) mediated 100 MPa inaccessible, mediated creep void growth >100,000 hours0 days 0 hours 0 weeks 0 months

Viscous GB sliding life Model predicts full creep curves, including rupture time 6

6 B-501

1/6 /2 0 2 1 EVALUATING CREEP UNDER TRIAXIAL LOAD

We typically test creep specimens with uniaxial Error: 2D calibration/2D evaluation stresses 0.25

Occasionally we have biaxial test data 0.2 (pressure tubes) 0.15

Notched tests are difficult to interpret 0.1

Key question: how to extrapolate this data to 0.05 realistic 3D states of stress? 0

Usual engineering approach: find an effective stress measure that converts 3D 1D so that the 1D rupture correlation predicts 3D rupture

But we dont have 3D creep test data or long-term 2D data Error: 3D calibration/3D evaluation

We can use the physical model to predict triaxial 1

rupture and assess different engineering models 0.8 (or develop new ones!) 0.6 0.4 Key outcomes of study: 0.2

All the effective stress measures are about 0 equally accurate when calibrated and compared to biaxial rupture data

Some are much better than others when calibrated and evaluated against 3D data 7

7 TOOL #2 STAGGERED QUALIFICATION APPROACHES How would this work? Key questions

1. Initiate long-term property tests on many candidate 1. Can vendors/designers work like this? You wont have materials (you can terminate the tests for the materials certain design data in the beginning and the mean of the that dont pan out) property distribution might change.

2. Use the short-term test results, the best available 2. Can regulators work like this? Youll be asked to assess processing information (in-situ process monitoring, designs with uncertain design data and/or accept designs advanced characterization), and material simulations to configured for alterations if long-term testing results predict long-term properties with uncertainty change the design assumptions. 4

3. As tests from #1 conclude, updated models in #2 to 3. Can codes and standards bodies work like this? It may provide new best estimates and uncertainties require a move towards probabilistic design.

Property distributions Short-term Medium-term Extrapolation, modeling and simulation Long-term Full design life 8

8 B-502

1/6 /2 0 2 1 ARE STAGGERED QUALIFICATION APPROACHES FEASIBLE?

What if analysis pretending that 316H is a new material. Targets 200,000 hours0 days 0 hours 0 weeks 0 months life because we have actual rupture data for this time Good news: average rupture stress never goes below initial lower bound Bad news: average and lower bound (design values) decrease a new data becomes available We need a better way to quantify uncertainty 9

9 TOOL #3: UNCERTAINTY QUANTIFICATION THROUGH BAYESIAN INFERENCE Challenges applying staggered, Current process probabilistic approach with conventional modeling:

Mechanisms not present in short-term data! Available rupture Predicted rupture

Little opportunity to take advantage of data strength improved processing (data stays in database)

Doesnt take advantage of all available data Empirical model + frequentist statistics 5 to narrow/improve statistical estimates

Processing data

Microstructural characterization Improved process using microstructure data Physical models have a better chance of accurately capturing long-term properties from Available rupture short term data data Predicted rupture Bayesian inference provides a framework for strength feeding in incomplete processing and microstructure information to yield better Processing/

predictions microstructure characterization 10 Physical model +

Bayesian inference 10 B-503

1/6 /2 0 2 1 A HIGH LEVEL DESCRIPTION OF BAYESIAN INFERENCE Statistical inference: deduce properties of a underlying probability distribution, often one that is difficult to sample directly Example:

Traditional approach: fit a deterministic model to the average response of several tension tests Inference: infer the distribution of the model parameters that explains the variation in the test data Importance:

Quantify uncertainty in model predictions - not just a predicted material property + a confidence interval, but an understanding of what causes the variation in the property A method for understanding microstructural variation from limited characterization data, but lots of high Youngs modulus Yield stress Hardening modulus throughput property measurements 11 11 COMBINING INFERENCE WITH PHYSICALLY-BASED MODELS Linking microstructural statistics to the corresponding material property statistics Experimental rupture distribution Why?

If we can characterize the microstructure coming out of the process we can translate that directly to (long-term?) property predictions

We can tune the process (via experimentation or 6

process modeling) to produce better materials Example

Back to wrought Grade 91

Grain boundary diffusivity is a key property controlling rupture life

What distribution of GB diffusivity explains distribution of Grade 91 rupture life?

How could we control GB diffusivity (via GB energy) to improve the rupture life of the material?

Inferred GB diffusivity 12 distribution 12 B-504

1/6 /2 0 2 1 ONE ROUTE TOWARDS RAPID QUALIFICATION Alter or confirm Ongoing

Provides initial, uncertain design/component conventional predictions for initial design service property testing Calibration/inference data

Extrapolates with physical conditions/service life model, hopefully providing better long-term design data Physical model for

Updates design material Evaluate long-term component/design properties of data to ensure ongoing safe interest operation

Amenable to probabilistic design methods Surrogate modeling Appropriate statistical bounds Microstructural characterization Update design Inference for material data uncertainty in model predictions Prior distributions Posterior distributions 13 13

SUMMARY

Modeling and simulation can play a role in accelerating the qualification of new AMT materials Key gaps:

- Building regular, owner, and codes/standards confidence in new approaches

- Benchmark studies to test out rapid qualification approaches 7

Low hanging fruit: try with well-characterized wrought material

Round robin benchmarks for nuclear materials + AMTs

- Improved data-driven methods for material science problems and ways to combine data-driven and physically-based modeling

Comparatively sparse datasets

Physical constraints on model predictions

- Better ways to bridge length scales and time scales in multiscale modeling 14 14 B-505

1/6 /2 0 2 1 ACKNOWLEDGEMENTS Others at ANL: Andrea Rovinelli, Andy Nicolas, Noah Paulson, Aritra Chakraborty, Xuan Zhang, Sam Sham NRC: especially Shah Malik and Amy Hull. ANL Task order Assess State of Knowledge of Modeling and Simulation and Microstructural Analysis for Advanced Manufacturing Technologies - reports on process modeling (1) and microstructural modeling (2) 15 15 8

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1/6/2021 Click to edit Master title style

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- Second level Cold *Spray Third level Development for Coatings

- Fourth level

>> Fifth level Kumar Sridharan (University of Wisconsin, Madison)

George Young (Kairos Power, Alameda, CA)

NRC Workshop on Advanced Manufacturing December 7th to 10th, 2020 1

ClickMembers Other to edit Master of thetitle Team style

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- Second level Kairos Power University of Wisconsin

Third level Hwasung (Sung) Yeom

- Fourth level Steven Huang

>> Fifth level Kyle Quillin Micah Hackett Evan Willing Mia Lenling Argonne National Tyler Dabney Laboratory Sam Sham Nicholas Pocquette Mark Messner 4/27/2020 2 2

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1/6/2021 Cold Click Sprayto editProcessMaster title style

[Courtesy UW-Madison]

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>> Fifth level Zn cold spray coating on steel substrate Powder particles of the coating material propelled at supersonic velocities by a gas onto the surface of a part to form a coating or deposit Particle temperature is low - particles and deposition occurs in solid state Process performed at ambient temperature and pressure, and at very high deposition rates 4/27/2020 3 3

Simulation of Particle-Substrate Impact Modeling, Lane Meddaugh, Univ. Wisconsin Impact of Al-particle on substrate showing jetting of oxide layer - a self-cleaning process (courtesy Dr. B.

Jodoin, University of Ottawa, Canada) 4 4

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1/6/2021 LowClickPowderto edit Particle MasterTemperature title style

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>> Fifth level high particle velocity process Low particle temperature confers several advantages:

Little or no oxide inclusions in the coating/deposited material Ideally suited for spraying metallic materials (e.g., Al, Cu, Ni, alloys, reactive (Ti) and refractory metals (Ta), cermets, e,g, Al/Al2O3, WC-Co)

Recently ceramics as well, TiO2 (Japan), Ti-Al-C (UW-Madison) 4/27/2020 5 5

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Manufacture of near-net shape products Additive manufacturing, 3D-printing Repair and dimensional restoration 4/27/2020 6 6

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1/6/2021 Cold Click Spray to edit Laboratory Master title at University style of Wisconsin, Madison (est. 2012)

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>> Fifth level Robot for pre-programmed Sample stage and dust Sound-proof spray booth movement of spray gun collector (below that) 4000-34 KINETIK System, from ASB Industries/CGT-GmBH Spray booth from Noise Barriers Robot controlled (Nachi system, from Antennen) Nitrogen/helium Robot controls (left) and gas cylinders spray gun control (right) 4/27/2020 7 7

Applications Click to editof Cold Spray Master for Nuclear title style Energy Systems - ATF (with Westinghouse)

Click to edit Master text styles 1300oC exposure:

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Very thin interdiffusion layer (2~3

µm)

No interface spallation observed Zr-alloy side almost 200m 4/27/2020 8 8

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1/6/2021 Cold ClickSpray to edit CrMaster Exposure titleatstyle 1300oC (with Westinghouse)

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- Second level Optimized Zirlo Optimized Zirlo

Third level coated with Cr (before test) - Fourth level (before test)

>> Fifth level Optimized Zirlo Optimized Zirlo coated with Cr (after test)

(after test)

Cr coating provides good protection against oxidation 4/27/2020 9 9

Applications of Cold Spray for Nuclear ClickSystems Energy to edit Master- ATF (with title style Westinghouse)

Click to edit Master text styles Cr-Coating developed at UW-

- Second level Madison (< 3 yrs)

Third level

- Fourth level Part of WECs EnCoreTM ATF

>> Fifth level program Joint UW-WEC patent, 2020 Technology transfer for full-length (12) coated cladding (called lead test rods, LTR)

In-reactor testing of LTR underway at a Utility Reactor, started in 2019 4/27/2020 10 10 B-511 5

1/6/2021 Cold Spray Coating of Zr-alloy Cladding Tubes High Temperature Oxidation and Microstructural Evolution of Cold Spray Chromium Coatings on Zircaloy-4 in Steam Environments, H. Yeom, B. Maier, G. Johnson, T. Dabney, M. Lenling, and K. Sridharan, Journal of Nuclear Materials, 526, 2019, 151737.

Development of Cold Spray Chromium Coatings for Improved Accident Tolerant Zirconium-alloy Cladding, B. Maier, H. Yeom, G. Johnson, T. Dabney, J. Walters, P. Xu, J. Romero, H. Shah, and K. Sridharan, Journal of Nuclear Materials, 519, 2019, p.

247.

Improving Deposition Efficiency in Cold Spraying Chromium Coatings by Powder Annealing, H. Yeom, T. Dabney, G.

Johnson, B. Maier, M. Lenling, and K. Sridharan, The International Journal of Advanced Manufacturing Technology, 100(5), 2019, p. 1373.

11 11 Conventional Click to editManufacturing Master titleof styleODS Steel Tubes - Slow and Expensive Process Click

Milled to edit->

powders Master cannedtext andstyles

- Second degassed at 400 level ºC -> multiple hot/

Third level warm extrusion steps (8 -10 steps) at

- Fourth level temperatures >>> 1000 Fifth level ºC and annealing.

Low strain rate extrusion May lead to grain anisotropy, and anisotropy in mechanical properties Melting processes cannot be used as they lead to upward stratification of Conventional fabrication of ODS steel oxide nanoparticles (heterogeneous tubes requires mechanical alloying and dispersion) multiple extrusion steps [G. Odette et al, Ann. Rev. Mater Res., 2008]

4/27/2020 12 12 B-512 6

1/6/2021 Particle Click toSize editDistributions Master title style for Ni and W Powders

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Eliminates multiple extrusion steps Eliminate ball milling step Faster and cheaper manufacturing process 4/27/2020 13 13 Free-Standing Click to edit ODS Master Cladding title Tube style Manufactured Using Gas Atomized Powder using Cold Spray

Click to edit Master text styles ODS -Steel Flat level Cross-section of ODS Free-standing ODS Second cladding tube cladding tube

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>> Fifth level Length: 204 mm (8) cladding tube O.D.: 11.5 mm Wall Thickness: ~ 1 mm Improving Deposition Efficiency in Cold Spraying Chromium Coatings by Powder Annealing, H. Yeom, T. Dabney, G. Johnson, B.

Maier, M. Lenling, and K. Sridharan, The International Journal of Advanced Manufacturing Technology, 100(5), 2019, p. 1373.

A Novel Approach for Manufacturing Oxide Dispersion Strengthened (ODS) Steel Cladding Tubes using Cold Spray Technology, B.

Maier, M.Lenling, H. Yeom, G. Johnson, S. Maloy, and Kumar Sridharan, Nuclear Engineering and Technology, 51, 4, 2019, p.

1069.

4/27/2020 14 14 B-513 7

1/6/2021 Cold Spray for Mitigation and Repair of Stress Stainless Steel Click to edit Master title style Canisters for Used Fuel Dry Cask Storage ClSCC in 304L stainless

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- Second level

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- Fourth level Traditional GTAW

>> Fifth level process

[Nuclear Waste Technical Review Board,2010]

Weld residual stress 4/27/2020 15 15 Cold Spray for Mitigation and Repair of Stress Stainless Click Steel Canisters to edit Master for Used title Fuel Dry Cask style Storage

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>> Fifth level CISCC produced by partnering lab PNNL using the Starting Powder MgCl2 Boiling TestApparatus X-ray Diffraction Patter of the Powder and the coating Dense cold spray coating on CISCC 4/27/2020 16 16 B-514 8

1/6/2021 Cold Spray for Mitigation and Repair of Stress Stainless Click Steel Canisters to edit for Used Master Fuel Dry title Cask style Storage

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>> Fifth level Microhardness the cold spray coating and substrate TEM image of cold spray coating and substrate Cold Spray Deposition of 304L Stainless Steel to Mitigate ChlorideInduced Stress Corrosion Cracking in Canisters for Used Nuclear Fuel Storage, H. Yeom, T. Dabney, N. Pocquette, K. Ross, F. E. Pfefferkorn, and K. Sridharan, Journal of Nuclear Materials, vol. 538, 2020,152254.

4/27/2020 17 17 Click to edit Master title style

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>> Fifth level Diffusion Barrier Coatings for Fluoride Salt-Cooled High Temperature Reactor (FHR)

- Preliminary Studies 4/27/2020 18 18 B-515 9

1/6/2021 Materials Corrosion in Molten Fluoride Salt is an Click to edit Master title style Important Consideration for FHR

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- Second level The less negative the

Third level free energy - Fourthof level formation>>of Fifth alevel metal-fluoride, is the more corrosion-resistant the metal is likely to be in molten fluoride salts W, Ni, Mo satisfy this requirement 4/27/2020 19 19 316 Stainless Steel after Corrosion Tests in FLiBe after 1000, Click 2000, to edit Master

& 3000hrs/700 oC title style

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>> Fifth 2000h level In 316 stainless steel 3000 hours0.0347 days 0.833 hours 0.00496 weeks 0.00114 months In 316 st. steel (left) and in graphite capsules (right)

Grain boundary attack dominates In graphite Graphite accelerates corrosion but also forms carbides 3000 hours0.0347 days 0.833 hours 0.00496 weeks 0.00114 months Corrosion of 316 Stainless Steel in High Temperature Molten Li2BeF4 (FLiBe) Salt, G. Zheng, B. Kelleher, G.

Cao, M. Anderson, K. Sridharan, T. R. Allen, Journal of Nuclear Materials, vol. 416, 2015, p. 143.

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1/6/2021 Click toDiffusion Tritium edit Master Through title style Materials Tritium will be generated due to neutron reaction with FliBe (coolant for FHR)

Click Tritium

KP-FHRs to edit Master text Management styles Strategy is to assure that all environmental releases

- Second are monitored andlevel comply with licensed pathways and limits

Third level The formation- ofFourth tritiumlevel fluoride will be mitigated through reactions with beryllium metal to avoid corrosion

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permeability

- Second Currently level several coatings (carbide, oxide, metallic) and methods evaluating (thermal

Third spray, level cold spray, explosion bonding, etc.)

Note Kairos- /Fourth level ANL (Messner & Sham) GAIN to develop ASME rules for

>> Fifth level corrosion resistant cladding Work performed by Kairos Power 4/27/2020 23 23 Investigating Ni-W Composite for a Combination Click of Corrosion to edit and Master Tritiumtitle style Diffusion Powder Type Sample ID Substrate Dimension (Quantity)

Click Pure toNiedit Master text styles 20190625n01/n02 1.25 x 6 (2)

- Second level

Third level Mixture of Ni and W (~16 wt.% Ni) 20190711n01/n02 1.25 x 6 (2)

- Fourth level Mixture of Ni and W (~10 wt.% Ni) 20190719n01/n02 1.25 x 6 (2)

>> Fifth level Mixture of Ni and W (~5 wt.% Ni) 20190725n01/n02 1.25 x 6 (2)

Ni-coated W 20190731n01/n02 1.25 x 6 (2)

Mixture of Ni and W (~2 wt.% Ni) 20191029n01/n02 1.25 x 6 (2)

Mixture of Ni and W (~1 wt.% Ni) 20191031n01/n02 1.25 x 6 (2)

Two 1.25 x 6 samples of each coating type produced for testing at Kairos One 1.25 x 2 sample produced for cross-section characterization at UW Atlantic Equipment Engineers provided the gas atomized 99.9% Ni-powder Tekna provided the 99.7% W-powder Global Tungsten and Powder provided 6% Ni-coated powder SS316H substrate was provided by McMaster-Carr.

4/27/2020 24 24 B-518 12

1/6/2021 Particle Click toSize editDistributions Master title style for Ni and W Powders As-received Ni powder

Click to edit Master text styles

- Second level

Third level Both powders sieved

- Fourth levelto -

25m before spraying>> Fifth level Average Ni particle size ~20m Average W particle size ~12m As-received W powder Ni-coated W powder sizes range from 5-32m 4/27/2020 25 25 Click to edit Master Microstructure of Ni and title Wstyle Powder

Both powders showed equiaxed and micron-scale grained microstructure

Click to edit Master text styles

Fine Ni-oxide

- Second particulates level were detected in Ni matrix as an impurity -

generally *shown in gas atomized powders Third level

- Fourth level Ni powder (cross-section) W powder (cross-section)

>> Fifth level W

Ni EDS analysis Ni W 4/27/2020 26 26 B-519 13

1/6/2021 Structure Click to edit of Ni-Coated Master title W Powder style Ni coating on W particle (deposited possibly by chemical vapor

Click to deposition edit Master (CVD), textless is very thin, styles than 500nm

- Second level Crosslevel

Third section images of as-received Ni-coated W powder

- Fourth level

>> Fifth level 1m 1m Individual particles are less than 5m.

4/27/2020 27 27 Pure Click Nito Coating edit Master title style Polished coating ~400-420m thick As-deposited pure Ni coating

Click to edit Master text styles

- Second level

Third level

- Fourth level

>> Fifth level Interface Polished to remove surface roughness 100m The pure Ni coating was polished to remove surface roughness and provide a more uniform coating for testing at Kairos 4/27/2020 28 28 B-520 14

1/6/2021 Pure Click W to Coating edit Master title style As-deposited coating ~7-20m thick

Click to edit Master text styles

- Second level

Third level

- Fourth level

>> Fifth level 4/27/2020 29 29 Click Ni-W Mixture to edit Coatings Master title style As-deposited 5 wt. % Ni coating

Click to edit Master text styles Pure Ni and W powders were blended together- inSecond level three compositions:

Third level

16 wt.% Ni

- Fourth level

10 wt.% Ni >> Fifth level

5 wt.% Ni 50m 50m 50m 16 wt. % Ni 10 wt. % Ni 5 wt. % Ni Coating thickness for all samples is ~ 75-90µm 4/27/2020 30 30 B-521 15

1/6/2021 16Click wt.%toNiedit Coating Master titleMapping

- EDS style

Click to edit Master text styles

- Second level

Third level

- Fourth level

>> Fifth level 50m Area fraction of W - 14.7%

Measured using image analysis Coating thickness ~75-90 µm 4/27/2020 31 31 10Click wt.%toNiedit Coating Master titleMapping

- EDS style

Click to edit Master text styles

- Second level

Third level

- Fourth level

>> Fifth level 50m Area fraction of W - 22.6%

Measured using image analysis Coating thickness ~75-90 µm 4/27/2020 32 32 B-522 16

1/6/2021 Click Ni 5 wt.% to editCoating Master title

- EDS style Mapping

Click to edit Master text styles

- Second level

Third level

- Fourth level

>> Fifth level 50m Area fraction of W - 22.6%

Measured using image analysis Coating thickness ~75-90 µm 4/27/2020 33 33 Coating from Ni-Click to coated Wedit powder Master title style particles

Click to edit Master text styles

- Second level

Third As-deposited level W coating Ni-coated

- Fourth level

>> Fifth level 2m Coating thickness ~ 5-10µm The Ni coating on the W powder particles was likely too thin to have any significant effect.

10m 4/27/2020 34 34 B-523 17

1/6/2021 Click toCycle Thermal edit Master Test title style

Click to edit Master text styles

- Second level

Third level

- Fourth level Samples moved in and out of

>> Fifth level furnace between 25 °C and 800

°C Coatings well-adhered to the Blistered pure Ni coating after thermal cycling substrate Only pure Ni sample showed minor blistering (not Ni/W mixtures)

Work performed by Kairos Power 4/27/2020 35 35 Click to editAcross Interdiffusion MasterInterface title style

Click to edit Master text Oxide styles Coating - Second level Oxide

Third level

- Fourth level Nominal 316SS composition

>> Fifth level Substrate EDS line scan

Diffusion of Fe and Cr into Ni coating and diffusion of Ni into substrate is ~40µm deep 4/27/2020 36 36 B-524 18

1/6/2021 Click to edit Deuterium Permeation Master title Tests style The permeability was measured at 500°C, 600°C and 700°C to provide a baseline to

Clickpermeation determining to edit Master reductiontext factor styles (PRF)

- Second level

Third level

- Fourth level

>> Fifth level No observable improvement in deuterium permeation resistance observed in these preliminary studies, but we intend to continue this work with other materials and compositions 5 wt.% Ni Coating Work performed by Kairos Power 4/27/2020 37 37 Ti2AlC Coatings Successfully Deposited: Example of a coating that may provide a combination of corrosion resistance and tritium diffusion resistance As-deposited As-received powders Cold sprayed coating Coated cladding sections After 1000oC test Underlying Zr-TEM of oxide layer Severe oxidation alloy protected alternating on the uncoated nanolaminates of Zirlo side Al2O3 and TiO2 Cold Spray Deposition of Ti2AlC Coatings for Improved Nuclear Fuel Cladding, B.R. Maier, B.L. Garcia-Diaz, B. Hauch, L.C.

Olson, R.L. Sindelar, and K. Sridharan, Journal of Nuclear Materials, 466, 2015, p. 712.

38 38 B-525 19

1/6/2021 Contact Click toInformation edit Masterand Questions title style Kumar Sridharan E-mail:

Click kumar.sridharan@wisc.edu to edit Master text styles Second

-Tel: level 608-263-4789

Third level

- Fourth level

>> Fifth level University of Wisconsin Cold Spray Laboratory uestions?

4/27/2020 39 39 B-526 20

1/6/2 0 2 1 In-situ Process Measurements for Monitoring, Control, and Simulation of AM Brandon Lane, Ph.D.

Intelligent Systems Division Engineering Laboratory National Institute of Standards and Technology Disclaimer: Certain commercial equipment, instruments, or materials are identified in this paper in order to specify the experimental procedure adequately. Such identification is not intended to imply recommendation or endorsement by NIST, nor is it intended to imply that the materials or equipment identified are necessarily the best available for the purpose.

NRC Public Workshop on Advanced Manufacturing - 12/10/2020 1

Outline

NIST Measurement Science for AM (MSAM)

EOS M270 Thermography

Additive Manufacturing Metrology Testbed

Industriallyrelevant process monitoring 1

Modelbased feedforward controls

Absolute thermometry

Other fun measurements!

Laser Processing Diffraction Testbed (LPDT)

Dissemination and use of measurements NRC Public Workshop on Advanced Manufacturing - 12/10/2020 2 2

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1/6/2 0 2 1 NIST Measurement Science for Additive Manufacturing (MSAM) Program

Part of Engineering Laboratory, 7 projects spanning most aspects of metal AM metrology

Also AM program in Materials Measurement Laboratory, www.nist.gov/additivemanufacturing collaborators throughout NIST, academia, govt., industry.

3 projects discussed today:

AM Machine and Process Control Methods for AM Insitu processing actions to PI: Dr. Ho Yeung enable improved part quality Metrology for RealTime Monitoring of AM Relative or lowfidelity PI: Dr. Brandon Lane measurements and relationship to part qualities Metrology for MultiPhysics AM Model Validation Highfidelity, absolute measurements &

PI: Dr. Thien Phan underlying physical principles NRC Public Workshop on Advanced Manufacturing - 12/10/2020 3 3

Insitu AM Metrology Capabilities 2

Additive Manufacturing Metrology Testbed (AMMT) EOSM270 LPBF Thermography System www.nist.gov/el/ammttemps www.nist.gov/el/lpbfthermography Optomec LENS MR7 w/ melt pool monitoring (Stratonics)

EOS M290 w/ SigmaLabs PrintRite melt pool monitoring https://www.z3dfab.com/

NRC Public Workshop on Advanced Manufacturing - 12/10/2020 4 4

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1/6/2 0 2 1 EOS M270 + Thermography System Partscale radiance temperature and cooling rate measurements during 3D part builds Rapid testing of different geometries in standard materials Camera information > New camera 1800 frames per second > 2400+ fps 40 s integration time (shutter speed) > HDR capabilities 360 pixel wide, 128 mm tall field of view > 320x256 pixels 44° viewing angle Viewable area on baseplate, 12 mm x 6 mm > Variable iFOV - 54 m x 36 m > min 45x30 m https://www.nist.gov/el/lpbfthermography PIs: Jordan Weaver, Brandon Lane NRC Public Workshop on Advanced Manufacturing - 12/10/2020 5 5

EOS M270 + Thermography System Mapped MP Length and Cooling rates in 3D build

Xorientation scans

Yorientation scans

Odd layer (#125)

Even layer (#126) 3 Leg 7 Leg 8 Leg 9 Leg 7 Leg 8 Leg 9 Heigel et al. (2020) Integrating Materials and Manufacturing Innovation. https://doi.org/10.1007/s40192020001708 Data: Heigel et al. (2020) J. Research NIST. https://doi.org/10.6028/jres.125.005 NRC Public Workshop on Advanced Manufacturing - 12/10/2020 6 6

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1/6/2 0 2 1 EOS M270 + Thermography System Mapped MP Length and Cooling rates in 3D build EBSD images from Stoudt et al. (2020) Integrating Materials and Manufacturing Innovation.

https://doi.org/10.1007/s40192020001726 All data available at www.nist.gov/ambench/

NRC Public Workshop on Advanced Manufacturing - 12/10/2020 7 7

Additive Manufacturing Metrology Testbed (AMMT) www.nist.gov/el/ammttemps 4

NRC Public Workshop on Advanced Manufacturing - 12/10/2020 8 8

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1/6/2 0 2 1 AMMT Guts The testbed facility, as shown in the simplified diagram on the right, contains

Process Chamber - a vacuum enclosure with rollout carriage, containing Powder Bed Fusion and Optical Metrology equipment, as well as Staring Imager

Laser Enclosure, including Laser Delivery Optics and InLine Process Monitoring tools

Radiometry Module with InLine Thermal Imaging, Illumination and future Spectral Radiometry instruments

Control and Support System (not shown),

including FPGAbased computer control, and process gas recirculation and conditioning system NRC Public Workshop on Advanced Manufacturing - 12/10/2020 9 9

Process Monitoring Data on the AMMT Part Design + Material data Digital Command Input Data Acquisition (DAQ)

CAD Geometry

100 kHz, synchronous command

100 kHz Analog encoder/readouts

Powder PSD + Composition

Galvo X,Y position [mm]

Galvo X,Y, LTZ position encoders [mm]

Laser Power [W]

Laser power monitor [W]

Trigger (for MPM camera)

Coaxial, Melt Pool Exsitu Characterization Monitoring Camera

XCT Layerwise Camera * ~20000 fps

Metallography (planned)

GigE, 10.6 MP (windowed)

120x120 pixel 5

~67 m/pixel

8 m/pixel Metadata

Documented experiment descriptions

Calibration

Alignment/registration www.nist.gov/el/ammttemps/datasets Praniewicz (2020) J. Research NIST (JRES) https://doi.org/10.6028/jres.125.031 Lane B (2020) J. Research NIST (JRES) https://doi.org/10.6028/jres.125.027 Lane B (2019) J. Research NIST (JRES) https://doi.org/10.6028/jres.124.033 NRC Public Workshop on Advanced Manufacturing - 12/10/2020 10 B-531

1/6/2 0 2 1 AMMT - Geometry/Thermal Modelbased Control

Geometric Conductivity Factor (GCF) - solid vs. powder in vicinity of melt pool

Residual Heat Factor (RHF) - time & distance from previous melt pool locations Part 1: No thermal control

Control: Laser power = f[GCF, RHF] Part 3: Highest thermal control RHF: Yeung H et al. (2020) Manufacturing Letters https://doi.org/10.1016/j.mfglet.2020.07.005 GCF: Yeung et al. (2019) Additive Manufacturing https://doi.org/10.1016/j.addma.2019.100844 NRC Public Workshop on Advanced Manufacturing - 12/10/2020 11 11 Example Use: Machine Learningbased Control AMMT scan strategy digital command Execute on AMMT, measure MP image features (area) 6 Neighboringeffect model (NBEM) Build datadriven model, predicting MP image area as function of scan strategy (Similar to RHF)

Now: Predict MP Area based on path 1

Future: Optimized path based on target MP area 1

Papers: Yeung et al (2020) Additive Manufacturing https://doi.org/10.1016/j.addma.2020.101383[2]

Yang et al. (2020 J. Comp. Inf. Sci. Eng. https://doi.org/10.1115/1.4046335 Dataset: Lane B (2019) https://doi.org/10.6028/jres.124.033 NRC Public Workshop on Advanced Manufacturing - 12/10/2020 12 12 B-532

1/6/2 0 2 1 AMMT - Radiance Temperature Calibration Trad(DL)

Example: 850 nm, 10001880 °C Tbb(V) TTSP(ALED) & V(Trad) (10001880oC)

Primary TSP 900 Thermogauge TSP 850 TISS 850 Source Imaging Standards HTBB Pyrometer (850 nm LED) system Melt Pool Source Custom designed TISS 850 LEDdriven source for insitu calibration Staring Imager in a measurement configuration, Staring Imager in calibration position with a high magnification lens and folding mirror (outside of the purge enclosure)

NRC Public Workshop on Advanced Manufacturing - 12/10/2020 13 13 AMMT - Hemispherical Reflectometer/Integrator Optical Layout Kirchoffs Law

= = 1 Dome Reflectometer Design 7 Designed to provide uniform hemispherical illumination in the sample position HemisphericalDirectional Reflectance Factor (HDRF) > surface emittance Deisenroth et al. (2020). Reflection, Scattering, and Diffraction from Surfaces VII (SPIE)https://doi.org/10.1117/12.2568179 Deisenroth et al. (2021) Measurement Uncertainty of Thermodynamic Surface Temperature Distributions for Laser Powder Bed Fusion Processes, J. Research NIST (in review, expect early 2021 www.nist.gov/people/daviddeisenroth)

NRC Public Workshop on Advanced Manufacturing - 12/10/2020 14 14 B-533

1/6/2 0 2 1 AMMT - Emittance/Reflectance & True T Example on highpurity 99.998% Ni, measured at 850 nm Emittance Emittance Uncertainty Temperature Temperature Uncertainty Reference values:

Krishnan, S., Yugawa, K. J. and Nordine, P. C.,

Optical properties of liquid nickel and iron, Phys. Rev. B 55(13), 8201-8206 (1997).

NIST Publications:

Deisenroth et al. (2020). SPIE https://doi.org/10.1117/12.2568179

Deisenroth et al. (2021) MeasurementUncertainty of Reference value of Thermodynamic Surface Temperature Distributions 1455 °C for Laser Powder Bed Fusion Processes, J. Research NIST (in review, expect early 2021 Krishnan and Yugawa www.nist.gov/people/daviddeisenroth )

measured value at 1491 °C NRC Public Workshop on Advanced Manufacturing - 12/10/2020 15 15 AMMT - Dynamic laser absorption + energy balance Dynamic laser coupling + melt pool emission + melt Timeintegrated reflected + absorbed energy (calorimetry) 8 pool morphology Lane et al. (2020) Additive Manufacturing https://doi.org/10.1016/j.addma.2020.101504 Deisenroth et al. (2020) Proceedings of SPIE https://doi.org/10.1117/12.2547491 Also see NIST Boulder: PI Brian Simonds, Ph.D.

Allen et al. (2020) Physical Review Applied https://doi.org/10.1103/PhysRevApplied.13.064070 NRC Public Workshop on Advanced Manufacturing - 12/10/2020 16 16 B-534

1/6/2 0 2 1 AMMT - Plume investigation Synchronous Coaxial + Staring imager for plume investigation Coaxial @ 10 K Hz, 95 us / SideView @10 K Hz, 98 us With Ar blow Without Ar blow Without Ar (i.e. in oxygen)

Coaxial camera 11 10 9

8 7

6 5

4 3

2 1

Sideview camera 20190515_plume_In625_ArFl_10k_98us_16bits_Gamma1pt3_exp23_2.mp4 20190515_plume_In625_Oxy_10k_98us_16bits_Gamma1pt3_exp24.mp4 20190515_plume_In625_ArBl_10k_98us_16bits_Gamma1pt3_exp22.mp4 Deisenroth et al. (2020) Proc. MSEC 2020 (copy available from authors)

NRC Public Workshop on Advanced Manufacturing - 12/10/2020 17 17 Laser Processing and Diffraction Testbed (LPDT)

Diffracted X ray Cone 220 Laser beam Incident Xray beam 200 111 9

Simulated measurement PIs: Thien Phan, Ph.D. (NIST EL)

Darran Pagan, Ph.D. (CornellCHESS/Penn. State)

Thermal simulation courtesy Kevontrez Jones (Northwestern U.)

Pagan et al. (2020) A Finite Energy BandwidthBased Diffraction Simulation Framework for Thermal Processing Applications.

JOM. https://doi.org/10.1007/s11837020044437 18 NRC Public Workshop on Advanced Manufacturing - 12/10/2020 18 B-535

1/6/2 0 2 1 NIST AM Insitu Data & Dissemination AMMT Website NIST AMMD NIST LPBF Thermography Website https://www.nist.gov/el/ammttemps/datasets https://ammd.nist.gov/

+ AMBench Website https://www.nist.gov/el/lpbfthermography/datasets https://www.nist.gov/ambench/benchmarktestdata Incorporation of AMMT data into database Updated insitu process monitoring Data visualization tools datasets from the AMMT Staring thermography system on EOS M270 AMBench has myriad exsitu data (res.

strain, structure, etc.)

IDETCCIE Conference, August 1516, 2020 https://event.asme.org/IDETCCIE2020/Program/Hackathon IMECE Conference, November 1415 2020 https://event.asme.org/IMECE/Program/Hackathon NRC Public Workshop on Advanced Manufacturing - 12/10/2020 19 19 oThien Phan (NIST EL)

+Jordan Weaver (NIST EL)

Acknowledgements: +Benjamin Molnar (NIST EL)

oSteven Grantham (NIST PML)

Sergey Mekhontsev (NIST PML)

Leonard Hanssen (NIST PML)

oHo Yeung (NIST EL)

AMMT Team * *David Deisenroth (NIST EL)

Jorge Neira (NIST PML)

EOS Thermography Team + *Vladimir Khromchenko (NIST PML) 10

Clarence Zarobila (NIST PML)

LPDT Team o *Jarred Tarr (NIST EL)

o+Alkan Donmez (NIST EL)

+Jarred Heigel (ThirdWave Systems, U.S.)

Ivan Zhirnov (Karlstad U., Sweden)

Daniel CardenasGarcia (Centro Nacional de Metrología, Mexico)

Igor Yadroitsev (Central U. Tech, South Africa) oDarren Pagan (Cornell / Penn. State) oKevontrez Jones (Northwestern U.)

NRC Public Workshop on Advanced Manufacturing - 12/10/2020 20 20 B-536

1/6/2 0 2 1 Questions?

NRC Public Workshop on Advanced Manufacturing - 12/10/2020 21 21 11 B-537

1/6/2 0 2 1 Additive Manufacturing Consortium Mark Barfoot Director, AM Programs mbarfoot@ewi.org 716.710.5597 1

EWI OVERVIEW

History

- Founded in 1984, EWIs comprehensive engineering services help companies identify, develop and implement the best options for their specificapplications.

Our Mission

- Break through our customers technical barriers, solve their manufacturing challenges, and further their success. 1

Expertise

- Industry experts in materials joining, forming, testing, modeling and additive manufacturing

Locations

- Headquartered in Columbus Ohio with technology centers in Buffalo, NY and Loveland, CO.

2 B-538

1/6/2 0 2 1 EWI AM Capabilities

EWI leads way in AM by evaluating new processes, developing material property data, and helping our clients adopt and implement stateoftheart technology to build their products.

- Recognized expertise in metal AM

- All 7 ASTM Additive technologies in house

- Extensive laboratory and testing capabilities

- Non profit

- Technology and vendor agnostic neutral party

Founded Additive Manufacturing Consortium (AMC) in 2009 3

Additive Manufacturing Consortium Mission: Accelerate and advance the manufacturing readiness of additive manufacturing technologies

Goals:

- Platform for collaboration across global industry, academia and government entities. 2

- Execute group sponsored projects focused on addressing precompetitive AM challenges

- Partner on government funding opportunities

- Forum for discussion/shaping AM roadmaps 4

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1/6/2 0 2 1 Direct Quotes from our members Leveraging membership We cant do fees and time to develop low TRL (Technology this alone Readiness Level)

Technical Interchange with like minded AM professionals Keep our company updated in terms of Sharing of R&D challenging solutions for Costs metal AM issues 5

Industries & Organizations & Partners Aerospace Defense Ship Building Automotive Medical Oil & Gas Consumer Products 3

Government Universities Powder/Material Mfg Service Bureaus OEMs Software 6

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1/6/2 0 2 1 Growth of AMC Members Increasing membership

65 Total Members

Increasing by 58 full members/year.

90% + retention rate 7

AMC Project Portfolio Total current project portfolio is:

+$4.5M in past project work

Over $2M cash/inkind per year of project work

Currently 6 8 projects/year 4

8 B-541

1/6/2 0 2 1 Benefits Summary

Network with like minded additive professionals

Technical discussions on latest AM work

Leverage your membership fees for combined project work

Allowances for foreground IP and confidentiality *

Ongoing Technical Communication

- Biweekly project teleconferences

- Quarterly technical meetings including tours of AM facilities

per membership and sponsorship agreement terms 9

Quarterly Meetings

AMC holds Quarterly Meetings at partner sites 5

Average attendance is 80140 people

- Includes AMC members and invited guests.*

10 B-542

1/6/2 0 2 1 Typical Quarterly Meetings & Tours Joe Gibbs Racing Honeywell NASA Marshall Space Flight Center 11 Typical Quarterly Meeting Agenda

Day 1 - Members only meeting

- Update on current AMC projects

Day 2 - General Session - latest AM news

- Evaluation of Laser Powder Bed Fusion AM to 6 Produce replacement legacy aircraft components

- Additive Manufacturing - A Users Perspective

- Advanced Finishing Methods in Additive Processes

- High Speed Thermography results on EOS M270

- High throughput Testing reveals rare, catastrophic defects 12 B-543

1/6/2 0 2 1 To be voted on AMC 2021 Down Selected Projects Feb 3-4,2020

- Materials

Continue Testing for IN625 & 718

Phase 2 - Material Characterization for high strength AL alloys

Microstructure evaluation of joint interfaces between additive & convention methods

- AM Machines & Tests

Continuation of NEW AM Technologies

Assessment of new metal AM technologies - Hybrid Systems

Materials Testing in AM - Does your coupon size, shape & surface condition matter?

Phase 2 - Evaluate correlation between powder analysis techniques in relation to the printed part quality (surface roughness, mechanical properties and dimensional accuracy)

Deeper dive into Velo System including distortion in support free geometries

Phase 2 - Factors affecting as build surface finish

- Technology Advancement

AM for tooling study

Continuation of Investigation into multilaser systems

Deeper Dive into LPBF Process restarts - whats really happening at microstructure level, and are we allowed to do process restarts?

- Post Processing & Finishing

Post Processing of AM Parts

- Simulation

AM Process simulation for parameter development 13 AMC 2020 Projects

Phase 6 Continuation of IN625/IN718 - Effect of thickness on microstructure

Phase 4 Material Characterization & Testing for high strength aluminum alloys (7075)

Phase 2a - Continuation of evaluating new AM technologies 7

Factors affecting AS built surfaces (vertical, upskin, downskin)

How to qualify machine performance across various manufacturers

Investigation into multilaser systems

Phase 3 - Evaluation of NDE techniques 14 B-544

1/6/2 0 2 1 2019 AMC Projects

Phase II: Evaluation of Post Process Techniques for AM

Processing a part using 8 post process techniques and comparing results. This year looking at the effect of post processing on fatigue results

Phase III: InProcess Monitoring

Evaluating the commercially available in-process monitoring systems for L-PBF and comparing their results.

Phase V: Continuing Further Testing on Current Projects IN 625 and IN 718 and Relating Microstructure to AM Properties - Fatigue &Creep

Studying the fatigue and creep resistance of AM printed parts 15 2019 AMC Projects

Evaluation and compare powder measurement techniques

Evaluation of available powder measurement techniques to determine what system works best for specific types of powder

Assessment of new AM metal AM technologies

Reviewing the new metal AM technologies and then comparing the properties of parts printed using those technologies 8

Feature wise Parameter development for LPBF

Looking at how parameters should be varied for specific types of geometries (ie: bridges or thin walls)

Phase II: Evaluation of NDE techniques for complex AM parts

Determining the best NDE techniques to analyze a complex AM part 16 B-545

1/6/2 0 2 1 How do I Join?

Complete Membership agreement

Current term is 20182021

Dues payable annually

Contact Mark Barfoot, Director of AM Programs

- Email at mbarfoot@ewi.org

- Phone at 716.710.5597 17 Next Meeting Feb 34th, 2020 - VIRTUAL tours and topics TBA shortly 9

Contact me if you are interested in coming as a guest 18 B-546

1/6/2 0 2 1 WHY JOIN AMC Develop strategic relationships/networks and advance AM technology in a precompetitive, collective manner that could provide value to our company and accelerate the introduction of AMbuilt parts into aerospace applications 19 10 Appendix: Past AMC Projects 20 B-547

1/6/2 0 2 1 2015 AMC Projects

Nickel Alloy 625

- Heat treatment and mechanical property development for LPBF

Nickel Alloy 718

- Heat treatment and mechanical property database development for LPBF and EBPBF

Monel 400 Process Development for LPBF: Phase 1

High Strength Aluminum Alloy Process Development for LPBF:

Phase 1

- Large literature review and feasibility study aimed at processing an aluminum alloy with similar properties to 6xxx and 7xxx series alloys.

21 2016 AMC Projects

Nickel Alloy 625: Phase 3

- Comparison of multiple LPBF platforms on the metallurgical and mechanical properties of deposited Nickel Alloy 625

Nickel Alloy 718: Phase 3

- Powder recycling study including powder characterization, UT inspection of coupons, and Fatigue testing 11

High Strength Aluminum Alloys for LPBF: Phase 2

- Investigation of multiple process and chemistry alterations targeted to deposit an aluminum alloy with properties at the level of the 7xxx series

Monel 400 Heat Treatment Optimization: Phase2

- Study to determine heat treatment, tensile properties, corrosion properties, and impact toughness for Monel 400 deposited using LPBF 22 B-548

1/6/2 0 2 1 2017 AMC Projects

InProcess Monitoring of Defects in LPBF:Phase 1

- Inprocess monitoring and defect rectification study utilizing multiple sensors

High Strength Aluminum Alloys for LPBF: Phase 3

- Heat treatment optimization through metallurgical and mechanical property evaluation for two high strength aluminum alloys

AM Powder Recycling and Reconditioning for LPBF:Phase 1

- Investigation of powder recycling and reconditioning through mixing and plasma spheroidization

Nondestructive PostProcess Evaluation of AM Components: Phase 1

- Evaluation of NDE techniques and their applicability to multiple types of LPBF defects 23 2018 AMC Projects

Evaluation of Post Process Techniques for AM

- Processing a part using 8 post process techniques and comparing results

Phase II: InProcess Monitoring & Defect Rectification

- Evaluate performance of different repair strategies 12 over varying LPBF defect modes and levels

Continuing Further Testing on Current Projects IN 625 and IN 718 and Relating Microstructure to AM Properties

- Effective of chemistry changes from different powder suppliers on microstructure and material properties 24 B-549

1/6/2 0 2 1 2018 AMC Projects

DED Multimaterial/ Repair

- Review of QuesTek Innovations for CALPHAD simulation and then produce a Swagelok component using DED

Comparison of Commercially Available AM Simulation Tool

- Evaluate software simulation capabilities and performance comparisons. Build a part and compare prediction to actuals

Stainless Steel MultiProcess AM

- Evaluating microstructure and results of stainless steel parts printed using LPBF and DED process 25 EWI is the leading engineering and technology organization in North America dedicated to developing, testing, and implementing advanced manufacturing technologies for industry.

Since 1984, EWI has offered applied research, manufacturing support, and strategic services to leaders in the aerospace, automotive, consumer electronic, medical, energy, government and defense, and heavy manufacturing sectors. By matching our expertise to the needs of forward thinking manufacturers, our technology team serves as a valuable extension of our clients innovation and R&D teams to provide premium, gamechanging solutions that deliver a competitive advantage in the global marketplace.

EWI FACILITIES AND LABS 13 Columbus, Ohio Buffalo, New York Loveland, Colorado EWI (Headquarters) Buffalo Manufacturing Works EWI Colorado 1250 Arthur E. Adams Drive 847 Main Street 815 14th Street SW Columbus, OH 43221 Buffalo, NY 14203 Loveland, CO 80537 614.688.5000 716.710.5500 970.635.5100 info@ewi.org drose@ewi.org mwillard@ewi.org 26 l Confidential to AMC members only. Do not distribute.

26 B-550

ML21113A082

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