ML22179A334

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NRC Public Meeting - Advanced Manufacturing Technologies, June 28, 2022
ML22179A334
Person / Time
Issue date: 06/28/2022
From:
Office of Nuclear Regulatory Research
To:
M. Yoo
References
Download: ML22179A334 (35)
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NRC Public Meeting Advanced Manufacturing Technologies US NRC June 28, 2022

NRC Draft Guidelines Document Laser - Directed Energy Deposition Mark Yoo Office of Nuclear Regulatory Research June 28, 2022

Outline

  • Overview of Laser-Directed Energy Deposition (L-DED)
  • Technical Basis for L-DED Draft Guidelines Document (DGD)
  • Tie to Draft AMT Review Guidelines (Table 1)
  • L-DED Technical Assessment

- Table 2A: Material-generic Process Topics

- Table 2B: 316L Material-Specific Properties / Performance Topics

  • Conclusions

Laser-Directed Energy Deposition

  • Process:

- Wire or powder fed through nozzle into laser for melting

- Fundamentally welding using robotics/

computer controls

  • Potential Applications Schematic of DED process

- Medium sized Class 1, 2, and 3 components

- Larger components than laser-powder bed fusion are possible due to faster production and greater build chamber volumes https://www.osti.gov/pages/servlets/purl/1437906 4

Draft AMT Review Guidelines

  • Provides guidelines to assist NRC staff reviewing requests to use AMTs and identifies the range of information that could be necessary in a submittal
  • General Review Philosophy:

- Sufficient: all important (i.e., safety-significant or safety-related) attributes for the specific application of an AMT are addressed in sufficient technical depth to justify its use.

- Flexible: a variety of both technical and regulatory approaches can be used to demonstrate that these important attributes are addressed.

- Minimize technical and regulatory burden: the level of detail in which a submittal must address the applicable requirements and technical basis may vary depending on the safety significance of the application and the maturity of the AMT.

Appendix A Process Flow Chart

  • Describes an approach to qualification and performance considerations

- Quality Assurance

- Process Qualification

  • Essential Variable Identification
  • Qualification Testing

- Supplemental Testing

  • As needed to demonstrate design requirements in applicable environmental conditions

- Production Process Control and Verification

- Performance Monitoring

Technical Basis for L-DED Guidelines AMT-Specific (Initial 5 AMTs) Generic

  • DGD is based on two technical documents Technical Regulatory Guidelines (ML21301A077) (Subtask 1A) (Subtask 2C)

Draft

- Technical letter report from Oak Ridge National Technical Letter Report Technical Assessment Guidelines Document LPBF LPBF Laboratory (ORNL) LPBF

- NRC staff technical assessment of L-DED Technical Letter Report Technical Assessment Draft Guidelines L-DED Document L-DED L-DED Draft Subtask 2C Final

  • DGD builds on the NRC technical Technical Letter Report Technical Guidelines Draft AMT Guidance Assessment Document Review Cold Spray Cold Spray for Initial Cold Spray Guidelines AMTs assessment and provides guidelines, when Technical Technical Draft Guidelines Letter Report Assessment finalized, to the NRC staff by identifying PM-HIP PM-HIP Document PM-HIP Expected to be developed Legend important considerations when reviewing Technical Letter Report Technical Assessment Draft Guidelines later after Contractor-developed Document EBW a submittal requesting the use of L-DED EBW EBW DOE-EPRI NRC Staff-developed demo project

L-DED Technical Basis Documents

  • Technical letter report on L-DED from ORNL

- Documents the current state of L-DED with respect to material microstructures and properties relative to conventional manufacturing

- Identifies technical and codes and standards gaps in ensuring quality and sufficient properties and performance for L-DED-fabricated components

  • NRC staff technical assessment

- Provides context to the gaps identified in the ORNL report from NRCs perspective

  • Considers other relevant technical information, such as NRC regulatory and research experience, technical meetings and conferences, codes and standards activities, EPRI and DOE research products

- Highlights key technical information related to L-DED-fabricated components in nuclear applications 8

Use of the Term Safety Significance

  • The safety significance of each identified difference/topic in the L-DED DGD refers to the impact on component performance.

- The overall impact to plant safety is a function of component performance and the specific component application (e.g., its intended safety function).

  • The L-DED DGD and its supporting documents do not address the impact on plant safety, as such an assessment would not be possible without considering a specific component application.

- In addition to the technical review guidelines in the L-DED DGD, the NRC staff should consider the specific component application and the potential for secondary consequences, such as debris generation and associated impacts, when assessing the impact to overall plant safety.

9

Tie to Draft AMT Review Guidelines (Table 1)

Process Supplemental Production Process Performance Difference / Topic Qualification Testing Control and Verification Monitoring Process-Driven: L-DED machine process control, Powder feedstock quality, Wire feedstock quality, L-DED build X X process management and control, Witness specimens, Thermal post-processing, Weldability / Joining Process and Properties: Local geometry impacts on component properties and performance, Heterogeneity and X X anisotropy in properties, Residual stress, Porosity, Surface finish*, Tensile properties, Initial fracture toughness Performance under Aging: Thermal aging, SCC and corrosion resistance, Fatigue, Irradiation effects, High X X Temperature Time- Dependent Aging Effects, Weld integrity

  • The applicable primary elements may vary on a case-by-case basis, depending on the licensees approach to demonstrating quality and safety.
  • Table 1 provides an example of applicable elements and reflects that not every element in Appendix A to the draft AMT review guidelines is applicable to every difference listed in Table 1.
  • also ties to Production Process Control and Verification 10

Tables 2A and 2B

  • Tables 2A and 2B provide the technical review guidelines
  • Material-generic vs. material-specific

- Table 2A lists the generic differences / topics (generally process focused)

- Table 2B lists the material-specific (generally properties and performance focused) differences / topics for L-DED 316L stainless steel

  • Differences identified in Table 2B involving material-specific properties and performance would likely need to be considered for any newly fabricated material (316L or not) using L-DED

- In general, material-specific data are important for any nuclear L-DED-fabricated component to ensure adequate component performance in the applicable environment 11

Content of Tables 2A and 2B

  • Difference

- Lists the differences between L-DED and traditional manufacturing identified in the NRC technical assessment

  • Key Technical Information

- Summarizes the key technical information documented in the NRC technical assessment for easy reference

  • Technical Review Guidelines

- Provides additional guidelines related to the differences between L-DED and traditional manufacturing that the staff should consider when evaluating how a licensees or applicants submittal addresses the differences between L-DED and traditional manufacturing 12

DGD Example - Table 2A, Process-Driven DGD Example - Table 2A, Process and Properties DGD Example - Table 2A, Process and Properties DGD Example - Table 2B, Process and Properties DGD Example - Table 2B, Performance Under Aging Conclusions

  • L-DED DGD has been developed as a "draft not for use"

- The DGD builds on the ORNL technical letter report and NRC staff technical assessment to provide the technical review guidelines and associated key technical information

  • The L-DED DGD is consistent with the draft AMT review guidelines and addresses the same primary elements

- Technology-specific DGDs are anticipated to be incorporated in some form into the final AMT guidance 18

References

  • Draft AMT Review Guidelines

- ADAMS Accession No. ML21074A037

  • L-DED Draft Guidelines Document

- ADAMS Accession No. ML22143A951

  • L-DED Technical Letter Report and Technical Assessment

- ADAMS Accession No. ML21301A077

  • NRC Public Site on AMTs

- https://www.nrc.gov/reactors/power/amts.html

Questions ?

NRC Draft Guidelines Document Cold Spray Bruce Lin Office of Nuclear Regulatory Research June 28, 2022

Outline

  • Overview of Cold Spray (CS)
  • Technical Basis for CS Draft Guidelines Document (DGD)
  • Tie to Draft AMT Review Guidelines (Table 1)
  • CS Technical Review Guidelines
  • Conclusions

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

  • Potential Applications Schematic of CS process

- Mitigation or repair of potential chloride-induced 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_transition_to_industry 23

Technical Basis for CS Guidelines AMT-Specific (Initial 5 AMTs) Generic

  • DGD is based on two technical documents Technical Regulatory Guidelines (ML21263A105) (Subtask 1A) (Subtask 2C)

Draft

- Technical letter report from Pacific Northwest Technical Letter Report Technical Assessment Guidelines Document LPBF LPBF National Laboratory (PNNL) LPBF

- NRC staff technical assessment of CS Technical Letter Report Technical Assessment Draft Guidelines L-DED Document L-DED L-DED Draft Subtask 2C Final

  • DGD builds on the NRC technical Technical Letter Report Technical Guidelines Draft AMT Guidance Assessment Document Review Cold Spray Cold Spray for Initial Cold Spray Guidelines AMTs assessment and provides guidelines, when Technical Technical Draft Guidelines Letter Report Assessment finalized, to the NRC staff by identifying PM-HIP PM-HIP Document PM-HIP Expected to be developed Legend important considerations when reviewing Technical Letter Report Technical Assessment Draft Guidelines later after Contractor-developed Document EBW a submittal requesting the use of CS EBW EBW DOE-EPRI NRC Staff-developed demo project

CS Technical Basis Documents

  • Technical letter report on CS from PNNL

- Provides an overview of CS technology and highlights important considerations for qualification of CS process

- Identifies knowledge gaps associated with using CS for nuclear power applications

  • NRC staff technical assessment

- Provides context to the gaps identified in the PNNL report from NRCs perspective

- Highlights key technical information related to the use of CS for nuclear applications

- Assesses the properties and performance characteristics of CS for both structural and nonstructural applications 25

Structural vs. Nonstructural

  • Structural applications

- Likely to be thicker

- Credit the CS material for load-bearing capacity such that either the CS material entirely or the CS material in conjunction with the substrate meet the full structural strength requirements

  • Nonstructural applications

- Likely to be thinner

- Do not credit the CS material for any load-bearing capacity

- Only credit the CS material for non-structural purposes, such as corrosion mitigation or wear resistance

  • The determination of whether a particular application is structural or non-structural will largely be dependent on whether the CS material is needed to meet structural requirements 26

Tie to Draft AMT Review Guidelines (Table 1)

Production Process Process Supplemental Performance Topic Control and Qualification Testing Monitoring Verification Process-Driven: Factory/field application, Power quality and processing, Surface preparation, Process parameter and controls, X X Post-processing, Witness specimens, Non-destructive examination Process and Properties: Local geometry impacts on component properties and performance*, Adhesion strength, Porosity, Edge X X effects, Tensile properties, Initial fracture toughness Performance: Corrosion/Erosion resistance, Wear resistance, SCC resistance, Fatigue resistance, Irradiation effects, Thermal X X aging, High temperature time- dependent aging effects

  • The applicable primary elements may vary on a case-by-case basis, depending on the licensees approach to demonstrating quality and safety.
  • Table 1 provides an example of applicable elements and reflects that not every element in Appendix A to the draft AMT review guidelines is applicable to every topic listed in Table 1.
  • also ties to Production Process Control and Verification 27

CS Technical Review Guidelines

  • Tables 2 and 3 provide the technical review guidelines

- Table 2 addresses CS process considerations

- Table 3 covers properties and performance characteristic for CS materials

  • Topics identified in Tables 2 and 3 involving CS process and properties and performance would likely need to be considered for application of CS in nuclear component

- Not all topics identified in the tables need to be addressed but only those that are relevant for the particular application

- In general, application-specific data will need to be generated to demonstrate adequate CS performance to meet the intended function of the CS materials 28

Content of Tables 2 and 3

  • Topic

- Identifies the key aspect of the CS process or property / performance characteristics

  • Key Technical Information

- Summarizes the key technical information associate with the specific topic for use of CS in nuclear applications

  • Technical Review Guidelines

- Provides additional guidelines to support the staffs evaluation of the proposed use of CS 29

DGD Example - Table 2 Process Consideration Topic Key Technical Information Technical Review Guidelines

  • Poor surface preparation results in poor Process Qualification adhesion, or bonding, to the substrate.
  • Through process qualification, the applicant should
  • Failure to remove oxide layers from a identify the necessary surface conditions including the substrate surface before CS application necessary surface roughness and cleanliness for can negatively impact coating achieving a good quality coating. Cleaning procedures performance. should not cause any damage to the surfaces that are
  • Surface preparation examples include grit to be coated that may detrimentally affect CS adhesion blasting, abrasive pads, and wire brushes or component performance.

Surface Preparation or wire wheels. Production Process Control and Verification

  • The surfaces to receive CS deposits
  • During CS application, measures should be employed should be cleaned to remove oil, grease, to protect the surface to be coated from dust, dirt, dirt, paint, oxides, and other foreign moisture, and other contaminants that may material that could affect CS adhesion. detrimentally affect CS adhesion.
  • Section 2.2.4 of the PNNL TLR discuss
  • The applicant can use a variety of post process quality surface preparation and post cleaning in testing such as adhesion testing and NDE to validate more detail. the adequacy of surface preparation practices and procedures.

DGD Example - Table 3 Properties and Performance Topic Key Technical Information Technical Review Guidelines

  • Adhesion strength of 10-20 kilopounds Process Qualification/Supplemental Testing/Performance Monitoring per square inch (ksi) is common on a
  • For process qualification and supplemental testing, the applicant should properly prepared surface, and provide an analysis, supported by sufficient data in representative or adhesion strengths greater than 30 ksi bounding environments (e.g. temperature, chemistry, stress), to show are not uncommon for CS adhesion adequate adhesion strength of the CS material to the substrate over the strength of higher strength alloys. intended service life.
  • Thick oxides and surface contamination o The corresponding analysis can demonstrate acceptable can significantly reduce the adhesion performance using approaches such as the following:

Adhesion strength of the CS coating. demonstrating adequate adhesion strength by adhesion tests Strength

  • Adhesion strength may be limited by experience from previous applications of CS in similar the bond strength of the epoxy when environments using similar process and material epoxy-based adhesion tests NDE may be used to confirm adhesion quality.

(ASTM-C633, ASTM-D4541) are used.

The triple-lug shear testing described in MIL-J-24445A can be used to reach adhesion values not limited to epoxy strength.

DGD Example - Table 3 Process and Properties Topic Key Technical Information Technical Review Guidelines

  • For corrosion resistance, the most Supplemental Testing/Performance Monitoring used coatings are forms of nickel,
  • Through supplemental testing and performance monitoring, the applicant copper, aluminum, or titanium. should provide an analysis, supported by sufficient data in representative
  • Short-term testing using ASTM or bounding environments, to show adequate corrosion/erosion resistance standards may be used to screen for the intended function of the CS component over the intended service corrosion and erosion resistance of life.

material combinations in o The corresponding analysis can demonstrate meeting design Corrosion / representative environments. requirements by using approaches such as the following:

Erosion demonstrating equal or superior performance by comparison to

  • Corrosion testing using Resistance representative test conditions may corrosion / erosion performance for substrate materials be necessary to demonstrate the (assuming similar in-service inspection frequency and methods) long-term behavior of CS protective addressing uncertainties in the data on corrosion / erosion and coatings. the implications to in-service performance through conservative design assumptions, additional margins in analyses, surveillance programs, in-service inspection, or additional performance monitoring as appropriate

Conclusions

  • CS DGD has been developed as a "draft not for use"

- The DGD builds on the PNNL technical letter report and NRC staff technical assessment to provide the technical review guidelines and associated key technical information

  • The CS DGD is consistent with the draft AMT review guidelines and addresses the same primary elements

- Technology-specific DGDs are anticipated to be incorporated in some form into the final AMT guidance 33

References

  • CS Draft Guidelines Document

- ADAMS Accession No. ML22143A952

  • CS Technical Letter Report and Technical Assessment

- ADAMS Accession No. ML21263A105

  • NRC Public Site on AMTs

- https://www.nrc.gov/reactors/power/amts.html

Questions ?

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