ML22280A112

Session 3 - Rapid Qualification of AMT Components - Is It Rocket Science?

ML22280A112
Person / Time
Issue date:	10/07/2022
From:	Cairns-Gallimore D, Raj Iyengar, Robert Roche-Rivera NRC/RES/DE, US Dept of Energy (DOE)
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RMI; RGR1
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Download: ML22280A112 (34)

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Rapid Qualification of AMT Components - Is it Rocket Science?

Moderators: Raj Iyengar (NRC) and Dirk Cairns-Gallimore (DOE-NE)

Panelists/Speakers:

Richard W. Russell (NASA)

Thierry Lebarbe (CEA, France)

Matt LeVasseur (BWXT)

Josh Brost (Relativity)

NASAs Certification and Qualification Strategies for Additively Manufactured Hardware Rick Russell, NASA Technical Fellow for Materials Rapid Qualification of AMT Components - Is it Rocket Science?

2022 NRC Standards Forum September 28, 2022 2

Additive Manufacturing at NASA

• Fully embraces advantages of AM

• Cost/lead time/part count reduction, new design and performance opportunities, rapid design-fail-fix cycles

• While fully understanding the challenges

• Especially in delivering high value, high performance AM hardware

• NASA has dual roles

• Drive and foster AM technology research and development in support of broad industry adoption and industrialization

• Develop protocols for spaceflight hardware certification for access to space that can safely meet mission objectives Todays focus 3

NASA-STD-6030: Summary of Methodology

• General Requirements

• Additive Manufacturing Control Plan (AMCP) and Quality Management System (QMS)

• Backbone that defines and guides the engineering and production practices

• Foundational Process Control Requirements

• Includes the requirements for AM processes that provide the basis for reliable part design and production

• Part Production Control Requirements

• Includes design, assessment controls, plans (PPP),

preproduction articles and AM production controls Locked Process!! 4

NASA-STD-6030: Key Elements Applicable Technologies Classification System Approach is heavily rooted in metallurgical understanding and respecting the evolving and meticulous metallic AM process 5

Equivalency

• One of this standards key strengths is its reliance on material engineering equivalence

• Methodology for evaluating the quality of AM materials that acknowledges the broad range of characteristics that must be assured for an alloy to meet all of its expectations.

• The enabler that allows the AM material ecosystem to remain healthy and self-consistent in the face of sensitive processes with a multitude of known and unknown failure modes.

• Requires reliable and diverse datasets, depth of knowledge in materials, good engineering judgement, and collaboration between engineering and quality assurance organizations.

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Fracture Control Framework for AM Parts

• Fracture control is reliant on understanding the design, analysis, testing, inspection and tracking of hardware.

• The adaptation of state-of-the-art AM technologies introduces new and unique challenges

• e.g. Multiple lasers and adaptive technologies

• For AM applications the application of conventional NDE techniques is questionable

• There is a need to produce alternate approaches through the adaptation of a Probabilistic Damage Tolerance Approach (PDTA)

• Computational modeling for AM These items

• Understanding the Effects of defects MUST

• In-situ monitoring and inspection Work together not separate 7

Rapid Qualification - Is there a path?

• Following NASA-STD-6030 the path to rapid qualification will be difficult

• Understanding the part classification is key

• Consequence of failure followed by risk evaluation

• Maturity of data is a must have

• Full understanding of existing data

• Establishment of machine-to-machine equivalency

• Material Equivalency

• Implementation of in-situ inspection, computational materials and machine learning is beginning - but there is a long road ahead of us

• Attention to this subject is high!!

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FROM RESEARCH TO INDUSTRY Rapid Qualification of AMT Components - Is it Rocket Science?

Feedback from CEA standardization experts T Lebarbé - C Pétesch French Alternative Energies and Atomic Energy Commission www.cea.fr 2022 NRC Standards Forum Rapid Qualification of AMT Components - Is it Rocket Science? 28/09/2022 9

Why it seems complicated?

Hes too Much to old to learn, you A code is not only a process or a material listen to still have me VOLUME I VOLUME III VOLUME IV VOLUME V VOLUME II Design Examination Welding Manufacturing Materials Methods operations 2022 NRC Standards Forum Rapid Qualification of AMT Components - Is it Rocket Science? 28/09/2022 10

Tools are already available Methods to implement new material or new process in all codes and standards are already existing The table of contents of the Material File shall be: M 116 SPECIFIC USE OF A NONREFERENCED RCCM MANUFACTURING PROCESS

1. Introduction Manufacturing processes not referenced by the RCCM can exceptionally be Presentation of the grades proposed by the Manufacturer, for a particular application. In these conditions, and Codes and standards dealing with these parts or products prior to the procurement of the materials, the Manufacturer must submit the following items to the Contractor for approval:

Reference Procurement Specifications in Tome 2 Industrial application and experience a) A procurement specification; for this purpose, it shall most frequently use

2. Physical properties a similar existing Reference Technical Specification, or a compatible

3. Base metal and welded joints mechanical properties for design and standard, stating the options systematically adopted analysis b) A first part qualification, according to the principle described in M 140 Justification of the applicability of the Design Rules (RB 3000) for the specified usage conditions c) A document package justifying the use of the grade for the targeted Basic mechanical properties application. This document package shall include at least the following Mechanical properties when creep is significant (if necessary) items:

Mechanical properties when irradiation is significant (if necessary)

• References to the existing standards and technical specifications

• The data needed for design Guaranty of the consistency between the properties of the final part

• Evidence that the material obtained by this new manufacturing laidon the plant and the material properties used to design the process is suitable to be employed for the targeted application component

• Evidence that the acceptance (destructive and nondestructive

4. Manufacturing tests) is appropriate for the inspections of the products resulting from this new manufacturing process Industrial experience Metallurgy RCCMRx

• Performance under the service conditions, for the targeted application

5. Fabrication

• Experience feedback: status for similar applications.

Industrial experience Forming operation ability

6. Welding Weldability (RS 1300)

With possibility to test and improve:

Industrial experience for the welding procedure qualification Code Cases, Rules in Probationary Phase.

Industrial experience for the repair welding procedure qualification

7. Controllability

8. In service behavior Thermal ageing, corrosion, erosioncorrosion, irradiation, 2022 NRC Standards Forum Rapid Qualification of AMT Components - Is it Rocket Science? 28/09/2022 11

With clear objectives Qualification objectives through the qualification file:

• Demonstrate the capability to manufacture the component

• Define validity domain of the manufacture program

• Check that the final component has the requiered properties

• Define the relevant delivered conditions and criteria A qualification file can be modulated:

• Depending on the material use

• Depending on the component type

• Depending on the environment

• Depending on the dammages

• Depending on the code classification

• Depending on the safety classification 2022 NRC Standards Forum Rapid Qualification of AMT Components - Is it Rocket Science? 28/09/2022 12

AM Qualification steps overview Filer Operators products Qualification Process Part HIP Qualification Tool Qualification Qualification Qualification Qualification Reference Procurement Manufacture procurement spec programme spec Filer products Qualification Production Heat machine component component treatment Powder / fil Technical Acceptance of qualification filler materials report

• Chemical (essentials Operator parameters) composition Acceptance Acceptance Certificate ?

• Mechanical caracterisation tests tests Tool Certificate?

properties

• Accepance Acceptance tests tests AM between material and process 2022 NRC Standards Forum Rapid Qualification of AMT Components - Is it Rocket Science? 28/09/2022 13

So what?

For us, Rapid Qualification of AMT Components is NOT a Rocket Science BUT:

Need to clarify the process and steps of qualification Need to define the range of expected feedback Need to plan the feedback acquisition, maybe faster :

for small parts for parts with low safety or pressure level Need to discuss with safety authorities or notified body To keep in mind that The nuclear industry has specificities in term of quality insurance and qualification that could make the transfer from R&D to industry really challenging Codes and standards and more generally standardization can facilitate the transfer from research to industry A strong collaboration is needed between all partners in a supported framework 2022 NRC Standards Forum Rapid Qualification of AMT Components - Is it Rocket Science? 28/09/2022 14

Thank you for your attention French Alternative Energies and Atomic Energy Commission www.cea.fr 2022 NRC Standards Forum Rapid Qualification of AMT Components - Is it Rocket Science? 28/09/2022 15

Predictive Technologies and Nuclear Product Qualification Matthew LeVasseur, Director of Research BWXT Advanced Technologies LLC 16

Advanced Reactor Development Power Rapid qualification to change the economics of new nuclear Space o Qualification is ultimately about confidence in Propul-system behavior. Three predictive approaches:

sion 1. Multi-physics simulation

2. Predictive manufacturing

3. Digital Twin Remote Power Terrestrial

& Heat BWXT is developing a capability for rapid Clean /

and optimized:

Mobile

• Design Power

• Manufacture

• Qualification of nuclear products 17

BWXT Capability: Rapid Product Development Early R&D Lab Scale Pilot Scale Production NRC Cat 1 Design, fabrication development; surrogate specimen Reactors and fuel elements Sol-Gel kernels development for a variety of customers and PVD coating MRL TRL 1 MRL TRL 4 MRL TRL 6 MRL TRL 9 18

Manufacturing Data for Confidence in the As-built Raw image Computer Vison AI/ML data model detected features enhanced detection infer quality Digital Twin of As-Built characteristics Data for understanding components and systems from the inside out Process data patterns to characterize as-built for quality features of interest to promote successful design, build and test 19

Multi-Physics Simulation for Predictive Behavior Data Model (Digital Twin) Digital Twin of a tensile bar View of Tensile Bar Converted to a simulation mesh To predict fracture location and time Integrated mechanical, thermal and/or neutronics simulation and analyses 20

Design Iteration, Optimization and Predictive Performance CORTESTM Engineering Design Platform is a BWXT patent pending, Ai-driven nuclear design suite, here identifying valid design space.

TRISO thermal and transient simulation experiments Reduce trial and error Virtual space-filling experiments for non-linear, hyper-dimensional design region 21

Thank You!

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NRC Standards Forum Josh Brost Vice President of Business Development jbrost@relativityspace.com The content of this presentation is confidential and proprietary to Relativity Space, Inc., and is provided for the sole purpose of 23 evaluating the provision of launch insurance and services. This presentation and its contents are subject to the applicable non-disclosure agreement with Relativity and may not be disclosed to any third party or used for any other purpose without the express written consent of Relativity.

WE DESIGN, BUILD, & FLY ENTIRELY 3D PRINTED ROCKETS 24

AEROSPACE HAS FALLEN BEHIND OTHER INDUSTRIES Automotive Silicon Fab Aerospace 60 15 20 20 60 180 NUMBER OF MONTHS TO DESIGN, INTEGRATE, AND TEST PRODUCT TRENDS OVER THE LAST 50 YEARS DARPA TRACKED DATA, 1960-2010 25

WE CREATED AN ENTIRELY NEW VALUE CHAIN Our Full Stack Approach Radically Simplifies the Supply Chain, Reduces Capex Needs, and Rewrites the Incentives Traditional Aerospace Fundamental Change to PRODUCT CONSTRAINTS 100x Fewer Components, delivering more reliable vehicles 100x Fewer Suppliers, minimizing supply chain risks RIGID FACTORIES: FIXED TOOLING, TECHNICIANS SCALABLE AUTONOMOUS PLATFORM 100,000-1M Part Count ~1,000 Part Count 100X less Touch Labor, reducing cost and increasing reliability 18-month build time 2-month build time 48-month iteration time 6-month iteration time 9x Faster Production, enabling Complex Supply Chain (~X,000 vendors) Simple Supply Chain (<100 vendors) responsive manufacturing High Physical Complexity High Digital Complexity 8x Faster Iteration, enabling

$Billion Factory CapEx $Million Factory CapEx faster improvements 26

27 3D PRINTER TECHNOLOGY 28

EXPERTISE ACROSS ADDITIVE PLATFORMS Two basic printing methods span sub-millimeter to 10s of meters, multiple metals, and unparalleled scalability STARGATE WAAM PRINTERS BY CLASS PRINTER TYPE POWDER BED FUSION PRINTERS DEVELOPMENT PRODUCTION Engine Component Manufacturing: Injectors, Thrust Chamber, & Nozzle Materials and Controls Short Barrels, Tank Primary application Payload Fairing & Stage 1 Manufacturing R&D Domes 29

STARGATE - WIRE ARC ADDITIVE MANUFACTURING Relativity is the first commercial company to use WAAM for large-scale operational applications

• Stargate is the proprietary 3D-printing platform in our Factory Operating System, created to produce large-scale metal structures

• Enabled by Relativitys innovative tech stack, which leverages autonomy, advanced simulation, machine learning, and robotics

• Able to perform additive manufacturing, in-situ monitoring, NDE and subtraction capabilities in a single print cell

• We are developing the capability to print using all weldable metals Human Algorithm Automated RT Review 30 In-Cell Subtractive Capabilities

CURRENT INSPECTION & VALIDATION METHODS

• Nondestructive Evaluation (NDE) Methods:

• Automated Radiographic Testing (RT)

• Visual Inspection Testing (VT)

• (Fluorescent) Dye Penetrant Testing (PT)

• Ultrasonic Testing (UT)

• Electro Magnetic Acoustic Testing (EMAT)

• Phased Array Ultrasonic Testing (PAUT)

• Buckling Testing

• Post-test Analysis Correlation

• Redundant human data review to ensure part quality Stage 1 Iron Bird Testing 31

FLAW ACCEPTANCE CRITERIA SUBSTANTIATION

• Pressure cycles applied to pressure vessels with maximum allowable flaw sizes artificially induced.

• Tracking crack growth over cycles to validate fatigue and damage tolerance estimates.

Artificial Linear Defect Additional Crack Growth over Life Cycles 32

DISTORTION COMPENSATION Additive technology requires compensation during the production process DESIGN CAD FEA MODELING: Thermo-Mechanical Model P S Residual Stresses Distortion Prediction 33

QUESTIONS?

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