ML23324A233

S0P2 - Focht - NRC AMT Activities Overview v2.0

ML23324A233
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Issue date:	10/24/2023
From:	Eric Focht NRC/RES/DE
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Eric Focht 301-415-2094
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OVERVIEW OF U.S. NRC AMT ACTIVITIES Eric Focht (eric.focht@nrc.gov)

U.S. NRC Office of Nuclear Regulatory Research Division of Engineering - Materials Engineering Branch 2023 NRC Workshop on Advanced Manufacturing Technologies for Nuclear Applications October 24-26, 2023 NRC HQ, Rockville, MD The views expressed by the author do not necessarily reflect those of the Nuclear Regulatory Commission

DRIVERS FOR NRC ACTIVITIES

• A variety of stakeholders are working toward more widespread use in both existing and future nuclear applications:

• Vendors and licensees/applicants

• Identifying candidate applications

• Developing technical bases for gaining regulatory acceptance

• Nuclear Energy Institute - Developed advanced manufacturing methods (AMM) roadmap to understand industry needs/interests and assist with regulatory acceptance (2019)

• Electric Power Research Institute - Developing techniques for large components in small modular reactors, developing data package for LPBF and WA-DED ASME draft Code Cases

• US Department of Energy - Developed the AMMT 2022 Roadmap

• Performing basic and applied research, technology development, data infrastructure, and developing a qualification framework to support AMT implementation 2

NRC AMT ACTIVITIES TIMELINE 3

2017 2018 2019 2020 2021 2022 2023 2017 AMT Workshop AMT Action Plan 2020 AMT Workshop AMT UNR initiated 2023 AMT Workshop 2023 AMT NDE Meeting Pre-AMT Action Plan Post-AMT Action Plan NRC begins AMT efforts

2017 NRC AMT WORKSHOP

• The objectives of the workshop were to cover topics including:

• The state-of-the-art of AM

• Industry activities

• Irradiation testing and effects on AM

• AM qualification

• Codes & standards

• NDE

• Cybersecurity

• Regulatory perspectives

• Outcomes:

• Proceedings of the workshop published as NUREG/CP-0310 (ML19214A205)

• Next steps included further engagement with industry.

4

AMT ACTION PLAN (2019-2022)

• The NRC completed the AMT Action Plan which accomplished the following objectives:

• Assessed the safety significant performance-based differences between AMTs and traditional manufacturing processes.

• Prepared the NRC staff for potential reviews (five AMTs, modeling, and NDE).

• Identified and addressed AMT characteristics pertinent to safety that are not managed or addressed by codes, standards, regulations, etc.

• Risk-informed and performance-based perspective

• Provided draft Staff guidance and tools for review consistency, communication, and knowledge management.

• Revision 1 of the AMT Action Plan was published in June 2020 (ML19333B980).

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AMT ACTION PLAN (CONT.)

• NRC AMT Action Plan products:

• Technical Letter Reports (TLRs)

• Provide technical bases information and gap analyses

• Prepared by NRC contractors (to date, DOE labs)

• Technical assessments (TAs)

• Provides the NRC staff perspective on key aspects of the AMT for safety and component performance.

• Draft guidelines documents (DGDs)

• Informed by the TA and TLR and generated by the NRC staff for each AMT.

• Please visit the NRC AMT public website to download the available reports:

• https://www.nrc.gov/reactors/power/am ts.html#status Technical Letter Report LPBF Technical Letter Report L-DED Technical Letter Report Cold Spray AMT-Specific (Initial 5 AMTs)

Generic Technical (Subtask 1A)

Final Guidance for Initial AMTs Regulatory Guidelines (Subtask 2C)

Technical Letter Report PM-HIP Technical Letter Report EBW NRC Staff-developed Contractor-developed Legend Technical Assessment LPBF Draft Guidelines Document LPBF Draft Guidelines Document L-DED Technical Assessment L-DED Draft Guidelines Document Cold Spray Technical Assessment Cold Spray Draft Guidelines Document PM-HIP Technical Assessment PM-HIP Technical Assessment EBW Draft Guidelines Document EBW Expected to be developed later after DOE-EPRI demo project Subtask 2C Draft AMT Review Guidelines 6

AMT ACTION PLAN PRODUCTS 7

Subtask Actions/Deliverables Status 1A AMT processes under consideration Additive Manufacturing (AM) - Laser Powder Bed Fusion Complete - ML20351A292 AM - Directed Energy Deposition (DED)

Complete - ML21301A077 Cold Spray Complete - ML21263A105 Powder Metallurgy (PM) - Hot Isostatic Pressing (HIP)

Complete - ML22134A437 Electron Beam (EB) welding Complete - ML22143A927 1B Inspection and NDE NDE gap analysis Complete - ML20349A012 1C Modeling and Simulation of Microstructure M&S gap analysis to predict microstructures Complete - ML20269A301 ANL M&S gap analysis to predict material performance Complete - ML20350B550

AMT ACTION PLAN PRODUCTS 8

Subtask Actions / Deliverables Status 2A 50.59 process Finalize document incorporating feedback from Regional staff regarding the 10 CFR 50.59 process Complete - ML21200A222 2B Assessment of regulatory guidance Path forward on guidance development or modification Complete - ML20233A693 2C AMT Guidance Document Draft AMT Review Guidelines Complete - ML21074A037 Draft Guidelines Documents for specific AMTs AM-Laser Powder Bed Fusion - ML21074A040 AM-Laser-Directed Energy Deposition - ML22143A950 Cold Spray - ML22143A950 3A/3B External / Internal Interactions Continued communication with NRC staff and external stakeholders for AMT-related activities Ongoing as needed 3C Knowledge Management Plan Develop Knowledge Management Plan Complete - internal 3D Workshop Hold public workshop Complete - Public Meeting Summary: ML20357B071 RIL: Part 1 Part 2 3E Material Information course Training course and course materials First 6 seminars complete - internal

2020 NRC AMT WORKSHOP

• The objectives of the workshop were to cover topics including:

• nuclear industry implementation plans

• codes and standards activities

• research findings

• qualification & aging management

• regulatory approaches in other industries.

• Key Takeaways:

• AMTs are being incorporated!

• Use of PM-HIP with EBW for larger nuclear components looks promising, but requires larger HIP and EBW capabilities

• AMT technologies evolve quickly, outpacing the qualification and licensing process

• Target applications to optimize unique AM characteristics

• SDOs need continual communication to reduce redundant standards development 9

2020 NRC AMT WORKSHOP:

NEXT STEPS 10 Nuclear industry / NRC: Use data from existing AMT applications to help justify and increase confidence in further applications of AMTs Nuclear industry / NRC: Potential nuclear applications of AMTs may benefit from non-nuclear applications.

Support intelligent, performance-based qualification framework This is an ongoing process as experience is gained from existing nuclear applications of AMT components (e.g., thimble plugging device, channel fastener).

Non-nuclear applications in relevant service conditions (e.g., temperature) are helping to inform NRC assessments of AMTs DOE AMMT Roadmap and the America Makes Roadmap are helping greatly in this area.

My Perspective Selected Next Steps

2020 NRC AMT WORKSHOP:

NEXT STEPS 11 Continue developing technical basis for utilizing these technologies in nuclear applications Gain ASME acceptance and obtain regulatory approval ASME activities to develop data packages for Code Cases are helping greatly in this area.

ASME Code Cases have been and/or are being developed for LPBF, PM-HIP, and DED.

My Perspective Selected Next Steps Continue to evaluate research needs and technology gaps EPRI and DOE efforts are supporting this area.

The NRC to continues to assess AMTs and perform gap analyses. Knowledge/data gaps may help identify research needs.

2023 MEETING ON NDE OF AM COMPONENTS

• The meeting focused on the state-of-the-art of NDE of AM components, as well as key challenges associated with the use of these technologies. Specific topics included:

• Ultrasonic testing (phased array, FMC/TFM)

• Process compensated resonance testing

• Qualification

• Structure-property relationships

• In-process monitoring

• Key Takeaways:

• Integrate NDE with the design and manufacturing process of AM components.

• Continue NRC engagement to inform staff of applicable challenges relevant to the adoption of AM components in nuclear plants.

• The final surface condition of AM components is an important consideration for examinations.

• Standardization of NDE calibration methods and how that applies to the different AM manufacturing processes is needed.

• Staff gained a better understanding of AM microstructures and effects on material properties.

12 NATIONAL LABORATORIES Meeting summary: ML23153A010

CURRENT NRC AMT ACTIVITIES

• Continue to prepare:

• Technical preparedness

• AMT assessments, NDE of AMT components, data & modeling for qualification

• Products: technical letter reports, technical assessments

• Regulatory preparedness

• Regulatory guidance

• Communications and Knowledge Management

• Internal & external interactions, KM, workshops, staff training

• Reports in review:

• Wire-arc directed energy deposition

• Hybrid manufacturing

• In-process monitoring 13

THE END 14