Enclosure 2: Additive Manufacturing Presentation. · 2017-06-20 · ENCLOSURE 2 M170149 Additive...
Transcript of Enclosure 2: Additive Manufacturing Presentation. · 2017-06-20 · ENCLOSURE 2 M170149 Additive...
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ENCLOSURE 2
M170149
Additive Manufacturing Presentation
Non-Proprietary Information – Class I (Public)
INFORMATION NOTICE
Enclosure 2 is a non-proprietary version of the Additive Manufacturing Presentation from Enclosure 1, which has the proprietary information removed. Portions that have been removed are indicated by open and closed double brackets as shown here [[ ]].
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General Aspects ofAdditive Manufacturing(Open Session)
Presenters: Felipe Betancor, Edison Engineer – Additive ManufacturingMyles Connor, Lead Materials EngineerFrancis Bolger, New Product Introduction Manager
June 7th, 2017
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Safety Moment:Questioning Attitude
• Why?• Avoid dependence on unsubstantiated
assumptions or opinions
• When?• At all times!
• How?• Consider “what-if’s”• Stop when unsure
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Aspects of Additive ManufacturingTopics of Discussion for Open Session
• Introduction
• General Electric and Additive Manufacturing
• The 3D Printing Process
• Applications of Additive Manufacturing in Nuclear Industry
• Show and Tell
• Looking Forward
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IntroductionSynopsis and Meeting Objectives
Additive Manufacturing (AM) is the process of building 3D objects by adding layer-upon-layer of material under computer control.• AM Variants: Technique; Material; Building Method• Direct Metal Laser Melting (DMLM)
Objectives of Meeting
• Provide an overview of DMLM and why it is important for the nuclear industry.
• Present GEH’s current DMLM knowledge base, qualification strategy, and regulatory acceptance path.
• Obtain NRC’s perspective on the adequacy of the plan.
June 7, 2017Aspects of Additive Manufacturing4
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Industrial Solutions Plainville, CT
AMWGreenville, SC
LEAP Fuel Tip Production Auburn, AL
CATAPittsburgh, PA
GE Aviation Cincinnati, OH
Energy ConnectionsBielsko-Biala, Poland
Innovation CenterIstanbul, Turkey
Adv. Mfg. CenterDetroit, MI
Global Research CenterNiskayuna, NY
Avio AeroCameri, Italy
Building a Global Additive NetworkCustomer Experience CenterMunich, Germany
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GE’s Grasp in Additive Manufacturing
Over $3B InvestedOver 10 Years of R&D
Center for Additive Technology Advancement
Advanced Manufacturing Works
GE Aviation Additive Manufacturing Production Center
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Source: EPRI.com
Source: genewsroom.com
Source: Energy.gov
Source: designnews.com
Source: optics.org
Source: metal-am.com
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DMLM Description
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Additive (3D Printing) ProcessDirect Metal Laser Melting (DMLM)
Powder Bed
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Intricate Designs that conventional
manufacturing processes cannot achieve
Reference: Within Labs, UK
Reference: metalbot.org
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Before and After DMLMGas Atomization: Powder Development Post-Processing: Heat Treatment
• Powder Chemistry
• Powder Size
• Stress Relieving
• Hot Isostatic Pressing (HIP)
• Solution Annealing12
3
4
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Value and Benefits• Speed of Delivery
• Rapid Prototyping• On-Demand Parts Reduced Inventory• Obsolete Parts Scan, Model, Print• Emergent Parts Outage Demand
• Design for Performance• Geometric Freedom Performance Enhancements• Weight Reduction
• Cost Reduction• Low Volume Parts• Complex Multi-Component Assemblies
• Enhanced Chemistry Control • Alloy Control Favorable to Nuclear Environment
Cos
t
Complexity
June 7, 2017Aspects of Additive Manufacturing11
Additive ManufacturingTraditional Manufacturing
Area of Opportunity
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Already Demonstrating Success
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LEAP Engine Nozzle Story
Video: https://youtu.be/rMzVSbNebCg
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Delivering Results
Five Years of Dedicated Research, Optimization, and Development
Material Properties for AM 316L and IN718 Consistently Met or Surpassed Reference Properties
from Wrought Material
Significant Work Towards Demonstrating Successful Part Implementation Has Yielded Promising Results
Successfully Issued ASTM StandardUpdating EPRI Guidance for Reactor Internal Materials
Developing and Implementing Quality Assurance Requirements
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Application Examples
Channel Fastener
Fuel Bundle Debris Filter
AVS Compliant Spring
FMCRD Labyrinth Seal
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Channel Fastener
Fuel Bundle Debris Filter
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AVS Compliant Spring
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Fine Motion Control Rod Drive (FMCRD) Labyrinth Seal
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June 7, 2017Aspects of Additive Manufacturing19
Looking Forward
Ensure Safety and
Compliance
Identify Applications
Validate Material
Properties
Develop Expertise
Control Quality
Evolve AM Landscape
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Questions?
20GEH Nuclear Energy: Additive Manufacturing
6/7/2017
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Thank you. This marks the end of the Open Session.
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General Aspects ofAdditive Manufacturing(Closed Session)
1
Presenters: Felipe Betancor, Edison Engineer – Additive ManufacturingMyles Connor, Lead Materials EngineerFrancis Bolger, New Product Introduction Manager
June 7th, 2017
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June 7, 2017Aspects of Additive Manufacturing
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Aspects of Additive ManufacturingFocus of Closed Session
• Deep Dive into Material Testing Results
• AM Process Qualification/Control
• Regulatory Acceptance
• Future Work
Objectives of Closed Session
• Provide an overview of DMLM and why it is important for the nuclear industry.
• Present GEH’s current DMLM knowledge base, qualification strategy, and regulatory acceptance path.
• Obtain NRC’s perspective on the adequacy of the plan.
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Principles of Material Quality
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Outline
June 7, 2017Aspects of Additive Manufacturing
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• Microstructure Characterization• Mechanical Properties• Irradiation Testing• Qualification and Process Control• Inspection and Validation Processes
Chemistry +
ProcessingMicrostructure
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June 7, 2017Aspects of Additive Manufacturing
5Aspects of Additive Manufacturing
AM 316L Virgin
Powder
AM 316L Product
316L Standard
C 0.018 0.019 ≤ 0.020S 0.002 0.003 ≤ 0.020N 0.10 0.09 0.060-0.10O 0.03 0.03Mn 1.41 1.27 ≤ 2.00P <0.030 <0.030 ≤ 0.030Si 0.50 0.50 ≤ 0.75Cr 17.3 17.0 16.0-18.0Ni 10.3 10.5 10.0-14.0Mo 2.29 2.16 2.00-3.00Cu 0.07 0.07B <0.010 <0.010Co 0.04 0.04 ≤ 0.050
Powder CharacterizationSupplier: [[ ]]Process: Gas AtomizedSize: -325 mesh 16 μm
Powder/Product Chemistry
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Non-Proprietary Information – Class I (Public)Top View 2 Top View 2
Cross-section View 4 Cross-section View 4
1
2
3 4
Building Direction
As-built Stress Relief
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Top View 2 Top View 2
Cross-section View 2 Cross-section View 4
Anneal HIP + Anneal
Good Density Low Porosity 100% Austenitic Grain Size 5 or Finer Microstructure Similar to Wrought
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1
2
3 4
Building Direction
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June 7, 2017Aspects of Additive Manufacturing
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Microstructure Characterization
Aspects of Additive Manufacturing
Strain: AM 316L (Electron Backscatter Diffraction Spectroscopy)
[[
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June 7, 2017Aspects of Additive Manufacturing
9Aspects of Additive Manufacturing
Microstructure Characterization
Aspects of Additive Manufacturing
AM 316L to Wrought 316L Comparison
Wrought 316LAM 316L
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Outline
June 7, 2017Aspects of Additive Manufacturing
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• Microstructure Characterization• Mechanical Properties• Irradiation Testing • Qualification and Process Control• Inspection and Validation Processes
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11GEH Nuclear Energy: Additive Manufacturing
3/1/2017
Committed to Reliability and Quality
Mechanical Testing:• Tensile• Charpy• Fatigue• Toughness• SCC
[[
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Mechanical Properties
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Tensile Testing: Ultimate Tensile Strength
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Mechanical Properties
June 7, 2017Aspects of Additive Manufacturing
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Tensile Testing: Yield Stress
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Mechanical Properties
June 7, 2017Aspects of Additive Manufacturing
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Tensile Testing: Elongation and Reduction of Area
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Mechanical Properties
June 7, 2017Aspects of Additive Manufacturing
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Charpy Test
Typical Charpy toughness for annealed 316L @ RT: 65~100 ft-lb
[[ ]]
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Mechanical Properties
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Fatigue Test for AM 316L
Fatigue Performance meets design limits.Machining and Surface Treatment Improve Life.
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Surface Roughness
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Design Principles
• Due to layer by layer build, the melt profile goes [[ ]] layers deep [[ ]]
• Top most layer exposed to least amount of heat• Down facing surfaces come out rougher than up
facing surfaces due to melt profile of the laser• There is no over melt in up facing surfaces
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Surface Roughness
June 7, 2017Aspects of Additive Manufacturing
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Surface Considerations
As-built surface finish significantly coarser than traditionally machined parts
Can be compensated for in most cases; must be accounted for in design phase
• Design to requirements ,(i.e. airflow, fluid flow, LCF/HCF, etc…) not solely based on past “normals”
Straight from the machine (as-built), parts will have:• [[ ]] RA [micro-inches]on the top facing surface (upskin)• [[ ]] RA on side walls• [[ ]] RA on down facing surfaces (downskins)
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Mechanical Properties
June 7, 2017Aspects of Additive Manufacturing
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Fracture Toughness: AM 316L
Positive and Consistent Fracture Toughness Response
Build
Dire
ctio
n [[
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Mechanical Properties
June 7, 2017Aspects of Additive Manufacturing
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Stress Corrosion Cracking: Crack Growth Rate
Continued SCC and IASCC In Progress
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Outline
June 7, 2017Aspects of Additive Manufacturing
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• Microstructure Characterization• Mechanical Properties• Irradiation Testing• Qualification and Process Control• Inspection and Validation Processes
Courtesy: University of Michigan
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June 7, 2017Aspects of Additive Manufacturing
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Irradiation PropertiesParameter 2 MeV Proton 5 MeV Fe++
Dose (dpa) [[
Temperature (○C)
Damage rate (dpa/s)
Beam current ( A) ]]Irradiation stage
Example of temperature distributionTemperature = 360 ± 4 ◦C for 2 MeV proton irradiation
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June 7, 2017Aspects of Additive Manufacturing
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Irradiation Properties
June 7, 2017Aspects of Additive Manufacturing
[[
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Irradiation Properties
June 7, 2017Aspects of Additive Manufacturing
]]
[[ Comparison to wrought data in progress…
Preliminary results show AM 316L performing as good (or better?) than wrought 316L
Tensile and SCC Coupons schedule for INL ATR irradiation starting 3rd Qrt 2017
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Let’s Take A Break
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Outline
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• Microstructure Characterization• Mechanical Properties• Irradiation Testing • Qualification and Process Control• Inspection and Validation Processes
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Process Quality
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Ensuring Robustness and Repeatability
Process Specification:• Pre-build Calibration• Laser Power and Size• Travel Speed and Path• Laser Dwell Time• Layer Thickness• Build Atmosphere• Pre-Heat Temperature
Powder Specification:• Traceable PO’s• Power Composition• Powder Size• Powder Reuse Procedure
Heat Treatment Spec:• Time• Temperature• Atmosphere
Material Specification:• Product Chemistry• Mechanical Properties
• Coupons on each plate• Embedded Serialization• Traceability to build
Input ControlProcess Control Output Control
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Qualification and Quality Control Strategy
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Industry Standards and GEH Programs
GEH QAPD NEDO-
11209-A
10CFR50 App B
NQA-1
GS-R-3
GEH Internal Reviews
KTA-1401
ISO 9001
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Outline
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• Microstructure Characterization• Mechanical Properties• Irradiation Testing • Process Control Description• Inspection and Validation Processes
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Inspection and Validation
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• Comparison to Wrought Properties- Industry Standards- GE Reference Databooks (Historic)
• Test Coupons with Each Print
• NDE Challenges
• Other Possible Techniques- [[
]]
[[
]]
[[
]]
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Regulatory Acceptance
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Reactor Internals
Non Internal
Fuel Bundle Component
Non-Code Code Safety Non-SafetyLead Use
BWRVIP-84
Approval
Code-Case Approval
Implementation
GEH Internal Fabrication Quality Approval and Customer Documentation
Customer Approval
GEH Materials Baseline (Powder Spec, Machine Parameters, ASTM Specification Compliance, Post-Treatment,
Mechanical Test Data, Technical Report, GEH Internal Approval)
Application Quality Requirements
10 CFR 50.59
Justification and Evaluation (LUA
Report)
Target Applications
Target Requirements
Regulatory Touchpoints
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ASTM Standard Compliance
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ASTM 3184 - 16
• Additively Manufactured UNS S31603.
• Ensure Mechanical Properties Compliance.
• Requires Manufacturing Plan to control input, processing, outputs.
• Requires test plan with acceptance criteria including tensile test specimens (X,Y,Z direction).
• Supplier and Purchaser decide on adequacy of control elements.
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Elements of Quality Documentation for example AM Application
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BWRVIP 84 Technical Basis Report will contain• [[
]]
LUA Report (e.g. debris filter) will contain• Material quality details (as
described for BWRVIP 84)• Specific part dedication,
including:o [[
]]
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Dedication Procedure for example AM Application
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Commercial Grade, Safety Related Component• Supplier of AM Parts Treated as Non-Safety Supplier (For Now).
• Responsible Design Engineer Provides Justification of Equivalency between Performance of Part and Test Coupon On Same Plate.
• Steps Need to Be Taken to Ensure All Parts are traceable to the common build plate.
• Inspection Techniques [[ ]] Must Be Vetted.
• Follow Regulatory Requirements:• 10 CFR 50 Appendix B• EPRI NP-5652• EPRI TR- 102260
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Current and Future Activity
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DOE Program - CFA-15-8309Environmental Cracking and Irradiation Resistant Stainless Steel by Additive Manufacturing
• Objective: Evaluate the stress corrosion cracking susceptibility, corrosion fatigue, and irradiation resistance of the additively manufactured 316L stainless steel in nuclear environment.
• Participants: GEGR (Rebak - PI), ORNL (Muth), U of M (Was), GEH (Connor)
• Activities: Study DMLM material nanostructure and optimize the material. Proton irradiation [[ ]]to a dose in the range [[ ]].
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DOE Program - CFA-16-10393Irradiation Testing of LWR Additively Manufactured Materials
• Objective: Perform full irradiation / PIE on structural materials produced by DMLM
• Participants: GEH (Connor - PI), INL (NSUF facility)
• Activities: Obtain microstructural characterization, mechanical properties, stress corrosion crack growth data for un-irradiated Type 316L and IN 718 (GEH) and corresponding irradiated data to [[ ]] (INL at the ATR)
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GEH Additive Timeline2017 Materials Qualification PlanComplete unirradiated materials testing on 316L and IN718Complete proton/ion irradiation of 316L (U. of Michigan)Initiate neutron irradiation of 316L and IN718 (INL’s ATR)Print and “qualify” representative nuclear componentComplete CFA-15-8309 report to DOE
2018+ Materials Qualification PlanIssue Lead Use Next Generation Debris Filter Report (TBD)Issue BWRVIP 316 technical basis report (TBD)BWR reactor deployment of 316L parts (TBD)Complete PIE mechanical testing on 316L and IN718
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Summary
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• DMLM parts will provide value for nuclear application
• When fabricated and treated in a controlled manner, DMLM material exhibits adequate properties for nuclear application
• Within the existing regulatory framework, DMLM material can be qualified for use
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Questions?
41GEH Nuclear Energy: Additive Manufacturing
6/7/2017
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