Integrating Cold Spray AM as a PM Technique with HIP for High Temperature Metallic Alloys

To maintain the United States' leadership in global nuclear energy, it is crucial to overcome the high costs and performance limitations of current reactor components. While advanced manufacturing techniques, such as powder metallurgy-hot isostatic pressing, offer potential cost reductions, they face challenges in high-temperature nuclear environments due to degradation mechanisms such as creep and fatigue. These limitations hinder the progress of next-generation nuclear reactors. An innovative approach is proposed, which combines advanced powder engineering, high-deposition-rate solid-state additive manufacturing, and hot isostatic pressing post-processing. The proposed additive manufacturing technology consolidates feedstock into structures without melting, preserving the powder’s intrinsic properties. By optimizing powder characteristics and refining the additive manufacturing and hot isostatic pressing processes, the proposed approach aims to produce defect-free, structurally sound materials with improved radiation tolerance, high-temperature properties, and enhanced fatigue and creep resistance. In Phase I, the following will be done: Improve powder characteristics, including particle size distribution and composition, to meet nuclear application standards; optimize novel additive manufacturing processing parameters to create high-quality deposits with minimal defects; perform hot isostatic pressing postprocessing to enhance microstructural integrity and particle bonding, improving fatigue and creep resistance; optimize materials development using Integrated Computational Materials Engineering; and prepare for testing and evaluation of the materials' performance in nuclear environments in Phase II. This project will accelerate the development of advanced nuclear reactor components, improving their performance in high-temperature environments. The technology has broader applications in other industries requiring high-performance materials, such as aerospace and energy sectors. The successful integration of these materials into nuclear reactors will reduce costs, enhance safety, and support the deployment of nextgeneration fission reactors.