High Performance Cold Spray Nozzle Design using Compressed Air for Repair of Nuclear Components

The SBIR Program aims to develop and demonstrate a high-performance cold spray (CS) nozzle prototype that utilizes nitrogen instead of costly helium for structural repairs in nuclear applications. Cold spray technology accelerates micron-sized particles in a supersonic gas jet, which bond to surfaces upon impact, offering significant advantages over other repair methods. In nuclear applications, CS shows great potential for repairing active leaks, applying protective coatings, and addressing stress corrosion cracking in reactor components. Continuum Dynamics, Inc. (CDI), in collaboration with Applied Research Laboratory (ARL) at Penn State University (PSU), has previously demonstrated an innovative nozzle design that uses nitrogen as the carrier gas, reducing the reliance on expensive helium. In this effort, CDI will implement several design improvements specifically tailored for nuclear applications, including a compact form factor for repairs in confined spaces, a novel powder injection system to prevent nozzle clogging, and increased nozzle thermodynamic efficiency at lower operating pressures, making the CS system more portable. Additionally, the proposed work will result in the development of a CS modeling tool for rapid design and analysis of CS parameters. In Phase I, the project will focus on designing and demonstrating a CS nozzle that can be retrofitted to existing CS systems. Phase II will build upon the results from Phase I, focused on optimizing the design and commercializing the nozzle for broader use such as for additive manufacturing of new parts. A successful Phase I/Phase II endeavor will result in a validated, high-performance Cold Spray (CS) system capable of providing efficient, cost-effective structural repair solutions for nuclear power plant applications. The specially designed CS nozzle, featuring a compact form and open outer structure, allows for precise application in confined and challenging areas within nuclear facilities, including areas subject to high corrosion or wear, such as steam generator tubes, valve seats, and piping. This design ensures versatility and ease of use, essential for nuclear environments with restricted access. Utilizing nitrogen as the carrier gas, the system avoids reliance on scarce and expensive helium, providing significant operational cost savings. Additionally, an innovative particle injection system allows for operation with compressed air, potentially reducing costs even further. This CS system addresses the nuclear industry's need for portable, robust, and cost-effective repair technology that can be used on-site, reducing downtime and extending the life of critical components. Beyond nuclear applications, this technology has extensive commercial potential in other critical sectors, such as energy, aerospace, and defense. For commercialization, CDI intends to collaborate with manufacturing partners to license the CS technology. An additional commercialization avenue lies in the development and support of a software application tailored to nuclear industry needs as part of this work. By offering a combination of advanced hardware and specialized software, CDI aims to become a leader in cold spray technology, providing comprehensive design, support, and consulting services to the nuclear power industry. CDI estimates cumulative sales revenues of $6 M and additional cumulative software licensing revenues of $6 M during the first 10 years of commercialization.