Manufacturing Method to Produce Near Net Shape PM-HIP Components

Many United States nuclear reactors are nearing the end of their operating lives or retiring due to challenging market conditions. This creates an opportunity for more efficient and affordable advanced nuclear reactors. Rapid deployment of these reactors will be critical to secure the energy, environmental, and national security benefits provided by nuclear energy. However, declines in domestic manufacturing capabilities have driven up manufacturing cost and time for reactor parts, presenting a critical threat to American competitiveness in nuclear energy. State-of-the-art manufacturing methods do not produce parts that are robust enough for the corrosive and high-temperature conditions of advanced reactor designs. An advanced manufacturing method (powder metallurgical hot isostatic pressing followed by electrochemical post-processing) is being developed to economically produce parts with the corrosion and high-temperature resistance needed for advanced reactor designs. It can be installed throughout the United States, enabling a robust supply chain for reactor parts and competitive American manufacturing base. Decreasing the manufacturing cost and time for reactor components will enable more rapid deployment of advanced nuclear reactors. Powder metallurgical hot isostatic pressing was used to make cylindrical parts that were evaluated under conditions relevant to advanced nuclear reactor operations. The molten salt corrosion resistance of the cylindrical parts was equivalent or superior to parts made via traditional methods. An electrochemical post-processing method achieved effective treatment with lower costs than conventional chemical pickling (by ~62%) and lower environmental impacts (eliminated toxic/regulated by-products). The improved powder metallurgical hot isostatic pressing process and electrochemical post-processing method will be scaled-up to a demonstration nuclear reactor component. Manufacturing of parts with high-temperature, corrosion, and irradiation properties needed for advanced nuclear reactors will be demonstrated. The electrochemical post-processing step will also be demonstrated with materials and parts relevant to other markets. Phase II will establish the commercial readiness of this approach and lay the foundation for a robust domestic manufacturing base. Successful commercialization of this advanced manufacturing method will improve the competitiveness of the domestic manufacturing base. This will benefit the American nuclear reactor sector by decreasing the manufacturing cost and time for critical reactor components, enabling more rapid deployment of advanced nuclear reactors. It will help other markets that may use this manufacturing process, including aerospace, oil and gas, and defense industry, to provide broader economic and national security benefits.