Session 2 A – Power generation
Wednesday 11 June 08:30
HIP Technology for hard facing materials in nuclear power plants
David Stewart, Rolls-Royce, Derby, United Kingdom
David Stewart is an Engineering Specialist in the Materials, Chemistry and Corrosion department of Rolls-Royce plc. He specializes in surface engineering, tribology and powder based technologies and currently manages a number of HIP-related work programmes. He graduated from the University of Nottingham with a PhD on studies of the sliding wear resistance of thermally sprayed conventional and nanocomposite WC-Co coatings and has worked previously in both the nuclear industry and the Rolls-Royce gas turbine manufacturing supply chain
Hard facing materials used for galling resistance in components such as valves in nuclear reactors have traditionally been based on the stellite family of alloys. These are carbide containing, cobaltbased materials which possess both corrosion resistance and wear resistance. However, corrosion of wear products from these materials may become activated in the neutron flux to form the cobalt-60 isotope which is a significant contributor to work force dose accumulation. As such there is a drive to change to low cobalt based alloys which possess the same corrosion and galling resistance, against the challenge of increasing plant lifetimes. The cobalt base alloy materials are typically weld deposited with the type of deposition method evolving over the years. This presentation will review the changes in both material and manufacturing for these applications and, specifically the introduction of HIP technology and the advantages that it brings.
Wednesday 11 June 09:00
PM-HIP research, applications and technology gaps for the electric power industry
David W. Gandy, Electric Power Research Institute, Charlotte, United States
David Gandy is a Technical Executive within EPRI’s Nuclear Materials area. He is currently leading EPRI’s PM-HIP research whichincorporates projects across both fossil and nuclear related programs. Mr Gandy is a ASM Internal Fellow and has 30 years of experience in the Power Industry.
Abstract The Electric Power Research Institute (EPRI) and Carpenter Technology have partnered with several valve manufacturers to develop ASME Boiler and Pressure Vessel Code Cases and Data Packages for two alloys produced by powder metallurgy and Hot Isostatic Processing (PM-HIP): Grade 91 (UNS K90901) and Type 316L Stainless Steel (UNS S31603). The two alloys are mainstay materials in the fossil and nuclear industries, respectively, for piping, valves, pump housings, and other pressure retaining applications.
This paper reviews the two Code Cases and discusses the application of PM-HIP technology to other alloys and components of interest
to the electric power industry. Potential alloy applications range from conventional low alloy steels for pressure vessels, nozzles, or piping applications, to nickel-based alloys for nuclear vessel internals and ultra-supercritical component applications, to hard-facing alloys for wear applications, and to alloys for higher temperature reactors, etc. The major commonalities among these materials include:
1) data generation and acceptance by the applicable Code and regulatory body and
2) the large size of many of these components which are currently restricted by the size of the HIP vessel.
This paper will attempt to identify not only the PM-HIP equipment and ancillary needs required for the electric power industry, but will also define several of the current gaps in the technology faced by this industry. Lastly, it will provide a Roadmap for industry to achieve greater acceptance and use of PM-HIP for pressure retaining applications.
Wednesday 11 June 09:30
Hot Isostatic Pressing for the production of bimetallic nozzle for nuclear application
Benjamin Picqué, Aubert & Duval, Pamiers, France, Denis Cedat, AREVA, Le Creusot, France
Benjamin Picqué. After a PhD Thesis in the Ecole des Mines de Paris (Sophia-Antipolis) in the field of materials & numerical modelling, Benjamin Picqué has firstly been in charge of the R&D department (2004-2008) and of the Technical Development department for jet engine components (2008 -2012) at Aubert & Duval, specialized in new materials and hot transformation processes in Pamiers plant. Since end of 2012, he is in charge of the technical development of the Net Net Shape and Net Shape HIP parts activity.
Denis Cedat. With a PhD thesis in the field of materials & mechanics (2005-2008), Denis Cedat is a Metallurgy & Powder metallurgy Expert since 2010 in Areva Technical Center in Le Creusot, France.
The research and development ENERPOUDRE program aims at replacing the current method of coated manufacturing forgings by a new process using the Hot Isostatic Pressing (HIP) in order to achieve significant productivity gains. Indeed, this method provides directly, from metal powders put in a container and compacted at high temperature under high pressure, bimetallic near net shape parts, having at least forgings properties. The part of the study is a bimetallic Surge Nozzle (AREVA NP application), made of low alloy steel powders for the body and stainless steel powders for the coating layer. The HIP process is innovative and offers many benefits versus the conventional forging process with a simplification of the future production route, a better controllability of the part and a shorter lead-time by reducing machining and welding operations. This paper reviews the powder manufacturing, the part process, the numerical modelling results for calculation of hipping deformations, the ultrasonic tests and the design of parts produced with the mechanical characteristics obtained.
Wednesday 11 June 10:00
Development of volumetrically efficient metal canisters for the encapsulation and consolidation of low packing density immobilised wasteforms
Sam Moricca, Synroc, ANSTO, Lucas Heights, Australia