Westinghouse Improves Nuclear Power with 3D Printed Nozzles

Westinghouse Electric Company is revolutionizing the nuclear power sector with its pioneering use of 3D printed nozzles. These advanced nozzles significantly enhance debris capture and fuel endurance, representing a major leap forward in nuclear fuel assembly technology. By delivering four lead test assemblies to Alabama Power’s Joseph M. Farley Nuclear Plant, Westinghouse showcased the practical benefits of additive manufacturing (AM). With a remarkable 30% increase in resistance to debris, the new nozzles mitigate the risk of leaks and improve the safety and efficiency of nuclear operations. This advancement, backed by extensive research and collaboration with global partners, underscores the transformative impact of AM on the nuclear industry.

Did You Know That 3D Printing is Revolutionizing the Nuclear Power Industry?

It’s fascinating, isn’t it? Modern technology is continually evolving, and with the advent of 3D printing, also known as additive manufacturing (AM), we’ve been able to witness remarkable transformations in various sectors. However, one of the most thrilling and perhaps lesser-known advancements is happening in the realm of nuclear power. To be specific, Westinghouse Electric Company is facilitating this progress with its groundbreaking 3D printed nozzles. So, how exactly is Westinghouse redefining the game? Let’s delve into the intricate details.

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Westinghouse’s 3D Printed Nozzles: A Game-Changer for Nuclear Power

Why 3D Printed Nozzles?

When it comes to nuclear power, safety, efficiency, and reliability are paramount. Traditional manufacturing methods often faced limitations, particularly with the complexity and precision required for components in nuclear reactors. Enter 3D printing—a technology that offers unprecedented design flexibility, production speed, and cost-efficiency.

Westinghouse Electric Company has leveraged this cutting-edge technology to develop what they proudly claim as the first-of-its-kind filtering bottom nozzles. These nozzles are crucial for improving debris capture and fuel endurance in nuclear settings.

The Core Issue: Debris Fretting

Debris fretting is a significant concern in nuclear reactors, especially in Pressurized Water Reactors (PWR). It’s the primary culprit behind leaks in fuel assemblies, jeopardizing both the efficiency and safety of the reactors. The new 3D printed nozzles target this issue head-on by enhancing debris capture.

Real-world Application: Alabama Power’s Joseph M. Farley Nuclear Plant

Westinghouse has already put theory into practice. They delivered four lead test assemblies, incorporating these innovative nozzles, to Alabama Power’s Joseph M. Farley Nuclear Plant, operated by Southern Nuclear. The objective? To mitigate the risk of leakage and enhance the durability and safety of their fuel rods by effectively addressing the problem of debris fretting.

Here’s how the additively manufactured components performed:

Parameter	Conventional Methods	3D Printed Nozzles
Debris Resistance	Standard efficiency	30% increase in resistance
Design Flexibility	Limited	Enhanced design flexibility
Leakage Risk	Considerable	Significantly reduced

The results were promising, showcasing a notable 30% increase in resistance to debris, thanks to the advanced design flexibility enabled by 3D printing.

Tarik Choho’s Insight

According to Tarik Choho, President of Nuclear Fuel at Westinghouse, the impact of this innovation is immediate and substantial. He remarked, “Our additive manufacturing technology is allowing us to achieve breakthrough performance with an immediate positive impact for our customers. This significant technology innovation for PWR reactors mitigates the risk of leakage in the fuel rods due to the accumulation of debris, strengthening the safety and efficiency of our customers’ operations.”

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Westinghouse’s Commitment to Additive Manufacturing in Nuclear Power

A History of Innovation

Westinghouse is no newcomer to 3D printing in the nuclear industry. They embarked on their AM journey back in 2015 with the first material irradiation study of AM nuclear components. Building on this foundational work, two years later, they announced plans to install an additively manufactured thimble plugging device in a commercial reactor. The device, crucial for holding nuclear fuel and preventing debris release, pioneered the use of AM 316L stainless steel alongside conventional 304 stainless steel.

Collaborations and Support

The US Department of Energy (DoE) has been a significant ally in Westinghouse’s additive manufacturing adventures. Supported by federal funding, Westinghouse has explored cost-effective 3D printing techniques for nuclear components, such as powder bed fusion and direct energy deposition. These initiatives aim to address significant safety concerns, focusing on how neutron radiation affects AM-produced zirconium alloys used in light water reactors.

Expanding Horizons: International Installations

In 2022, Westinghouse’s Swedish division achieved another milestone by installing the world’s first 3D printed nuclear fuel debris filters, named StrongHold AM filters. These were installed in nuclear power plants across Scandinavia, including Finland’s Olkiluoto plant and Sweden’s Oskarshamn plant, developed in collaboration with Finnish company Teollisuuden Voima Oyj (TVO) and OKG in Sweden.

AM and the Nuclear Sector: A Perfect Partnership

Rapid Prototyping and Custom Components

One of the standout advantages of 3D printing in the nuclear sector is the ability to rapidly prototype and create custom components. Traditional manufacturing methods are often slow and rigid, making it challenging to react swiftly to emerging needs or to customize parts for specific reactor models. AM changes the game by allowing for quick and flexible production runs.

Material Specialization

The nuclear industry requires materials that can withstand extreme conditions—high temperatures, intense radiation, and caustic environments. 3D printing technology has enabled the development of specialized materials tailored to meet these challenging requirements. For instance, Westinghouse’s work on AM 316L stainless steel and zirconium alloys is pushing the boundaries of what’s possible in material science for nuclear applications.

Enhancing Operational Efficiency and Sustainability

Discussing operational safety, Dr. Xuan Zhang of Argonne National Laboratory and Niall O’Dowd, Founder of Phase3D, emphasized their collaboration in advancing AM for nuclear applications. Phase3D’s real-time inspection technology ensures quality and reliability by detecting anomalies during the 3D printing process. This innovation directly addresses critical challenges in material qualification and operational safety, aiming to enhance efficiency, reduce waste, and promote sustainable manufacturing practices.

Industry Milestones and Future Potential

Back in 2020, Oak Ridge National Laboratory (ORNL) along with the Tennessee Valley Authority (TVA) and nuclear fuel supplier Framatome, developed and installed the first-ever 3D printed fuel assembly brackets for Browns Ferry Nuclear Plant in Alabama. This remarkable achievement was a significant step under ORNL’s Transformational Challenge Reactor (TCR) program, which aims to expedite nuclear energy deployment in the US, making it both faster and more cost-effective.

From pioneering thimble plugging devices to innovative nuclear fuel debris filters, Westinghouse, alongside various industry collaborations, is pushing the envelope in leveraging 3D printing for nuclear power applications.

The Road Ahead for 3D Printing in Nuclear Power

Building on Success

Given the impressive performance of the 3D printed nozzles and other AM components, it’s clear that there is a substantial future for 3D printing in the nuclear power industry. The continued development and implementation of additive manufacturing techniques promise to further enhance the efficiency, safety, and sustainability of nuclear power plants worldwide.

Continued Innovation and Collaboration

As more industry leaders and research institutions recognize the benefits of AM, expect more groundbreaking developments. Collaborative efforts between tech companies, research labs, and nuclear power operators will likely accelerate the adoption of 3D printing, bringing new levels of precision and customization to nuclear components.

Ongoing Research and Development

To support these advancements, ongoing research is crucial. Westinghouse and its partners must continue to explore new materials, methods, and quality assurance processes to ensure the highest standards of safety and reliability. With strong backing from governmental organizations like the DoE, there’s a bright future for R&D in this space.

Conclusion

It’s a thrilling time for anyone fascinated by the intersection of technology and energy. Westinghouse’s use of 3D printed nozzles exemplifies how advanced manufacturing techniques can dramatically enhance traditional industries like nuclear power. By addressing critical issues such as debris fretting and enabling more flexible, efficient production, 3D printing is already showing its worth. And this is just the beginning.

So next time you think about nuclear power, remember that beyond the atoms and reactors, there’s a layer of cutting-edge technology ensuring everything runs smoothly and safely. And who knows—maybe this is the spark that ignites your curiosity about the incredible world of additive manufacturing.

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