Cold Spray metal powder deposition with 9 %Cr-steel applied for the HCPB First Wall fabrication: Proof of concept and options for ODS steel processing

At the KIT a hybrid manufacturing concept for nuclear fusion First Walls is developed combining aspects of conventional and Additive Manufacturing (AM) technologies. The state of the art for ITER does not cover all specifications of a DEMO relevant First Wall. Thus, additional R&D-work has been initiated in terms of manufacturing. The AM technology basis used in the presented process combination is Cold Spray metal powder deposition applied in alternation with machining including the feature of filling grooves temporarily with a water-soluble granulate for creation of closed channels and cavities. Thus, the technology provides the option to manufacture shells with a thin gas tight membrane on top of previously machined structures. This membrane is used as pressure seal and makes the joining of shells by Hot Isostatic Pressing (HIP) into one monolithic body possible. This paper describes the manufacturing process and recalls differences and common aspects with regard to conventional concepts of First Wall manufacturing. The achievement of Technology Readiness Level TRL 3 by mechanical qualification and comparison of the results to other HIP joint experiments is also demonstrated. Finally, an outlook is given concerning integration options of the technology into manufacturing of shells with cooling channel structures using Oxide Dispersion Strengthened (ODS) materials

Creep strength and minimum strain rate estimation from Small Punch Creep tests

A new standard is currently being developed under the auspices of ECISS/TC 101 WG1 for the small punch testing technique for the estimation of both tensile and creep properties. Annex G of the new standard is covering the assessment and evaluation of small punch creep (SPC) data. The main challenge for estimating uniaxial creep properties from SPC data is the force to equivalent stress conversion between SPC and uniaxial creep tests. In this work a range of SPC assessment methodologies, benchmarked for the standard, are compared for verifying the best practice used in the standard. The estimated equivalent stresses for SPC are compared to uniaxial creep stresses at equal rupture times, using three alternative models. In-depth analyses are performed on SPC and uniaxial creep data for P92, F92 and 316 L steel tested within an inter-laboratory round robin. The formulation for SPC equivalent creep strain rate in the standard is also assessed

Small punch creep testing of P92 steel and weld for inter-laboratory comparison and standardization

The small punch creep (SPC) test is a miniature technique that can provide information on creep properties from in service materials or on local material properties such as heat affected zones in weldments. The code of practice (CoP) for the small punch testing technique is currently being transformed into an EN standard. To qualify the selected test specifications and to quantify inter-laboratory data scatter a round-robin was launched for the standardization effort. SPC and reference uniaxial creep tests are performed on P92 steel at temperatures of 600, 625 and 650°C. In parallel a testing programme on P92 welds have been started in the European Creep Collaborative Committee (ECCC). In this paper the initial test results of both these testing programmes are assessed and compared. The initial results show that the SPC time to rupture data scatter is reasonable and that inter-laboratory results are comparable at all specified force levels and temperatures. From the weld tests on specimens targeted to be positioned in different heat affected zones it can be shown that rupture times are indeed affected but no clear reduction in strength can be determined for the short term SPC test. It is clear that the bi-axial stress state and the different stress evolution during the SPC test in comparison to a uniaxial creep test is a challenge when attempting to formulate load to stress transformation equations. Robust estimates on the uniaxial stresses for P92 are acquired by both new approaches and by isothermal determination of force over stress ratios using the classical CoP methodology. This work aims to aid the development of the new standard and to highlight the usability of the method for remaining life or life extension assessments.JRC.G.I.4-Nuclear Reactor Safety and Emergency Preparednes

European Standard on Small Punch Testing of Metallic Materials

Life extension of aging nuclear power plant components requires knowledge of the properties of the service-exposed materials. For instance, in long term service the tensile and creep properties might decline and the ductile-to-brittle transition temperature (DBTT) might shift towards higher temperatures. Monitoring of structural components in nuclear power plants receives much attention — in particular in the context of lifetime extension of current plants, where the amount of material available for destructive testing is limited. Much effort has therefore been invested in the development of miniature testing techniques that allow characterizing structural materials with small amounts of material. The small punch (SP) test is one of the most widely used of these techniques. It has been developed for nuclear applications but its use is spreading to other industries. Although the SP technique has been used for more than 30 years, there is currently no standard covering its most widely used applications. Within the auspices of ECISS TC 101 “Test methods for steel (other than chemical analysis)” WG 1 is currently developing an EN standard on the “Small Punch Test Method for Metallic Materials”. The standard will address small punch testing for the determination of tensile/fracture properties as well as small punch creep testing. This paper gives an overview of the state-of-the art of the SP tests and describes the scope of the standard under development.JRC.G.I.4-Nuclear Reactor Safety and Emergency Preparednes

Cold Spray metal powder deposition with 9 %Cr-steel applied for the HCPB First Wall fabrication: Proof of concept and options for ODS steel processing

At the KIT a hybrid manufacturing concept for nuclear fusion First Walls is developed combining aspects of conventional and Additive Manufacturing (AM) technologies. The state of the art for ITER does not cover all specifications of a DEMO relevant First Wall. Thus, additional R&D-work has been initiated in terms of manufacturing. The AM technology basis used in the presented process combination is Cold Spray metal powder deposition applied in alternation with machining including the feature of filling grooves temporarily with a water-soluble granulate for creation of closed channels and cavities. Thus, the technology provides the option to manufacture shells with a thin gas tight membrane on top of previously machined structures. This membrane is used as pressure seal and makes the joining of shells by Hot Isostatic Pressing (HIP) into one monolithic body possible. This paper describes the manufacturing process and recalls differences and common aspects with regard to conventional concepts of First Wall manufacturing. The achievement of Technology Readiness Level TRL 3 by mechanical qualification and comparison of the results to other HIP joint experiments is also demonstrated. Finally, an outlook is given concerning integration options of the technology into manufacturing of shells with cooling channel structures using Oxide Dispersion Strengthened (ODS) materials