Engineering topics

Frederick, Greg

Publications and source records attributed to Frederick, Greg.

10 records

DOE OSTI2023

Collaborative Study on Weldability of Irradiated Stainless Steel 304 Materials Removed from The NRU Reactor

A collaborative research on developing advanced welding technologies for irradiated stainless steel 304 materials between CNL and ORNL has been established to support both U.S. and Canadian interests in evaluation of weld repair techniques on irradiated materials to support continuous operation of commercial nuclear power. The work utilizes unique material from the National Research Universal (NRU) reactor and the specialized welding hot cell facility at ORNL. The objective is to explore suitable welding technique and parameters and to determine the helium concentration limitation in terms of irradiated stainless-steel weldability. An additional objective is to develop the knowledge and understanding of cracking mechanisms induced by high concentration of helium in the process of weld repair of the irradiated structural alloys. This report summarizes the experimental welding evaluation on irradiated material from the NRU reactor containing helium concentrations ranging from 12 to 45 atomic parts per million (appm).

36 MATERIALS SCIENCE↗

DOE OSTI2022

Weldability of irradiated Stainless Steel 304 materials harvested from the National Research Universal (NRU) reactor

In this work, the weldability of the neutron-irradiated Stainless Steel 304 (SS 304) materials containing estimated helium levels of 12 to 44 appm has been studied through a Collaborative Research and Development Agreement between the Canadian Nuclear Laboratories and Oak Ridge National Laboratory. The work utilizes a SS 304 component harvested from the National Research Universal reactor. Laser beam welding was used to explore suitable welding conditions and associated parameters, to determine helium concentration limits for successful welding of irradiated stainless-steels. The experimental results show that maximum fusion zone void sizes, fusion zone void quantity and total heat affected zone helium-induced crack length generally increased with increasing He levels and effective weld heat input. A proper combination of welding parameters with low effective heat input, such as, laser power, weld travel speed and wire feed speed, were shown to improve the welding quality, and potentially reduce the length and probability of the formation of grain boundary helium-induced cracking and voids of irradiated SS 304 even with He concentrations as high as about 44 appm.

36 MATERIALS SCIENCE↗

DOE OSTI2021

Conduct weld campaign (FY-21-1) on irradiated materials provided by the Canadian Nuclear Laboratory (CNL), including baseline post-weld evaluation and testing

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2021

Suppression of Helium Induced Cracking in Laser Repair Welding of Highly Irradiated Stainless Steels

Welding repair of irradiated nuclear reactor materials such as austenitic stainless steels used for the reactor internals has been challenging due to irradiation generated helium in the material matrix over an extended period of time. In this study, improved laser welding techniques, including the novel Auxiliary Beam Stress Improved (ABSI) technique that proactively manages the stresses during laser repair welding is investigated to substantially reduce or avoid the occurrence of intergranular helium-induced cracking (HeIC). Here, laser weld cladding, with and without ABSI technique, was applied to deposit weld metal on irradiated stainless steel (Type 304 L) blocks with various helium concentrations up to approximately 20 atomic parts per million (appm). Welded samples were cross-sectioned and analyzed using optical and electron microscopes. It was found that, with the improved laser welding techniques, no macroscopic (millimeter-sized) cracks were observed in any of the samples. Microscopic (less than 50 μm) cracks were present in the heat affected zone. Statistical analysis on the sample with the highest helium concentration (~20 appm) reveals that the ABSI technique could effectively reduce the size and amounts of microscopic cracks.

36 MATERIALS SCIENCE↗

DOE OSTI2018

High Performance Computing Tools to Advance Materials Joining Technology

In this project, an in-house HPC finite element code was developed with novel computational schemes that provided fast and high-fidelity simulation capability for welding processes and allied manufacturing processes such as metal additive manufacturing processes. Benchmark comparison confirmed that, for the testing cases studied, the newly developed in-house code resulted in increases in computational speed in the ranges of 100x to 1000x depending on the size and complexity of the testing cases, when compared to today’s commercial welding process simulation tools. As demonstrated by the selected examples in this report, the breakthrough increases in computational simulation speeds achieved by the in-house HPC code means that high fidelity simulations of certain complex welding problems that would require months even years of computational time with today’s commercial code could be solved in two to three days. Similar order of magnitudes of reduction in computational times for metal additive manufacturing process were also achieved.

36 MATERIALS SCIENCE↗

DOE OSTI2018

Prediction of residual stresses in a multipass pipe weld by a novel 3D finite element approach

Due to enormous computation cost, current residual stress simulation of multipass girth welds are mostly performed using two-dimensional (2D) axisymmetric models. The 2D model can only provide limited estimation on the residual stresses by assuming its axisymmetric distribution. In this study, a highly efficient thermal-mechanical finite element code for three-dimensional (3D) model has been developed based on high performance Graphics Processing Unit (GPU) computers. Our code is further accelerated by considering the unique physics associated with welding processes that are characterized by steep temperature gradient and a moving arc heat source. It is capable of modeling large-scale welding problems that cannot be easily handled by the existing commercial simulation tools. To demonstrate the accuracy and efficiency, our code was compared with a commercial software by simulating a 3D multi-pass girth weld model with over 1 million elements. Our code achieved comparable solution accuracy with respect to the commercial one but with over 100 times saving on computational cost. Moreover, the three-dimensional analysis demonstrated more realistic stress distribution that is not axisymmetric in hoop direction.

Huang, Hui↗

DOE OSTI2018

STRESS AND DISTORTION SIMULATION OF ADDITIVE MANUFACTURING PROCESS BY HIGH PERFORMANCE COMPUTING

Numerical simulation is an efficient way to better understand the thermal and mechanical evolution during additive manufacturing (AM) and to design and optimize the process. However, with today’s computational tools, pass-by-pass thermal-mechanical numerical simulation of the AM process is extremely time-consuming. In this study, a new finite element code recently developed in house at Oak Ridge National Lab was used for additive manufacturing simulation. Our new code effectively utilizes GPU based high-performance computers to allow for realistic simulation of the transient thermal and mechanical response of materials during additive manufacturing. A benchmark study on a cylinder model by powder bed selective laser melting was carried out and distortion profile was compared to the experimental measurements. The accuracy and efficiency of the code was also demonstrated by analyzing a wire and arc additive manufacturing (WAAM) model which consists of a base plate and four deposited layers.

Huang, Hui↗

DOE OSTI2018

ADVANCED WELDING TECHNOLOGY DEVELOPMENT FOR NUCLEAR REACTOR REPAIR

Welding is widely used for repair, maintenance, and upgrade of nuclear reactor components. As a critical technology for supporting the extension of nuclear power plant service lifetimes beyond 60 years, there has been an industry need in further developing welding technology for highly irradiated materials. During welding of irradiated materials, Helium, which is a transmutation byproduct from Boron and Nickel contained in the structural alloys, can coalesce into bubbles along grain boundaries in the material under driving forces of high temperature and thermal tensile stress. This leads to embrittlement and potential intergranular cracking in the Heat Affected Zone (HAZ) of the weld. In this paper, irradiated 304 stainless steel coupons containing 5, 10 and 20 ppm Boron prior to radiation were successfully welded by advanced laser beam welding (LBW) and friction stir welding (FSW). Facilities and welding machine design, welding processes development, cold material welded joints evaluation, process safety control and documentation, and irradiated material welding are discussed. Both laser and friction stir welded coupons of the irradiated material exhibited high welding quality and surface finish. No Helium induced welding defects were observed on the weld surfaces or adjacent base metals.

Tang, Wei↗

DOE OSTI2017

Complete Report on the Development of Welding Parameters for Irradiated Materials

The advanced welding facility at the Radiochemical Engineering Development Center of Oak Ridge National Laboratory, which was conceived to enable research and development of weld repair techniques for nuclear power plant life extension, is now operational. The development of the facility and its advanced welding capabilities, along with the model materials for initial welding trials, were funded jointly by the U.S. Department of Energy, Office of Nuclear Energy, Light Water Reactor Sustainability Program, the Electric Power Research Institute, Long Term Operations Program and the Welding and Repair Technology Center, with additional support from Oak Ridge National Laboratory. Welding of irradiated materials was initiated on November 17, 2017, which marked a significant step in the development of the facility and the beginning of extensive welding research and development campaigns on irradiated materials that will eventually produce validated techniques and guidelines for weld repair activities carried out to extend the operational lifetimes of nuclear power plants beyond 60 years. This report summarizes the final steps that were required to complete weld process development, initial irradiated materials welding activities, near-term plans for irradiated materials welding, and plans for post-weld analyses that will be carried out to assess the ability of the advanced welding processes to make repairs on irradiated materials.

36 MATERIALS SCIENCE↗

DOE OSTI2017

Report Summarizing the Effort Required to Initiate Welding of Irradiated Materials within the Welding Cubicle

The advanced welding facility within a hot cell at the Radiochemical Engineering Development Center of Oak Ridge National Laboratory (ORNL), which has been jointly funded by the U.S. Department of Energy (DOE), Office of Nuclear Energy, Light Water Reactor Sustainability Program and the Electric Power Research Institute, Long Term Operations Program and the Welding and Repair Technology Center, is in the final phase of development. Research and development activities in this facility will involve direct testing of advanced welding technologies on irradiated materials in order to address the primary technical challenge of helium induced cracking that can arise when conventional fusion welding techniques are utilized on neutron irradiated stainless steels and nickel-base alloys. This report details the effort that has been required since the beginning of fiscal year 2017 to initiate welding research and development activities on irradiated materials within the hot cell cubicle, which houses welding sub-systems that include laser beam welding (LBW) and friction stir welding (FSW) and provides material containment within the hot cell.

36 MATERIALS SCIENCE↗