Metal AM Steel Capsules Endure Nuclear Reactor Testing

The U.S. Department of Energy’s Oak Ridge National Laboratory (ORNL), Oak Ridge, Tennessee, has achieved a significant milestone in nuclear component innovation by successfully testing two additive manufactured (AM) stainless steel experimental capsules at its High Flux Isotope Reactor (HFIR). This accomplishment is a crucial step in proving that additively manufactured components can meet the stringent safety standards required for nuclear applications.

These capsules are designed to hold sample materials during irradiation experiments, allowing researchers to study how these materials respond in a nuclear reactor. They serve as a critical pressure and containment barrier, ensuring safety during experimentation.

An ORNL team employed a laser powder-bed system at the lab’s Manufacturing Demonstration Facility (MDF) to print the capsules using 316H stainless steel. This specific steel is being evaluated for its high-temperature strength, corrosion resistance, and proven nuclear-grade performance, making it suitable for reactor environments.

After assembly, the capsules were qualified for insertion into HFIR by ORNL’s Irradiation Engineering group. They underwent a month-long irradiation cycle and were removed intact, setting a precedent for future nuclear component designs using AM.

Ryan Dehoff, director of the MDF, stated, “As we demonstrate the reliability of these printed components, we envision a future where additive manufacturing becomes standard in producing critical reactor parts.” HFIR offers one of the highest neutron flux environments globally, allowing for rigorous testing of fuels and materials under nuclear conditions.

The use of additive manufacturing could significantly reduce the time and costs associated with producing experimental capsules, thereby driving innovation in nuclear science and technology. This work is supported by the DOE Office of Nuclear Energy’s Advanced Materials and Manufacturing Technologies program, emphasizing its importance in addressing pressing challenges in nuclear energy research.