Small modular reactors (SMRs) offer a reliable and cost-effective solution to energy needs in Canada. These compact nuclear reactors provide a secure source of clean zero-carbon energy sources for Canadian, reducing reliance on fossil fuels and enhancing energy resilience in remote areas. To ensure the longevity and affordability of SMRs, it is crucial to utilize advanced materials capable of withstanding the high temperature and corrosive conditions inherent to these reactors.

Laser directed energy deposition (DED), an additive manufacturing (AM) process, has gained increasing interest in processing materials with advanced functionalities. This project aims to optimize laser DED parameters for a high-temperature corrosion-resistant nickel-based superalloy, with the goal of making it more affordable and accessible for SMRs. With the aid of laser DED, nickel-based superalloys will be used for critical components of SMRs. Key objectives of this project include overcoming metallurgical challenges during the laser processing, such as avoiding the formation of defects due to incomplete fusion and alloying element vaporization. Through a combination of experimental design, mechanical, microstructural, and corrosion analyses, this research aims to comprehensively unravel the difficulties during laser DED of nickel-based superalloys.

At the completion of this project, the successful processing of a new high-temperature corrosion-resistant superalloy using laser DED will lead to Canadian-made AM solutions for producing on-demand parts for SMRs that can be utilized in rural and remote communities in Western Canada. This will support Canada's plans to encourage the deployment of nuclear SMRs in Canada as affordable, reliable future energy systems.