| Phase: |
Theme |
| Theme: | Grids and Storage (T06) |
| Status: | Active |
| Start Date: | 2024-04-01 |
| End Date: | 2026-03-31 |
| Principal Investigator |
| Yakout, Mostafa |
Project Overview
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.
Outputs
| Title |
Category |
Date |
Authors |
| Additive Manufacturing of High-Temperature Corrosion-Resistant Materials for Use in SMRs University of Alberta | Activity | 2025-03-04 | Yakout, M. |
| Laser Powder Bed Fusion of Inconel 617 for High-Temperature Gas-Cooled Small Modular Reactors (SMRs)Small modular reactors (SMRs) based on high-temperature gas-cooled reactor (HTGR) technology produce low CO2 emissions per unit of energy, are easy to manufacture, and reduce financial risk due to their small size and modular design. HTGR-SMRs operate at elevated temperature conditions (above 750°C); therefore, their components should be manufactured using materials that demonstrate high strength, corrosion resistance, and creep resistance at high temperatures, such as Inconel 617 (IN617). Laser powder bed fusion (L-PBF), an advanced additive manufacturing (AM) process, is employed to fabricate complex IN617 structures for the rapid production of HTGR-SMR modules, offering a significant reduction in material waste compared to traditional manufacturing methods (e.g., casting). However, the rapid heating and cooling rates in L-PBF can lead to metallurgical defects, such as hot cracking, alloy segregation, and undesirable phase formation, that affect the mechanical properties of parts produced. To mitigate these metallurgical defects, it is important to determine the optimum L-PBF process parameters to generate a stable microstructure and enhanced mechanical properties. This work presents a preliminary analysis of high-density IN617 samples fabricated using the L-PBF process. These samples were successfully produced under different process parameters, covering a wide range of laser energy density to identify the optimum energy required for complete melting. Density measurements and microstructural analysis were conducted using a scanning electron microscope (SEM). Finally, the study outlines future work needed to achieve full optimization of fabrication parameters for producing critical components for HTGR-SMRs that operate under extreme environmental conditions. University of Alberta | Activity | 2025-03-04 | Krutskaya Yepez, Asad Asad, Gloria Ghobrial, Yakout, M. |
| Is Alberta's workforce ready for the challenges of nuclear power? University of Alberta | Activity | 2024-11-22 | Yakout, M. |
