Continuous tempering effect induced PWHT alternative technology using wire arc additive manufacturing for application in replacing nuclear pressurized water reactor system repairing: CALPHAD, FEM simulation, and EBSD investigation
This study proposes an effective repair technology using arc additive manufacturing for pressurized water reactors (PWRs) in nuclear power plants (NPP) aimed at avoiding complete replacements and post-weld-heat treatments (PWHTs) of component parts while ensuring safety and reliability. Effective re...
| Main Authors: | , , , , , , |
|---|---|
| Format: | Article |
| Language: | English |
| Published: |
Elsevier
2023-07-01
|
| Series: | Journal of Materials Research and Technology |
| Subjects: | |
| Online Access: | http://www.sciencedirect.com/science/article/pii/S2238785423013406 |
| _version_ | 1797745288846245888 |
|---|---|
| author | Junyeong Kim Jong-Hun Kim Jungsoo Park Seungyeop Baek Ninshu Ma Seung-Joon Lee Dongjin Kim |
| author_facet | Junyeong Kim Jong-Hun Kim Jungsoo Park Seungyeop Baek Ninshu Ma Seung-Joon Lee Dongjin Kim |
| author_sort | Junyeong Kim |
| collection | DOAJ |
| description | This study proposes an effective repair technology using arc additive manufacturing for pressurized water reactors (PWRs) in nuclear power plants (NPP) aimed at avoiding complete replacements and post-weld-heat treatments (PWHTs) of component parts while ensuring safety and reliability. Effective repair technology is defined as economic and process efficiency, because of maintenance costs and radiation exposure, and it is critical in related industries. The technology is designed to relieve the hardness and martensite fraction of the welding heat affected zone (HAZ) of low alloy steels (SA508) in PWRs penetration/nozzles by heat source generated in the WAAM process, thus ensuring structural integrity. In the first layer of wire arc additive manufacturing processes, 89.6% of the martensite phase was formed in the HAZ of SA508, which was significantly reduced to 45.7% due to repetitive thermal behaviors at the third layer. The resulting process dramatically reduced hardness from 450Hv in the initial layer additive manufacturing to 320Hv in 3 layers without additional heat treatments. Moreover, the study quantitatively investigated the martensite starting temperature (Ms) and bainite starting temperature (Bs) and analyzed the microstructure and mechanical behavior of the developed process using thermodynamic calculation (CALPHAD), finite element method (FEM) simulation, and microstructure quantitative analysis by electron backs-catter diffraction (EBSD). The proposed technologies and their quantitative analysis results can be a substantial alternative to the repair technology for penetration/nozzles in nuclear primary water cooling reactor applications, complying with ASME Sec.IX Qw-462.12 and ISO 15614-1. |
| first_indexed | 2024-03-12T15:21:15Z |
| format | Article |
| id | doaj.art-d936bad43cc042d18634495524a69255 |
| institution | Directory Open Access Journal |
| issn | 2238-7854 |
| language | English |
| last_indexed | 2024-03-12T15:21:15Z |
| publishDate | 2023-07-01 |
| publisher | Elsevier |
| record_format | Article |
| series | Journal of Materials Research and Technology |
| spelling | doaj.art-d936bad43cc042d18634495524a692552023-08-11T05:33:31ZengElsevierJournal of Materials Research and Technology2238-78542023-07-012529612988Continuous tempering effect induced PWHT alternative technology using wire arc additive manufacturing for application in replacing nuclear pressurized water reactor system repairing: CALPHAD, FEM simulation, and EBSD investigationJunyeong Kim0Jong-Hun Kim1Jungsoo Park2Seungyeop Baek3Ninshu Ma4Seung-Joon Lee5Dongjin Kim6Department of Mechanical Engineering, Graduate School, Chosun University, 309, Pilmun-daero, Dong-gu, Gwang-Ju, Republic of KoreaDepartment of Advanced Materials Engineering, Tech University of Korea (TU Korea), Siheung 15073, Republic of KoreaDepartment of Mechanical Engineering, Graduate School, Chosun University, 309, Pilmun-daero, Dong-gu, Gwang-Ju, Republic of KoreaMulti Materials Research Center, Korea Automotive Technology Institute (KATECH), 471-4, Gwangsan-gu, Gwang-Ju, Republic of Korea; Joining and Welding Research Institute (JWRI), Osaka University, 11-1 Mihogaoka, Ibaraki, Osaka 567-0047, JapanJoining and Welding Research Institute (JWRI), Osaka University, 11-1 Mihogaoka, Ibaraki, Osaka 567-0047, JapanDepartment of Advanced Materials Engineering, Tech University of Korea (TU Korea), Siheung 15073, Republic of Korea; Co-Corresponding author.Advanced Joining and Additive Manufacturing R&D Department, Korea Institute of Industrial Technology (KITECH), 156 Gaetbeol-ro, Yeonsu-gu, Incheon 21999, Republic of Korea; Corresponding author.This study proposes an effective repair technology using arc additive manufacturing for pressurized water reactors (PWRs) in nuclear power plants (NPP) aimed at avoiding complete replacements and post-weld-heat treatments (PWHTs) of component parts while ensuring safety and reliability. Effective repair technology is defined as economic and process efficiency, because of maintenance costs and radiation exposure, and it is critical in related industries. The technology is designed to relieve the hardness and martensite fraction of the welding heat affected zone (HAZ) of low alloy steels (SA508) in PWRs penetration/nozzles by heat source generated in the WAAM process, thus ensuring structural integrity. In the first layer of wire arc additive manufacturing processes, 89.6% of the martensite phase was formed in the HAZ of SA508, which was significantly reduced to 45.7% due to repetitive thermal behaviors at the third layer. The resulting process dramatically reduced hardness from 450Hv in the initial layer additive manufacturing to 320Hv in 3 layers without additional heat treatments. Moreover, the study quantitatively investigated the martensite starting temperature (Ms) and bainite starting temperature (Bs) and analyzed the microstructure and mechanical behavior of the developed process using thermodynamic calculation (CALPHAD), finite element method (FEM) simulation, and microstructure quantitative analysis by electron backs-catter diffraction (EBSD). The proposed technologies and their quantitative analysis results can be a substantial alternative to the repair technology for penetration/nozzles in nuclear primary water cooling reactor applications, complying with ASME Sec.IX Qw-462.12 and ISO 15614-1.http://www.sciencedirect.com/science/article/pii/S2238785423013406Low alloy steelWire arc additive manufacturingNuclear powerPWREBSD |
| spellingShingle | Junyeong Kim Jong-Hun Kim Jungsoo Park Seungyeop Baek Ninshu Ma Seung-Joon Lee Dongjin Kim Continuous tempering effect induced PWHT alternative technology using wire arc additive manufacturing for application in replacing nuclear pressurized water reactor system repairing: CALPHAD, FEM simulation, and EBSD investigation Journal of Materials Research and Technology Low alloy steel Wire arc additive manufacturing Nuclear power PWR EBSD |
| title | Continuous tempering effect induced PWHT alternative technology using wire arc additive manufacturing for application in replacing nuclear pressurized water reactor system repairing: CALPHAD, FEM simulation, and EBSD investigation |
| title_full | Continuous tempering effect induced PWHT alternative technology using wire arc additive manufacturing for application in replacing nuclear pressurized water reactor system repairing: CALPHAD, FEM simulation, and EBSD investigation |
| title_fullStr | Continuous tempering effect induced PWHT alternative technology using wire arc additive manufacturing for application in replacing nuclear pressurized water reactor system repairing: CALPHAD, FEM simulation, and EBSD investigation |
| title_full_unstemmed | Continuous tempering effect induced PWHT alternative technology using wire arc additive manufacturing for application in replacing nuclear pressurized water reactor system repairing: CALPHAD, FEM simulation, and EBSD investigation |
| title_short | Continuous tempering effect induced PWHT alternative technology using wire arc additive manufacturing for application in replacing nuclear pressurized water reactor system repairing: CALPHAD, FEM simulation, and EBSD investigation |
| title_sort | continuous tempering effect induced pwht alternative technology using wire arc additive manufacturing for application in replacing nuclear pressurized water reactor system repairing calphad fem simulation and ebsd investigation |
| topic | Low alloy steel Wire arc additive manufacturing Nuclear power PWR EBSD |
| url | http://www.sciencedirect.com/science/article/pii/S2238785423013406 |
| work_keys_str_mv | AT junyeongkim continuoustemperingeffectinducedpwhtalternativetechnologyusingwirearcadditivemanufacturingforapplicationinreplacingnuclearpressurizedwaterreactorsystemrepairingcalphadfemsimulationandebsdinvestigation AT jonghunkim continuoustemperingeffectinducedpwhtalternativetechnologyusingwirearcadditivemanufacturingforapplicationinreplacingnuclearpressurizedwaterreactorsystemrepairingcalphadfemsimulationandebsdinvestigation AT jungsoopark continuoustemperingeffectinducedpwhtalternativetechnologyusingwirearcadditivemanufacturingforapplicationinreplacingnuclearpressurizedwaterreactorsystemrepairingcalphadfemsimulationandebsdinvestigation AT seungyeopbaek continuoustemperingeffectinducedpwhtalternativetechnologyusingwirearcadditivemanufacturingforapplicationinreplacingnuclearpressurizedwaterreactorsystemrepairingcalphadfemsimulationandebsdinvestigation AT ninshuma continuoustemperingeffectinducedpwhtalternativetechnologyusingwirearcadditivemanufacturingforapplicationinreplacingnuclearpressurizedwaterreactorsystemrepairingcalphadfemsimulationandebsdinvestigation AT seungjoonlee continuoustemperingeffectinducedpwhtalternativetechnologyusingwirearcadditivemanufacturingforapplicationinreplacingnuclearpressurizedwaterreactorsystemrepairingcalphadfemsimulationandebsdinvestigation AT dongjinkim continuoustemperingeffectinducedpwhtalternativetechnologyusingwirearcadditivemanufacturingforapplicationinreplacingnuclearpressurizedwaterreactorsystemrepairingcalphadfemsimulationandebsdinvestigation |