US laboratory backs 3D printing for reactor parts, aiming to speed approvals, cut costs, and boost safety in next-gen nuclear systems.
New research led by the US Argonne National Laboratory could speed up approval of advanced nuclear reactor materials .The team has submitted a draft Code Case to the American Society of Mechanical Engineers.
It supports Laser Powder Bed Fusion, a high-precision 3D printing method. This would allow its use in high-temperature reactor components.The move could enable faster production. It may strengthen supply chains. It also allows more flexible designs for next-generation nuclear systems. It also aims to improve safety, reliability, and cost efficiency in nuclear energy.Recently, ANL researchers have used supercomputers to model turbulent flow, improving understanding of heat transfer and advancing the development of safer, more reliable, carbon-free nuclear energy systems.Next-gen reactor partsThe new proposal would allow the use of Laser Powder Bed Fusion , an advanced additive manufacturing process, for producing high-temperature reactor components. LPBF builds complex metal parts layer by layer using a high-powered laser to fuse fine powder, enabling precise control over material properties and geometry.This development is significant for the nuclear energy sector. Traditionally, reactor components require long manufacturing times, strict certification processes, and limited design options due to conventional fabrication methods such as forging and casting. By introducing LPBF, engineers can produce intricate, high-performance parts that were previously difficult or impossible to manufacture.The adoption of LPBF represents a breakthrough in applied materials science. It can enhance the performance of critical components by optimizing microstructures and improving resistance to extreme heat and radiation. At the same time, it reduces material waste and shortens production timelines, which is crucial for scaling up next-generation reactor technologies.Importantly, this approach strengthens the nuclear supply chain by enabling localized, on-demand production of components. It also enhances design flexibility, enabling safer, more efficient reactor systems.Reactor design accelerationThe project was achieved through collaboration between ANL, Oak Ridge National Laboratory, Idaho National Laboratory, and Los Alamos National Laboratory under the US Department of Energy Office of Nuclear Energy’s Advanced Materials and Manufacturing Technologies program.The AMMT program focuses on advancing modern manufacturing methods, including Laser Powder Bed Fusion , Directed Energy Deposition , and Powder Metallurgy Hot Isostatic Pressing . These technologies are critical for developing high-performance materials, improving production efficiency, and overcoming key challenges in nuclear energy systems.Researchers worked to translate cutting-edge materials science and manufacturing innovations into standardized codes and regulatory pathways. This effort is essential for ensuring that new technologies can be safely approved and adopted in real-world reactor applications.According to ANL, aligning research with industry standards helps reduce deployment barriers and supports faster commercialization of advanced reactor designs. It also strengthens the nuclear supply chain by enabling more flexible, efficient, and scalable manufacturing solutions.In another project, ANL researchers are replacing traditional approximations with high-performance computing to model turbulent flow in nuclear reactors. Using advanced computational fluid dynamics codes like Nek5000 and NekRS , they simulate complex fluid and gas behavior with high precision. These tools enable detailed analysis of heat transfer and gas mixing, critical for reactor safety. The models are tailored to predict risks such as hydrogen accumulation in containment systems, a key concern after the Fukushima Daiichi nuclear disaster. Accuracy was validated through the international PANDA experiment, successfully predicting flow behavior without prior experimental data.
ANL Argonne National Laboratory Directed Energy Deposition Laser Powder Bed Fusion Nuclear Energy Nuclear Reactor Materials Powder Metallurgy Hot Isostatic Pressing US Department Of Energy Office
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