Molybdenum 3D Printing Objects to Be Used in Nuclear Industry

Recently, French nuclear industry leader Framatome manufactured the world's first uranium and molybdenum objects using 3D printing technology. BWX Technologies, a nuclear fuel and component supplier based in Virginia, has successfully applied three-dimensional printing technology to manufacture core structural components for nuclear power propulsion design, which was previously impossible with conventional manufacturing methods.

BWX worked with researchers at Oak Ridge National Laboratory to use an electron beam melting system to print complex parts made of molybdenum, which is a refractory metal with high temperature and wear resistance. During the 3D printing process, each millimeter-thick layer is captured digitally, and then used to verify the integrity of the component. The Office of Nuclear Energy of the U.S. Department of Energy provided nearly $10 million in funding for this research in 2018 for additive manufacturing and data science innovation.

Michael Kirka, a materials scientist at Oak Ridge National Laboratory, said that in this project, they used their core expertise in material processing to provide targeted solutions to the demanding requirements of nuclear energy applications.

Considering the extreme environment required to manufacture parts with strong materials, the manufacture of refractory materials, such as molybdenum is extremely difficult. The team used the facilities of the Oak Ridge National Laboratory to be able to design complex geometries that cannot be achieved with conventional technology. Today, the ability to produce materials that meet the requirements of the component level opens the door to the design of new advanced reactors, which may produce higher efficiency at a lower cost.

Joe Miller, president of BWX, said that the case shows that the cost-share program can bring huge benefits to the nuclear industry. The project uses BWX's expertise in design, data science, advanced manufacturing. The laboratory’s facilities and field experts have realized an unprecedented manufacturing process in the field of high-temperature materials.

Framatome will continue to develop 3D printing technology for the production of irradiation targets and other uranium and molybdenum components such as fuel plates for research reactors. BWX's latest technology is expected to be commercialized, which will greatly reduce the overall development and manufacturing costs for fourth-generation advanced reactors.

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