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Reinforcing the exit hole from friction stir welding and processing
After friction stir welding/processing (FSW/P), an exit hole remains at the end of the run, which can be the weakest region of the welded/processed workpiece. In addition, tensile residual stress around the exit hole resulting from heating during FSW/P facilitates incipient crack initiating from the exit hole under external loading. Current solutions include removing or repairing the exit hole, which are time-consuming and costly. Here, we propose a novel method to reinforce the exit hole by applying an additional FSW/P pass around it, in a way that replaces preexisting tensile residual stress with compressive residual stress. Under external loading, there is no evident strain accumulation around the exit hole, and the workpiece ultimately fails along the FSW/P heat affected zone. This method provides a more convenient way to reinforce the exit hole than the current exit-hole repair or removal methods for industrial applications.
Measuring of plasma properties induced by non-vacuum electron beam welding
Electron beam plasma measurement was realised by means of DIABEAM system invented by ISF RWTH Aachen. The Langmuir probe method is used for measurement. The relative simplicity of the method and the possibility of dispersion of high power on the probe allow its application for the investigation of high-power electron beams. The key element of the method is a rotating thin tungsten wire, which intersects the beam transversely on its axis and collects part of the current by itself. The signals, which are registered in the DIABEAM as a voltage, were taken in the form of amplitude. The conversion of the probe current into the distribution along the beam radius was realised using the Abel's method. A voltage-current characteristic was built for the beam current. The local electron density as well as the electron temperature, the floating potential and the plasma potential were measured and calculated by means of this characteristic.
RESULTS OF A VIRTUAL ROUND ROBIN STUDY TO ESTIMATE PROBABILITY OF DETECTION FOR DISSIMILAR METAL WELDS
This paper presents efforts to overcome challenges with empirical probability of detection (POD) estimations in the nuclear power industry through the utilization of a novel virtual flaw method. A virtual round robin (VRR) study was conducted under the Program for Investigation Of NDE by International Collaboration (PIONIC), organized by the United States Nuclear Regulatory Commission (NRC) utilizing data generated by the virtual flaw method. Analysis of results from the VRR was performed by teams from Pacific Northwest National Laboratory (PNNL), Electric Power Research Institute (EPRI), and Aalto University. Empirically derived POD estimations are presented, and challenges associated with obtaining these estimations are discussed. The virtual flaw method is introduced and some details of its implementation for the VRR activity are described. Results from POD analysis of the VRR data by PNNL, EPRI, and Aalto University are presented and a discussion regarding differences in analysis results is provided. Finally, potential future efforts to improve the application of the virtual flaw method and its estimation of POD are discussed.
Final Report: Characterization of Canister Mockup Weld Residual Stresses
Stress corrosion cracking (SCC) of interim storage containers has been indicated as a high priority data gap by the Department of Energy (DOE) (Hanson et al., 2012), the Electric Power Research Institute (EPRI, 2011), the Nuclear Waste Technical Review Board (NWTRB, 2010a), and the Nuclear Regulatory Commission (NRC, 2012a, 2012b). Uncertainties exist in terms of the environmental conditions that prevail on the surface of the storage containers, the stress state within the container walls associated both with weldments as well as within the base metal itself, and the electrochemical properties of the storage containers themselves. The goal of the work described in this document is to determine the stress states that exists at various locations within a typical storage canister by evaluating the properties of a full-diameter cylindrical mockup of an interim storage canister. This mockup has been produced using the same manufacturing procedures as the majority of the fielded spent nuclear fuel interim storage canisters. This document describes the design and procurement of the mockup and the characterization of the stress state associated with various portions of the container. It also describes the cutting of the mockup into sections for further analyses, and a discussion of the potential impact of the results from the stress characterization effort.
Second Annual Progress Report on Radiation Tolerance of Controlled Fusion Welds in High Temperature Oxidation Resistant FeCrAl Alloys
The present report summarizes and discusses the current results and on-going activity towards developing a modern, nuclear grade FeCrAl alloy designed to have enhanced radiation tolerance and weldability under the Department of Energy (DOE) Nuclear Energy Enabling Technologies (NEET) program.
Quarterly Management Document – FY17, 4th Quarter, Physics-based Creep Simulations of Thick Section Welds in High Temperature and Pressure Applications
During the 4th quarter of FY17 modeling and simulation development of creep in nickel-based alloys was continued with a focus on incorporation of simulated alloy microstructures into the creep model. Additionally, the model was calibrated with experimental creep data from Alloy 617. Experimental data collection also continued with creep tests, stress drop tests and characterization of alloy microstructures.
A System-Level Framework For Fatigue Life Prediction of PWR Pressurizer-Surge-Line Nozzle under Design-Basis Loading Cycles. A complete tensile test based material properties database and preliminary results on 3D weld process modeling, thermal-mechanical stress analysis and environmental fatigue testing
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Quarterly Management Document – FY20, 1st Quarter, Multi-pass Hybrid Laser Arc Welding of Alloy 740H
During the first quarter of FY20, work focused on implementing a subcontract with Penn State University to collaborate on the project. Significant delays prevented the subcontract from being placed until the end of December. As a result only limited progress was made on the project. Required equipment was researched and ordered during the first quarter but will not be delivered until the middle of the second quarter of FY20. Delays are not expected to adversely impact the schedule of the project.
Quarterly Management Document – FY20, 2nd Quarter, Physics-based Creep Simulations of Thick Section Welds in High Temperature and Pressure Applications
During the 2nd quarter of FY20, calibration of the creep model was made using experimental creep data on base metal at temperatures between 700-800 C. The model simulated primary and secondary creep behavior at these temperatures but tended to over estimate creep strain in the tertiary regime at 700 C while underestimating it at higher temperatures. Additional issues were also discovered and will be looked at in greater detail in the 3rd quarter of FY20.
Modeling and Simulation of Austenitic Welds and Coarse-grained Specimens: Part II
The Pacific Northwest National Laboratory (PNNL) is conducting confirmatory research for the U.S. Nuclear Regulatory Commission (NRC) to evaluate commercially available nondestructive examination (NDE) modeling and simulation software used in the nuclear industry. Simulation results from ultrasonic testing (UT) models can inform the design and qualification of inspection techniques and help interpret inspection results. CIVA is a modeling and simulation package developed by the French Alternative Energies and Atomic Energy Commission (CEA). CIVA was selected for this study because it is readily available and has been used for NDE in the US commercial nuclear power industry. This report is focused on completing the efforts initiated in the previous PNNL report to evaluate UT modeling and simulation performance, reliability, and accuracy in relation to common inservice inspection (ISI) scenarios in nuclear power plants (NPP). This work will be used to provide guidance when establishing methods to perform and evaluate simulations for more standardized model implementation, simulation analysis, and interpretation of results.
2023 SRNL Aging and Lifetimes Report: Tritium Aging of Welded and Additively Manufactured Austenitic Stainless Steels
This report documents work performed in fiscal year 2023 at Savannah River National Laboratory (SRNL) collaborating with Sandia National Laboratories in support of the Aging and Lifetimes program. This work supports Gas Transfer Systems (GTS) design by measuring the mechanical behavior of structural materials used in GTS. Data on properties in relevant conditions are crucial for GTS lifetime assessments and predictions. To simulate relevant conditions, SRNL, in concert with the Savannah River Site, thermally pre-charges test specimens with tritium and stores them at -80°C to allow the tritium decay product, helium-3, to build up while limiting tritium diffusion. According to test plans based on how much helium-3 has accumulated, specimens are removed from storage and tested. Results from mechanical testing provide an empirical basis for GTS design as well as insight to how these structural materials degrade in a tritium environment.
Non-Intrusive Load Monitoring Of Welding Processes [Slides]
Abstract not provided.
Improving the Deformation of Welded Pipe for Pipelines
The probability of cracks and fractures in pipe expansion is studied. A means of decreasing defect frequency in the deformation of pipe for major pipelines is proposed.
Friction-Stir-Weld Connectors for Cables and Conductors Phase 1 Final Technical Report
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