Innovative Manufacturing of Nuclear Components

Project summary

Rethinking nuclear component fabrication.

This DFA research proposal is a partnership between the University of Derby, Loughborough University and an industrial partner.

Conventional manufacturing of nuclear components relies extensively on forgings, with individual parts welded together followed by subtractive finishing processes. The research seeks to innovate nuclear manufacturing by streamlining these conventional methods.

Additive manufacturing of critical components can integrate numerous parts that would otherwise require extensive welding, replace a forging that requires expensive tooling, and achieve near net shape, reducing subtractive machining. A further dividend is the functional integration of sensory devices within the manufacturing process, enabling health condition monitoring of the asset during service.

Aims and objectives

The proposed EngD aims to develop a protocol for evaluating and evidencing that a new material and fabrication method, using additive manufacturing, meets all the sector regulatory requirements, and to apply the protocol to demonstrate regulatory compliance for selected cases.

Research objectives:

• Select case study components for design appraisals.
• Augment current practice by applying uncertainty methods with risk quantification.
• Conduct evaluations of additively manufactured components, comparing simulation and experiment with risk quantification.
• Evaluate the integration of sensors in additively manufactured components.
• Define and use a new material model and design protocol to demonstrate regulatory compliance.

Alignment to STAND-UP impact targets