In a groundbreaking move, Westinghouse Electric Company has harnessed the power of additive manufacturing to create bottom nozzles for fuel assemblies, significantly boosting debris capture and fuel endurance. Delivered to Alabama Power’s Joseph M. Farley Nuclear Plant in early 2024, these 3D printed marvels have transformed debris resistance from a modest 65% to an impressive 96%.
Debris fretting—where debris wears on fuel rod cladding—is a leading cause of leaks in Pressurized Water Reactor (PWR) fuel assemblies. Enter 3D printing, with its unparalleled design flexibility, enabling the creation of nozzles that drastically reduce the diameter of debris entering the reactor. Tests have shown a remarkable 30% improvement in debris resistance with these new components.
"Over the past decade, Southern Nuclear has spearheaded industry advancements in fuel resiliency," remarked Pete Sena, President of Southern Nuclear. He underscored the critical role of the existing nuclear power fleet in America’s clean energy supply and highlighted how these innovations are set to deliver safer, more affordable, and more reliable carbon-free nuclear power for decades to come.
Westinghouse is no stranger to pioneering additive manufacturing in the nuclear sector. They conducted the first material irradiation study of AM components in 2015, installed the first safety-related AM component in 2020, and recently produced their 1,000th AM component for VVER-440 Fuel in 2024.
By continuously pushing the envelope in nuclear and clean power technologies, Westinghouse solidifies its status as a global leader in carbon-free energy solutions, driving the future of sustainable power with innovative precision.
Source: valvemagazine.com