Materials Engineering for the next Nuclear Generation
Stephen J Garwood
Director Engineering & Technology
Rolls-Royce, Submarines
©2008 Rolls-Royce Group plc�The information in this document is the property of Rolls-Royce Group plc and may not be copied or communicated to a third party, or used for any purpose other than that for which it is supplied without the express written consent of Rolls-Royce Group plc.
This information is given in good faith based upon the latest information available to Rolls-Royce Group plc, no warranty or representation is given concerning such information, which must not be taken as establishing any contractual or other commitment binding upon Rolls-Royce Group plc or any of its subsidiary or associated companies.
Title - Arial 28pt
Rolls-Royce data – strictly private
Disclaimer!
Filename
2
Rolls-Royce data – strictly private
Outline
Filename
3
Rolls-Royce data – strictly private
Filename
4
(On the Threshold of a Dream)
Or are we!
Rolls-Royce data – strictly private
Days of Future Passed - Timeline
Filename
5
Rolls-Royce data – strictly private
Filename
6
The Queen opened Calder Hall in October 1956
The Queen has opened the world's first full-scale nuclear power station, at Calder Hall in Cumberland.
A crowd of several thousand people gathered to watch the opening ceremony, which was also attended by scientists and statesmen from almost 40 different countries.
The Lord Privy Seal, Richard Butler, described the event as "epoch-making".
He added, "It may be that after 1965 every new power station being built will be an atomic power station."
Rolls-Royce data – strictly private
UK’s Nuclear Power Stations 1980��R W Nichols�26th Hatfield Lecture�1975� ‘Steels contribution to Nuclear Power - Its Problems & Promise’��(Willoughby & Garwood - Metal Construction�Oct 1980)
Filename
1980 Reactor Systems
Filename
8
Rolls-Royce data – strictly private
Filename
Historical perspective
Filename
10
Admiral Hyman G Rickover USN
“Father of the nuclear navy”
1900 – 1986
SSN 571 USS Nautilus
Rolls-Royce data – strictly private
Rickover on Rolls-Royce….
Filename
11
“I formed a very good impression of the Rolls-Royce team; the leading men in it are competent and imaginative and, in my view, are capable of doing a first class job.”
Rolls-Royce data – strictly private
Filename
12
RR Nuclear Engineering
Rolls-Royce data – strictly private
Filename
13
Operational support
The Rolls-Royce submarines business provides full range nuclear services to the UK Navy
●
●
●
●
●
Waterfront support
Prototyping of RN reactor plants
Faslane
Vulcan
Build yard - Astute
HPV, NMS
Core Manufacture
Submarines HQ
Submarines 2007
Turnover: £265m
People: 1738
Plymouth
Derby
Barrow
●
Bristol - JET
Rolls-Royce data – strictly private
Rolls-Royce on Raynesway
Filename
14
Rolls-Royce data – strictly private
Vulcan Naval Reactor Test Establishment�at Dounreay
Filename
15
Rolls-Royce data – strictly private
Reactor core development
Filename
16
0
B
Z
G
H
Normalised to S5W
Core type
Key:
Power
Lifetime
2
4
6
8
A(S5W)
Rolls-Royce data – strictly private
History of Submarine Build Programmes
Filename
Burdekin & Capability Study
Burdekin Review (2003)
Filename
Nuclear Propulsion Capability Study
Periodic Safety & Availability Review
Nuclear Propulsion Critical Technology
Next Generation Nuclear Propulsion Plant
The Present
Material Factors influencing Reactor performance
PWR Reactor Pressure Vessel steels
Structural Integrity Assessment
Filename
19
Rolls-Royce data – strictly private
Royal Navy nuclear submarine fleet
Filename
20
D
D
HMS Valiant
Valiant class
HMS Warspite
Resolution class
D
HMS Dreadnought
Dreadnought class
D
D
HMS Churchill
Churchill class
HMS Conqueror
D
HMS Courageous
D
D
HMS Resolution
HMS Renown
D
HMS Repulse
D
HMS Revenge
Trafalgar class
Astute class
D
HMS Swiftsure
Swiftsure class
HMS Vanguard
Vanguard class
HMS Victorious
HMS Vigilant
B
B
Astute
Artful
B
Ambush
B
Audacious
HMS Sovereign
HMS Superb
HMS Sceptre
HMS Spartan
HMS Splendid
HMS Trafalgar
HMS Turbulent
HMS Tireless
HMS Torbay
HMS Trenchant
HMS Talent
HMS Triumph
HMS Vengeance
D
B
Decommissioned
In-build
D
D
D
Rolls-Royce data – strictly private
Trafalgar class – Reactor Compartment
Filename
21
Rolls-Royce data – strictly private
Submarine - Nuclear Propulsion Plant
Filename
22
Reactor Compartment
Reactor
Compartment
Reactor
Core
Pressuriser
Steam Generator
Decay Heat
Removal Tank
Ion
Exchange Column
MUD Vessel
Primary Shield
Tank
Turbo Generator (AC)
Main Turbine
Gearbox
Condenser
Main
Feed Pump
Diesel Tank
Auxiliary
Power
AC & DC
Surge Tank
Main
Coolant Pump
Reactor
Compartment
Rolls-Royce data – strictly private
Factors influencing reactor materials performance
Filename
23
material
loading
environment
composition
mechanical working
welding
thermal treatments
microstructure
defects
pressure
residual stress
thermal
structural
temperature
water chemistry
electrochemical potential
pH; cleanliness
radiation
corrosion
radiation hardening
fatigue
fracture
plastic deformation
embrittlement
radiation creep
environmentally assisted cracking
Rolls-Royce data – strictly private
Nuclear fission
Filename
24
Fission of U235 is caused by low energy “slow” neutrons. When fission occurs, fast neutrons are produced.
Fast neutrons are either converted to slow neutrons by collisions within the moderator (water) or are absorbed by surrounding materials where they cause radiation damage.
Rolls-Royce data – strictly private
Displacement cascade
Filename
25
Rolls-Royce data – strictly private
Primary circuit materials
Filename
26
ferritic steels
austenitic stainless steels
martensitic stainless steels
cobalt alloys (Stellite)
nickel-copper alloys
zirconium alloys
nickel alloys
Rolls-Royce data – strictly private
Materials performance in PWRs -��(Ted Darby RR Fellows Lecture – Materials Performance in Pressurised Water Reactors)
Filename
27
Rolls-Royce data – strictly private
Factors affecting stainless steel component integrity
Filename
28
material
loading
environment
composition
thermal treatments
welding process
microstructure
cold work
residual stress
thermal
structural
strain rate
temperature
water chemistry
electrochemical potential
flow rate
radiation
corrosion
thermal ageing
sensitisation
fatigue
fracture
plastic deformation
environmentally assisted cracking
Rolls-Royce data – strictly private
Cracking in welded seal sample
Filename
29
IGSCC
TGSCC in weld HAZ
Rolls-Royce data – strictly private
Intergranular Stress Corrosion Cracking
Filename
30
Rolls-Royce data – strictly private
Sensitisation - Cr depletion at grain boundary
Filename
31
Rolls-Royce data – strictly private
IGSCC mechanism
Filename
32
Rolls-Royce data – strictly private
EAC mechanism understanding – crack tip studies
Filename
33
IGSCC in non-sensitised materials and “special” grain boundaries…
Rolls-Royce data – strictly private
PWR fuel assembly
Filename
34
ABB 17x17 PWR fuel assembly picture courtesy of ABB Atom AB
Alloy 625 (Ni-base) �Zry-4
Stainless Steel Type 304L
Zry-4 (low Sn), SRA�Zirlo
Duplex
M5
UO2,Gd2O3
He
Zry-4 (low Sn)
Zry-4 (low Sn), RXA
Inconel X-718 (Ni-base)
fuel rod bowing
Rolls-Royce data – strictly private
Zr performance: corrosion and hydriding
Zr + 2H2O ZrO2 + 4H
Filename
35
centreline
cladding
oxide
water flow
Fuel Pellet
gap
fuel rod temperature profile
Rolls-Royce data – strictly private
Zircaloy corrosion mechanism
Filename
36
Rolls-Royce data – strictly private
Zircaloy-4 corrosion & SPP dissolution�
Filename
37
(Garzarolli, ASTM STP 1423)
Rolls-Royce data – strictly private
Hydride blister in fuel cladding
Filename
38
Ref. A. M. Garde, G. P. Smith, and R. C. Pirek, “Effects of Hydride Precipitate Localization and Neutron Fluence
on the Ductility of Irradiated Zr-4”, ASTM STP 1295, 1996.
Rolls-Royce data – strictly private
DHC mechanism in zirconium alloys
Filename
39
Rolls-Royce data – strictly private
DHC initiated at notch in irradiated Zircaloy-2
Filename
40
grain boundary
Rolls-Royce data – strictly private
DHC threshold and crack growth rate
Filename
41
KIH
1cm/day
Rolls-Royce data – strictly private
Hydrogen solubility in irradiated Zircaloy
Filename
42
80
70
60
50
40
30
20
10
0
100
125
150
175
200
225
250
275
300
325
350
Temperature oC
Hydrogen concentration (ppm)
Tssp
Tssd
hydride dissolution
hydride precipitation
Rolls-Royce data – strictly private
DHC mechanism and critical temperatures
Filename
43
TMIN
Temperature
DHC growth
rate
TDAT
TRIT
TMAX
Hydrogen diffusion
to crack tip
Hydride
precipitation
Hydride
fracture
Over-temperature
Rolls-Royce data – strictly private
CANDU reactor fuel channel
Filename
44
Rolls-Royce data – strictly private
DHC in CANDU pressure tubes
Filename
45
Rolls-Royce data – strictly private
Catastrophic failure of cylindrical pressure vessel
Filename
46
Rolls-Royce data – strictly private
MV Kurdistan�April 1979
Filename
47
Rolls-Royce data – strictly private
Filename
48
Rolls-Royce data – strictly private
Fracture Mechanics Concepts
Filename
49
Rolls-Royce data – strictly private
Fracture Mechanics Concepts
Filename
50
J F Knott
Hatfield Lecture
“Quantifying The Quality of Steel”
Rolls-Royce data – strictly private
K I Reference Curve
Filename
51
Rolls-Royce data – strictly private
Master Curve
Filename
52
Rolls-Royce data – strictly private
Failure Probability
Filename
53
Rolls-Royce data – strictly private
Reactor pressure vessel
Filename
54
Rolls-Royce data – strictly private
RPV steel – �corrosion� fatigue
Filename
55
Rolls-Royce data – strictly private
Ductile – brittle transition in ferritic steels
Filename
56
Temperature
Ductile / Brittle Transition
Stress
Impact Energy
Yield Strength
Fracture Strength
Upper Shelf�(Ductile)
Lower Shelf�(Brittle)
Temperature
DBTT – irradiation shift
irradiation hardening
Rolls-Royce data – strictly private
Reactor Pressure Vessel
Filename
57
OUST
ALARP
IOF
TAGSI
Rolls-Royce data – strictly private
Failure Analysis Diagram
Filename
58
Rolls-Royce data – strictly private
TWI - Biaxial Wide Plate�A533B
Filename
59
Rolls-Royce data – strictly private
Filename
60
TWI Biaxial Test A533B
Rolls-Royce data – strictly private
Biaxial & Uniaxial Wide Plates�A533B
Filename
61
Rolls-Royce data – strictly private
Filename
62
Rolls-Royce data – strictly private
Ductile-Brittle�Transition Curve��A533B��Effect of Constraint
Filename
63
Rolls-Royce data – strictly private
Factors affecting Actual to Predicted Fracture Behaviour
Filename
64
Rolls-Royce data – strictly private
Big Bang video
Filename
65
Rolls-Royce data – strictly private
Irradiation damage mechanism in steels
Filename
66
Irradiation shift results from hardening due to both matrix damage and solute, e.g. copper precipitation.
In addition, phosphorus segregation to grain boundaries can cause further embrittlement.
Rolls-Royce data – strictly private
Fracture mechanisms and mechanics
Filename
67
Rolls-Royce data – strictly private
3D Atom Probe data for RPV steel aged at 365˚C
Filename
68
10nm
1.5 at.% Ni
0.3 at.% Ni
Before ageing 100hrs 1000hrs 3000hrs 10000hrs
Rolls-Royce data – strictly private
3D Atom Probe analysis of RPV steel aged at 365˚C
Filename
69
Cu Ni Mn Si
5nm
Rolls-Royce data – strictly private
Cu precipitates in RPV steel
Filename
70
5nm
P1
P2
P3
C
C
Sn
Rolls-Royce data – strictly private
Filename
71
Consequences
steam line
brittle fracture boundary
irradiation shift
coolant pressure (bar)
coolant temperature (oc)
“Boot diagram”
Rolls-Royce data – strictly private
Possible contribution by TJW to an SJG talk covering “Activities/issues on irradiation embrittlement of RPV materials and how industry will solve these in the future, base materials and welds” (SJG email 28/09/08).��Draft 2 10/10/08
©2008 Rolls-Royce Group plc�The information in this document is the property of Rolls-Royce Group plc and may not be copied or communicated to a third party, or used for any purpose other than that for which it is supplied without the express written consent of Rolls-Royce Group plc.
This information is given in good faith based upon the latest information available to Rolls-Royce Group plc, no warranty or representation is given concerning such information, which must not be taken as establishing any contractual or other commitment binding upon Rolls-Royce Group plc or any of its subsidiary or associated companies.
Title - Arial 28pt
Rolls-Royce data – strictly private
Current issues (1)
Filename
73
Rolls-Royce data – strictly private
Current Issues (2)
Filename
74
Rolls-Royce data – strictly private
Current issues (3)
Filename
75
Rolls-Royce data – strictly private
Potential solutions (1)
Filename
76
Rolls-Royce data – strictly private
Potential solutions (2)
Filename
77
Rolls-Royce data – strictly private
Potential solutions (3)
Filename
78
Rolls-Royce data – strictly private
Potential solutions (4)
Filename
79
Rolls-Royce data – strictly private
Ductile – brittle transition in ferritic steels
Filename
Temperature
Ductile / Brittle Transition
Stress
Impact Energy
Yield Strength
Fracture Strength
Upper Shelf�(Ductile)
Lower Shelf�(Brittle)
Temperature
DBTT – irradiation shift
irradiation hardening
Irradiation shift – fracture toughness
Filename
shift
Irradiation damage mechanism in steels
Filename
Irradiation shift results from hardening due to both matrix damage and solute, e.g. copper precipitation.
In addition, phosphorus segregation to grain boundaries can cause further embrittlement.
Model of a displacement cascade ca 2002
Filename
With thanks to Brian Wirth, University of California, Berkeley
Solute atom
(e.g., Cr, Cu,
Mn, Ni)
Self-interstitial
Atom (SIA)
Vacancy
Filename
Low Nickel Weld
0.073at% Ni
~ 0.5at% Cu
High Nickel Weld
1.58at% Ni
~ 0.5at% Cu
Irradiated to 33 mdpa
Irradiated to 30 mdpa
Atom Probe Data
3DAP micrograph
Filename
In addition to Cu, clusters also contain a large proportion of Mn and Ni, some Si, occasionally P. They may also contain up to 50% Fe (disputed). Mn and Ni tend to be segregated to the interface.
J.M. Hyde, and C.A. English, “An Analysis of the Structure of Irradiation induced Cu-enriched Clusters in Low and High Nickel Welds.” Materials Research Society Symposium: Microstructural Processes in Irradiated Materials, MRS Proceedings vol. 650 (2001), paper R6.6
Filename
Data from Mike Miller using the LEAP (IGRDM-12)
Simulated microstructure after irradiation
Filename
With thanks to Stéphanie Jumel, EDF, France
End of life microstructure for a weld with 0.3% Cu
Vacancy
SIA
Cu
Mn
Ni
Box 29x29x29 nm
The Present
Filename
Filename
Filename
Sheffield Forgemasters
The Future - On The Threshold of a Dream
Filename
What the papers say!
Filename
UK’s Nuclear Power Stations�2008
Filename
Filename
Filename
Next Generation in the UK
Filename
I Want That One!
Filename
UK vs Rest of World
Filename
Filename
Design – Future Concepts
Filename
PILM - CADMID
Filename
‘Cradle to Graveside’
A533BclassI A508classIII HY80
Filename
Filename
Submarines Engineering Population - 2008
Filename
Skill
Graduate
Engineers -
Submarines
Applied Science
13
Controls
97
Design
150
Electrical
22
Materials
47
Mechanical
40
Nuclear
25
Product Definition
25
Safety & Reliability
68
Service
118
Support
28
Thermo Fluids
81
Test
28
Total
850
Age groups
The Elements of SQEP Resource
Filename
Engineering Competency Assessment
Nuclear Training Requirements Plan
Suitably Qualified and Experienced Personnel (SQEP)
Local Management Assessment
Nuclear Training Committee
Training Management Process Coordinates:
Career Structure Boardings
Filename
University Technology Centres & Liaison Teams
Solid Mechanics
Oxford
Vibration
Imperial College
Combustion Aerodynamics
Loughborough
University Gas Turbine Partnership (UGTP)
Cambridge (Whittle lab)
Performance
Cranfield
Materials Partnership
Cambridge, Birmingham & Swansea
Heat Transfer and Aerodynamics
Oxford (Osney lab)
Control & Systems Engineering
Sheffield
Aero-thermal Systems
Sussex
Advanced Electrical Networks
Strathclyde
Gas Turbine Transmission Systems
Nottingham
Systems & Software Engineering
York
Materials Damping Technology
Sheffield
Design Partnership (with BAE)
Cambridge, Sheffield & Southampton
Computational Fluid Dynamics
Oxford
Noise
Southampton
Manufacturing Technology
Nottingham
Thermo-fluid Systems
Surrey
RR Submarines University Links
Manchester, Newcastle, Cambridge, Imperial, Bristol, Leeds, Nottingham, Loughborough, Oxford,
Birmingham, Sheffield.
Filename
A Nuclear Future
Filename
Filename
1956: Queen switches on nuclear power
This new power, which has proved itself to be such a terrifying weapon of destruction, is harnessed for the first time for the common good of our community. �
The Queen�
Sir Edwin Plowden, chairman of the Atomic Energy Authority, also stressed the ground-breaking nature of the new power station.
"Nothing that comes after will be able to detract from the importance of this first great step forward," he said.
Her Majesty the Queen gave her speech in the shadow of the massive chimneys of the Windscale plant, where explosives were made for Britain's first atomic bomb, and she gave a timely reminder of the more sinister origins of the technology.
"This new power, which has proved itself to be such a terrifying weapon of destruction," she said, "is harnessed for the first time for the common good of our community."
At 1216 GMT, she pulled the lever which would direct electricity from the power station into the National Grid for the first time.
A large clock on the wall of the power station registered the first kilowatts of energy to be produced.
The town of Workington, 15 miles (24 km) up the Cumberland coast from Calder Hall, became the first town in the world to receive light, heat and power from nuclear energy.
Within four hours, the first nuclear-powered electricity was reaching London.
The government expects to save about 40 million tons of coal by investing in the new technology, and it is planning to supply about 10% of the country's electricity needs from nuclear power within less than 10 years.
Calder Hall is known as a gas-cooled, graphite-moderated reactor, and uses the nuclear reaction in uranium rods to generate power.
Two other nuclear power stations are already under construction - one alongside the existing Calder Hall plant, to be known as Calder Hall B, and the other at Chapel Cross in Scotland.
A huge clock registered the first power to be transferred to the National Grid�
xxx
Filename
xxx
Filename
Key points
Filename
Going out with a bang!
Filename
To understand how safe a component is one needs to know its actual failure conditions!
Filename