In the aerospace field, 3D printing technology has been proven to be reliable and feasible for printing flame resistant plastic parts, metal structural components of aircraft isolation cabins, and functional components such as fuel injectors. What about the nuclear industry, which, like the aerospace industry, requires high-quality and high-strength components?
In fact, 3D printing technology has already been applied to the nuclear industry: the Sellafield nuclear reactor site in the UK uses 3D scanning and 3D printing technology to manufacture low-level radioactive waste containers for moving nuclear reaction waste; The Raja Ramanna Center for Advanced Technology of the Indian Ministry of Atomic Energy uses a laser direct manufacturing system to produce nuclear reactor prototypes; China’s CNNC North Nuclear Fuel Element Co., Ltd. prints fuel elements using selective laser melting technology; The use of arc welding additive manufacturing technology to produce high-performance components in UK nuclear power plants demonstrates the undeniable potential of 3D printing technology in the nuclear industry.
In recent years, the adoption rate of 3D printing has significantly increased in the development of new generation fusion reactors. Below is a detailed introduction to the various applications of 3D printing in the nuclear industry:
1、 Manufacturing and replacement of components
In the nuclear industry, additive manufacturing plays a crucial role in the production of complex components and prototypes. It can quickly manufacture complex designs, shorten delivery time, and reduce costs. 3D printing technology can also manufacture specialized parts with higher durability and precision, which is crucial for ensuring the safety and reliability of nuclear power plants. For example, the SLM series equipment BLT-S300 independently developed by Xi’an Bolite is a 3D printed CAP1400 prototype fuel assembly lower tube seat for China North Nuclear Fuel Element Co., Ltd. ; Chinese researchers are also using powder bed melting 3D printing technology to manufacture steel fusion reactor cladding components.
In addition, when the original component production molds are no longer available, or when remanufacturing is difficult and costly, 3D printing can be reverse engineered based on existing components to quickly manufacture suitable replacement parts, extend the service life of equipment, and enable old power plants to continue operating.
2、 Develop radiation resistant materials and tools
Special anti radiation materials and tools are required for maintenance and repair work in the radioactive environment of the nuclear industry. 3D printing can use radiation resistant materials to manufacture radiation resistant protective gloves, tool handles, detection equipment, etc. for maintenance and repair in radioactive environments, providing safety guarantees for workers and improving the efficiency of maintenance and repair work.
3、 Research and Design Verification
In the research and development process of the nuclear industry, rapid prototyping is crucial for verifying design solutions. 3D printing can quickly produce small models of nuclear facilities for studying their internal structure, fluid flow, thermal conductivity, and other characteristics. This helps R&D personnel to promptly identify design issues and optimize them, thereby shortening the R&D cycle and reducing R&D costs.
For example, small models of nuclear reactors with different materials and structures can be manufactured through 3D printing to study their internal structure, fluid flow, thermal conductivity, and other characteristics, as well as the performance changes of related materials in special environments such as radiation, high temperature, and high pressure, providing reference for the design of actual nuclear reactors. This also helps to develop new materials that are more suitable for nuclear industry applications, improving the safety and reliability of nuclear facilities. For example, some researchers in China are seeking to use composition optimized ceramic slurries through 3D printing technology to optimize the core tritium production equipment of nuclear fusion reactors.
4、 Optimize the performance of nuclear reactors
If the engine is the “heart” of an airplane, then a nuclear reactor can be called the “heart” of a nuclear power plant, so its performance and safety are key to the development of the nuclear industry. Through 3D printing, components with special internal structures can be manufactured to improve the thermal efficiency of nuclear reactors, while reducing local hotspots and stress concentration, and lowering potential safety risks. For example, recently, Westinghouse Electric Company in the United States used 3D printed filter nozzle components to significantly increase the debris barrier efficiency from 65% to 96%, improving the safety and efficiency of nuclear reactor operation and enhancing the efficiency of nuclear fuel recovery.
5、 Nuclear fuel production and optimization
Through 3D printing technology, new fuel component designs and manufacturing of nuclear fuel elements can be attempted to optimize the performance and reaction process of nuclear fuel, improve fuel utilization and combustion efficiency, and ultimately enhance the conversion efficiency of nuclear energy. For example, China’s CNNC North Nuclear Fuel Element Co., Ltd. prints fuel elements using selective laser melting technology.
Overall, 3D printing technology can manufacture components in the nuclear industry with complex structures and special materials. Research and development of different types of 3D printing technology applications in the nuclear energy field have become increasingly important for the development of the next generation of nuclear energy. However, the mature application of 3D printing in the nuclear industry is still limited, and the nuclear industry is still an overlooked field that should receive more attention. This is conducive to promoting the safe, efficient, and sustainable development of nuclear energy in the new era through 3D printing technology, including nuclear fission energy and even higher end nuclear fusion energy.
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