Abstract
The following report focuses on utilizing directed energy deposition (DED) for constructing the Transformational Challenge Reactor core. Multiple additive manufacturing processes are under investigation to evaluate the advantages and viability of each process for direct manufacturing of complex structures needed for future nuclear reactors. Technologies under investigation include binder jet, laser powder bed (LPB) fusion, electron beam powder bed fusion, and DED. Each process has advantages and disadvantages. For the core design, the current manufacturing approach consists of integrating LPB with DED. This hybrid manufacturing approach uses LPB for the core’s top and bottom manifold (where complexity is high) and DED for the manufacture of the cladding, where complexity is still high but geometric variability, size, and speed are better suited for DED. Research has focused on processing parameter development, evaluation of toolpath generation algorithms, core designs suitable for DED, manufacturing tolerances for integration of fuel elements, and seamless calibration and integration of LPB components into a DED build volume to create monolithic structures based on integrating these technologies. The following report highlights reactor core design as it relates to DED and experimental validation of test components necessary for finalizing the core design.
