NRC Technical Assessment of Powder Metallurgy—

Hot Isostatic Pressing

1. Introduction and Purpose

This document provides a U.S. Nuclear Regulatory Commission (NRC) technical assessment of
the process considerations and knowledge gaps related to the application of powder
metallurgy—hot isostatic pressing (PM-HIP) in the nuclear power industry. This assessment is
primarily based upon the technical information and gap analysis developed by Oak Ridge
National Laboratory (ORNL) in technical letter report (TLR) entitled “The Use of Powder
Metallurgy (PM) and Hot Isostatic Pressing (HIP) for Fabricating Components of Nuclear Power
Plants (NPPs),” (Agencywide Documents Access & Management System (ADAMS) Accession
No. ML22164A438) (hereafter referred to as the “ORNL TLR”). This assessment, combined with
the ORNL TLR, highlights key technical information related to the implementation of PM-HIP in
nuclear facilities and fulfills the deliverable for PM-HIP under Subtask 1A of the “Action Plan for
Advanced Manufacturing Technologies (AMTs), Revision 1,” dated June 23, 2020 (ADAMS
Accession No. ML19333B973).

2. NRC Identification and Assessment of Differences

This section describes the differences between PM-HIP and traditionally manufactured heavy
section large components, assesses the impact that the identified differences have on
component performance, and identifies specific technical considerations related to PM-HIP
components. The overall impact to plant safety (e.g., safety significance) of these identified
differences is a function of component performance and the specific component application
(e.g., its intended safety function). This report does not include impact on plant safety, as such
an assessment would not be possible without considering a specific component application.

The staff identified the differences between PM-HIP and traditional manufacturing processes by
reviewing the information and gap analysis rankings from the ORNL TLR, as well as other
relevant technical information (e.g., from NRC regulatory and research experience, technical
meetings and conferences, codes and standards activities, Electric Power Research Institute
and U.S. Department of Energy products and activities). The identified differences and their
significance originated either as important aspects or gaps of the PM-HIP process or component
performance as defined here:

 important aspect: part of the AMT fabrication process or component performance that
needs to be considered and carefully controlled during manufacturing

 gap: part of the AMT fabrication process or component performance that is not well
known or understood due to limited information and data

The results of this technical assessment are provided in two tables. Table 1 includes the powder
production and PM-HIP process considerations. Table 2 includes additional material-specific
considerations for producing PM-HIP components using American Society for Testing Materials
(ASTM) A508, “Standard Specification for Quenched and Tempered Vacuum-Treated Carbon
and Alloy Steel Forgings for Pressure Vessels,” Grade 3, Class 1 low-alloy steel (A508), which
is the alloy of primary interest from the nuclear industry for producing heavy section large
components. Components produced by PM-HIP using 316L stainless steel are generally smaller
in size and weight and have undergone an extensive development effort that has led to the
American Society of Mechanical Engineers (ASME) Boiler and Pressure Vessel Code (ASME
Code), Section III, “Rules for Construction of Nuclear Facility Components,” Division 1, Code
Case N-834, “ASTM A988/A988M-11 UNS S31603, Subsection NB, Class 1 Components
Section III, Division 1,” for Class 1 components. While Table 2 is based on the available
information in the open literature for A508-type low-alloy steels, the differences identified in
Table 2 involving material-specific properties and performance would likely need to be
considered for any new material to be fabricated using PM-HIP. In general, an important need
for any nuclear PM-HIP component is material-specific data for the proposed processing and
post-processing parameters to ensure adequate component performance in its environment,
including applicable properties (e.g., fracture toughness, tensile strength) and aging
mechanisms (e.g., thermal aging, irradiation effects, and stress corrosion cracking (SCC)).

The following columns in Tables 1 and 2 identify and provide technical information for the
PM-HIP process and component performance:

 Difference: Identification of corresponding gaps from Section 3.2 of the ORNL TLR.

 Definition: Brief description of the difference with the PM-HIP process.

 NRC Ranking of Significance: Discussion of two considerations:

o Importance: Impact on final component integrity considering the likelihood of

occurrence or magnitude of degradation in conjunction with the ease of detection
or ability to mitigate.
 A high ranking signifies that the difference has a significant impact on
component performance.

 A medium ranking signifies that the difference has a moderate impact on

component performance.

 A low ranking signifies that the difference has a minimal impact on

component performance.

o Knowledge/Manageability: Description of how well understood and

manageable the difference is.

 Key Technical Information: Technical information for the consideration of PM-HIP for
use in nuclear power plants.

Discussion of the corresponding ORNL gaps can be found in Section 3.2 of the ORNL TLR.

3. Codes and Standards

Section 3.3 of the ORNL TLR provides an overview of the ASME Code, including an analysis to
identify any gaps pertaining to using PM-HIP to fabricate heavy section, low-alloy-steel
components. For heavy section, low-alloy-steel components, there is a need to develop an
ASTM specification for PM-HIP low-alloy steel to use as a basis for an ASME Code, Section III,
Code Case and eventual inclusion in ASME Code, Section II, “Materials,” Part A, “Ferrous
Material Specifications,” and Part D, “Properties.” Key challenges include consistently
fabricating materials with sufficient starting and irradiated fracture toughness as described in
Tables 1 and 2.
 4. Summary and Conclusion

In Tables 1 and 2 of this report, the staff has identified and assessed the material-generic
differences for the PM-HIP process and component performance as well as the material-specific
differences for A508 low-alloy steel compared to conventional manufacturing. The staff has also
discussed gaps in existing codes and standards that should be addressed to support PM-HIP
use in nuclear applications, including the need to develop an ASTM specification and ASME
Code Case for PM-HIP of low-alloy steel to support eventual inclusion of this material in ASME
Section II.
 Table 1 Technical Information—PM-HIP Generic

Difference Definition NRC Ranking of Significance Key Technical Information

Metal powder Low  Producing metal powders by atomization is the preferred method
composition and since any composition can be produced accurately to
particle size The composition and particle specifications.
distribution covers size distribution of gas atomized – Depending on the reactivity of the metal powders, the proper
the production and metal powders must be carefully choice of atomization process must be considered since an
management of the controlled within specifications to increase in reactivity will potentially lead to an increase in
important physical ensure adequate properties and contamination of the metal powder.
characteristics of the
performance of the final product.  Optimal particle size should balance densification with the
powder before the However, commercial production likelihood of contamination.
Metal Powder build process. of gas atomized metal powders – Generally, smaller particle sizes help to achieve higher packing
Composition and is very mature and well density and greater densification after HIP but can also increase
Particle Size established. the likelihood of contamination due to their higher percentage of
Distribution1
surface area to volume.
 The particle size and size distribution characteristics of metal
powders are influenced by the atomization method and the
associated process parameters used in powder production.
 Sieving is an essential activity to effectively control the particle size
and size distribution.
– Sieving also ensures a proper size range for filling and packing
the inside of the steel can, which improves the densification and
microstructure of consolidated component after HIP.
This covers the Low  Inert gas atomization methods are superior to air and water
important atomization methods since the surface of the molten metal droplets
considerations of The method of melting the are protected by the inert gas atmosphere during solidification to
using gas elemental constituents of form powder with varying sizes with low oxygen content.
atomization for the stainless steels and low-alloy – Water atomization produces irregular-shaped particles with
commercial steels and the atomization higher oxygen levels compared to gas atomization.
Metal Powder production of high- environment can significantly  Gas atomization using primarily argon and nitrogen has emerged
Production by Gas quality metal powder affect the quality of the powder as the most popular method for producing high-quality powders
Atomization for manufacturing and resulting component that have spherical morphology and accurate and reproducible
PM-HIP components. properties and performance. compositions of a wide range of stainless steels, low-alloy steels,
However, these powder and nickel-based alloys.
production methods have been  Important gas atomization parameters that are optimized in order
studied carefully and are well to produce desirable particle size and size distribution include high
established. gas-to-metal ratio, melt superheat, and gas recirculation.
 Difference Definition NRC Ranking of Significance Key Technical Information

The can serves as Medium  ASTM PM-HIP specifications require that the can material be
the pressure vessel selected to ensure that it has no deleterious effect on the final
containing the metal Scaling up the fabrication of product.
powder and must steel cans from design  The materials used for fabricating the can must have high strength
form an impenetrable specifications for producing for dimensional stability and ductility for plastic deformation during
seal between the heavy section large components the dimensional reduction of the can to the fully dense product.
metal powder and by PM-HIP has been – The materials typically used for fabricating the can are stainless
pressurized gas successfully demonstrated in steel and low-carbon steels due to the combination of strength
during HIP. initial applications. Design and ductility properties.
Producing heavy models for predicting the volume  The wall thickness of the can is important to consider. The can
section large steel shrinkage of heavy section large must be thick enough not to crack or fail during the HIP process
requires fabricating steel cans have been but not too thick since a thick wall will resist plastic deformation
cans of successfully demonstrated to be compared to a thinner wall.
corresponding size. accurate with low or no  The steel can must also be weldable to ensure mechanical integrity
This covers the distortions. However, the design of the can during volumetric shrinkage associated with HIP.
important and fabrication of large cans is  The design and geometric dimensions of the component are
Design and considerations of dependent on component- important factors that need to be optimized for predicting the
Fabrication of designing and specific properties and volume shrinkage and minimizing post-HIP machining of the can
Heavy Section fabricating these characteristics (e.g., complexity from the product.
Large Steel Cans2 cans, including the of the component geometry). – For example, differences in the thickness of sections should be
use of modeling to considered in the design and fabrication of the cans as they will
predict the impact the densification of the can and powder due to uneven
densification of the cooling rates.
can and metal  For the complex can designs, models are required for predicting
powders during HIP the volumetric shrinkage.
to achieve the – This especially applies to very large can designs since less
dimensional experience and knowledge are available due to the limited
tolerances required number of large products that are typically produced by
for a component. PM-HIP.
 The accuracy of modeling to predict the volume shrinkage of the
large can will influence the can design, including selection of
material, complexity of the component geometry, and HIP
parameters.
 Large complex-shaped components will likely need a
demonstration run to verify the HIP procedure, including shrinkage
prediction and achievement of dimensional tolerances.
 Difference Definition NRC Ranking of Significance Key Technical Information

 Dimensions of the steel can may be intentionally oversized due to

uncertainties in precisely predicting the volume shrinkage of the
powder and deformation behavior of the steel can during HIP.
 Most models that have been developed are based on continuum
mechanics, such as micromechanical simulations and constitutive
relations, using the finite element method for calculating the
distributions of stress and density of the metal powder enclosed
can. These approaches consist of plasticity models to understand
the mechanical properties, such as yielding and hardening of the
metal powder during compaction and continuum models for
predicting the effects of sintering on changes in grain size,
densification, and plastic deformation of the metal powders.
This covers the High  Proper degassing conditions must be used for successful
important desorption of all adsorb molecules associated with contamination.
considerations Improper filling, degassing, and – Degassing effectiveness is influenced by the combination of the
related to the process vacuum annealing can cause vacuum pump properties (pressure, flow rate, etc.) and the
for filling, degassing, contamination of the metal design and placement of the degassing ports and lines
and vacuum powder and can adversely affect connecting to the pump.
annealing of metal densification. This can have a – The temperature during degassing is an important consideration
powders before HIP. significant impact on final to prevent contaminant gases from forming stronger bonds
product performance. There is (e.g., oxides and nitrides) with the metal powder particles.
Filling, Degassing,
limited industry experience with – Air is the most common contributor to contamination of metal
and Vacuum
properly filling large cans for powder.
Annealing of Metal
PM-HIP, especially for  Improper filling may result in non-uniform packing of stainless steel
Powders3
components with complex and low-alloy-steel powders, particularly in large, complex-shaped
shapes. Also, vacuum steel cans.
degassing has not been – This may result in different local tap densities of the powder
effectively demonstrated on the inside and cause non-uniform consolidation and local density
large cans needed for heavy variations of the HIP component. These issues may
section PM-HIP components, subsequently impact component properties and performance.
and degassing will be more  Scaling up the HIP process to larger components makes degassing
challenging as the component more challenging due to the greater volume of gas to remove.
size increases.
 Difference Definition NRC Ranking of Significance Key Technical Information

This covers the Medium  Understanding and optimizing HIP process parameters (e.g., time,
important temperature, pressure) is important for producing components with
considerations Improper HIP parameters may the required microstructure and mechanical properties. For
regarding the HIP affect the densification and example, the HIP process parameters should be optimized to
process parameters microstructure and can impact reduce and eliminate pores to achieve high theoretical density of
that are used mechanical properties of the the metal.
specifically to large component. Although  Non-uniform densification can occur, depending on the HIP
manufacture heavy optimized HIP parameters have parameters for applied pressure, temperature, heating rate, and
section large been developed for various component size. Rapid heating rate combined with large
HIP Parameters for components. other applications, optimization component sizes can cause preferential densification of the metal
Heavy Section for producing heavy section powder, especially near the surface of the can, which can result in
Large Components large components has not been distortions.
consistently demonstrated.  For cans with complex geometries, differences in the thickness of
Post-HIP heat treatment can sections will enhance the distortions due to uneven cooling rates
help obtain the required caused by gas flow disturbances on the surface of the component.
microstructure and properties. – Reducing the cooling rate can reduce the temperature
differences but will add time to the cooling cycle and may affect
the resulting mechanical properties.
 Proper HIP parameters combined with rapid cooling rates through
the use of argon cooling systems can eliminate the need for post-
process heat treatment.
Witness specimens High  The use of witness specimens and protrusions may be the only
and protrusions practical method to measure the density of heavy section large
are test specimens Protrusions and witness components.
that are fabricated specimens can be used to  Material for conducting microstructure, mechanical properties, and
concurrently with measure the density and corrosion tests can be machined directly from a separately
end-use mechanical properties of heavy produced witness specimen or from a protrusion on the
components and section large components to component(s) that have undergone HIP.
Witness Specimens used to provide demonstrate process control.  Use of witness specimens and protrusions should demonstrate that
and Protrusions confirmation of However, it has not been they are representative of the component’s performance.
build quality and demonstrated that protrusions or – Dimension and size relative to the component are two important
product witness specimens can be factors for witness specimens.
performance. acceptably relied upon to verify – The dimension, size, number, location, and orientation relative
material properties that are to the steel can are important factors for protrusions.
representative or bounding of – For producing heavy section large components by PM-HIP, the
the entire component, or at least dimensions of the witness specimens and protrusions may need
to match the largest thickness of the component. This can
 Difference Definition NRC Ranking of Significance Key Technical Information

those critical locations that ensure that microstructural inhomogeneities that may occur in
govern the design requirements. the heavy section large component are captured in the witness
specimens and protrusions for correlation between mechanical
properties measurements.
– Microstructural inhomogeneities can be due to variations with
tap density of the metal powder and variations in localized
densification rates and cooling rates between the surface and
internal location.
This refers to any Low  Depending on the can removal method, a fairly rough surface may
combination of be left. Lack of post-HIP machining or surface processing (such as
machining, finish Post-HIP surface finish can be a peening or grinding) may lead to greater susceptibility to SCC,
grinding, and other potential concern, depending on corrosion, and fatigue.
surface treatments the can removal method.  If can removal is done by acid pickling, the effects of the acid on
that are employed However, machining to the final the component surface should be carefully considered and
both to remove the dimensions and surface post- mitigated as needed.
Can Removal/ can after completing processing steps can make  For low-alloy-steel materials, the can removal should be done by
Surface Finish/ HIP and to meet the surface finish similar to machining rather than acid pickling due to the susceptibility of
Processing final dimensional conventionally manufactured low-alloy steel to acid.
requirements for the components. The machinability  Because machining can be used to meet the final dimensional
component. of the PM-HIP component would tolerances for a component, the dimensions of the steel can are
not be expected to differ sometimes intentionally oversized. Due to uncertainties in precisely
significantly from conventionally predicting the volume shrinkage of the powder and deformation
manufactured components. behavior of the steel can during HIP, oversizing and machining
may be more practical for producing heavy section large
components for nuclear reactors by PM-HIP.
Note 1: Difference combines the “Composition assurance of the gas atomized metal powders” and “Powder particle size distribution” ORNL gaps from Section 3.2
of the ORNL TLR.
Note 2: Difference combines the “Fabrication of heavy section large steel cans” and “Predicting the volume shrinkage of heavy section large components during
HIP” ORNL gaps from Section 3.2 of the ORNL TLR.
Note 3: Difference combines the “Filling the large Steel Can with the metal powders,” “Degassing and vacuum annealing of metal powders,“ and “Scale Up of the
Vacuum System for Degassing Powders in Heavy Section Large Steel Can” ORNL gaps from Section 3.2 of the ORNL TLR.
 Table 2 Technical Information—PM-HIP A508 Material-Specific

Difference Definition NRC Ranking of Significance Key Technical Information

Impact toughness can be High  To date, large components produced by PM-HIP have
correlated to fracture not been able to produce sufficient impact toughness
toughness, which is a Producing heavy section large consistently across the component.
measure of the material’s low-alloy-steel components by  A number of microstructural or composition variations
ability to resist the PM-HIP with consistent and may contribute to reduced impact toughness values
propagation of flaws. acceptable impact toughness is a as well as increased toughness variability.
significant challenge. Consistent – Oxygen contamination or varying oxygen levels
process control through the may contribute to reduced impact toughness in
fabrication process (powder PM-HIP low-alloy-steel components.
production, handling, storage,  Control of the oxygen and other contamination in
Impact Toughness1 degassing, and conducting HIP) PM-HIP produced large components needs to be
is needed to achieve managed effectively through the powder production,
densification, minimize handling, storage, and degassing stages.
contamination, and produce  Optimizing HIP process parameters and post-HIP
optimal toughness properties. heat treatment would be expected to improve impact
toughness values and consistency.
 Given that PM-HIP A508 is a new product form that
may behave differently from that of forgings, the
correlation between acceptable Charpy impact and
fracture toughness properties of PM-HIP A508 should
be demonstrated.
SCC refers to stress crack Low  PM-HIP is not expected to significantly change the
initiation and subsequent SCC performance in these materials, but test data
crack growth of Low-alloy-steel materials would be helpful to confirm this expectation.
susceptible materials generally do not come into  Lack of post-HIP machining or surface processing
operating under contact with the light-water may lead to greater susceptibility to SCC.
Stress Corrosion approximately constant reactor (LWR) environment due  SCC is a common failure mode in nuclear power plant
Cracking (SCC) stress in a corrosive to the use of stainless steel applications but has generally not been a significant
environment. cladding, so SCC is not likely to issue in low-alloy-steel components due to the use of
occur. stainless steel cladding to separate the low-alloy steel
from the coolant. In addition, water chemistry is tightly
controlled to reduce the corrosion potential of the
system.
 Difference Definition NRC Ranking of Significance Key Technical Information

 SCC in medium-strength unclad low-alloy steels, such

as A508, has not been observed in primary pressure
boundary LWR environments.
Fatigue refers to the Medium  Very few publications were found that discuss fatigue
initiation and propagation of PM-HIP low-alloy steels.
of cracks due to cyclic Fatigue is an important design  Lack of post-HIP machining or surface processing
loading with or without requirement for some nuclear may lead to greater susceptibility to fatigue.
environmental effects components. Limited data  Optimizing HIP process parameters, post-HIP heat
playing a significant role in suggest that fatigue performance treatment, and post-HIP surface finish processing
Fatigue the process. may be similar to wrought would be expected to improve fatigue susceptibility.
materials.  PM-HIP materials should demonstrate sufficient
strength to mitigate high-cycle fatigue and sufficient
ductility to mitigate low-cycle fatigue.
 Data in representative environments are important to
support fatigue calculations, including environmentally
assisted fatigue in PM-HIP materials.
Irradiation effects refer to High  Low-alloy steels in the wrought condition are
the impact of neutron susceptible to irradiation effects, including
irradiation on various Irradiation effects are a significant embrittlement, at LWR-relevant temperatures and
aspects of material aging effect for low-alloy-steel neutron doses.
properties and reactor pressure vessel  PM-HIP-produced low-alloy steels are expected to
Irradiation Effects
performance, including, components. Very limited data exhibit similar irradiation responses to wrought steels
but not limited to, loss of are available on neutron- having similar chemical compositions and
fracture toughness, irradiated PM-HIP low-alloy-steel microstructures, but test data are needed to confirm
irradiation assisted SCC, materials. this expectation.
and void swelling.
 Difference Definition NRC Ranking of Significance Key Technical Information

Other material aging Medium  There are limited data on other material aging effects,
effects include corrosion, such as corrosion, wear, and thermal aging on
wear, and thermal aging. There are limited data on these low-alloy-steel PM-HIP materials in LWR
Thermal aging refers to other aging effects that can environments.
the change in impact component performance.  Corrosion and wear are not expected aging
microstructure after The applicability and importance mechanisms for stainless-steel-clad low-alloy-steel
Other Material Aging
significant time at elevated of mechanisms will depend on reactor pressure vessel components but may be
(Corrosion, Wear,
temperature, which can the design requirements and important for other low-alloy steel components.
Thermal Aging)
alter mechanical plant-specific application of the  Thermal aging in particular can be highly sensitive to
properties, including component. microstructure and chemical composition, which may
reductions in fracture be different in a PM-HIP material.
toughness and ductility
and increases in hardness
and strength.
Tensile properties refer to Low  The tensile properties of PM-HIP components have
the material’s ultimate been observed to be comparable to or better than
tensile and yield strength A reasonable body of data to date those of components produced by traditional casting,
as well as ductility shows that tensile properties of forging, drawing, and rolling methods.
Tensile Properties
measures such as percent PM-HIP A508 components
elongation and percent should meet or exceed those of
reduction of area at forged A508.
failure.
Note 1: Difference corresponds to the “Impact toughness variability of heavy-section large components” ORNL gap from Section 3.2 of the ORNL TLR.
B. Smith 12

Impending Publication - The Use of PM-HIP for Fabricating Components of NPPs DATE June 17, 2022

DISTRIBUTION:
MYoo, RES/DE/CIB
MHiser, RES/DE/CMB
JMcKirgan, RES/DE
LLund, RES/DE
RTregoning, RES/DE
RIyengar, RES/DE/CIB
IAnchondo-Lopez, R-IV/DRS/EB2
CFairbanks, NRR/DNRL/NVIB
RDavis, NRR/DNRL/NPHP
ABuford, NRR/DNRL/NVIB
MMitchell, NRR/DNRL/NPHP
AHiser, NRR/DNRL
DRudland, NRR/DNRL
BThomson, NRR/DNRL
BSmith, NRR/DNRL

ADAMS Accession No.: ML22164A37; ML22164A439

OFFICE RES/DE/CIB RES/DE/CMB RES/DE
LLund
NAME MYoo MY MHiser MH
JMcKirgan for JM
DATE Jun 14, 2022 Jun 16, 2022 Jun 17, 2022
OFFICIAL RECORD COPY