"This work in advanced manufacturing, particularly in using additive manufacturing, is about making a difference," said Roy, who also holds the position of Building a World of Difference Faculty Fellow in Engineering at Iowa State University.
Roy emphasized the importance of nuclear energy as a clean power source. "One of the major things that excites me about this project is working with nuclear energy," he explained. "It's the largest source of clean power in the United States. This emission-free electricity is important for the future."
According to the U.S. Energy Information Administration, nuclear power accounts for about 19% of the U.S.'s electricity, while about 10% is generated from wind turbines.
Roy's project, titled "Developing a Robust Ecosystem for Additive Manufacturing of Tungsten for Extreme Applications and Management," brings together a team of experts from the University of North Dakota and three Department of Energy labs: Ames National Laboratory, Argonne National Laboratory, and Oak Ridge National Laboratory.
The research focuses on using tungsten, a material known for its high-temperature resilience, erosion resistance, and minimal radioactive tritium retention, making it ideal for fusion reactor components. However, traditional manufacturing processes for tungsten are challenging due to its hardness and brittleness.
To overcome these challenges, the research team will explore the potential of 3D printing tungsten-based alloys using laser powder-blown directed-energy deposition. This method involves printing the material layer by layer under oxygen-controlled conditions using a laser, which allows for more efficient processing of the tough metal.
The project will not only focus on the physical aspects of printing but also on developing physics-based modeling and computational simulations to support the experimental work. These simulations, enhanced with machine learning and AI tools, will help the researchers refine the printing process and create tungsten alloys capable of withstanding the extreme conditions of nuclear reactors.
"We'll start with pure tungsten," Roy said. "Eventually we'll develop new alloys to resolve this cracking challenge."
Roy emphasizes the collaborative nature of the project, stating, "This is a real DREAM-TEAM. Nothing like this project can be done alone."
Related Links
Iowa State University
Nuclear Power News - Nuclear Science, Nuclear Technology
Powering The World in the 21st Century at Energy-Daily.com
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