Westinghouse AM Innovation Said to Enhance Nuclear Safety

Westinghouse Electric Co. reports that it used additive manufacturing (AM) to fabricate bottom nozzles that improve debris capture and fuel endurance within its fuel assemblies. The nozzles were integrated into four Lead Test Assemblies delivered to Alabama Power’s Joseph M. Farley Nuclear Plant operated by Southern Nuclear, in the first quarter of 2024.

Debris-wearing action on the fuel rod cladding—known as debris fretting—is the main source of leaks in pressurized water reactor (PWR) fuel assemblies. AM technology offers improvements in debris filtering thanks to enhanced design freedom that reduces the diameter of debris that can enter into the reactor. In testing, the additively manufactured components demonstrated a 30% improvement in debris resistance, according to Westinghouse.

“Our additive manufacturing technology is allowing us to achieve breakthrough performance with an immediate positive impact for our customers,” says Tarik Choho, Westinghouse president of Nuclear Fuel. “This significant technology innovation for PWR reactors mitigates the risk of leakage in the fuel rods due to the accumulation of debris, strengthening the safety and efficiency of our customers’ operations.”

This milestone demonstrates Westinghouse’s role in the nuclear industry to achieve solutions using AM techniques. In 2015, the company conducted the first-ever material irradiation study of AM nuclear components. In 2020, Westinghouse installed the first-ever safety-related AM component, a Thimble Plugging Device, into an operating commercial reactor, and in 2024 Westinghouse produced the 1,000th Additive Manufacturing Component for VVER-440 Fuel.

Sources: Press materials received from the company and additional information gleaned from the company’s website.