An Overview of Materials Technology at IGCAR

Dr. Baldev Raj

Distinguished Scientist & Director

INDIRA GANDHI CENTER FOR ATOMIC RESEARCH KALPAKKAM – 603 102

Institut de Soudure, May 10, 2007

Indian Energy Growth Scenario

COAL

Th-FBR

U-FBR

OIL GAS HYDRO

U-PHWR

Resource Potential Energy Growth

Target of GDP growth rate: 10 % (2007 – 2012)

Energy Target : 400 GWe ( to reach world average in per capita generation)

~ 275~ 0

5305

3699

2454

1620

1000613

0

1000

2000

3000

4000

5000

6000

2002 2012 2022 2032 2042 2052

Time periodPe

r Cap

ita G

ener

atio

n (k

Wh)

Stage – I PHWRs•15 - Operating• 3 - Under construction• Several others planned• Scaling to 700 MWe• Gestation period being

reduced• POWER POTENTIAL ≅

12,000 MWe

LWRs• 2 BWRs Operating• 2 VVERs under

construction

Three Stage Nuclear Power Program

Stage - IIFast Breeder Reactors

• 40 MWth FBTR -Operating since 1985

• Technology Objectives realised

• 500 MWe PFBR-Under Construction

• Technology development forclosing the fuel cycle

• POWER POTENTIAL ≅540,000 MWe

Stage – III and BeyondThorium Based Reactors

• 30 kWth KAMINI- Operating

• 300 MWe AHWR-BEING LAUNCHED

• POWER POTENTIAL IS 155,000 GWe-y

•Availability of ADS can enable early introduction of Thorium on a large scale

•Participation in ITER for fusion energy

81

91

8582

8075

7167

60

90868484

7975

6972

90

50

55

60

65

70

75

80

85

90

95

1995-96 1996-97 1997-98 1998-99 1999-00 2000-01 2001-02 2002-03 2003-04

Ava

ilabi

lity/C

apac

ity F

actor

(%) -

---->

MISSION OF IGCARESTABLISH SODIUM COOLED FAST BREEDER REACTORS (FBR)

TECHNOLOGY & ASSOCIATED FUEL CYCLE FACILITIES

BASED ON

broad based multidisciplinary programme of scientific research and advanced engineering development.

development and applications of new and improved materials, techniques, equipment and systems for FBRs.

basic research to achieve breakthroughs in fast reactor technology.

VISION STATEMENTTO BE A GLOBAL LEADER IN SODIUM COOLED FAST

BREEDER REACTORS AND ASSOCIATED FUEL CYCLE TECHNOLOGIES IN THE YEAR 2020 AD

SAFETY

MATERIALSDEVELOPMENT

ELECTRONICS&

INSTRUMENTATION

INFRASTRUCTURALSUPPORT

SODIUMTECHNOLOGY

REACTOR ENGINEERING

REACTORPHYSICS

REACTORDESIGN

FBR &CLOSED FUEL

CYCLETECHNOLOGY

Basic Sciences

MaterialsTechnologyat IGCAR

Mission Oriented

Service Oriented

Bas

ic R

esea

rch

Tech

nolo

gy d

evel

opm

ent

Physical Metallurgy and Characterization

Mechanical Behaviourand Characterization

Post Irradiation Examination and Robotics

Material Mechanics and Technology

Nondestructive Testing and Evaluation

Corrosion Science and Technology

Basic Research in Material Science

Innovative Designs and Synthesis

•Fracture & Damage Mechanics Based Evaluationof FBR Materials•Studies on Fatigue and/or Creep Crack Growth•Welding Technology & Weldability Studies•Development of Hardfacing & Repair Welding Technology•Materials Development & Processing Technology •Tribological Studies

•Tensile Properties at Different Temperatures

•Creep, Low Cycle Fatigue& Creep-Fatigue Interactions

•Structural Integrity & Life Assessment

•Thermo-Mechanical Fatigue Studies

•Material Development forFBRs

•Creep & Fatigue Studiesin Flowing Na

•Analytical & High Resolution Microscopy•Thermo-Physical Studies -Modeling/Experiments•Synthesis of Novel Materials•Micro-Chemical StudiesUsing EPMA

•Embrittlement Studies in Ferritic Steels•Design of Reprocessing& FBR Materials

•Ion Beam Applications & Radiation Damage•Positron Annihilation &Defect Spectroscopy

•Light Scattering & Soft Condensed Matter•Superconductivity; SQUIDS •High Pressure Studies & Material Synthesis

•X-Ray & Crystal Growth•Surface Science &Nanomaterials

•Theory & ComputerSimulations

•Post Irradiation Examination of FBTR Fuel & Structural Materials •Development of RoboticsDevices for in-Service Inspection of PFBR & Reprocessing Plants•Development of RemoteHandling Equipment•Development of Miniature Specimen Testing Techniques•Failure Analysis of Engineering Components

•NDE for Quality Assurance & in-ServiceInspection•Expertise to Strategic & Core Sectors •Acoustic Emission & Infrared Thermographyin Characterizing Various Deformation Processes•Application of Micromagnetic, XRD &Ultrasound Techniques inMicrostructural Studies

•Design, Fabrication & Assembly of Irradiation Experiment Capsules•Precision Machining, Welding & Assemblyof Small & Miniature Components •Making of Calibration Defects for Nondestructive Testing•Studies on Temperature Distribution during Welding

•Localized & Microbial Corrosion Studies•Biodegradation & Alkali Aggregate Reactions in Concrete•Stress Corrosion Studies•Compatibility Studies in Nitric Acid & Na

•Molten Salt Corrosion & Development of Protective Coatings•Development of Online Corrosion Monitoring Techniques

NDE SETUP for Na EXPOSURE

25.0°C

35.0°C

26

28

30

32

34

7.1% 58.9% 74.2%

THERMAL IMAGES for DEFORMATION

DROP-WEIGHT TESTING MACHINE

SQUID MAGNETOMETER

SQUID Sensor

THERMO-MECHANICAL FATIGUE MACHINE

LASER WELDING OF MINIATURE RUPTURE

DISC

NITRIC ACIDLOOP

HIGH-RESOLUTION ELECTRON MICROSCOPE

ROBOT for STEAM GENERATOR

INSPECTION

HOT CELL FACILITY

PROGRAMME

Approach to Big Leap in FBR Programme

FBTR

PFBR

1200 MWt

500 MWe

Pool Type

Fuel: UO2-PuO2

40 MWt

13.5 MWe

Loop type

Fuel: PuC - UC

FBTR PFBR• 400 r-y worldwide FBR operational experience• Rich experience with MOX fuel • 30 y of focused R&D programme involving

extensive testing and validation• Material and Manufacturing Technology

Development and Demonstration• Science based technology• Peer Reviews• Synergism among DAE, R&D Institutions and

Industries

PFBR FLOW SHEET

Fuel Fuel -- Oxide or Metal Oxide or Metal Clad & Wrapper Clad & Wrapper

Ferritic / Martensitic Steels9Cr-1Mo; Mod. 9Cr-1Mo-V-Nb9Cr-2Mo-V-Nb; 12Cr-1Mo-V-W;

Current generation

Immediate Future

Future

Oxide dispersion strengthened (ODS) steels13Cr-1.5Mo-2.9Ti-1.8Ti2O3, 13Cr-1.5Mo-2.2Ti -0.9Ti2O3-0.5Y2O3, 12Cr-0.03C-2W- 0.3Ti-0.24Y2O3, 9Cr - 0.13C- 2W + Ti + Y2O3

Reprocessing - Stainless steel, Ti & Zr based alloys, Ceramic & Nano Coatings

Waste management – Synroc & Glass Matrices

Austenitic stainless steelType 316 & modifications15Cr-15Ni-Ti-C (Alloy D9) & its improved versions

Material Development for Improved Performance for FBRs

EXAMINATION OF RADIOACTIVE COMPONENTS INSIDE HOTCELLS

PHWR fuel bundle

FBTR fuel pins

View of the Hot cell Facility at IGCAR for Examination of Radioactive Components

Failure of PHWR pin due to PCI / SCC

Photomosiac of the FBTR fuel sectionExamination PHWR pressure tube inside hot Cell

(Failure due to overheating during dry Quarantine)INCREASE IN BURN UP ACHIEVED BASED ON THESE EXAMINATIONS

CHALLENGING ANALYSES FOR FINALISING PFBR DESIGN CHALLENGING ANALYSES FOR FINALISING PFBR DESIGN

Buckling of main and inner vessels under seismic Buckling of main and inner vessels under seismic forces to demonstrate required factor of safety in design forces to demonstrate required factor of safety in design

Seismic design of Nuclear Island Seismic design of Nuclear Island Connected Buildings (NICB)Connected Buildings (NICB)

Seismic analysis of Seismic analysis of reactor assembly reactor assembly

Numerical simulation of thermal hydraulics Numerical simulation of thermal hydraulics of hot pool in reactor assembly of hot pool in reactor assembly

Control plug

Core

Heat exchanger

Stratification

Control plug

Core

Heat exchanger

Large reduction in life at 773 and 823 K due to DSA

At 873 K creep and oxidation are dominant damage mechanisms

Increase in half-life stress with decreasing strain rate due to DSA

at 773 & 823 KHigher stress response shortens

both crack initiation and propagation phases

773 , 823 K – DSA873 K – Creep & Oxidation

LOW CYCLE FATIGUE of 316L(N) SS

Cells – Non DSA regime

Planar slip bands DSA regime

Void swelling and Positron Annihilation Studies on 20% CW D9 Alloy with 0.15 and 0.25 Ti

Swelling studies at 100 DPA Isochronal Positron Annihilation studies

30 appm Helium pre-implanted + 5 MeV Ni++ ion irradiation ; Damage rate : 7x10-3 dpa/s

Model alloy without Ti

Ti : 0.25 Ti/C = 6

Ti : 0.15 Ti/C = 4

(823K) (923K)

LOWER SWELLING AT PEAK SWELLING TEMPERATURE MORE NUMBER DENSITY OF CARBIDES

REDUCTION IN THE PEAK SWELLING TEMPERATURE PRECIPITATION OF CARBIDES AT LOWER TEMPERATURE

Ti IN AUSTENITE INCREASES VACANCY MIGRATION & PROMOTES SWELLING

FOR Ti/C = 6

A

B

100 1000 1000100

Temperature: 700oC

300

200

ALLOY D9MIDHANI

Ti/C = 4Ti/C = 6Ti/C = 8

Stre

ss, M

Pa

Rupture Life, h

Ti/C : 4 – Better Creep Resistance And Fatigue Life

Ti/C : 6 – Better Void Swelling Resistance

Ti/C : 6 – Preferred choice on the basis of void swelling resistance since accumulated creep for desired residence time does not become life limiting

20% CW

1 0 0 00 . 0 0 2

0 . 0 1

A l lo y D 9S o lu t io n A n n e a le dT e m p e r a t u r e 9 2 3 KS t r a in R a t e 3 x 1 0 - 3 s - 1

T i / C R a t io = 4 T i / C R a t io = 8 T i / C R a t io = 6

Tota

l Str

ain

Ampl

itude

N u m b e r o f R e v e r s a ls T o F a i lu r e

0.035-0.045Carbon

0.01Sulphur

0.005Boron

1.65-2.35Manganese

2.0-2.5Molybdenum

0.005Nitrogen

13.5-14.5Chromium

14.5-15.5Nickel

Development of Alloy D9I SS- Target Composition

2 4 6 8 10

100

1000

10000

973 KD9I SS/.025P.75Si

Rupt

ure

life,

h

Ti/C, wt%

250 MPa200 MPa175 MPa

Slower Sensitisation Kinetics in 316SS - GBE

% of CSL boundaries increased to 70% in B from 25% in A;

Time for sensitisation is increased 10 times.

0.1500

1.0 10 100 1000773

823

873

923

973

1023

1073

1123

1173

550

600

650

700

750

800

850

900Critical cooling rate - 1 K / h

No attack

316(L)Modified 316(N)

TIME, h

TEM

PER

ATU

RE,

°C

TEM

PER

ATU

RE,

K

Critical cooling rate - 160 K / hModified 316(N) 316(L)

Partial attack AttackA B

GRAIN BOUNDARIES

CorrosionSliding

&Creep

Diffusion

SegregationPrecipitation

AFTER GBE

RANDOM SPECIALBEFORE GBE

GRAIN BOUNDARY ENGINEERING –towards Ductile Ferritics

0

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0.8

0.9

1

0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1

Fraction of crack resistant boundaries

Prob

abili

ty o

f Per

cola

tion

Even

t

PERCOLATION MODEL TO PREDICT % FAVOURABLE BOUNDARIES TO ARREST CRACK GROWTH

3-D POISSON VORNOI GRAIN POLYHEDRA

0.3% CSL

EBSD OF N&T MODIFIED 9Cr-1Mo STEEL

251

205

168

373 38

8

379

590

28528

6

476 57

1

22426

1

246

348

269

258

287

227

20724

1

433

234

253

268

202

0

100

200

300

400

500

600

700

As

Nor

mal

ised

stee

l

No

defo

rmat

ion

Roo

mTe

mpe

ratu

reFo

rgin

g (R

F)

Hot

Tem

pera

ture

Forg

ing

(HF)

Roo

mTe

mpe

ratu

reR

ollin

g(R

R1)

Roo

mTe

mpe

ratu

reR

ollin

g(R

R2)

Cry

orol

ling

(CR

)

Stan

dard

(5

64 V

HN

)

Thermomechanical Treatments

Ave

rage

mic

roha

rdne

ss (V

HN

)

As-deformed

Deformed & 973C treated (A)

Deformed & 1223K/2hrs treated (B)

Deformed & 1223K/2hrs, 1033K/2hrs treated (C)

% CSL BOUNDARIES STABLE AT 1023K FOR 8,500 h

400 450 500 550 600 650 700 750 800 850400

450

500

550

600

650

700

750

800

850

R = 0.9952Test Data

ANN

Pre

dict

ed

Experimental

UTS Data Best Linear Fit

ArtificialNeural

Network

Yield strength

UTS

Uniform elongationTest Temperature

C

Ni

Cr

MnMo

COMPOSITION

FERRITE NUMBER IN SS WELDS

UTS IN SS

SOLIDIFICATION MODE IN SS WELDS

DYNAMIC MATERIALS MODEL –PROCESSING MAPS OF 304L SS

SAFE PROCESSING WINDOW

0.5 μm

1.5 μmMap representing the domain of various processes for 304L

INDUSTRIALVALIDATION

FEM Based Process Design for Plate Forming

Petal

Material & Frictional Property Data : Flow curves, E, Poisson’s ratio, Friction

factor

FEM Model for Petal Forming

Validation and Tuning-upof the FEM Model

FEM Simulation of Petal Forming

Correction of Die and Punch

Profile for springback

Formed Petal Profile within Desired

Tolerance limits?

Extract Sectional Profilesof the Die and the Punch

(Final Profile Designs)

No Yes

FEM Simulation of Double CurvaturePlateForming on 300 mm X 300 mm X 15 mm

thick plates {316L(N)}

Bending trials on 300 X 300 mm X 15 mm thick plates in Fomas Ltd.

Comparision of Results of Simulation and Experiments

Finalisation of FEM Solution Scheme for Petal Forming

The error in the model prediction is within 250 μm

Formed Petal Tooling

Main vessel

Safety vessel

Thickness : Cylindrical portion : 15 mmDished end : 20 mm

Specified Form Tolerance : 12 mm Achieved Tolerance : 9.5 mm

Thickness : Cylindrical portion : 25 mmDished end : 30 mm

Specified Form Tolerance : 12 mm Achieved Tolerance : 8 mm

o Distortion control by …Suitable choice of welding heat input, joint type, root gap & welding sequence

Welding ConsumablesFiller wires & electrodes developed indigenously

Hardfacing Technology For FBR Core And Grid Plate Co-base Stellite hardfacing alloys not preferred due to induced activity from Co60; Ni-base Colmonoy alloys chosen to replace Stellites

Colmonoy GTAWon 316LN SS

Colmonoy-5/Colmonoy-5 combination offers minimum friction behaviour among Colmonoy alloys;

Even after prolonged exposure, hardness of Colmonoy at 550°C is higher than room temp. hardness of Stellite-6 up to 40 years

Hard facing of bottom plate of grid platePFBR Grid Plate assembly

(Hard facing zone on bottom plate)

Flux Assisted GTAW

Weld bead in multi-pass TIG Weld bead in A-TIG

IR T

herm

al im

age

7 passes 1 pass

Refinement of microstructure in the centre

Increase in the penetration in single pass A-TIG welding of stainless steels are due to arc constriction and reversal of Marangoni flow.

10 mm

Diffused arc in TIG

Constricted arc in A-TIG 77

Type 316LN Multi-pass

Weld

111Type 316LN A-TIG Weld

Impact Toughness, J

Material

Technologies for FBRTechnologies for FBR

Existing beamlines at 1.7MV Tandetron accelerator

Fatigue Testing in Sodium

Penetration

Enhancing Flux

Activated TIG

welding of

Dummy Fuel

Subassembly

Materials Development for Reprocessing Applications

Undesirable Optimised

Ti-5%Ta-1.8% Nb Alloy

Coatings and Surface Modification

Double Oxide Coating on Titanium for Reconditioning (DOCTOR)

Passivation technology for austenitic stainless steels

Electrodes for Electrochemical Processes

Thermochemically Glazed MOCTA with Pt and Pt+Ir (MOCTAG)

Pt Electroplated Titanium

Noble metal based Bulk Metallic Glasses and Coatings

Dissolver, Evaporator, HLAW Storage Materials

Nitric acid Grade NAG 304L SS, NAG 310L SS, HNS

Titanium, Ti-5% Ta Alloy, Ti-5%Ta-1.8% Nb Alloy

200-500 nm

TiO2

HIGH BURN UP ~ 200 GWd/t

HIGH BREEDING RATIO ~ 1.5

LONG PLANT LIFE ~ 100 YEARS- Prediction of materials behaviour- Assessment of Residual life- Knowledge based innovative technologies

- NDE and In-service inspection

COST COMPARABLE TO FOSSIL POWER

1980’s

CENTRE FOR

EXCELL-ENCE

DEDICATIONVISION

SYSTEMATIC EXPERIMENTATION

Multi-disciplinary Professionals

Understanding Material Degradation

Identifying Critical Areas

Instrumentation& Sensors

Field Implementation

Modeling & Software

Validation

NDE Science & Technology

Successful

Flight to

Excellence

Robustness

Success

- IGCAR

Personnel Training

-610

-810

-1010

1A 100A 1μm

MIC

ROST

RUCT

URE

/ D

EFEC

T

[m]10-4

10-2

m100μ 10mm

Dimensions of various structural featuresDimensions of various structural features

Adopted from IZFP, Saarbrucken

ND

T TE

CHN

IQU

ES

10

100A

-10

1A

10-8

10-6 -2

10mm

10-4

10 [m]

1μm m100μ

Resolution of NDE Techniques

Adopted from IZFP, Saarbrucken

Development of eddy current sensors for ISIDevelopment of eddy current sensors for ISI

Differential type sensor with a ferrite core opening of 25Differential type sensor with a ferrite core opening of 25microns has demonstrated capability to detect shallow cracksmicrons has demonstrated capability to detect shallow cracksof 25 microns deep, besides detection of seam weldof 25 microns deep, besides detection of seam weld

Focused eddy current sensor developed for detection of shallow cracks and scratches in calandria tubes of PHWR and typical signals from reference notches.

0 20 40 60 80 100

-2

0

2

4

6

45μ

75μ

23μ

Sig

nal A

mpl

itude

, Vol

ts

Scan Distance, mm

Ultrasonic TOFD and SAFT for Evaluation of Flaws in Weldments - An Alternative to Radiography

Radiography-Not portable-Radiation hazards

Back wall

EP

ICP

Back wall

SAFT images

TOFD image

Cluster of pores

EP Cracks ICP EPICP

PQ

ICP

P

QQP

ICP

Defects P & Q Missed by radiographyPicked by SAFT Confirmed by destructive metallography

Porosities

Incomplete penetration (ICP)

Excess penetration (EP)

Trans. Crack Carbon Steel, 20 mm

A

B

C

D

Inner Surface Profiling of Dissolver Vessel in Lead Mini Cell using LASER Triangulation Technique

In-house Development in Collaboration with CAT, Indore

Position sensitive device for triangulation (~ 2-3 microns) for non-contact inspection of reprocessing vessel- 11N HNO3 at high temperature

Weld internal profile

PSD

Automated imaging for stainless steels NDEAutomated imaging for stainless steels NDE

05

1015

20250

510

1520

253035

0.0

0.2

0.4

0.6

Dept

h, m

m

Y Axis, mm X Axis, mm

Application of imaging scheme to stainless steel weld having defects

Eddy current image of a service induced fatigue crack in a stainless steel flange

This scheme has demonstrated reliable detection of defects as shallow as 0.2 mm deep and displayed three-dimensional pictures of defects with a ten-fold reduction in imaging time

NDE USING SQUIDs

SQUID output vs distance of the weldment sample after magnetisation

-5

0

5

10

15

0 50 100 150 200 250 300

Distance (mm)

SQU

ID o

utpu

t (0)

15.2954 0

6.67455 0

5.26860 0

4.89565 0

3.90938 0

3.90857 0

* virgin* 50 cycle* 100 cycle* 150 cycle* 200 cycle * 250 cycle

Sample : Stainless steel 316 L(N)Temperature : 600 oC, Strain rate : 3x10-3s-1

SQUID output Vs No. of cycles of the weldment sample

02468

1012141618

0 50 100 150 200 250

No of cycles

SQUI

D o

utpu

t (0)

X-Y Scanner

IGCAR- SQUID

Ferro Fluids – Sealants, Sensors and Optical Filters

Ferrofluid Sealing exploits the response of a ferrofluid to an applied magnetic field.

Ferrofluid assumes the shape of a "liquid O-ring" and produces a hermetic seal.

Ferrofuids are synthesised for specific applications involving leak free sealing, magnetic domains viewing and for magnetic leak based sensors and optical filters

Tunable Optical Filter

Optical probe for defect detection

undesirable desirable

New Technology DevelopmentNew Technology Development

J.Philip…..Baldev Raj, Indian Patent 501/MUM/2002

• A unique technique for in-situ measurement of weak forces (10-11 to 10-13 N) between emulsion drops (J.Philip…Baldev Raj; Physical Review Letters, 2002 & Langmuir 2002 )

• First experimental evidence for stretching and collapse of polymer layers under association with ionic surfactants (J.Philip…..Baldev Raj; Macromolecule, 2003 & Phys. Rev. E 2002)

• Based on the force data a new process was invented to enhance the stability of ferrofluid emulsions, which can be extended to other products too

10-13

10-12

10-11

40 60 80 100 120 140 160 180

0 mM0.20.530.721.332.66

Forc

e (N

)

Interdroplet spacing (nm)

Repulsion between the emulsion drops is extended by using polymer-surfactant complexation

Comprehensive In-Service Inspection of PFBR Vessels

MV-SV interspace – 300 ± 50 mm

Temperature during ISI – 423 K

Half vertical section of Reactor assembly

ISI Device

13 08 09

05

27100

27700

NITROGEN IN

NITROGEN OUT

MV/SV ISI Vehicle

ACB Plug

Dissimilar &In-situ weldInspection

DeviceAirlock

chamber

Visual Inspection ModuleIm

age

of a

wel

d cr

ack

Mar

king

s on

su

rfac

e

SPIDER ROBOT On Mockup Steam Generator Tube Sheet

Winch mechanism being used in PFBR SGTF during RFECT campaign

RFEC PROBEExciter

Receiver

Depleted Urings

WINCH

Flexible probe with WC rings for negotiation of bends

0 200 400 600 800 1000 1200

0

1

2

3

4

5

Wavelet Signal (db-10)

Raw Signal

Bend region

RFE

C o

utpu

t, Vo

lts

Scan distance, mm0 200 400 600 800 1000 1200

0

1

2

3

4

5

Wavelet Signal (db-10)

Raw Signal

30% Defect

Bend region

RFEC

out

put,

Volts

Scan distance, mm

Wavelet transform method for suppression of bend signalsEnhanced performance

with WC rings20 30 40 50 60 70 80 90 100

-0.01

0.00

0.01

0.02

0.03

0.04

0.05

0.06

0.07

0.08

0.09

0.10 9Cr-1Mo, 400 HzInter-coildistance 40 mm

Pb Air WC

RFE

C S

igna

l Am

pltid

ue, V

olts

Distance, mm

Development of Comprehensive Technology for ISI of PFBR Steam Generator Tubes

Remedial measures:(i) Chamfering of root edges to reduce stress concentration (ii) Shot peening blade roots to induce compressive

stresses (iii) Increased radii at the steps of lacing rods (iv) Ripple springs at bottom of blade root and the disc(v) Turbine trip based on the rate of increase in frequency

(df/dt) and absolute high frequency with time delay.

Main cause of failure at the fir tree root – FatigueResonance Crack initiation Propagation

FMPT revealing root crack

Material quality, in-situ inspection techniques, design modifications, vibration analysis / control, operational

practices ---- Improved Performance

Failed turbine blades in the LP sideCrack

Modeling & residual stress measurements

CRACK

514

504

482

452

514

LOCATION OCRACKING

stress concentration sites

Multiple Crack Initiation sites

Presence of Inclusions NPCIL,BARC,IGCAR

Comprehensive strategy for management of 220 MWe Nuclear steam turbine blades – Feedback from failure investigations

HP Turbine Blade and Shroud / Understrap

HP BLADE FAILURE DUE TO FATIGUE & P SEGREGATION

Development of repair welding techniques

Remedial measures:HP blade: Material chemistry to avoid Phosphorous segregation, improved fitment to the root

Shroud: Change of material with higher strength

Under-strap: Design modification with increased width and thickness at the edges to reduce stresses

Shroud

Understrap

Failed HP blade

Intergranular fracture due to GB P segregation

(In-situ Auger spectroscopy)

Crack

Crack

Cracked Repaired

Monel-400 Heat-Exchanger from a PHWR

Sludge deposition on tube Sheet leading to Crevice Corrosion

Through & Through Opening And Intergranular Corrosion At The Defective Location Due To Sludge Deposit

Recommendations•ECT of tubes for defect estimation

•Continuous Blow down to avoid build-up of tube sheet deposits

• Online Polishing of Condensate Water

•Change in material for future SG

The Early Choice of Material - Alloy 400 (High Cu content, IGC) (RAPS & MAPS)

Next Generation – Alloy 600 (SCC & Pitting)

Current Generation – Alloy 800 (From NAPS onwards)

244.6 K

378.0 K

260

280

300

320

340

360

646.3 K

1149.2 K

700

800

900

1000

1100

Flames directly impinging on the tubes ( > 993K)

Reflections from metal pieces used for fastening thermocouples

Flames in background

Infrared Imaging of Ammonia Cracker Unit at Heavy Water Plant (HWP), Tuticorin

LI01

Damage Assessment of a Conical Inlet in HWP (T) Outer skin at 393 K – Abnormality at 623 K

Thermography as a non-contact condition monitoring tool through identification of abnormal hot spots

The expertise developed have been effectively put to use for Life Extension / Failure Analysis

in other Core Sectors likeDefense

Aerospace

Oil and Petrochemical

Fertilizer industries

Expertise Offered to other Core Sectors

NDE Technology for Space Application NDE Technology for Space Application Detection of cracks in maragingsteel weldments by UT and advanced signal processing methodsPyros indispensable to any space craft – PSLV, GSLV, Satellites

Most critical and one shot devices.

Pyros such as cable cutters and initiators examined by neutron radiography using KAMINI national facility.Excellent example of team work between two institutions IGCAR-ISRO and utilisation of national facility for national cause.Neutron radiography of a Pyro

ChargeCharge O ringsO rings

Advanced ultrasonic method for defect characterisation in a Maraging steel rocket motor casing --- The defect is characterised to be linear type based on ultrasonic signal analysis. Close examination of radiographs indicated that the defect is found to be interconnected porosity.Spurred a generic programme on pattern recognition approaches In collaboration with ISRO

ROCKET MOTOR CASING OF PSLV

Aero-Engine Turbine Blade

Protective heat resistant coating – Spalled and DetachedGamma prime precipitates coarsened - Grain growth observed Creep Growth in turbine blades caused total failure

Cause of failure: Over temperature exposure due to faulty temperature indicator

Creep cavities, grain boundary cracking and absence of fine γ’

precipitates in the matrix

Decohesion of aluminideprotective coating

Cracking along grain boundaries

Failed II stage turbine blades New and failed turbine blade

Nickel based super alloy with

protective Aluminide Coating

Improved Protective Coating

Multi-NDE Techniques For Defect DetectionIn collaboration with IAF

-1.0 -0.8 -0.6 -0.4 -0.2 0.0 0.2 0.4 0.6 0.8 1.0-1.0

-0.8

-0.6

-0.4

-0.2

0.0

0.2

0.4

0.6

0.8

1.0

Mixer Output

Probe Tilt

Crack

Imag

inar

y C

ompo

nent

, V

Horizontal Output, V

Crack of 4 mm length, after two- frequency mixing.

-1.0 -0.8 -0.6 -0.4 -0.2 0.0 0.2 0.4 0.6 0.8 1.0-1.0

-0.8

-0.6

-0.4

-0.2

0.0

0.2

0.4

0.6

0.8

1.0

Mixer Output

Probe Tilt

Crack

Imag

inar

y Co

mpo

nent

, V

Horizontal Output, VCrack of 2 mm length

Fatigue crack detection using ECT

Fatigue cracks in a compressor disc of an Aeroengine after 2000

flying hours

COMPRESSOR DISCS OF AERO ENGINES

NUMBER OF LANDINGS

-6000

RE

SID

UAL

STR

ESS

, MP

a

-200

-400

-500

-300

-100

100

0

800400

1200

XRD based Residual Stress Measurements for Life Assessment of Undercarriages of Fighter Aircrafts

Residual stress variation as a function of number of landings (550 MPa Compressive stress in new landing gears)

K

7-FRONT8-REAR

5-FRONT6-REAR

3-FRONT4-REAR

9

10

VIEW -K

2

1

REGIONS OF RESIDUAL

MAIN LANDING GEAR STRUT

STRESS M EASUREMENTS

Stress critical regions and corresponding residual stress values after 3600 landings (900 MPa Compressive stress in new landing gears)

RES

IDU

AL

STR

ESS

, MP

a

-600 0

-400

-500

-300

-100

-200

0

300DEPTH IN MICRONS

100 200

Residual stress as a function of depth in the landing gear after 1200 landings

12345678910

519

592501

657621

480

438

621592

402

798

846831

854826779

763

847850756

843844853897837821861874812860

LOCATIONTOP

RESIDUAL STRESS (MPa)COMPRESSIVE

DEPTH BELOWTOP SURFACE10μ 200μ

On-line structural integrity assessment of CO2 absorber vessel

Ultrasonic testing to exactly map the cracks in the weld region

AE monitoring for three months to identify the locations of crack growth/ formation of new cracks

Repeat ultrasonic testing after AE monitoring, to confirm AE findings and map the cracks to check for entry of cracks into parent metal of the vessel

Acoustic techniques assured thatCrack did not enter the parent metalNo concern of integrity and hence recommended forcontinuous operation

Reboiler Heat Exchanger of a Fertilizer Plant

The failed Heat exchangerCause of failure:

Crevice corrosion between tube and tube sheet caused

failure of the HE

Recommendations:

Tubes inside the tube sheet to be expanded to the designed

length

Wall Thinning On The Stainless Tube

Corrosion Damage On Tube Sheet

Failed Tube-Tubesheet Location

Corrosion Damage On Tube Sheet & Tube Surface

Characterisation and Conservation of Objects of Cultural Heritage

Identification and Application of NDE methods for characterising and fingerprinting metallic art objects (south Indian bronzes)

(DST-IGCAR-Govt. Museum over 200 rare pieces investigated)

Delhi Iron Pillar –Insight into fabrication technology

Ardhanareswarar– 11th century Rustless Wonder – Delhi

Iron Pillar

Clinical Diagnostics and Healthcare Clinical Diagnostics and Healthcare ––Development of New NonDevelopment of New Non--invasive Techniquesinvasive Techniques

Thermal Imaging techniques for

Detection of vascular disorders (left deep vein thrombosis condition is indicated)

Early Detection of cancers

Collaboration with DAE Hospital and KJ Hospital, Chennai. Reliability being established through number of cases and application of mathematical models for feature identification and evaluating severity and depth

RobustFast

BreederTechnology

EfficientReprocessing

InnovativeDesign

AdvancedMaterials

MetallicFuels

Towardsenergy

security

GOALS

Front End

Longer plant lifeCost-effectiveness

Fuel economy

GOALS

Back End

Fuel recoveryHigh performance

Waste management

Network withindustries

Interact withAcademics &

R&D Institutes

HOLISTIC APPROACH:FBR TECHNOLOGY OF INDIA

FBR with 100 years lifeClosing Fuel Cycle with 200,000 MWd/tHigh Breeding Ratio (1.5)High reliabilityCost-effective manufacturingHolistic project & Plant management philosophiesThe aim is to provide electricity at a very competitive price

Material limited performance(MLP) of components

Design limited performance (DLP) of components

∫ )).(( DLPMLPMax.

F B T RAuroville, Pondicherry

Science and art belong to the whole world, and before them vanish the barriers of nationality

Theosophical Society, Chennai

Kanchipuram Mamallapuram

Kalpakkam

Towards Energy Security for Indian Prosperity