Institution news
Q: Please can you briefly explain your role and involvement with structural integrity of advanced manufactured materials/assets?
Adam Cooper (AC): Over the last five years I have been involved in developing new understanding of the processes in advanced manufacturing that influence the performance of nuclear structural materials.
During my postdoctoral Research Associate role within the EPSRC New Nuclear Manufacture (NNUMAN) programme grant, I helped develop new physical understanding of powder metallurgy hot isostatic pressing (PM-HIP) technology; in particular the underlying mechanisms of ductile fracture, through a combination of experimental work (3D X-ray tomography, electron microscopy, mechanical testing, etc.) and numerical modelling including ductile damage mechanics. This research work has provided new information that has been used to strengthen the HIP material “Code Case” to the American Society of Mechanical Engineers (ASME), contributing to a Guideline Specification for PM-HIP 316L for use in Class III nuclear components, by the Electric Power Research Institute (EPRI).
I have also been involved in developing new understanding surrounding the mechanisms of microstructural evolution and plasticity development in powder during PM-HIP; probing the influence of powder size distribution on localised recrystallisation.
Q: What is the number one challenge for adopting new testing methods for advanced manufactured assets?
AC: In my opinion, one of the biggest challenges in developing new testing methods for advanced manufactured materials is ensuring that these new testing methods are not designed based solely on the testing of materials manufactured from conventional manufacturing, and that material performance phenomena influenced by any advanced manufacturing processes can be captured by the test methods and results that they generate.
Q: What is the most exciting development in this field at the moment, either within your company or in the industry in general?
AC: Whilst advanced manufacturing technologies offer the design freedom to manufacture complex geometric components with improved structural integrity and reduced overall cost and material wastage, for me, the use of PM-HIP to manufacture multi-material components is the most exciting development – offering huge potential in moving away from problematic and costly dissimilar metal welds.
Q: Where do you see the future of the industry in the next 5 years?
AC: I hope to see the industry beginning to generate large volumes of realistic test data paired with in-depth mechanistic understanding, encouraging the nuclear industry to integrate some of these technologies into their manufacturing supply chain. I hope to see us moving away from ‘prototype demonstration’ to real-world mock-up components and subject these to realistic in-service environments – essential if we are aid innovation in the nuclear industry (something that is, in principle, difficult to do).
Q: What key things can attendees expect learn from your presentation?
AC: The realistic pitfalls of powder-metallurgy manufactured components – not just the advantages but an appreciation of the current knowledge gaps. The challenge now is the generate realistic test data (paired with mechanistic understanding) to overcome the knowledge gaps so as to provide the nuclear regulator with the necessary information to view these technologies favourably – and to justify moving away from ‘tried and tested’ (but costly) conventional manufacturing processes.
Q: What other topics are you looking forward to hearing about and discussing at the upcoming seminar?
AC: I’m looking forward to hearing about advanced welding techniques and new and novel structural integrity tools.
Q: Why do you feel it is important for all professionals to join this seminar?
AC: Broadening your knowledge is an important part of development – no matter what stage of your career. There are many different industries where advanced manufacturing can make an impact over the next decade, discussing the opportunities (and challenges) between industries (and specialisms) can provide valuable insight to overcome the hurdles within each industry.
Optimising Structural Integrity: Advanced Manufacturing, Materials Development and Analysis Methods takes place on 5 November 2019 at One Birdcage Walk, London.
Attendees will gain a clear understanding of new testing and modelling methods that will improve the prediction and monitoring of structural integrity of advanced manufactured components. Join to hear case study insights from engineers who are adopting innovative advanced material and manufacturing technologies and modelling solutions to reduce risk and obtaining more reliable assets, including
- Nuclear AMRC
- Rolls Royce
- Coventry University
- Health and Safety Executive
- Wood Plc
- TWI
- Frazer Nash
This seminar will seek to address the topic in a holistic manner which is not covered elsewhere, enabling attendees to improve reliability while reducing cost and eliminating waste. To book your place visit www.imeche.org/structuralintegrity.