Primary Circuit Materials and Manufacturing

PHYS65410 Primary Circuit Materials and Manufacturing 15 Full year Postgraduate Taught Level 6 John Francis Unit coordinator 1 FHEQ level (Framework for Higher Education Qualifications) ' Masters/Integrated Masters P4 ' European Credit Transfer & Accumulation System Rating : 7.5 This unit provides a comprehensive overview of the welding and cladding processes that are relevant to the fabrication of primary circuit components in a pressurised water reactor. Emerging near-net shape manufacturing processes are also introduced. The physics of heat source-material interactions is covered for key welding processes, together with an overview of the working principles and necessary equipment. The metallurgy of welding is also covered, and specific considerations for primary circuit materials are explored. Links between manufacturing choices and through-life structural performance are made through considering the factors that affect the development of the mechanical properties of welds, residual stresses and distortion, and common weld defects. Strategies for inspection and quality assurance are outlined and related to the requirements in relevant engineering codes and standards. Learning is reinforced through the consideration of case studies that have received considerable attention in the engineering literature. Finally, emerging trends in manufacturing practice are highlighted.   This unit provides a comprehensive overview of the welding and cladding processes that are relevant to the fabrication of primary circuit components in a pressurised water reactor. Emerging near-net shape manufacturing processes are also introduced. The physics of heat source-material interactions is covered for key welding processes, together with an overview of the working principles and necessary equipment. The metallurgy of welding is also covered, and specific considerations for primary circuit materials are explored. Links between manufacturing choices and through-life structural performance are made through considering the factors that affect the development of the mechanical properties of welds, residual stresses and distortion, and common weld defects. Strategies for inspection and quality assurance are outlined and related to the requirements in relevant engineering codes and standards. Learning is reinforced through the consideration of case studies that have received considerable attention in the engineering literature. Finally, emerging trends in manufacturing practice are highlighted.   The unit aims to:  - Explain how welded joints influence (and can limit) the through-life structural performance of nuclear components.  - Introduce the welding, cladding and near-net shape manufacturing processes that are relevant to the manufacture of primary circuit components in pressurised water reactors.  - Review basic concepts of welding metallurgy together with factors that affect the weldability of materials that are relevant to primary circuit components.- Describe non-destructive examination techniques and how they can be applied to detect the presence of common weld/manufacturing defects.  - Identify and review trends in manufacturing practice for primary circuit components in pressurised water reactors.   ILO 1Describe the principles of operation for welding processes that are relevant to nuclear manufacturing, including the main characteristics and associated advantages and disadvantages for each process, and explain relevant methods of process control.ILO 2Apply principles of welding metallurgy and combine them with an understanding of welding process technology to qualitatively predict features of the resulting microstructures and the resulting variations in mechanical properties across welded joints.  ILO 3Describe the concept of weldability and use it to specify the elements of a suitable heat treatment schedule for a welded joint.ILO 4Evaluate and compare welding procedures that involve different welding processes and weld pass sequences in regard to the development of residual stresses and distortion.ILO 5Select appropriate non-destructive evaluation techniques for welded and clad components based on an understanding of the defects that can form with different welding processes and weld configurations and justify the choices that are made.ILO 6Describe key requirements in engineering codes and standards that apply to the manufacture and inspection of pressure retaining components in nuclear plant and explain their significance for nuclear manufacturing. Students are taught via directed reading (pre-course) and directly in appropriately equipped rooms at the institution delivering the module, or through distance (online) delivery. Learning is consolidated in tutorial and review sessions.· Pre-course directed reading· Direct Teaching· Review sessions· Tutorial sessions Students are able to exercise their intellectual skills through in-class discussion, tutorial sessions, the completion of a coursework assignment, and in a final examination.· In-class discussion· Tutorial sessions· Post-course assignment· Final examination Students are able to exercise their practical skills through tutorial sessions and completion of the coursework assignment.Tutorial sessionsPost-course assignment  Students are able to enhance their transferable skills through in-class discussion, tutorial sessions, and the completion of the post-course assignment.· In-class discussion· Tutorial sessions· Post-course assignment 0 Other 50% 1 Written exam 50% Unseen Examination and Post-Course Assignment Exam: through final mark within 3 weeks of the examinationPost-course Assignment: through written comments and final grade within 3 weeks of submission. No pre-requisites, but pre-course reading of parts of the N06 delivery is required.  N Sindo Kou, “Welding Metallurgy”, Third Edition, John Wiley & Sons, 2021. R. W. Messler Jr, “Principles of Welding: Processes, Physics, Chemistry, and Metallurgy”, John Wiley & Sons, 1999. John C. Lippold, Damian J. Kotecki, “Welding Metallurgy and Weldability of Stainless Steels”, Wiley-VCH, 2005. Lectures 25 Tutorials 10 0 115