PM-HIP to Revitalize Large-Scale Components

The demand for large-scale components, weighing at least 10,000 lbs., has surged across sectors such as aerospace, defense, nuclear, oil, gas, renewables, and construction. However, traditional manufacturing techniques like casting and forging have declined in the U.S., leading to supply chain shortages as production increasingly shifts overseas. Oak Ridge National Laboratory (ORNL) researchers are initiating advanced manufacturing technologies to revitalize the production of these large metal parts via powder metallurgy-hot isostatic pressing (PM-HIP).

The PM-HIP technology could bring large-component manufacturing back to the U.S. by improving upon older methods. Senior ORNL research scientists Jason Mayeur and Soumya Nag are at the forefront of this initiative, enhancing PM-HIP with modern advancements such as 3D-printing techniques, including wire-arc additive manufacturing (WAAM), hybrid manufacturing, in-situ monitoring, and advanced computational modeling. These improvements not only increase the precision and effectiveness of PM-HIP but also reduce costs, making it a more attractive option for American manufacturing.

Mayeur emphasizes that PM-HIP can diversify the supply chain for producing large-scale metal parts, which are becoming harder to source through traditional methods. The technology is particularly relevant for the nuclear and hydroelectric sectors and the Department of Defense (DoD). Unlike conventional casting and forging, PM-HIP involves creating pre-formed hollow molds, or cans, filled with metal powder. After sealing the cans and removing gases, they undergo heating and pressurization in a specialized furnace, sintering the metal powder into the desired shape.

Mayeur’s expertise in computational solid mechanics enables him to enhance the PM-HIP process through simulations that predict material behavior under various conditions. This helps address challenges such as shrinkage during manufacturing, where the volume of the metal powder decreases by about 30%, but not uniformly. His models guide the iterative design process, ensuring dimensional accuracy.

Nag complements Mayeur’s work with his background in materials science and manufacturing. His focus is on evaluating the quality of the HIP can fabrication and utilizing additive manufacturing (AM) techniques. He highlights how the combination of AM’s design flexibility with PM-HIP’s reliability can lead to the production of complex, custom energy-related parts.

Supported by the Advanced Materials and Manufacturing Technologies Office (AMMTO) and the Office of Nuclear Energy, their work is part of a larger initiative to advance manufacturing technologies that can enhance the reliability and economic viability of nuclear energy.