Nuclear Components Manufacturing Service

Use nuclear-qualified alloys such as 304L/316L (ASME SA-240), Inconel 600/690, and zirconium alloys for fuel rod or core-facing parts. Select materials with low neutron absorption cross-section, minimal activation potential, and proven radiation embrittlement resistance.

Design for steady-state and transient thermal profiles per RCC-M subsection B and ASME Section III. Model creep-fatigue interactions with elastic-plastic FEA. Include expansion joints, bellows, and stress-relieving geometries in components exposed to >300°C continuous operation.

Define weld joint geometry per RCC-M C700 or ASME IX. Apply full penetration GTAW or SAW for Class 1 and 2 pressure boundary joints. Conduct radiographic (RT), ultrasonic (UT), and dye penetrant (PT) tests on critical joints. Include post-weld heat treatment where required.

Specify metal-to-metal or spiral wound gaskets with controlled preload zones. Perform helium leak tests (<1×10⁻⁹ Pa·m³/s) for primary seals. Apply double containment strategies and redundant sealing when parts interface with radioactive fluid loops.

Evaluate cumulative fatigue damage per ASME NB-3222.4 or RCC-M Appendix Z. Apply seismic load envelopes and modal analysis for anchoring systems. Design anchor bolts and supports to meet site-specific SSE/OBE requirements with safety margins ≥2.0.

Apply ISO 286-1 or ASME Y14.5 tolerancing with clearance or transition fits. For sliding assemblies within reactor internals, maintain tolerance stack-up control ≤±0.1 mm. Define GD&T for interface surfaces critical to bolting, sealing, or alignment during core operations.

Limit Ra to ≤0.8 µm for fluid-contact surfaces. Apply electropolishing or mechanical polishing for coolant-exposed internals. Eliminate burrs and particulates through validated deburring, washing, and 100% visual/borescope inspection to prevent flow blockage and fuel damage.

Maintain full traceability from ingot to final component via heat number, lot number, and process route card. Archive inspection reports (RT, UT, PMI), material certs (EN 10204 3.2), and welding logs. Ensure QMS alignment with ISO 19443 and IAEA GS-R Part 2.

Perform hydrostatic, pneumatic, and functional qualification tests per component class. Use 3D CMM for dimensional verification and perform hardness (≥HB200), tensile, and Charpy impact tests on production samples. Verify NDT personnel certification to ISO 9712 or ASNT SNT-TC-1A.

Design and document per ASME Section III (NCA/NB/NC/ND) or RCC-M (French PWR standard). Ensure conformity with national authorities (e.g., NRC, NNSA, CNSC) via independent third-party inspections. Prepare Design Specification, Design Reports, and Stress Analysis Reports for licensing.

Use high-strength, radiation-resistant alloys such as Inconel 600, Hastelloy, or stainless steel (316L). For components exposed to extreme radiation and temperatures, select materials certified to ASTM A240, ASME SA-240, or UNS N06600. Ensure lot traceability with mill test reports (MTR) and certificates of compliance.

Apply ASME Section III or RCC-M welding codes for high-pressure boundary components. Use full penetration welding with GTAW or SAW techniques. Post-weld heat treatment (PWHT) should follow NQA-1 or ASME Boiler and Pressure Vessel Code requirements to relieve residual stresses and ensure crack resistance.

Design with thermal conductivity in mind—materials such as copper alloys (C11000) and aluminum are ideal for heat exchangers. Use thermal modeling (FEA) to optimize component performance under cyclic thermal stress. Ensure fatigue life per ASME III Section NC or RCC-M Section M for long-term stability under operating conditions.

Use corrosion-resistant coatings such as oxide or PVD coatings, ensuring compliance with ASTM B633 or ASME SA-249 for radiation-exposed surfaces. Design components to avoid stress corrosion cracking (SCC) and galvanic corrosion in high-radiation environments, following ANSI/ANS 57.1 and ASTM G48 standards.

Perform fatigue analysis as per ASME Section III or RCC-M to ensure components withstand cyclic loads. Validate stress ranges and design for a minimum of 10⁶ cycles in operational environments. For seismic components, perform dynamic analysis to comply with seismic qualifications outlined in NRC Regulatory Guide 1.60 and IEEE 344.

Apply tight tolerances for critical parts that interact with nuclear safety systems. Maintain features such as bores, keyways, and threads with tolerances of ±0.01 mm or tighter. Use GD&T per ASME Y14.5 or ISO 1101 for geometric controls. Ensure part alignment with dowel pins, jigs, and fixtures to minimize assembly deviations.

Design sealing interfaces with metal-to-metal or elastomer seals, ensuring tightness per API 6A for high-pressure, high-temperature seals. Conduct helium leak tests (<1×10⁻⁹ Pa·m³/s) and pressure decay tests in compliance with ASME Section III and RCC-M requirements for primary containment components.

Use NDT methods such as ultrasonic testing (UT), radiographic testing (RT), and eddy current testing (ET) to inspect critical welds and components. Perform 100% inspection on safety-critical components to detect internal flaws. Follow ASME V or RCC-M standards for acceptance criteria and validation.

Maintain complete traceability from raw material to finished part. Include material certificates, welding procedure qualification records (WPQR), and NDT reports. Store component-specific documentation in an enterprise resource planning (ERP) system to support regulatory audits and meet NRC or DOE reporting standards.

Ensure designs meet nuclear industry standards, including ASME Section III, RCC-M, and ISO 9001/14001. Conduct compliance assessments with relevant nuclear authorities (e.g., NRC, CNSC) to ensure safety margins and operational effectiveness. Maintain records in compliance with 10 CFR Part 50 and related guidelines.