Oak Ridge and A.J. Tuck Electroform Leak-Free HIP Cans onto 3D-Printed Forms

en.Wedoany.com Reported - Oak Ridge National Laboratory, in collaboration with A.J. Tuck Company, has developed a manufacturing method that combines 3D printing with electroforming to produce complex, leak-free hot isostatic pressing (HIP) cans. HIP cans are sealed containers used to consolidate metal powders into high-performance components under high temperature and high pressure, with applications including advanced nuclear energy systems.

The research addresses the issue that the U.S. forging and casting supply chain remains largely concentrated overseas. ORNL research associate scientist Vanshika Singh stated that the project demonstrates electroforming can produce leak-free HIP cans for advanced nuclear applications, potentially enabling domestic manufacturing of such components and reducing supply chain pressure.

The process begins with a 3D-printed polymer form that defines the component's shape. The form is then placed in an electroplating bath, where an electric current is applied to deposit a dense metal shell approximately 2 to 3 millimeters thick over the printed geometry. After an acid solution dissolves and removes the polymer, a hollow metal structure remains, which is then filled with metal powder, sealed, and processed in a hot isostatic pressing unit. ORNL mechanical engineer Amiee Jackson noted that electroforming enables rapid fabrication of intricate, high-precision shapes while avoiding many of the limitations of traditional manufacturing methods.

In the first phase, five leak-free cylindrical cans were produced, each 15.2 centimeters tall and 10.2 centimeters in diameter, featuring an integrated port design that eliminates the need for separate welding operations. The second phase is underway, applying the process to more complex geometries, including impellers and valves used in nuclear systems.

A.J. Tuck Company president Dara Williams stated that the verified production of leak-free HIP cans at such precision truly opens the door for domestic nuclear manufacturing in the United States. The project team has also filed an invention disclosure and a provisional patent application covering the technology.