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Laser beam welding is one of the jointing processes by irradiating laser beam on the material surface locally and widely used at various industrial fields. Toshiba has developed various laser-based maintenance and repair technologies and already applied them to several existing nuclear power plants. Laser cladding is a technique to weld the corrosion resistant metal onto a substrate surface by feeding filler wire to improve the corrosion resistance. Temper-bead welding is the heat input process to provide the desired microstructure properties of welded low alloy steels without post weld heat treatment, by inducing proper heat cycle during laser welding. Both laser welding technologies would be performed underwater by blowing the shielding gas for creating the local dry area. In this report, some evaluation results of material characteristics by temper-bead welding to target at Reactor Coolant System nozzle of PWR are presented.

The authors have applied laser peening without coating (LPwC) to metallic materials. Compressive residual stress nearly equal to the yield strength of the materials was imparted on the surface. Accelerating stress corrosion cracking (SCC) tests showed that LPwC had a significant effect to prevent the SCC initiation of sensitized materials of SUS304, Alloy 600 and the weld metal, Alloy 182. Push-pull type fatigue testing demonstrated that LPwC drastically enhanced the fatigue strength of fillet-welded rib-plates of SM490A.

Decommissioning of aged nuclear reactors is planned, and cutting technologies for thick structure are necessary to reduce storage space of radioactive wastes. Though thermal cutting technology is suitable for cutting thick materials, radioactive fume is one of the problems due to increase the environmental dose. A water jet-guided laser cutting technology is one of the solutions for cutting irradiated materials, because radioactive fume is confined in the water and doze level won’t be increased. However, this technology was developed for precision machining like dicing and slotting of silicon wafers, cutting thick materials by using this process is very diffcult. In this study, cutting technology for thick material with a water jet-guided laser was discussed. Phenomenon during cutting thick stainless steel was observed by using high speed camera and optimum conditions for both water jet and laser cutting were derived. Finally, 50mm thick stainless steel plate was successfully cut by using this technology.

Stress Corrosion Cracking (SCC) is one of the major concerns for aged nuclear reactors. SCC-susceptible materials have been employed in a wide variety of applications in the nuclear industry. Laser Peening (LP) is a method for the SCC mitigation that eliminates surface tensile stress using impulsive effect of high-pressure plasma induced by irradiation with high-power laser pulses in the water. To apply LP to nuclear reactor internals, Toshiba has developed a new process which needs no protective coating on the materials and optimizes the conditions for the laser irradiation. Its effects for stress improvement and SCC-mitigation of laser-peened materials were confirmed through SCC tests for austenitic stainless steels and nickel-based alloys. Also integrity of the laser-peened materials was confirmed through various examinations. Toshiba developed the LP system for the core shroud and the reactor bottom part of BWRs, and has been applying it to actual Japanese nuclear reactors since 1999. For PWRs, Toshiba developed the system for Bottom-Mounted Instrumentation (BMI) nozzles and other Reactor Vessel (RV) nozzles, and has been applying it to Japanese PWRs since 2004. So far Toshiba has already completed LP operations for 2 PWR plants and 8 BWR plants in Japan. In consideration of extending the LP system to BWRs and PWRs overseas, a portable LP system equipped with a small size laser oscillator has been developed. We confirm the possibility that the portable LP system makes the outage period shorter.Copyright © 2011 by ASME

In repair welding for nuclear reactor vessel, low alloy steels are affected by heat input during welding process. The conventional repair welding for wall steel constructions requires post weld heat treatment (PWHT) to achieve the desired microstructure properties. However, post weld heat treatment is very difficult for some structures in operating plants. In such case, temper-bead welding technique is available as a repair welding method. Temper-bead welding employs a multi-pass deposition of welding metal. Each layer of beads provides heat for thermal treatment of the previous weld bead or layer, which lowers hardness of the heat affected zone (HAZ) and improves mechanical properties like the toughness. Toshiba has developed underwater laser cladding and laser seal welding techniques for reactor components repair welding. In this report, some experimental results of laser based underwater temper-bead welding are presented.

Multifunction laser welding head has been developed. The head is able to perform not only underwater laser welding as repair, but also laser peening as preventive maintenance and laser ultrasonic testing as inspection. By using the effect of color aberration with optics, laser beam was focused to the ideal spot size on each process. Underwater laser welding was carried out onto EDM slit with the developed head and sealing ability with deposited weld metal was confirmed. As preventive maintenance, laser peening was also performed on the material surface with the developed head, and stress improvement ability was confirmed. For inspection with the developed head, a new method of visualizing weld defects in water by laser-ultrasonics has developed. Furthermore, developing synthetic aperture focus technique for visualized inspection surfaces 2-dementionally, the inspection result like penetrant testing despite underwater environment was achieved. Therefore, practicality of the developed head on each process was confirmed.Copyright © 2009 by ASME

Laser peening introduces compressive residual stress on metal surface by irradiating laser pulses underwater without any surface preparations. The process utilizes the impulsive effect of high-pressure plasma generated through ablative interaction of each laser pulse with material. Laser peening systems, which deliver laser pulses with mirrors or through an optical fiber, were developed and have been applied to preventive maintenance against stress corrosion cracking (SCC) in nuclear power reactors since 1999. Each system was composed of laser oscillators, a beam delivery system, a laser irradiation head, remote handling equipment and a monitor/control system. Beam delivery with mirrors was accomplished through alignment/tracking functions with sufficient accuracy. Reliable fiber-delivery was attained by the development of a novel input coupling optics and an irradiation head with auto-focusing. At present, we are developing a newer concept and the prototype system has been just completed, which is extremely small, reliable and easy-handled.Copyright © 2008 by ASME

Laser peening is a process to improve residual stress from tensile to compressive in surface layer of materials by irradiating high-power laser pulses on the material in water. Toshiba has developed a laser peening system composed of Q-switched Nd:YAG laser oscillators, laser delivery equipment and underwater remote handling equipment. We have applied the system for Japanese operating BWR power plants as a preventive maintenance measure for stress corrosion cracking (SCC) on reactor internals like core shrouds or control rod drive (CRD) penetrations since 1999. As for PWRs, alloy 600 or 182 can be susceptible to primary water stress corrosion cracking (PWSCC), and some cracks or leakages caused by the PWSCC have been discovered on penetrations of reactor vessel heads (RVHs), reactor bottom-mounted instrumentation (BMI) nozzles, and others. Taking measures to meet the unconformity of the RVH penetrations, RVHs themselves have been replaced in many PWRs. On the other hand, it’s too time-consuming and expensive to replace BMI nozzles, therefore, any other convenient and less expensive measures are required instead of the replacement. In Toshiba, we carried out various tests for laser-peened nickel base alloys and confirmed the effectiveness of laser peening as a preventive maintenance measure for PWSCC. We have developed a laser peening system for PWRs as well after the one for BWRs, and applied it for BMI nozzles, core deluge line nozzles and primary water inlet nozzles of Ikata Unit 1 and 2 of Shikoku Electric Power Company since 2004, which are Japanese operating PWR power plants. In this system, laser oscillators and control devices were packed into two containers placed on the operating floor inside the reactor containment vessel. Laser pulses were delivered through twin optical fibers and irradiated on two portions in parallel to reduce operation time. For BMI nozzles, we developed a tiny irradiation head for small tubes and we peened the inner surface around J-groove welds after laser ultrasonic testing (LUT) as the remote inspection, and we peened the outer surface and the weld for Ikata Unit 2 supplementary. For core deluge line nozzles and primary water inlet nozzles, we peened the inner surface of the dissimilar metal welding, which is of nickel base alloy, joining a safe end and a low alloy metal nozzle. In this paper, the development and the actual application of the laser peening system for PWR power plants will be described.Copyright © 2006 by ASME

Laser peening is a surface enhancement process that introduces compressive residual stress on materials by irradiating laser pulses under aqueous environment. The process utilizes the impulsive effect of high-pressure plasma generated by ablative interaction of each laser pulse. Around a decade ago, the authors invented a new process of laser peening without any surface preparation, while the conventional types required coating that prevented the surface from melting. Taking advantage of the new process without surface preparation, we have applied laser peening without coating (LPwC) to nuclear power plants (NPPs) as a preventive maintenance against stress corrosion cracking (SCC). Toshiba released the first LPwC system in 1999, which delivered laser pulses through waterproof pipes with mirrors. In 2002, fiber-delivery was attained and significantly extended the applicability. Now, the development of the third generation system has been just accomplished, which is extremely simple, reliable and easy-handled.Laser peening is a surface enhancement process that introduces compressive residual stress on materials by irradiating laser pulses under aqueous environment. The process utilizes the impulsive effect of high-pressure plasma generated by ablative interaction of each laser pulse. Around a decade ago, the authors invented a new process of laser peening without any surface preparation, while the conventional types required coating that prevented the surface from melting. Taking advantage of the new process without surface preparation, we have applied laser peening without coating (LPwC) to nuclear power plants (NPPs) as a preventive maintenance against stress corrosion cracking (SCC). Toshiba released the first LPwC system in 1999, which delivered laser pulses through waterproof pipes with mirrors. In 2002, fiber-delivery was attained and significantly extended the applicability. Now, the development of the third generation system has been just accomplished, which is extremely simple, reliable and easy-handled.

In nuclear power plants, irradiated materials like Control Rod (CR) should be stored underwater after service. Due to reducing the storage space, underwater cutting technology is expected. In this study, we developed underwater cutting technology of thick stainless steel with YAG laser in order to cut used CR. Preliminary tests were performed with flat plate test-pieces to optimize the cutting conditions. Due to creating a local dry area between nozzle and test-piece, high-pressure air was blown from the nozzle. Underwater laser cutting was carried out by laser irradiation power of 4 kW, changing the parameters of cutting speed, distance between the nozzle and test-piece, and thickness of the test-piece. We also investigated the wastes like dross and aerosols by laser cutting. Amount of dross was approximately 0.1 kg/m after cutting a 14 mm thick stainless steel plate, which is estimated to be less than other cutting method. Based on these results, we developed underwater cutting system of CR test-piece with YAG laser as a mock-up test. In the cutting torch, there was tracking system was introduced to keep the distance between the nozzle and the test-piece constant, and cutting monitor was also set-in to detect whether the test-piece was successfully cut or not. We have already tried to cut the CR test-piece with this facility and successfully cut in half.

A technology to prevent the occurrence of Intergranular Stress Corrosion Cracking (IGSCC) by irradiating a high power Nd:YAG laser beam was developed. Laser Desensitization Treatment (LDT) process was realized by irradiating a laser beam onto the sensitized Heat Affected Zone (HAZ) surface of SUS304 stainless steel. LDT was formed by both a molten layer of approximately 0.2mm depth and a solution heat treated layer. The results of a Creviced Bent Beam (CBB) test showed that no cracks had appeared on the surface of LDT. After LDT was applied in the vicinity of welding joints on the inside surface of pipes, tensile residual stress was measured there. On the other hand, the tensile stress of outside surface of the pipes was decreased. From these results, LDT processing on the inside surface of a pipe can be expected to prevent the occurrence of IGSCC owing to the effect of both metallurgical improvement and decrease of the residual stress on the outside surface of the pipe. We developed the LDT processing system and successfully applied on the pipes of some actual nuclear power plants.A technology to prevent the occurrence of Intergranular Stress Corrosion Cracking (IGSCC) by irradiating a high power Nd:YAG laser beam was developed. Laser Desensitization Treatment (LDT) process was realized by irradiating a laser beam onto the sensitized Heat Affected Zone (HAZ) surface of SUS304 stainless steel. LDT was formed by both a molten layer of approximately 0.2mm depth and a solution heat treated layer. The results of a Creviced Bent Beam (CBB) test showed that no cracks had appeared on the surface of LDT. After LDT was applied in the vicinity of welding joints on the inside surface of pipes, tensile residual stress was measured there. On the other hand, the tensile stress of outside surface of the pipes was decreased. From these results, LDT processing on the inside surface of a pipe can be expected to prevent the occurrence of IGSCC owing to the effect of both metallurgical improvement and decrease of the residual stress on the outside surface of the pipe. We developed the LDT processing sy...