DOE Funding Opportunity DOE FOA-0001817 - Energy.gov

DOE Funding OpportunityDE-FOA-0001817Scott J. Shargots – Principle InvestigatorJoseph E. Ramsey – Project ManagerDecember 18, 2019 2019 BWX Technologies, 2019Inc. BWXAll rightsTechnologies,reserved. ReprintedInc. All rightswith reserved.permission.Reprinted with permission.

Company HighlightsBWXT is one of the world’s most prolific nuclear technology innovation companies and the sole manufacturer of navalnuclear reactors for U.S. submarines and aircraft carriers.NYSE: BWXT6,250300 highly skilledemployeescommercial nuclearsteam generatorsmanufactured 1.8 billionUSD1.5 million in 2018 revenuesCanada DeuteriumUranium (CANDU)fuel bundles provided1114major manufacturingfacilities totaling 3.8million square feetU.S. Department of Energylaboratories, environmentalcleanup projects and NASA sites60 8,000 years manufacturing navalnuclear componentsand reactorsfuel elements delivered to U.S.national laboratories, universitiesand international customers 2019 BWX Technologies, Inc. All rights reserved. Reprinted with permission.

Our HistoryWe have been at the forefront of the commercial nuclear power generation and government nuclearindustries for decades, achieving an impressive number of firsts along the way.HISTORY OF INNOVATIONNUCLEAR FLEETEXPANDING CAPABILITIES1850s1950s2000sOur heritage dates back to theinvention of the water tube boilerby Stephen Wilcox, who laterfounded The Babcock & WilcoxCompany.Our naval nuclearlineage began withthe USS Nautilus, theworld’s first nuclearpowered submarine.We completed key acquisitions anda successful spin-off of our powergeneration business while developingnew, advanced technologies. 2019 BWX Technologies, Inc. All rights reserved. Reprinted with permission.3

BWXT, A Complete Life Cycle Provider – What We DoAdvanced TechnologiesEnvironmental ManagementRadiochemistry Advanced Reactors Design Developmental Testing Manufacturing DevelopmentIncluding Additive Radioisotope Development Waste Management Facility Decontamination,Decommissioning & Demolition Remediation & Restoration Medical Isotope Production Research & Development Processing, Packaging &Delivery ServicesCommercial Nuclear FuelLaboratory ServicesResearch Test Reactors CANDU Fuel Fuel Handling & EngineeredSolutions Nuclear Non-Proliferation Failure Analysis Nondestructive Evaluation &Inspection Systems Strategic Materials Fuel Plates & TargetManufacturing Fuel Powder Low-Enriched UraniumFuel DevelopmentCommercial NuclearComponentsNaval Nuclear PropulsionSpace Applications Design Engineering Precision Manufacturing Nuclear Fuel Nuclear Thermal Propulsion Reactor Design & FuelDevelopment Ground Testing Steam Generators Heat Exchangers Reactor VesselsComplex OperationsManagement Nuclear Facilities & OperationsManagement Nuclear Materials Management Environmental Safety & HealthManagementNuclear Services Steam Generator Services PWR Heat Exchanger Services Reactor Services 2019 BWX Technologies, Inc. All rights reserved. Reprinted with permission.4

Funding Opportunity: DE-FOA-0001817 FOA Title: U.S. Industry Opportunities for AdvancedNuclear Technology Development Topic: Establishment of an integrated, advancedmanufacturing and data science driven paradigm foradvanced reactor systems Award (ID) Number: DE-NE0008744 Awardee: BWXT Nuclear Energy, Inc. Awardee DUNS #: 829891394 Collaborator: Oak Ridge National Laboratory /Manufacturing Demonstration Facility (FFRDC)Arcam Spectra H Installed atORNL-MDF 2019 BWX Technologies, Inc. All rights reserved. Reprinted with permission.5

DE-FOA-0001817 - Acknowledgements BWXT Brian BargerJason BrownAndrew Chern*Travis Fritts*Chris FolmarDanny Galicki*James GallierDon HillRuss Jensen Ryan Kitchen*Matt LeVasseurTravis McFalls*Matt Preston*Dudley RaineRyan ZieglerBryan ZilkaDave ZillesORNL Jason AllenXiang (Frank) ChenRyan DuncanBetsy EllisMichael KirkaKory LintonVincent PaquitXin Sun*Co-located at ORNL / MDF 2019 BWX Technologies, Inc. All rights reserved. Reprinted with permission.6

ObjectivesID4BT Rapid DevelopmentParadigm Technology Driven Enabling theCommercialization of HighPower Dense NuclearDesignsReactor Design GEN IV Compact Cost Effective Inherently SafeAdvanced Materials Technology Leap Not AM Today Increased SafetyMarginsAdditive Manufacturing Unique Geometries Improved ThermalEnergy Management Customized Design 2019 BWX Technologies, Inc. All rights reserved. Reprinted with permission.7

ID4BT Integrated 3D Design, Build, Test, & Data ScienceIntegrated Design RequirementsDevelopment Mechanical Design Core Physics Thermal Analysis VHTR Concept UHTR ConceptBuild AM HAST X AM Mo AlloysTest Chemical Analysis Mechanical Tests PowderCharacterizationData Science In-situ monitoring 3D part reconstruction 2019 BWX Technologies, Inc. All rights reserved. Reprinted with permission.8

Why Electron Beam Additive Technology?oThe benefits of EBM over other AM technologies: Low risk of contamination due to processing in a vacuum Pre/Post heating allows builds to be performed at elevatedtemperatures Accurate and fast beam location control Precision control over processing parameters and scanstrategy» Precise pre/post heating during builds» Manipulate grain microstructure (equiaxed vs columnar)oArcam Spectra H 6kW beam power 250mm x 250mm x 430mm build volume BWXT has the first operational unit in the U.S. 2019 BWX Technologies, Inc. All rights reserved. Reprinted with permission.9

Hastelloy X Build Overview – Spectra HAccomplishments:ooMay 2019Dec. 201970 Builds over 7 monthsParameter Development Arcam Algorithm DefectsVisual DefectsSurface FinishPorosity and MicrostructureSurfaceFinishTensile Tests:oAs-built Configuration oYS exceeds ASTM standardsUTS exceeds ASTM standards» In 2 of 3 configurationsAfter Post-Processing Heat Treat YS exceeds ASTM standardsUTS exceeds ASTM standards» In 2 of 3 configurations% Elongation exceeds ASTM standards 2019 BWX Technologies, Inc. All rights reserved. Reprinted with permission.10

Molybdenum Build Overviewo Phase 1 Development Mini-vat builds of pure Moly on theArcam S12 Moly alloy melt tests on the ArcamS12LOF Defect onsurface of Mo Build 4Virgin Moly Powdero Phase 2 Development Large builds of pure Moly on theArcam Spectra H Mini-vat builds of Moly alloys on theArcam S12 or othero Phase 3 Development Large builds of Moly alloys on theArcam Spectra HMoly Build 4NIR Image fromMoly build 7showing fewdefectsOptical Image ShowingCrack Free Walls 2019 BWX Technologies, Inc. All rights reserved. Reprinted with permission.11

Data Science Development and Digital Twinso Machine learning algorithms for predictionof build effects and property predictiono Develop accurate 3D digital twino GD&T /- 90um on edges /- 180 um edge to edgeo Pore DetectionSignificantporosity detectedduringfabrication of thissolid structure(top)Verification ofimprovement(below) 100um or larger at 99.99% detection 15% false positiveso Working method for in-situ crack detection 2019 BWX Technologies, Inc. All rights reserved. Reprinted with permission.12

SummaryoDesign oHastelloy X Builds oBuilds completeExcellent mechanical propertiesAcceptable as-built surface finishesAcceptable GD&TCoreArrangement3D Digital TwinMolybdenum TestBuildHAST X Thin Wall TestBuildMolybdenum Builds oCompleted multiple design/analysis iterationsContinue developing the VHTR and UHTR conceptsSuccessful crack free bulk buildsMoly alloy melt test reveal crack free melt poolsData Science Accurately develop 3D digital twin of as-built part99.99% pore detectionSuccessfully providing feedback loop to build strategyWorking on feedback loop to design/analysis software 2019 BWX Technologies, Inc. All rights reserved. Reprinted with permission.13

years manufacturing naval nuclear components and reactors 1.8 billion USD in 2018 revenues . Our naval nuclear lineage began with the USS Nautilus, the world’s first nuclear- . Nuclear Fuel Nuclear Serv