A new ORNL program could simplify manufacturing large metal in the US
The project, Rapid Research on Universal Near Net Shape Fabrication Strategies for Expedited Runner Systems, or "Rapid RUNNERS," received DOE funding of $15 million over three years.
A novel manufacturing initiative for large metal components could play a crucial role in revitalizing American manufacturing, particularly in the clean energy sector.
This innovative approach, according to researchers at Oak Ridge National Laboratory (ORNL), could significantly shorten lead times for essential parts and boost economic growth in the energy manufacturing industry.
The project, known as “Rapid RUNNERS” (Rapid Research on Universal Near Net Shape Fabrication Strategies for Expedited Runner Systems), has secured $15 million in DOE funding over three years. Its goal is to develop a system for producing large hydropower turbine runners, which are the rotating parts that convert water flow into electricity.
The project will leverage 3D printing—also known as additive manufacturing—along with traditional manufacturing techniques to produce these runners domestically. Robotic welding technology will be employed to build the runners layer by layer, using metal deposits.
Adam Stevens, an R&D staff member at ORNL and the project’s technical lead, emphasized the transformative potential of this approach.
“This could revolutionize the forging and casting processes for large-scale metal parts,” Stevens said.
Currently, most of these large metal components are manufactured overseas, and replacement parts can take years to arrive when they fail, leading to significant downtime, lost revenue, and delays in renewable energy production. Automated additive manufacturing methods, however, can rapidly produce components that are nearly the final size and shape, known as near-net-shape, before undergoing final machining. This method reduces material waste and downtime compared to traditional manufacturing processes.
“Producing one of these components can take around 18 months. If a hydropower turbine is out of commission because of a missing part, that’s 18 months of lost clean energy production. This new approach could address a critical gap in our domestic industrial capabilities,” Stevens said, pointing out the substantial impact of this progress.
Near-net-shape manufacturing refers to producing a component as close to its final dimensions as possible, which minimizes the need for extensive finishing work. The convergence of manufacturing techniques allows for incorporating necessary machining and finishing directly into the additive manufacturing process. Given the complexity of hydropower turbines, which typically require extensive manual welding and finishing, this new method could dramatically streamline production.
Brian Post, who leads ORNL’s Disruptive Manufacturing Systems Development group, and Jay Tiley, head of the lab’s Materials Structures and Processing Section, are principal investigators for the project.
The Manufacturing Demonstration Facility (MDF) at ORNL, backed by DOE’s Advanced Materials and Manufacturing Technologies Office, is providing the necessary resources and expertise. The MDF serves as a hub for a nationwide consortium collaborating with ORNL to drive innovation and transformation in U.S. manufacturing.
To showcase the system’s capabilities, the program will produce three Francis runners—a specific type of large stainless-steel turbine used in hydropower dams. The first runner will be a prototype for testing, while the second is being developed for potential installation at the Tennessee Valley Authority’s Ocoee Dam in Parksville, Tennessee. The Ocoee Dam, standing 135 feet tall and spanning 840 feet across the Ocoee River, houses five generating units that together produce 24 megawatts of electricity.
Read more about the project in this ORNL news release.
Like what you've read?
Forward to a friend!