• Hydropower fleet over 2,200 plants, 65 years old, relies on large bespoke parts hard to source. • Supply chain strains: long lead times, disappearing suppliers, aging infrastructure threaten reliability. • EPRI pioneers convergent manufacturing, blending conventional metal stock with 3D printed features. • RD&D project with SRP and LEAS produced a hydropower wicket gate via wire‑arc DED. • Wire‑arc DED enables large‑area additive parts, cutting schedules and meeting stringent utility standards. • EPRI’s AM3 program tackles barriers-experience, codes, qualification-to accelerate adoption.
Article Summaries:
- EPRI, Salt River Project (SRP) and Lincoln Electric Additive Solutions (LEAS) completed a first‑of‑its‑kind demonstration of convergent manufacturing for a hydropower wicket gate. Using wire‑arc directed energy deposition (DED), the team printed a CF3M stainless‑steel “leaf” onto a forged 316L bar, cutting wire use by about 50 % and simplifying handling. The project met stringent utility standards through extensive inspection-including penetrant, radiography, ultrasonic testing, and mechanical testing-showing that large‑area DED can deliver high‑quality, economically viable big parts for aging hydropower infrastructure. The success paves the way for broader adoption of additive manufacturing in the energy sector.
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