US nuclear plants are aging, with more than two thirds of the fleet past 40 years of operation and many pursuing license renewal into the 2050s. A key maintenance challenge is flow accelerated corrosion in carbon steel components such as cross-under piping, feedwater systems, and steam turbine parts. If left unmanaged, FAC can lead to wall thinning, costly repairs, and major component replacement. High Velocity Thermal Spray, or HVTS, is a cold applied metallic cladding method that protects susceptible surfaces without welding. Because it avoids heat affected zones, it can be applied during planned outages without extending them. One plant used phased HVTS to protect about 8,000 square feet of cross-under piping per unit, and inspections found areas treated in 2009 still in good condition after roughly 15 years. The article is sponsored by Integrated Global Services, so the case study is vendor supplied. Still, it offers a useful look at how targeted surface engineering can help preserve existing nuclear assets and support long term carbon free power generation.
