The Rapid RUNNERS initiative, led by the U.S. Department of Energy’s Oak Ridge National Laboratory (ORNL), aims to revolutionize hydropower manufacturing by leveraging additive manufacturing (AM) techniques to produce large metal turbine runners. These runners, critical components of hydropower systems, convert the pressure and flow of water into electricity. Currently, manufacturing these components is time-intensive, often requiring up to 18 months when produced overseas. Rapid RUNNERS seeks to drastically reduce this timeline, enhance domestic manufacturing capabilities, and support renewable energy production.
The program, officially titled Rapid Research on Universal Near Net Shape Fabrication Strategies for Expedited Runner Systems, has secured $15 million in funding over three years. By combining advanced robotic welders with conventional machining techniques, the initiative promises to produce near-net-shape runners that require minimal finishing. This approach eliminates the long lead times and high labor intensity associated with traditional forging and casting processes.
Reinvigorating Domestic Manufacturing
Currently, the majority of large turbine runners are fabricated internationally, leading to significant delays when replacements are needed. Such delays can result in months—or even years—of lost renewable energy production. Adam Stevens, an R&D staff member at ORNL and technical lead for Rapid RUNNERS, highlights the urgency: “For every month a hydropower turbine is idled, thousands of megawatt-hours of renewable electricity are forfeited. This initiative aims to close the gap in the domestic industrial base.”
By enabling the rapid production of runners domestically, the program ensures greater energy reliability, reduces dependency on international supply chains, and fosters economic growth within the U.S. manufacturing sector.
Advanced Manufacturing Techniques
Central to the project is the application of convergent manufacturing, a process that combines additive manufacturing with traditional machining and finishing. Using robotic welders, metal is deposited layer by layer to form near-final shapes, which are then refined using conventional tools. This hybrid approach reduces waste, minimizes downtime, and allows for more complex geometries and material combinations than traditional methods.
The initiative also addresses critical issues such as cavitation—a common cause of turbine failures. By applying cavitation-resistant coatings through AM, the lifespan and reliability of turbine runners can be significantly improved. “Additive manufacturing allows for the creation of shapes and material properties that were previously unattainable,” explains Curt Jawdy, head of R&D at the Tennessee Valley Authority (TVA).
Demonstrating Potential with Francis Runners
The program will fabricate three Francis runners, a type of stainless-steel turbine commonly used in hydropower dams. The first runner will serve as a prototype for testing, while the second, measuring approximately five feet in diameter, will be installed at the Ocoee Dam in Tennessee. The third, a massive 15-foot turbine weighing over 46 tons, is intended for installation at TVA’s Wilson Dam, which boasts 21 generating units with a combined capacity of 653 megawatts.
These demonstrations highlight the scalability and versatility of the Rapid RUNNERS approach, paving the way for broader adoption in other industries requiring large-scale metal components.
Collaboration and Innovation
Rapid RUNNERS brings together a consortium of partners, including Huntington Ingalls-Newport News Shipbuilding, the Electric Power Research Institute, Open Mind Technologies, ARC Specialties, and Voith Group-Hydropower. Each collaborator contributes unique expertise in areas such as robotic hardware, manufacturing strategies, and technoeconomic analysis.
The Manufacturing Demonstration Facility (MDF) at ORNL serves as the hub for the project, providing resources and fostering collaboration. Supported by the DOE’s Advanced Materials and Manufacturing Technologies Office, the MDF is instrumental in driving innovation and inspiring the next generation of manufacturing solutions.
The Future of Domestic Manufacturing
Beyond hydropower, the hybrid-manufacturing platform developed through Rapid RUNNERS has the potential to impact a wide range of industries, including defense, shipbuilding, and municipal infrastructure. By enabling the domestic production of infrastructure-scale components, the program enhances worker productivity and strengthens the U.S. industrial base.
Joe Hoagland, TVA’s Vice President of Innovation and Research, emphasizes the broader significance of the initiative: “This program fulfills TVA’s mission summarized by three ‘E’s: for Energy, it improves reliability; for the Environment, it maximizes renewable energy production; and for Economic development, it creates high-quality jobs in the U.S.”
Conclusion
Rapid RUNNERS exemplifies the transformative potential of additive manufacturing in addressing critical challenges within the energy sector. By reducing production times, enhancing component reliability, and revitalizing domestic manufacturing, the program supports the dual goals of economic growth and energy sustainability. As the initiative progresses, it promises to not only reshape hydropower manufacturing but also establish a new standard for producing large-scale metal components across industries.
