NEWS


C


MAKING THE GLOBAL LEAP IN NUCLEAR WELDING TECHNOLOGY


ompletion of the first full- sized Small Modular Reactor (SMR) nuclear vessel


demonstrator assembly at Sheffield Forgemasters has signalled a global leap in welding technology. The company has pioneered the


industrialisation of Local Electron-Beam Welding (LEBW), and complete weld- assembly of the vessel marks a pivotal moment in welding development, taking less than 24 hours to complete four, thick, nuclear-grade welds, typically requiring a year of work to complete. With a diameter of 3 m and a wall


thickness of 200 mm, the construction of the vessel showcases the reliability and capabilities of (LEBW), setting a dramatic new standard for weld-joining thick-walled components, previously unrivalled in a demonstrator model. Professor Jesus Talamantes-Silva,


Research, Design and Technology Director at Sheffield Forgemasters, says: “We are delighted to have reached a significant milestone in assembling a nuclear vessel demonstrator, using electron beam welding for the first time at this scale, with 100% success and no defects.” The company’s RD&T team deployed


specially developed parameters, meticulously fine-tuned during the welding development stage, including innovative sloping-in and sloping-out techniques to start and finish the weld,


ensuring a clean and complete weld join. Sheffield Forgemasters is said to be the


only company in the UK with the capability to manufacture the large forgings required for SMRs, and it now has years of developmental lead on global competitors in welding thick-walled assemblies. Dr Michael Blackmore, Senior


Development Engineer and Project lead says: “The implication of this technology within the nuclear industry is monumental, potentially taking high-cost welding processes out of the equation. “Not only does this reduce the


need for weld-inspections, because the weld-join replicates the parent material, but it could also dramatically speed up the roll-out of SMR reactors across the UK and beyond, that’s how disruptive the LEBW breakthrough is.” The demonstration of LEBW


technology’s potential opens new horizons for more efficient, low cost and less time-heavy nuclear assemblies and also has far-reaching implications for other projects which require thick-walled welded assemblies. Dr Jacob Pope, Development Engineer


and LEBW machine tool installation lead adds: “We thank the Government’s Department for Energy Security and Net Zero for enabling the project through its Nuclear Innovation Programme. We also thank our esteemed partner, Cambridge Vacuum Engineering, for their invaluable


6 / WELDING WORLD MAGAZINE - ISSUE 02 - March 2024


support throughout this endeavour. Their remote and on-site assistance played an instrumental role in the success of this milestone, highlighting the collaborative spirit that drives us forward.” The company is positioned to


expand into nuclear fabrication after recently passing a highly testing audit to regain coveted ASME status as a key supplier of heavy forgings and castings to the civil nuclear power market. ASME NPT (Nuclear Partials) is an


advanced accreditation, enabling the business to become the only UK producer of heavy forgings and castings able to physically weld-fabricate such safety critical components for the heart of a nuclear power plant. Ian Nicholls, group technical director,


explains: “Sheffield Forgemasters has passed the ASME audit to qualify as a Materials Organisation with NPT status. The accreditation is a huge development with enhanced requirements and disciplines embracing all our processes, employees and selected sub-suppliers.” Sheffield Forgemasters first


gained ASME accreditation as a Nuclear Materials Organisation in 1992 and will now continue its work to develop manufacturing technologies for the next generation of SMR civil nuclear power plants.


www.sheffieldforgemasters.com


Page 1  |  Page 2  |  Page 3  |  Page 4  |  Page 5  |  Page 6  |  Page 7  |  Page 8  |  Page 9  |  Page 10  |  Page 11  |  Page 12  |  Page 13  |  Page 14  |  Page 15  |  Page 16  |  Page 17  |  Page 18  |  Page 19  |  Page 20  |  Page 21  |  Page 22  |  Page 23  |  Page 24  |  Page 25  |  Page 26  |  Page 27  |  Page 28  |  Page 29  |  Page 30  |  Page 31  |  Page 32  |  Page 33  |  Page 34  |  Page 35  |  Page 36  |  Page 37  |  Page 38  |  Page 39  |  Page 40  |  Page 41  |  Page 42  |  Page 43  |  Page 44