NuclearAMRC Q4 2013

news ISSUE 13

Tools for the new generation World-leading manufacturing for Hinkley Point and beyond

EDF milestone Sharing in Growth Nnuman research EUROPEAN UNION Bloodhound SSC Investing in Your Future European Regional Triple Bar training Development Fund 2007-13

ALSO IN THIS ISSUE SME open house EDF agreement ‘a significant milestone’ for new build

First of a new generation: the proposed new reactors at Hinkley Point

EDF Energy and the UK government have agreed linked to the consumer price index. If EDF confirms Vincent de Rivaz, EDF Energy chief executive, commercial terms for EDF’s proposed Hinkley that it will also build new capacity at Sizewell, said: “The project will kick start the UK nuclear Point C power station, a vital step towards a new that price is reduced to £89.50/MWh to reflect programme and will help rebuild the nation’s generation of nuclear power stations in the UK. economies of scale. industrial stamina. The progress so far on the project reflects the great skill and determination of a world The long-awaited deal sets the financial structure for The Department of Energy and Climate Change class team which is ready to get to work and turn the long-term supply of low-carbon electricity from (DECC) forecasts that electricity from Hinkley Point Hinkley Point C into a reality.” new reactors at Hinkley Point. EDF still has to make a C will be competitive with future gas generation final investment decision on the project. prices. The contract will last for 35 years from The agreement was welcomed by the other UK new the date of commissioning, and will give EDF an build groups. “This is a significant milestone in the development of estimated rate of return of around 10 per cent. new nuclear power stations in the UK,” commented “This is important in sustaining momentum behind Mike Tynan, chief executive of the Nuclear AMRC. EDF also announced details of the investment the UK nuclear programme,” said Alan Raymant, “Utilities, developers and investors need confidence consortium for Hinkley Point C. EDF Group will chief operating officer for Horizon Nuclear Power. in both long-term cost and revenue profiles for retain 45-50 per cent of the venture, with reactor “We’re some way from our own price negotiations making a final investment decision, and I’m sure that provider Areva taking 10 per cent. Following the with government, but when we get to that stage this announcement will be welcomed by everyone government’s go-ahead for Chinese investment in we are confident we’ll reach a deal that’s fair for bill involved in UK new nuclear build. UK nuclear generation (see box), China General payers and works for investors.” Nuclear Corporation and China National Nuclear “The Nuclear AMRC looks forward to the Hinkley “This is an extremely important and symbolic Corporation will take a total 30-40 per cent stake. Point scheme moving forward with EDF Energy, and milestone in the journey to delivering new nuclear Other interested parties may take up to 15 per cent is already working closely with EDF and Areva to power stations for the UK,” said Robert Zadora, of the venture. develop the UK supply chain.” executive director of NuGen. “It shows progress and The consortium will invest around £16 billion in commitment, and gives potential investors in UK new Both Areva and EDF are using the Nuclear AMRC’s two EPRs at Hinkley Point, including £14 billion nuclear more clarity, and a welcomed boost.” Fit For Nuclear programme to identify potential in construction costs. Around 57 per cent of the suppliers of manufactured components. Fit For • Fit For Nuclear: namrc.co.uk/work-with-us/f4n construction value could be spent in the UK, Nuclear lets companies measure their operations EDF says. • UK new build plans: against the standards required to supply the nuclear namrc.co.uk/intelligence/uk-new-build-plans industry, and take the necessary steps to improve EDF confirmed that it has finalised terms with the their readiness. four top-tier suppliers to the project: Bouygues TP/Laing O’Rourke for civil works; Costain for The new deal guarantees a price for electricity from marine work; Alstom for turbines; and Areva for Hinkley Point C under the contract for difference instrumentation and controls, the nuclear steam mechanism, which also applies to windfarms and supply system and fuel. other low-carbon sources. The price is £92.50/MWh,

Shovel-ready: preparing the ground for Hinkley Point C

Nuclear AMRC news Q4 2013 2 Tynan View The

The price of nuclear renaissance

Much of the reaction to the agreement between EDF Energy and the UK So, EDF will move forward to a final investment decision at Hinkley Point. government focused on the headline price that will be paid over the next 35 Of the other new build groups, Horizon Nuclear Power needs Hitachi to years – £92.50 per MWh, around twice the current wholesale price. How is take its Advanced Boiling Water Reactor (ABWR) through the generic design such a price justified? assessment process, which could take four years. And NuGen will need to decide on which technology it will deploy at Moorside, Sellafield, before it can Proponents will claim that increasing demand for low-carbon electricity has even apply for planning permission. to be met by a significant baseload generation technology, and that nuclear power is the obvious choice. High capital costs are offset by significantly lower All of this means that we will not see a new nuclear power station generating costs for operation through the 60-year life of the stations – however the electricity in the UK until sometime in the 2020s. And who will actually investment risk has to be paid for, and this is reflected in the price needed to construct these stations? Commitments are being made by the developers attract that investment. to support UK manufacturers, but to what extent? Where will the high value components and fabrications be made? Opponents will say that uncertainties over ultimate waste disposal from the stations and decommissioning costs add an unacceptable cost burden to the New nuclear reactor technology for the UK is likely to be French, American or consumer and that greater emphasis should be placed on other forms of Japanese, so many people are questioning how much of these big infrastructure renewable energy. schemes will truly be “Made in Britain”. Our mission at the Nuclear AMRC is to maximise the involvement of UK manufacturers. We will do this through Ultimately, the domestic, industrial and commercial sectors of our economy two major programmes: the civil nuclear Sharing in Growth programme that demand electricity at the press of a button, irrespective of whether the sun is now helping UK manufacturers increase their competence, capability and shines or the wind blows. Given that over 40 per cent of the UK electricity cost effectiveness to secure lucrative contracts at home and abroad; and our generating capacity is currently met by coal-fired power stations, we will innovative industry-led advanced manufacturing R&D programme. need to take tough decisions if we want to move to a low-carbon economy, stabilise electricity prices and secure our own supply of energy With the UK new build programme passing a major milestone, we are for the UK. looking forward to playing an exciting role in a new era of civil nuclear power for the UK.

Go-ahead for China investment

The UK government has confirmed that Chinese companies can invest in the involvement of participating Chinese companies, and will work to develop nuclear power generation in Britain. relationships and interest in areas of manufacturing and business support which will lead to new opportunities for the UK.” Chancellor George Osborne announced that Chinese companies can take a stake – including potential majority stakes – in UK nuclear new build consortia The announcement follows the signing of a memorandum of understanding while visiting Taishan nuclear power station, a collaboration between EDF and on civil nuclear collaboration between the UK and China. The memorandum the China General Nuclear Power Company. sets the strategic framework for collaboration on investment, technology, construction and expertise. “This is a significant and welcome investment announcement for the UK’s nuclear new build programme and supporting supply chain, which could As well as supporting Chinese investment in the UK, the agreement will make lead to real export potential for UK manufacturers into China’s internal, sure that British companies such as Rolls-Royce, International Nuclear Services fast-growing, multi-billion pound nuclear new build market,” commented and engineering companies such as Mott MacDonald can be part of China’s Martin Ride, supply chain consultant at the Nuclear AMRC. “We welcome multi-billion pound new nuclear programme.

3 namrc.co.uk Nnuman marks first year of next-generation

Laser welding: new ways to join high performance alloys for nuclear components research

Welding New 16kW laser robotic welding facilities have now been commissioned at The University of Manchester’s Manufacturing Technology Research Laboratory. Initial research will focus on thick- section narrow groove welding for SA508 Grade 3 Class 1 steel, a high-performance ferritic steel used in nuclear pressure vessels.

Fuels Two trailblazer projects are underway to develop new materials for nuclear fuel pellets and cladding.

The University of Manchester is working with Mittweida University in Germany on novel brazing techniques for silicon carbide composites. This material could significantly improve the performance Collaboration for the next generation: of light water reactor fuel cladding, especially in case Nnuman team members of accidents, but problems in joining the material have limited its use. A year after its launch, the Nnuman research The Nnuman programme is also investigating programme is investigating key areas of innovative improvements in deep hole drilling techniques, using The Manchester team is also investigating how nuclear manufacturing and analysing data from trials the Nuclear AMRC’s TBT ML700 machine. The composite ceramics can be used in fuel pellet at the Nuclear AMRC. first stage of work focuses on drill tube stability – an composition to improve the trade-off between initial project investigating the frequency response of good fission gas retention and good thermal Nnuman (New nuclear manufacturing) is a five year, the drill tube is now nearing completion. The next conductivity. £8 million collaboration between the Universities of stage will apply high frequency assisted machining Manchester and Sheffield, part-funded by EPSRC. at the tool itself, with the aim of reducing cutting Future development The two universities are working with industrial force and improving process reliability by breaking The Nnuman programme will continue for another partners on a series of research projects into long swarf into short discontinuous chips which are four years, producing significant experimental data, innovative manufacturing technologies for the next more easily evacuated and less likely to block the interpretation and publications over a range of generation of nuclear power. drill tube. manufacturing technologies. The project now involves 32 post-doctoral Near-net shape manufacturing As the programme develops, the Nnuman researchers, technicians, academics and professional consortium will build on a growing range of support staff, plus senior academics and industry Nnuman is concentrating on the hot isostatic participants and collaborators from industry and secondees. pressing (hipping) technique, which creates near-net academia. It will also call on the capabilities of some shape components by pressing metal powder into of the world’s most advanced nuclear research Highlights of the first year’s work are outlined the desired shape under very high pressures and below. facilities, including The University of Manchester’s temperatures. Dalton Cumbrian Facility (DCF) which officially Machining In parallel with process development work at the opened in September. Research at the DCF focuses Nuclear AMRC, the Manchester team is looking on the potentially damaging effects of radiation on a The Nuclear AMRC machining team in Sheffield wide range of materials. have been subjecting samples of 304L stainless steel at the nature and significance of defects in hipped to deliberate abuse, to better understand the effects structures. A three month trailblazer project is The most promising new processes will be of machining parameters on product performance. underway, to be followed by an in-depth study of the developed towards production readiness in The samples have undergone detailed materials link between powder characteristics and component collaboration with the Nuclear AMRC and the analysis at The University of Manchester’s Dalton microstructure and performance, including analysis of National Nuclear Laboratory (NNL), ensuring that Nuclear Institute. Initial results indicate that some environmental and irradiation effects. UK manufacturers can gain long-term benefits from of the residual stresses do not increase as the level the Nnuman research. of machining abuse increases, with surface damage • www.dalton.manchester.ac.uk/nnuman apparently limited to a relatively shallow depth – in some cases, as little as 20 microns.

Nuclear AMRC news Q4 2013 4 Nuclear manufacturers prepare to share in growth

The first companies to secure long-term support CNSIG includes a four-year programme of business CNSIG is aimed at companies which are already from the civil nuclear Sharing in Growth programme development and training for the most promising strong contenders for nuclear work, but which are now starting their development projects. manufacturers of mechanical equipment suitable can develop their capabilities for the global market, for the civil nuclear sector. The support is tailored notes Jonathan Matthews, supplier development The £76 million civil nuclear Sharing in Growth to the needs of the participating companies, and is executive at Rolls-Royce. (CNSIG) programme aims to develop the UK worth around £1 million to each project. manufacturing supply chain and help UK companies “All these companies recognise that to compete win work in nuclear programmes – including new The first successful companies from the first round globally, you need good people, processes and build, operations and decommissioning – at home of applications to CNSIG are now beginning to people allied to a nuclear culture, all of which will and overseas. It is part-funded by government work with the Nuclear AMRC and Rolls-Royce be supported through Sharing in Growth,” says through the Regional Growth Fund, and led by the (see below). All four are established suppliers to Matthews, “Qualifying companies will have existing Nuclear AMRC with support from Rolls-Royce and the civil nuclear sector, but are looking to further experience in nuclear or similar industries, a desire other industry leaders. develop their capabilities. to grow and develop their market share in nuclear, and the ability to promote collaborative working.” “Sharing in Growth is an innovative programme that “NES is an established supplier to the civil nuclear will prepare the UK supply chain to win contracts sector, but we are constantly looking to improve A second round of applications closed in October. in the national and international civil nuclear our efficiency and competitiveness in the market,” Details of further participating companies will be marketplace,” explains Mike Tynan, chief executive says Anthony Cundall, director of business announced in the new year. of the Nuclear AMRC. “It is a programme that will development at NES. “We are also looking to help create and sustain long-term capability in UK develop stronger international opportunities. The • To find out more about the civil nuclear advanced manufacturing, and help build a new era support we will receive in the civil nuclear Sharing in Sharing in Growth programme, visit: of civil nuclear generating capacity in the UK.” Growth programme will take us to the next level and namrc.co.uk/work-with-us/sig help us to compete globally.”

Sharing in growth: Research for growth As well as long-term business development, the The programme is supporting research into the first four civil nuclear Sharing in Growth programme innovative techniques for nuclear manufacturing Goodwin International – an established (CNSIG) is supporting industry-led research at the such as hot isostatic pressing (hipping) and electron manufacturer of components for the civil nuclear Nuclear AMRC. beam welding. The Nuclear AMRC has some of industry, from primary pump casings to complete the largest and most advanced hipping and e-beam The Nuclear AMRC and key industrial partners sub-assembled components. Based in Stoke-on- facilities of any research centre. are already working on a series of projects under Trent, Goodwin has produced machined casings CNSIG, with support from the Regional Growth CNSIG-backed research is also exploring new ways since 1883, and has ASME N-Stamp and NCA3800 Fund. The research aims to make a significant to optimise factory layout and process flow for the certification as well as RCC-M approvals. improvement to manufacturing capabilities and help large and complex components used across the • www.goodwininternational.co.uk UK companies compete globally, and covers areas nuclear industry. in welding, machining, assembly and cladding of civil NES Ltd – a provider of design, manufacture, test, nuclear components. • For more information about CNSIG-supported commissioning, installation and training services for research, contact Dr Alan McLelland: the nuclear decommissioning, defence and new [email protected] build markets, based in Wolverhampton. With a history going back over 200 years, NES has worked on nuclear power stations since the 1960s. • www.nes-limited.com

Tata Steel Projects – a leading provider of design, manufacture and construction services to a variety of industrial sectors, based in York. Part of the international Tata Steel group, it has 60 years’ experience supplying the nuclear industry with waste transport and spent fuel flasks. • www.tatasteeleurope.com

Therco – a market-leading manufacturer of air- cooled and tubular heat exchangers, used in nuclear, coal and hydroelectric power stations worldwide. Based in Sheffield, Therco’s specialised machine Joined-up research: the Nuclear AMRC’s shop is capable of producing heat exchangers up to small electron beam welding chamber 14 metres in length and 40 tonnes in weight. • www.thercoheatexchangers.com

5 namrc.co.uk New machining centre brings unique capabilities

The latest machining centre to be installed in the Mazak originally designed the Orbitec for a US The Orbitec can carry out a range of specialist Nuclear AMRC workshop is the first of its kind in customer serving the oil and gas market, and the machining operations, including facing and Europe, and offers unique capabilities for making technology is only now reaching the market. The phonographic finishing of flange surfaces; conical complex high-precision components for the energy Nuclear AMRC’s machine is currently the only one boring of taper holes; face and end milling; plus and oil and gas industries. in Europe. trepanning, threading, internal grooving, drilling and concave machining. Its rotary table takes a square The Mazak Orbitec 20 features a unique turning “It’s ideal for oil and gas parts, particularly long pipes 630mm pallet, with maximum load of 1500kg. and facing headstock, capable of generating turned with threaded or connector features on the end, features while keeping the workpiece stationary. It because it removes the need to spin a very long Like all the Nuclear AMRC’s resources – including is ideal for parts which are too large or awkwardly pipe,” says Dawson. “It’s also particularly adept at state-of-the-art machining centres from Mori-Seiki, shaped for conventional turning machines, and can pump and valve housings which have lots of circular Starrag, TBT and Hermle – the Orbitec is available carry out high-precision four-sided machining in a or cylindrical features. Now we can do it all with an for collaborative research and process development single set up. integrated CNC turning and facing head.” projects with UK manufacturers. Key research areas include advanced machining techniques for “It’s a unique capability for the production of Initial trials have shown that the Orbitec can also large valve bodies and similar complex precision parts with circular features which would be too provide a dramatic improvement in surface finish. components, and on-machine inspection of long or heavy or out-of-balance to be done in a “Because the component is clamped very rigidly, thread forms. conventional horizontal lathe,” says Stuart Dawson, we can take a much greater depth of cut,” Dawson head of machining at the Nuclear AMRC. “It takes explains. “It’s quicker, gives better process security • To find out more about the Orbitec and other away problems caused by asymmetrical out-of- and robustness, and better surface finish. We see machining capabilities, contact Stuart Dawson: balance rotating parts, and clamping supposedly huge numbers of oil and gas applications, from [email protected] circular parts in three-jaw chucks.” pump and valve bodies to risers to pipe connectors and choke valves.”

Inside the Orbitec: unique abilities for external and internal machining of circular features

Nuclear AMRC news Q4 2013 6 Groundwork for giant new machines

Work has begun to prepare the Nuclear AMRC workshop for its newest and largest machining centres. The two machines will be the biggest of their kind available for collaborative research anywhere in the world.

The machines – a purpose-built vertical turning lathe from Dörries Scharmann, and a Soraluce FX12000 floor-type milling and boring centre – will be used to produce large representative-sized parts for the nuclear industry and other high-value sectors.

The vertical turning lathe (VTL) will be capable of working on parts of up to five metres diameter and over three metres height. It will offer full milling and deep drilling capabilities, and is designed for the largest high-value components for Heavy engineering: virtual image of the Soraluce the nuclear industry, including full-scale reactor internal parts. It is also ideal for and Dörries VTL in the Nuclear AMRC workshop machining offshore wind turbine shafts and the largest jet engine fan casings. The VTL is funded by the High Value Manufacturing Catapult. Preparatory work to construct the foundations required for the huge new The Soraluce will be capable of working on parts up to 12 metres in length machines began in October. Creating the foundations will take around 20 weeks and five metres diameter, and can complete five-sided machining of complex – while this could disrupt work in the rest of the Nuclear AMRC, careful planning parts in a single set up. It will be used to develop and demonstrate advanced and specialist contractors mean the workshop will be closed for just three weeks manufacturing processes for large pressure vessels, high-value reactor internals in November. The Soraluce will then take around 12 weeks to install, and the and offshore wind turbine hubs. VTL 14 weeks. “The Soraluce and Dörries VTL are an absolutely unique resource,” says “It is a real heavy engineering challenge,” Dawson notes. “But we will be the Nuclear AMRC machining head Stuart Dawson. “No other research centre only research centre in the world with these capabilities and, from summer anywhere in the world has the physical size or research capability of these 2014, these very large machines will be available to manufacturers for machines, as far as we’re aware.” collaborative projects.” Robotic machining offers major cost savings Process to part: a robotic machine tool being developed at the Nuclear AMRC

An innovative approach to machining features on Josh Barnfather, a postgraduate researcher at this means a potential saving of almost £280,000. large power plant vessels could potentially reduce the Nuclear AMRC, assessed the feasibility Machining time is longer, however, due to the lower costs by over 80 per cent, according to a study by of the concept by reviewing the portable metal removal rates of the robotic tools. Nuclear AMRC researchers. machining techniques used in other industries and benchmarking their performance across a range of “This is a high-level analysis, but we are looking The “process-to-part” approach uses portable measures. at more detailed studies on specific features to robotic machine tools to carry out a range of realise the conceptual benefits,” notes Barnfather. operations on large and unwieldy components He also used virtual reality simulations to investigate “It’s unlikely that robotics could completely replace and assemblies. These tools are already used in how robotic machine tools could be deployed in a machine tools because of the tolerances demanded industries such as aerospace, oil and gas, marine and factory. Their performance was compared with that by many components, but it does show the great wind energy, typically for machining features which of conventional machine tools, based on data from potential for process-to-part machining to improve do not require the highest levels of precision. the Nuclear AMRC workshop. supplier competitiveness in the nuclear industry.”

For large nuclear vessels, robotic machining can Barnfather’s analysis showed that the cost of • For more information, contact Josh Barnfather: potentially be used to mill, drill and tap features such machining could be reduced by up to 88 per cent [email protected] as weld preps, nozzle opening profiles, pipe/vessel for a representative vessel, thanks largely to the facing and holes. lower cost of the robotic tools. For a typical vessel requiring around 1700 hours of feature machining,

7 namrc.co.uk Triple Bar sets new skills standard

Manufacturers can offer their staff a new introduction to the nuclear sector, but customised for manufacturers. For example, the Existing Sites course focuses developed in collaboration with industry experts and leading suppliers. on what people need to know to have unescorted access to current nuclear sites, which is less relevant for people working in a manufacturing environment. The Triple Bar Nuclear Manufacturing is a short course developed by the The new Manufacturing course instead highlights nuclear quality and assurance National Skills Academy Nuclear Manufacturing, a collaboration between the issues, while embedding knowledge about the nuclear industry and its required National Skills Academy for Nuclear, Semta and the Nuclear AMRC. behaviours into the manufacturing supply chain.

It is based on the established Triple Bar Existing Sites course, but tailored to the “Nuclear quality and safety are absolutely fundamental to the manufacture of specific needs of the civil nuclear manufacturing supply chain. components,” Valentine notes.

“It’s aimed at people without a nuclear background,” explains Annette Valentine, The course has been developed in collaboration with established nuclear Nuclear AMRC training and skills development manager. “It’s a good way manufacturers, including Rolls-Royce and NES Ltd. Training will be delivered for companies to help people get to a certain level of awareness of nuclear by members of NSA Nuclear’s high quality provider network, including the manufacturing, from which they can develop more specialised skills.” AMRC Training Centre.

The Triple Bar Nuclear Manufacturing has three modules – nuclear awareness, • For more information, contact Dawn Vinall at NSA Nuclear Manufacturing: behaviours and quality assurance – which are based on the established courses [email protected] AMRC Training Centre welcomes first intake

AMRC expands into castings technology

Nuclear AMRC partners can now access state-of-the-art castings expertise, as Castings Technology International (CTI) joins the University of Sheffield AMRC.

AMRC acquired CTI’s buildings and assets, Faces of the future: new apprentices at the AMRC Training Centre come from a wide range of companies including ongoing research work, commercial contracts and consultancy, in August. The The new AMRC Training Centre has welcomed its dedicated building, a 5,500 sq m building located acquisition allows the AMRC’s world-leading first class of 150 advanced apprentices. alongside the Advanced Manufacturing Park, will research centres to offer state-of-the-art open its doors in the new year. castings technologies to their industrial The apprentices come from a wide range of partners, adding breadth and depth to the manufacturers with operations in the Sheffield The AMRC Training Centre, supported by the group’s collaborative research capabilities. city region, including Nuclear AMRC members Regional Growth Fund and European Regional Tata Steel, Rolls-Royce, Sheffield Forgemasters, Development Fund, provides training in the CTI is a world-leading provider of technology, Newburgh Engineering and Nikken, and from the practical and academic skills that manufacturing expertise and services to the cast metals AMRC group itself. companies need to compete globally. As well sector, providing a wide range of contract as apprenticeships, it links with both Sheffield R&D services to manufacturers around Aged from 16 up, the apprentices will spend a year universities for higher-level education up to the world. learning fundamental skills at the Training Centre doctorate and MBA level, and offers a range of • www.castingsdev.com before completing their apprenticeships at their courses for continuing professional development. employers. • To find out more about the AMRC Training Their first term will be spent in training workshops Centre, go to: www.amrctraining.co.uk on the AMRC campus. The Training Centre’s

Nuclear AMRC news Q4 2013 8 Main image: Nuclear AMRC NC programmer Mathew Challinor and Bloodhound’s Mark Elvin examine the completed rear sub-frame Right: Bloodhound gang: Nuclear AMRC machining team with Bloodhound engineers Nuclear AMRC completes Bloodhound machining

The Nuclear AMRC’s machining experts have for the centre’s capabilities. The project also aims to “The HEC performed faultlessly,” says production handed over their finished Bloodhound components enthuse a new generation about the excitement of engineer Andrew Wright, who led the machining of to the team building the world’s first 1000mph car. engineering, a goal it shares with the AMRC group. the side walls. “We needed a large machine which was able to machine the face in a single setting. The Nuclear AMRC produced seven large “It’s an inspirational project – as the tagline says, it’s The indexing table allowed us to reach all the areas components for Bloodhound’s rear sub-frame, an engineering adventure – and being associated we had to machine holes in, without having to reset the assembly that holds the car’s rocket engine in with that helps us inspire the next generation of the part – we could just rotate the table to reach place and provides vital stability. Each part had to engineers,” Dawson notes. those faces.” be machined from a solid block of aerospace-grade aluminium, to precise specifications, with no room The rear assembly includes the most complex and Wright used software from Nuclear AMRC member for mistakes. high-value machined part on the entire car, the Edgecam to produce the side walls. “The accuracy diffuser floor, which will sit beneath Bloodhound’s of Edgecam’s toolpaths was vital in allowing us to The team spent around a year making the seven hybrid rocket engine and provide the downward achieve the extremely tight tolerances required,” components, slotting the work in between force to keep the car on the ground as it reaches he says. “The main concern when I started commercial and research projects on some of the 1000mph. Producing the floor, which features programming was that the part would distort Nuclear AMRC’s most powerful machining centres. a complex lattice structure on one side and and we’d struggle to maintain wall thicknesses. aerodynamically sculpted reverse, took 192 hours The components were assembled for the first time in Fortunately, Edgecam’s roughing strategy and profiling of machining on the Nuclear AMRC’s Hermle C60 cycles provided the solution.” October. The assembly is now being integrated into five-axis mill-turn centre. the car at Bloodhound’s technical centre in Bristol. The AMRC group continues to produce vital “We couldn’t have made life harder for Nuclear components for the car. The AMRC with Boeing is “The work for Bloodhound has many of the key AMRC – one billet for each highly complex features of nuclear manufacturing, in terms of currently producing the front suspension housing on component and the team delivered them all right first its new Scharmann Ecospeed, a high-performance low-quantity, right-first-time machining,” says Stuart time and to the most exacting standard,” says Conor Dawson, head of machining at the Nuclear AMRC. machining centre which is optimised for large La Grue of Bloodhound. “The Nuclear AMRC team aerospace-style structural parts. “We used all the same manufacturing principles have worked closely with the Bloodhound team to of de-risking the process, offline toolpath collision manufacture an assembly that represents one tenth • To see video of the diffuser floor machining, go to: checking and simulation, and using low risk machining of the car, and taking delivery has been a huge step namrc.co.uk/nuclear/bloodhound-diffuser cycles. This wasn’t about maximising productivity, it towards getting the car rolled out.” • For more information about Bloodhound SSC, visit: was about not scrapping the part and making sure it www.bloodhoundssc.com was absolutely correct first time.” The final parts to be completed were the two structural side walls – 1.6 by 1 metre panels which The Bloodhound car will carry the Nuclear AMRC’s were among the first finished components to be logo as it attempts to set new land speed records in produced on the Nuclear AMRC’s new Starrag South Africa in 2015-16, providing a global showcase HEC1800 horizontal boring centre. 9 namrc.co.uk SMEs see how to make it smarter

Over 40 delegates from smaller manufacturing Soon after his visit, companies spent a day at the Nuclear AMRC, Goodwin received a discovering how the technologies being developed new machining enquiry at the centre can help their businesses become and immediately Big resources for smaller businesses: delegates learn more competitive. contacted AMRC about electron beam welding at the Nuclear AMRC business specialists The Make it Smarter day in late September was about how he could aimed at small and medium enterprises (SMEs) from approach the work in a the Yorkshire region which have not previously smarter way. “I realised that the Nuclear AMRC is a Mike Tynan, chief executive of the Nuclear AMRC, worked with the University of Sheffield AMRC. resource we can work with,” he says. introduced the opportunities for manufacturers of The Nuclear AMRC, like the other centres in the investment in new nuclear power stations, in the As well as practical demonstrations, the day AMRC cluster, is part-funded by the European UK and worldwide. The UK government wants the included presentations from senior AMRC directors Regional Development Fund, and is committed to developers of new reactors to place at least 60 per on the challenges and opportunities facing UK working with local SMEs to increase the wealth of its cent of their value with domestic suppliers. manufacturers. home region. “That is challenging for the UK supply chain,” Professor Keith Ridgway CBE, executive dean of the AMRC researchers and partners demonstrated Tynan noted. “It’s been 20 years since we’ve built University of Sheffield AMRC, discussed how the the state of the art in machining, tooling, welding, a reactor here.” But the UK is fast developing its UK can increase manufacturing’s share of GDP from robotics, metrology and virtual reality, and showed capabilities, with the Nuclear AMRC at its centre. the current 12 per cent to a target 25 per cent. how companies can gain real business benefits “The market that we operate in is a global by deploying these technologies in their own “The only way to do that over the next 20 years market,” he said. “It’s often easy to forget that the production. is to make it smarter,” he said. “If you can reduce opportunity for us is worldwide. You need to start machining time by a factor of five, the Far East can’t For many, the scale and sophistication of the to think what that means for the UK.” compete with us.” Nuclear AMRC’s facilities proved an eye-opener. • To find out more about how SMEs can work Early machining projects at the original AMRC with “It was like walking into a dream – I’ve never walked with AMRC, contact Shirley Harrison: Boeing cut machining time by between five and 40 into a shop and seen an eight metre Mori Seiki and [email protected] times, Ridgway noted. “From a machining point of all these other machines,” says Ben Goodwin of view, we’re very competitive because we can make BRG Developments, a small precision machining it smarter. We need competitiveness, and you get contractor based near York. “It was almost that competitiveness through the technology.” overwhelming and there was a lot to absorb all day, but I learned a lot, particularly from Sandvik’s tooling presentation.”

Innovation support for offshore wind

The Nuclear AMRC is supporting process innovation in the offshore wind There are currently over 40 offshore wind projects proposed around the UK’s industry through a new government-backed programme. shores, with total investment estimated at up to £100 billion.

Grow:OffshoreWind offers a range of technical, market and funding support Companies looking to expand their manufacturing capabilities for this to manufacturers which can produce parts for offshore wind turbines market can receive up to 50 per cent funding for process technology and supporting infrastructure. The programme is led by Grant Thornton innovation projects. Qualifying projects can access the large-scale technology with support from the Manufacturing Advisory Service, industry group demonstration facilities at the Nuclear AMRC, as well as the facilities of the RenewableUK and the University of Sheffield AMRC, and funding from the other centres in the High Value Manufacturing Catapult. Regional Growth Fund. • www.growoffshorewind.com

Nuclear AMRC news Q4 2013 10 IFA forges ahead with new nuclear division

Sheffield-based Independent Forgings & Alloys (IFA) is launching a dedicated nuclear products division to provide value-added components to the civil and marine sectors.

The firm has provided open-die forgings to the UK nuclear industry since the 1950s, and has been closely tracking nuclear projects over the past three years, says chief executive Andy McGuinness.

“Following the recent UK government announcement to kickstart the new build programme at Hinkley Point C, we have already seen positive market interest Nuclear ambition: IFA’s Simon Walker, Martin and fresh enquiries from suppliers in UK and Europe who recognise our forging Burnham, Andy McGuinness and Simon Muter capabilities for the nuclear sector,” McGuinness notes.

The firm is now investing around £1.3 million to expand its production “The people who make reactor parts, pumps or valves or heat exchangers are capabilities to meet the anticipated demand for specialist forgings for nuclear looking at component suppliers to provide more added value in machined parts projects. or in sub-assembly of component parts,” Muter says. “We’re in a good position “We have three new forge furnaces going in, which will be able to handle larger to offer higher value forgings with machined features, but we recognise that we diameter and longer components,” says Martin Burnham, director at IFA. “We’re need to allocate bespoke resources to succeed in the nuclear sector. There’s a also looking at expanding our CNC capabilities, so that we can go further up the high burden on quality assurance and process controls, which means we have to supply chain than ever before. We want to go to the next stage so there’s more dedicate resources to do that effectively.” added value.” Forgings are vital for many high integrity nuclear applications, as they offer IFA has supplied ring, bar and flat forgings for the nuclear sector since the superior material properties to castings or machined bar stock. IFA can produce early days of the Magnox programme. These have previously been machined forgings up to eight tonnes in weight in a range of nuclear grade alloys, and has by other contractors to create components such as reactor nozzles, heat an array of nuclear industry approvals and qualifications. In late 2012, IFA was exchangers, and bodies and components for pumps and valves. The new one of 25 UK manufacturers to sign memoranda of understanding with Areva to IFA Nuclear Products Division will seek to carry out more of the machining supply products and services for the proposed reactors at Hinkley Point C. work in-house. IFA was one of the first manufacturers to join the Nuclear AMRC as a Tier Two Equipment manufacturers in the civil nuclear industry are looking to streamline member, and among the first to complete theFit For Nuclear assessment. their supply chains, notes Simon Muter, business development manager, who The new division will be working with the Nuclear AMRC to develop its is leading the new nuclear division alongside Burnham. The team also includes machining techniques, Burnham notes. sales manager Simon Walker and accounts manager Tony Savile. • www.independentforgings.com Mazak and BOC join Nuclear AMRC

Machine tool group Yamazaki Mazak and industrial sector,” says Alan Mucklow, group product manager BOC is joining as a Tier Two member. Part of the gas supplier BOC are the latest companies to join Europe at Yamazaki Mazak. “Typically, the sector is Linde Group, BOC is the UK’s leading supplier of the Nuclear AMRC. machining large complex parts, many of which are industrial gases and related engineering services. not ideally suited to traditional machining methods. It is an established supplier to the nuclear industry, Mazak is taking Tier One membership, giving working with all the UK’s existing fleet as well as it a seat on the Nuclear AMRC’s board. The “Modern machining technology, such as the Orbitec decommissioning sites. company will work alongside the centre’s machining 20, enables a much safer and more efficient experts and partner companies to develop new process. We look forward to working closely with BOC will provide the Nuclear AMRC with speciality machining processes to produce large and complex the Nuclear AMRC and the power generation gases and technical expertise to support work in components for the power generation and oil and sector to help solve the manufacturing challenges areas such as welding, hot isostatic pressing (hipping) gas sectors. the sector faces.” and cryogenic machining.

“Our membership of the Nuclear AMRC offers As part of its membership, Mazak is providing an • Mazak: www.mazak.eu us the opportunity to make a real contribution to Orbitec machine plus training and support to the • BOC: www.boconline.co.uk helping UK manufacturers solve the machining Nuclear AMRC (see p6). problems associated with the power generation

11 namrc.co.uk Work with us

The Nuclear AMRC is here to support manufacturing companies, from global giants to SMEs, which are seriously interested in winning business in the nuclear sector. If we can help your company, we want to hear from you.

Our R&D capabilities, training courses and determine our research and support programmes. quality support programmes are open to all UK We are led by our member companies on a manufacturers. consortium basis: our members decide what we do, what our core research projects will be, and what We can collaborate on specific R&D projects, skills and quality support we provide. using our expertise and facilities to help resolve your manufacturing problems and give you real We offer two tiers of membership, based on the competitive advantage. Your company invests size and market position of your company. Our directly in the research and has exclusive access to members include manufacturers from along the any resulting intellectual property. We can also join supply chain, plus specialist equipment and service or lead externally-funded collaborative research providers. projects. To find out more about how we can help your Full membership of the Nuclear AMRC gives access business, contact Martin Ride: to our generic projects and the opportunity to [email protected]

Supported by:

Technology Strategy Board Driving Innovation

Tier 1 members:

Contact us: Tier 2 members:

Tel: +44 (0)114 222 9900 Email: [email protected] Online: namrc.co.uk Twitter: @NuclearAMRC

Nuclear AMRC The University of Sheffield, Advanced Manufacturing Park, Brunel Way, Rotherham S60 5WG

Manufacturing Technology Research Laboratory The University of Manchester, Sackville Street, Manchester M13 9PL

Nuclear AMRC news Q4 2013 12