DENSAMET® Tungsten Division Prismatic Machining Division Valve Stems Division Antennas Division...

DENSAMET® Tungsten Division

Prismatic Machining Division

Valve Stems Division

Antennas Division

Manufacturing Success - 14 March 2012

High value manufacturing, an SME Case Study

Ian Warrington, Project Manager

MG Sanders Ltd




Antennas Division

“SME`s make up a half of all jobs in the UK and account for half of our GDP” (B2B Int.)

•An overview of our capability•Contract Case Study-Future Energy




Antennas Division

Situated in Stone, 30 miles north of Birmingham in Central England.

Established 38 years

Under new ownership since January 2006:

Rubicon Partners Industries LLP.

55 employees, T/O £8.5m (2011)

7000m2 Engineering & Metallurgical facility




Antennas Division

◄ Tungsten LB-SRP

ActivityTungsten alloy blending, pressing & vacuum sintering

Multi–axis CNC Milling, Turning, Grinding, EDM: Tungsten (W), Refractory and exotic Ni, Fe, Al based alloys

Pre-production – Prototype Manufacture

Clean room assembly

High Volume Pharmaceutical Valve Stem production

Design & Manufacture of UHV & VHF Military Antennas

‘End of life’ process re-definition and manufacture

Reverse Engineering & Sub-Contract manufacture




Antennas Division

Quality ApprovalsISO 9001AS 9100 Rev B




Antennas Division

◄ Tungsten LB-SRP

Some of our customers:




Antennas Division

◄ Tungsten LB-SRP

ActivityTungsten alloy blending, pressing & vacuum sinteringDesgination WH9075C WH9570C WH9070F WH9375F WH9560F WH9766FAMS7725D Class 1 Type 1 Class 3 Type 1 Class 1 Type 2 Class 2 Type 2 Class 3 Type 2 Class 4 Type 2

Composition wt.%W 90 95 90 93 95 97Ni 7.5 3.5 7 5.25 3 2Cu 2.5 1.5 - - - -Fe - - 3 1.75 2 1

Nominal Density g/cc 17.2 18.0 17.1 17.6 18.1 18.5

Typical Hardness HV10 300 310 290 310 310 310

Max. Hardness HRC 32 34 32 33 34 35

Typical Tensile Strength MPa

700 650 900 900 900 900

Elongation % on 16mm GL 3 1 20 20 15 2




Antennas Division

◄ Tungsten LB-SRP

ActivityMulti–axis CNC Milling, Turning, Grinding, EDM: Tungsten (W), Refractory and exotic Ni, Fe, Al based alloys




Antennas Division

◄ Tungsten LB-SRP

ActivityHigh Volume Pharmaceutical Valve Stem productionCirca 1.2m/month




Antennas Division

◄ Tungsten LB-SRP

Activity

HF, VHF and UHF Bowman Manpack and Vehicle Elevated or Ground based units

Design & Manufacture of Military Broadband Antennas




Antennas Division

AEROSPACE Control surfacesFlutter weights

Boeing 737/767/777ATR 76

Airbus Military




Antennas Division

AW101AW139AW149

Lynx Wildcat

AEROSPACERotor Balance




Antennas Division

F1 Aerodynamic Ballast




Antennas Division

Nuclear Engineering- Radiation ShieldingOil Well Logging Instrumentation

Nuclear Waste Encapsulation Shielding - Sellafield




Antennas Division

LHC Tungsten Cylinder Inserts (for Target Attenuator experimental Areas)CLIC RF Accelerating Structures –UKTI- OMIS/STFC supportUltra precise machining, diffusion bonding




Antennas Division

Identify innovative & technically demanding opportunities, in Tungsten and other exotic materials or processes, that can be commercially exploited to generate incremental high value revenue.

Business Development-Access New Markets

Focus on materials competence, skills and future markets




Antennas Division

The world's largest Fusion tokamak, JET (Joint European Torus), has produced 16 megawatts of fusion power and proved the technical feasibility of fusion using deuterium and tritium, currently considered the most efficient fuels. The challenge now is to prove fusion can work on a power plant scale.

Business Development – Future Energy

1st wall upgrade to the Joint European Torus (JET) – €48m budget – EFDA funded (EU Commission) to evaluate materials for ITER construction

Identify tender opportunities -expression of interest




Antennas Division

Evaluate Plasma surface interaction for ITER materials: Beryllium

W-coated CFC

Inconel + Be

Bulk W-LBSRP

Previously CFCW Divertor Module - power handling surface.




Antennas Division

•Validation of CATIA V/STEP models and provision of full manufacturing drawings

•Fusion related materials understanding

•Development of manufacturing processes and techniques

•Production of tooling and jig fixtures

•Complex 5 axis machining

•Accurate, clean assembly of complex geometry items for UHV and demanding environments (JET QUA 500) •Comprehensive inspection to CAD models including CMM, Surface Measurement & SPC.

Competencies & skills




Antennas Division

•

Contract Award

Time from expression of interest to tender response deadline = 3 months.

Complex tender to interpret: CATIA V model, prototype design & materials/technical specification.

Open comments & questions circulated to invited tendering companies.

As a potential new supplier an audit visit followed tender submission to assess capability.

Contract preparation forms, followed by agreement in principle (without prejudice), fixed price & rigid contractual terms (EU Commission), bank guarantee.




Antennas Division

Formal contract award (12 months + from Expression of Interest)

Value: €5.3m

Prototypes (including orders outside of contract) to test and allow final design freeze for manufacture.

Deliverables & Milestones mutually acceptable & achievable, including payments.

Contract Award




Antennas Division

Tungsten - LBSRP

Tungsten LBSRP

MGS Tungsten

for plasma facing

components -

independently

tested & qualified;




Antennas Division

50 assemblies / 80Kg each

5 exotic materials

1,600 parts /assembly

80,000 parts total

Clean room assembly

50μm reference tolerances




Antennas Division




Antennas Division

Installation of a solid tungsten divertor modulebetween neighbours with dedicated spinalRemote Handling toolCourtesy M. Woollard




Antennas Division

Wall & Divertor completed mid 2011




Antennas Division

The next steps :

International fusion research is following a roadmap to achieve power generation within 30 years. It focuses on three main projects:

ITER – a multinational project (47%) EU, with a €10bn budget that is being built in the south of France. ITER will be a 500 megawatt tokamak (equivalent to a small power plant) and aims to confirm that fusion power will be possible on a commercial scale; IFMIF (International Fusion Materials Irradiation Facility) – a device that will test the materials needed in a fusion power station, planned to operate in parallel with ITER;

Business Development




Antennas Division

ITER Divertor targets




Antennas Division

Business Development

DEMO – a demonstration power plant supplying fusion electricity to the grid. This is being designed now and would be constructed during ITER and IFMIF operation. If successful, it will be followed by the first generation of commercial fusion power stations.

We are looking for partners to collaborate in these high value manufacturing opportunities.

Thank you for your attention!

DENSAMET® Tungsten Division Prismatic Machining Division Valve Stems Division Antennas Division...

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