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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
DENSAMET® Tungsten Division
Prismatic Machining Division
Valve Stems Division
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
DENSAMET® Tungsten Division
Prismatic Machining Division
Valve Stems Division
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
DENSAMET® Tungsten Division
Prismatic Machining Division
Valve Stems Division
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
DENSAMET® Tungsten Division
Prismatic Machining Division
Valve Stems Division
Antennas Division
Quality ApprovalsISO 9001AS 9100 Rev B
DENSAMET® Tungsten Division
Prismatic Machining Division
Valve Stems Division
Antennas Division
◄ Tungsten LB-SRP
Some of our customers:
DENSAMET® Tungsten Division
Prismatic Machining Division
Valve Stems Division
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
DENSAMET® Tungsten Division
Prismatic Machining Division
Valve Stems Division
Antennas Division
◄ Tungsten LB-SRP
ActivityMulti–axis CNC Milling, Turning, Grinding, EDM: Tungsten (W), Refractory and exotic Ni, Fe, Al based alloys
DENSAMET® Tungsten Division
Prismatic Machining Division
Valve Stems Division
Antennas Division
◄ Tungsten LB-SRP
ActivityHigh Volume Pharmaceutical Valve Stem productionCirca 1.2m/month
DENSAMET® Tungsten Division
Prismatic Machining Division
Valve Stems Division
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
DENSAMET® Tungsten Division
Prismatic Machining Division
Valve Stems Division
Antennas Division
AEROSPACE Control surfacesFlutter weights
Boeing 737/767/777ATR 76
Airbus Military
DENSAMET® Tungsten Division
Prismatic Machining Division
Valve Stems Division
Antennas Division
AW101AW139AW149
Lynx Wildcat
AEROSPACERotor Balance
DENSAMET® Tungsten Division
Prismatic Machining Division
Valve Stems Division
Antennas Division
F1 Aerodynamic Ballast
DENSAMET® Tungsten Division
Prismatic Machining Division
Valve Stems Division
Antennas Division
Nuclear Engineering- Radiation ShieldingOil Well Logging Instrumentation
Nuclear Waste Encapsulation Shielding - Sellafield
DENSAMET® Tungsten Division
Prismatic Machining Division
Valve Stems Division
Antennas Division
LHC Tungsten Cylinder Inserts (for Target Attenuator experimental Areas)CLIC RF Accelerating Structures –UKTI- OMIS/STFC supportUltra precise machining, diffusion bonding
DENSAMET® Tungsten Division
Prismatic Machining Division
Valve Stems Division
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
DENSAMET® Tungsten Division
Prismatic Machining Division
Valve Stems Division
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
DENSAMET® Tungsten Division
Prismatic Machining Division
Valve Stems Division
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.
DENSAMET® Tungsten Division
Prismatic Machining Division
Valve Stems Division
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
DENSAMET® Tungsten Division
Prismatic Machining Division
Valve Stems Division
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.
DENSAMET® Tungsten Division
Prismatic Machining Division
Valve Stems Division
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
DENSAMET® Tungsten Division
Prismatic Machining Division
Valve Stems Division
Antennas Division
Tungsten - LBSRP
Tungsten LBSRP
MGS Tungsten
for plasma facing
components -
independently
tested & qualified;
DENSAMET® Tungsten Division
Prismatic Machining Division
Valve Stems Division
Antennas Division
50 assemblies / 80Kg each
5 exotic materials
1,600 parts /assembly
80,000 parts total
Clean room assembly
50μm reference tolerances
DENSAMET® Tungsten Division
Prismatic Machining Division
Valve Stems Division
Antennas Division
DENSAMET® Tungsten Division
Prismatic Machining Division
Valve Stems Division
Antennas Division
DENSAMET® Tungsten Division
Prismatic Machining Division
Valve Stems Division
Antennas Division
Installation of a solid tungsten divertor modulebetween neighbours with dedicated spinalRemote Handling toolCourtesy M. Woollard
DENSAMET® Tungsten Division
Prismatic Machining Division
Valve Stems Division
Antennas Division
Wall & Divertor completed mid 2011
DENSAMET® Tungsten Division
Prismatic Machining Division
Valve Stems Division
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
DENSAMET® Tungsten Division
Prismatic Machining Division
Valve Stems Division
Antennas Division
ITER Divertor targets
DENSAMET® Tungsten Division
Prismatic Machining Division
Valve Stems Division
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!