Ebflow electron beam (EB) welding innovation, pioneered by Cambridge Vacuum Engineering (CVE), has the potential to revolutionize the speed of constructing small nuclear power stations. In a trial led by Sheffield Forgemasters, CVE’s Ebflow technology was used to significantly reduce the time required to weld a small modular reactor (SMR) pressure vessel demonstrator from over a year to less than 24 hours.
This development could have a profound impact on nuclear reactor production globally and help address the energy market gap in the UK. As part of a project funded by the government, Sheffield Forgemasters integrated Ebflow, operating in a local vacuum environment, into a custom large-scale EB facility at its Brightside Lane facility. This enabled the completion of four thick nuclear-grade welds on vessels with a diameter of three meters and a wall thickness of 200mm.
In addition to reducing welding time by an impressive 99%, Ebflow also ensured the superior quality and precision of welds necessary for the safe operation of SMRs, establishing a new benchmark for welding thick-walled components. Ebflow represents a cutting-edge fusion welding technique with diverse applications across industries, including oil and gas, nuclear power generation, and shipbuilding.
Unlike traditional methods, Ebflow does not require the introduction of additional materials to make the join, resulting in unparalleled levels of precision and efficiency, particularly suited for the intricate welding demands of critical energy applications such as mini nuclear reactors.
Bob Nicolson, the Managing Director at CVE, expressed enthusiasm about the collaboration with Sheffield Forgemasters, highlighting the significant impact of Ebflow technology on sustainable advancements in the energy sector. He emphasized the urgency of addressing climate change, noting that more governments are committing to net zero emissions by 2050. Nicolson stressed the importance of embracing technologies like Ebflow to accelerate the deployment of low carbon energy production.
Sheffield Forgemasters, as the sole UK company capable of manufacturing the large forgings needed for SMRs, has gained a substantial developmental lead over global competitors in welding thick-walled assemblies, thanks to Ebflow. Dr. Michael Blackmore, the Senior Development Engineer and Project Lead at Sheffield Forgemasters, highlighted the transformative potential of industrialized Electron Beam Welding technology in the nuclear industry, potentially eliminating high-cost welding processes.
Professor Jesus Talamantes-Silva, the Research, Design, and Technology Director at Sheffield Forgemasters, expressed delight in achieving a significant milestone by assembling a nuclear vessel demonstrator using electron beam welding at a scale for the first time, with a remarkable 100% success rate and no defects. Jacob Pope, the Development Engineer and LEBW machine tool installation lead at Sheffield Forgemasters, acknowledged the Department for Energy Security and Net Zero for enabling the project through its Nuclear Innovation Program.
Pope also expressed gratitude to Cambridge Vacuum Engineering for their invaluable support, both remotely and on-site, which played a crucial role in the project’s success. Ebflow has been developed over several years of research and innovation by experts at CVE, with its main office in Cambridge, UK, and additional offices in Beijing, China, and Massachusetts, USA. The company also maintains a widespread network of agents around the world.
Aquasium Technology Ltd, known as Cambridge Vacuum Engineering (“CVE”), specializes in creating and developing process solutions. With over six decades of experience, CVE focuses on manufacturing electron beam (EB) systems for various industries such as aerospace, nuclear, automotive, oil and gas, and sensors. The company predominantly exports its systems, with approximately 95% of its products reaching markets in the USA, China, India, and Europe.
CVE’s lineup of EB welding equipment includes systems ranging from 50-200kV, capable of delivering beam powers up to 100kW. The company boasts a skilled team of designers and engineers dedicated to crafting customized manufacturing equipment that meets the unique requirements of their clients. Ebflow represents a compact vacuum electron beam welding solution, designed for easy transport and on-site operation, enabling welding of significantly larger structures than traditional vacuum chambers allow.
It functions without the need for a full vacuum chamber, instead utilizing a local, coarse vacuum only where necessary. Ebflow boasts exceptional efficiency in welding thick-section metals, achieving joint completion rates far exceeding conventional methods. Its speed is remarkable, with a capability of 200mm per minute in 150mm thick steel, making it the fastest option for thick-section welding to date.
Specializing in high-integrity forgings and castings, Sheffield Forgemasters tackles the world’s most intricate engineering projects. Operating from a single Sheffield site, the company boasts a fully integrated manufacturing process, encompassing steel-making, forging, foundry work, machining, and testing. With the capability to produce some of the largest custom-engineered steel products globally, they handle castings up to 350 tonnes and forgings up to 200 tonnes in finished weight.
Their reach extends to global markets, serving industries such as Defence, Civil Nuclear, Offshore, Power Generation, Renewables, Steel Plant, Steel Processing, and Ingot & Bar. Acquired by the Ministry of Defence in August 2021, Sheffield Forgemasters is set to receive significant investments for the revitalization of its defence-critical plant and equipment.
