The new 3D printing press developed by UKAEA offers new opportunities to produce highly specialized fusion ingredients.
The UK Atomic Energy Agency (UKAEA) has started using two additive (3D printing) machines that will use complementary methods to manufacture components for future fusion machines.
At the recently opened Central Support Facility (CSF), UKAEA commissioned an electron beam 3D printing machine, which is primarily used to incorporate tungsten into components, along with selective laser manufacturing machines.
Overcoming the challenges of fusion machines with 3D printing
Fusion energy is set to play an important role in the global low-carbon energy future. However, components within future fusion power plants must operate under complex and difficult conditions such as extreme temperatures, high neutron fluxes, and strong magnetic fields.
As a result, there is a complex combination of materials and precision engineering.
The manufacturing of additives is suitable for the production of materials with complex designs, and at low volumes, each fusion machine is very individual and is ideal for sectors such as fusions where custom-made components are required.
As a result, UKAEA believes 3D printing can play an important role in the future of fusion, reducing the costs associated with precision manufacturing. The organization commissions the machinery to demonstrate two complementary additive manufacturing methods for producing fusion ingredients.
“We’re looking for a way to help you get started,” said Roy Marshall, Head of Operations for UKAEA’s manufacturing, installation and maintenance.
“UKAEA believes that additive manufacturing is essential to developing these components on a scale that makes fusion commercially viable.”
Components for Manufacturing Plasma
The first machine, the Emelt E-Beam Powder Bed Fusion (E-PBF) additive manufacturing machine, utilizes electron beam technology to bind tungsten powder to solid components that are almost 100% density.
Emert machines are used to organize tungsten into other materials such as copper, chromium zirconium, stainless steel, and Eurofer 97.
Meanwhile, SLM280 – Selective Laser Manufacturing – is used to experiment in the production of components with complex geometries and materials combinations essential for successful fusion plants.
The SLM280 is manufactured by Nikon SLM, provided by Kingsbury Maching Tools, and supported by Additure.
Both 3D printing technologies support the production of plasma-oriented components exposed to extreme temperatures during their operational lifecycle. The machines also reduce their reliance on traditional technologies such as welding, thereby reducing the number of manufacturing operations and participating in the process.
Supporting integrated research and development at central support facilities
CSF combines this technology with dedicated workshops located in a single building alongside UKAEA’s manufacturing support team and special technique groups to promote collaboration and fusion research and development between manufacturing teams.
UKAEA is currently working to prepare its commercial partners for large-scale production essential to future fusion energy plants.
Both machines begin production of challenging geometry and conduct experiments to explore the properties of the material in which the additive is produced.
This work is followed by an early stage of production, which includes a layer of tungsten and copper chromium zirconium.
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