Sheffield Forgemasters’ completion of the first full-sized Small Modular Reactor (SMR) nuclear vessel demonstrator assembly represents a “global leap” in welding technology, particularly in the industrialisation of Local Electron-Beam Welding (LEBW). The complete weld-assembly of the vessel is a “pivotal moment” in global welding development, as it took less than 24 hours to complete four, thick, nuclear-grade welds, which would typically require a year of work to complete. This demonstration showcases the reliability and capabilities of LEBW, setting a dramatic new standard for weld-joining thick-walled components that were previously untested on a demonstrator model.
The construction of the nuclear vessel demonstrator evidences the successful development of LEBW technology. Sheffield Forgemasters deployed specially developed parameters, including innovative sloping-in and sloping-out techniques, ensuring a clean and complete weld-join. The company’s adeptness in manufacturing and forging required large forgings for SMRs means it is the only company in the UK with that capability. Additionally, it now boasts of years of developmental lead over global competitors in welding thick-walled assemblies.
Dr Michael Blackmore, Senior Development Engineer and Project lead, highlights that the implication of LEBW technology in the nuclear industry is significant. It could potentially reduce the need for weld-inspections, and speed up the roll-out of SMR reactors in the UK and beyond, disrupting traditional high cost welding processes.
Furthermore, the demonstration of LEBW technology’s potential opens new horizons for more efficient, low-cost, and less time-heavy nuclear assemblies, with far-reaching implications for other projects requiring thick-walled welded assemblies. Dr Jacob Pope, Development Engineer and LEBW machine tool installation lead, expressed appreciation for the Government’s Department for Energy Security and Net Zero for enabling the project through its Nuclear Innovation Program.
In conclusion, the construction of the first full-sized Small Modular Reactor (SMR) nuclear vessel demonstrator assembly at Sheffield Forgemasters represents a significant breakthrough in Local Electron-Beam Welding (LEBW) technology, providing dramatic new standards and capabilities for weld-joining thick-walled components. The company’s years of developmental lead offer an advantage over global competitors in welding thick-walled assemblies, potentially reducing the cost and time associated with nuclear assemblies. The implications extend beyond nuclear energy to other projects requiring thick-walled welded assemblies.
