Overview
The challenges of manufacture for fusion include unusual materials, and extremes of pressure and temperature. Similar challenges are shared in many academic and industrial applications across the globe. Consequently, STG frequently collaborates with clients beyond the field of fusion to address their manufacturing challenges.
STG capabilities are focused on the high-temperature joining challenges of metals and ceramics by use of vacuum manufacturing techniques such as diffusion bonding, electron-beam welding, and vacuum brazing. The use of controlled vacuum environments makes these processes particularly well-suited to the stringent, repeatable manufacture of sensitive components.
The facility also hosts various related techniques for component cleaning and high-temperature processing such as ultrasonic cleaning, induction heating, and ceramic furnaces.
At STG, after manufacturing, we have a range of in-house testing capabilities, which include CMM laser metrology, optical diagnostics, and vacuum leak detection.
We offer a diverse range of expertise that can be applied to address your unique challenges. We offer:
- a ‘one-stop shop’ for prototyping, from offering advice and consultancy, through to the design and manufacture, and transition to production
- a range of processing techniques using air and vacuum furnaces, brazing, welding, and diffusion bonding equipment
- flexibility to work at low and high TRL, from a basic sketch to a full technical specification
- a front door to other services at UKAEA including advanced machining, materials analysis, and a vast range of custom testing (heat flux, vacuum, pressure, magnetic fields, neutronic and more)
If any of these capabilities are of interest to you, please contact us to find out more.
Specialist joining technologies supporting internal UKAEA development, high-tech industry and research institutions globally.
Capabilities
3 Vacuum Furnaces
Working volume:
Up to 1.4 x 0.9 x 0.7m
Maximum temperature:
Up to 1190C
Vacuum pressure:
<1E-5mBar (cold), <1E-3mBar (peak)
Vacuum quality:
Leak up rate <5microns/h (<6E-3mBar/h). Suitable for titanium.
Partial pressure options:
~0.1mBar Nitrogen or Argon
Hot-zones:
All-metal molybdenum / graphite
Options:
Fully programmable, residual gas analysis, 3-point calibrated thermocouple, calibrated pressure gauge, thermal uniformity survey
2x 500C diffusion bonding furnaces
Working volume:
Up to 200mm diameter x 300mm length
Maximum temperature & load:
Up to 500C at 5000kg load
Vacuum pressure:
<1E-5mBar (cold), <1E-3mBar (peak)
Vacuum quality:
Leak up rate <5microns/h (<6E-3mBar/h). Suitable for titanium.
Partial pressure options:
None
Hot-zones:
All-metal molybdenum
Options:
Residual gas analysis, 3-point calibrated thermocouple, calibrated pressure gauge, thermal uniformity survey
2x Electron beam welders (60kV)
Working volume:
Up to 500mm length scale
Maximum power:
3kW (50mA @ 60kV)
Vacuum pressure:
<1E-5mBar (cold), <1E-3mBar (peak)
Vacuum quality:
Suitable for titanium.
Options:
CNC weld patterns, residual gas analysis, 3-point calibrated thermocouple, calibrated pressure gauge
3x air furnaces
Working volume:
Up to W 300 x L 450 x H 600 mm
Maximum temperature:
Up to 1100C
Options:
3-point calibrated thermocouple, thermal uniformity
1x Electron beam evaporator, 1x Magnetron sputterer
Working volume:
Up to 300mm dia x 30mm height
Coating materials:
Titanium, Gold, Aluminium, Copper, Nickel (many more on request)
Coating thickness:
Up to 10 microns
Vacuum pressure:
<1E-5mBar
Vacuum quality:
Suitable for titanium.
Options:
Ar ion sputtering, multi-layer coatings, residual gas analysis, calibrated pressure gauge
RF brazing / localised heating
Spot welding
Orbital TIG welding (Swagelok M200)
Assembly in ISO clean room conditions
Helium leak testing – Ambient or elevated temperatures
Thermal cycling – 300C in air or 1100C in vacuum
High heat flux testing by EB or RF heating
Optical stress bi-refringence / polarisation
Bespoke solutions – Thermal shock
Our services
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Diffusion bonding
Diffusion bonding involves the joining of parent materials, below their melting point, by heating and applying force in a clean vacuum environment.
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Electron beam welding
We develop novel welded solutions for fusion challenges, but also supply components to imaging, beam-line, and aerospace customers.
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Special Techniques Group
Specialist joining technologies supporting internal UKAEA development, high-tech industry and research institutions globally
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Vacuum brazing
Vacuum brazing involves the joining of parent materials, below their melting point, by using a molten filler metal in a clean vacuum environment.
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Viewport design and manufacture
We design and manufacture custom viewports based on our fusion diagnostic windows. These have been proven for decades in JET to operate under harsh conditions while maintaining minimal optical distortion.