Overview
Our Special Techniques Group has a range of expertise to address specialist manufacturing challenges. It offers:
- a ‘one-stop shop’ for prototyping – from consultancy to design, manufacture and transition to production
- advanced machining of a wide variety of specialist materials
- a range of processing techniques using air and vacuum furnaces, brazing, welding, and diffusion bonding equipment
- flexibility to work at low and high technology readiness levels (TRL) – from a basic sketch to a full technical specification
- a gateway to other services at UKAEA including materials analysis, and a vast range of custom testing (heat flux, vacuum, pressure, magnetic fields, neutronic and more)
The challenges of manufacture for fusion include unusual materials and extremes of pressure and temperature. There are similar challenges in many academic and industrial applications across the globe. We frequently work with clients beyond the fusion energy sector on their manufacturing challenges. An example is with vacuum viewports for quantum science.
Machining
Our machining team’s capabilities include:
- state of the art 5-axis Computer Numerical Control (CNC) machining
- Electrical Discharge Machining (EDM) wire cutting
- additive manufacturing – Electron Beam (EB) and laser
- conventional machining – including milling and turning
- offline (Computer-Aided Design) CAD / (Computer-Aided Manufacturing) CAM programming and Coordinate Measuring Machine (CMM) inspection
- consultancy – including outsourcing of components and technical design and advice
High temperature joining and processing
Our capabilities are focused on the high-temperature joining challenges of metals and ceramics by use of vacuum manufacturing techniques such as:
- diffusion bonding
- manual and beam welding
- vacuum brazing
- air furnaces
The use of controlled vacuum environments makes these processes particularly well-suited to the stringent, repeatable manufacture of sensitive components.
Testing
We have a range of post-manufacture testing capabilities. These include:
- CMM laser metrology
- optical diagnostics
- vacuum leak detection
Special Techniques Group
Expertise in specialist joining technologies – supporting fusion energy research at UKAEA, high-tech industry and research institutions globally.
Our services
Select one of our Special Techniques Group services for more information.
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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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Machining
Our manufacturing team provides a diverse portfolio of machining specialisms for precision components and demanding materials.
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Special Techniques Group
Specialist manufacturing 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 viewports based on our fusion diagnostic windows – proven to operate under harsh conditions with minimal optical distortion.
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Welding
We develop novel welded solutions for fusion challenges, but also supply components to imaging, beam-line, and aerospace customers.
