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DENSAMET® Tungsten Division Prismatic Machining Division Valve Stems Division Antennas Division Manufacturing Success - 14 March 2012 High value manufacturing,

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Presentation on theme: "DENSAMET® Tungsten Division Prismatic Machining Division Valve Stems Division Antennas Division Manufacturing Success - 14 March 2012 High value manufacturing,"— Presentation transcript:

1 DENSAMET® Tungsten Division Prismatic Machining Division Valve Stems Division Antennas Division Manufacturing Success - 14 March 2012 High value manufacturing, an SME Case Study Ian Warrington, Project Manager MG Sanders Ltd

2 DENSAMET® Tungsten Division Prismatic Machining Division Valve Stems Division Antennas Division “ SME`s make up a half of all jobs in the UK and account for half of our GDP” (B2B Int.) An overview of our capability Contract Case Study-Future Energy

3 DENSAMET® Tungsten Division Prismatic Machining Division Valve Stems Division Antennas Division Situated in Stone, 30 miles north of Birmingham in Central England. Established 38 years Under new ownership since January 2006: Rubicon Partners Industries LLP. 55 employees, T/O £8.5m (2011) 7000m 2 Engineering & Metallurgical facility

4 DENSAMET® Tungsten Division Prismatic Machining Division Valve Stems Division Antennas Division ◄ Tungsten LB-SRP Activity Tungsten alloy blending, pressing & vacuum sintering Multi–axis CNC Milling, Turning, Grinding, EDM: Tungsten (W), Refractory and exotic Ni, Fe, Al based alloys Pre-production – Prototype Manufacture Clean room assembly High Volume Pharmaceutical Valve Stem production Design & Manufacture of UHV & VHF Military Antennas ‘End of life’ process re-definition and manufacture Reverse Engineering & Sub-Contract manufacture

5 DENSAMET® Tungsten Division Prismatic Machining Division Valve Stems Division Antennas Division Quality Approvals ISO 9001 AS 9100 Rev B

6 DENSAMET® Tungsten Division Prismatic Machining Division Valve Stems Division Antennas Division ◄ Tungsten LB-SRP Some of our customers:

7 DENSAMET® Tungsten Division Prismatic Machining Division Valve Stems Division Antennas Division ◄ Tungsten LB-SRP Activity Tungsten alloy blending, pressing & vacuum sintering

8 DENSAMET® Tungsten Division Prismatic Machining Division Valve Stems Division Antennas Division ◄ Tungsten LB-SRP Activity Multi–axis CNC Milling, Turning, Grinding, EDM: Tungsten (W), Refractory and exotic Ni, Fe, Al based alloys

9 DENSAMET® Tungsten Division Prismatic Machining Division Valve Stems Division Antennas Division ◄ Tungsten LB-SRP Activity High Volume Pharmaceutical Valve Stem production Circa 1.2m/month

10 DENSAMET® Tungsten Division Prismatic Machining Division Valve Stems Division Antennas Division ◄ Tungsten LB-SRP Activity HF, VHF and UHF Bowman Manpack and Vehicle Elevated or Ground based units Design & Manufacture of Military Broadband Antennas

11 DENSAMET® Tungsten Division Prismatic Machining Division Valve Stems Division Antennas Division AEROSPACE Control surfaces Flutter weights Boeing 737/767/777 ATR 76 Airbus Military

12 DENSAMET® Tungsten Division Prismatic Machining Division Valve Stems Division Antennas Division AW101 AW139 AW149 Lynx Wildcat AEROSPACE Rotor Balance

13 DENSAMET® Tungsten Division Prismatic Machining Division Valve Stems Division Antennas Division F1 Aerodynamic Ballast

14 DENSAMET® Tungsten Division Prismatic Machining Division Valve Stems Division Antennas Division Nuclear Engineering- Radiation Shielding Oil Well Logging Instrumentation Nuclear Waste Encapsulation Shielding - Sellafield

15 DENSAMET® Tungsten Division Prismatic Machining Division Valve Stems Division Antennas Division LHC Tungsten Cylinder Inserts (for Target Attenuator experimental Areas) CLIC RF Accelerating Structures –UKTI- OMIS/STFC support Ultra precise machining, diffusion bonding

16 DENSAMET® Tungsten Division Prismatic Machining Division Valve Stems Division Antennas Division Identify innovative & technically demanding opportunities, in Tungsten and other exotic materials or processes, that can be commercially exploited to generate incremental high value revenue. Business Development-Access New Markets Focus on materials competence, skills and future markets

17 DENSAMET® Tungsten Division Prismatic Machining Division Valve Stems Division Antennas Division The world's largest Fusion tokamak, JET (Joint European Torus), has produced 16 megawatts of fusion power and proved the technical feasibility of fusion using deuterium and tritium, currently considered the most efficient fuels. The challenge now is to prove fusion can work on a power plant scale. JET (Joint European Torus) Business Development – Future Energy 1st wall upgrade to the Joint European Torus (JET) – €48m budget – EFDA funded (EU Commission) to evaluate materials for ITER construction Identify tender opportunities -expression of interest

18 DENSAMET® Tungsten Division Prismatic Machining Division Valve Stems Division Antennas Division Evaluate Plasma surface interaction for ITER materials: Beryllium W-coated CFC Inconel + Be Bulk W- LBSRP Previously CFC W Divertor Module - power handling surface.

19 DENSAMET® Tungsten Division Prismatic Machining Division Valve Stems Division Antennas Division Validation of CATIA V/STEP models and provision of full manufacturing drawings Fusion related materials understanding Development of manufacturing processes and techniques Production of tooling and jig fixtures Complex 5 axis machining Accurate, clean assembly of complex geometry items for UHV and demanding environments (JET QUA 500) Comprehensive inspection to CAD models including CMM, Surface Measurement & SPC. Competencies & skills

20 DENSAMET® Tungsten Division Prismatic Machining Division Valve Stems Division Antennas Division Contract Award Time from expression of interest to tender response deadline = 3 months. Complex tender to interpret: CATIA V model, prototype design & materials/technical specification. Open comments & questions circulated to invited tendering companies. As a potential new supplier an audit visit followed tender submission to assess capability. Contract preparation forms, followed by agreement in principle (without prejudice), fixed price & rigid contractual terms (EU Commission), bank guarantee.

21 DENSAMET® Tungsten Division Prismatic Machining Division Valve Stems Division Antennas Division Formal contract award (12 months + from Expression of Interest) Value: €5.3m Prototypes (including orders outside of contract) to test and allow final design freeze for manufacture. Deliverables & Milestones mutually acceptable & achievable, including payments. Contract Award

22 DENSAMET® Tungsten Division Prismatic Machining Division Valve Stems Division Antennas Division Tungsten - LBSRP Tungsten LBSRP MGS Tungsten for plasma facing components - independently tested & qualified;

23 DENSAMET® Tungsten Division Prismatic Machining Division Valve Stems Division Antennas Division 50 assemblies / 80Kg each 5 exotic materials 1,600 parts /assembly 80,000 parts total Clean room assembly 50μm reference tolerances

24 DENSAMET® Tungsten Division Prismatic Machining Division Valve Stems Division Antennas Division

25 DENSAMET® Tungsten Division Prismatic Machining Division Valve Stems Division Antennas Division

26 DENSAMET® Tungsten Division Prismatic Machining Division Valve Stems Division Antennas Division Installation of a solid tungsten divertor module between neighbours with dedicated spinal Remote Handling tool Courtesy M. Woollard

27 DENSAMET® Tungsten Division Prismatic Machining Division Valve Stems Division Antennas Division Wall & Divertor completed mid 2011

28 DENSAMET® Tungsten Division Prismatic Machining Division Valve Stems Division Antennas Division The next steps : International fusion research is following a roadmap to achieve power generation within 30 years. It focuses on three main projects: ITER – a multinational project (47%) EU, with a €10bn budget that is being built in the south of France. ITER will be a 500 megawatt tokamak (equivalent to a small power plant) and aims to confirm that fusion power will be possible on a commercial scale; IFMIF (International Fusion Materials Irradiation Facility) – a device that will test the materials needed in a fusion power station, planned to operate in parallel with ITER; ITER Business Development

29 DENSAMET® Tungsten Division Prismatic Machining Division Valve Stems Division Antennas Division ITER Divertor targets

30 DENSAMET® Tungsten Division Prismatic Machining Division Valve Stems Division Antennas Division Business Development DEMO – a demonstration power plant supplying fusion electricity to the grid. This is being designed now and would be constructed during ITER and IFMIF operation. If successful, it will be followed by the first generation of commercial fusion power stations. We are looking for partners to collaborate in these high value manufacturing opportunities. Thank you for your attention!


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