CVE Host Plenary Session at ICAPP 2023

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International Congress on Advances in Nuclear Power Plants

CVE recently presented at the 2023 International Congress on Advances in Nuclear Power Plants (ICAPP), in conjunction with the 38th Korea Atomic Power Annual Conference.

Bob Nicolson, Managing Director, and Chris Punshon, Head of New Energy Applications, presented on “High Power, Local Vacuum Electron Beam and Laser Welding Solutions for Nuclear Applications”, as highly respected specialists in the field, following an invitation to be plenary speakers from the Technical Programme Committee.

The International Congress on Advances in Nuclear Power Plants (ICAPP) is a forum for leaders of the nuclear community to exchange information, present results from their work, review the state of the industry, and discuss future directions and needs for the deployment of new nuclear power plant systems around the world. The technical programme of the ICAPP 2023 consisted of 3 plenary sessions, 1 panel session and more than 40 parallel sessions.

Running alongside the International Nuclear Energy Expo 2023, the congress took place on the 23rd-27th April 2023 at The Hwabaek International Convention Centre (HICO) in Gyeongju, Korea.

Figure 1. Bob Nicolson (left), Chris Punshon (right).

 

Figure 2. ICAPP Conference 2023.

 

Figure 3. High Power, Local Vacuum Electron Beam and Laser Welding Solutions for Nuclear Applications.

Figure 4. CVE presented as part of Plenary 2.

First Electron Beam Welding of Wind Turbine Monopile

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First Electron Beam Welding of Wind Turbine Monopile Achieves Dramatic Results

A collaboration between Cambridge Vacuum Engineering (CVE), SSE Renewables, Sif Group, and TWI, has resulted in the first-ever electron beam welded section to be incorporated in an offshore wind turbine monopile foundation (transition piece). The resulting monopile is set for installation in the second phase of Dogger Bank Wind Farm, which is located more than 130km off the Northeast coast of England.

Monopiles are currently fabricated using conventional techniques such as submerged arc welding (SAW), but the consortium has demonstrated that electron beam (EB) welding is significantly quicker, cheaper, cleaner, more energy efficient and produces high quality welds with excellent fatigue properties.

Innovative Ebflow Technique is 25 x Faster and Uses 90% Less Energy

The type of electron beam welding technology used – called EbflowTM – is an innovative development within the electron beam welding industry. Instead of welding inside a costly and size-limiting vacuum chamber, Ebflow uses a local vacuum system that creates and maintains a vacuum around only the seam that is being welded. This technique unleashes the potential to use EB welding on large structures, such as the biggest monopiles, while reducing costs and enhancing productivity. The technology – developed by CVE – has been shown to weld monopiles at least 25 times faster than current methods, whilst using 90% less energy, costing 88% less, and producing 97% less CO2 emissions than SAW methods.

The project required installation of an Ebflow system at Sif’s Maasvlakte 2 facility in Rotterdam to perform several longitudinal welds on 2750 mm length seams on 8m diameter rolled cans with a wall thickness of between 67-85mm. Qualification of the welding machine, weld procedures and operators were witnessed by third party inspectors and the regulatory body, DNV, which subsequently issued a technology qualification for EB welding and non-destructive testing (NDT) of the longitudinal seams produced with the process. The comprehensive performance testing programme proved that Ebflow produces welds with fatigue strength that is at least as good, if not better, than observed in equivalent arc welded joints.

The resulting can was incorporated into a monopile transition piece in January 2023 and is scheduled to be installed offshore as part of a foundation in Dogger Bank Wind Farm in late 2023.

Figure 1. The project team at Sif’s Maasvlakte 2 facility.

First-In-Class Project

Olly Cass, SSE Renewables Project Director for Dogger Bank Wind Farm said: 

“This is a ‘first-in-class’ project, establishing this UK innovation as a world-leading technology. With monopile type foundations accounting for over 90% of foundations used in UK projects, Ebflow RPEB could realise significant cost savings on future projects.

“These substantial savings will not only benefit the UK offshore engineering industry but could be passed on to UK energy consumers.

“We’re proud to be pioneering this innovative technique on Dogger Bank Wind Farm by demonstrating its capabilities on a critical offshore component and this would not have been possible without the great collaborative work with Cambridge Vacuum Engineering (CVE), Sif Group, and TWI. We’re excited about what could be achieved by scaling up this method to pick up the pace as we work towards net zero targets.”

Dogger Bank Wind Farm is a joint venture between SSE Renewables, Equinor and Vårgrønn. The farm is being built in three 1.2GW phases and is expected to start generating power this summer.

Figure 2. Submerged arc welding vs. Ebflow.

Visit Us at Coiltech Deutschland 2023

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International Coil Winding Exhibition

CVE are exhibiting at Coiltech Deutschland 2023 in Augsburg, Germany. You can find CVE’s stand in Halle 2, stand number B34, where Sales Manager, Chris Coaster, and Consultant, Nick Edge, will be pleased to discuss CVE’s electron beam welding machines for the fabrication of EV powertrain components.

CVE’s Development Engineering Manager, Alex O’Farrell, will be presenting at the conference on Wednesday 29th March 2023 at 11:00 in Halle 3. Alex will present under the Manufacturing Technologies Session, chaired by G. Fabri, from University of L’Aquila, and the title of his presentation is “High Quality Welding of Stator Hairpins and Copper Conductors”.

Coiltech is an international coil winding exhibition and conference, which will take place in Augsburg, Germany, between Wednesday 29th and Thursday 30th March 2023.

The exhibition covers the following key areas:

  • Materials, machines and techniques for the development, manufacture and maintenance of electric motors, transformers and generators
  • Power distribution and industrial transformers
  • Drive solutions for electromobility
  • Coils in general

 

Image 1. Booth 2B34.

 

Image 2 and 3. O’Farrell’s presentation on electron beam welding of copper hairpins.

23rd Technical Sessions on Welding and Joining Technologies

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CVE Attend the 23rd Technical Sessions on Welding and Joining Technologies

This week, CVE are at the 23rd Technical Sessions on Welding and Joining Technologies, in Irun, San Sebastian, Spain. Running between the 7th and 9th March 2023, the conference serves as a meeting point for the exchange of knowledge among experts in the welding sector, as well as to update and contrast the opinions of the speakers and attendees. It also represents an opportunity for the dissemination of technical knowledge, offering a means for the development of new technologies in the field of joining technologies.

The session is organised by CESOL, the Spanish Association of Welding and Joining Technologies, an independent and non-profit association of people and companies at the service of welding and other joining technologies. CESOL was created in 1993, and is the result of the merger of ADESOL, the Spanish Association for the Development of Welding, created in 1977, and CES, the Spanish Centre for Welding and Joining Technologies, created in 1988.

CVE’s Development Engineering Manager, Alex O’Farrell, presented on the 7th March at the 1st Technical Session on Welding. His presentation was titled “Electron Beam Welding of Copper Electrical Conductors for Electric Vehicles.”

 

About the Conference

The main objective of the session is to disseminate the know-how of the latest achievements in the field of joining, coating, additive manufacturing and related processes like structural integrity, inspection, quality and environmental management.

The conference will offer welding professionals, their employers, scientists, fabricators and welding-products suppliers the best framework to exchange ideas and information, share knowledge resources, an establish a dialogue intended to open new research directions and to join together in partnerships for new projects development. This 23rd Sessions can be an opportunity to advance in the welding profession, its products and its practices and to continue driving the welding industry forward.

The topics covered include:

  • New technologies in welding and cladding processes and their applications
  • Materials joining processes
  • New inspection techniques
  • Mechanical behaviour of welded joints (fracture mechanical test, distortion and residual stresses)
  • Design and modelling processes of welded joints
  • Weldability of new materials
  • Adhesive bonding and structural applications
  • Characterization of materials
  • Corrosion
  • Additive manufacturing
  • Welding automation
  • Failure analysis
  • Health and safety (occupational exposures, welding fumes)
  • Developments in personnel certification and welding codes

 

The following industries are also represented:

 

For more information about Alex’s presentation please email sales@camvaceng.com.

CVE Win Faraday Challenge Funding

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CVE Win Faraday Challenge Funding

Cambridge Vacuum Engineering (CVE) has received funding from Innovate UK under the Faraday Battery Challenge.

A partnership between Innovate UK, UK Battery Industrialisation Centre, and The Faraday Institution, has be constructed to create a challenge that supports the research and development of the most promising, innovative, and sustainable battery technologies for the propulsion of electric vehicles in the automotive sector.

The result is £27.6 million in funding being invested across 17 research and innovation projects and facilities that will drive the growth of a strong battery business in the UK.

Electron Beam Welding

CVE’s proposal, EB-Bat, in collaboration with Delta Cosworth and TWI, will use the funding to design, build and test an electron beam (EB) welding machine that can weld battery busbar components.

Electron beam welding is potentially 20 times faster than laser welding. You can deflect and refocus electron beams much faster than laser beams, as this is achieved using magnetic fields, without moving parts as the welds are made. Plus, EBs do not suffer from reflectivity from copper and aluminium, making more consistent and reliable welds.

The EB-Bat project will provide a compelling demonstration of the process performance, productivity, quality, and economics to the automotive manufacturing sector with an aim to secure funding to take it into production.

Other benefits of welding battery busbars using electron beam over current laser welding methods include:

  • Energy savings
  • Smaller factory footprint
  • A reduction in scrap
  • Welding fume control

Figure 1. Electron beam column with rapid wide range deflection.

Figure 2. Busbar battery welding.

Project Partners

The project partners combine a wealth of experience in the automotive industry, with Delta Cosworth, electric vehicle specialists developing innovative battery solutions and part of the wider Cosworth Group; and TWI as a world-leading welding and materials development organisation. CVE, the lead partner in the project, are designers and manufacturers of electron beam and laser welding machines for many applications, including turbochargers.

 

Simon Dowson, Managing Director at Delta Cosworth, commented:

“Developing and manufacturing batteries is one of our core capabilities at Delta Cosworth. We have already made leaps and bounds in delivering flexible battery solutions, our Cylindrical Scalable Modules being at the centre of our battery offering. Creating, more efficient and reliable ways to manufacture our batteries like electron welding will aid us in maximising our battery technology’s potential and give us the possibility to transfer new manufacturing techniques across the wider Cosworth group.” 

 

Tony Harper, Challenge Director for the Faraday Battery Challenge, said:

“As we move towards a net zero future the UK’s electric vehicle industry must continue to evolve. These winning projects have all shown how their ideas can potentially accelerate the development of technologies or business practices in the UK. I look forward to seeing how their innovations help to significantly advance the performance characteristics of batteries for electric vehicles.​”

 

Find out more about the funding in the UK’s Research and Innovation’s announcement: Delivering the Future of Battery Technology.

Welding and Joining Matters Journal Feature

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Welding and Joining Matters

CVE featured in The Welding Institute’s Winter 2022 edition of the Welding and Joining Matters journal.

Launched in Spring 2022, the committee of Welding and Joining Matters is formed of professional members of The Welding Institute. It is a lively and easily read journal covering all aspects of welding, joining, and fabrication as well as inspection and structural performance of all classes of materials and welded products.

It has articles of interest for all personnel working in these industries, from practitioners and technicians on the shop floor, to inspectors, welding coordinators, welding engineers, incorporated and chartered engineers as well as managers, researchers, and designers of fabricated equipment and structures.

The journal is available as electronic and hard copy publication, which is published four times a year.

Authored by Chris Punshon, CVE’s Head of New Energy Applications, you can read CVE’s featured article below or download it as a PDF.

Find out more about the journal on The Welding Institute’s website.

CVE Exhibit at Fabtech 2022

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CVE Exhibit at Fabtech 2022

CVE exhibited at Fabtech 2022 from the 8th of November to the 10th of November, in Atlanta, Georgia, USA.

 

FABTECH is North America’s largest metal forming, fabricating, welding and finishing event. It provides a convenient ‘one-stop shop’ venue where you can meet with world-class suppliers, see the latest industry products and developments, find the tools to improve productivity, and increase profits. They strongly believe in the power of in-person events to discover, educate, and motivate the metal fabrication industry.

 

Tony Slater, Technical Sales Manager, and Steve Horrex, Sales Director, were at Booth C13212 exhibiting our product lines:

Exhibition Information

The show encompassed three halls at the Georgia World Congress Center in Atlanta. Attendees will found a variety of technology pavilions dedicated to Forming & Fabricating, Tube & Pipe, METALFORM, Welding, Finishing, 3D/Additive Manufacturing and Robotics & Industrial Automation. Featured technologies included:

  • Additive Manufacturing / 3-D Printing
  • Arc Welding
  • Assembly
  • Automation
  • Bending & Forming
  • Brazing & Soldering
  • Business Services
  • Coil Processing
  • Cutting
  • Fastening & Joining
  • Finishing/Paint & Powder Coating
  • Finishing/Plating
  • Gases & Gas Equipment
  • Hydroforming
  • Inspection & Testing
  • Job Shop/Contract Mfg.
  • Lasers
  • Lubrication
  • Maintenance & Repair
  • Material Handling
  • Metal Suppliers
  • Plate & Structural Fabricating
  • Press Brakes
  • Punching
  • Resistance Welding
  • Robotics
  • Roll Forming
  • Safety & Environmental
  • Saws
  • Software, Machine Controls
  • Stamping
  • Thermal Spraying
  • Tool & Die
  • Tooling
  • Tube & Pipe Fabricating or Welding
  • Tube & Pipe Producing
  • Waterjet
  • Welding Consumables
  • Welding Machines

 

For more information, please visit the organiser’s website.

75th International Institute of Welding Assembly

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Innovative Welding and Joining Technologies

CVE attended the 75th International Institute of Welding (IIW) Annual Assembly and Conference, 17th-22nd July 2022, in Tokyo, Japan.

The Japan Institute of Welding, The Japan Welding Society, and The Japan Welding Engineering Society hosted the event, with support from the Tokyo Convention and Visitors Bureau.

The theme was innovative welding and joining technologies to achieve carbon neutrality and promote sustainable development.

The conference covered a range of other topics, including:

  • Additive manufacturing technology and efficient engineering
  • Artificial intelligence (AI) and digital transformation (DX)
  • Hydrogen (including fuel ammonia), renewable and nuclear energy, electrification
  • New materials
  • Future technologies
  • Other fundamentals

The IIW opening ceremony.

Max Nentwich (front left) and Chris Punshon (front middle) attending an IIW presentation.

Presentations

CVE colleagues Chris Punshon, Head of New Energy Applications, Alex O’Farrell, Development Engineering Manager, and Max Nentwich, Head Laser Development Engineer, presented papers at the conference, with topics spanning local vacuum power beam welding, copper welding for electric vehicles, and laser welding in a vacuum.

The details of the papers are as follows:

  • Doc.IV-1507-2022 Local Vacuum Electron Beam and Laser Solutions in New Energy Applications – New Developments and Regulatory Position, Chris Punshon, et al.
  • Doc.IV-1506-2022 Removing The Bottleneck In Welding Of Electrical Conductors for Electric Vehicles, Alex O’Farrell, et al.
  • Doc.IV-1508-2022 Interaction of Protective Gas with Process Emissions in Vacuum Laser Welding, Max Nentwich, et al.
Local Vacuum Power Beam Welding

Chris is the UK delegate for IIW Commission IV (Power Beam Processes) and acted as a session chair for Commission IV. He also presented on local vacuum electron beam welding.

His paper was titled the Local Vacuum Electron Beam and Laser Solutions in New Energy Applications – New Developments and Regulatory Position.

This follows a series of development projects using CVE’s local vacuum technology, Ebflow, including welding of 200mm thick steel, pressure vessel manufacture, pilot at Dogger Bank wind farm, and wind tower manufacturing.

Chris Punshon was a session chair for Commission IV (Power Beam Processes).

Interaction of Protective Gas with Process Emissions in Vacuum Laser Welding

Max Nentwich, working as part of a knowledge transfer partnership (KTP) between Cambridge Vacuum Engineering and Cranfield University, presented a paper on the Interaction of Protective Gas with Process Emissions in Vacuum Laser Welding.

Max Nentwich presented on laser welding in vacuum.

Welding Electrical Conductors for Electric Vehicles

Alex’s paper, titled Removing the Bottleneck in Welding of Electrical Conductors for Electric Vehicles, focused on how the industry can increase the rate of joining electrically conducting components and the criticality of this to improving electric vehicle manufacturing.

Max Nentwich presented on behalf of Alex O’Farrell.

Further Information

The CVE team then attended the adjacently-running Japan International Welding Show at Tokyo International Exhibition Centre.

If you are interested in the above topics, please get in touch by emailing sales@camvaceng.com.

CVE Exhibit at Battery Show North America 2022

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Electron Beam for Electric Vehicles

CVE are exhibiting at Battery Show North America, in Novi, Michigan, 13-15 September 2022.

You can find us at stand 2345.

CVE colleagues Tony Slater, Technical Sales Manager, Nick Edge, Consultant, and Ellen Cormack, Marketing Manager, would like to talk to visitors about manufacturing electric vehicle (EV) powertrain components, including batteries, motor stators and hairpins, inverters, and shunt resistors.

CVE stand 2345.

Tony Slater (left), Technical Sales Manager, Nick Edge (right), Consultant.

Battery Show North America

Battery Show North America brings together engineers, business leaders, top-industry companies, and innovative thinkers to discover ground-breaking products and create powerful solutions for the future.

From raw materials to components, find what you need to power your next project. The Battery Show brings together more than 750 suppliers showcasing the latest solutions across the transportation, stationary, portable, and industrial sectors.

We were joined on the UK Pavilion (stand 2345) by:

  • Autocraft Solutions Group
  • Avocet Battery Materials – ABM
  • Breathe Battery Technologies
  • Cosworth
  • Eatron Technologies
  • Invest North East England (Electric North East England)
  • Helix
  • Paragraf®
  • RML Group
  • TeraView
  • Transense Technologies plc
  • Williams Advanced Engineering

The largest battery and electric vehicle technologies trade show in North America.

Exclusive access to hours of education presented by top-industry experts.

Discover advanced battery and electric vehicles technologies and innovations.

Innovate UK Knowledge Transfer Partnership Awards

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Overview

CVE is delighted to announce that our Knowledge Transfer Partnership (KTP) associate, Max Nentwich, is a finalist in the Innovate UK KTP Awards 2022.

Knowledge Transfer Partnerships

KTPs, organised by Innovate UK KTN, connect businesses with academia to deliver innovation projects led by graduates.

The projects focus on some of the world’s most pressing problems, and the programme accelerates these ambitious ideas into real-world, commercial solutions. It does this through connecting businesses with new partners, ideas, or academia.

The KTP Awards

The KTP Awards celebrate the most creative, effective, and interesting people and projects out of around 800 KTPs that are active right now.

Max is a finalist for the Future Leader Award. This award is for associates who have shown exceptional skills, above and beyond the normal expectations of a KTP Associate, in driving and delivering innovation strategy, demonstrating great teamwork, and outstanding leadership potential.

Max’s work with CVE in includes an innovative laser in vacuum window protection solution and is in partnership with Cranfield University.

There are an additional six awards available:

  • Best Knowledge Transfer Partnership
  • Technical Excellence Award
  • The Changing the World Award
  • Business Impact and Transformation
  • KTP Academic of the Year Award
  • Best Knowledge Base KTP Support Team Award

Innovate UK KTP Awards – 12 October 2022.

Max Nentwich, Cambridge Vacuum Engineering / Cranfield University is a Future Leader Award finalist.

Join the Ceremony

The ceremony will take place on Wednesday 12th October, in-person and online. You can register your attendance via Innovate UK’s website.

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