At Holdson, we’re proud to collaborate with the UK Atomic Energy Authority (UKAEA) on a project that aims to advance the use of refractory metals, specifically tungsten, in nuclear energy applications.
Alongside other trusted partners and suppliers, we are developing and testing tungsten samples using advanced manufacturing and post-processing techniques. This project is contributing invaluable insights into how tungsten can be utilised more effectively within nuclear environments.
Why tungsten?
Tungsten is an incredibly resilient material with properties that make it highly suitable for nuclear energy applications. As one of the most heat-resistant metals, tungsten has a melting point of over 3,400°C, making it an ideal candidate for components that need to withstand extreme thermal conditions. Tungsten’s high density and ability to resist radiation damage also make it particularly advantageous for use in fusion reactors and other energy-intensive applications within the nuclear sector.
The challenge?
Despite these advantageous properties, tungsten poses several challenges when it comes to machining and post-processing. The metal is notoriously brittle, which makes it difficult to cut, shape, or polish using traditional methods. This brittleness can lead to cracking and other structural issues, especially when creating complex or delicate geometries that are often necessary in nuclear applications. Tungsten’s hardness and toughness make it challenging to achieve the smooth, precise finishes required for optimal thermal and mechanical performance.
The solution?
Our electrochemical polishing (ECP) process is uniquely suited to overcome the challenges associated with post-processing tungsten, providing several key advantages for nuclear applications:
- Polishing internal channels for enhanced thermal management
In nuclear environments, maintaining controlled thermal conditions is critical. electroform™ allows us to polish internal channels with precision, enabling better heat dissipation and preventing hotspots. This capability is especially useful for components that need to channel coolant or other fluids effectively within a fusion reactor or other high-heat environments.
- Handling complex geometries and lattice structures
Advanced nuclear components often feature intricate lattice structures designed to reduce weight while maintaining structural integrity. Traditional machining and polishing methods struggle with such complex geometries, especially with a brittle material like tungsten. electroform™ can navigate and polish these structures efficiently, ensuring that each part meets stringent quality standards without risking damage to the material.
- Consistent, high-quality surface finishes
Electrochemical polishing provides a uniform finish, which is essential for maintaining the structural integrity and performance of tungsten components in nuclear applications. A smooth, consistent surface helps minimise stress points, which can otherwise exacerbate tungsten’s brittleness and make it more susceptible to cracking under pressure.
Facilitating research and development in nuclear energy
Through our collaboration with UKAEA, we’re facilitating the segmentation, post-processing, and rigorous testing of tungsten samples. This work is directly contributing to research and development efforts aimed at finding safer, more efficient ways to use tungsten in nuclear applications. Our advanced post-processing capabilities are helping to refine the material’s surface properties, allowing for better performance analysis and more reliable data on tungsten’s suitability for long-term use in nuclear reactors.
The future of tungsten in nuclear energy
With electroform™, we’re not just refining the post-processing capabilities for tungsten; we’re setting the stage for the broader adoption of refractory metals in critical industries like nuclear energy. By offering a solution that can efficiently post-process tungsten to meet the demanding requirements of nuclear applications, we’re helping to unlock the potential of this metal in a way that was previously unachievable with traditional manufacturing techniques.
As we continue to work with UKAEA and our partners, we’re excited to contribute to a future where materials like tungsten play an essential role in advancing cleaner and more sustainable energy sources. Our commitment to innovation and precision in post-processing makes Holdson a trusted partner in this pioneering journey, and we look forward to sharing more developments as we progress. For more information about our work with tungsten and other refractory metals, or to learn how electroform™ can support your advanced manufacturing needs, please contact us directly.
