Case Study
Sheffield Forgemasters successfully completed casting trials of a pioneering hollow steel ingot at its Brightside Lane foundry in late 2010, marking the culmination of more than a year of research and development aimed at transforming how large cylindrical forgings are manufactured for the civil nuclear sector. The project was led by Dr Jesus Talamantes-Silva, Engineering & Technology Director.
The Challenge
Producing cylindrical forgings from conventional solid steel ingots is resource-intensive, requiring multiple heating cycles, extensive machining, and generating significant material waste. Key components such as nuclear steam generator transition cones and spent fuel waste casks demand high-integrity cylindrical forms, yet conventional production methods meant a substantial proportion of raw steel was discarded at considerable cost.
The Approach and Trial
The solution was to cast an ingot already containing a central void, eliminating many downstream processes. Though hollow ingots had been produced at Brightside Lane before 1980, the capability had since lapsed, with only a handful of companies worldwide having maintained it. Dr Talamantes-Silva’s team spent over 12 months refining casting parameters using finite element analysis and solidification modelling before committing to a full-scale trial.
The resulting 160-tonne hollow ingot was successfully cast and demoulded, with results described as “extremely promising.” Further destructive testing was planned to validate the material properties before the process could be considered fully proven.
"This process aims to reduce many of the costs and processes involved in manufacturing critical forgings for the power generation industry. We are in the early stages of refining the process, but the results so far are extremely promising."
Dr Jesus Talamantes-Silva, Engineering and Technology Director, Sheffield Forgemasters
Expected Benefits
Fewer heating cycles, significantly less material waste, and a more efficient route to critical nuclear components – strengthening Sheffield Forgemasters’ ability to compete for civil nuclear contracts on a global level.
