The Materials Processing Institute (MPI) has been instrumental in achieving the UK’s first large-scale production of fusion-ready steel – a groundbreaking advancement that promises to significantly reduce manufacturing costs for advanced structural materials and enhance the efficiency of future nuclear fusion power plants.
This milestone was delivered through the £12 million NEURONE (Neutron Irradiation of Advanced Steels) Consortium, a collaboration led by the UK Atomic Energy Authority’s (UKAEA) Materials Division, MPI, and a network of academic and industrial partners.
Using its state-of-the-art 7-tonne Electric Arc Furnace (EAF) at its Middlesbrough campus, MPI successfully produced 5.5 tonnes of fusion-grade reduced-activation ferritic-martensitic (RAFM) steel. These high-performance steels are critical for next-generation nuclear fusion reactors, designed to withstand extreme conditions such as temperatures of up to 650°C and intense neutron radiation.
The project focused on adapting EAF technology by integrating advanced purification and heat treatment processes. This innovative approach has the potential to slash the cost of RAFM steel production by up to ten times.
Richard Birley, MPI’s NEURONE project lead and Group Leader for Materials Development and Powder Metallurgy, said:
“As the only UK facility capable of producing RAFM steel at this scale, this is a groundbreaking moment for nuclear fusion research and development. These trials mark a significant step towards cost-effective manufacturing of fusion steels for future commercial fusion programmes.
“MPI’s involvement in this project highlights its position as a national leader in the research and innovation that is driving the transition to a low-carbon future. By utilising its expertise and state-of-the-art infrastructure, we are playing a crucial role in positioning the UK at the forefront of nuclear fusion technology.”
David Bowden, Group Team Leader for Materials Science and Engineering at UKAEA and NEURONE programme lead, added:
“One of the major challenges for delivering fusion energy is developing structural materials able to withstand the extreme temperatures and high neutron loads required by future fusion power plants. The production of 5.5 tonnes of fusion-grade RAFM steel lays the foundation for cost-effective manufacturing of these materials.”
In addition to this achievement, NEURONE has developed more than 50 variants of advanced reduced-activation ferritic-martensitic (ARAFM) steel alloys for further analysis. This evolution of RAFM steel presents significant opportunities for UK steel manufacturers to contribute to future activities, including forging, rolling, and optimising manufacturing processes.
The Consortium, which was established to research, test, and develop advanced steels, includes representatives from leading academic institutions such as Swansea, Sheffield, Birmingham, Imperial College London, Manchester, Bristol, Strathclyde, and Oxford universities, as well as Sheffield Forgemasters and The Australian Nuclear Science and Technology Organisation.