Research and development for industry: Advanced ... - CSIR

ENABLING TECHNOLOGIESCSIR experts in laser sources Kwanele Nyangaza, left, andGary King assembling a state-of-the-art solid-state laser.Water tank leaks atKoeberg Power Stationsealed with new laser process| 64 |Advanced photonicsmanufacturing facilityto ensure new laser-based productsThe CSIR is set to establish an advanced photonics manufacturing facility to bridge the gap between laboratory demonstratorsand commercial products. This will allow the transfer of laser technology in the form of advanced photonics products to theSouth African and international industries, says Dr Daniel Esser, project manager and laser sources research group leader.The CSIR is keen tocollaborate with existing andnew industrial partners todevelop niche products thatcould provide South Africanindustry with a competitiveadvantage.“One of the cornerstones of thestrategy is to build and supportprogrammes that will stimulategrowth in this importanttechnology sector,” explainsHardus Greyling of the CSIR.“The establishment of such afacility will therefore directlysupport the photonics strategyby creating an environmentwhere technological innovationcan be transferred in astructured way to industrialpartners.”Esser adds: “This will be awell-equipped facility, with themindset of advanced productdevelopment, in contrast to aresearch lab.”He says that the goal of the facilitysupports the CSIR’s strategyaround advanced manufacturingand smart product development.The CSIR is known fordemonstrating state-of-the-artlaser technologies. “Our focusnow is to develop these lasers toa state which can be adopted byindustry,” says Esser. “Researchersin this area have already identifiedniche application areas madepossible through the uniqueproperties and wavelengths of ourlaser technology.“The unique propositionresulting from our technologyis rugged mountingtechniques, thermalmanagement, and in-depthknowledge of solid-state lasersystems,” he says. “This is whathas put our laser technologydemonstrators at the leadingedgeof innovation.”The CSIR holds more thanfive world records relating togroundbreaking discoveries inlaser sources, made in recentyears. “These lasers can beused for a number of tasks,including medical applications,due to their uniquewavelength,” explains Esser.These world records wererecognised by the internationalcommunity in the formof published papers andinternational invited talks.“More importantly however,we have produced technologydemonstrators for each of thenew concepts which havebeen acknowledged by localstakeholders,” says Esser.“The next step is to take thesetechnology demonstratorsto advanced products. Todo this, we need to put inplace an advanced photonicsmanufacturing facility.”– Mzimasi GcukumanaEnquiries:Dr Daniel Esserdesser@csir.co.zaFollowing the successful demonstrationof a world-first laser-cladding processtwo years ago, the CSIR and Eskomwelding engineers recently testedthis technology during a scheduledmaintenance operation at KoebergPower Station, Cape Town.The provisionally patented laserbeam-welding and leak-sealing technologywas developed for Eskom in collaborationwith Eskom welding engineers. Thetechnology provides significant support inthe maintenance of South Africa’s powerstations, particularly in sealing and repairingleaking water vessels without having todrain them before conducting the repairwork.During 2011, CSIR laser engineers HermanRossouw and Corney van Rooyen aswell as Eskom welding engineer PhilipDoubell repaired a unit water storage tankin a drained condition during a scheduledmaintenance outage. This feat was eclipsedin February 2012 when the same teamsealed cracks on another tank – fullycharged with water, and the unit on fullgenerating mode. “The idea was to performthe work without impacting on Koeberg’spower generation capacity,” says theCSIR’s Herman Burger.According to Eskom’s engineeringprogrammes manager, Anton Kotze,the maintenance work was successfullycompleted by the CSIR in collaborationwith Eskom’s research, technology anddevelopment team with the required leaksealing and overlays being applied in eightareas on the refuelling water storage tank.“This is probably the first time that laserbasedrefurbishment technology wasused for leak sealing in the nuclear powerindustry,” says Burger.“We would like to express our appreciationfor the efforts made by CSIR engineers –Herman Rossouw and Corney van Rooyen– and their work ethic, professionalismand positive attitude,” says Kotze.Previously, the 18 m high stainlesssteel tank with its 15 m diameter wasrefurbished using arc-welding processes.“These caused undesirable effects suchas thermal distortion. The very low heatinput associated with the CSIR’s laserprocess eliminates these problems andin addition enables Eskom to use localsuppliers to conduct refurbishmentactivities of this nature,” explains Burger.He says that the success of therefurbishment work – during a scheduledmaintenance downtime – is a tellingexample of the strategic importanceof laser technology for industry. “In anenvironment with stringent requirementson quality and turnaround time, wesuccessfully performed work that has notbeen done in South Africa before,” notesBurger.Eskom’s nuclear spokesperson, Tony Stott,commented on the excellent, safe andinnovative approach used in conductingthis refurbishment work. “The success ofthe project is attributed to the continueddedication of the CSIR and the soundpartnership with Eskom,” states Stott.– Mzimasi GcukumanaEnquiries:Herman Burgerhburger@csir.co.zaThe water storage tank at Koeberg that has been repaired with anew laser process, while in use.The process as seen up close.| 65 |