Damage of actively cooled plasma facing components of magnetic confinement controlled fusion machines

Plasma facing components (PFCs) of magnetic fusion machines have high manufactured residual stresses and have to withstand important stress ranges during operation. These actively cooled PFCs have a carbon fibre composite (CFC) armour and a copper alloy heat sink. Cracks mainly appear in the CFC near the composite/copper interface. In order to analyse damage mechanisms, it is important to well simulate the damage mechanisms both of the CFC and the CFC/Cu interface. This study focuses on the mechanical behaviour of the N11 material for which the scalar ONERA damage model was used. The damage parameters of this model were identified by similarity to a neighbour material, which was extensively analysed, according to the few characterization test results available for the N11. The finite elements calculations predict a high level of damage of the CFC at the interface zone explaining the encountered difficulties in the PFCs fabrication. These results suggest that the damage state of the CFC cells is correlated with a conductivity decrease to explain the temperature increase of the armour surface under fatigue heat load.     

Proposal for a new technique to join CFC composites to copper

The divertor design of the ITER fusion machine comprises the joint between CFC composites and the copper alloy heat sink. The main problem of the CFC–Cu joint manufacturing is the large thermal expansion mismatch of the components and the very high contact angle of molten copper on carbon substrates. The aim of this work is to develop a new technique to join CFC composite to pure copper. In order to increase the wettability of CFC by molten copper, the composite surface was modified by direct reaction with group VI transition metals which form a carbide layer and allow a large reduction of the contact angle. A morphological analysis and the mechanical and thermal shock tests were performed to characterize the CFC–Cu joined samples.     

Towards the development of workable acceptance criteria for the divertor CFC monoblock armour

The plasma-facing components (PFCs) of the ITER divertor will be subjected to high heat flux (HHF). Carbon–fibre composite (CFC) is selected as the armour for the region of highest heat flux where the scrape-off layer of the plasma intercepts the vertical targets (VT). Failure of the armour to heat sink joints will compromise the performance of the divertor and could ultimately result in its failure and the shut down of the ITER machine. There are tens of thousands of CFCs to CuCrZr joints. The aim of the PFC design is to ensure that the divertor can continue to function even with the failure of a few joints. In preparation for writing the procurement specification for the ITER vertical target PFCs, a programme of work is underway with the objective of defining workable acceptance criteria for the PFC armour joints.     

Thermal fatigue damage in monofilament reinforced copper for heat sink applications in divertor elements

In fusion reactor systems extreme conditions require materials with high temperature and radiation resistance. The divertor component consists of a plasma facing W plate attached to a Cu heat sink to extract the heat from the nuclear reaction chamber coolant. The Coefficient of Thermal Expansion (CTE) mismatch between the W plate and the Cu heat sink causes interface delamination reducing the long term stability of the divertor.To avert this problem, composites are developed as interlayer materials with a high thermal conducting Cu matrix reinforced with up to 50 vol.% SiC or W monofilaments to increase the mechanical strength and to reduce the CTE mismatch. Thermal stresses are transferred from the macroscopic interface between the components into the bulk of the composite. Oscillating micro stresses may lead to fiber delamination and matrix damage during thermal cycling. Different matrix alloys, fiber materials and interface designs are investigated.In situ neutron diffraction performed during thermal cycling show the effect of bonding strength on the stress amplitudes expected under service conditions. The long term stability is tested by measurements after further ex situ cycling. Thermal fatigue damage and its propagation are visualized by in situ as well as ex situ high resolution synchrotron tomography. The combination of both methods helps to understand the strain induced damage mechanisms. Weak bonding leads to delamination of the fiber-matrix interfaces. Strong bonding causes severe matrix deformation and damage. Fiber cracks originating from sample production cause accumulating thermal fatigue damage during thermal cycling.     

Engineering studies for the installation of an axi-symmetric metallic divertor in Tore Supra

Tore Supra (TS) has been designed to operate using technologies that allow long plasma operation (a few minutes), by means of superconducting magnets and actively-cooled high heat flux plasma facing components (PFCs). Actively cooled tungsten PFC will be used in the baffle area of the first ITER divertor. In order to validate such a technology fully (industrial manufacturing, operation with long plasma duration), the implementation of a tungsten axi-symmetric divertor in the tokamak Tore Supra has been studied [1]. With this second major upgrade, Tore Supra should be able to address the problematic of long plasma discharges with a metallic divertor.The proposed divertor is made up of two stainless steel casings containing a copper coil winding located at the top and bottom area of the vacuum vessel. These casings are firmly maintained by connection beams and protected by PFC. This paper describes the mechanical design of this major component and its integration in TS, the associated electromagnetic and thermomechanical analysis, the manufacturing issues and finally the integration of ITER representative PFCs.     

Ultrasonic test of carbon composite/copper joints in the ITER divertor

The vertical targets of the ITER divertor consist of high flux units (HFU) actively cooled: CuCrZr tubes armoured by tungsten and carbon/carbon fibre composite (CFC). The armour is obtained with holed parallelepiped blocks, called monoblocks, previously prepared and welded onto the tubes by means diffusion bonding. The monoblock preparation consists in the casting of a layer of copper oxygen free (Cu OFHC) inside the monoblock hole.Each HFU is covered with more than 100 monoblocks that have to be joined simultaneously to the tube. Therefore, it is very important to individuate any defects present in the casting of Cu OFHC or at the interface with the CFC before the monoblocks are installed on the units.This paper discusses the application of non-destructive testing by ultrasound (US) method for the control of the joining interfaces between CFC monoblocks and Cu OFHC, before the brazing on the CrCrZr tube.In ENEA laboratory an ultrasonic technique (UT) suitable for the control of these joints with size and geometry according to the ITER specifications has been developed and widely tested. Real defects in this type of joints are, however, still hardly detected by UT. The CFC surface has to be machined to improve the mechanical strength of the joint. This results in a surface not perpendicular to the ultrasonic wave. Moreover, CFC is characterized by high acoustic attenuation of the ultrasonic wave and then it is not easy to get information regarding the Cu/CFC bonding. Nevertheless, the UT sharpness and simplicity pushes to perform some further study. With this purpose, a sample with artificial defects induced on the CFC/Cu interface during the Cu casting, has been manufactured and investigated, both by pulse-echo technique and by different techniques. The results obtained by the UT on this sample are reported and compared with X-ray method.     

Improvement of non destructive infrared test bed SATIR for examination of actively cooled tungsten armour Plasma Facing Components

For steady state (magnetic) thermonuclear fusion devices which need large power exhaust capability and have to withstand heat fluxes in the range 10–20 MW m^?2, advanced Plasma Facing Components (PFCs) have been developed. The importance of PFCs for operating tokamaks requests to verify their manufacturing quality before mounting. SATIR is an IR test bed validated and recognized as a reliable and suitable tool to detect cooling defaults on PFCs with CFC armour material. Current tokamak developments implement metallic armour materials for first wall and divertor; their low emissivity causes several difficulties for infrared thermography control. We present SATIR infrared thermography test bed improvements for W monoblocks components without defect and with calibrated defects. These results are compared to ultrasonic inspection. This study demonstrates that SATIR method is fully usable for PFCs with low emissivity armour material.     

Fabrication and characterization of tungsten and graphite based PFC for divertor target elements of ITER like tokamak application

The development of the fabrication technology of macro-brush configuration of tungsten (W) and carbon (graphite and CFC) plasma facing components (PFCs) for ITER like tokamak application is presented. The fabrication of qualified joint of PFC is a requirement for fusion tokamak. Vacuum brazing method has been employed for joining of W/CuCrZr and C/CuCrZr. Oxygen free high conductivity (OFHC) copper casting on W tiles was performed followed by machining, polishing and ultrasonic cleaning of the samples prior to vacuum brazing. The W/CuCrZr and graphite/CuCrZr based test mockups were vacuum brazed using silver free alloys. The mechanical shear and tensile strengths were evaluated for the W/CuCrZr and graphite/CuCrZr brazed joint samples. The micro-structural examination of the joints showed smooth interface. The details of fabrication and characterization procedure for macro-brush tungsten and carbon based PFC test mockups are presented.     

Ultrasonic techniques for quality assessment of ITER Divertor plasma facing component

The divertor is one of the most challenging components of ITER machine. Its plasma facing components contain thousands of joints that should be assessed to demonstrate their integrity during the required lifetime. Ultrasonic (US) techniques have been developed to study the capability of defect detection and to control the quality and degradation of these interfaces after the manufacturing process. Three types of joints made of carbon fibre composite to copper alloy, tungsten to copper alloy, and copper-to-copper alloy with two types of configurations have been studied. More than 100 samples representing these configurations and containing implanted flaws of different sizes have been examined.US techniques developed are detailed and results of validation samples examination before and after high heat flux (HHF) tests are presented. The results show that for W monoblocks the US technique is able to detect, locate and size the degradations in the two sample joints; for CFC monoblocks, the US technique is also able to detect, locate and size the calibrated defects in the two joints before the HHF, however after the HHF test the technique is not able to reliably detect defects in the CFC/Cu joint; finally, for the W flat tiles the US technique is able to detect, locate and size the calibrated defects in the two joints before HHF test, nevertheless defect location and sizing are more difficult after the HHF test.     

Erosion and Modifications of Tungsten-Coated Carbon and Copper Under High Heat Flux

Tungsten-coated carbon and copper was prepared by vacuum plasma spraying (VPS) and inert gas plasma spraying (IPS), respectively. W/CFC (Tungsten/Carbon Fiber-Enhanced material) coating has a diffusion barrier that consists of W and Re multi-layers pre-deposited by physical vapor deposition on carbon fiber-enhanced materials, while W/Cu coating has a graded transition interface. Different grain growth processes of tungsten coatings under stable and transient heat loads were observed, their experimental results indicated that the recrystallizing temperature of VPS-W coating was about 1400℃ and a recrystallized columnar layer of about 30μm thickness was formed by cyclic heat loads of 4 ms pulse duration. Erosion and modifications of W/CFC and W/Cu coatings under high heat load, such as microstructure changes of interface,surface plastic deformations and cracks, were investigated, and the erosion mechanism (erosion products) of these two kinds of tungsten coatings under high heat flux was also studied.     

Infrared thermography inspection for monoblock divertor target in JT-60SA

Carbon fiber composite (CFC) monoblock divertor target is required for power handling in JT-60SA. Quality of the targets depends on a joining technology in manufacturing process. To inspect the quality of more than 900 target pieces, efficient non-destructive inspection is needed. An infrared thermography inspection (IR inspection), has been proposed by ITER and IRFM, where the quality between CFC and a cooling tube is examined by a use of transient thermal response at a rapid switch from hot to cold water flow. In JT-60SA divertor target, a screw tube will be employed to obtain high heat transfer efficiency with simple structure. Since the time response of the screw tube is much faster than that of smooth tube, it is required to confirm the feasibility of this IR inspection. Thus, the effect of joining defects on transient thermal response of the targets has been investigated experimentally by using the mock-up targets containing defects which are artificially made. It was found that the IR inspection can detect the defects. Moreover, screening criteria of IR inspection for acceptable monoblock target is discussed.     

Effect of stationary high heat flux and transient ELMs-like heat loads on the divertor PFCs

The experimental evaluation of the divertor plasma facing components (PFCs) lifetime under transient events, such as edge localized modes (ELMs) and high heat flux (HHF) thermal fatigue expected during ITER normal operations and slow transient events is here presented. The experiments have been performed in the frame of an EU/RF collaboration. For carbon fiber composite material the erosion is caused by PAN fiber damage whilst the erosion of tungsten is determined by the melt layer movement and crack formation. The conclusion of this study is that, in addition to the structural change produced in the armor materials by ELMs-like loads, some mock ups showed also a degradation of the thermal fatigue performances     

One-step brazing process for CFC monoblock joints and mechanical testing

A new method of joining CFC to copper (CFC/Cu) and CFC/Cu to CuCrZr alloy (CFC/Cu/CuCrZr) was previously developed for the flat-type configuration. The joining technique foresees a single-step brazing process: the brazing of the three materials (CFC, Cu and CuCrZr) can be performed in a single heat treatment using the same non-active brazing alloy. The composite surface was previously modified by solid state reaction with chromium with the purpose of increasing the wettability of CFC by the brazing alloy.The feasibility of this process also for monoblock geometry is described in this work. The thermal fatigue resistance of the joined samples (quenching from 450 °C to RT; 50 cycles) was tested and the joints were characterized by apparent shear tests before and after thermal fatigue. The apparent shear strength of the CFC/Cu/CuCrZr joined samples was unaffected after these thermal fatigue tests.     

Non-destructive methods for the defect detection in the ITER high heat flux components

This paper discusses the application of non-destructive testing (NDT) by ultrasonic technique for the control of the joining interfaces of the ITER divertor vertical target plasma facing units. The defect detection capability has to be proved for both metal to metal and metal to carbon/carbon fibre composite (CFC) joints because these two types of joints have to be realized for the manufacturing of the high heat flux units. In this paper the UT results coming from the investigation performed during the manufacturing, but also after the thermal fatigue testing (up to 20 MW/m²) of six mock-ups manufactured using the Hot Radial Pressure technology (HRP) in ENEA labs are presented and compared with the evidences from the final destructive examination. Regarding the Cu/CFC joint, the effectiveness of the ultrasonic test has been deeply studied due to the high acoustic attenuation of CFC to ultrasonic waves. To investigate the possibility to use the ultrasonic technique for this type of joint, an ‘ad hoc’ flat Cu/CFC joint sample, that reproduces the actual annular joint interfaces, was manufactured. This flat sample has the advantage of being easily tested by probes with different geometry and frequency. UT results are compared with X-ray and eddy current testing of the same sample.     

Design feasibility study of a divertor component reinforced with fibrous metal matrix composite laminate

Fibrous metal matrix composites possess advanced mechanical properties compared to conventional alloys. It is expected that the application of these composites to a divertor component will enhance the structural reliability. A possible design concept would be a system consisting of tungsten armour, copper composite interlayer and copper heat sink where the composite interlayer is locally inserted into the highly stressed domain near the bond interface. For assessment of the design feasibility of the composite divertor concept, a non-linear multi-scale finite element analysis was performed. To this end, a micro-mechanics algorithm was implemented into a finite element code. A reactor-relevant heat flux load was assumed. Focus was placed on the evolution of stress state, plastic deformation and ductile damage on both macro- and microscopic scales. The structural response of the component and the micro-scale stress evolution of the composite laminate were investigated.     

Technological review of the HRP manufacturing process R&D activity

ENEA and Ansaldo Nucleare S.p.A. have been deeply involved in the European International Thermonuclear Experimental Reactor (ITER) R&D activities for the manufacturing of high heat flux plasma-facing components (HHFC), and in particular for the inner vertical target (IVT) of the ITER divertor.This component has to be manufactured by using both armour and structural materials whose properties are defined by ITER. Their physical properties prevent the use of standard joining techniques. The reference armour materials are tungsten and carbon/carbon fibre composite (CFC). The cooling pipe is made of copper alloy (CuCrZr-IG).During the last years ENEA and Ansaldo have jointly manufactured several actively cooled monoblock mock-ups and prototypical components of different length, geometry and materials, by using innovative processes: HRP (hot radial pressing) and PBC (pre-brazed casting).The history of the technical issues solved during the R&D phase and the improvements implemented to the assembling tools and equipments are reviewed in the paper together with the testing results.The optimization of the processes started from the successful manufacturing of both W and CFC armoured small scale mockups thermal fatigue tested in the worst ITER operating condition (20 MW/m²) through the achievement of record performances obtained from a monoblock medium scale mockup.On the base of these results ENEA-ANSALDO participated to the European programme for the qualification of the manufacturing technology to be used for the procurement of the ITER divertor IVT, according to the F4E specifications. A divertor inner vertical target prototype (400 mm total length) with three plasma facing component units, was successfully tested at ITER relevant thermal heat fluxes.Now, ANSALDO and ENEA are ready to face the challenge of the ITER inner vertical target production, transferring to an industrial production line the experience gained in the development, optimization and qualification of the PBC and HRP processes.     

Feasibility study of an actively cooled tungsten divertor in Tore Supra for ITER technology testing

In order to reduce the risks for ITER Plasma Facing Components (PFCs), it is proposed to equip Tore Supra with a full tungsten divertor, benefitting from the unique long pulse capabilities, the high installed RF power and the long experience with actively cooled high heat flux components of the Tore Supra platform. The transformation from the current circular limiter geometry to the required X-point configuration will be achieved by installing a set of copper poloidal coils inside the vacuum vessel. The new configuration will allow for H-mode access, providing relevant plasma conditions for PFC technology validation. Furthermore, attractive steady-state regimes are expected to be achievable. The lower divertor target design will be closely based on that currently envisaged for ITER (W monoblocks), while the upper divertor region will be used to qualify the main first wall heat sink technology adopted for the ITER blanket modules (CuCrZr copper/stainless steel) with a tungsten coating (in place of the Be tiles which ITER will use). Extended plasma exposure will provide access to ITER critical issues such as PFC lifetime (melting, cracking, etc.), tokamak operation on damaged metallic surfaces, real time heat flux control through PFC monitoring, fuel retention and dust production.     

Mechanical analysis of the joint between Wendelstein 7-X target elements and the divertor frame structure

The target elements of the actively cooled high heat flux (HHF) divertor of Wendelstein 7-X are made of CFC (carbon fiber-reinforced carbon composite) tiles bonded to a CuCrZr heat sink and are mounted onto a support frame. During operation, the power loading will result in the thermal expansion of the target elements. Their attachment to the support frame needs to provide, on the one hand, enough flexibility to allow some movement to release the induced thermal stresses and, on the other hand, to provide enough stiffness to avoid a misalignment of one target element relative to the others. This flexibility is realized by a spring element made of a stack of disc springs together with a sliding support at one of the two or three mounting points. Detailed finite element calculations have shown that the deformation of the heat sink leads to some non-axial deformation of the spring elements. A mechanical test was performed to validate the attachment design under cyclic loading and to measure the deformations typical of the expected deformation of the elements. The outcome of this study is the validation of the design selected for the attachment of the target elements, which survived experimentally the applied mechanical cycling which simulates the thermal cycling under operation.     

Pre-series and testing route for the serial fabrication of W7-X target elements

The fabrication of the actively cooled high-heat flux divertor of the WENDELSTEIN 7-X stellarator (W7-X) requires the delivery of 890 target elements, which are designed to withstand a stationary heat flux of 10 MW/m². The organization of the manufacturing and testing route for the serial fabrication is the result of the pre-series activities. Flat CFC Sepcarb^® NB31 tiles are bonded to CuCrZr copper alloy cooling structure in consecutive steps. A copper layer is active metal cast to CFC tiles, and then an OF-copper layer is added by hot isostatic pressing to produce bi-layer tiles. These tiles are bonded by electron beam welding onto the cooling structure, which was manufactured independently. The introduction of the bi-layer technology proved to be a significant improvement of the bond reliability under thermal cycling loading. This result is also the consequence of the improved bond inspections throughout the manufacturing route performed in the ARGUS pulsed thermography facility of PLANSEE. The repairing process by electron beam welding of the bonding was also qualified. The extended pre-series activities related to the qualification of fabrication processes with the relevant non-destructive examinations aim to minimize the risks for the serial manufacturing and to guarantee the steady-state operation of the W7-X divertor.