Thermal analysis and tests of W/Cu brazing for primary collimator scraper in CSNS/RCS

To the transverse beam collimation system in a rapid cycling synchrotron,an important component is the primary collimator,which improves emittance of the beam halo particles such that the particles outside the predefined trajectory can be absorbed by the secondary collimators.Given the material properties and power deposition distribution,the beam scraper of the primary collimator is a0.17 mm tungsten foil on a double face-wedged copper block of 121.5 mm x 20 mm.The heat is transferred to the outside by a φ34 mm copper rod.In this paper,for minimizing brazing thermal stress,we report our theoretical analysis and tests on brazing the tungsten and copper materials which differ greatly in size.We show that the thermal stress effect can be controlled effectively by creating stress relief grooves on the copper block and inserting a tungsten transition layer into the copper block.This innovation contributes to the successful RD of the primary collimator.And this study may be of help for working out a brazing plan of similar structures.     

W/Cu和W/C涂层的循环热负荷实验

用等离子体喷涂和热压方法制作了W /Cu梯度功能材料和W /C涂层 ,其中W/C涂层具有多层的钨 (W )、铼 (Re)扩散阻挡势垒。为了试验这些复合材料能否经受聚变等离子体破裂时的高热负荷 ,用大功率ND :YAG激光进行了模拟实验。结果表明 :在 1 0 0～ 4 0 0MW /m2 的瞬时 (脉冲宽度为 4ms)热负荷作用下 ,经过 2 0 0～ 70 0次热循环 ,未发现W /Cu复合体的开裂。其中在 1 2 3MW /m2 的功率密度下作用70 0次后 ,发现等离子体喷涂试样表面的再结晶现象和严重的晶界腐蚀 ,由于激光的冷效应 ,晶粒生长的趋势并不明显 ,再结晶层的晶粒呈垂直于表面的柱状结构。W/C试样的退火实验表明 ,钨涂层的再结晶温度稍高于 1 4 0 0℃。在更高的功率密度下 (3 98MW /m2 )出现了明显的腐蚀坑 ,坑内呈疏松的蜂窝结构 ,坑的边缘形成了沉积区 ,能谱分析表明沉积区集聚了大量的金属杂质。等离子体喷涂试样比热压试样更易产生晶界的断裂和裂纹。在同等的热负荷条件下 ,W /CuFGM的质量损失低于石墨材料     

Axial strain localization of CuCrZr tubes during manufacturing of ITER-like mono-block W/Cu components using HIP

Two forms of axial strain localization of CuCrZr tubes, i.e., cracking and denting, were observed during the manufacturing of ITER-like mono-block W/Cu components for EAST employing hot isostatic pressing (HIP). Microscopic investigations indicate that the occurrence of axial strain localization correlates to the heavily deformed Cu grains and elongated Cr-rich precipitates as well as highly anisotropic microstructures, which impair the circumferential ductility. Annealing the as-received tubes at 600 °C alleviates cracking due to partial recrystallization of Cu grains. However, the annealed tubes are still sensitive to wall thinning (caused by non-uniform polishing or tube bending), which results in denting. Denting may cause bonding flaws at CuCrZr/Cu interfaces and the underlying mechanisms are discussed. To some extent, denting seems do not affect the high heat flux performance of components. In this paper, we demonstrate that testing only the axial mechanical properties is not enough for manufacturers who use HIP or hot radial pressing technologies, especially for those anisotropic tubes.     

High heat load tests on W/Cu mock-ups and evaluation of their application to EAST device

Tungsten has been considered as the primary candidate plasma-facing materials (PFM) for the EAST device. Three actively cooled W/Cu mock-ups with an interlayer made of tungsten-copper alloy (1.5 mm) were designed and manufactured. The tungsten armors, pure sintered tungsten plate (1 mm) and plasma-sprayed tungsten coatings (0.3 and 0.9 mm), were bonded to the interlayer by brazing and depositing respectively. All mock-ups can withstand high heat flux up to 5 MW/m² and no obvious failure was found after tests. The thermal performance experiments and microstructure analyses indicated the structure of mock-ups possess good thermal contact and high heat transfer capability. WCu alloy as an interlayer can largely reduce the stress due to the mismatch and improve the reliability. The mock-up with 0.9 mm coating had the highest surface temperature than the other two mock-ups, delaminations of this mock-up were found in the near surface by SEM. The primary results show that pure sintered tungsten brazed to WCu alloy is a possible way, and thick plasma-sprayed coating technique still need to be improved.     

Manufacturing and testing of W/Cu mono-block small scale mock-up for EAST by HIP and HRP technologies

ITER-like W/Cu mono-block plasma-facing components (PFCs) will be used in vertical target regions of the experimental advanced superconducting tokamak (EAST) divertor. The first W/Cu mono-block small scale mock-up with five W mono-blocks has been manufactured successfully by technological combination of hot isostatic pressing (HIP) and hot radial pressing (HRP). The joining of a W mono-block and a pure copper interlayer was achieved by means of HIP technology and the bonding strength was over 150 MPa. The good bonding between the pure copper interlayer and a CuCrZr cooling tube was obtained by means of HRP technology. In order to understand deeply the process of HRP, the stress distribution of the mock-up during HRP process was simulated using ANSYS code. Ultrasonic Nondestructive Testing (NDT) of the W/Cu and Cu/CuCrZr interfaces was performed, showing that excellent bonding of the W/Cu and Cu/CuCrZr interfaces. The thermal cycle fatigue testing of the mock-up has been carried out by means of an e-beam device in Southwest Institute of Physics, Chengdu (SWIP) and the mock-up withstood 1000 cycles of heat loads up to 8.4 MW/m² with the cooling water of 2 m/s, 20 °C, 0.2 MPa.     

钨/铜界面处氢原子与空位相互作用的第一性原理计算

钨/铜界面是聚变堆偏滤器的重要连接界面,在高热流密度和强中子辐照下会成为氢同位素渗透滞留的高速通道和捕获陷阱。本文利用第一性原理方法研究了钨/铜界面处氢原子与点缺陷的相互作用,考察了氢原子的滞留行为和空位在界面处的形成行为,分析了氢原子的优先占据位置及氢原子与空位的作用机理。结果表明：在钨/铜界面中,氢原子稳定存在于钨/铜界面中间及铜晶格中;对于空位,界面附近的铜空位不稳定,会自发移动到钨/铜界面的顶端表面,而钨空位相对稳定存在;相比于铜空位,钨空位吸引氢原子的能力更强。氢原子的存在会抑制铜空位的迁移现象,从而可能形成氢泡。     

Manufacturing and High Heat Flux Testing of Brazed Flat-Type W/CuCrZr Plasma Facing Components

Water-cooled flat-type W/Cu Cr Zr plasma facing components with an interlayer of oxygen-free copper(OFC) have been developed by using vacuum brazing route.The OFC layer for the accommodation of thermal stresses was cast onto the surface of W at a temperature range of 1150oC-1200 oC in a vacuum furnace.The W/OFC cast tiles were vacuum brazed to a Cu Cr Zr heat sink at 940 oC using the silver-free filler material Cu Mn Si Cr.The microstructure,bonding strength,and high heat flux properties of the brazed W/Cu Cr Zr joint samples were investigated.The W/Cu joint exhibits an average tensile strength of 134 MPa,which is about the same strength as pure annealed copper.High heat flux tests were performed in the electron beam facility EMS-60.Experimental results indicated that the brazed W/Cu Cr Zr mock-up experienced screening tests of up to 15 MW/m~2 and cyclic tests of 9 MW/m~2 for 1000 cycles without visible damage.     

Numerical Calculation of the Peaking Factor of a Water-Cooled W/Cu Monoblock for a Divertor

In order to accurately predict the incident critical heat flux (ICHF, the heat flux at the heated surface when CHF occurs) of a water-cooled W/Cu monoblock for a divertor, the exact knowledge of its peaking factors (fp) under one-sided heating conditions with different design parameters is a key issue. In this paper, the heat conduction in the solid domain of a water-cooled W/Cu monoblock is calculated numerically by assuming the local heat transfer coefficients (HTC) of the cooling wall to be functions of the local wall temperature, so as to obtain fp. The reliability of the calculation method is validated by an experimental example result, with the maximum error of 2.1% only. The effects of geometric and flow parameters on the fp of a water-cooled W/Cu monoblock are investigated. Within the scope of this study, it is shown that the fp increases with increasing dimensionless W/Cu monoblock width and armour thickness (the shortest distance between the heated surface and Cu layer), and the maximum increases are 43.8% and 22.4% respectively. The dimensionless W/Cu monoblock height and Cu thickness have little effect on fp. The increase of Reynolds number and Jakob number causes the increase of fp, and the maximum increases are 6.8% and 9.6% respectively. Based on the calculated results, an empirical correlation on peaking factor is obtained via regression. These results provide a valuable reference for the thermal-hydraulic design of water-cooled divertors.     

The Effects of Nonuniform Thermal Boundary Condition on Thermal Stress Calculation of Water-Cooled W/Cu Divertors

The thermal boundary condition has very important effects on the accuracy of thermal stress calculation of a water-cooled W/Cu divertor. In this paper, phase-change heat transfer was simulated based on the Euler homogeneous phase model, and local differences of liquid physical properties were considered under one-sided high heating conditions. The steady-state temperature field and thermal stress field under nonuniform thermal boundary conditions were obtained through numerical calculation. By comparison with the case of traditional uniform thermal boundary conditions, the results show that the distribution of thermal stress under nonuniform thermal boundary conditions exhibits tbe same trend as that under uniform thermal boundary conditions, but is larger in value. The maximum difference of maximum von Mises stress is up to 42% under the highest heating conditions. These results provide a valuable reference for the thermal stress caleulat.ion of water-cooled W/Cu divertors.