Design and Analysis of the Laser Robotic Welding System for ITER Correction Coil Case

ITER correction coil (CC) cases have characteristics of small cross section, large dimensions, and complex structure. The cases are made of heavy thick (20 mm), high strength and high toughness 316LN austenitic stainless steel. The laser welding is used for the case closure welding, due to its low heat input and deformation. According to the structural size and feature of the two types of cases, a set of laser welding workstation for the ITER CC case closure welding is designed. A slip plate module for the welding robot is designed to increase its workspace. According to the result of the movement simulation of the welding robots, the workstation is successful to cover all weld seams on the cases. Also, the welding platform and fixtures (includes the special welding tilter of the SCC) of the BTCC case and the SCC cases are designed. To verify the design structural feasibility of the welding tilter of SCC, the structural analysis for the rotating process has been formed in detail by using ANSYS. The simulating results show that the stress of the welding tilter can meet both static and fatigue criteria, and thus the basic structure is valid.     

Validation of welding technology for ITER TF coil structures

Japan Atomic Energy Agency (JAEA), acting as the Japan Domestic Agency (JADA) in the ITER project is responsible for the procurement of 9 Toroidal Field (TF) coil winding packs (WPs), structures for 19 TF coils (including one spare), and assembly of the WPs and the coil structures for 9 TF coils [1]. The TF Coil structures which support large electromagnetic force generated in TF coils under the cryogenic temperature (about 4 K), are very large welded structures composed of a coil case and structural attachments made of high strength and high toughness stainless steel. JAEA has been performing welding trials for heavy thickness materials since 2008 and is planning fabrication of full-scale mock-ups of main sub-components (1 set for the inboard side and 1 set for the outboard side) in 2011 in order to investigate the technical issues for manufacturing the TF coil structures. This paper presents the results of welding trials and the status of full scale mock-ups fabrication to confirm the validity of welding technology and manufacturing design before fabricating the actual products.     

The Laser Welding with Hot Wire of 316LN Thick Plate Applied on ITER Correction Coil Case

ITER correction coil (CC) cases have characteristics of small cross section, large dimensions, and complex structure. The cases are made of heavy thick (20 mm), high strength and high toughness austenitic stainless steel 316LN. The multi-pass laser welding with hot wire technology is used for the case closure welding, due to its low heat input and deformation. In order to evaluate the reliability of this welding technology, 20 mm welding samples with the same groove structure and welding depth as the cases were welded. High purity argon was used as the shielding gas to prevent oxidation because of the narrowness and depth of the weld. In this paper investigation of, microstructure characteristics and mechanical properties of welded joints using optimized welding parameters are presented. The results show that the base metal, fusion metal, and heat affected zone (HAZ) are all have fully austenitic microstructure, and that the grain size of fusion metal was finer than that of the base metal. The welding resulted in an increase of hardness in the fusion metal and HAZ. It was confirmed that the tensile strength of fusion metal was higher than that of base metal and the impact toughness value is higher than industry standard requirement. Thus, this welding process was determined to be reliable for manufacture of the ITER CC cases manufacture.     

Low-temperature mechanical properties of superconducting radio frequency cavity materials

Low-temperature mechanical behaviors have been investigated for the constituent materials of superconducting radio frequency cavities. Test materials consist of small grain Nb, single crystal Nb, large grain Nb (bicrystal), Ti45Nb-Nb weld joint (e-beam welded), and Ti-316L bimetal joint (explosion welded). The strength of all test metals displayed strong temperature dependence and the Ti-316L bimetal showed the highest strength and lowest ductility among the test materials. The fracture toughness of the small grain Nb metals decreased with decreasing test temperature and reached the lower shelf values (30-40 MPa √m) at or above 173 K. The Ti45Nb base and Ti45Nb-Nb weld metals showed much higher fracture toughness than the small grain Nb. An extrapolation and comparison with existing data showed that the fracture toughness of the small grain Nb metals at 4 K was expected to be similar to those at 173 and 77 K. The results from optical photography at a low magnification and fractography by a scanning electron microscope were consistent with corresponding mechanical properties.     

Fatigue assessment of the ITER TF coil case based on JJ1 fatigue tests

The material of the TF coil case in the ITER requires to withstand cyclic electromagnetic forces applied up to 3 × 10⁴ cycles at 4.2 K. A cryogenic stainless steel, JJ1, is used in high stress region of TF coil case. The fatigue characteristics (S–N curve) of JJ1 base metal and welded joint at 4.2 K has been measured. The fatigue strength of base metal and welded joint at 3 × 10⁴ cycles are measured as 1032 and 848 MPa, respectively. The design S–N curve is derived from the measured data taking account of the safety factor of 20 for cycle-to-failure and 2 for fatigue strength, and it indicates that an equivalent alternating stress of the case should be kept less than 516 MPa for the base metal and 424 MPa for the welded joint at 3 × 10⁴ cycles. It is demonstrated that the TF coil case has enough margins for the cyclic operation. It is also shown the welded joint should be located in low cyclic stress region because a residual stress affects the fatigue life.     

Thermal analysis of toroidal field coil in EAST at 3.7 K

The thermal performance of toroidal field (TF) coil is studied at 3.7 K in Experimental Advanced Superconducting Tokamak device (EAST) to obtain the higher stability for the higher plasma parameters operation. It is a good way to lower the operating temperature of TF coil to acquire the higher stability margin. This paper describes the structure and cooling process design of TF coil and case firstly. Based on the thermal load in the case, the thermal performance of the TF coil is performed at the plasma disruption state. The helium temperature in the cable-in-conduit conductor (CICC) and case is evaluated during the 1.5 MA plasma disruptions. Then, the experimental results of TF coil which has been cooled at 3.7 K and discharged in 10 kA are shown including the thermal loss evaluation. Finally, the thermal stability performance of TF coil is analyzed according to the 3.7 K experimental results and the stability prediction is performed at 1.5 MA plasma current operations.     

Creep rupture strength of activated-TIG welded 316L(N) stainless steel

316L(N) stainless steel plates were joined using activated-tungsten inert gas (A-TIG) welding and conventional TIG welding process. Creep rupture behavior of 316L(N) base metal, and weld joints made by A-TIG and conventional TIG welding process were investigated at 923 K over a stress range of 160-280 MPa. Creep test results showed that the enhancement in creep rupture strength of weld joint fabricated by A-TIG welding process over conventional TIG welding process. Both the weld joints fractured in the weld metal. Microstructural observation showed lower δ-ferrite content, alignment of columnar grain with δ-ferrite along applied stress direction and less strength disparity between columnar and equiaxed grains of weld metal in A-TIG joint than in MP-TIG joint. These had been attributed to initiate less creep cavitation in weld metal of A-TIG joint leading to improvement in creep rupture strength.     

Mechanical tensile test of the full-size ITER TF conductor jacket materials at 4.2 K

316LN stainless steel is selected as a material for toroidal-field (TF) conductor jacket of International Thermonuclear Experimental Reactor (ITER). In order to evaluate the true mechanical performance of the jacket material at 4.2 K and its suitability as the ITER TF conductor jacket, the mechanical properties of the full-size TF conductor jacket tube and sub-size specimens at 4.2 K and 300 K were investigated according to ASTM standards. The measured yield strength and elongation at 4.2 K for sub-size specimens and full-size tubes are more than 950 MPa and 20%, respectively. In addition, the fractographies of all fractured specimens were observed using scanning electron microscope (SEM). These results suggest that the TF conductor jacket can satisfy ITER requirements and the result of the full-size tube at 4.2 K is more representative and important for practical applications.     

Cyclic testing of shear keys for the ITER magnet system

Shear keys are to be used to support the out-of-plane loading of the toroidal field (TF) coils during a plasma pulse in ITER. At the inner intercoil structures (IIS) a set of poloidal shear keys is used to take the shear load at each connection between adjacent TF coils. Solid circular keys have been selected as reference. At the outer intercoil structures (OIS) adjustable conical shear keys and friction joint based shear panels are used to take the shear load. Low voltage electrical insulation is required at the flanges of the IIS and OIS, plus for all the bolts, poloidal keys and adjustable keys. This electrical insulation has to withstand large compression associated with some shear or slippage. A ceramic coating was selected for this purpose. The main scope of the experimental campaign was the mechanical testing of the shear keys and the electrical insulation in operational conditions relevant to ITER. Both keys were made of Inconel 718, provided with a ceramic alumina coating and inserted into flanges made of cast AISI 316 LN. The adjustable conical shear key was pre-loaded at room temperature and subject to cyclic shear loads of 2.5 MN for a large number of cycles (about 30,000) at cryogenic temperature (77 K). The conical key and the alumina coating remained undamaged after the test. Another test campaign was then performed with higher shear loads (up to 3 MN) to reach a sufficient safety margin even with the friction effect due to the pre-load. A set of 15,000 cycles were completed followed by some cycles at higher loads to reach the ultimate limit, which is the shear load to be experienced by the key in case of a poloidal field (PF) coil short.     

主管道材料高温力学性能研究

提供核电厂破前漏（LBB）设计所需材料性能参数需要测量主管道母材和焊接材料在高温下的力学性能（包括材料在地震环境下的高温动态力学性能）。基于万能伺服材料试验机和高速材料试验机测量了核电厂主管道母材控氮00Cr17Ni12Mo2不锈钢及焊接材料OK Tigrod 316L在高温（350℃）下的静动态拉伸力学性能、裂纹扩展率和静动态断裂韧性。与主管道母材和焊接材料的常温力学性能相比,2种材料在350℃下的静动态拉伸力学性能以及OK Tigrod 316L在350℃下的静动态断裂韧性都较常温有较大幅度的降低,2种材料在350℃下的抗裂纹扩展性能较常温略有下降。研究成果可为核电厂管道的LBB设计提供试验技术和材料参数支持。     

主管道用材中低加载速率下常温断裂性能研究

核电厂主管道在长期服役下,母材及焊接处可能出现裂纹,需要对主管道材料及焊接材料在中低加载速率下的断裂性能进行研究,避免主管道在强地震冲击下可能出现的双端剪切断裂。基于Instron VHS高速材料试验机,开发了一套材料在中低加载速率下的断裂性能测试方法,测量了核电厂主管道材料控氮00Cr17Ni12Mo2及焊接材料OK Tigrod 316L在0.5 m/s加载速率以内的常温断裂性能。结果表明,常温下核电厂主管道材料控氮00Cr17Ni12Mo2在0.5 m/s冲击速率以内并不启裂,焊接材料OK Tigrod 316L在0.5 m/s加载速率以内的断裂韧性并未出现明显的规律性变化。      

Structural alloys for superconducting magnets in fusion energy systems

The behaviour of selected alloys for superconducting magnet structures in fusion energy systems is reviewed with emphasis on the following austenitic stainless steels (AISI grades 304, 310S and 316), nitrogen-strengthened austenitic stainless steels (types 304LN, 316 LN and 21Cr---6Ni---9Mn) and aluminum alloys (grades 5083, 6061 and 2219). The mechanical and physical properties of the selected alloys at 4 K are reviewed. Welding, the properties of weldments, and other fabrication considerations are briefly discussed. The available information suggests that several commercial alloys have adequate properties at 4 K and sufficient fabrication characteristics for the large magnet structures needed for fusion energy systems.     

焊接残余应力对316LN不锈钢应力腐蚀裂纹扩展速率的影响

核电站不锈钢管道焊接过程中引入的残余应力对焊接接头的应力腐蚀开裂性能有较大影响。本文针对一AP1000主管道316LN不锈钢焊接模拟件进行残余应力分析和应力腐蚀裂纹扩展速率测量,得到了焊后原始状态和去应力热处理状态的焊接热影响区材料在高温高压水中的应力腐蚀裂纹扩展速率。实验结果表明,焊接残余应力明显提高了热影响区的应力腐蚀裂纹扩展速率,且在含氢的压水堆一回路正常水化学下焊接残余应力的影响更加显著。     

The Investigation on Welding Processes for SUS316LN Tubes Used in Superconducting Magnetic System of EAST

The force flow cooled superconducting cable-in-conduit conductor （CICC） is used in both of EAST toroidal field （TF） and poloidal field （PF） coils. The conductor consists of multi-stage NbTi superconducting cable and 1.5 mm thick square jacket. The cable is pulled through in a thin wall circular jacket and then compacted to square cross-section conductor. The jacket material is SUS316LN austenitic stainless steel seamless tubes （about 10 m each）, which is assembled by butt-welding up to 600 m. The results of the welding procedure investigation and quality assurance procedures carrying out are described in this paper.     

Stressed capsules of austenitic and martensitic steels irradiated in SINQ Target-4 in contact with liquid lead-bismuth eutectic

In the MEGAPIE target, the steels used for the proton beam entrance window and other components in the spallation reaction zone suffer not only from the irradiation damage produced by protons and neutrons but also from the corrosion and embrittlement induced by liquid lead-bismuth eutectic (LBE). Although these effects have been separately studied by a number of authors, the synergistic effects of irradiation, LBE corrosion and embrittlement are little understood. This work presents detailed analyses of two stressed capsules made of the austenitic steel EC316LN and the martensitic steel 9Cr2WVTa, which were irradiated in SINQ Target-4 in contact with LBE at calculated temperatures of 315 and 225 °C, respectively. The Electron Probe Microanalysis (EPMA) on the cross-sections of the capsules showed that the stagnant LBE induced only slight corrosion on both capsules and no cracks existed in the wall of the EC316LN capsule. Some cracks were observed in the electron beam weld (EBW) and its vicinity of the 9Cr2WVTa capsule, which can be attributed to the high stress inside the wall, the hardening of the material induced by either welding (without re-tempering) or irradiation, and the effects of LBE embrittlement.     

Analysis of tensile deformation and failure in austenitic stainless steels: Part II - Irradiation dose dependence

Irradiation effects on the stable and unstable deformation and fracture behavior of austenitic stainless steels (SSs) have been studied in detail based on the equivalent true stress versus true strain curves. An iterative finite element simulation technique was used to obtain the equivalent true stress-true strain data from experimental tensile curves. The simulation result showed that the austenitic stainless steels retained high strain hardening rate during unstable deformation even after significant irradiation. The strain hardening rate was independent of irradiation dose up to the initiation of a localized necking. Similarly, the equivalent fracture stress was nearly independent of dose before the damage (embrittlement) mechanism changed. The fracture strain and tensile fracture energy decreased with dose mostly in the low dose range <∼2 dpa and reached nearly saturation values at higher doses. It was also found that the fracture properties for EC316LN SS were less sensitive to irradiation than those for 316 SS, although their uniform tensile properties showed almost the same dose dependencies. It was confirmed that the dose dependence of tensile fracture properties evaluated by the linear approximation model for nominal stress was accurate enough for practical use without elaborate calculations.     

Technical aspects and manufacturing methods for JT-60SA toroidal field coil casings

JT-60SA is a superconducting tokamak machine to be assembled in Naka site, Japan, designed to contribute to the early realization of fusion energy by supporting the exploitation of ITER and research toward DEMO.In the frame of the Broader Approach Agreement a contract between ENEA and Walter Tosto (Chieti, Italy) started on July 2012 for the construction of 18 TF coil casings for JT-60SA. Two different sets of 9 casings each will be progressively delivered, from 2013 to the end of 2015, to ASG Superconductors (Genoa, Italy) and to Alstom (Belfort, France), where the integration of the winding pack into the casing will be carried out.Each TF coil casing (height 7.5 m and width 4.5 m) consists of four main components: one “Straight Leg Outboard” and one “Curved Leg Outboard” both with their own covers, “Straight Leg Inboard” and “Curved Leg Inboard”. The casing components are segmented in forgings and plates made of FM316LNL. The straight leg outboard is composed of two wings welded to a central core and two elbows welded at the ends with a cooling channel installed inside. Elbows of straight leg outboard are segmented in two half-elbows machined from 1 rough forging and welded to the central core made by plate. Welding of wings to the central core is performed in EBW (electron beam welding) and the straight part is welded to the elbows by NGTIG (TIG narrow gap) process. The curved leg outboard is composed of two wings welded to a central core for a final shape of “D”. Other supports are welded by TIG or Electrode process.This paper describes the technical design solutions, the manufacturing methods defined and the particular processes adopted, such as welding (EB, TIG), non-destructive examinations (NDE), vibration stress relief (VSR) and laser tracker survey, most of which have been validated by the construction of two different sets of full scale mock-ups representing the straight and the curved legs.     

Analysis of welding distortion due to narrow-gap welding of upper port plug

Narrow-gap welding is a low distortion welding process. This process allows very thick plates to be joined using fewer weld passes as compared to conventional V-groove or double V-groove welding. In case of narrow-gap arc welding as the heat input and weld volume is low, it reduces thermal stress leading to reduction of both residual stress and distortion. In this present study the effect of narrow-gap welding was studied on fabrication of a scaled down port plug in the form of a trapezoidal box made of 10 mm thick mild steel (MS) plates using gas tungsten arc welding (GTAW). Inherent strain method was used for numerical prediction of resulting distortions. The numerical results compared well with that of the experimentally measured distortion. The validated numerical scheme was used for prediction of weld induced distortion due to narrow-gap welding of full scale upper port plug made of 60 mm thick SS316LN material as is proposed for use in ITER project. It was observed that it is feasible to fabricate the said port plug keeping the distortions minimum within about 7 mm using GTAW for root pass welding followed by SMAW for filler runs.     

Analysis of tensile deformation and failure in austenitic stainless steels: Part I - Temperature dependence

This paper describes the temperature dependence of deformation and failure behaviors in the austenitic stainless steels (annealed 304, 316, 316LN, and 20% cold-worked 316LN) in terms of equivalent true stress-true strain curves. The true stress-true strain curves up to the final fracture were calculated from tensile test data obtained at −150 to 450 °C using an iterative finite element method. Analysis was largely focused on the necking and fracture: key parameters such as the strain hardening rate, equivalent fracture stress, fracture strain, and tensile fracture energy were evaluated, and their temperature dependencies were investigated. It was shown that a significantly high strain hardening rate was retained during unstable deformation although overall strain hardening rate beyond the onset of necking was lower than that of the uniform deformation. The fracture stress and energy decreased with temperature up to 200 °C and were nearly saturated as the temperature came close to the maximum test temperature 450 °C. The fracture strain had a maximum at −50 to 20 °C before decreasing with temperature. It was explained that these temperature dependencies of fracture properties were associated with a change in the dominant strain hardening mechanism with test temperature. Also, it was seen that the pre-straining of material has little effect on the strain hardening rate during necking deformation and on fracture properties.     

High temperature design curves for high nitrogen grades of 316LN stainless steel

Nitrogen alloyed low carbon grade 316L(N) stainless steel (SS) is a major structural material for high temperature structural components of sodium cooled fast reactors. With a view to significantly enhance the high temperature mechanical properties of 316L(N) SS and thereby increase the design life of structural components from 40 years to 60 years, the influence of nitrogen content on the tensile and creep properties of this steel has been investigated. Four heats of 316LN SS with 0.07, 0.11, 0.14, and 0.22 wt.% nitrogen were used in this investigation. Tensile tests were carried out at various temperatures between room temperature and 850 °C. Creep tests were carried out at 650 °C at various stress levels in the range of 140-225 MPa. The maximum rupture life in these tests was 16,000 h. The tensile and creep data were analysed according to RCC-MR nuclear code procedures and the design curves have been generated. The tensile and creep strength of 316L(N) SS have been found to improve significantly by increasing the nitrogen content.