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.     

基于束流环形高斯模型对上海硬X射线自由电子激光装置的束流刮束器进行活化分析

在建的上海硬X射线自由电子激光装置(Shanghai HIgh repetition rate XFEL aNd Extreme light facility,SHINE)的加速器隧道内,采用束流刮束器刮掉束晕外围张角比较大的电子,刮束器的束流损失率为0.1‰。本文采用蒙特卡洛程序FLUKA,用SOURCE程序实现电子束在3σ_beam外的高斯分布,以尽量真实模拟电子在束流刮束器处的丢失情况,解决了低功率刮束情况下蒙特卡洛模拟无统计性结果的难题。利用束流环形高斯模型对刮束器的活化进行了分析,结果表明环形高斯模型可以更真实地再现电子在束流刮束器的丢失情况;5年运行后距刮束器30 cm处的剩余剂量率达到了数百μSv/h至数mSv/h,和国外类似装置计算结果相当;通过对放射性核素的种类分析,结果证明刮束器(钨)的放射性废物处置难度不大。     

The present status of R&D for the muon target at J-PARC: The development of silver-brazing method for graphite

At the J-PARC muon science facility, the muon target was made of an isotropic graphite (IG-43). The energy deposited by the proton beam is estimated to be 3.3 kW on graphite and 600 W on the copper frame. To alleviate the thermal stress, a titanium stress absorber is inserted between the graphite and the copper. Although graphite is known to be difficult to be brazed, the titanium is attached to the graphite through silver-brazing. In this report, we will describe the development of a silver-brazing method for graphite in the fabrication of the J-PARC muon target. A capillary test between the graphite and the titanium was performed to determine the optimal brazing conditions. The test involved bonding graphite and titanium plates while varying the gap between them in order to determine the brazing material and the optimal surface treatment of graphite. Subsequently, a trial muon-production target was fabricated using this optimized brazing method. Specimens were cut from the trial target, and bending test experiments were performed to determine the tensile and shear strength of the interface. As a result, it was confirmed that graphite could be bonded adequately through the silver-brazing.     

Vacuum joints of dispersion-strengthened copper and its applications in synchrotron radiation front end

Masks are critical elements of synchrotron radiation front end that are exposed to high temperature and stress.The absorber material is typically comprised of dispersion-strengthened copper,which can retain high performance at elevated temperature.Joining processes under vacuum,including brazing and electron beam welding,are novel approaches for prolonging the absorber and for reducing power densities.The mechanical properties of brazed joints and electron beam welded joints of dispersion-strengthened copper workpieces are evaluated by tensile testing at 20,100,and 200 C.The testing results indicate that the tensile strength and elongation of both vacuum joints decrease with increasing temperature.Compared to brazed joints,electron beam welded joints have higher tensile strength,better ductility,and more stable performance.A novel welded mask with a total length of 600 mm is presented and shown to be practical for use in the highest heat load front end in the Shanghai synchrotron radiation facility phase-Ⅱ beamline project.     

Silicon doped carbon/Cu joints based on amorphous alloy brazing for first wall application

Amorphous ribbon-type filler-metals represent a promising selection for joining heterogeneous materials together. In this work, rapidly solidified ribbon-type Ti based amorphous filler with a melting temperature of 850 °C and a thickness up to 20 μm is used to join silicon doped carbon to pure copper. SEM examinations demonstrate that a high quality brazed joints could be acquired. The brazed seam has a uniform structure and pore free along its entire length. TiC and ZrC are formed near the interface of carbon and filler-metal when the brazing holds enough time. Using very thin Mo and Cu foil (0.2 mm in thickness) as multiple interlayer are very effective to mitigate the thermal stress occurred in the interface between carbon and copper. The shear strength of this carbon-multiple interlayer-copper joint is more than 20 MPa, and the rupture is mainly occurred on the carbon side.     

BES Ⅲ束流管应力场的有限元分析与实验研究

束流管位于北京谱仪Ⅲ（BES Ⅲ）中心位置,是最小壁厚为0.6 mm的真空薄壁夹层圆管。新一代北京正负电子对撞机（BEPC Ⅱ）在运行时将会有更多的高次模辐射（HOM）和同步辐射（SR）热负荷作用于束流管的内表面,使束流管内产生辐射热应力。本文从数值模拟和实验两方面对BES Ⅲ束流管应力场进行研究,结果表明,束流管在一端完全固支一端轴向自由的约束条件下,当内部辐射热负荷达到最大值750 W时,束流管各零部件--铍管、铝放大腔、过渡银环、铜管、不锈钢法兰的最大应力分别为21.9、6.9、5.0、9.1、24.4 MPa,束流管整体安全系数为11.0。目前束流管正在安全运行,保证了BEPC Ⅱ的正常工作和BES Ⅲ的精确粒子探测。     

Heat load behaviors of plasma sprayed tungsten coatings on copper alloys with different compliant layers

Plasma sprayed tungsten (PS-W) coatings with the compliant layers of titanium (Ti), nickel-chromium-aluminum (NiCrAl) alloys and W/Cu mixtures were fabricated on copper alloys, and their properties of the porosity, oxygen content, thermal conductivity and bonding strength were measured. High heat flux tests of actively cooled W coatings were performed by means of an electron beam facility. The results indicated that APS-W coating showed a poorer heat transfer capability and thermo-mechanical properties than VPS-W coating, and the compliant layers improved W coating performance under the heat flux load. Among three compliant layers, W/Cu was the preferable because of its better effects on heat removal and stress alleviating. The optimization of W/Cu compliant layer found that 0.1 mm and 25 vol.%W was optimum compliant layer structure for 1 mm W coating, which induced a 23% reduction of the maximum stress compared to the sharp interface, and the plastic strain was reduced to 0.01% from 1.55%.     

基于LaBr3(Ce)晶体耦合SiPM阵列的可变角分辨率伽玛相机的设计与研制

编码孔径成像技术由于探测效率高、信噪比高、角分辨率好、成像质量稳定可靠等优点而广泛应用于核安全、核设施的去污及退役的测量、核医学等领域。建立通过改变编码准直器和探测器之间距离进而实现可变角分辨的伽玛成像系统。整个成像系统主要由编码准直器、位置灵敏探测(position sensitive detector, PSD)、数据采集卡以及图像重建系统组成。该成像系统的编码准直器采用修正均匀冗余阵列(modified uniformly redundant array, MURA)编码方式,为了保障对较高能量射线的探测能力,编码准直器的材料采用含钨量90%的钨铜合金,PSD通过LaBr₃(Ce)晶体耦合SiPM阵列组成,重建算法采用的是直接互卷积算法,快速高效。测试结果显示,整个位置灵敏探测器的平均能量分辨率为4.96%(662 keV);该辐射成像系统可以准确地对Am-241、Cs-137、Co-60进行清晰成像,并通过改变编码准直器和探测器之间的距离成功分辨出两个Cs-137点源的位置。     

基于DEM的重金属颗粒流靶区输运过程研究

基于固体和液体散裂靶,近期国内外研究学者提出了一种新概念重金属颗粒流散裂靶。加速器驱动次临界系统(ADS)中重金属散裂靶在高能质子轰击作用下,出现能量沉积现象,而这些热量必须进行有效冷却以保证ADS的安全性。本文针对这种新概念颗粒流靶对靶区产生的高额热量的导出效果进行了模拟分析。首先采用蒙特卡罗程序计算450 Me V质子束轰击钨靶后能量沉积的空间分布,并将此作为颗粒流的体热源输入,基于计算流体力学-离散单元法(CFD-DEM)耦合方法对ADS靶区两种不同直径颗粒流的输运过程进行了模拟研究。结果表明,随颗粒直径的减小,靶区内温度分布更为均匀,颗粒流的流动特性更接近流体,颗粒导热性能增强;颗粒流靶中热应力可局限在单个颗粒内部而承受更高的能量沉积,具有更高的安全限值以及更广阔的应用前景。     

Efficiency increase of volume reflection of high-energy protons in a bent crystal with increasing curvature

Volume reflection in a bent crystal with increasing curvature has been considered by simulation for 7-TeV protons. It has been shown that a non-reflected beam fraction, which appears due to volume capture of particles into channeling states, is significantly reduced in comparison with the case of uniformly bent crystals. This allows increasing noticeably the deflection efficiency of protons by the sequence of such crystals, which can be used as a primary collimator for the LHC collimation system.     

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.     

Development of a Small-Aperture Slit System for a High Collimator Ratio at the Thermal Neutron Radiography Facility in JRR-3

A small-aperture slit system has been developed and installed to enhance the collimator ratio (“L/D”) of the thermal neutron radiography facility (TNRF) in JRR-3. The degree of unsharpness on neutron images is reduced by increasing the L/D. The small-aperture slit system increased the L/D by creating a small aperture size (“D”). Image sharpness improved when the aperture size was reduced to below 10mm by 10mm in the TNRF. On the other hand, there was almost no difference in unsharpness on images obtained above 10mm by 10mm in aperture size. These results indicate that an aperture size of less than 10mm by 10mm should be used for high-spatial-resolution imaging at the TNRF. The beam area of the small-aperture slits was relatively small in comparison with that of a conventional large collimator, though gradually increasing with increasing aperture size. Even with an aperture size of 5mm by 5 mm, the practical beam area for imaging examinations corresponded to around 25mm by 20 mm, which is enough area to carry out high-spatial-resolution imaging.     

Development of the plasma facing components for the dome-liner component of the ITER divertor

On the basis of the design and the specification of the dome-liner elaborated by EFDA, a manufacturing route based on high temperature brazing has been developed and proved by means of the fabrication and testing of several samples and mock-ups. The dome is protected with tungsten armour tiles joined onto heat sinks obtained from a bimetallic plate made of precipitation hardened copper–chromium–zirconium alloy and stainless steel realized by explosion bonding. The brazed joint between the tungsten tiles and the heat sink has been qualified by means of thermal fatigue tests on small-scale mock-ups in reactor relevant conditions. The properties of the explosion bonding joint between the front copper alloy plate to the rear steel backing has been assessed by means of an extensive metallurgical and mechanical test program according to the specification provided by EFDA. The dimensional stability during the fabrication route has been investigated by means of the realization of a relevant curved component that has been dimensionally tested after the completion of each step of the manufacturing route. The results of the experimental activity are presented and discussed in this paper.     

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.     

CSNS/RCS中主要阻抗元件的仿真计算研究

中国散裂中子源（CSNS）快循环同步加速器（RCS）是强流质子加速器,对环中真空元件的阻抗研究是判断束流能否稳定运行的重要依据。通过正确估算环中元件阻抗,可及时对元件的阻抗进行有效控制和防止束流不稳定性发生,从而减小束流损失。本文利用CST电磁场仿真软件给出了RCS环中高频腔及准直器的耦合阻抗,并探讨了bus-bar结构对高频腔本身及束流稳定的影响,发现需重新设计bus-bar结构使腔固有频率大于10 MHz才能彻底解决因共振可能引起的丢束。此外,计算表明,主准直器屏蔽有利于减小耦合阻抗及损失功率,在安装代价较小的情况下需对主准直器进行屏蔽。     

Elastic–plastic analysis of the steel-to-tungsten transition joint for a high performance divertor

The use of tungsten as a plasma-facing material necessitates a transition joint to the oxide dispersion strengthened (ODS) steel or ferritic steel (FS) structural material of the primary coolant loop at the end of the divertor target plate where the surface heat flux is very low. A critical issue in the transition joints is the coefficient of thermal expansion (CTE) mismatch between the tungsten (or tungsten-alloy) and ODS steel, which can lead to unacceptably high thermal stresses during steady state and ratcheting during cyclic loads. Detailed 2D and 3D thermo-mechanical analyses were conducted to study the behavior of a transition from tungsten to FS with an intermediate layer of tantalum, located outside of the high heat flux region. The results include plastic strains under various loading conditions including fabrication processes, warm and cold shutdown, and allow for plastic behaviors leading to stress relaxation. The accumulation of plastic deformation may cause ratcheting. Modifications were proposed to the transition joint design in order to eliminate stress concentration and ratcheting under cyclic loading. The results of the modified design exhibited less plastic deformation in the joints as well as no ratcheting caused by warm and cold shutdown.     

Design optimization of plasma facing component with functional gradient material Cu/W interlayer

In the current water cooled divertor concept, tungsten is an armor material and CuCrZr is a structural material. The difference in thermal expansion coefficient between tungsten and copper alloy causes a thermal mismatch between them resulting in accumulation of stresses which would yield failure of the joint. To reduce such stresses, a functionally graded material or a graded layer is introduced between tungsten and copper alloy. A fabrication via a powder metallurgy process such as SPS (Spark Plasma Sintering) is proposed. In this work, an actively cooled component composed of a functionally graded W/Cu is simulated under high heat flux using the finite element modeling method. Thermo-mechanical behaviors, due to the existence of temperature gradient, are analyzed by a modification of the layer compositions and the number of layers. Such behaviors are evaluated to determine the optimal water cooled divertor design. It appears that the copper concentration in the interlayer defines the mechanical response. We suggest, as a conclusion, to use three layers having an optimized copper concentration to fabricate them using SPS technology.     

探伤加速器可调准直器的设计

本文基于6 MeV探伤加速器设计了照射野可调准直器,其主要由4个具有2自由度的准直块首尾交错布置而成,准直块采用厚43 mm的钨镍铁对无用X射线进行屏蔽。通过控制准直块纵向和横向驱动电机实现准直器开口自动调节,从而实现X射线照射野的自动调节,以满足工业探伤和工业CT对X射线源不同照射野的需求。准直块采用交错式设计实现了准直块排布在同一平面,使准直器结构紧凑,并有效减小了X射线的漏射。     

大束流场发射阴极X射线管的阳极设计

采用蒙特卡罗软件和有限元分析软件分析了固定阳极X射线管中电子轰击阳极靶的能量沉积和热量传输过程,固定阳极由铜棒和钨片组成。研究了在不同形状、尺寸和占空比的电子束脉冲轰击下,阳极靶面不同厚度的钨片和相邻铜棒的温度上升过程。结果表明,钨片厚度存在最优值,但最优值与具体使用条件相关;在脉冲成像方式下,固定阳极靶能承受更强束流强度的轰击。因此,采用固定阳极靶方案,研制140 kV高压、10 mA以上电流、直径1 mm以下有效焦点的场发射阴极X射线管是可行的。     

FEM investigation and thermo-mechanic tests of the new solid tungsten divertor tile for ASDEX Upgrade

A new solid tungsten divertor for the fusion experiment ASDEX Upgrade is under construction at present. A new divertor tile design has been developed to improve the thermal performance of the current divertor made of tungsten coated fine grain graphite. Compared to thin tungsten coatings, divertor tiles made of massive tungsten allow to extend the operational range and to study the plasma material interaction of tungsten in more detail. The improved design for the solid tungsten divertor was tested on different full scale prototypes with a hydrogen ion beam. The influence of a possible material degradation due to thermal cracking or recrystallization can be studied. Furthermore, intensive Finite Element Method (FEM) numerical analysis with the respective test parameters has been performed. The elastic–plastic calculation was applied to analyze thermal stress and the observed elastic and plastic deformation during the heat loading. Additionally, the knowledge gained by the tests and especially by the numerical analysis has been used to optimize the shape of the divertor tiles and the accompanying divertor support structure.This paper discusses the main results of the high heat flux tests and their numerical simulations. In addition, results from some special structural mechanic analysis by means of FEM tools are presented. Finally, first results from the numerical lifecycle analysis of the current tungsten tiles will be reported.