Laser Powder Bed Fusion (LPBF) of Glenn Research Copper 84 (GRCop-84), a Cr2Nb (8 at. % Cr, 4 at. % Nb) precipitation hardened alloy, produces a fully dense high conductivity alloy with a yield ...strength of 500 MPa and ultimate tensile strength (UTS) of 740 MPa, superior to other competing copper alloys, and 20% elongation at fracture for material stressed perpendicular to the build direction. The high thermal stability of the Cr2Nb precipitate in the copper matrix reduces coarsening and maintains a 300 MPa yield, 520 MPa UTS and 26% elongation after a 900 °C, 5-h heat treatment, while a 3 h 450 °C heat treatment increases yield to 810 MPa, UTS to 970 MPa with 9% elongation at fracture, for samples stressed perpendicular to the build direction. Tensile strength anisotropy based on print direction was attributed to internal stress and columnar grain formation. Void nucleation during tensile fracture was initiated by brittle fracture of precipitate particles within the copper matrix. Fracture cusps contain matching precipitate fragment geometry on opposing sides located near the cusp center in at least 80% of fracture cusps. An optimal precipitate size of 100 nm is predicted for maximum tensile strength from precipitates on fracture surfaces, while tensile testing with varying heat treatments shows maximum strength with 100 nm and smaller precipitates. Cr2Nb precipitates are shown to transition between polycrystalline and monocrystalline structures at high temperature.
•Additive manufacturing enables rapid construction of lower hybrid launcher waveguides for fusion reactors.•Surface of selective laser melted (SLM) material is rough leading to arcing and RF ...losses.•Surface finishing of SLM printed components is a key enabling technology for use in RF structures.•Wet blasting and vibratory finishing methods reduce surface roughness.•Chemical etching results in anisotropic etch rates that follow laser hatch pattern in printed material.
Recent advances in selective laser melting (SLM) 3D printing technology allows additive manufacture of lower hybrid current drive (LHCD) RF launchers from a new material, Glenn Research Copper 84 (GRCop-84), a Cr2Nb (8 at. % Cr, 4 at. % Nb) precipitation hardened alloy, in configurations unachievable with conventional machining. Rough surfaces in additive manufactured components are a limiting factor in RF structures. Surface roughness increases RF losses and impedes conditioning by trapping gas and contaminants that induce arcing by evolving from the surface at high power. SLM printed GRCop-84 is post-processed with mass finishing to reduce surface roughness. Wet blasting, vibratory finishing, and chemical etching remove adhered powder grains from SLM printed GRCop-84. Profilometry and scanning electron microscopy were used to quantify resulting surface quality. Chemical etching is examined to remove zinc contamination from wire electrical discharge machining slag prior to vacuum use. Etch rates in SLM printed GRCop-84 are anisotropic, and etch times should be limited to prevent pitting corresponding to the laser hatch pattern. Vibratory mass finishing and mechanical polishing produced surfaces suitable for low RF loss. Use of chemo-mechanical finishing is recommended for the interior of SLM printed structures.
•GRCop-84 can be additively manufactured at full density.•Tensile strength exceeds CuCrZr and other high conductivity copper alloys.•Stable precipitates allow sustained high temperature ...operation.•Comparison to similar copper alloys predicts good nuclear response.•No voids observed at 20 dpa self-similar ion irradiation.
Recent advances in selective laser melting (SLM) 3D printing technology allow additive manufacture of lower hybrid current drive (LHCD) RF launchers from a new material, Glenn Research Copper 84 (GRCop-84), a Cr2Nb (8 at. % Cr, 4 at. % Nb) precipitation hardened alloy, in configurations unachievable with conventional machining. Tensile strength and thermal conductivity are compared to other competing high conductivity copper alloys for fusion use. Swelling and conductivity at 100 DPA when exposed to the Hanford Fast Flux Test Facility neutron spectrum is predicted in the 1–2 % and 65−70% IACS range, respectively, by comparison to copper alloys with similar precipitate and grain size. Self-similar ion irradiation of a GRCop-84 target at 430 °C to 20 DPA resulted in no noticeable void formation in FIB cross sections or TEM lamella.
•Laser Powder Bed Fusion additive manufacturing enables rapid construction of lower hybrid launchers for fusion reactors.•Surface roughness depends on print angle, 45° overhangs do not require ...supports.•0.5 mm thick walls warp during the print process, 1 and 1.5 mm thick walls eliminates warping.•Sinusoidal motion of the build plate induced a 5 mm period 40 μm pk-pk surface waviness.•.Dimensional accuracy was within 40 μm, batch-to-batch variation was 10 μm.
Laser Powder Bed Fusion (L-PBF), also known as Selective Laser MeltingTM (SLMTM), allows additive manufacture of lower hybrid current drive (LHCD) Radio Frequency (RF) launchers from a new material, Glenn Research Copper 84 (GRCop-84), a Cr2Nb (8 at. % Cr, 4 at. % Nb) precipitation hardened alloy, in configurations unachievable with conventional machining. The resolution and geometric limitations are tested to explore the limitations of L-PBF printing of GRCop-84. Printing holes in the vertical and horizontal direction are examined to determine the minimum cooling channel diameter. Internal stress limits the minimum thickness of vertical walls and septa to 1 mm, thinner walls warp during printing. Roughness is minimized on vertical surfaces and increases on both upper and lower surfaces as angle increases. Accuracy within 40 μm is typical on well supported structures.
Ion cyclotron range of frequencies (ICRF) heating will be the sole auxiliary heating method on SPARC for both full-field (Bt0 ~ 12 T) D–T operation and reduced field (Bt0 ~ 8 T) D–D operation. Using ...the fast wave at ~120 MHz, good wave penetration and strong single-pass absorption is expected for D–T(3He), D(3He), D(H) and 4He(H) heating scenarios. The dependences of wave absorption on ${k_\parallel }$, 3He concentration, resonance location, antenna poloidal location and losses on alpha particles and ash have been studied. The antenna loading has been assessed by comparison with the Alcator C-Mod antennae. An antenna spectrum of ${k_\parallel }\sim 15\text{--}18\,{\textrm{m}^{ - 1}}$ is shown to be good for both core absorption and edge coupling. For the control of impurity sources, the antenna straps are rotated ~10° to be perpendicular to the B field and the straps can run with different power levels in order to optimize the antenna spectrum and to minimize the image current on the antenna frame. Combining the physics constraints with the SPARC port design, maintenance requirement and contingency against antenna failure during D–T operation, we plan to mount on the inner wall of the vacuum vessel a total of 12 4-strap antennae in 6 ports while keeping 3-strap antennae that are insertable and removable on port plugs as the backup option.
The Fusion Nuclear Science Facility (FNSF) is examined here as part of a two step program from ITER to commercial power plants. This first step is considered mandatory to establish the materials and ...component database in the real fusion in-service environment before proceeding to larger electricity producing facilities. The FNSF can be shown to make tremendous advances beyond ITER, toward a power plant, particularly in plasma duration and fusion nuclear environment. A moderate FNSF is studied in detail, which does not generate net electricity, but does reach the power plant blanket operating temperatures. The full poloidal Dual Coolant Lead Lithium (DCLL) blanket is chosen, with alternates being the Helium Cooled Lead Lithium (HCLL) and Helium Cooled Ceramic Breeder/Pebble Bed (HCCB/PB). Several power plant relevant choices are made in order to follow the philosophy of targeted technologies. Any fusion core component must be qualified by fusion relevant neutron testing and highly integrated non-nuclear testing before it can be installed on the FNSF in order to avoid the high probability of constant failures in a plasma-vacuum system. A range of missions for the FNSF, or any fusion nuclear facility on the path toward fusion power plants, are established and characterized by several metrics. A conservative physics strategy is pursued to accommodate the transition to ultra-long plasma pulses, and parameters are chosen to represent the power plant regime to the extent possible. An operating space is identified, and from this, one point is chosen for further detailed analysis, with R=4.8m, a=1.2m, IP=7.9 MA, BT=7.5T, βN<2.7, n/nGr=0.9, fBS=0.52, q95=6.0, H98 ∼1.0, and Q=4.0. The operating space is shown to be robust to parameter variations. A program is established for the FNSF to show how the missions for the facility are met, with a He/H, a DD and 5 DT phases. The facility requires ∼25years to complete its DT operation, including 7.8 years of neutron production, and the remaining spent on inspections and maintenance. The DD phase is critical to establish the ultra-long plasma pulse lengths. The blanket testing strategy is examined, and shows that many sectors have penetrations for heating and current drive (H/CD), diagnostics, or Test Blanket Modules (TBMs). The hot cell is a critical facility element in order for the FNSF to perform its function of developing the in-service material and component database. The pre-FNSF R&D is laid out in terms of priority topics, with the FNSF phases driving the time-lines for R&D completion. A series of detailed technical assessments of the FNSF operating point are reported in this issue, showing the credibility of such a step, and more detailed emphasis on R&D items to pursue. These include nuclear analysis, thermo-mechanics and thermal-hydraulics, liquid metal thermal hydraulics, transient thermo-mechanics, tritium analysis, maintenance assessment, magnet specification and analysis, materials assessments, core and scrape-off layer (SOL)/divertor plasma examinations.
Overview of the SPARC tokamak Creely, A. J.; Greenwald, M. J.; Ballinger, S. B. ...
Journal of plasma physics,
10/2020, Letnik:
86, Številka:
5
Journal Article
Recenzirano
Odprti dostop
The SPARC tokamak is a critical next step towards commercial fusion energy. SPARC is designed as a high-field ($B_0 = 12.2$ T), compact ($R_0 = 1.85$ m, $a = 0.57$ m), superconducting, D-T tokamak ...with the goal of producing fusion gain $Q>2$ from a magnetically confined fusion plasma for the first time. Currently under design, SPARC will continue the high-field path of the Alcator series of tokamaks, utilizing new magnets based on rare earth barium copper oxide high-temperature superconductors to achieve high performance in a compact device. The goal of $Q>2$ is achievable with conservative physics assumptions ($H_{98,y2} = 0.7$) and, with the nominal assumption of $H_{98,y2} = 1$, SPARC is projected to attain $Q \approx 11$ and $P_{\textrm {fusion}} \approx 140$ MW. SPARC will therefore constitute a unique platform for burning plasma physics research with high density ($\langle n_{e} \rangle \approx 3 \times 10^{20}\ \textrm {m}^{-3}$), high temperature ($\langle T_e \rangle \approx 7$ keV) and high power density ($P_{\textrm {fusion}}/V_{\textrm {plasma}} \approx 7\ \textrm {MW}\,\textrm {m}^{-3}$) relevant to fusion power plants. SPARC's place in the path to commercial fusion energy, its parameters and the current status of SPARC design work are presented. This work also describes the basis for global performance projections and summarizes some of the physics analysis that is presented in greater detail in the companion articles of this collection.
•GRCop-84 braze wetting is similar CuCrZr, though less than oxygen free copper, wet sanding to 240 grit (Ra=0.24 µm) was considered the optimal surface roughness.•High intergranular diffusion rates ...occur for silver containing brazes in GRCop-84.•Active brazes such as Ticusil, Cusil-ABA, and Palcusil-25 wet titanium-zirconium-molybdenum alloy without a plating as does 50Au-50Cu braze, allowing direct brazing to GRCop-84 for the construction of plasma facing limiters.•Sulfamate nickel plating on titanium-zirconium-molybdenum promotes wetting of non-active brazes such as cusil while plating GRCop-84 with copper greatly enhances braze wetting.•Silver diffusing through GRCop-84 depleted Cr2Nb precipitates from the copper grain and deposited agglomerations of coarsened precipitates within silver-rich regions of intergranular diffusion once a density threshold was reached.
Laser Powder Bed Fusion (L-PBF) of Glenn Research Copper 84 (GRCop-84), a Cr2Nb (8 at. % Cr, 4 at. % Nb) precipitation hardened alloy, produces a fully dense, high conductivity alloy with a yield strength of 500 MPa and ultimate tensile strength (UTS) of 740 MPa with 20% elongation; superior to other competing copper alloys. Braze wetting characteristics of GRCop-84 with Ag-Cu-X, and Au-Cu brazes were similar to CuCrZr, but less than oxygen free copper. No difference in wetting was observed between infill and surface contour areas in L-PBF GRCop-84. Wet sanding to 240 grit (Ra=0.24 µm) was considered the optimal surface condition. Silver diffusing through GRCop-84 depleted Cr2Nb precipitates from the copper grain and deposited agglomerations of coarsened precipitates within silver-rich regions of intergranular diffusion once a density threshold was reached. Microstructure modification was minimized with 50Au-50Cu braze implying that silver caused precipitate coarsening and agglomeration, and not high temperature exposure. Coarsened precipitates were observed on the surface within braze pools implying a contribution to braze wetting. Palcusil-25, Ticusil, CuSil-ABA, and 50Au-50Cu brazes were suitable for brazing to unplated Titanium-Zirconium-Molybdenum (TZM), while sulfamate nickel plating to allows wetting with CuSil or other non-active brazes. Vacuum brazing techniques were developed to join a 1 mm thick layer of TZM to the front of additive manufactured GRCop-84 waveguides considering the brazing characteristics of both GRCop-84, TZM, and internal stress from the difference in coefficient in thermal expansion.
•Additive manufacturing is an enabling technology for rapid construction of lower hybrid launcher waveguides for fusion reactors.•Surface of selective laser melted (SLM) material is rough leading to ...arcing and RF losses.•Required surface roughness is determined by skin depth, conductivity, and frequency.•Surface roughness in SLM printed GRCop-84 is the dominant loss mechanism.•An RMS surface roughness of Rq = 0.3 μm is recommended for minimum loss at 4.6 GHz.
Recent advances in selective laser melting (SLM) 3D printing technology allow additive manufacture of lower hybrid current drive (LHCD) RF launchers from a new material, Glenn Research Copper 84 (GRCop-84), a Cr2Nb (8 at.% Cr, 4 at.% Nb) precipitation hardened alloy, in configurations unachievable with conventional machining. Rough surfaces in additively manufactured components are a limiting factor that increases RF losses. Surface roughness was found to be the dominant loss mechanism in SLM printed waveguide components. Wet blasting removes adhered powder grains from SLM printed GRCop-84 while vibratory mass finishing smooth’s and flattens waveguide surfaces. Mechanical polishing produced surfaces with low RF loss, however a further mass finishing step is recommended for the interiors of waveguides where polishing is not possible. Power loss in the upcoming LHCD launcher system for DIII-D is used to predict driven current in the plasma.
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