Aiello, G.

Grossetti, G.

Mazzocchi, F.

Meier, A.

Scherer, T.

Schreck, S.

Spaeh, P.

Strauß, D.

Vaccaro, A.

English

KITopen

KIT – University of the State of Baden-Wuerttemberg and National Research Center of the Helmholtz AssociationInstitute for Applied Materials – Applied Materials Physicswww.kit.eduDiamond window for the ITER EC H&CD Upper Launcher -Status of design, testing and qualificationG. Aiello, G. Grossetti, F. Mazzocchi, A. Meier, T. Scherer, S. Schreck, P. Spaeh,D. Strauss, A. VaccaroInstitute for Applied Materials2OutlineG. Aiello – US-EU-JPN RF Heating Technology Workshop 2016Hotel Leinsweiler Hof, Germany23.09.16• The ITER EC H&CD Upper Launcher• Design philosophy of the window unit• Design optimized by FEM analyses and ASME code • Assembling sequence of the unit• Qualification program• First results of qualification• Conclusions and outlookInstitute for Applied Materials3The ITER EC H&CD Upper LauncherThe Upper Launcher consists of an assembly of ex-vessel WGs and an in-vessel port plug.G. Aiello – US-EU-JPN RF Heating Technology Workshop 2016Hotel Leinsweiler Hof, Germany23.09.16Institute for Applied Materials4Proposed design in 2013 (Workshop in Speyer)G. Aiello – US-EU-JPN RF Heating Technology Workshop 2016Hotel Leinsweiler Hof, Germany23.09.16Institute for Applied Materials5Current design of the window unitG. Aiello – US-EU-JPN RF Heating Technology Workshop 2016Hotel Leinsweiler Hof, Germany23.09.16Institute for Applied Materials6Optimization by FEM analysesG. Aiello – US-EU-JPN RF Heating Technology Workshop 2016Hotel Leinsweiler Hof, Germany23.09.16• Lower seismic loads acting on the units.• Design more compact and feasible to manufacture.• Second tritium barrier and real-time monitoring of interspaces.Institute for Applied Materials7Application of ASME III – NCG. Aiello – US-EU-JPN RF Heating Technology Workshop 2016Hotel Leinsweiler Hof, Germany23.09.16• Lower number of joints.• No steps at the joint locations (full penetration butt joints).• Reduction of the EB welding thickness.• Design affected by the requirements of examination (joints fully radiographed).Institute for Applied Materials8Exploded view of the window unit G. Aiello – US-EU-JPN RF Heating Technology Workshop 2016Hotel Leinsweiler Hof, Germany23.09.16TL sidePlasma sideInstitute for Applied Materials9Assembling sequence of the unitG. Aiello – US-EU-JPN RF Heating Technology Workshop 2016Hotel Leinsweiler Hof, Germany23.09.161EBEB23 EBBrazingInstitute for Applied Materials10Assembling sequence of the unitG. Aiello – US-EU-JPN RF Heating Technology Workshop 2016Hotel Leinsweiler Hof, Germany23.09.1645EBEBEBInstitute for Applied Materials11Assembling sequence of the unitG. Aiello – US-EU-JPN RF Heating Technology Workshop 2016Hotel Leinsweiler Hof, Germany23.09.166EB 7EBInstitute for Applied Materials12Window qualification programG. Aiello – US-EU-JPN RF Heating Technology Workshop 2016Hotel Leinsweiler Hof, Germany23.09.16Window unit is qualified viaASME code (III – NC, V, IX) Ad hoc program• The window unit cannot be entirely covered by Codes & Standards.• Functional, design, safety, operational, quality requirements (Component Requirements Document) and requirements related to the loading conditions (Component Load Specification) are being defined for the unit.• Procedure and acceptance criteria for qualification of welded joints.• Procedure and acceptance criteria for NDE of welded joints.• Design criteria and allowable limits for the metallic parts.• Dedicated testing program being developed in the context of F4E-OPE467.• Design criterion based on the fracture mechanics method for the diamond disc.Institute for Applied Materials13Design criteria for metallic partsG. Aiello – US-EU-JPN RF Heating Technology Workshop 2016Hotel Leinsweiler Hof, Germany23.09.16Damage limitsCorrelation damage limits – ASME service levels• Mechanical load: criteria #1, #2 and #3.• Mechanical + thermal load: criteria #1, #2, #3 and #4.• Fatigue load: criterion #5. Institute for Applied Materials14Design criterion for the diamond discG. Aiello – US-EU-JPN RF Heating Technology Workshop 2016Hotel Leinsweiler Hof, Germany23.09.16Failure to fracture is the main failure mode to be considered for the diamond disc.KI ≤ Kcβ = factor depending on geometry element – crackσ0 = reference stress in case of no cracka = length of the crack(For a/b ≤ 0.4) (For a/b ≤ 0.13)Kc = 5.3 ± 1.3 MPa m1/2(M.D. Drory et al., J. Am. Ceram. Soc., Vol. 74, No. 12, December 1991)Stress intensity approach:Stress intensity factorFracture toughness of diamond(G. Petrucci “Lezioni di Costruzione di Macchine”)Institute for Applied Materials15Testing program for the window prototypeG. Aiello – US-EU-JPN RF Heating Technology Workshop 2016Hotel Leinsweiler Hof, Germany23.09.16• Geometrical check (e.g., cuffs centricity)• Optical check• Mechanical check (bow after brazing)• Vacuum leakage check for braze• Braze inspection (CT) • Tanδ check at disc centerBRAZEDDISC• Geometrical check (d, D, surface roughness)• Optical check (cracks, impurities)• Mechanical check (bow)• Tanδ check (disc area mapping and at center)BARE DISCASSEMBLY • Geometrical check• Tanδ check at disc center• High power MW test (short and long pulse)• Vacuum leakage check for all joints• Cooling pressure testing• Permeation test by Deuterium• Seismic test• Overpressure testInstitute for Applied Materials16Qualification of the bare discsG. Aiello – US-EU-JPN RF Heating Technology Workshop 2016Hotel Leinsweiler Hof, Germany23.09.16Laser engravingfor identificationInstitute for Applied Materials17Brazed disc inspection at KIT by CTG. Aiello – US-EU-JPN RF Heating Technology Workshop 2016Hotel Leinsweiler Hof, Germany23.09.16Brazing regionDisc edgeTop side of the diamond discInstitute for Applied Materials18Conclusions and outlookG. Aiello – US-EU-JPN RF Heating Technology Workshop 2016Hotel Leinsweiler Hof, Germany23.09.16• The design of the window unit was optimized by FEM analyses and in accordance with the ASME III - NC.• The window unit shall be qualified by the ASME code and a specific program.• Definition of the specific qualification program is on going and first results were obtained.• Technical Specifications for the manufacturing of the window prototype are approaching the final phase in order to start the call for tender by F4E.This work was/is  partly supported by Fusion for Energy under the contract No. F4E-2010-GRT615 and F4E-2013-OPE467. The views and opinions expressed herein reflect only the author’s views. Fusion for Energy is not liable for any use that may be made of the information contained therein.

Diamond window for the ITER EC-H&CD upper launcher status of design, testing and qualification

https://publikationen.bibliothek.kit.edu/1000063331/144130948

Diamond window for the ITER EC-H&CD upper launcher status of design, testing and qualification

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