government labs 1.nrl 2.llnl 3.snl 4.lanl 5.ornl 6.pppl universities 1.ucsd 2.wisconsin 3.georgia...
TRANSCRIPT
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Government Labs1. NRL2. LLNL3. SNL4. LANL5. ORNL6. PPPL
Universities1. UCSD2. Wisconsin3. Georgia Tech4. UCLA5. U Rochester6. PPPL7. UC Santa Barbara8. UNC9. DELFT
Industry1. General Atomics2. Titan/PSD3. Schafer Corp4. SAIC5. Commonwealth Tech6. Coherent7. Onyx8. DEI9. Mission Research Corp10. Northrup11. Ultramet, Inc12. Plasma Processes, Inc13. Optiswitch Technology14. Plasma Processing, Inc
IFE First Wall Survival Development and Testing of an Armored Ferritic
L L Snead, G. R. Romanoski, C. A. Blue, and J. Blanchard
Presented at the 16th TOFE, Madison Wisconsin September 16, 2004
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HAPL IFE First Wall Materials
• Carbon and refractory metals (tungsten) considered - Reasonably high thermal conductivity at high temperature
(~100-200 W/m-K)
- Sublimation temperature of carbon ~ 3370°C
- Melting point of tungsten ~3410°C
• In addition, possibility of an engineered surface to provide better accommodation of high energy deposition is considered
- tungsten coated ferritic or SiC
- carbon brush structures
- tungsten foam
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Unique Threats to IFE First Wall
• Intense cyclic heating
- stresses and sublimation due to pulse heating (Renk talk this session)
- cyclic stress induced debonding
- long-tem thermal stability
• Surface removal due to high energy ions.
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Temporal Distribution of Heat Flux
Debris Ions
10ns 0.2s 1s 2.5s
FastIons
Ph
oton
sEnergyDeposition
Instantaneous Heat Flux10 MW/m2 (MFE) = 104 MW/m2 (IFE)
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Effect of Heat Flux on W-Armor Coated SiC
200
600
1000
1400
1800
2200
2600
3000
Surface
1 micron
5 microns
10 microns
100 microns
Time (s)
3-mm Tungsten slab
Density = 19350 kg/m3
Coolant Temp. = 500°C
h =10 kW/m2-K154 MJ DD Target Spectra
0 1 2 3 4 5 6 7 8 9 10
Time (microseconds)
Raffray data
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Fabrication Process : W/F82H
• Two processes for bonding low activation ferritic to tungsten are considered: Diffusion Bonding and Plasma Spray:
I. Diffusion-bonded tungsten foil (.1 mm thickness) - Allows the best possible mechanical properties and surface integrity - Tungsten will remain in the un-recrystallized state - No porosity
--> Plates of W/Fe (ORNL) have been produced and are being tested.
II. Plasma-sprayed tungsten transition coatings - Allows for a graded transition structure by blending tungsten and steel powders in an intermediate layer to accommodate CTE mismatch. - Resulting microstructure is recrystallized but small grain size - May be spayed in vacuum or under a cover gas (wall repair) - Variable porosity
--> Plates of W/Fe (Plasma Processed Inc.) have been produced and are being tested.
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Testing of Armored Ferritic : W/F82H
• The primary concern for armored materials is the survival of the interface:
--> CTE mismatch produced during processing--> Stressed induced during pulsed heating--> Stability of a “ductile” interfacial region on long-term annealing
Temperature (°C)
Spec
imen
Exp
ansi
on (
ppm
)
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High Density Infrared (HDI) Plasma Arc Lamp Technology
Unique high density infrared plasma arc lamp Most powerful radiant arc
lamp in the world
Broad area processing with high radiant energies
Conservative heating rates 2,000C/s to 20,000C/s Allows controlled diffusion on nanometer scale
Able to melt Rhenium Melting point of 3180C
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Thermal Fatigue Testing
Rep rate: 10HzMax. flux: 20.9MW/m2 (20ms)Min. flux: 0.5MW/m2(80ms)Duration: 1000 cyclesSubstrate temp. (bottom): 600 ºC
Substrate material: F82H steelCoating material: tungsten (100µm-thick)Specimen size: 25 x 25 x 5 (mm)
W coated specimen
Cooling table 0
5
10
15
20
25
-200 0 200 400 600 800 1000Time (ms)
Heat flux (MW/m
2)
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Thermal Fatigue Testing
IR testing closely matches stress state at interface.
Flexural tests will be performed on samples that incorporate the W armor and substrate to quantify the mechanical strength of the interface at different cycle durations and following thermal aging.
-200
-100
0
100
200
0 0.5 1 1.5 2 2.5 3 3.5
HAPL baseline
Infrared heating
Stress (MPa)
depth (mm)
Armor interface
Stre
ss (
MP
a)
Depth (mm)
Blachard results
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Thermal Fatigue Testing
Rep rate: 10HzMax. flux: 20.9MW/m2 (20ms)Min. flux: 0.5MW/m2(80ms)Duration: 1000 cyclesSubstrate temp. (bottom): 600 ºC
Substrate material: F82H steelCoating material: tungsten (100µm-thick)Specimen size: 25 x 25 x 5 (mm)
W coated specimen
Cooling table 0
5
10
15
20
25
-200 0 200 400 600 800 1000Time (ms)
Heat flux (MW/m
2)
QuickTime™ and aDV/DVCPRO - NTSC decompressorare needed to see this picture.
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• No obvious degradation of adhesion of W to F82H following fatigue testing• For these fatigue tests, carbide dissolution indicating interface >900°C
As Deposited
DiffusionBonded
PlasmaSprayed
1000 shot, 20 MW/m2
W Coated F82H After Thermal Fatigue Testing
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W Coated F82H After 10,000 Cycle Fatigue Testing
In interface over-temperature (>900°C) a W-Fe intermetallic forms.
Formation of W-Fe brittle phase will likely lead to interface fracture and coating failure.
Isothermal aging experiments will be performed on W / F82H samples to demonstrate the temperature and time limitations of the interface.
WFeW
F82HSteel
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10
100
1000
104
0.001 0.01 0.1 1 10 100
Time (milliseconds)
IFE
~104 MW/m2
~ 10 sec
2005 IR upgrade ~100 / 2MW m ~ 1 msec
IR ThermalFatigueFacility~20 / 2MW m ~ 20 msec
> 0.1 / 2MJ m
~ 0.2 / 2MJ m
~ 0.2 / 2MJ m
2heat flux
Thermal Fatigue Facility Upgrades for Prototype Testing (complete 2005)
• Continuous operation: 1 msec, 5 Hz at 100 MW/m2
• 300 cm2 surface area irradiation
• Front surface temperature monitoring
• Fabrication of cooled prototype plasma spray tungsten armored low-activation ferritic
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Helium ManagementAt room temp. growth of He bubbles beneath the surface causes blistering at ~3 x 1021/m2 and surface exfoliation at ~1022/m2.
For IFE power plant, MeV He dose >>> 1022/m2 .
MeV Helium
MeV Helium
First Wall Armor
200
600
1000
1400
1800
2200
2600
3000
Surface
1 micron
5 microns
10 microns
100 microns
Time (s)
3-mm Tungsten slab
Density = 19350 kg/m3
Coolant Temp. = 500°C
h =10 kW/m2-K154 MJ DD Target Spectra
vacancy
0 1 2 3 4 5 6 7 8 9 10
Time of microseconds
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0
500
1000
1500
2000
2500
0 1 2 3 4 5
Minutes
0
2
4
6
8
10
Effect of Iterative Implant/Anneal on Retained Helium
1.3 MeV He implantationPoly-X tungsten targetResistive Heating
A series of implantation to 1019 He/m2 for1, 10, 100 and 1000 cycles has been completed
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Effect of Iterative Implant/Anneal on Retained Helium
1.3 MeV He implantationPoly-X tungsten targetResistive Heating
Implantation to 1019 He/m2 for1, 10, 100 and 1000 cycles
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Total 3He dose
(1019 He/m2)
Proton Yield
(10%)
1 10
2 13
3 70
5 2000
10 7100
Determination of critical step size
For Single-X W critical step size ~3·1016 Helium doses implanted at 850°C and flash-annealed at
2000°C in 1000 cycles
0
100
200
300
400
500
600
700
800
0 2 4 6 8 10 12
Critical Step Size
Normalized Accumulation
1016
He/m2
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0
50
100
150
200
250
300
350
400
12.8 12.9 13 13.1 13.2 13.3 13.4 13.5
Energy (MeV)
Proton Yield
1000 steps (850/2000)
1 step as-implanted (850)
1 step annealed (850/2000)
100 steps (850/2500)
Update on Effect of Peak Annealing Temperature
• Single x annealed at 2500°C shows significantly less He retention than 2000°C anneal.
• Annealing temperature plays a significant role in retained He and critical dose. As part of the chambers study we need to make precise assessment of implantation and annealing temperatures to focus experiment.
2500°C
2000°C
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Concluding Remarks
• The HAPL program has selected refractory armored low-activation ferritic steel as it’s prime candidate first wall.
• Currently, optimization of the plasma-sprayed W/F82H steel in near completion and mechanical testing underway.
• IFE-unique critical-issues are being pursued- X-ray and ion ablation and roughening (Renk and Latkowski)- thermal fatigue of tungsten ferritic interface- long-term thermal stability- helium management
Special issue of Journal of Nuclear Materials on subject of HAPL chamber currently being assembled.
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SiC without coating
SiC
W coating
IR processing
10µm
Interface
SiC was removed by sublimation of the surface of the SiC prior to ordering the W powder melt. Rough interface was formed.
Fabrication Process : W/SiC
Tungsten Powder
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The Path to Develop Laser Fusion Energy
Phase IIValidatescience &technology2006 - 2014
Phase IIIEngineeringTest Facilityoperating 2020
Full size laser: 2.4 MJ, 60 laser lines Optimize targets for high yield Develop materials and components. 300-700 MW net electricity Resolve basic issues by 2028
Phase IBasic fusionscience &technology1999- 2005
Ignition Physics Validation•MJ target implosions•Calibrated 3D simulations
Target Design & Physics
•2D/3D simulations•1-30 kJ laser-target expts
Full Scale Components
•Power plant laser beamline •Target fab/injection facility •Power Plant design
Scalable Technologies
•Krypton fluoride laser•Diode pumped solid state laser•Target fabrication & injection•Final optics•Chambers materials/design
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Chamber Progress -1 Operating windowsEstablishing Chamber operating windows is a multidisciplinary, simulation intensive, process...........Here is an example for a 154 MJ target.
UCSDWisconsinLLNLGA
Target Physics:gives target emissions(neutrons, x-rays, ions)
Chamber Physics:What hits wall: "threat spectra"
Materials:How wall responds to"threat spectra"
Target Injection Survival:allowed chamber conditions(gas, wall temperature)
0 2 4 6 8 10time (? )sec
Surface1 micron5 microns10 microns100 microns
Surface1 micron5 microns10 microns100 microns
3000
2600
2200
1800
1600
1200
600
200
Tungsten first wall temperature staysbelow melting point (tungsten melts at 3410 C)
Tem
per
atu
re (C
)
154 MJ targetNo gas6.5 m radius
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Summary of Thermal Fatigue Experiment
•Thermal fatigue experiments were carried out successfully using IR processing facility. Preliminary results showed tungsten coating was stable following the heat load (10Hz, 23.5MW/m2 (10ms), 1000cycles).
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Porous W StructureMonolithic W
Candidate First Wall Structure W/LAF (W/SiC Backup)
LAF(~600°C max) or ODS(~800°C) structure, possibly both.
Liquid MetalHelium,or
Salt Coolant?
Development of Armor fabrication process and repair
He management mech. & thermal fatigue testing
Surface Roughening/Ablation
Underlying Structurebonding (especially ODS)high cycle fatiguecreep rupture
Armor/Structure Thermomechanicsdesign and armor thicknessfinite element modelingthermal fatigue and FCG
Structure/Coolant Interfacecorrosion/mass transfercoating at high temperature?
Modeling Irradiation Effectsswelling and embrittlement
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Helium Management (ORNL, Delft, UNC)
Parametric Study
Variables Techniques Data
Materials Temp. Dose
Single-X Irrad. Temp Total Dose Nuclear Reaction Analysis N He,% retention
Poly-X Anneal Temp Dose Increment Thermal Desorption Diffusivity/Activation Energy
CVD Anneal Rate TEM/SEM Defect size and distribution
Foam
• weak dependence on material type
• strong dependence on implantation temperature
• annealing from 800-2000°C diffuses significant helium
----> there are knobs to turn that delay exfoliation in W