Publications

Abstract not provided.

Abstract not provided.

This paper describes the liquid metal integrated test system (LIMITS) at Sandia National Laboratories. This system was designed to study the flow of molten metals and salts in a vacuum as a preliminary study for flowing liquid surfaces inside of magnetic fusion reactors. The system consists of a heated furnace with attached centrifugal pump, a vacuum chamber, and a transfer chamber for storage and addition of fresh material. Diagnostics include an electromagnetic flow meter, a high temperature pressure transducer, and an electronic level meter. Many ports in the vacuum chamber allow testing the thermal behavior of the flowing liquids heated with an electron beam or study of the effect of a magnetic field on motion of the liquid. Some preliminary tests have been performed to determine the effect of a static magnetic field on stream flow from a nozzle.

Abstract not provided.

A FORTRAN computer code has been written to calculate the heat transfer properties at the wetted perimeter of a coolant channel when provided the bulk water conditions. This computer code is titled FILM-30 and the code calculates its heat transfer properties by using the following correlations: (1) Sieder-Tate: forced convection, (2) Bergles-Rohsenow: onset to nucleate boiling, (3) Bergles-Rohsenow: partially developed nucleate boiling, (4) Araki: fully developed nucleate boiling, (5) Tong-75: critical heat flux (CHF), and (6) Marshall-98: transition boiling. FILM-30 produces output files that provide the heat flux and heat transfer coefficient at the wetted perimeter as a function of temperature. To validate FILM-30, the calculated heat transfer properties were used in finite element analyses to predict internal temperatures for a water-cooled copper mockup under one-sided heating from a rastered electron beam. These predicted temperatures were compared with the measured temperatures from the author's 1994 and 1998 heat transfer experiments. There was excellent agreement between the predicted and experimentally measured temperatures, which confirmed the accuracy of FILM-30 within the experimental range of the tests. FILM-30 can accurately predict the CHF and transition boiling regimes, which is an important advantage over current heat transfer codes. Consequently, FILM-30 is ideal for predicting heat transfer properties for applications that feature high heat fluxes produced by one-sided heating.

Helium-cooled, refractory heat exchangers are now under consideration for first wall and divertor applications. These refractory devices take advantage of high temperature operation with large delta-Ts to effectively handle high heat fluxes. The high temperature helium can then be used in a gas turbine for high-efficiency power conversion. Over the last five years, heat removal with helium was shown to increase dramatically by using porous metal to provide a very large effective surface area for heat transfer in a small volume. Last year, the thermal performance of a bare-copper, dual-channel, helium-cooled, porous metal divertor mock-up was evaluated on the 30 kW Electron Beam Test System at Sandia National Laboratories. The module survived a maximum absorbed heat flux of 34.6 MW/m2 and reached a maximum surface temperature of 593 °C for uniform power loading of 3 kW absorbed on a 2-cm2 area. An impressive 10 kW of power was absorbed on an area of 24 cm2. Recently, a similar dual-module, helium-cooled heat exchanger made almost entirely of tungsten was designed and fabricated by Thermacore, Inc. and tested at Sandia. A complete flow test of each channel was performed to determine the actual pressure drop characteristics. Each channel was equipped with delta-P transducers and platinum resistance temperature devices (RTDs) for independent calorimetry. One mass flow meter monitored the total flow to the heat exchanger, while a second monitored flow in only one of the channels. The thermal response of each tungsten module was obtained for heat fluxes in excess of 5 MW/m2 using 50 °C helium at 4 MPa. Fatigue cycles were also performed to assess the fracture toughness of the tungsten modules. A description of the module design and new results on flow instabilities are also presented.

Abstract not provided.

In the authors initial high heat flux tests on small mockups armored with W rods, done in the small electron beam facility (EBTS) at Sandia National Laboratories, the mockups exhibited excellent thermal performance. However, to reach high heat fluxes, they reduced the heated area to only a portion ({approximately}25%) of the sample. They have now begun tests in their larger electron beam facility, EB 1200, where the available power (1.2 MW) is more than enough to heat the entire surface area of the small mockups. The initial results indicate that, at a given power, the surface temperatures of rods in the EB 1200 tests is somewhat higher than was observed in the EBTS tests. Also, it appears that one mockup (PW-10) has higher surface temperatures than other mockups with similar height (10mm) W rods, and that the previously reported values of absorbed heat flux on this mockup were too high. In the tests in EB 1200 of a second mockup, PW-4, absorbed heat fluxes of {approximately}22MW/m{sup 2} were reached but the corresponding surface temperatures were somewhat higher than in EBTS. A further conclusion is that the simple 1-D model initially used in evaluating some of the results from the EBTS testing was not adequate, and 3-D thermal modeling will be needed to interpret the results.

Task T-222 of the International Thermonuclear Experimental Reactor (ITER) program addresses the manufacturing and testing of permanent components for use in the ITER divertor. Thermalhydraulic and critical heat flux performance of the heat sinks proposed for use in the divertor vertical target are part of subtask T-222.4. As part of this effort, two single channel, medium scale, bare copper alloy, hypervapotron mockups were designed, fabricated, and tested using the EB-1200 electron beam system. The objectives of the effort were to develop the design and manufacturing procedures required for construction of robust high heat flux (HHF) components, verify thermalhydraulic, thermomechanical and critical heat flux (CHF) performance under ITER relevant conditions, and perform analyses of HHF data to identify design guidelines and failure criteria and possibly modify any applicable CHF correlations. The design, fabrication, and finite element modeling of two types of hypervapotrons are described; a common version already in use at the Joint European Torus (JET) and a new attached fin design. HHF test data on the attached fin hypervapotron will be used to compare the CHF performance under uniform heating profiles on long heated lengths with that of localized, highly peaked, off nominal profiles.

Thermal response and thermal fatigue tests of four 5 mm thick beryllium tiles on a Russian divertor mock-up were completed on the Electron Beam Test System at Sandia National Laboratories. The beryllium tiles were diffusion bonded onto an OFHC copper saddleblock and a DSCu (MAGT) tube containing a porous coating. Thermal response tests were performed on the tiles to an absorbed heat flux of 5 MW/m{sup 2} and surface temperatures near 300{degrees}C using 1.4 MPa water at 5.0 m/s flow velocity and an inlet temperature of 8-15{degrees}C. One tile was exposed to incrementally increasing heat fluxes up to 9.5 MW/m{sup 2} and surface temperatures up to 690{degrees}C before debonding at 10 MW/m{sup 2}. A third tile debonded after 9200 thermal fatigue cycles at 5 MW/m{sup 2}, while another debonded after 6800 cycles. In all cases, fatigue failure occurred in the intermetallic layers between the beryllium and copper. No fatigue cracking of the bulk beryllium was observed. During thermal cycling, a gradual loss of porous coating produced increasing sample temperatures. These experiments indicate that diffusion-bonded beryllium tiles can survive several thousand thermal cycles under ITER relevant conditions without failure. However, the reliability of the diffusion bonded Joint remains a serious issue.

High heat flux testing for the United States fusion power program is the primary mission of the Plasma Materials Test Facility (PMTF) located at Sandia National Laboratories - New Mexico. This facility, which is owned by the United States Department of Energy, has been in operation for over 17 years and has provided much of the high heat flux data used in the design and evaluation of plasma facing components for many of the world's magnetic fusion, tokamak experiments. In addition to domestic tokamaks such as Tokamak Fusion Test Reactor (TFTR) at Princeton and the DIII-D tokamak at General Atomics, components for international experiments like TEXTOR, Tore-Supra, and JET also have been tested at the PMTF. High heat flux testing spans a wide spectrum including thermal shock tests on passively cooled materials, thermal response and thermal fatigue tests on actively cooled components, critical heat flux-burnout tests, braze reliability tests and safety related tests. The objective of this article is to provide a brief overview of the high heat flux testing capabilities at the PMTF and describe a few of the experiments performed over the last year.